325 A FM L XIM Hydraulic System Testing and Adjusting

325, 325L EXCAVATOR 7LM00001-UP (MACHINE) POWERED BY 3...
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Product: EXCAVATOR
Model: 325-A FM L EXCAVATOR 7LM00001
Configuration: 325, 325L EXCAVATOR 7LM00001-UP (MACHINE) POWERED BY 3116 ENGINE
Testing and Adjusting

325, 325L, AND 325N 325LN EXCAVATORS HYDRAULIC AND ELECTRONI
Media Number -SENR5406-01Publication Date -01/12/1993Date Updated -26/06/2007
SENR54060003
Hydraulic System Testing And Adjusting
General Information
NOTE: This manual is divided into the following three main sections:
1. Electronic System Testing And Adjusting

2. Checking Procedures
3. Hydraulic System Testing And Adjusting
NOTE: As a general rule, if there is a doubt as to the cause of a problem, the electronic
system should be checked first.
Reference: For information on Systems Operation of the above, make reference to:
"Systems Operation, Electronic System", Form NO. SENR5404 and/or "Systems
Operation, Hydraulic System", Form NO. SENR5405.
Introduction
This manual contains information on the troubleshooting procedures of the electronic
control and hydraulic systems in the 325, 325 L, and 325 N Excavator. For
troubleshooting the engine components, refer to the module Systems Operation,
Testing And Adjusting, Basic Engine Components 3116 Engine, Form No. SENR3583.
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Checking Procedures
In each checking procedure, it is assumed that the engine operation is normal unless
otherwise specified.
Electronic Control System
The monitor and electronic controller are the main components of the electronic control
system. The monitor and electronic controller have a self diagnostic function. Self
diagnostic checks of the monitor, electronic controller, and the communication line
between them are the first steps when troubleshooting the problem(s) in the electronic
system.
Action alarm indicators on the monitor panel, alert an operator to a problem in the
electronic system. The controller service program "Data Mode" can also be used to
identify the problems (see the section of this module "Data Mode"). If the service
program is activated during machine operation, problem(s) that are monitored by the
monitoring system are indicated on the character display. If the service program is
activated when the machine operation is stopped, all existing problems and past
problems (problems that have not been corrected) are indicated on the character
display. To activate the controller service program "Data Mode", refer to the "Data
Mode" section in this module.
Operational Tests
If the electronic power unit control system display indicates it is operating correctly,
then do operational tests. Operate the machine, following the procedures described in
the section "Hydraulic System Testing And Adjusting". Compare the results of the
operational tests with specifications to determine the extent of the trouble. In
operational tests, it is important to determine whether or not enough hydraulic force or
implement speed is a problem that extends over the entire machine or with only a
specific operation.
If there are any faults in the circuits between the main or pilot pumps and the control
valves, the overall performance of the machine will decrease. This type of problem in
the hydraulic system is not detected by the self diagnostic functions of the electronic
control system described above (no action alarm indication on character display.). To
detect such a problem, it is necessary to check the flow characteristics of the pumps,
the main relief pressure, pilot pressure, etc.
Introduction
Hydraulic oil pressure can remain in the hydraulic systems

on this machine after the engine and pump have been
stopped. Serious injury can be caused if this pressure is not
released before any service is done on the hydraulic systems.
To prevent possible injury, refer to section, Release Of
Pressure In The Hydraulic System, before any fitting, hose or
component is loosened, tightened, removed or adjusted.
When possible, the bucket must always be lowered to the

ground before service is started. When it is necessary for the
boom to be in the raised position while tests or adjustments
are done, be sure that boom, stick and bucket have correct
support.
Swing lock must be engaged before service is started.
Always move the machine to a location away from the travel

of other machines. Be sure that other personnel are not near
the machine when the engine is running and tests or
adjustments are being made.
During diagnosis of the hydraulic system, remember that correct oil temperature, flow,
and pressure are necessary for correct operation. Pump output (oil flow) is a function of
engine speed (rpm). Oil pressure is caused by resistance to the flow of oil.
Visual Checks
A visual inspection of the system is the first step when troubleshooting a problem.
Make the inspection with the engine off and the implements lowered to the ground.
1. Check the level of the oil in the hydraulic tank. Slowly loosen the hydraulic tank air
vent plug and release the pressure before the filler cap is removed.
2. Remove the filter element and check it for material that would give an indication of
damage to a component.
3. Inspect all lines and connections for damage or leaks.
4. Inspect control linkage for bent, broken, or damaged components.
Checks During Operation

The checks during operation can be used to find leakage in the system. They can also
be used to find a valve, pump, motor, or cylinder that is not working correctly. The
speed of rod movement or the torque on a motor can be used to check the condition of
the cylinders, motors, and pumps.
Operational Tests
NOTE: For specifications given in "Operational Tests", a "NEW" specification is the
performance that can be expected for a new machine. A "REBUILD" specification is
the performance target to use after rebuilding the components of a system. A machine
that performs beyond "SERVICE LIMIT" specifications should be checked for
improper maintenance or adjustment, component wear, or failure.
Specifications given in charts for a machine equipped with 6150 mm (20 ft 2 in) boom,
3200 mm (10 ft 6 in) stick, and SAE 1.1 m3 (1-1/2 yd3) bucket.
NOTE: The power mode selector switch must be placed at Mode III position, unless
otherwise specified, during tests.
Operational Test Preparations
1. Engine speed:
Excavator with no load at high idle, 2050 ± 50 rpm
2. Hydraulic oil temperature: 55 ± 5°C (131 ± 9°F)
NOTE: Fully move the stick in and out several times until the normal hydraulic
oil temperature is reached.
3. Relief valve pressure settings are set according to specification.
Reference: Make reference to the section in this module "Relief Valves",

"Specifications".
Travel Test On Level Ground
Test Preparation:
1. Set engine speed and increase the hydraulic oil to normal operating temperature.
Reference: Make reference to the section "Operation Tests Preparation"
2. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft)
long.
4. Draw a 25 m (82.5 ft) straight line on travel test ground as a reference line.
5. Position the machine so that one track is in line (parallel) with the reference line. Put
the machine in the travel test position as shown in the illustration.
6. The bucket must be empty.
Test Procedure:
1. Start the engine and place the power mode selector switch in mode III position. Place
the engine speed dial at position "10" and the travel speed switch in HIGH (rabbit)
position. Move the machine by operating both travel levers at the same time.
2. The first 5 m (16.5 ft) are for a preliminary run. Measure the time required for the
machine to travel the remaining 20 m (66 ft) in each direction (FORWARD and
REVERSE).
3. Measure the travel deviation from the reference line.
4. Repeat the above procedure with the travel speed switch in LOW (turtle) position.
NOTE: The following chart represents the time (in seconds) it should take to complete
the 20 m (66 ft) test run:
NOTE: The following chart represents the travel deviation from the reference line:
Travel On Level Ground (Optional Test)

NOTE: If suitable ground (as stated in Step No.2 in "Test Preparation" for "Travel On
Level Ground") cannot be found, the following test should be done as a substitute.
Test Preparation:
2. Place the machine on level ground.
3. Raise a track for the test as shown in the illustration.
4. Put a mark on a shoe of the raised track.
Test Procedure:
1. Start the engine and place the power mode selector switch in power Mode III
position. Run the raised track with the engine speed dial at position "10" (high idle) and
the travel speed switch in HIGH (rabbit) position.
2. Measure the time required for the track to make three complete turns (revolutions) in
each direction (FORWARD and REVERSE).
3. Repeat the above procedure with the travel speed switch in LOW (turtle) position.
Drift On Slope
Measuring the amount of drift of the machine on a slope will determine if there is a
need to check the travel brake.
Test Preparation:
1. Place the machine on a slope of 12°. The slope surface must be hard and smooth.
2. Put the implements in the position shown in the illustration.
3. Bucket should be empty.
Test Procedure:
325, 325L EXCAVATOR 7LM00001-UP (MACHINE) POWERED BY... Page 10 of 56
1. Put marks on both track and ground to indicate its relative position to the slope.
2. Stop the engine and time three minutes (using a stopwatch).
3. Measure (with a scale) the distance the tracks have moved on the slope.
Swing Speed And Over Swing (On Level Ground)
Measuring the swing speed and over swing of the machine will determine if there is a
need to check the swing motor and/or anti-reaction valve.
Test Preparation:
2. Place the machine on level ground as shown in the illustration.
3. Put marks on both inner and outer races of the swing bearing to indicate relation of
two positions.
4. The bucket should be empty.
Test Procedure (Over Swing):
1. Start the engine and place the power mode selector switch in power Mode III
position. Place the engine speed dial at position "10" (high idle).
2. Move the swing control lever to the RIGHT or LEFT until the machine completes a
360° swing operation. Return the swing control lever to the NEUTRAL position at the
end of the 360° swing operation and measure the amount of over swing by measuring
the distance between the marks on the swing bearing.
NOTE: Use a reference point that is visible from the operator's seat as a indicator of
when to stop the 360° rotation.
Test Procedure (Speed):
1. Move the swing control lever to the LEFT or RIGHT and measure the time it takes
to complete a 180° swing operation.
Swing Speed And Drift (On A Slope)
Measuring the swing speed on a slope will determine if there is a need to check the
swing motor and/or anti-reaction valve. Measuring the swing drift on a slope will
determine if there is a need to check the swing parking brake.
Test Preparation:
1. Place the machine on a 12° slope.
2. Place the implements at maximum reach and fill the bucket with soil. The bucket
should be positioned above the ground to clear any obstructions.
Test Procedure (Speed):
1. Stop the machine on a slope of 12°. Place the upper structure at a 90° angle to the
lower structure as shown in the illustration.
2. Measure the time needed to swing the upper structure 90° counterclockwise. Do the
same for a 90° swing clockwise.
Test Procedure (Drift):
1. Stop the machine on a slope of 12°.
2. Place the upper structure at a 90° angle to the tracks as shown in the illustration.
3. Put marks on the inner and outer races of the swing bearing.
4. Stop the engine.
5. Leave the machine in this position for three minutes, and measure swing drift on the
circumference of the swing bearing.
6. Rotate the upper structure 180° from the original position as described in Step 1.
7. Repeat Steps 2 through 5.
Test Procedure (Drift):
1. Stop the machine on a slope of 12°.
2. Place the upper structure at a 90° angle to the tracks as shown in the illustration.
3. Put marks on the inner and outer races of the swing bearing.
4. Stop the engine.
5. Leave the machine in this position for three minutes, and measure swing drift on the
circumference of the swing bearing.
6. Rotate the upper structure 180° from the original position as described in Step 1.
7. Repeat Steps 2 through 5.
Cylinder Drift
Test Preparation:
2. Place the machine on level ground as shown in the illustration.
3. Fill the bucket with soil.
Test Procedure (For Boom And Stick Cylinders):
1. Fully extend the bucket cylinder.
2. Fully retract the stick cylinder.
3. Raise the boom until its upper surface becomes parallel to the ground.
4. Measure each cylinder's length from pin to pin.
5. Stop the engine.
6. Leave the machine in this position for three minutes, then measure each cylinder's
length from pin to pin for drift.
Test Procedure (For Bucket Cylinder):
1. Fully extend the bucket cylinder.
2. Raise the boom high enough until the stick is perpendicular to the ground.
3. Measure each cylinder's length from pin to pin.
4. Stop the engine.
5. Leave the machine in this position for three minutes, then measure each cylinder's
length from pin to pin for drift.
Cylinder Operating Speed
Test Preparation:
1. Place the machine on level ground.
2. Bucket must be empty.
Test Procedure (Boom Cylinders):
1. Fully retract bucket and stick cylinders.
Extension test;
Measure the time required for the boom cylinders to reach full extension position
starting with the bucket on the ground.
Retraction test;
Measure the time required for the bucket to come in contact with the ground from the
full extension position of the boom cylinders.
Test Procedure (Stick Cylinder):
1. Position the upper surface of the boom parallel to the ground and fully extend the
bucket cylinder.
Extension test;
Measure the time required for the stick cylinder to reach full extension position from
full retraction position.
Retraction test;
Measure the time required for the stick cylinder to reach full retraction position from
full extension position.
Test Procedure (Bucket Cylinder):
1. Position the upper surface of the boom parallel and the stick perpendicular to the
ground.
Extension test;
Measure the time required for the bucket cylinder to reach full extension position from
full retraction position.
Retraction test;
Measure the time required for the bucket cylinder to reach full retraction position from
full extension position.
Release Of Pressure In The Hydraulic

System
Release the pressure in the implement hydraulic circuits (boom, stick, and bucket)
before any hydraulic lines or components are disconnected or removed.
1. Fully retract the stick cylinder rod.
2. Adjust the position of the bucket so that it will be flat on the ground when the boom
is lowered.
3. Lower the boom until the bucket is flat on the ground.
4. Shut off the engine and put the hydraulic activation control lever in the UNLOCK
position.
5. Move the control levers for boom, stick, and swing to all full stroke positions. This
will release any pressure that might be present in the pilot system.
6. Slowly loosen the air vent plug on the hydraulic tank and release the pressure.
7. Tighten the air vent plug on the hydraulic tank.
8. The pressure in the hydraulic system has been released and lines and components
can be removed.
Pressure Adjustment
Specifications
NOTE: A new or rebuilt machine must perform according to NEW or REBUILD
specifications. A machine that performs beyond SERVICE LIMIT specifications must
be checked for improper adjustment, wear, or damage of relief valves or pumps.
Adjustment Procedures
NOTE: Values given above are approximate. Use a pressure gauge for adjustment.
Relief Valve Adjustment Preparation
Pump Compartment
(1) Tap (power shift pressure). (2) Tap (upper pump). (3) Tap (lower pump).
1. Place the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure
In The Hydraulic System".
3. Connect a 49 000 kPa (7100 psi) pressure gauge to either the main pump tap (2) or
tap (3).
4. Connect a 4900 kPa (700 psi) pressure gauge to tap (1).
5. Start the engine and move the stick IN and OUT to its full travel position. Do this
operation several times until the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°
F).
6. Place the power mode selector switch in Mode III position.
7. Place the engine speed dial at position "10". Check that engine speed under no load
is at 2050 ± 50 rpm with AEC switch in the OFF position. (Read rpm 3 seconds after
the speed dial switch has been placed in position "10".)
NOTE: See the section, "Operational Test Preparations" for the specified engine rpm
for dial position "10".
NOTE: Normal operations (see characteristic curve) of the engine and pumps are
necessary for the pressure adjustment. If the results of the pressure adjustment are not
correct, then the engine and pump characteristic curve needs to be checked.
Temporary Setting Of The Main Relief Valve Pressure
NOTE: The purpose for "Temporary Setting Of The Main Relief Pressure" is done so
implement line relief valves and travel relief valves can be adjusted.
Top Of Main Control Valves

(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.
1. Slowly move the bucket control lever to the bucket open position (full cylinder rod
retraction).
2. Check to be sure the main relief valve pressure setting is 31 400 ± 490 kPa (4550 ±
72 psi).
NOTE: Always make final pressure adjustments on pressure rise.
3. Loosen locknut (5) and turn plunger (4) clockwise until it bottoms out. Tighten
locknut (5).
4. Loosen locknut (7) and turn adjuster (6) clockwise a quarter turn. Tighten locknut
(7).
Adjustment Of Line Relief Valve Pressure
Preparation
1. Start the service program "Calibration Mode" and keep the power shift pressure
constant at 2950 kPa (430 psi). Read the pressure gauge attached at tap (1) to monitor
the power shift pressure.
NOTE: For further information of "Calibration Mode", see the section in this module
"Calibration Mode".
NOTE: During line relief adjustment, do not turn the engine OFF to prevent a change
in power shift pressure.
2. Use the pressure gauge at tap (2) to read the line relief pressure for boom and bucket
circuits. Use the pressure gauge at tap (3) to read the line relief pressure for stick
circuit. For line relief pressure settings for the implement circuits see the section,
"Pressure Adjustment, Specifications".
NOTE: After adjustment of the line relief valves, return the main relief pressure to its
normal setting.
Main Control Valve Compartment (Viewed From Machine Front)

(9) Line relief valve (bucket cylinder head end). (10) Line relief valve (stick cylinder head end).
NOTE: Rod end line relief valves of boom, stick, and bucket are located under the
main control valves.
Right Front Of Swing Motor

(11) Boom drift reduction valve. (12) Line relief valve (boom cylinder head end).
Line Relief Valve (typical all cylinders)

(13) Locknut. (14) Screw.
Adjustment (Stick Cylinder)
1. To adjust the pressure in the stick cylinder rod end, move the stick control lever to
full stick OUT (rod retracted) position. Check the pressure in the stick cylinder rod end
at tap (3).
2. Return the stick control lever to the NEUTRAL position. Loosen locknut (13) and
turn screw (14) until line relief valve pressure at tap (3) reads 33 800 ± 1470 kPa (4900
± 215 psi). Turning screw (14) clockwise increases the pressure and turning screw (14)
counterclockwise decreases the pressure.
3. To adjust the pressure in the stick cylinder head end, move the stick control lever to
full stick IN (rod extended) position. Check the pressure at tap (3).
4. Return the stick control lever to the NEUTRAL position. Adjust the line relief valve
pressure in the same manner as the stick rod end.
NOTE: Always make final pressure adjustment on pressure rise.
Adjustment (Bucket Cylinder)
1. To adjust the pressure in the bucket cylinder head end, move the bucket control lever
to full bucket CLOSE (rod extended) position. Check the pressure in the bucket
cylinder head end at tap (2).
2. Return the bucket control lever to the NEUTRAL position. Adjust the line relief
valve pressure in the same manner as described for the stick cylinder.
3. To adjust the pressure in the bucket cylinder rod end, move the bucket control lever
to full bucket OPEN (rod retracted) position. Check the pressure at tap (2).
valve pressure to 33 800 ± 1470 kPa (4900 ± 215 psi) using the same procedure as that
described for the stick cylinder.
Adjustment (Boom Cylinder)
1. To adjust the pressure in the boom cylinder head end, move the boom control lever
to full boom RAISE (rod extended) position. Check the pressure in the boom cylinder
head end at tap (2).
valve pressure in the same manner as described for the stick cylinder.
3. To adjust the pressure in the boom cylinder rod end, move the boom control lever to
full boom DOWN (rod retracted) position. Check the pressure at tap (2).
4. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve
pressure to 33 800 ± 1470 kPa (4900 ± 215 psi) using the same procedure as that
described for the stick cylinder.
NOTE: If an appropriate location is not available for full retraction of the boom
cylinder, reverse the line relief valves of the head end and rod end by switching the
valves. Adjust the pressure of the line relief valve now attached in the head end. Once
adjusted, return the respective relief valves to their original positions and cancel the
function of the service program "Calibration Mode". Refer to the section in this
module, "Calibration Mode Stop Procedure".
Travel Crossover Relief Valve Adjustment
Sprocket (Left Track)

(16) Sprocket. (17) Stopper.
Travel Brake Valve (Left Track)

(18) Screw. (19) Locknut. (20) Crossover relief valve (forward left travel). (21) Crossover relief valve
(reverse left travel).
Pump Compartment
Preparation
1. Start Service Program "Calibration Mode" and maintain power shift pressure at 2950
kPa (430 psi). Read the pressure gauge at tap (1) for the power shift pressure settings.
NOTE: During this test, to prevent a change in power shift pressure do not turn the
engine start switch to OFF position.
2. Block forward left travel, by putting stopper (17) in position on the gear of sprocket
(16), as shown above.
Adjustment Procedure
1. Slowly move the left travel control lever to full FORWARD position and check the
pressure of crossover relief valve (20) at tap (3).
2. Return the control lever to the NEUTRAL position and adjust relief valve pressure.
To adjust crossover relief valve (20), loosen locknut (19) and turn screw (18) until the
pressure gauge at tap (3) reads 36 800 ± 1470 kPa (5350 ± 215 psi).
3. Tighten locknut (19) to a torque of 44 ± 5 N·m (32 ± 4 lb ft).
4. Position stopper (17) to block reverse left travel.
5. Slowly move the left travel control lever to full REVERSE position and check the
pressure of crossover relief valve (21) at tap (3). Adjust the pressure of crossover relief
valve (21) in the same manner as described for crossover relief valve (20).
6. Adjust the pressure of crossover relief valves of right travel motor in the same
manner as described for the left travel motor. Use the pressure gauge at tap (2) to read
the pressure.
7. After completion of adjustment, stop the function of the service program

"Calibration Mode". Refer to the section "Calibration Mode Stop Procedure".
Swing Motor Relief Valve Pressure Adjustment
Swing Motor Compartment

(22) Relief valve (right swing). (23) Relief valve (left swing). (24) Locknut. (25) Plug.
Preparation
2. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (3).
3. Start the engine and place the engine speed dial at position "10" with the power
mode selector switch at Mode III position.
4. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).
5. Place the swing lock pin in the LOCKED position (if equipped), or engage the swing
brake.
1. Slowly move the swing control lever for a full RIGHT swing operation and check
the pressure of relief valve (22).
2. Return the swing control lever to the NEUTRAL position. Loosen locknut (24) and
turn plug (25) until line relief valve pressure at tap (3) reads 29 400 ± 980 kPa (4250 ±
140 psi). Turning plug (25) clockwise increases the pressure and turning plug (25)
3. To adjust the relief pressure for left swing, slowly move the control lever to a full
LEFT swing operation and check the pressure of crossover relief valve (23).
4. Return the swing control lever to the NEUTRAL position. Adjust the relief valve
pressure in the same manner as the swing right relief valve.
NOTE: Always make final pressure adjustment on the pressure rise.
Main Relief Valve Adjustment
NOTE: Pressure adjustments to the main relief valve should be done by first adjusting
the travel operation of the main relief valve and then adjusting the implement operation
of the main relief valve. Any adjustment to the travel operation of the main relief valve
will change the pressure setting to the implement operation of the main relief valve.
Top Of Main Control Valves

(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.
Preparation
2. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (3).
3. Start the engine and place the engine speed dial at position "10" with the power
mode selector switch at Mode III position.
4. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).
Adjustment Procedure (In Travel Operation)

1. Block forward left travel by putting stopper (17) in position on the gear of sprocket
(16).
Pump Compartment
2. Slowly move the left travel control lever to full FORWARD position and check main
relief valve pressure at tap (3).
3. Return the control lever to the NEUTRAL position.
4. Loosen locknut (7) and turn adjuster (6) until the pressure gauge at tap (3) reads 34
300 ± 490 kPa (5000 ± 72 psi). Tighten locknut (7) to a torque of 59 ± 10 N·m (44 ± 7
lb ft).
Reference: Turning plunger (4) clockwise increases the pressure. Turning plunger (4)
Adjustment Procedure (Implement Operation)
1. Slowly move the control lever to full bucket OPEN (bucket cylinder full retraction)
position and check the main relief valve pressure at tap (2).
2. Return the control lever to the NEUTRAL position and adjust main relief valve
pressure to 31 400 ± 490 kPa (4550 ± 72 psi).
3. To adjust, loosen locknut (5) and turn plunger (4) until the pressure gauge at tap (2)
reads 31 400 ± 490 kPa (4550 ± 72 psi). Tighten locknut (5) to a torque of 50 ± 10 N·m
(37 ± 7 lb ft).
Reference: Turning plunger (4) clockwise increases the pressure. Turning plunger (4)
Pilot Relief Valve Adjustment
Preparation
Pilot Oil Manifold Compartment

(26) Pilot relief valve. (27) Tap. (28) Locknut. (29) Screw.
1. Place the machine on level ground and stop the engine.
3. Connect a 49 000 kPa (7100 psi) pressure gauge to either the main pump tap (2) or
tap (3).
4. Connect a 4900 kPa (700 psi) pressure gauge to tap (1) and tap (27).
5. Start the engine and move the stick IN and OUT to its full travel position. Do this
operation several times until the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°
F).
6. Place the power mode selector switch in Mode III position.
7. Place the engine speed dial at position "10". Check that engine speed under no load
is at specified rpm with AEC switch in the OFF position. (Read rpm 3 seconds after the
speed dial switch has been placed in position "10".).
NOTE: See the section, "Operation Test Preparations" for the specified engine rpm for
dial position "10".
NOTE: Normal operations (see characteristic curve) of the engine and pumps are
necessary for the pressure adjustment. If the results of the pressure adjustment are not
correct, then the engine and pump characteristic curve needs to be checked.
1. Loosen locknut (28) of pilot relief valve (26).
2. Turn screw (29) until the pressure gauge reads 3450 + 200 - 0 kPa (500 + 39 - 0 psi).
Reference: Turning screw (29) clockwise increases the pressure and turning screw (29)
Adjustment Of Automatic Travel Speed Travel Change Valve
Preparation
1. Reset main relief valves. Refer to the section, "Main Relief Valve Adjustment".
Pump Compartment
(1) Tap (lower pump).
3. Install 49 000 kPa (7100 psi) pressure gauge at tap (1) of the rear pump.

(2) Tap.
4. Install 4900 kPa (700 psi) pressure gauge at tap (2) of pilot oil manifold.
Travel Motor (Left Track)

(3) Hose assembly. (4) Tee. (5) Signal line (two speed travel). (6) Elbow (two speed travel port).
5. Disconnect signal line (5) from the travel motor. Install tee (4) (8T8902) on elbow
(6) that the signal line was removed from and connect signal line (5) to tee (4). Attach
nipple (6V3965) and O-ring seal (3J1907) to tee and install 4900 kPa (700 psi) pressure
gauge to the nipple with test hose assembly (6V3014) and coupler assembly (6V4143).
6. Start the engine and raise the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).
7. Place the power mode selector switch in power Mode III position and maintain the
maximum no load speed of 2050 ± 50 rpm with AEC switch OFF.

8. Block the forward left travel by putting stopper (8) in position on the gear of
sprocket (7), as shown above.
9. Place the travel speed control switch in HIGH (rabbit) position.
10. The pressure gauge at tap (2) should read 3450 kPa (500 psi).

(9) Automatic travel speed change valve. (A) Viewed from (A) side.
Automatic Travel Speed Change Valve (Viewed From A)

(9) Automatic travel speed change valve. (10) Screw. (11) Locknut.
1. While reading the pressure gauges connected to the signal pressure line (5) and at tap
(1), slowly move the left travel control lever/pedal to the FORWARD position. When
the pressure at tap (1) reads 32 400 ± 980 kPa (4700 ± 140 psi), the pressure gauge
connected to signal line (5) should reduce to 0 kPa (0 psi).
NOTE: These pressures indicate that the automatic travel speed change valve has
caused the travel motor to shift to LOW (tortoise) speed.
2. Slowly return the left travel control lever/pedal to the NEUTRAL position.
3. If the pressure gauge connected to signal line (5) does not read 0 kPa (0 psi) at the
time the system pressure at tap (1) reads 32 400 ± 980 kPa (4700 ± 140 psi), then adjust
automatic travel speed change valve (9) as follows:
a. Loosen locknut (11) and turn screw (10) until the pressure gauge connected to line
(5) reads 0 kPa (0 psi) when the pressure gauge at tap (1) reads 32 400 ± 980 kPa (4700
± 140 psi).
b. Tighten locknut (11) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).
NOTE: Turning screw (10) clockwise increases the pressure. Turning screw (10)
4. Repeat Step 1.
5. Slowly move the travel control lever/pedal towards the NEUTRAL position until the
pressure gauge at tap (1) decreases to 18 600 ± 980 kPa (2700 ± 140 psi). Now the
pressure gauge connected to signal line (5) will read 3450 kPa (500 psi).
NOTE: These pressures indicate when the automatic travel speed change valve causes
the travel motor to shift to HIGH (rabbit) speed.
Pump Flow Tests
Controller Compartment
(1) Controller alarm lamp. (2) Controller.
Right Console
(3) Monitor. (4) Monitor panel.
NOTE: Before starting pump flow tests, check the action alarm indicators on controller
(2) and monitor panel (4). If they indicate normal, then perform the operational tests.
NOTE: If operational tests (for example, cycle times) indicates that a slow implement
problem is common to the circuits of one pump, then the problem is most likely in the
hydraulic system. Then perform the "Pump Flow Tests".
NOTE: If the operational tests indicate a implement speed problem common to both
pump circuits, then the engine, fuel, or working altitude may be the problem.
Main Pump Constant Horsepower Control Test
Illustration Of Flow Meter Tool Layout 1 (Hydraulic Horsepower Control Test) (Main Pumps)
(1) Sleeve. (2) Reusable coupling. (3) O-ring seal. (4) Coupler. (5) Nipple. (6) Plug. (7) O-ring seal.
(8) Bolt. (9) Washer. (10) Adapter. (11) Flange. (12) Hose. (13) Delivery line (front pump). (14)
Delivery line (rear pump). (15) O-ring seal. (16) Cover. (17) Fitting. (18) Front pump. (19) Rear
pump. (20) Adapter. (21) O-ring seal. (22) Coupling assembly. (23) O-ring seal. (24) Tee. (25) Return
line. (26) Portable Hydraulic Tester. (27) Swing motor.
Preparation (Upper Pump)
Circuit Diagram For Flow Test (Hydraulic Constant Horsepower Control)(Upper Pump)
(12) Hose. (13) Delivery line (upper pump). (14) Delivery line (lower pump). (16) Cover. (18) Upper
pump. (19) Lower pump. (24) Tee. (26) Portable hydraulic tester (flow meter). (27) Swing motor. (28)
Main control valves. (29) Tap (upper pump). (30) Gauge. (31) Gauge. (32) Tap (power shift pressure).
(33) Tap (lower pump). (34) Multitach.
Pump Compartment
(12) Hose. (13) Delivery line (upper pump). (14) Delivery line (lower pump). (18) Upper pump. (19)
Lower pump. (29) Tap (upper pump). (32) Tap (power shift pressure). (33) Tap (lower pump).

(12) Hose. (24) Tee. (25) Return line. (27) Swing motor.
Portable Hydraulic Tester (Flow Meter)

(12) Hose (upper pump charge line). (26) Portable hydraulic tester (flow meter). (34) Multitach. (35)
Valve (flow meter).
To prevent personal injury or equipment damage from

failure of the flow meter or associated circuit components
because of blocked pump flow, make sure before starting the
engine that the flow meter valve is fully open (turned
counterclockwise).
1. Position the machine on level ground and stop the engine.
3. Install the following tools in accordance with flow meter tool layout illustration and
circuit diagram.
a. Disconnect delivery line (13) from upper pump (18).
b. Install cover (16), O-ring seal (15), flange (11), bolt (8), and washer (9) to the end of
delivery line (13).
c. Disconnect return line (25) from swing motor (27).
d. Install tee (24) and two O-ring seals (23) to the swing motor (27) return port.
Connect return line (25) to tee (24).
e. Connect portable hydraulic tester (26) between upper pump (18) and tee (24) with
two hoses (12).
f. Install pressure gauge (31) at power shift pressure tap (32). Install pressure gauge
(30) at upper pump tap (29). [A 49 000 kPa (7100 psi) pressure gauge can be used in
place of pressure gauge (31) and (30).] Tap (32) is used to measure the power shift
pressure. Taps (29) and (33) are used to measure the upper pump and lower pump
delivery pressure.
g. Install multitach group (34) on the engine. This is used to read engine speed.
4. Start the engine and place the power mode selector switch in Mode III position.
5. Place the engine speed dial at position "10" and maintain the maximum no load
speed at 2050 ± 50 rpm with the AEC switch OFF. (Read the rpm three seconds
elapsed time after the engine speed dial has been placed in position "10").
6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil
temperature, move the stick IN and OUT its full travel several times.
Preparation (Lower Pump)
Circuit Diagram For Flow Test (Hydraulic Constant Horsepower Control)(Lower Pump)
pump. (19) Lower pump. (24) Tee. (26) Portable hydraulic tester (flow meter). (27) Swing motor. (28)
Main control valves. (29) Tap (upper pump). (30) Gauge. (31) Gauge. (32) Tap (power shift pressure).
(33) Tap (lower pump). (34) Multitach.
Pump Compartment
(12) Hose (lower pump charge line). (19) Lower pump. (32) Tap (power shift pressure). (33) Tap
(lower pump).
Perform the same preparation as that described for the upper pump flow test under
constant horsepower control except Step 3. Use the following procedure in replacement
for Step 3, for the lower pump (19).
a. Disconnect delivery line (14) from lower pump (19).
delivery line (14).
e. Connect portable hydraulic tester (26) between lower pump (19) and tee (24) with
two hoses (12).
f. Install pressure gauge (31) at power shift pressure tap (32). Install pressure gauge
(30) at lower pump tap (33). [A 49 000 kPa (7100 psi) pressure gauge can be used in
place of pressure gauge (31) and (30).] Tap (32) is used to measure the power shift
pressure. Taps (29) and (33) are used to measure the upper pump and lower pump
delivery pressure.
g. Install multitach group (34) on the engine. This is used to read engine speed.
Test Procedure
NOTE: Perform the upper and lower pump flow tests one at a time.

engine that the flow meter valve (35) is fully open (turned
counterclockwise).
To prevent personal injury and/or equipment damage from

failed lines or components while the flow meter is returned to
the open flow position after a flow test, slowly open the flow
meter valve and monitor pump flow at the same time to make
sure flow increases. If pump flow does not increase as the

flow meter is opened, shut the engine off and determine what
is causing the pump not to upstroke.
1. With the engine running, start the service program "Calibration Mode" and maintain
the power shift pressure at a constant pressure of 1910 ± 50 kPa (270 ± 7 psi). The
power shift pressure is read at tap (32), using pressure gauge (31).
NOTE: During this test, do not turn the starter switch to the OFF position to prevent
any change in power shift pressure. See the section in this module "Calibration Mode
Stop Procedure".
NOTE: To start service program "Calibration Mode" see the section in this module
"Calibration Mode Start-up".
2. Slowly turn valve (35) of portable hydraulic tester (26) clockwise and record pump
flow at each of the following pressure points. Use pressure gauge (30) at tap (29) or
(33) for this pressure reading.
P-Q Characteristic Curve
NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To
get more accurate test results, each of measurements should be corrected by calculating
as follows.
Flow corrected = (Flow measured × 2000) ÷ RPM measured
1. Any flow readings must be done only in upstroke (pressure rise).
2. The pump flow changes approximately 10 liter/min. (2.6 U.S. gpm) for each 100 kPa
(14 psi) of power shift pressure.
Negative Flow Control Test
Illustration Of Flow Meter Tool Layout 1 (Negative Flow Control Test) (Main Pump)
(1) Sleeve. (2) Reusable coupling. (3) O-ring seal. (4) Coupler. (5) Nipple. (6) Plug. (7) O-ring seal.
(8) Bolt. (9) Washer. (10) Adapter. (11) Flange. (12) Hose. (13) Delivery line (front pump). (14)
Delivery line (rear pump). (15) O-ring seal. (16) Cover. (17) Fitting. (18) Front pump. (19) Rear
pump. (20) Adapter. (21) O-ring seal. (22) Coupling assembly. (23) O-ring seal. (24) Tee. (25) Return
line. (26) Portable Hydraulic Tester. (27) Swing motor.
Preparation (Upper Pump)
Circuit Diagram For Negative Flow Control Test (Upper Pump)

pump. (19) Lower pump. (26) Portable hydraulic tester (flow meter). (27) Swing motor. (28) Main
control valves. (29) Tap (upper pump). (30) Gauge. (31) Gauge. (32) Tee. (33) Tap (lower pump).
(34) Multitach. (36) Negative flow control line (upper pump). (37) Plug. (38) Hose assembly. (39)
Pilot oil manifold. (40) Tap. (41) Negative flow control line (lower pump).
Pump Compartment
(12) Hose. (13) Delivery line (upper pump). (14) Delivery line (lower pump). (18) Upper pump. (19)
Lower pump. (29) Tap (upper pump). (32) Tap (power shift pressure). (33) Tap (lower pump).

(12) Hose. (24) Tee. (25) Return line. (27) Swing motor.
Portable Hydraulic Tester (Flow Meter)

(12) Hose (upper pump charge line). (26) Portable hydraulic tester (flow meter). (34) Multitach. (35)
Valve (flow meter).
Pump Compartment
(39) Pilot oil manifold. (40) Tap. (46) Pilot relief valve.
Illustration Of Tool Layout 2 (Negative Flow Control Test) (Main Pump)

(7) O-ring seal. (18) Upper pump. (19) Lower pump. (31) Gauge. (32) Tee. (36) Negative flow
control line (upper pump). (37) Plug. (38) Hose assembly. (39) Pilot oil manifold. (40) Tap. (41)
Negative flow control line (lower pump). (42) Nipple. (43) O-ring seal. (44) Cap. (45) Coupler
assembly.
1. Position the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. See the section in this module "Release
Of Pressure In The Hydraulic System".
3. Install the following tools in accordance with flow meter tool layout illustrations and
circuit diagram.
a. Disconnect delivery line (13) from upper pump (18).
delivery line (13).
e. Connect portable hydraulic tester (26) between upper pump (18) and tee (24) with
two hoses (12).
f. Remove negative flow control line (36) from port of upper pump (18) and install
plug (37) and o-ring seal (43) in open end of negative flow control line (36).
g. Connect two tees (32) together using and o-ring seal (43). Install one end of the tees
to negative flow control line (36) port of upper pump (18). Install nipple (42) and o-
ring seal (7) in each tee (32). Connect test hose assembly [thread size: 11/16-16UN, 1
m (3.3 ft) long](38) and two coupler assemblies (45) between nipple (42) on one tee
and tap (40) of pilot oil manifold (39).
h. Install 4900 kPa (700 psi) pressure gauge (31) to nipple (42) on the second tee.
Install cap (44) and o-ring seal (43) on the open end of second tee (32). Install pressure
gauge (30) at upper pump tap (29). [A 49 000 kPa (7100 psi) pressure gauge can be
used in place of pressure gauge (30)]. Gauge (31) is used to measure the negative
control flow. Gauge (30) is used to measure the upper pump or lower pump delivery
pressure.
i. Install multitach group (34) on the engine. This is used to read engine speed.
4. Start the engine and place the power mode selector switch in Mode III position.
5. Place the engine speed dial at position "10" and maintain the maximum no load
speed at 2050 ± 50 rpm with the AEC switch OFF. (Read the rpm three seconds
elapsed time after the engine speed dial has been placed in position "10").
6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil
temperature, move the stick IN and OUT its full travel several times.
Preparation (Lower Pump)
Circuit Diagram For Negative Flow Control Test (Lower Pump)

pump. (19) Lower pump. (26) Portable hydraulic tester (flow meter). (27) Swing motor. (28) Main
control valves. (29) Tap (upper pump). (30) Gauge. (31) Gauge. (32) Tee. (33) Tap (lower pump).
(34) Multitach. (36) Negative flow control line (upper pump). (37) Plug. (38) Hose assembly. (39)
Pilot oil manifold. (40) Tap. (41) Negative flow control line (lower pump).
Pump Compartment
(12) Hose (lower pump charge line). (19) Lower pump. (32) Tap (power shift pressure). (33) Tap
(lower pump).
Perform the same preparation as that described for the upper pump negative pump flow
control test except Step 3. Use the following procedure in replacement for Step 3, for
the lower pump (19).
a. Disconnect delivery line (13) from lower pump (19).
delivery line (14).
e. Connect portable hydraulic tester (26) between lower pump (19) and tee (24) with
two hoses (12).
f. Remove negative flow control line (41) from port of lower pump (19) and install
plug (37) and o-ring seal (43) in open end of negative flow control line (41).
g. Connect two tees (32) together using and o-ring seal (43). Install one end of the tees
to negative flow control line (41) port of lower pump (19). Install nipple (42) and o-
ring seal (7) in each tee (32). Connect test hose assembly [thread size: 11/16-16UN, 1
m (3.3 ft) long](38) two coupler assemblies (45) between nipple (42) on one tee and tap
(40) of pilot oil manifold (39).
h. Install 4900 kPa (700 psi) pressure gauge (31) to nipple (42) on the second tee.
Install cap (44) and o-ring seal (43) on the open end of second tee (32). Install pressure
gauge (30) at lower pump tap (33). [A 49 000 kPa (7100 psi) pressure gauge can be
used in place of pressure gauge (30)]. Gauge (31) is used to measure the negative
control flow. Gauge (30) is used to measure the upper pump or lower pump delivery
pressure.
i. Install multitach group (34) on the engine. This is used to read engine speed.
Test Procedure
NOTE: Perform the upper and lower pump negative flow control tests one at a time.

engine that the flow meter valve (35) is fully open (turned
counterclockwise).
To prevent personal injury and/or equipment damage from

failed lines or components while the flow meter is returned to
the open flow position after a flow test, slowly open the flow
meter valve and monitor pump flow at the same time to make
sure flow increases. If pump flow does not increase as the
flow meter is opened, shut the engine off and determine what
is causing the pump not to upstroke.
1. Place the power mode selector switch in the Mode III position.
2. Negative flow control test for the upper and lower pumps must be done one at a
time.
3. Slowly turn valve (35) of portable hydraulic tester (26) clockwise until the pump
delivery pressure setting is 6850 kPa (1000 psi).
4. Adjust pilot relief valve of pilot oil manifold (39) until pressure gauge (31)
connected to tee (32) reads 2450 kPa (355 psi).
5. Record the negative control flow at the following pressure point.
P-Q Characteristic Curve [Negative Flow Control at 6850 kPa (1000 psi) Pump Delivery Pressure]
NOTE: Flow specifications given above are based on an engine speed of 2000 rpm. To
get more accurate test results, measured flow should be corrected by calculating as
follows:
Flow corrected = (Flow measured x 2000) ÷ rpm measured
NOTE: Flow measurements must be taken only in pressure rise.
Pump Flow Adjustment

Pump Output Flow Adjustment
Pump Compartment
(1) Locknut. (2) Setscrew. (3) Locknut. (4) Setscrew.
Output flow adjustment procedure for the upper and lower pumps are the same. Use
locknut (1) and setscrew (2) for the upper pump adjustment and locknut (3) and
setscrew (4) for the lower pump adjustment.
1. Loosen locknut (1).
2. Turn setscrew (2) until adjusted to the correct specification.
Turning setscrew (2) clockwise increases the flow rate. Turning setscrew (2)
counterclockwise decreases the flow rate by the same amount as shown in the
clockwise rotation. A quarter turn of setscrew (2) changes the flow rate as follows;
a. Approximately 19 liter/min (5.0 U.S. gpm) at a system pressure of 14 700 kPa

(2150 psi) or 17 700 kPa (2550 psi) where the first stage spring in the pump
regulator activates.
b. Approximately 7 liter/min (1.9 U.S. gpm) at a system pressure of 24 500 kPa
(3550 psi) or 34 300 kPa (5000 psi) where the second stage spring in the pump
regulator activates.
4. Perform the same procedure for the lower pump as that described for the upper pump
output flow adjustment except use locknut (3) and setscrew (4).
Maximum Pump Flow Adjustment
Pump Compartment
(5) Locknut. (6) Setscrew. (7) Setscrew. (8) Locknut.
Maximum pump flow adjustment procedure for the upper and lower pumps are the
same. Use locknut (5) and setscrew (6) for the upper pump adjustment and locknut (7)
and setscrew (8) for the lower pump adjustment.
Turning setscrew (6) clockwise decreases the flow rate. Turning setscrew (6)
counterclockwise increases the flow rate by the same amount as shown in the
clockwise rotation. A quarter turn of setscrew (6) changes the flow rate by
approximately 1.5 liter/min (0.4 U.S. gpm).
maximum pump flow adjustment except use locknut (7) and setscrew (8).
Negative Flow Control Adjustment
pc Pump Compartment
(9) Setscrew. (10) Locknut. (11) Setscrew. (12) Locknut.
Negative flow control adjustment procedure for the front and rear pumps are the same.
Turning setscrew (9) clockwise decreases the flow rate. Turning setscrew (9)
counterclockwise increases the flow rate by the same amount as shown in the
clockwise rotation. A quarter turn of setscrew (9) changes the flow rate by
approximately 5 liter/min (1.3 U.S. gpm) at a system pressure of 2450 kPa (355 psi).
maximum pump flow adjustment except use locknut (12) and setscrew (11).
Copyright 1993 - 2023 Caterpillar Inc. Sun Jun 25 07:31:04 UTC+0300 2023
All Rights Reserved.
Private Network For SIS Licensees.

325 A FM L XIM Hydraulic System Testing and Adjusting

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325, 325L EXCAVATOR 7LM00001-UP (MACHINE) POWERED BY 3...

Testing and Adjusting

Hydraulic System Testing And Adjusting

1. Electronic System Testing And Adjusting

Electronic Control System

Hydraulic oil pressure can remain in the hydraulic systems

When possible, the bucket must always be lowered to the

Swing lock must be engaged before service is started.

Always move the machine to a location away from the travel

3. Inspect all lines and connections for damage or leaks.

4. Inspect control linkage for bent, broken, or damaged components.

Checks During Operation

Operational Test Preparations

Excavator with no load at high idle, 2050 ± 50 rpm

2. Hydraulic oil temperature: 55 ± 5°C (131 ± 9°F)

3. Relief valve pressure settings are set according to specification.

Reference: Make reference to the section in this module "Relief Valves",

Travel Test On Level Ground

Reference: Make reference to the section "Operation Tests Preparation"

6. The bucket must be empty.

3. Measure the travel deviation from the reference line.

Travel On Level Ground (Optional Test)

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground.

3. Raise a track for the test as shown in the illustration.

4. Put a mark on a shoe of the raised track.

2. Put the implements in the position shown in the illustration.

3. Bucket should be empty.

2. Stop the engine and time three minutes (using a stopwatch).

Swing Speed And Over Swing (On Level Ground)

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground as shown in the illustration.

4. The bucket should be empty.

Test Procedure (Over Swing):

Test Procedure (Speed):

Swing Speed And Drift (On A Slope)

1. Place the machine on a 12° slope.

Test Procedure (Speed):

Test Procedure (Drift):

1. Stop the machine on a slope of 12°.

4. Stop the engine.

7. Repeat Steps 2 through 5.

Test Procedure (Drift):

1. Stop the machine on a slope of 12°.

4. Stop the engine.

7. Repeat Steps 2 through 5.

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground as shown in the illustration.

3. Fill the bucket with soil.

Test Procedure (For Boom And Stick Cylinders):

1. Fully extend the bucket cylinder.

2. Fully retract the stick cylinder.

4. Measure each cylinder's length from pin to pin.

5. Stop the engine.

Test Procedure (For Bucket Cylinder):

1. Fully extend the bucket cylinder.

3. Measure each cylinder's length from pin to pin.

4. Stop the engine.

Cylinder Operating Speed

1. Place the machine on level ground.

2. Bucket must be empty.

Test Procedure (Boom Cylinders):

1. Fully retract bucket and stick cylinders.