STUDENT MANUAL

TECHNICAL INSTRUCTION

COURSE: 320C Excavator

TOPIC: Systems Operation, Testing and
Settings

TECHNICAL DEVELOPMENT DCSE0060

MAY, 2006 Prepared by Jorge Gorritti Rey
Course: 320C Excavator 1 Student Material
DCSE0060

INDEX

Page

INDEX 1
COURSE DESCRIPTION 3
Summary and Labs during the Course........................................................ 3
General Objectives........................................................................................................ 4
Requirements................................................. .................................................. .......... 4
COURSE AGENDA 5
NECESSARY MATERIAL 6
Literature................................................. .................................................. ............6
Reference Literature................................................................................................. 6
Training Material........................................................................................................ 6
Necessary Tools........................................................................................................ 7

MODULE 1: INTRODUCTION TO THE EXCAVATOR 9

Lesson 1.1: Familiarization................................................................................. 12

Sheet 1.1: Safety................................................................................................. 13
Sheet 1.2: Machine Specifications................................................................. 15
Sheet 1.3 Daily Maintenance........................................................................ 16
Sheet 1.4 Service Points................................................................................. 18
Sheet 1.5: Cabin Controls................................................................................. 19
Sheet 1.6: Operation .......................................................................................22

MODULE 2: ELECTRICAL, ELECTRONIC AND MONITOR SYSTEMS 23

Lesson 2.1: Using Electrical Schematics....................................................................... 26

Ref Text: Troubleshooting Sensors................................................................. 26
Laboratory 2.1: Electrical Diagram................................................................. 28
Lab 2.2: Boot and Load Scheme................................................. 30
Laboratory 2.3: Sensor Evaluation........................................................ 31
Lab 2.4: Evaluating a Relay........................................................ 32
Lab 2.5: Evaluating the starting and charging system................................. 33
Lesson 2.2: Electronic System................................................................................. 35
Lesson 2.2.1: Generalities................................................................................. 36
Lesson 2.2.2: System Operation................................................................. 37
Lesson 2.3: Monitoring System................................................................................. 40
Lesson 2.3.1: Monitor Functions................................................................. 41
Laboratory 2.6: Monitoring System................................................................. 43
Laboratory 2.6: Diagnosis........................................................................ 46

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DCSE0060

MODULE 3: ENGINE 47

Lesson 3.1: 3066 Engine Systems....................................................................... 50

Worksheet 3.1: Components........................................................................ 52
Worksheet 3.2: Major Systems................................................................. 53
Sheet 3.2A: Intake and Exhaust System................................................. 53
Sheet 3.2B: Lubrication System....................................................................... 54
Sheet 3.2C: Cooling System........................................................................ 55
Sheet 3.2D: Electrical System........................................................................ 55
Lesson 3.2: Fuel System................................................................................. 56
Worksheet 3.3: Components........................................................................ 56
Reference Text: Injection Pump................................................................. 57
Reference Text: Governor........................................................................ 59
Worksheet 3.4: Engine Testing................................................................. 60

MODULE 4: HYDRAULIC SYSTEM 61

Lesson 4.1: General Information........................................................................ 64

Worksheet 4.1: Hydraulic System................................................................. 65
Worksheet 4.2: Electronic Control........................................................ 67
Worksheet 4.3: Pilot System Circuit................................................. 68
Lesson 4.2: Main Hydraulic Pump................................................................. 69
Worksheet 4.4: Main Pump................................................................. 70
Worksheet 4.5: Pump Operation................................................................. 72
Lesson 4.3: Implement System........................................................................ 75
Worksheet 4.6: Main Control Valve....................................................... 76
Worksheet 4.7: Engine Speed Test................................................. 77
Worksheet 4.8: Traffic Tests................................................................. 78
Worksheet 4.9: Overdraw and Spin Tests................................................. 79
Worksheet 4.10: Cylinder Shift Test........................................ 80
Worksheet 4.11: Cylinder Speed Test........................................ 81
Worksheet 4.12: Pressure Testing................................................................. 82
Worksheet 4.13: Drain Flow Testing....................................................... 87
Reference Text: Flow Meter........................................................................ 89
Worksheet 4.14: Flow Testing................................................................. 90

SURVEY 95

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DCSE0060

COURSE DESCRIPTION

COURSE: 320C HYDRAULIC EXCAVATOR

Duration time: 5 days (40 hours)

Number of Participants: 8 Students

ADDRESSED TO This course has been designed for mechanics, service technicians,
instructors, technical communicators, supervisors and service engineers
who work with Caterpillar machinery.

SUMMARY
The course will be held 50% in the classroom and 50% on the machine according to the
availability of this.

The classroom class will be a presentation of the 320C Excavator. In each

module will review the location of components as well as the operation
of the various systems of the machine using presentations, the manual
service, the respective diagrams and a machine.

During the labs you will have the opportunity to operate the machine and
perform some tests and adjustments. Finally there will be a discussion in
class to demonstrate what has been learned.

Short written review assessments will be conducted at the end of each module.
to evaluate performance as well as skills testing
acquired in each laboratory.

EXERCISES
DURING THE MODULE 1: INTRODUCTION TO THE MACHINE
COURSE Safety regulations, technical specifications, location of
Major components, service points and maintenance tasks
programmed, cabin controls and excavator operation

MODULE 2: ELECTRICAL SYSTEM AND MONITOR

Using the electrical schematic, evaluating sensors, starting test and
Charging, Using the Monitor, and Calibrations with the ET or Monitor

MODULE 3: ENGINE
Engine system component location, test for high
Idle RPM and Full Load RPM, Low Idle RPM and Boost Pressure
engine oil

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DCSE0060
 MODULE 4: HYDRAULIC SYSTEM
Location of hydraulic system components in the schematic and in the
machine. Flow tests, cycle times, pressures and flow,
adjustments if necessary, flow path in the diagram and the machine

GOALS
GENERAL At the end of this course, students will be able to perform the following:
following processes:

 Locate major components and service points according to the

Operation and Maintenance Manual, perform maintenance and
Daily Inspection of 320C Excavator

 Check the starting and charging system.

 Explain the operation of the 3066 engine systems,

Check the engine RPM at high, low idle and pressure.
engine oil.

 Locate electrical components and diagnose the system

excavator electronics using the ET or Monitor

 Explain the operation of the Hydraulic Implement System,

locate the components on the machine and the diagram, perform the
Pressure, cycle time and flow testing

REQUIREMENTS
Students must have basic knowledge of:

 Hydraulics.
 Electricity.
 Use of Tools.
 English (preferred)
 ET Management

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DCSE0060
 COURSE AGENDA

FIRST DAY Tomorrow  Initial Presentation, Expectations

 Pre-Test
 Module 1, Introduction to the Machine
 Familiarization Laboratory

Late  Module 2: Electrical

 Sensors and Starter Laboratory

SECOND DAY Tomorrow  Module 2, Electronic and Monitor

 Laboratory Monitor Use

Late  Module 3, Engine

 Engine Evaluation Laboratory

THIRD DAY Tomorrow  Module 4, Hydraulic System

 Laboratory: Operation Tests

Late  Module 4, Main Pump

 Laboratory: Flow Testing

FOURTH DAY Tomorrow  Module 4, Hydraulic Diagrams

Late  Laboratory: Pressure Testing

FIFTH DAY Tomorrow  Laboratory: Hydraulic Tests with the

ET and the Monitor

Late  General Review

 Final Exam
 Final Survey

Class Schedule: from 8:10am to 5:00pm

Recommended Intermediate Times: 10:15 am and 3:00 pm Duration: 15 minutes

Recommended Lunch Time: 12:00 m (1:00 pm) Duration: 60 minutes

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DCSE0060

NECESSARY MATERIAL
LITERATURE
  RENR3812 Service Manual: 320C (SBN1-UP)
 SSBU7342 Operation and Maintenance 320C
 RENR7090 Electrical Diagram: 320C
 RENR3819 Hydraulic Diagram: 320C

REFERENCE LITERATURE

 ASHQ5393 Specifications Brochure: 320C

 SEBD0518 Know Your Cooling System
 SEBD0717 Fuel and your Engine
 SEBD0640 Oil and your Engine
 SEBD0979 Coolant and your Engine
 PEHP6001 How to take a good oil sample
 TEJB1015 Analyzing an SOS report
 NENG2500 Caterpillar Service Technology Tools & Shop Products
Guide
 PECP6026 A Safe Source
 SMHS7531 Special Instruction: “Using the Repair Kit”
Sure Seal Connectors 6V-3000)”
 SEHS9615 Special Instruction: “DT Connector Maintenance”
 SEHS9065 Special Instruction: “Using the Tool for
“CE connectors”
 SEHS8038 Special Instruction: “Using the Tool for
“VE connectors”
 NEHS0605 Tool Operation Manual: 9U-7400 Multitach
 NEHS0565 Tool Operation Manual: 4C9910 Portable
Hydraulic Tester
 NEHS0818 Tool Operation Manual: 198-4240 Digital
Pressure Indicator Group

TRAINING MATERIAL

 CD presentation Excavator
 Videos Operation Excavators
 Components for assembly and disassembly

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DCSE0060

NECESSARY TOOLS
TESTS OF
OPERATION
  1_ Stopwatch
TESTS OF  1_ 5P3277 Tape measure (tape measure)
PRESSURE
 1_ 150 mm ruler (scale)
 1_ 6V3121 or 9U7400 Tachometer (multitach group)
 1_ 1643310 or 8T0470 Thermometer (thermometer)

 2_ 8T0855 Manometer 500 PSI (pressure gauge)

 2_ 8T0856 Manometer 870 PSI (pressure gauge)
 2_ 8T0859 Manometer 3500 PSI (pressure gauge)
 3_ 8T0861 Manometer 8700 PSI (pressure gauge)
 1_ 1U5481 Pressure gauge group
 1_ 1U5482 Hoses and adapters
(pressure hose and adapter)
 1_ 1984240 Digital pressure gauge (digital pressure indicator)
 1_ Mechanic's tool box (mechanic's toll box)
 1_ Laptop with ET (CAT Electronic Technician)
 1_ 1714400 Communications adapter group
(Com Adapter II)
 1_ 1464080 or 9U7400 or 6V3121 Multimeter (multimeter)
 1_ 1888588 Electrical test tee
 1_ FT2542 Track block assembly

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DCSE0060

NECESSARY TOOLS
TESTS OF (a bomb)
FLOW
  2_ 6V3965 Coupling (nipple ass)
 1_ Measurable container with a  4_ 4C6481 Coupling
capacity of 40 liters  4_ 4C6482 Coupling (nipple)
 1_ Low pressure hose, 20mm internal  1_ 4I6140 Coupling (coupling)
diameter and 2 meters  2_ 4I6141 Coupling (coupling)
long  4_ 8C9026 Adapter (adapter)
 4_ 6V8398 O-ring seal  9_ 6K6307 O-ring seals
 1_ 6V9830 Plug  1_ 6V9854 Swivel elbow
 1_ 6V9509 Cap with seal  2_ 1P3703 Rectangular seal
 1_ 4C9910 Flow Meter (Portable Flow  4_ 8T4184 Screw (bolt)
Meter)  4_ 8T4223 Washer (hard washer)
 1_ 6V9840 Swivel tee  4_ 6V0400 Half flange
 1_ 9U7335 Blocking cover  1_ 1U8292 Adapter (adapter)
 1_ 1U8303 Adapter (fitting)  1_ 8T5082 Union
 16_ 5K9090 O-ring seals  1_ 8T8902 Elbow
 2_ 5P0201 10 meter hose (hose)  5_ 6V3989 Nipple
 4_ 5P1010 Coupling (sleeve)  5_ 6V4143 Coupling
 4_ 4C8767 Coupling  4_ 6V8397 O-ring seals
 8_ 7M8485 O-ring seals  2_ 6V8716 Seal connector
 4_ 3J1907 O-ring seals  2_ 6V9508 Cap with seal
 4_ 7M8485 O-ring seals  1_ 6V9829 Plug
 5_ 6V3014 Hose  4_ 6V9832 Plug

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Course: 320C Excavator 9 Student Material

DCSE0060 Module 1

MODULE 1

INTRODUCTION TO THE
320C EXCAVATOR
Ferreyros S.A.A. Technical Development
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Course: 320C Excavator 10 Student Material

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 STAR

END
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............ 2. Locate all service points, filter locations and water intakes.
Course: 320C Excavator 11 Student Material
DCSE0060 Module 1

MODULE 1

INTRODUCTION TO THE 320C EXCAVATOR

The purpose of this module is to familiarize the student with the

Excavator features, locate the main components,
cabin controls and indicators, daily maintenance check and
operation of the machine. The module includes a questionnaire and exercises in the
machine

This module consists of a lesson and its laboratories.

GOALS

At the end of the module, the student will be able to

1. Perform a walk-around inspection of the machine, locating and explaining

All warning and safety labels

samples, in addition to the procedures for checking the levels of the

compartments and make fluid changes; perform daily check
inspection according to a worksheet

3. Identify each of the excavator operating controls:

Steering levers and pedals, implement control, indicators
alert and switches.
 4. Perform the start-up procedure, safe shutdown of the machine and
demonstrate the operation of the controls

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DCSE0060 Module 1

Lesson 1.1 Familiarization

This lesson helps you become familiar with the main features of the
Excavator and with the basic practices for the correct maintenance of the
machine

CLASS Product presentation and general views of the machine,

general characteristics and technical specifications, location of
main components and inspection criteria.

LABORATORIES - Discuss in class the sales specifications of the excavator in

Worksheet No. 1.2
- Walk through the machine with the daily maintenance checklist
and the inspection route in Work Sheets No. 1.3 and No. 1.4.
- Identify the cabin components on Worksheet No. 1.5
- Start the Excavator and test its basic functions on the Worksheet.
Work No. 1.6

MATERIAL _ 320C Excavator

NECESSARY _ Tool Box
_ RENR 3810 Service Manual
_ Student Handbook
_.SSBU 7342 Operation and Maintenance Manual
_ ASHQ 5393 Specifications Catalog
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WORKSHEET 1.1 SAFETY

INSTRUCTIONS Answer the questions.

Where do we find information about security related to

the use and maintenance of the machine?

What conservation measures should be taken with labels and messages?

security and information?

This symbol that

is he warning us?

What danger
related to the
connection of
auxiliary cables
boot
We must have
present?

Welding in
machines and
engines with
controls
electronic

1. Turn off the engine. Place the switch in the OFF position.
2. If equipped, turn the battery switch to the OFF position. If not equipped,
master switch, disconnect the negative battery cable
3. Connect the ground wire. Position the clamp as close to the ground as possible.
welding. Make sure the electrical path from the ground cable to the
component does not pass through any bearing. protect:

Drivetrain Bearings,Hydraulic Components,Components

Electrical, Other machine components
4. Protect all wire harnesses from slag or welding residue

5. Follow welding procedures to join materials

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DCSE0060 Module 1

WORKSHEET 1.1 SAFETY

(continuation)

INSTRUCTIONS Answer the questions.

What does this say?

label and why
is it important?

What is the proper procedure to avoid accidents?

 What happens if we ignore this warning?

Description System System

International English
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2 Displacement (Cylinder capacity)

3 Net power at the flywheel

Course: 320C Excavator 4 Maximum altitude without
15 calculation of Student Material
DCSE0060 power reduction Module 1
5 Operating weight (LC long rail)
WORKSHEET 1.2 MACHINE SPECIFICATIONS
6 Turning speed

7 laboratory
This Maximumallows
travel speed
you to review the general information of the machine
8 Maximum flow main system of
MATERIAL - 320C ASHQ5393 Specifications Catalog
implements
NECESSARY - Student Handbook
9 Maximum hydraulic turning pressure
INSTRUCTIONS Fill in the requested data with the help of the publication
10 Shipping length with boom
reach and arm R3.9B
SERIES: 11 Boarding height with large boom
volume and arm M2.4C
12 Minimum loading height with boom
reach and arm R2.9B
13 Bucket digging force
(SAE) high volume boom
14 Loading a service bucket
heavy duty, 6 tooth, undercarriage
long, reach boom, R2.5B arm
(highest density material)
15 Lifting capacity, boom
reach, bucket 3m from the ground,
R2.5B arm, load radius on the
side 7.5m

CAPABILITIES

16 Fuel tank
17 Cooling system
18 Engine oil
19 Swing control box
20 Final drive (each)
21 Hydraulic system (including tank)
22 Hydraulic tank
Ferreyros S.A.A. Technical Development
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ITEM Description Page Check in machine

1 Displacement alarm
Course: 320C Excavator Prove 16 Student Material
DCSE0060 2 Coolant level of the Module 1
cooling system
Find out
3 Engine oil
WORKSHEET 1.3level DAILY MAINTENANCE
Find out
4 Water separator of the
MATERIAL - 320C Excavator
fuel system
NECESSARY - Operation
Drain and Maintenance Manual SSBU7342
5 - Student
Water Handbook
and sediments of the
fuel tank
INSTRUCTIONS Using an Excavator and the operation and maintenance manual, perform
Drain
the
6 following
SystemDaily Maintenance tasks (or every 10 hours)
oil level
hydraulic
Find out
7 Railing
Review
8 Indicators and gauges
Prove
9 Adjusting the chains
Inspect
10 Seat belt
Inspect
11 Inspection around the
machine
Carry out
12 Radiator core
Clean
13 Windows
Clean
14 Boom, arm and linkage
spoon (first 100
hours or machines at work
severe)
Lubricate
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4 DMO DISPLACEMENT
WORKSHEET 1.3 DAILY INSPECTION

INSPECTION ROUTE SHEET 320C

5 6
GUIDE WHEEL
3 SHOES
10 SIDE PLATFORM CHAINS
RADIATOR BOLTS
SPOON
OUTSIDE CABIN
HOUR METER
FRAME
ROLLERS
1 PINES
GUIDE WHEELS
SPROCKET
FINAL CONTROL
2 ROLLERS
Grease nipples
CYLINDER OF
GUARDS SPOON
CHASSIS ARM
FEATHER
HOSES
SPINNING MOTOR
TURNTABLE

TOWERS OF
9 MAIN
CHASSIS
HOSES
COUNTERWEIGHT
TAPAS

FINAL CONTROL LADDER

SPROCKET RAILING
ROLLERS SIDE PLATFORM
HYDRAULIC OIL FRAME BATTERIES
7 FILTERS BOLTS NIPPLE
BOMBS CHAINS HYDRAULIC TANK
HOSES SHOES FILTERS
VALVES GUIDE WHEEL
AISLE
8 ENGINE
SUPPORTS
ENGINE OIL
REFRIGERANT
TAPAS OF
INJECTORS
ADMISSION
EXHAUST
TURBO
SUMP
VALVE
BOMBS
COOLER FILTERS
HOSES
HOSES
GIRDLES
Grease nipples
PULLEYS
SW IVEL
FAN
SPINNING MOTOR
VALVE
TURN VALVES
MAJOR
TANK OF
FUEL

1 Inspect the
cylinders
hydraulic by
damage or
wear
excessive
guards, supports
6 Inspection feet, clean the
stairs, surfaces
 leaks, repair any
avoiding escape
7 Inspect the
pollution
hydraulic system by

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DCSE0060 Module 1
Check in machine /
ITEM Description Page
observation / hours

WORKSHEET 1.4 SERVICE POINTS

SAMPLING
MATERIAL - 320C Excavator
NECESSARY 1 - Operation
Engine oiland Maintenance Manual SSBU7342
2 - Student
Hydraulic system oil
Handbook
3 Final drive oil
INSTRUCTIONS 4 the
Using Gearbox oil rotation
Excavator and the operation and maintenance manual locate
Service points coolant
5 Engine on the machine

OIL CHANGES

1 Final controls
2 Hydraulic system
3 Rotation control box
4 Engine

LEVELS

1 Refrigerant
2 Engine oil
3 Hydraulic system oil
4 Final drive oil
5 Rotation control oil
6 Fuel
7 Windshield clean water

FILTERS AND GRIDS

1 Cabin air filter

2 Primary engine air filter
3 Secondary engine air filter
4 Hydraulic tank grate
5 Hydraulic system oil filter
(drain box)
6 Hydraulic system oil filter
(pilot)
7 Hydraulic system oil filter
return
8 Engine crankcase breather
9 Engine oil filter
10 Primary fuel filter
11 Secondary fuel filter
12 Fuel tank grille
13 Pump strainer
resupply
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DCSE0060 Module 1

WORKSHEET 1.5 CABIN CONTROLS

MATERIAL - 320C Excavator

NECESSARY - Operation and Maintenance Manual SSBU7342

INSTRUCTIONS Identify the indicated controls and explain their functions

3
9

4
7

10
Number Check in Name Function
machine
1 Left console

2 Hydraulic lock control

3 Shift pedal
left
4 Shift pedal
right
5 Left universal lever

6 Horn

7 Shift lever
left
8 Shift lever
right
9 Electronic monitor board

10 Manual idle lowering

11 Right universal lever

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DCSE0060 Module 1

WORKSHEET 1.5 CABIN CONTROLS (continued)

Number Check in Name Function

machine
12 Hour meter

13 Ashtray

14 Speed control
of the engine and switch
engine start
15 Board of
switches of
software
16 Reservation controls

17 Air control
conditioning and the
heating
18 Board of
switches
19 Board of
side instruments
right
20 Operator's seat
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DCSE0060 Module 1

WORKSHEET 1.5 CABIN CONTROLS (continued)

Number Check in Name Function

machine
21 Cancel alarm
translation

22 AEC Control of
Automatic Speed
of the Engine
23 Speed Control
of displacement

24 Window washing
superior
25 Windshield wiper
superior
26 Lights

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Course: 320C Excavator 22 Student Material
DCSE0060 Module 1

WORKSHEET 1.6
OPERATION OF THE 320C EXCAVATOR

This laboratory consists of a worksheet that will allow you to develop the
skills to operate the machine.

MATERIAL - 320C Excavator

- Operation and Maintenance Manual SSBU7342
- Student Handbook

INSTRUCTIONS Using an Excavator and the Operation Manual, perform the tasks described below.
indicate and write down the procedure performed

START 1 Move the pilot lock lever to the operating position (down),
turn the ignition key to ON what do you see on the monitor?

If you change the position of the accelerator, do you see anything?

Leave it at low RPM and start it, what happens?

Move the hydraulic lock lever to locked (up) and start,

what's going on?

Back up MOTOR 2 Locate the backrest controls under the right armrests,
with the machine on move the Speed Mode control
(central) to Manual what happens on the monitor?

Now the Engine RPM control, move it and note what happens

AEC 3 Set the AEC (Automatic Engine Speed Control) to OFF and
accelerate to maximum RPM, note, after 2 seconds what happens

Switch the AEC to ON and note what happened after 5 seconds

Press the switch above the right stick (Low Idle) and score
RPM, press it again what happened?

IMPLEMENTS 4 With the engine at low RPM move the control levers right and
left in various directions and note which implement moves
Control Forward Back Right Left Go ahead and Go ahead and Back and Back and
right left right left
RIGHT

LEFT

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DCSE0060 Module 2
 MODULE 2

SYSTEMS
ELECTRIC
ELECTRONIC
AND MONITOR

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Course: 320C Excavator 24 Student Material

DCSE0060 Module 2
 START

END

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Course: 320C Excavator 25 Student Material

DCSE0060 Module 2

MODULE 2:

ELECTRICAL, ELECTRONIC AND SYSTEMS

 MONITORING
Electronic systems are used on all Caterpillar machines,
Electrical systems feed these, in the C series of excavators there are
changes in the monitoring system with respect to previous versions, to perform
Diagnostics and calibrations can use either the monitor or the ET

The purpose of this module is to familiarize the student with the system
electrical, electronic and monitor on the machine.

It consists of three lessons:

REFERENCE -Electrical system. Analog
Troubleshooting Sensors.
-Electronic system
-Monitoring system.

GOALS

At the end of the module, the student will be able to:

1. Given an electrical schematic of the machine and the Student Manual,

obtain the requested information.

2. Using the service information locate the components of

input, control and output of the ECMs, and demonstrate the logic of
operation

3. Given an Excavator, the worksheets and the Service Manual

appropriate, properly use the functions of the Monitor of the
machine.

4. Given an Excavator, the worksheets and the Service Manual

appropriate, properly use the functions of the Technical ET
Electronic for obtaining codes and performing calibrations

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DCSE0060 Module 2

LESSON 2.1: USING THE ELECTRICAL DIAGRAM

TEXT OF

The technician must use the diagnostic information from the electronic system
provided by the different controls. If a technician suspects (based
 in the diagnostic information) that an analog sensor is the culprit of the
fault, he can quickly check if the sensor or the wiring is the cause
of the fault. Using a Digital Multimeter, the 7X1710 test leads and
the appropriate module from the service manual, you can measure the DC voltage of
the output signal on the cable and compare with the specification in the manual.

If there is no signal present, it will be necessary to determine if there is voltage.

source and if the ground circuit is good. If both are within the
specified, the sensor must be replaced.
If any measurement is not within the specification, it will be necessary
continue to locate the fault.

The following measurements will be typical for an analog sensor.

temperature with the sensor connected to the control and the main switch
on:

Pin A to Pin B: Regulated 5.0 VDC power supply to the control

electronic
Pin C to Pin B: 1.99 - 4.46 DCV from sensor
The voltage signal on pin C will be different for each sensor type.
to be used. The output is proportional to the measured parameter
(temperature, pressure, etc.) Technicians should refer to the module
of service appropriate to the individual specifications of each
sensor.

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DCSE0060 Module 2

REFERENCE TEXT:

Troubleshooting Digital Sensors.

He mechanic has to use the information of diagnosis of the system

electronic provided by the different electronic controls. If a
mechanic suspects (based on diagnostic information) that a sensor
digital is guilty of the fault, he can quickly check if the sensor or the
wiring of the same is the culprit of the failure. Using a Digital multimeter,
a few test leads and the appropriate module from the service manual, the
DC output voltage on the signal cable can be measured and compared
 with the specification of the manual.

If there is a signal, but not within the specification, the sensor must be
replaced.
If there is no signal, it will be necessary to check if there is source voltage and if
the ground circuit is good. If both are within specification,
the sensor must be replaced.
If any measurement is not within the specification, it will be necessary
continue evaluating the circuit.

Additionally, using a 9U7330 (FLUKE 87) or a digital multimeter

Caterpillar 146-4080 Digital the operability of a PWM sensor can be
determined. The Digital Multimeter has the ability to measure voltage of
CC, frequency and charge cycle.

Using the 7X1710 test lead and the digital multimeter terminals
connected between the signal wire (pin C) and ground (pin B) in the connector of the
sensor, the mechanic can quickly analyze the condition of the sensor.

The following measurements would be typical for a temperature sensor

PWM with sensor connected to controller and main switch on:

Pin A to Pin B = Supply Voltage

Pin C to Pin B = 0.7 - 6.9 DCV, on DC voltage scale
Pin C to Pin B = 4.5 - 5.5 kilocycles, on the frequency scale
Pin C to Pin B= 5% - 95%, on the % charge cycle scale

DC voltage can vary between different types of PWM sensors, but

WIRE
The COLOR
frequency must always beCIRCUIT DESCRIPTION
within the specification of the sensor, and the
to which
charge cycle should always it belongs
be greater than 0% (usually between 5% - 10%)
101and up to 95% in high (but never 100%)
in low
200
321
H465
892
K904

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Course: 320C Excavator 28 Student Material

DCSE0060 Module 2

LABORATORY 2.1 ELECTRICAL DIAGRAM

INSTRUCTIONS Using the RENR 7090 electrical diagram

of the 320C Excavator
Answer the following questions
1. What do the following lines represent?
– Solid black (negative voltage)
– Solid red (positive voltage)
– Black interleaved (signal)
– Discontinuous any color (voltage of another signal)
– Solid Blue (Ground)

2. What does the thin black line with the L# designation mean (e.g.
 L22, L39..)?
L= inductive / coil.
3. What is the part number of the service manual?
– Starting and Charging
– Engine / Pump Control:

4. Complete this table

5. Locate and identify the CONN 2 connector in coordinates and silhouette in

machine
connector located in the cabin

6. Locate the hydraulic oil level switch at coordinates and

silhouette on machine

7. What is the part number of the switch?

COMPONENT LOCATION NUMBER OF WITH WHAT ECM IS
SCHEME
8. Is this
SILHOUETT
connector Sure PART CONNECT
Seal or Deutsh? How do you tell them apart?
STRAIGHT TRAVEL E
SWITCH
TEAM ECM
STAR RELAY 9. Does the connector part attached to the switch have pins
Engine ECMor sockets, and
how many?; is said connector a receptacle or a plug?
BACKUP RESISTOR Engine ECM
FUEL SENDER Engine ECM
WATER SEPARATOR Engine
10. What harness is this attached to, and what is the ECM
harness part number?
SENSOR
HYDRAULIC LOCK ECM OF THE
SOLENOID IMPLEMENT

11. Finally where does it connect, to which ECM?

COMPONENT HARNESS PARAMETERS
NUMBER OF LOCATION NUMBER PERFORMANC DEACTIVATION POSITION
PART IN OF E OF
CONTACTS
HARNESS CABLES either
STRAIGHT
Ferreyros S.A.A.TRAVEL Technical Development
SWITCH
Jorge Gorritti – May 2006 Student Manual 320C - Module 2
2
STAR RELAY 2
Course: 320C Excavator 29 Student Material
BACKUP RESISTOR
DCSE0060
3 Module 2

FUEL SENDER

WATER SEPARATOR 3 DIAGRAM

LABORATORY 2.1 ELECTRICAL
SENSOR (CONTINUATION)
HYDRAULIC LOCK 2
SOLENOID
12. What does NOTE C mean? In the diagram

13. What do the following codes indicate?

to. MID 069 CID 1161 FMI 18 = sensor supply failure

b. MID 069 CID 0376 FMI 5 = current below normal

c. MID 069 CID 0190 FMI 2 = erratic or incorrect data

Complete the table:

CONTINUATION

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DCSE0060 Module 2

LABORATORY 2.2 STARTING AND CHARGING SCHEME

INSTRUCTIONS Using the RENR 7090 electrical diagram of the 320C Excavator
Complete the circuit wiring and understand its operation
 COMPONENT POINTS TO WORTH VALUE READ
MEASURE SPECIFIED
--
SENDER: HYDRAULIC OIL TEMPERATURE SENDER
SUPPLY VOLTAGE
Ferreyros S.A.A. Technical Development
Jorge Gorritti – May 2006 SIGN Student Manual 320C VOLTAGE
- Module 2

REFERENCE VOLTAGE
Course: 320C Excavator
(PULL UP) 31 Student Material
DCSE0060 SENSOR: PUMP DISCHARGE PRESSURE SENSOR Module 2
SUPPLY VOLTAGE
SIGN VOLTAGE
LABORATORY 2.3 SENSOR EVALUATION
REFERENCE VOLTAGE
(PULL UP) – If you have
INSTRUCTIONS Using the excavator's
FREQUENCY SENSOR: electrical
SPEEDdiagram,
SENSORthe service manual
RENR
SIGN 3814 and the appropriate tools evaluate the following sensors
HEART
ENDURANCE
REFERENCE VOLTAGE ENDURANCE
(PULL UP) – If you have
SOLENOID: HYDRAULIC LOCK SOLENOID
SUPPLY VOLTAGE VOLTAGE
ENDURANCE ENDURANCE
 A: SUPPLY
B: EARTH
C: SIGNAL

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DCSE0060 Module 2

LABORATORY 2.4 EVALUATION OF A RELAY

Evaluate the machine's Main Relay

Location in the Diagram:

Location on the Machine (silhouette):
Part Number:

1. Activate the relay, if possible

turn on all accessories
, the engine may be off
or on

2. Connect the multimeter and read

at the terminals
24V: will read more than 22V
12V: will read more than 11V
 3. Measure the voltage at the terminal
from relay the battery

24 VOLTS

4. Check the
contacts (switch),
Connect the
multimeter and perform
Next steps

5. If the contacts are closed, it will read less than 1V (24V) or 0.5V (12V).
6. Disconnect the positive input terminal (A) to the coil, the contacts
They will change position, in a good relay you will hear a “click”
7. Measure the voltage across the contacts:
- Relay previously closed and now open: Will read the 24V system voltage
(12V)
- Relay previously open and now closed: Will read 1V (24V) or 0.5V (12V)
8. When (A) is disconnected the voltage across the terminals should
toggle between 24V and 1V (12V and 0.5V)

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DCSE0060 Module 2

LABORATORY 2.5 STARTING AND CHARGING SYSTEM

INSTRUCTIONS Perform the following Electrical System tests

Ferreyros S.A.A. Technical Development
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DCSE0060 Module 2

LABORATORY 2.5

(continuation)
INSTRUCTIONS Answer the following questions
Ferreyros S.A.A. Technical Development
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DCSE0060 Module 2

Lesson 2.2: Electronic System

This lesson allows you to identify the function of electronic components

CLASS Presentation of general concepts of the system

LABORATORIES Given the student manual, worksheets, and in-class explanation,

Identify the input components and evaluate them according to the procedure
appropriate in laboratory sheets

MATERIAL  Student Material

NECESSARY  RENR 3814 Service Manual
 320C Excavator
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DCSE0060 Module 2

Lesson 2.2.1: Generalities

The machine's electronic control system controls the hydraulic system,
Every electronic system has these components:

INPUT COMPONENTS: They are sensitive to physical variations in

temperature, pressure or movement, and transform it into electrical signals
or electronic, which the ECM receives.

ECM: Processes information from input components that indicate the

Machine status. The result of the information processed by the ECM
It is used to send electrical or electronic signals to the components of
exit.

OUTPUT COMPONENTS: They will transform the electronic signal

coming from the ECM, in a mechanical or hydraulic activation that would control
the pump and the diesel engine
 “NO LOAD Engine Speeds” engine speeds
Selecting the dial Speed (RPM)
THE ECM IS USED1 TO CONTROL SENSORS, ACTUATORS,
1000
AND ALL THE ELECTRONIC
2 SYSTEMS THAT CAN 1100BE
INPUT DEVICES3 AND OUTPUT DEVICES. 1200
4 1300
5 1470
6 1590
GRADES 7 1700
8 1800
9 1900
10 1970
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Course: 320C Excavator 37 Student Material

DCSE0060 Module 2

Lesson 2.2.2: System Operation

1. Engine Speed Regulation

The machine ECM receives a signal from the speed selector and
transmits (as PWM) to the engine ECM, there are 10 no-load speeds

2. Pump regulation

PS “Power Shift” pressure limits hydraulic power

delivered by the pump (Power = Flow X Pressure), this power is
affected by engine speed position and working mode
 IN THIS CASE THE ECM WILL CONTROL THE SOLENOID PRESSURE, THE PUMP
FUEL AND ENGINE SPEED.

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DCSE0060 Module 2

3 Automatic Engine Speed Control (AEC)

This control automatically reduces engine speed when there is no
load (NO LOAD) for more than 3 seconds

(1) AEC switch

(2) ON indicator
AEC / MODE Position of Position of Position of the Description
the speed of the switch
switch engine Low's manual
4 Low
AECIdle Control (LOW IDLE) Idle
First state When
OFFthere is no load
5 toand
10 the joysticks OFF
are in neutral, it reduces
After the speed
3 seconds withoutof the
motor, the switch is located on the right joystick load reduces speed
at 100 RPM
Second state Neither
ON the AEC nor5 the LOW IDLE work
to 10 with the backup
OFF After 3switch.
seconds without
switch) in MAN (manual) load (or with a load)
very light)the system
AEC slows down
at 1300 RPM
Manual low in ON or OFF 3 to 10 ON The speed is reduced to
empty 1000 - 1100 RPM
Manual low in OFF 4 or less Switch to OFF The speed is
empty restores
Ferreyros S.A.A. Technical Development
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DCSE0060 Module 2

5 Locking turning system

zz

WITH THE HYDRAULIC CONTROL LOCK IT CAN BE BLOCKED

 THE HYDRAULIC SYSTEM, BUT IT WILL ONLY BLOCK
THE HYDRAULIC SYSTEM BUT NOT THE OTHER SYSTEMS,
FROM THE MACHINE.

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DCSE0060 Module 2

Lesson 2.3: Monitoring System

This lesson allows you to familiarize yourself with the main components of the
Monitoring System on C Series Excavators

CLASS Presentation of general concepts of the system

LABORATORIES
Given the student manual, worksheets, and in-class explanation,
Identify the input components and evaluate them according to the procedure
appropriate in laboratory sheets

MATERIAL  Student Material

NECESSARY  RENR 3814 Service Manual
 Operation and Maintenance Manual SEBU 7342
 320C Excavator
Ferreyros S.A.A. Technical Development
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DCSE0060 Module 2

Lesson 2.3.1 Monitor Functions

Place the
numbers at
functions
1

(1 ) Light of
warning 3 2
(2 ) Indicator
speed selector
4
of the engine 5
(3 ) Level of
fuel
(4 ) Temperature
hydraulic oil 9
(5) Temperature 6
coolant of the
engine
(6 ) Window of
messages
10
7

The monitoring system

communicates with 11 14
the CAN Data Link

12 13
8

Item Name Function

Up key GO UP
Right key GO RIGHT
Selection key SELECT
Menu key SELECT MENU
Left key GO LEFT
Down key GO DOWN
Cancel key CANCEL ANY FUNCTION
Approve key SELECT AND APPROVE
How many levels of
 warning does this machine have?

IT HAS 3 CATEGORIES OF
WARNING

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DCSE0060 Module 2

Main Menu You have four main options

Ferreyros S.A.A. Technical Development
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DCSE0060 Module 2

LABORATORY 2.6 MONITOR SYSTEM

INSTRUCTIONS On the machine, perform the procedures indicated to you.
Ferreyros S.A.A. Technical Development
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DCSE0060 Module 2

LABORATORY 2.6 MONITOR SYSTEM

(continuation)
INSTRUCTIONS Answer the following questions with the summarized procedure
1.What does the monitor screen show when you turn the power switch on?
backup in manual?

ALL THE STATUS COMES OUT ON THE MONITOR OIL PRESSURE FUEL
LEVELS AND RPMS
2.How can I change the language?
SELECTED: SETING
DISPLAY SETUP
LANGUAGE SETTING
AND WE SELECT THE LANGUAGE.
3.How does the operator know when the filter service is required?
fuel?

A WARNING CATEGORY APPEARS ON THE MONITOR

4.After performing maintenance, how do I reset the maintenance intervals?

zero maintenance?
WE SELECT: SERVICE :/ MAINTENANCE

(IN WHICH ALL RECORDED DIAGNOSTICS ARE RESET)

5.How do I change the tool type?

WE SELECT: SERVICE
ECM CONFIGURATION

7.How can you see the engine RPM?

WE SELECT: MENU
PERFORMANCE

8.How do I view diagnostic codes?

WE SELECT: MENU
SERVICE
DIAGNOSIS
9. What types of information do I get from Status mode?

WE CAN SEE THE INPUT STATES OF THE SENSORS AND THE SWITCHES
FROM THE ECM
Ferreyros SAA Technical Development
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DCSE0060 Module 2

LABORATORY 2.6 MONITOR SYSTEM

(continuation)
INSTRUCTIONS Perform PRV calibration using the monitor
Ferreyros S.A.A. Technical Development
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DCSE0060 Module 2

LABORATORY 2.7 DIAGNOSIS

INSTRUCTIONS Calibrations with the Electronic Technician
How do you find diagnostic codes?

Perform the calibration shown

IMF Type of fault Causes

00 Valid data but over the range of Signal below normal, Signal short to battery, Needs calibration
normal operation sensor
01 Data valid but below range Time Delay, Signal Below Range
normal operation
02 Erratic, intermittent or faulty data Connection failure, intermittent or erratic signal, software was changed,
incorrect signal with electromagnetic noise, signal out of range
03 Voltage above normal or short high Damaged sensor or switch, damaged harness, ECM failure, sensor with high
voltage,
04 Voltage below normal or short Damaged sensor or switch, damaged harness, ECM failure, sensor with low voltage,
low circuit shorted to ground
05 Below normal current or Open circuit or poor harness connection, switch left open
open circuit
06 Current above normal or circuit Harness short to ground, relay shorted, ECM failed
with short to ground
07 Mechanical system does not respond Component responds inappropriately or gets stuck in one position,
properly failed component, engine off, machine used improperly
08 Abnormal period, pulse or rate Intermittent or poor harness connection, misfiring engine, noisy signal
due to interference, loss of mechanical devices
09 Abnormal update ECM not communicating properly with Data Link, transmission ratio
Abnormal data, CAT CAN Data Link failed, malfunction of the
software
10 Abnormal range of change Very fast signal changes, out of range
11 Unidentifiable failure mode Mechanical failure or damage to multiple circuits
12 Bad device or component Failure in electronic control, Data Link or multiple controls with error
software
13 Out of calibration Data out of range, calibration required
14 Unused
15 Unused
16 Parameter not available The control does not support that parameter
17 Module not responding Control does not respond to data
18 Failure in supply to the sensor Failure in supply
19 Unknown condition
20 Unused

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Course: 320C Excavator 47 Student Material
DCSE0060 Module 3

MODULE 3

ENGINE

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Course: 320C Excavator 48 Student Material

DCSE0060 Module 3

START

END

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DCSE0060 Module 3
 MODULE 3 – ENGINE

The purpose of this module is to show the operation of the system

Engine mechanic 3066 identifying its components and procedures
adjustment.

This module consists of lessons and their laboratories.

GOALS

At the end of the module, the participant will be able to

1. Given a worksheet, Service Manual and an Excavator, perform the

100% monitoring of engine systems flow: cooling,
intake and exhaust, fuel and lubrication.

2. Given a worksheet, Service Manual and an Excavator, explain

the operation of the fuel system

3. Given a worksheet, a 320C Excavator, Service Manual and

appropriate tools, perform diagnostic tests on the 3066 engine

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DCSE0060 Module 3

LESSON 3.1 ENGINE SYSTEMS 3066

This lesson allows you to become familiar with the main engine systems and their
 operation.

CLASS The class consists of the presentation of general views of the engine, its
main systems.

LABORATORIES - Identify system components according to the Sheet

Work 3.1
- Trace the main flows of the engine systems according to the
Worksheet 3.2
- Describe the operation of the fuel system, in the data sheet.
work 3.3
- Perform engine performance tests 30666 according to the specification sheet.
work 3.4

MATERIAL _ 320C Excavator (or spare 3066 engine)

NECESSARY _ Tool Box
_ Service Manual Engine 3066 SENR5546
_ Student Handbook

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DCSE0060 Module 3

WORKSHEET 3.1 MAIN SYSTEMS

Procedure Complete the required

__ Valves of
Exhaust

__ Valves of
Admission

Number of cylinders
Cylinder configuration
Valves per cylinder
Displacement
Caliber or diameter of the cylinder
Piston stroke
Type of combustion
Firing order
Direction of rotation (seen from the flywheel)

Place the Check Number in Name

machine
numbers Fan
respective and Coolant line
place them in the Turbocharger
machine Exhaust manifold
Exhaust
Crankshaft cover
Sump
Flywheel housing

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DCSE0060 Module 3

WORKSHEET 3.1 COMPONENTS (continued)

Procedure Complete the required

Place the
numbers
respective and
place them in the
machine

Check Number in Name

machine
Inlet manifold
Crankcase breather
Oil cooler
Throttle lever
Air inlet heater
Secondary fuel filter
Fuel lines
Water drain
Hose for the crankcase breather
Drain for the cylinder block
Oil pressure relief valve
Manual stop lever
Oil filter and oil filter base
Fuel injection pump

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DCSE0060 Module 3

WORKSHEET 3.2 MAIN ENGINE SYSTEMS

INSTRUCTIONS Use the following diagrams to search the machine and identify the
Engine system components: Intake and exhaust, lubrication,
cooling, also identify the flow in the different systems.
 3.2.A : INTAKE AND EXHAUST SYSTEM

Air heater Exhaust manifold

Combustion chamber Exhaust valve

Escape from the Intake valve

turbocharger
Turbine Air intake

Compressor Intake manifold

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DCSE0060 Module 3

3.2.B: LUBRICATION SYSTEM

Place the Turbocharger Oil pressure relief valve

numbers that Valve mechanism Timing gear
correspond Oil supply line Oil filter
Camshaft Crankshaft
Fuel injection pump Oil bypass valve
Oil cooler Suction bell
 Main oil gallery Oil pump
Piston cooling jet

# Name # Name # Name

Radiator External line Cylinder block
Thermostat Butt Water pump

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DCSE0060 Module 3

3.2.C. COOLING SYSTEM

 3.2.D. ELECTRICAL SYSTEM

(1) Air inlet heater

(2) Indicator
(3) Relay
(4) Relay
(5) Alternator
(6) Pilot light for
battery charge
(7) Switch for
starting engine
(8) Starting engine
(9) Battery
(A) 1 gauge wire
(B) 6 gauge wire
(D) 18 gauge wire

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DCSE0060 Module 3

LESSON 3.2 FUEL SYSTEM

WORKSHEET 3.3 FUEL SYSTEM

Procedure Complete the required

Place the
numbers
respective and
place them in the
machine

Check Number in Name

machine
Secondary fuel filter
Fuel supply for fuel injection nozzle
Fuel injection nozzle
Supply line for the secondary fuel filter
Fuel tank
Fuel return valve
Fuel injection pump
Fuel transfer pump
Fuel return line

Trace the flow path, indicating the different pressures

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DCSE0060 Module 3

REFERENCE TEXT: FUEL SYSTEM

Procedure Complete the required

Bomb of
Injection:
OPERATION
The vertical slot at the top
of the barrel and the recess in the
bottom make it possible
the injection cycle
←

Motion
Vertical Three stages of the cycle of
injection:
1. FILL
2. INJECTION
3. RELIEF
→

Movement of
Rotation

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DCSE0060 Module 3

TO. No flow

B. Flow
partial

C. Maximum
flow
 Mechanical governors for diesel engines consist of 2
GOVERNOR Basic mechanisms. The mechanism for measuring speed and the mechanism for change
speed.
ESSENTIAL
Mechanism for measuring the
speed.
←

Mechanism for changing

speed.
→

Increased load
←

Load shedding
→

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DCSE0060 Module 3

There are two screws

adjustment, which limit the
arm travel
Governor control between
the LOW positions IN
VACUUM and HIGH VACUUM.
(low idle and high idle)

And a stop screw for

limit the amount of
 fuel

FUEL SETTING or
FULL LOAD

This stop can be fixed or

elastic (spring or strap),
if the load increases
will allow you to enter
more fuel up to
collide with another screw
fixed stop

FULL TORQUE
CURVE
Machine OF THE
Model: Series Hours:
ENGINE
Engine Model: Series Arrange
TMI specification: 0K7338 ment:

PROOF SPECIFIED READING GRADES

Speed: Low Idle Speed - 900 +/- 20 RPM
Speed: High Idle speed - 1970 +/- 40 RPM
Speed: Full Load - 1800 +/- 20 RPM
Inlet Air Pressure 26 to 31 inHG 87 to 104 kPa
Boost Pressure 35+/-5 inHG 120+/-18 kPa
Maximum torque boost pressure TC (Boost) 29.6 to 17.6 inHG 100 to 59.6 kPa
Maximum air intake restriction 30in WTR 1.18 inHG 4 kPa
Maximum exhaust gas restriction 27in WTR
Crankcase gas pressure (engine crankcase p, blowby)
Compression pressure (300 RPM) 384 to 427 PSI 2646 to 2942
kPa
Air intake temperature (inlet air temperature) 50 to 122 °F 10 to 50 °C
Air temperature after turbo
Air temperature after post cooler
Turbo Temperature
Exhaust gas temperature (exhaust Temp)
Radiator upper tank coolant temperature
Coolant temperature water pump inlet 192+/-5 °F 89+/-3 °C
Differential water temperature (delta in-out) 7 +/- 8 °F 4 +/-5 °C
Water pump pressure increase (delta 12 PSI)
Engine oil pressure
- Low idle, 14 PSI 98 kPa
- With load at 1500 RPM, 28 to 57 PSI 196 to 392 kPa
- in all cases, maximum 64 PSI
Engine oil temperature (engine oil Temp.) 140 to 158 °F 60 to 70 °C
Fuel pressure
- Low idle
Ferreyros minimum 7.3 PSI
S.A.A. Technical Development
Jorge Gorritti (rated
- Full load RPM) PSI
– May 06 29 to 42 PSI 200 to 400
Student kPa 320C - Module 3
Manual
- Maximum admission 6 PSI 40 kPa
Injector opening pressure 3200 to 3342 PSI 22048 to 23026
kPa
Course: 320C temperature
Fuel intake Excavator 60 87 +/- 9 °F 30 +-- 5 °C Student Material
DCSE0060 Module 3
FL (Full Load) Static Fuel Setting 0.366 in 9.3 mm
FT (Full Torque) Static Fuel Setting 0.354 in 9.0 mm
Fuel Injection Timing 16° BTC
WORKSHEET
Intake and exhaust valve clearance mm. 3.4 ENGINE TESTING0.013066
in 0.25 mm

MATERIAL 1- 320C Excavator

2 3 4 5 6 PROM.
NECESSARY
Cylinder temperature - Service Manual Engine 3066 SENR5546 and sheet
Exhaust manifold temp. TMI Engine Specifications
Difference between cylinders not greater than 70°C Handbook
- Student (158°F)
INSTRUCTIONS Complete the required information
 Ferreyros S.A.A. Technical Development
Jorge Gorritti – May 06 Student Manual 320C - Module 3

Course: 320C Excavator 61 Student Material

DCSE0060 Module 4

MODULE 4

HYDRAULIC SYSTEM
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 62 Student Material

DCSE0060 Module 4
 START

END

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 63 Student Material

DCSE0060 Module 4

MODULE 4:

HYDRAULIC SYSTEM

This module will show the operation of the hydraulic pump and the
hydraulic system.

The operation of the pump will be studied, its components and the
set points as well as explaining flow, pressure graphs and their
critical points, we will also identify the rest of the system components
hydraulic, we will follow the path of the oil flow for translation, rotation,
implements and pilot system, pressure tests will be carried out, times
cycle and adjustment procedures according to the service manual.

This module consists of lessons and their laboratories

GOALS

1. Given a worksheet, the hydraulic schematic and the service manual

Identify all components of the hydraulic pump
 2. Given the service manual and the hydraulic diagram, color the flows of
oil for pump operations

3. Given the student manual and the hydraulic diagram, locate all the
Hydraulic system components on the worksheet and on the machine

4. Given a hydraulic system diagram and colored markers, trace the

oil flow at a certain movement position.

5. Given a worksheet, 320C Excavator, the Test Manual and

Appropriate adjustments and tools, perform the procedures of the
operational tests: cycle time and cylinder displacement, tests
Pressure: Relief Valves and Flow Testing: Pump Performance
Using the flow meter, make any required adjustments.

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 64 Student Material

DCSE0060 Module 4

LESSON 4.1: GENERAL INFORMATION

This lesson allows you to become familiar with the general hydraulic system and the
pilot system

CLASS The class consists of the presentation of the hydraulic system

LABORATORIES - Identify components of the hydraulic system and the pilot system
according to the Worksheet
- Trace the main flows of the systems according to the Sheet
Job

MATERIAL _ 320C Excavator

NECESSARY _ Tool Box
_ RENR 3816 and RENR3817 Service Manual
_ Student Handbook
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 65 Student Material

DCSE0060 Module 4

WORKSHEET 4.1: HYDRAULIC SYSTEM

INSTRUCTIONS Complete the requested

The excavator is controlled by the following three systems:

- The main hydraulic system controls the cylinders, the motors

translation and the swing motor
- The pilot hydraulic system that supplies oil to the main pump
and the control circuits
- The electronic control system that regulates the diesel engine and the
bombs

( ) Left pump
( ) Right pump
( ) Pilot pump
( ) Proportional
reducing valve
(power shift
pressure)
( ) Delivery line
(right pump)
( ) Delivery line
(left pump)

(...) Main relief

valve
 (...) Right control
valve body
(...) Left control
valve body
( ) Main control
valve

Locate the components on your hydraulic schematic

Ferreyros SAA Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 66 Student Material

DCSE0060 Module 4

WORKSHEET 4.1: HYDRAULIC SYSTEM

Number Name System

Swing motor
Left travel motor
Right travel motor
Arm cylinder
Left travel brake valve
Right travel brake valve
Bucket cylinder
Boom cylinder
Swivel union
Main control valve
Left pump
Pilot pump
Right pump
Cooler
Hydraulic tank
Drain filter
Pilot relief valve
Pilot filter
INSTRUCTIONS Trace the flow path of the main systems (use a different color)

Ferreyros SAA Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 67 Student Material

DCSE0060 Module 4

WORKSHEET 4.2 ELECTRONIC CONTROL

INSTRUCTIONS: Explain the functions of the system

Control System It consists of the ECM and the MONITOR
Electronic Functions:
- Controls the discharge flow of the pumps:

- Controls the engine speed

- Controls some electronic components of the hydraulic system

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 68 Student Material

DCSE0060 Module 4

WORKSHEET 4.3 PILOT SYSTEM CIRCUIT

The pressure is limited by the relief valve, the pilot oil performs the
following functions:
- 1.Creates pilot pressure to control the output flow of the pumps
- 2.Creates pilot control pressure for implements, swing and travel
Circuits - 3.Creates pilot pressure to automatically control devices

Instructions: 1.Power Shift Pressure System

Follow the route of the

flow in their
diagrams and notes 2.Pilot control valve circuit
the operation

3.Pressure-activated switch circuit

 4.Straight valve circuit

5.Swing parking brake

6. Pen priority

7. Turn priority

8.Automatic change of travel speed

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 69 Student Material

DCSE0060 Module 4

LESSON 4.2: MAIN HYDRAULIC PUMP

This lesson allows you to become familiar with the main hydraulic pump

CLASS The class consists of the presentation of the hydraulic system

LABORATORIES - Identify the main pump components and how they work
Using the PQ curve in the worksheet
- Map out the main flows for the different work positions

MATERIAL _ 320C Excavator

NECESSARY _ Tool Box
_ RENR 3816 Service Manual
_ Student Handbook
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 70 Student Material

DCSE0060 Module 4

WORKSHEET 4.4 MAIN PUMP

Procedure Identify the components in the table

# Name # Name # Name

PRV Reducing Valve Pressure port of Port of entry from

proportional (Power Shift) pump power change hydraulic tank
Pressure) right (Power Shift)
Pressure)
Case drain port Pilot pressure port Left pump
towards the PRV
Right pump discharge Housing Pressure port of
pump power change
left (Power Shift)
Pressure)
Left pump discharge Pressure sensor port NFC port signal flow
negative left pump
(Negative flow control
pressure for left pump)
Pilot pressure relief The port was entering with Pilot pump
a bomb
NFC port signal flow Pressure sensor port
right pump negative
(Negative flow control
pressure for right pump)
Ferreyros SAA Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 71 Student Material

DCSE0060 Module 4

WORKSHEET 4.4: MAIN PUMP

(CONTINUATION)
INSTRUCTIONS: Identify the components in the machine

Explain the operation of the pump governor and the PQ curve.

Ferreyros SAA Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 72 Student Material

DCSE0060 Module 4

WORKSHEET 4.5: PUMP OPERATION

INSTRUCTIONS: Trace the flow path and explain how it works.

STAND BY
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 73 Student Material

DCSE0060 Module 4

WORKSHEET 4.5: PUMP OPERATION

(CONTINUATION)
INSTRUCTIONS: Trace the flow path and explain how it works.

UP STROKE
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 74 Student Material

DCSE0060 Module 4

WORKSHEET 4.5: PUMP OPERATION

(CONTINUATION)
INSTRUCTIONS: Trace the flow path and explain how it works.

FROM STROKE
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 75 Student Material

DCSE0060 Module 4

LESSON 4.3: IMPLEMENT SYSTEM

This lesson allows you to become familiar with the hydraulic system of implements

CLASS The class consists of the presentation of the hydraulic system

LABORATORIES - Identify the components of the system and how they function in the
worksheets
- Map out the main flows for the different work positions

MATERIAL _ 320C Excavator

NECESSARY _ Tool Box
_ RENR 3816 Service Manual
_ Student Manual and copies for tracing
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 76 Student Material

DCSE0060 Module 4

WORKSHEET 4.6:
MAIN CONTROL VALVE
INSTRUCTIONS: Fill in the numbers

Solenoid valve Control valve Line relief valve

straight march straight march arm
(stick cylinder head end)
Track control valve Control valve of the Main relief valve
right Feather II
Optional valve Arm Control Valve Line relief valve
Yo ladle
(bucket cylinder rod end)
Control valve of the Swing control valve Right block
ladle
Control valve of the Track control valve Left block
Feather I left
Arm Control Valve Line relief valve
II feather
(boom cylinder rod end)

The main valve is between the pumps and the actuators (cylinders and
engines), this controls its operation depending on the operation of the
excavator
Procedure Trace the flow path and explain the operation of the circuits in the
sheets and manual delivered

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4
Course: 320C Excavator 77 Student Material
DCSE0060 Module 4

WORKSHEET 4.7
ENGINE SPEED TESTS

Procedure Perform the requested tests following the procedure in the manual.
RENR service 3817

HEAT THE HYDRAULIC OIL

55° +/- 5° C (131° +/- 9° F)

Item Specs Reading

New Rebuilt Limit of

service

High in vacuum (1) 1860 +/- 50 RPM (2) 1660 to 1910(1)

1970 +/- 50 RPM (3) 1770 to 2020(3)

Low idle 900 +/- 50 RPM 900 +/- 100

Empty lowering of a 1100 +/- 50 RPM 1100 +/- 100

touch

Maximum speed 1720 RPM (5) 1670 RPM (5) 1620 (5)
with load (4)

Reduced speed 1300 +/- 50 RPM 1300 +/- 100

AEC (6)

(1) AEC in OFF

(2) 3 seconds after setting the speed to 10
(3) Engine RPM within 3 seconds after putting the
engine speed at 10
(4) Pressure is relieved from both pumps (STALL)
(5) Minimum RPM
(6) AEC in ON

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4
Course: 320C Excavator 78 Student Material
DCSE0060 Module 4

WORKSHEET 4.8 TRANSIT TESTS

Procedure Perform the requested tests following the procedure in the manual.
RENR service 3817
Temperature
At the distance
55 +/- 5° C preliminary
5 m.
131 +/- 9 °F
B: Distance of
measurement 20 m.

C: Height of the
ladle on the floor
0.5 to 1 m

The distance traveled must be at least 25 meters, draw a line on the

floor and start the engine
Set engine speed to 10, AEC to OFF
Empty bucket, position the tracks parallel to the line, switch
speed on HIGH
Operate both pedals, start timing after 5m and measure the
deviation

Translation Time (last 20 meters)

Translation speed New Rebuilt Limit of Reading

service
HIGH Forward 14 seconds or 25 seconds or 16 seconds or
Reverse less less less
LOW Forward 22 seconds or 23.5 seconds or 25 seconds or
Reverse less less less

Deviation distance (from straight line to end)

Translation speed New Rebuilt Limit of Reading

service
HIGH Forward 800 mm (31.5 “) 1200 mm (47.2 “) 1500 mm (59.1”)
Reverse or less or less or less
Fall in Placemmthe (59.1”)
machine in a
LOW Forward 800 mm (31.5 “) 1200 mm (47.2 “) 1500
Earring or less or less or
Reverse 12°less
slope, bucket
empty and implements according to
the figure

Measure the drop after 3

minutes

Drop specification: 0mm Reading:

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 79 Student Material

DCSE0060 Module 4
 WORKSHEET 4.9 SPIN AND OVER SPIN TESTS

Procedure Perform the requested tests following the procedure in the manual.
RENR7305 service
Temperature

55 +/- 5° C

131 +/- 9 °F

A: Upper frame
B: Underframe
C: Brand

Place a mark

Leveling machine, Empty bucket

Move the joystick fully in one direction
Cylinder and stop
Drift (Empty in neutral at
Bucket)
180°, Measure the distance of the marks and the time
Item New Rebuild Service Limit
Distance of over Overswing
turn Boom Cylinder 6.0 mm (0.24 inch) or 12.0 mm (0.47 inch) or 24.0 mm (0.94 inch) or

Reading:
New Item Rebuilt
less Limit of less less
Service
Stick Cylinder
Turn to the10.0 mm (0.39 inch) 15.0 mm (0.59 inch) or 25.0 mm (0.98 inch) or
Right
right or less less 1400
lessmm (51
1100 mm (43.3 1200 mm (47.2
inches) or
Left Turn to the inches) or less inches) or less
less
Bucket 10.0 mm (0.39 inch) 15.0 mm (0.59 inch) or 25.0 mm (0.98 inch) or
left
Cylinder
or less less less
Turning time
180° Swing Time

Reading:
Service

Right:
Turn to the
Cylinder Slip (Loaded Bucket)
right 4.2 seconds 4.6 seconds or 5.2 seconds
Left:
Item or less less
New or less
Reading.........
Turn to the
Item
left New Rebuilt Limit of
Boom Cylinder 6.0 mm (0.24 inches) or
less

Stick Cylinder 12.0 mm (0.47 inches)

or less

Ferreyros S.A.A. Bucket Cylinder 30.0 mm (1.18 inches) Technical Development

Jorge Gorritti- May 06 or less Manual 320C - Module 4
Student

Course: 320C Excavator 80 Student Material

DCSE0060 Module 4

WORKSHEET 4.10
 CYLINDER DRIFT TESTS
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service

Temperature: Machine level, extend implements, raise boom until pin

that holds the arm is at the same height as the pen support pin.
Extend the bucket cylinder and retract the arm cylinder, extend the bucket cylinder
arm 70 mm (2.8 inches), measure the distances between the pins of the
cylinders, wait a few minutes and measure, note the difference

Empty ladle, 5 minutes

Readings:

Full ladle, 3 minutes

320C (1050kg 2310lb) 320CL (1200kg 2650lb)

CYLINDER OPERATING SPEED

Item New Rebuilt, Limit Reading
maximum value maximum of
service

Feather Extension 2.8 +/- 0.5 sec 3.2 sec 3.6 sec

Retraction 1.9 +/- 0.5 sec 2.2 sec 2.4 sec

Arm Extension 3.2 +/- 0.5 sec 3.7 sec 4.2 sec

Retraction 2.4 +/- 0.5 sec 2.6 sec 3.0 sec

Ladle Extension 3.3 +/- 0.5 sec 3.8 sec 4.3 sec
Ferreyros S.A.A. Technical Development
Jorge Gorritti- May 06 Retraction 1.8 +/- 0.5 sec 2.1 sec 2.3Manual
Student sec 320C - Module 4

Course: 320C Excavator 81 Student Material

DCSE0060 Module 4

WORKSHEET 4.11
CYLINDER SPEED TESTS
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Speed of
boom cylinders (A) Extension

(B) Retraction

Horizontal machine,
Empty bucket, retract
arm cylinders and
ladle, place ladle
on the ground and measure the time

Speed of
arm cylinders (A) Extension

(B) Retraction

Horizontal machine, bucket

empty, position the surface
upper bucket parallel
to the ground, measure the time

Speed of
(A) Extension
cylinders of the
ladle
(B) Retraction

Horizontal machine, bucket

empty, position the surface
top of the parallel boom
to the ground and the arm
perpendicular, measure the time

ITEM CHECK VALVE

1 (A) Main relief valve
2 (B) Boom cylinder line (head end)
3 (C) Boom cylinder line (rod end)
4 (D) Stick cylinder line (head end)
5 (E) Stick cylinder line (rod end)
6 (F) Bucket cylinder line (head end)
7 (G) Bucket cylinder line (rod end)
8 (H) Swing (right)
9 (I) Swing (left)
10 (J) Left travel crossover relief valve for forward travel
(upper valve)
11 (K) Left travel crossover relief valve for reverse travel
(lower valve)
12 (L) Right travel crossover relief valve for forward travel
(upper valve)
13 (M) Right travel crossover relief valve for reverse travel
(lower valve)
14 (N) Pilot relief valve
15 (O) Main control valve
16 (P) Pilot filter
Ferreyros SAA 17 (Q) Travel motor (right) Technical Development
Jorge Gorritti- May 06 18 (R) Travel motor (left) Student Manual 320C - Module 4
19 (S) Swing motor

Course: 320C Excavator 82 Student Material

DCSE0060 Module 4

WORKSHEET 4.12 PRESSURE TESTING

Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
LOCATION OF RELIEF VALVES

Ferreyros SAA Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 83 Student Material

DCSE0060 Module 4

WORKSHEET 4.12 PRESSURE TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service

Heat the oil to operating temperature: 55 +/- 5° C (131 +/- 9 °F)

To adjust the pressures, normal engine operation and the

bomb
 If these values are not reached, the flow test must be performed to check
the characteristic of the pump Flow/Pressure curve

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 84 Student Material

DCSE0060 Module 4

WORKSHEET 4.12 PRESSURE TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service

Pilot Pressure

Reading:

_____________
Relief valve
major
Reading: Start the engine
Operating temperature
______________ AEC in OFF and speed 10
Measure the pressure at (30) should be
595 +/- 29 PSI (4100 +/- 200 kPa)

(28) Locknut
(29) Setscrew
(30) Pressure tap
(31) Pilot filter

Relief valves -Start the engine

of line -Temperature 55° +/-
5° C (131° +/-9° F)
-AEC in OFF and
speed 10
-Measure the pressure in
(1) must be:

4950 +/- 72 PSI

(34300 +/- 490kPa)

(1) Pressure tap (right pump delivery pressure)

(2) Pressure tap (left pump delivery pressure)
(3) Pressure tap (power shift pressure)

Connect 8700 PSI gauges to (1) and (2), and 870PSI to (3)
Temporarily increase
the valve setting
main relief

(4) Adjustment
screw
(5) Locknut
(6) Main relief valve

Start the engine until the system reaches operating temperature.

hydraulic, AEC switch to OFF and engine speed 10
On the MONITOR enter service mode and set the PRV to 420PSI (2900 kPa)
“fixed power shift pressure”
Make the holes and write down the values
The pressure must be 36800 ± 1470 kPa (5350 ± 215 psi).

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 85 Student Material

DCSE0060 Module 4

WORKSHEET 4.12 PRESSURE TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service

(7) Line relief

 valve (boom
cylinder rod Readings:
end)
(8) Line relief - Feather
valve (bucket extended
cylinder head
end) ________________
(9) Line relief - Feather
valve (stick retracted
cylinder head
end) ________________

(10) Boom drift

reduction valve Readings:

(11) Line relief - Ladle

valve (boom extended
cylinder head
end) ________________
- Ladle
withdrawn

________________

(12) Line
relief valve
(stick cylinder Readings:
rod end)
(13) Stick drift - Arm
reduction extended
valve
________________
- Arm
withdrawn

________________

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 86 Student Material

DCSE0060 Module 4

WORKSHEET 4.12 PRESSURE TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Relief valve
of rotation Connect 8700 PSI pressure gauge
In (2)
Reading:
Disconnect the electrical connector
Turn right (28) of the solenoid valve
 Turning parking brake (29)
___________

Turn left

___________
Engine start, AEC in OFF and
speed in 10
Slowly move the joystick to turn
right to the top and score, repeat for
left turn
Read the value, it should be:
26000 ± 980 kPa (3750 ± 140 psi).

Connect a 8700 PSI pressure gauge to (1) for the engine valve.
Relief valve Right translation, 870 PSI at (3) and 8700 PSI at (3) for the other engine
crusade of Temporarily increase main relief
translation Lock the sprocket
Engine start, AEC in OFF and
speed at 10 up to temperature
of operation

Readings: Using the MONITOR set the PRV to

2900 kPa 420 PSI
Right caterpillar
Advance: Move the control to forward one track forward.
A blocked track, Measure the pressure,
___________ Move the control back, measure, repeat
For the other caterpillar
Reverse:
The value should be: 36800 ± 1470 kPa (5350 ± 215 psi).
___________

Left caterpillar (18) Locknut

Advance: (19) Adjustment screw
(20) Crossover relief
___________ valve (forward left
travel)
Reverse: (21) Crossover relief
valve (reverse left
___________ travel)
(22) Locknut
(23) Adjustment screw

Ferreyros SAA Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 87 Student Material

DCSE0060 Module 4

WORKSHEET 4.13 DRAIN FLOW TESTING

Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Box Drain
main pump

Pressure:
Normal: 14.5 PSI
Disconnect line (1) and put in “no load” at 1860 RPM and
A plug in (2), a line operating temperature
To the hose that goes to the
Measurable deposit.

Start the engine, EAC in OFF Drain flow with 2 pumps:

Speed at 10, hold the - Raise the BOOM with the joystick holding for 1 minute, measure the amount
Peaks: 21.8 PSI Drain flow with right pump:
- Close the BUCKET with the joystick holding for 1 minute
Drain flow with left pump:
Flows: - Disconnect the harness from the
Parking brake solenoid turn
Right pump: - Move the turn joystick to a
side against the brake keeping
_________ 1 minute
measure the flow
Left pump: Repeat three times and get average

__________ At 5076 PSI (35000 kPa) flows:

- 1 pump 17.3 Lmin (4.57 US gpm)
2 Pumps: - 2 pumps 26.0 Lmin (6.87 US gpm)

__________ Drain temperature 20°C higher than

suction

Box Drain Disconnect line (1) from the “T”

swing motor and put a plug in (2), a
the line to the hose that goes to the
Measurable deposit.

Disconnect the solenoid valve

Flow: From the turning parking brake

_________ Start the engine, EAC in OFF

Speed at 10, hold the
in “no load” at 1860 RPM and
operating temperature

Move the steering joystick against the brake for 1 minute, repeat three times.
measurement

For a pressure of 26000 ± 980 kPa (3750 ± 140 psi) the values are:
- New swing motor..... ...... 30L/min (7.9 US gpm)
- Rebuilt swing motor.. 35 L/min (9.2 US gpm)

Ferreyros SAA Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 88 Student Material

DCSE0060 Module 4

WORKSHEET 4.13 DRAIN FLOW TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Box Drain
engine of
translation _________

Right engine:

_________

Left engine:
 Block a caterpillar
Install the lines as shown

Start the engine, EAC OFF

Speed at 10, hold the
in “no load” at 1860 RPM and
operating temperature

Move the translation control of the

Caterpillar evaluated at full speed for 1 minute
Under pressure from:
34300 ± 490 kPa (4950 ± 72 psi)

- New travel motor..... ...... 15 L/min (4.0 US gpm)

- Rebuilt travel motor.. 18 L/min (4.78 US gpm)
Flow blockage
(brake solenoid
parking lot) (3) 6V-9509 Face
seal plug
With implements in (4) 6V-8398 O-Ring
neutral, solenoid on seal
OFF and pressure (5) Case drain hose
must (6) Connector
be 0 PSI (7) Remote drain
hose
Reading: (8) Container for
measuring

When rotating, solenoid

in ON and pressure
same as the pilot

(1) 8T-0856 Pressure

Gauge
(2) 6V-3989 Fitting
(3) 6V-4143 Coupler
(4) 177-7860 Hose
Assembly
(5) Swing motor
(6) Connector at rear of
swing motor
(7) 6V-8397 O-Ring Seal
(8) 6V-3965 Fitting
Assembly
(9) 3J-1907 O-Ring Seal
(10) Pilot hose
(11) 8T-8902 Tee
Reading:

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 89 Student Material

DCSE0060 Module 4

REFERENCE TEXT:
- Flow
FLOW METER - Pressure
- Temperature
In any case - Speed
hydraulic system
This team measures
digital way:
 Pressure:
Specs: 0 to 500 bar (0 to 6800 PSI)
Temperature
Flow: 10 to 120°C (50 to 250 °F)
13 to 475 L/min (3.5 to 125 gpm) Speed
0 to 6000 RPM

Always connect with

the open valve

TEST METHODS

Online. In “Tee”
Close the valve creating pressure, compare with the Move an actuator, close the valve, the
pump specification, 20% to 30% of pressure increases until the relief opens, the
loss indicates damage or wear flow drops to zero
Move all the actuators, one at a time, the
readings should be similar or there is a leak

Online Directional Actuators

Check for internal leaks in cylinders and control Connect the meter instead of the actuators
Operate the control where I connect the meter, close and close the valve, if it is different from
the valve fully, the reading is the relief previous specifications or tests indicate
Compare the flow specified on the engine against Leaks in the control or actuators
reading under normal engine load

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 90 Student Material

DCSE0060 Module 4

WORKSHEET 4.14 FLOW TESTING

Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Constant Power Flow Control
Procedure Identify the components and trace the flow path (use the code below).
colors)
Start the engine, EAC in OFF Speed at 10, operating temperature
On the MONITOR set the PRV to a value on the pressure gauge
2400 ± 50 kPa (350 ± 7 psi).
Using the flowmeter, increase the pressure of the pump being evaluated (pressure gauge) and
Write down the flow values in the respective table
Correct flow to specified values at 1800RPM
( Flow measured x 1800 RPM )
Corrected flow = -----------------------------------------
( RPM read )
Plot the read values and trace the curve comparing it to the specification

(10)Portable hydraulic tester

(flow meter)
(22) Multi-tap
(26) Valve
( ) Pressure tap (left pump
delivery pressure)
( ) Pressure tap (right pump
delivery pressure)
( ) Pressure tap (power shift
pressure)

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 91 Student Material

DCSE0060 Module 4

WORKSHEET 4.14 FLOW TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Pump Flow Test
Points to Measure
Right pump 9800 kPa 15700 kPa 19600 kPa 25500 kPa 29400 kPa
1425 PSI 2300 PSI 2850 PSI 3700 PSI 4250 PSI
Measured flow
L/min (US gpm)
Temperature
 °C (°F)
Engine RPM

Corrected flow
L/min (US gpm)
Specs 172 +/- 10 135 +/- 10 110 +/- 10 86 +/- 10 75 +/- 10
L/min (US gpm) 45.4 +/- 2.6 35.6 +/- 2.6 29 +/- 2.6 22.7 +/- 2.6 19.8 +/- 2.6
Left pump

Measured flow
L/min (US gpm)
Temperature
°C (°F)
Engine RPM

Corrected flow
L/min (US gpm)
Specs 172 +/- 10 135 +/- 10 110 +/- 10 86 +/- 10 75 +/- 10
L/min (US gpm) 45.4 +/- 2.6 35.6 +/- 2.6 29 +/- 2.6 22.7 +/- 2.6 19.8 +/- 2.6

Graph and
analyze

Ferreyros SAA Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 92 Student Material

DCSE0060 Module 4

WORKSHEET 4.14 FLOW TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Negative Flow Control
Procedure Identify the components and trace the flow path (use the code below).
colors)
Start the engine, EAC in OFF Speed at 10, operating temperature
On the MONITOR set the PRV to a value on the pressure gauge
2350 kPa (340 PSI).
Using the flowmeter, increase the pressure of the tested pump (pressure gauge) to
6850 kPa (1000 psi) and record the flow value in the table
Correct flow to specified values at 1800RPM

( Flow measured x 1800 RPM )

Corrected flow = -----------------------------------------
( RPM read )

Values should be taken while increasing pressure

(10)Portable hydraulic tester

(flow meter)
(22) Multi-tap
(26) Valve
( ) Pressure tap (left pump
delivery pressure)
( ) Pressure tap (right pump
delivery pressure)
( ) Pressure tap (power shift
pressure)

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 93 Student Material

DCSE0060 Module 4

WORKSHEET 4.14 FLOW TESTING

(continuation)
Procedure Perform the requested tests following the procedure in the manual.
RENR3817 service
Negative Flow Test
Point to Measure
Right pump 2350 kPa
340 PSI
Measured flow L/min (US gpm)
Temperature °C (°F)
Engine RPM
Corrected flow L/min (US gpm)
Specifications L/min (US gpm)
NEW E
Specifications L/min (US gpm) C
 LIMIT 100 +/- 10
Left pump 26 +/- 2.6
80
Measured flow L/min (US gpm) 21
Temperature °C (°F)
Engine RPM
Corrected flow L/min (US gpm)
Specifications L/min (US gpm)
NEW
Specifications L/min (US gpm)
SERVICE LIMIT 100 +/- 10
26 +/- 2.6
80
21

Locate the point and

analyze

Ferreyros S.A.A. Pilot Pump Flow Test Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4
Point to Measure
Gear Pump 4100 ± 200 kPa (595 ± 29 psi).
Measured flow L/min (US gpm)
Course: 320C Excavator Temperature °C (°F) 94 Student Material
DCSE0060 Module 4
Engine RPM
Corrected flow L/min (US gpm)
Specifications L/min (US gpm) 36 +/- 2
WORKSHEET 4.14 FLOW TESTING
NEW 9.5 +/- 0.5
(continuation)
Specifications L/min (US gpm) 30
Procedure Perform the requested
SERVICEtests following the procedure in the manual.
LIMIT 7.9
RENR3817 service
Pilot Pump Flow
Procedure Identify the components and trace the flow path (use the 30
10 20 code
40 below).
50 60 70 80 90 100
colors)
Start the engine, EAC in OFF Speed at 10, operating temperature
Using the flowmeter, increase the pressure of the tested pump (pressure gauge) to
4100 ± 200 kPa (595 ± 29 psi).and record the flow value in the table
Correct flow to specified values at 1800RPM

( Flow measured x 1800 RPM )

Corrected flow = -----------------------------------------
( RPM read )

Values should be taken while increasing pressure

Ferreyros S.A.A. Technical Development

Jorge Gorritti- May 06 Student Manual 320C - Module 4

Course: 320C Excavator 95 Student Material

DCSE0060 FINAL SURVEY
NAME (OPTIONAL): _____________________________________________________________

DATE: __________________COURSE:__________________INSTRUCTOR:_______________

Mark X in the table from 10% to 100% (10% minimum, 100% maximum)

1. From the Instructor

Do you have mastery and knowledge of the subject and the material used?
Does it encourage group participation?
Is your presentation clear and does it use good instructional methods?
Does it answer the questions that are asked?
2. From the course material
Does it have a good presentation?
Does it contain necessary and important information?
Does it facilitate the development of the topics?
 Does it facilitate the development of the practical part?
3. Course development
Were all the topics covered?
Was the depth of the theoretical topics sufficient?
Are the objectives of each module clear and satisfactory?
Were the course objectives met?
Was classroom time enough?
Was the time for the practical part sufficient?
Was the practical part important and well developed?
Classroom facilities, laboratories and use of equipment
audiovisual was of quality?
4. From the student
Were you properly prepared (did you meet the prerequisites)?
to receive this course?
Were your expectations met?
How much did the course increase your knowledge on the topic?
How much will the course help your specific job?
Will you have access to the tools used in the course?
Will you be able to apply what you have learned in your daily work?
Did it keep your interest and attention throughout the course?
What was the degree of participation of the group?
5. Questions
What was the most useful thing about the course?

_________________________________________________________________________________
What was the least useful part of the course and what questions did you have?

What would you suggest to add or remove from the course to improve it?

What courses or tools do you need to improve?

Any other comments?

Ferreyros S.A.A. Technical Development

Jorge Gorritti - May 06 Student Manual 320C - Survey

Course: 320C Excavator 96 Student Material

DCSE0060 FINAL SURVEY
Ferreyros SAA Technical Development
Jorge Gorritti - May 06 Student Manual 320C - Survey
TECHNICAL DEVELOPMENT
MAY, 2006