Service Training

MALAGA
365C-385C HYDRAULIC EXCAVATORS

LAB
EXERCISES
Francis
Apr 12
 CHAPTER : Lab Exercises

CONTENT

Front page _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 1

Content _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 2
Lab Exercises A, B, C, D _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 3
Lab Exercises E, F, G _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 4
Lab Exercises H _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 5
Module Objectives A, B, C, D _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 6
Module Objectives E, F, G _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 7
Module Objectives H _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 8
345C Pressure Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 9
365C Pressure Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 10
385C Pressure Specifications _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 11
345C Engine Performance Test (quick Test) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 12
345C Main Pump de stroking pressure test (quick Test) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 13
365C/385C Engine Performance Test (quick Test) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 14
365C/385C Main Pump Margin Pressure Test _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 15
365C Main Pump de stroking pressure test (quick Test) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 16
385C Main Pump de stroking pressure test (quick Test) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 17
365C/385C Pilot and Line Relief Valves Pressure Test _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Page 18
365C/385C Signal Relief Valves (Hi/Low) and Swing Relief valves Pressure Test _ _ _ _ _ _ _ _ _ Page 19

Service Training Malaga 2

 CHAPTER : Lab Exercises

LABORATORY EXERCISES

The following section provides lab exercises to reinforce the course presentation. The section provides directions to set up,
facilitate and assist during the student lab exercises. The labs are "hands on" labs. The actual student lab sheets information
along with accompanying materials are located in this lab exercises module (see the content page for proper identification).
Check handout at the beginning of each lab, have all students review the lab description to be sure the student understands
what to do.

NOTE:Discuss safety procedures with the students for each shop lab exercise (i.e. safety glasses, clothing).

Lab A: Locate and Identify the major components of Hydraulic, Electronic Control Systems
and the new Monitor Panel. 30 min

Lab B: Display and Record Monitor Main Menu and Sub menus
Display and Record Number of Logged Error
Display and Record Number of Summary Logged Events
Display and Record Machine Status
Display and Record Service Option Menu and Perform the List of Calibration Option
Display and Record the Gain Response Settings (365C/385C)
At the Configuration, Display and record All Categories of parameters Available 60 min

Lab C: 345C Engine Performance Test

345C Test and adjust De stroking Pressure (Reference Point) 90 min

Lab D: 365C/385C Engine Performance Test

365C/385C Test and adjust Pump Margin Pressure
365C/Test and adjust De stroking Pressure (Reference Point)
385C/Test and adjust De stroking Pressure (Reference Point) 120 min

NOTE : Total Lab Time is based on the number of students and the machine

Service Training Malaga 3

 CHAPTER : Lab Exercises

LABORATORY EXERCISES Cont...

Lab E: Test and Adjust Pilot System Relief Valve

Test and Adjust Boom Line Relief Valves
Test and Adjust Bucket Line Relief Valves
Test and Adjust Stick Line Relief Valves
Test and Adjust Travel Line Relief Valves 120 min

Lab F: Test and Adjust Implement Signal Pressure Relief Valves - Low (365C/385C)
Test and Adjust Travel Signal Pressure Relief Valve - High (365C/385C)
Test and Adjust Implement Swing Relief Valves (Right / Left Motors) 120 min

Lab G: Connect ET Service Tool and and perform the following calibrations:
345C
- Engine Speed
- PS Pressure valve

385C/365C
- Control Valves - All Valves + Individual Valve
- PS Pressure valve
- Check Valves - BLCV
- Lever/Pedal/Attch - All + Individual
- Engine Speed 120 min

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 CHAPTER : Lab Exercises

LABORATORY EXERCISES Cont...

Lab H: From Device Test menu, select Power Shift pressure and change it.
From Override Parameter menu, (check on the machine to decide which test to run)
From Configuration - parameter Setting, modify the Gain and Response Settings (365C/385C)
From Tool Program menu, select Tool number 6 and program the following parameters:
345C
a) Tool Name (Hammer)
b) Max Dial
c) Flow Setting
d) Nominal Pressure
365C/385C
a) Tool Name (Shear)
b) Max Dial
c) Aux Valve Mode
d) Extend Flow Setting
e) Retract Flow Setting 90 min

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 CHAPTER : Lab Exercises

MODULE OBJECTIVES
AFTER COMPLETION , THE STUDENT WILL BE ABLE TO :

Conduct Lab A Given a machine and Lab A Work sheets, locate and identify
90% hydraulic and electronic system components and new monitor panel . 30 min

Conduct Lab B Given a machine, the appropriate service literature, tools to:
Display and Record Monitor Main Menu and Sub menus
Display and Record Number of Logged Error
Display and Record Number of Summary Logged Events
Display and Record Machine Status
Display and Record Service Option Menu and Perform the List of Calibration Option
Display and Record the Gain Response Settings (365C/385C)
At the Configuration, Display and record All Categories of parameters Available 60 min

Conduct Lab C Given a machine, the appropriate service literature, tools to do:
1. 345C Engine Performance Test
2. 345C Test and adjust De stroking Pressure (Reference Point) 90 min

Conduct Lab D Given a machine, the appropriate service literature, tools to do:
1. 365C/385C Engine Performance Test
2. 365C/385C Test and adjust Pump Margin Pressure
3. 365C/Test and adjust De stroking Pressure (Reference Point)
4. 385C/Test and adjust De stroking Pressure (Reference Point) 120 min

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 CHAPTER : Lab Exercises

MODULE OBJECTIVES Cont...

Conduct Lab E Given a machine, the appropriate service literature, tools to:
Test and Adjust Pilot System Relief Valve
Test and Adjust Boom Line Relief Valves
Test and Adjust Bucket Line Relief Valves
Test and Adjust Stick Line Relief Valves
Test and Adjust Travel Line Relief Valves 120 min

Conduct Lab F Given a machine, the appropriate service literature, tools to:
Test and Adjust Implement Signal Pressure Relief Valves - Low (365C/385C)
Test and Adjust Travel Signal Pressure Relief Valve - High (365C/385C)
Test and Adjust Implement Swing Relief Valves (Right / Left Motors) 120 min
Conduct Lab G Given a machine, the appropriate service literature, tools to:
Connect ET Service Tool and and perform the following calibrations
345C
- Engine Speed
- PS Pressure valve
385C/365C
- Control Valves - All Valves + Individual Valve
- PS Pressure valve
- Check Valves - BLCV
- Lever/Pedal/Attch - All + Individual
- Engine Speed 120 min

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 CHAPTER : Lab Exercises

MODULE OBJECTIVES Cont...

Conduct Lab H Given a machine, the appropriate service literature, tools to perform the following tasks:
1. From Device Test menu, select Power Shift pressure and change it.
2. From Override Parameter menu, (check on the machine to decide which test to run)
3. From Configuration - parameter Setting, modify the Gain and Response Settings (365C/385C)
4. From Tool Program menu, select Tool number 6 and program the following parameters:
345C
a) Tool Name (Hammer)
b) Max Dial
c) Flow Setting
d) Nominal Pressure
365C/385C
a) Tool Name (Shear)
b) Max Dial
c) Aux Valve Mode
d) Extend Flow Setting
e) Retract Flow Setting 90 min

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 CHAPTER : Lab Exercises

345C PRESSURE SPECIFICATIONS

345C PRESSURE SPECIFICATIONS

Pressure Change With One
RELIEF VALVE SPECS ACTUAL Turn of Adjustment Screw TOOLS REQUIRED

Main Relief Valve 35000 +/- 500

Main Relief Valve : 14400 kPa
Main Relief Valve (Heavy Lift) 36000 +/- 500

Boom Cylinder Head / Road End

Stick Cylinder Head / Road End 38000 +/- 1000 Line Relief Valve : 9300 kPa
Bucket Cylinder Head / Road End

Right Swing Motor Swing Relief Valve (Right) : 6800 kPa

31400 +/- 1000
Left Swing Motor Swing Relief Valve (Left) : 10000 kPa
Travel Crossover Relief Valves 37780 +/- 1480 Travel : 10000

Pilot Relief Valve 4660 +/- 100 Pilot : 690 kPa

Counterweight Cylinder 26000 +/- 500

CYLINDER OPERATING SPEED (Seconds)

To achieve these specifications :
Extension 3.6 +/ - 0.5 - 6900 mm Boom
Boom - 3350 mm Stick
Retraction 2.6 +/ - 0.5 - 1.9 m Bucket
Extension 4.0 +/ - 0.5
Stick
Retraction 3.1 +/ - 0.5
Extension 4.5 +/ - 0.5
Bucket
(1.9 m) 2.5 +/ - 0.5
Retraction

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 CHAPTER : Lab Exercises

365C PRESSURE SPECIFICATIONS

365C PRESSURE SPECIFICATIONS

Pressure Change With One
RELIEF VALVE SPECS ACTUAL Turn of Adjustment Screw TOOLS REQUIRED
Signal relief Valve (Boom)
32000 +/- 500 Implement : 10600 kPa
Signal relief Valve (Stick)
Signal relief Valve (Heavy Lift)
35000 +/- 500 Travel : 7050 kPa
Signal relief Valve (Travel)

Margin pressure (Front / Rear P) 1960 +/- 50

Boom Cylinder Head / Road End

Stick Cylinder Head / Road End 37000 +/- 490 Line Relief Valve : 6850 kPa
Bucket Cylinder Head / Road End

Right Swing Motor

28950 +/- 500 Swing : 10000 kPa
Left Swing Motor

Travel Crossover Relief Valves 39250 +/- 1500 Travel : 10000

Pilot Relief Valve 4120 +/- 100 Pilot : 690 kPa

Differential Relief Valves 3000 +/-50

Counterweight Cylinder 20600 +/- 500

CYLINDER OPERATING SPEED (Seconds)

To achieve these specifications :
Extension 5.2 +/ - 0.5 - 7800 mm Boom
Boom
Retraction 2.9 +/ - 0.5 - 3600 mm Stick
- 2.7 m Bucket
Extension 5.1 +/ - 0.5
Stick
Retraction 2.9 +/ - 0.5
Bucket Extension 3.7 +/ - 0.5
V-Family Retraction 1.7 +/ - 0.5
Bucket Extension 4.3 +/ - 0.5
W-Family Retraction 2.1 +/ - 0.5

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 CHAPTER : Lab Exercises

385C PRESSURE SPECIFICATIONS

385C PRESSURE SPECIFICATIONS

Pressure Change With One
RELIEF VALVE SPECS ACTUAL Turn of Adjustment Screw TOOLS REQUIRED
Signal relief Valve (Boom)
32000 +/- 500 Implement : 10600 kPa
Signal relief Valve (Stick)
Signal relief Valve (Heavy Lift)
35000 +/- 500 Travel : 7050 kPa
Signal relief Valve (Travel)

Margin pressure (Front / Rear P) 1960 +/- 50

Boom Cylinder Head / Road End

Stick Cylinder Head / Road End 37000 +/- 490 Line Relief Valve : 6850 kPa
Bucket Cylinder Head / Road End
Right Swing Motor
28700 +/- 500 Swing : 10000 kPa
Left Swing Motor

Travel Crossover Relief Valves 40500 +/- 1500 Travel : 13600

Pilot Relief Valve 4120 +/- 100 Pilot : 690 kPa

Differential Relief Valves 3000 +/-50

Counterweight Cylinder 20600 +/- 500

CYLINDER OPERATING SPEED (Seconds)

To achieve these specifications :
Extension 5.8 +/ - 0.5 - 8400 mm Boom
Boom
Retraction 3.1 +/ - 0.5 - 3700 mm Stick
- 3.5 m Bucket
Extension 5.1 +/ - 0.5
Stick
Retraction 3.2 +/ - 0.5
Bucket Extension 4.1 +/ - 0.5
H-Family Retraction 2.2 +/ - 0.5
Bucket Extension 5.2 +/ - 0.5
J-Family Retraction 2.7 +/ - 0.5

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 CHAPTER : Lab Exercises

345C ENGINE PERFORMANCE TEST

SYSTEM PROCEDURES SPECS ACTUAL

FL RPM
- QUICK TEST - HORSEPOWER MAIN 1800
ADJ SCREW RELIEF (345C)
VALVE SYSTEM
PRESS.
ENGINE PERFORMANCE 2 PUMPS 18650/
PRESSURE 19650 kPa
TEST
BOOST
60000 kPa (as a ref. only)
Pressure 120.7 - 163.3 kPa
Gauge
Test Preparation :
ENGINE PERFORMANCE CHART
Oil temp. 55
Dial : 10 FL SYS. PRESS. Max Flow 2 P
MODEL RPM kW (PS disconnec) (at 0 sys press.)
Connect a gauge to the pump delivery
pressure tap
345C 1800 257 19150 720 +/-6L
Screw counterclockwise by tree turns
the Main Relief Valve 365C 1800 323 21820 800 +/-12L
Disconnect the PS pressure solenoid
Activate the Main Menu - Performance - RIGHT PUMP POWER SHIFT (PS) 385C 1800 413 22100 1008 +/-12L
MESSAGE
ENG SPEED PRESS. TAP PRESSURE CENTER
Slowly actuate "Stick in" and hold the CONNECTOR
joys tick in this position.
Observe the Eng. rpm on Center Display BOOST
while turning clockwise the Main Relief PRESSURE
Valve, when the Eng. rpm decrease (As ref. only)
to the Full load rpm. the system press.
should be between 18650 and 19650 kPa
and the boost press. 120.7 - 163.3 kPa (as
a ref. only)

Tool Required : KEYPAD

Wrench 27
Hex Wrench 3/8

OK

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 CHAPTER : Lab Exercises

345C MAIN PUMP DE STROKING PRESSURE TEST

SYSTEM PROCEDURES SPECS (kPa) ACTUAL

HORSEPOWER
ADJ SCREW ACTUATOR
ACTUATOR
Tetra
- QUICK TEST - Gauge PRESS. TAP 500 to 600 kPa
RIGHT
MAIN PUMP DIS. PRESS.
13600+/-500
DE STROKING PRESSURE
(Reference Point) ACTUATOR
Pressure 500 to 600 kPa
Gauge LEFT
Test Preparation : (60000 kPa) DIS. PRESS.
Oil temp. 55 13600+/-500
Dial : 5
Install fabricated cover block Cover Block
Screw counterclockwise by tree turns
the Main Relief Valve DE STROKING PRESSURE CHART
Connect a gauge to the pump delivery
pressure tap of the pump been tested SYS. PRESS. PS PRESS. ACTUATOR
MODEL (required) PRESS.
Connect a gauge to the Power Shift (required)
pressure tap 345C 13600 1690 500 to 600 kPa
Connect a tetra gauge to the actuator RIGHT PUMP
PRESS. TAP Pressure
pressure tap of the pump been tested Gauge 365C 16400 1470 10 to 50 kPa
From the monitor, activate the Main Menu - (6000 kPa)
Service - Devise Test - and select Power 385C 15590 1520 10 to 50 kPa
Shift Pres
Input a power shift press. of 1690 kPa at the
power shift pressure gauge. MESSAGE
CENTER
Slowly actuate "Stick in" and hold the
joys tick in this position. MAIN
Observe the actuator press. gauge while RELIEF
turning clockwise the Main Relief Valve, VALVE
when actuator press. begins to increase KEYPAD
the Pump delivery press. should be
between 13100 and 14100 kPa.
Tools Required :
Wrench 36 + Wrench 24 (Power Adj. Screw)
Wrench 27 + Hex Wrench (Main Relief Valve) POWER SHIFT OK
PRESS. TAP

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 CHAPTER : Lab Exercises

365C/385C ENGINE PERFORMANCE TEST

SYSTEM PROCEDURES SPECS ACTUAL

SIGNAL FL RPM
RELIEF L-S SIGNAL PORT (A)
- QUICK TEST - VALVE 1800

(365C) SYSTEM
PRESS.
ENGINE PERFORMANCE 2 PUMPS 21320/
PRESSURE 22320 kPa
TEST
BOOST
(as a ref. only)
121.6 - 164.6 kPa *
Test Preparation :
ENGINE PERFORMANCE CHART
Oil temp. 55 FL SYS. PRESS. Max Flow 2 P
Dial : 10 L-S SIGNAL MODEL kW (PS disconnec) (at 0 sys press.)
PORT (B) RPM
Change the L-S signal line from position (A)
to position (B) Pressure 345C 1800 257 19150 720 +/-6L
Gauge
Connect a of 60000 kPa pressure gauge
(60000 kPa) 365C 1800 323 800 +/-12L
to the pump output pressure tap 21820
Start the engine and adjust Signal Relief
Valve 21820 kPa L-S SIGNAL LINE 385C 1800 413 22100 1008 +/-12L
With ET connected to Machine Electronic
ECM, activate override parameters, select MESSAGE BOOST
Impl. Pump Power Shift Press. Sol., input CENTER PRESSURE
the max. PS press. value (Amps) (As ref. only)
On the Monitor, activate the Main Menu -
Performance - Select Engine Speed.
Slowly actuate "Stick in" to stall it and hold
the joys tick in this position.
Observe the Eng. rpm on Center Display
should be at full load (1800 +/- 10 rpm)
Consider the boost pressure (121.6 -
164.6 kPa) as a reference only.
KEYPAD

Tool Required :

Wrench 24 + 3/8 Hex Wrench (Main Relief Valve)

REAR PUMP OK
PRESS. TAP *133.5 - 180.8 kPa for 385C

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 CHAPTER : Lab Exercises

MAIN HYDRAULIC PUMP MARGIN PRESSURE TEST

SYSTEM PROCEDURES SPECS ACTUAL

365C MARGIN PRESSURE TEST Diff. press. Gauche

FRONT 1960 +/- 100
Front Pump
Test Preparation : Load Sensing
Oil temp. 55 Signal Line REAR 1960 +/- 100
Dial : 10
Gain : Normal
Disconnect the Load Sensing line from the
regulator on the pump that is not being tested
Activate the Main Menu - Service - Status - Output
Status - select Boom Extend
Slowly move boom up joys tick until the display
reading value is 1.00* Amps. Hold the joys tick in Front Pump
this position. Margin Press.
Measure the pressure of the Differential Pressure Adj. Screw
Gauge
Screw in or out margin pressure adjustment
if the pressure value is out of specs Front/Rear
Pump
* 1.1 Amps depending on Machine Serial Number
Pressure Front Pump
Tools Required : Tap Load Sensing
Wrench 13 + Hex wrench 4 Pressure Tap

385C MARGIN PRESSURE TEST

Diff. press. Gauche FRONT 1960 +/- 100
Front/Rear
Test Preparation : Pump
Pressure
REAR 1960 +/- 100
Oil temp. 55 Tap
Dial : 10
Gain : Normal
Disconnect the Load Sensing line from the Front Pump
regulator on the pump that is not being tested Margin Press.
Activate the Main Menu - Service - Status - Output Adj. Screw
Status - select Boom Extend
Slowly move boom up joys tick until the display
reading value is 1.00 Amps. Hold the joys tick in
this position.
Measure the pressure of the Differential Pressure
Gauge
Screw in or out margin pressure adjustment
if the pressure value is out of specs Rear Pump
Margin Press.
Adj. Screw
Tools Required :
Wrench 17 + Hex wrench 5

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 CHAPTER : Lab Exercises

365D PUMP DE STROKING PRESSURE TEST

PROCEDURES SYSTEM
SIGNAL DE STROKING PRESSURE CHART
RELIEF L-S SIGNAL PORT (A)
- QUICK TEST - VALVE SYS. PRESS. PS PRESS. ACTUATOR
MODEL (required) PRESS.
(required)
345C 13600 1690 500 to 600 kPa

PUMP DE STROKING
365C 13500 1240 10 to 50 kPa
PRESSURE TEST Rear Pump Actuator “M1"
385C 15590 1520 10 to 50 kPa Pressure Connector

Test Preparation :
Oil temp. 55
Dial : 5
Install a pressure gauge to Main Pump delivery
pressure connector L-S SIGNAL Tetra
Install a Tetra Gauge to actuator “M1" pressure PORT (B) Pressure Gauge
connector of the pump been tested Gauge
Install a pressure gauge to Power Shift pressure (60000 kPa)
connector
Change the L-S signal line from Port (A) to Port (B)
Screw counterclockwise by tree turns the Signal
Relief Valve
Use the ET (Override Parameters) to set the Power L-S SIGNAL
Shift Pressure to 1240 kPa at the pressure gauge. LINE
Begin by entering 0.389 Amps approx.
Slowly actuate bucket close to stall and hold the Pressure Power Shift
joys tick in this position. Gauge Pressure
Observe the actuator ("M1") press. gauge while (6000 kPa)
turning clockwise the Signal Relief Valve, when
Connector
actuator press. begins to increase (tetra gauge :
10/50 kPa) the pump discharge press. should be
between 13000 and 14000 kPa.

Main Pump
Tool Required : Pressure
delivery
Wrench 24 + 3/8 Hex Wrench (Main Relief Valve) Connector

Rear Pump
Power Control
Adj. Screw

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 CHAPTER : Lab Exercises

385C MAIN PUMP DE STROKE PRESSURE TEST

PROCEDURES SYSTEM

MAIN PUMP Tetra DE STROKING PRESSURE CHART

Gauge
DE STROKING PRESSURE SYS. PRESS. PS PRESS. ACTUATOR
(Reference Point) Rear Pump Actuator MODEL (required) PRESS.
(required)
Pressure Connector
345C 13600 1690 500 to 600 kPa

- QUICK TEST -
365C 16400 1470 10 to 50 kPa

Adapter
Plate 385C 15590 1520 10 to 50 kPa

Test Preparation :

Dial : 5 Pressure
Oil temp. 55 Gauge
Install the adapter plate (actuator pressure (60000 kPa)
connector). Details on page ??
Install a pressure gauge to Main Pump delivery
pressure connector
Install a Tetra Gauge to actuator pressure Front/Rear Main Pump
connector of the pump been tested Rear Pump Delivery Pressure
Install a pressure gauge to Power Shift pressure Power Control
Connector
connector Adj. Screw
Change the L-S signal line from Port (A) to
Port (B)
Screw counterclockwise by tree turns the Signal
Relief Valve L-S SIGNAL
Use the ET (Override Parameters) to set the LINE
power Shift Pressure to 1520 kPa at pressure
gauge. Begin by entering 0.430 Amps approx.
Slowly actuate bucket close to stall and hold the
joys tick in this position.
Observe the actuator press. gauge while turning
clockwise the Signal Relief Valve, when L-S SIGNAL
actuator pressure begins to increase (tetra PORT (B)
gauge : 10/50 kPa) the pump discharge pressure
should be between 15090 and 16090 kPa.
L-S SIGNAL
PORT (A)
PS port connection Pic Missing
Tools Required :
Wrench 36 & 24 (for power screw)
wrench 29+ Screw Driver (for LRV)
SIGNAL
RELIEF
VALVE

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 CHAPTER : Lab Exercises

385C MAIN PUMP DE STROKE PRESSURE & ENGINE PERFORMACE TEST

Tooling

8T8902

2 x 6V3965

8T1905
4 x 9X2537
5 x 206-9289
6V8730 6V8636

6V9829 6V9508

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 CHAPTER : Lab Exercises

SYSTEM PROCEDURES SPECS ACTUAL

Pressure
Gauge
(6000 kPa)
PILOT 4100 +/- 100
PILOT PRESSURE PRESSURE

Test Preparation :
Oil temp. 55 HYD.
Dial : 10 PRV LOCK
2 Spd
Gain : Normal Mode
AEC switch in position 1 (Max RPM)

PILOT
Tools Required : MANIFOLD

Wrench 16 mm
Allen Wrench 5 mm PILOT
PRESSURE
TAP ADJ.
NOTE : SCREW
A full turn changes the pressure by
690 kPa approx.

Stick HIGH BOOM

LINE RELIEF VALVES (rod) SIG. RV Boom
LOW (rod) BUCKET 37000 +/-
Test Preparation : FRONT SIG. RV 490
Bucket STICK
Oil temp. 55 (365C)
Gain : Normal Mode (rod)
OUT
TRAVEL 39200 +/-
Select engine speed dial 2 (this selection Crossover) 1470
depends on main pumps condition)
REV REV LOWER OPEN OPEN

Turn the adjustment screw clockwise on

High
R7X R2
signal relief valve for 1 full turn
HPC-ON

Move joystick of the LRV circuit been tested R5

HPC-OFF
R6X Pressure
to stall, hold the joystick in this position. Gauge
FWD FWD IN CLOSE CLOSE
(60000 kPa)
Check the pressure. The recorded pressure
value is the actual Line Relief Valve setting Stick
(head) RAISE
REAR PUMP
Note : don’t blow the line relief valve for
more than 10 seconds PRESSURE
Boom
Tools Required: (head) LEFT SIDE
R-TRV L-TRV STK BM BK ATTCH

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 CHAPTER : Lab Exercises

SYSTEM PROCEDURES SPECS ACTUAL

SIGNAL RELIEF VALVES HIGH 35000 +/- 500

HIGH LOW 32000 +/- 500
SIG. RV
Test Preparation :
FRONT LOW
Oil temp. 55
Dial : 10 SIG. RV
Gain : Normal
RIGHT SIDE
OUT
BLOCK VALVE
Digging Mode (Low)

Select Digging Mode. REV REV LOWER OPEN OPEN

Move joy stick to the full Bucket Close R7X R2

position. Maintain this position HPC-ON

Pressure
HPC-OFF
R6X
Gauge
R5
Check/Adj. the Low Signal Relief Valve (60000 kPa)
FWD FWD IN CLOSE CLOSE
Heavy Lift Mode (High)

Select Heavy Lift Mode LEFT SIDE RAISE

BLOCK VALVE REAR PUMP

Move joy stick to the full Boom Up PRESSURE
position. Maintain this position

Check/Adj. the High signal Relief Valve

R-TRV L-TRV STK BM BK ATTCH

Tools Required :

NOTE :
A full turn changes the pressure by
Implements : 10600 kPa approx. LEFT SIDE
Travel : 7050 kPa approx

LEFT
SWING MOTOR Tools Required :
MOTOR
Pressure
Test Preparation : Gauge 28950 +/- 980
(60000 kPa) RIGHT
Disconnect the swing brake solenoid MOTOR
Turn left motor relief valves adjustment
screw clockwise by 90 degrees

Slowly move the joy stick to the full right/ NOTE :

left swing operation and check the pressure A full turn of plugs changes the
for the relief valve of the right/left Motor pressure by 10000 kPa approx. Pressure Tap

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