Service Training MALAGA

320B/330B Hydraulic Excavators II. PUMP / PUMP CONTROLS

HYDRAULIC TANK

Francis Jun 98

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

300B MAIN HYDRAULIC PUMP (SECTIONAL VIEW) NFC Adjustment

Pilot Pump

Pilot Pump Drive Gear

NFC Piston Barrel

Sleeve

Torque Piston

Power Screw Control piston Control Spring Actuator Spring

Retainer Pin

Piston

Actuator

Port Plate Max Angle Adjust.

Page:

2

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump controls

TWO PUMP CONTROLS (Standby)

NFC Adjustment

NFC Adjustment

PS Pressure from PRV

NFC Pressure

NFC Pressure

Horsp. Adjus.

Horsp. Adjus.

Actuator Piston

To Control Valve

To Control Valve PWM Press sensor Max Angle Adjustment

Page:

3

Max Angle Adjustment

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

TWO PUMP CONTROLS (2 Pumps Flow)

NFC Adjustment

NFC Adjustment

PS Pressure from PRV

NFC Pressure

NFC Pressure

Horsp. Adjus.

Horsp. Adjus.

Actuator Piston

To Control Valve

To Control Valve PWM Press sensor Max Angle Adjustment

Page:

4

Max Angle Adjustment

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

TWO PUMP CONTROLS (1 Pump Flow)

NFC Adjustment

NFC Adjustment

PS Pressure from PRV

NFC Pressure

NFC Pressure

Horsp. Adjus.

Horsp. Adjus.

Actuator Piston

To Control Valve

To Control Valve PWM Press sensor Max Angle Adjustment

Page:

5

Max Angle Adjustment

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

PUMP CONTROL SCHEMATIC (Two pumps flow)

NFC

PS PWM Sensor (Travel speed Control Valve)

UPPER PUMP

E

LOWER PUMP

* NFC

Page:

6

Horsepower Control Spool

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

PUMP CONTROL SCHEMATIC (One pump flow)

NFC

PS

PWM Sensor (Travel speed Control Valve)

UPPER PUMP

E

LOWER PUMP

* NFC

Page:

7

Horsepower Control Spool

Page:

320B PUMP DISTROKING PRESSURE

8

L/min 200 190

PUMP DESTROKING PRESSURE VERSUS P.S. PRESSURE SPEED DIAL POSITION 10

180

(P.S. Pressure Gauge value)

170 160 150 140 130 120 100

P.S. Press.

kPa

20000 1400

1300

kPa

1200

90 80 70 60 50 40

20000 kPa At 1300 kPa P.S. Press.

30

(Actuator Press Approx. 500 kPa)

20 10

kPa 4000

8000

12000

16000

20000

24000

28000

32000

36000

40000

44000

48000

320B - 330B HYDRAULIC EXCAVATORS

Sys. Press,

CHAPTER : Pump / Pump Controls

110

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

320B PUMP DE STROKING PRESSURE TEST

1

5

2

6

3

7

4

8 R

1. Remove the plugs and install gauges ( 0 - 25000 kPa ) in the actuator passages. Install ( 0 - 60000 kPa ) gauges at test points P1 and P2. 2. Install a pressure gauge ( 0 - 6000 kPa ) at the PS test point. 3. Start engine and warm up the Hydraulic oil to 55 deg C. 4. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. 5. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. 6. Press button 2 to increase the PS pressure until 1300 kPa is displayed on the PS pressure gauge. 7. Turn the main relief valve counterclockwise to decrease the relief pressure to ~ 10000 kPa. 8. Activate the bucket pilot control valve (for upper pump test or Swing pilot control valve for lower pump test) and then turn the main relief valve clockwise until the pressure reaches 20000kPa. The pressure at the gauge in the actuator passage should be approx. 500 kPa. Adjustment : The beginning of pump regulation can be adjusted with the Horsepower screw. It is important both pumps start to de stroke at the same pressure.

Horsepower Adj.

P1

NFC Adj. PS Test point Pilot Press. Outlet PS Press. Inlet NFC Adj.

Horsepower Adj.

Page:

9

Actuator passage plug (Adapt. 8T7860)

Q1 Max Adj. Q2 Max Adj. Actuator passage plug P2

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

320B NFC TEST

1

5

2

6

3

7

4

8 R

This test is done on one pump after the other. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Disconnect the NFC line from the pump actuator and block it with a plug. Connect a Tee with a quick connector on the NFC input on the pump. Disconnect the PS line from the pump and connect it to the NFC Tee. Remove a plug and install gauge ( 0 - 25000 kPa ) in the actuator passage. Connect one pressure gauge ( 0 - 4000 kPa ) to the Tee on the NFC input. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. Press button 2 to decrease the PS pressure until "300" is displayed on the panel. Start engine and warm up the Hydraulic oil to 55 deg C. Run the engine at LOW IDLE, the gauge on NFC input should show approx. 300 kPa, the gauge in the actuator passage shows 0 kPa. Press button 1 to increase the PS pressure until the pressure (NFC) reaches 1300 kPa. The pressure gauge at the actuator passage should be 500 kPa appro

ADJUSTMENT : If the 1300 kPa and 500 kPa are not correct adjust with the NFC adjusting screw. NOTE : Do not run the engine in H I, the hose to the NFC could burst.

Page:

10

322B PUMP DISTROKING PRESSURE L/min 200 190

PUMP DESTROKING PRESSURE VERSUS P.S. PRESSURE SPEED DIAL POSITION 10 (P.S. Pressure Gauge value)

180 170 160 150 140 130 120 100

P.S. Press.

19000 2100

2000

kPa 1900

90 80 70 60 50 40

19000 kPa At 2000 kPa P.S. Press.

Page:

30

(Actuator Press Approx. 500 kPa)

20 10

kPa

11

4000

8000

12000

16000

20000

24000

28000

32000

36000

40000

44000

48000

320B - 330B HYDRAULIC EXCAVATORS

Sys. Press,

CHAPTER : Pump / Pump Controls

110

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

322B PUMP DE STROKING PRESSURE TEST

1

5

2

6

3

7

4

8 R

1. Remove the plugs and install gauges ( 0 - 25000 kPa ) in the actuator passages. Install ( 0 - 60000 kPa ) gauges at test points P1 and P2. 2. Install a pressure gauge ( 0 - 6000 kPa ) at the PS test point. 3. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. 4. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. 5. Press button 2 to increase the PS pressure until 2000 kPa is displayed on the PS pressure gauge. 6. Start engine and warm up the Hydraulic oil to 55 deg C. 7. Turn the main relief valve counterclockwise to decrease the relief pressure to ~ 10000 kPa. 8. Activate the bucket pilot control valve (for upper pump test or Swing pilot control valve for lower pump test) and then turn the main relief valve clockwise until the pressure reaches 19000 kPa. The pressure at the gauge in the actuator passage should be approx. 500 kPa. Adjustment : The beginning of pump regulation can be adjusted with the Horsepower screw. It is important both pumps start to de stroke at the same pressure.

Horsepower Adj. NFC Adj. PS Test point Pilot Press. Outlet PS Press. Inlet NFC Adj.

Horsepower Adj.

P1 Actuator passage plug (Adadt. 8T7860) Q1 Max Adj. Q2 Max Adj. Actuator passage plug P2

Page:

12

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

322B NFC TEST

1

5

2

6

3

7

4

8 R

This test is done on one pump after the other. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Disconnect the NFC line from the pump actuator and block it with a plug. Connect a Tee with a quick connector on the NFC input on the pump. Disconnect the PS line from the pump and connect it to the NFC Tee. Remove a plug and install gauge ( 0 - 25000 kPa ) in the actuator passage. Connect one pressure gauge ( 0 - 4000 kPa ) to the Tee on the NFC input. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. Press button 2 to decrease the PS pressure until "300" is displayed on the panel. Start engine and warm up the Hydraulic oil to 55 deg C. Run the engine at L I, the gauge on NFC input should show approx. 300 kPa, the gauge in the actuator passage shows 0 kPa. Press button 1 to increase the PS pressure until the pressure (NFC) reaches 1300 kPa. The pressure gauge at the actuator passage should be 500 kPa approx.

ADJUSTMENT : If the 1300 kPa and 500 kPa are not correct adjust with the NFC adjusting screw. NOTE : Do not run the engine in H I, the hose to the NFC could burst.

Page:

13

325B PUMP DISTROKING PRESSURE L/min 250 240

PUMP DESTROKING PRESSURE VERSUS P.S. PRESSURE SPEED DIAL POSITION 10 (P.S. Pressure Gauge value)

230 220 210 200 190 180 170 150

P.S. Press.

20000 1900

1800

kPa 1700

140 130 120 110 100 90

20000 kPa At 1800 kPa P.S. Press.

Page:

80

(Actuator Press Approx. 500 kPa)

70 60

kPa

14

4000

8000

12000

16000

20000

24000

28000

32000

36000

40000

44000

48000

320B - 330B HYDRAULIC EXCAVATORS

Sys. Press,

CHAPTER : Pump / Pump Controls

160

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

325B PUMP DE STROKING PRESSURE TEST

1

5

2

6

3

7

4

8 R

1. Remove the plugs and install gauges ( 0 - 25000 kPa ) in the actuator passages. Install ( 0 - 60000 kPa ) gauges at test points P1 and P2. 2. Install a pressure gauge ( 0 - 6000 kPa ) at the PS test point. 3. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. 4. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. 5. Press button 2 to increase the PS pressure until 1800 kPa is displayed on the PS pressure gauge. 6. Start engine and warm up the Hydraulic oil to 55 deg C. 7. Turn the main relief valve counterclockwise to decrease the relief pressure to ~ 10000 kPa. 8. Activate the bucket pilot control valve (for upper pump test or Swing pilot control valve for lower pump test) and then turn the main relief valve clockwise until the pressure reaches 20000 kPa. The pressure at the gauge in the actuator passage should be approx. 500 kPa. Adjustment : The beginning of pump regulation can be adjusted with the Horsepower screw. It is important both pumps start to de stroke at the same pressure.

Horsepower Adj. NFC Adj. PS Test point Pilot Press. Outlet PS Press. Inlet NFC Adj.

Horsepower Adj.

Page:

15

P1 Actuator passage plug (Adadt. 8T7860) Q1 Max Adj. Q2 Max Adj. Actuator passage plug P2

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

325B NFC TEST

1

5

2

6

3

7

4

8 R

This test is done on one pump after the other. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Disconnect the NFC line from the pump actuator and block it with a plug. Connect a Tee with a quick connector on the NFC input on the pump. Disconnect the PS line from the pump and connect it to the NFC Tee. Remove a plug and install gauge ( 0 - 25000 kPa ) in the actuator passage. Connect one pressure gauge ( 0 - 4000 kPa ) to the Tee on the NFC input. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. Press button 2 to decrease the PS pressure until "300" is displayed on the panel. Start engine and warm up the Hydraulic oil to 55 deg C. Run the engine at L I, the gauge on NFC input should show approx. 300 kPa, the gauge in the actuator passage shows 0 kPa. Press button 1 to increase the PS pressure until the pressure (NFC) reaches 1400 kPa. The pressure gauge at the actuator passage should be 500 kPa approx.

ADJUSTMENT : If the 1400 kPa and 500 kPa are not correct adjust with the NFC adjusting screw. NOTE : Do not run the engine in H I, the hose to the NFC could burst.

Page:

16

330B PUMP DISTROKING PRESSURE L/min 250

PUMP DESTROKING PRESSURE VERSUS P.S. PRESSURE SPEED DIAL POSITION 10 (P.S. Pressure Gauge value)

240 230 220 210 200 190 180 170

20000

Sys. Press, P.S. Press.

1600

1500

1400

150 140 130 120 110 100 90

20000 kPa At 1500 kPa P.S. Press.

Page:

80

(Actuator Press Approx. 500 kPa)

70 60

kPa

17

4000

8000

12000

16000

20000

24000

28000

32000

36000

40000

44000

48000

320B - 330B HYDRAULIC EXCAVATORS

CHAPTER : Pump / Pump Controls

160

kPa

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

330B PUMP DE STROKING PRESSURE TEST

1

5

2

6

3

7

4

8 R

1. Remove the plugs and install gauges ( 0 - 25000 kPa ) in the actuator passages. Install ( 0 - 60000 kPa ) gauges at test points P1 and P2. 2. Install a pressure gauge ( 0 - 6000 kPa ) at the PS test point. 3. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. 4. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. 5. Press button 2 to increase the PS pressure until 1500 kPa is displayed on the PS pressure gauge. 6. Start engine and warm up the Hydraulic oil to 55 deg C. 7. Turn the main relief valve counterclockwise to decrease the relief pressure to ~ 10000 kPa. 8. Activate the bucket pilot control valve (for upper pump test or Swing pilot control valve for lower pump test) and then turn the main relief valve clockwise until the pressure reaches 20000 kPa. The pressure at the gauge in the actuator passage should be approx. 500 kPa. Adjustment : The beginning of pump regulation can be adjusted with the Horsepower screw. It is important both pumps start to de stroke at the same pressure.

Horsepower Adj. NFC Adj. PS Test point Pilot Press. Outlet PS Press. Inlet NFC Adj.

Horsepower Adj.

Page:

18

P1 Actuator passage plug (Adadt. 8T7860) Q1 Max Adj. Q2 Max Adj. Actuator passage plug P2

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

330B NFC TEST

1

5

2

6

3

7

4

8 R

This test is done on one pump after the other. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Disconnect the NFC line from the pump actuator and block it with a plug. Connect a Tee with a quick connector on the NFC input on the pump. Disconnect the PS line from the pump and connect it to the NFC Tee. Remove a plug and install gauge ( 0 - 25000 kPa ) in the actuator passage. Connect one pressure gauge ( 0 - 4000 kPa ) to the Tee on the NFC input. Enter the "Security Code" 0E323A by keeping the button 8, 3 and 4 pressed together for more than 2 seconds. Put the machine in Service Mode "Code 66", press button 3 to move the flashing digit to the 3rd number from the left. Press button 2 to decrease the PS pressure until "300" is displayed on the panel. Start engine and warm up the Hydraulic oil to 55 deg C. Run the engine at L I, the gauge on NFC input should show approx. 300 kPa, the gauge in the actuator passage shows 0 kPa. Press button 1 to increase the PS pressure until the pressure (NFC) reaches 1300 kPa. The pressure gauge at the actuator passage should be 500 kPa approx.

ADJUSTMENT : If the 1300 kPa and 500 kPa are not correct adjust with the NFC adjusting screw. NOTE : Do not run the engine in H I, the hose to the NFC could burst.

Page:

19

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

320B HYDRAULIC EXCAVATORS TROUBLESHOOTING GUIDE Tools : 3- Pressure Gauges

ENGINE R.P.M.

MAIN SYSTEM PRESSURE

H.I. 1st stage 1982 rpm H.I. 2nd stage 1882 rpm

Impl. / Travel 35000 kPa

PILOT PRESSURE 4000 kPa

INSTRUMENT PANEL Active Code

YES PUMP PERFORMANCE CHECK

ENGINE RPM

NO ACCORDING TO SPECS.

ADJ. RELIEF VALVES

Upper Pump Lower Pump at Relief (RPM) at Relief (RPM)

HIGHER THAN SPECS. SPECS LOWER THAN SPECS.

320B SPECS ( In Boom Prior. Economy Mode and Dial 10) UPPER PUMP (full bucket cyl. extension)

1800 + - 10 RPM

LOWER PUMP (Swing Left/Righ -Swing Brake "ON")

1800 + - 10 RPM

NOTE : Whith Power +, Dial 10 and Boom Prior. 2 Pumps F.L. (1800rpm) at 1000 kPa PS Press. approx. Page:

20

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

322B HYDRAULIC EXCAVATORS TROUBLESHOOTING GUIDE Tools : 3- Pressure Gauges

ENGINE R.P.M.

MAIN SYSTEM PRESSURE

H.I. 1st stage 2142 rpm H.I. 2nd stage 2042 rpm

Impl. / Travel 35000 kPa

PILOT PRESSURE 4000 kPa

INSTRUMENT PANEL Active Code

YES PUMP PERFORMANCE CHECK

ENGINE RPM

NO ACCORDING TO SPECS.

ADJ. RELIEF VALVES

Upper Pump Lower Pump at Relief (RPM) at Relief (RPM)

HIGHER THAN SPECS. SPECS LOWER THAN SPECS.

322B SPECS ( In Boom Prior. Economy Mode and Dial Position 10) UPPER PUMP (full bucket cyl. extension)

1900 + - 10 RPM

LOWER PUMP (Swing Left/Righ -Swing Brake "ON")

1900 + - 10 RPM

NOTE : Whith Power +, Dial 10 and Boom Prior. 2 Pumps F.L. (1950rpm) at 1170 kPa PS Press. approx.

Page:

21

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

325B HYDRAULIC EXCAVATORS TROUBLESHOOTING GUIDE Tools : 3- Pressure Gauges

ENGINE R.P.M.

MAIN SYSTEM PRESSURE

H.I. 1st stage 2180 rpm H.I. 2nd stage 2080 rpm

Impl. / Travel 35000 kPa

PILOT PRESSURE 4000 kPa

INSTRUMENT PANEL Active Code

YES PUMP PERFORMANCE CHECK

ENGINE RPM

NO ACCORDING TO SPECS.

ADJ. RELIEF VALVES

Upper Pump Lower Pump at Relief (RPM) at Relief (RPM)

HIGHER THAN SPECS. SPECS LOWER THAN SPECS.

325B SPECS ( In Boom Prior. Economy Mode and Dial posit. 10) UPPER PUMP (full bucket cyl. extension)

1910 + - 10 RPM

LOWER PUMP (Swing Left/Righ -Swing Brake "ON")

1910 + - 10 RPM

NOTE : Whith Power +, Dial 10 and Boom Prior. 2 Pumps F.L. (2000rpm) at 700 kPa PS Press. approx.

Page:

22

320B - 330B HYDRAULIC EXCAVATORS CHAPTER : Pump / Pump Controls

330B HYDRAULIC EXCAVATORS TROUBLESHOOTING GUIDE Tools : 3- Pressure Gauges

ENGINE R.P.M.

MAIN SYSTEM PRESSURE

H.I. 1st stage 1983 rpm H.I. 2nd stage 1883 rpm

Impl. / Travel 35000 kPa

PILOT PRESSURE 4000 kPa

INSTRUMENT PANEL Active Code

YES PUMP PERFORMANCE CHECK

ENGINE RPM

NO ACCORDING TO SPECS.

ADJ. RELIEF VALVES

Upper Pump Lower Pump at Relief (RPM) at Relief (RPM)

HIGHER THAN SPECS. SPECS LOWER THAN SPECS.

330B SPECS ( In Boom Prior. Economy Mode and Dial posit. 10) UPPER PUMP (full bucket cyl. extension)

1860 + - 10 RPM

LOWER PUMP (Swing Left/Righ -Swing Brake "ON")

1860 + - 10 RPM

NOTE : Whith Power +, Dial 10 and Boom Prior. 2 Pumps F.L. (1800rpm) at 688 kPa PS Press. approx.

Page:

23