312A Pump

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Producto: EXCAVATOR
Modelo: 312-A EXCAVATOR 6GK
Configuración: 312 TRACK-TYPE EXCAVATOR 6GK00001-UP (MACHINE) POWERED BY 3064 ENGINE
Pruebas y Ajustes
311 AND 312 EXCAVATORS HYDRAULIC AND ELECTRONIC SYSTEMS
Número de medio -SENR6124-02 Fecha de publicación -08/11/1995 Fecha de actualización -12/10/2001
Testing and Adjusting
I ntroduction
NOTE: This manual is divided into the following three main sections:
1. Electronic System Testing And Adjusting

2. Checking Procedures
3. Hydraulic System Testing And Adjusting
Electronic and Hydraulic Systems Testing And Adjusting sections are provided for the person who is
more familiar with the combined operation of the electronics and hydraulics.
NOTE: As a general rule, if there is a doubt to the cause of a problem, the electronic system should
be checked first.
Reference: For information on Systems Operation of the above, see the following: Systems
Operation, Electric And Electronic Systems, SENR6135 and/or Systems Operation, Hydraulic
System, SENR6136.
NOTE: This book has been completely changed from the former issue.
This manual contains information on the troubleshooting procedures of the electronic control and
hydraulic systems in the 311 and 312 excavators. For troubleshooting the engine components, refer to
the module Systems Operation, Testing And Adjusting, Basic Engine Components 3064 Engine,
SENR5546.
Checking Procedures
In each checking procedure, it is assumed that the engine operation is normal unless otherwise
specified.
Electronic Control System
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The monitor and electronic controller are the main components of the electronic control system. The
monitor and electronic controller have a self diagnostic function. Self diagnostic checks of the
monitor, electronic controller, and the communication line between them are the first steps when
troubleshooting the problem(s) in the electronic system.
Action alarm indicators on the monitor panel, alert an operator to a problem in the electronic system.
The controller service program "Data Mode" can also be used to identify the problems (see the section
of this module "Data Mode"). If the service program is activated during machine operation, problem
(s) that are monitored by the monitoring system are indicated on the character display. If the service
program is activated when the machine operation is stopped, all existing problems and past problems
(problems that have not been corrected) are indicated on the character display. To activate the
controller service program "Data Mode", refer to the "Data Mode" section in this module.
Operational Tests
If the electronic power unit control system display indicates it is operating correctly, then do
operational tests. Operate the machine, following the procedures described in the section "Hydraulic
System Testing And Adjusting". Compare the results of the operational tests with specifications to
determine the extent of the trouble. In operational tests, it is important to determine whether or not
enough hydraulic force or implement speed is a problem that extends over the entire machine or with
only a specific operation.
If there are any faults in the circuits between the main or pilot pumps and the control valves, the
overall performance of the machine will decrease. This type of problem in the hydraulic system is not
detected by the self diagnostic functions of the electronic control system described above (no action
alarm indication on character display.). To detect such a problem, it is necessary to check the flow
characteristics of the pumps, the main relief pressure, pilot pressure, etc.
Electronic Systems
Service Program
Electronic M onitor Panel
Electronic Monitor Panel

(1) Engine coolant temperature gauge. (2) Fuel gauge. (3) Action lamp. (4) Character display. (5) Monitor panel. (6)
Hydraulic oil temperature gauge. (7) Work mode selector switch. (8) Air heater indicator. (9) Charge alarm indicator. (10)
Engine coolant temperature alarm indicator. (11) Hydraulic oil temperature alarm indicator. (12) Engine oil pressure alarm
indicator. (13) Controller alarm indicator. (14) Monitor alarm indicator. (15) Work mode BOOM PRIORITY indicator.
(16) Work mode SWING PRIORITY indicator. (17) Power mode selector switch. (18) Power mode III indicator. (19)
Power mode II indicator. (20) Power mode I indicator. (21) Work mode FINE CONTROL indicator. (22) Light switch.
(23) Light 1 indicator. (24) Light 2 indicator. (25) Wiper 2 indicator. (26) Travel speed HIGH (rabbit) indicator. (27)
Travel speed LOW (tortoise) indicator. (28) Travel speed control switch. (29) AEC indicator. (30) Switch panel. (31) AEC
switch. (32) Wiper 1 indicator. (33) Washer indicator. (34) Washer switch. (35) Wiper switch. (36) Alarm cancel switch.
(37) Service switch. (38) Alarm cancel indicator.
I ntroduction
The Electronic Monitor Panel activates and displays the output received from the Electronic
Controller. The Electronic Controller is divided into two service program modes. Each program mode
has a particular function as follows:
1. Data Mode:
This program mode contains eight function modes and provides the necessary information for
the mechanic to easily determine the machine condition.
2. Calibration Mode:
This program mode contains ten function modes and provides information which should be
used to adjust and confirm system/component functions after replacement of electronic control
system components. This program mode is also used to help the mechanic troubleshoot the
machine problems.
To activate the program mode functions use the control switches provided on the electronic monitor
panel.
NOTE: Unexpected character display readings due to random operation of switches should be
disregarded.
To select a desired function mode, first start the proper service program mode (see the section "Data
Mode Start-Up" and/or "Calibration Mode Start-Up"). Then operate the control switch(es) as
specified, until the desired information is indicated on the character display.
When the selected service program function is no longer needed, use the proper procedure (see the
section "Data Mode Stop Procedure" and/or "Calibration Mode Stop Procedure") to cancel.
Data M ode
NOTE: Activation of service program "Data Mode" does not affect any machine controls and
operations except for the following:
The LED indicators for power mode switch, travel speed control switch, wiper switch, and light
switch come ON only in flashing mode during activation of service program "Data Mode".
The Data Mode contains the following function modes which provide eight categories of information:
* Power shift pressure.

* Engine speed.
* Engine coolant temperature.
* Hydraulic oil temperature.
* A/D (Analog/Digital) conversion.
* Real time error.
* Digital input.
* Output control display.
Data M ode Start-Up
Electronic Monitor Panel

(4) Character display. (17) Power mode selector switch. (18) Power mode III indicator. (36) Alarm cancel switch. (38)
Alarm cancel indicator.
NOTE: To access and view the eight available functions in Data Mode, the engine can either be
running or shut down. If the engine is running the eight Data Mode functions can be viewed as
operating values. If the engine is not running the key switch must be in the "ON" position.
1. Depress and hold alarm cancel switch (36) until alarm cancel indicator (38) starts flashing.
2. While alarm cancel switch (36) is depressed, push power mode selector switch (17) until power
mode III indicator (18) begins to flash. Release alarm cancel switch (36) and power mode selector
switch (17).
3. The service program "Data Mode" is now activated and character display (4) will display the first
function mode (power shift pressure) value.
NOTE: If switch (17) is held too long, the character display will sequence through the eight available
function modes in the Data Mode program.
Data M ode Function Selection
Electronic Monitor Panel (Data Mode Function Selection)

(4) Character display. (17) Power mode selector switch. (18) Power mode III indicator. (36) Alert cancel switch.
1. Repeatedly push first alarm cancel switch (36) and then power mode switch (17) until the desired
function mode is displayed on character display (4).
2. Each time both switches are pushed, the function mode changes in an increasing number sequence
of the eight function modes in a repetitious manner.
3. At the same time that the function mode character is displayed the corresponding switch indicator
comes on. To determine the function mode selected, look for the switch indicator which is flashing.
NOTE: If alarm cancel switch (36) is depressed for more than 2 seconds the Data Mode stops and
character display (4) displays the engine speed dial position.
NOTE: Accessing the "Data Mode Functions" must be performed in the sequence shown in the
following chart.
Each of the eight Data Mode functions has a designated indicator light. The following chart shows the
eight Data Mode functions and their designated indicator lights:
Power Shift Pressure
Electronic Monitor Panel (Power Shift Pressure)

(4) Character display. (17) Power mode selector switch. (18) Power mode III indicator. (36) Alarm cancel switch.
When this function mode is selected, power mode III indicator (18) flashes. The character display (4)
displays "P" in the first position and actual power shift pressure in the second and third positions. The
unit of power shift pressure is in kgf/cm2. 1 kgf/cm2 is approximately the same as 98 kPa (14.5 psi).
Engine speed
Electronic Monitor Panel (Engine Speed)

(4) Character display. (19) Power mode II indicator.
When this function mode is selected, power mode II indicator (19) flashes. Character display (4) will
display the engine speed in rpm, regardless of the machine load. Multiply the rpm values in character
display (4) by 10 to determine actual rpm.
Engine Coolant Temperature
Electronic Monitor Panel (Engine Coolant Temperature)

(4) Character display. (20) Power mode I indicator.
When this function mode is selected, power mode I indicator (20) flashes. Character display (4)
displays the engine coolant temperature within a range of 14°C to 127°C (57.2°F to 260.6°F). The
engine coolant temperature units are displayed in 1°C (1.8°F) increments.
NOTE: Character display (4) displays the engine coolant temperature in degrees Celsius.
Hydraulic Oil Temperature
Electronic Monitor Panel (Hydraulic Oil Temperature)

(4) Character display. (23) Light 1 indicator.
When this function mode is selected, light 1 indicator (23) flashes. Character display (4) displays the
hydraulic oil temperature within a range of 14°C to 127°C (57.2°F to 260.6°F). The hydraulic oil
temperature units are displayed in 1°C (1.8°F) increments.
NOTE: Character display (4) displays the hydraulic oil temperature in degrees Celsius.
A/D (Analog/Digital) Conversion
Electronic Monitor Panel (A/D Conversion)

(4) Character display. (24) Light 2 indicator.
When the analog/digital conversion function mode is selected, light 2 indicator (24) flashes. Character
display (4) displays the analog information for eight machine functions. A conversion chart is needed
to understand the digital information indicated. Description of the eight machine functions omitted
since this information is not needed for service or diagnosis.
Real Time Error Codes
Electronic Monitor Panel (Real Time Error Codes)

(4) Character display. (26) Travel speed HIGH (rabbit) indicator.
When this mode is selected, travel speed HIGH (rabbit) indicator (26) flashes. Character display (4)
displays the codes for problems that have occurred. They are displayed in an increasing number
sequence according to "Problem List" shown below, in a repetitious manner. A character display code
remains displayed for 2 seconds with an interval of 1 second between codes.
NOTE: A display code of [E00] indicates that there are no system errors.
NOTE: Go to the appropriate "Electronic Sequence Chart" to troubleshoot the problem of [E33] in
accordance with the following:
Digital I nput
Electronic Monitor Panel (Digital Input)

(4) Character display. (7) Work mode switch. (17) Power mode selector switch. (27) Travel speed LOW (tortoise)
indicator. (36) Alarm cancel switch.
When this mode is selected, travel speed LOW (tortoise) indicator (27) flashes. This mode displays 21
types of information on character display (4).
1. Depress and hold alarm cancel switch (36) and then depress work mode switch (7) until travel
speed LOW (tortoise) indicator (27) flashes. Release alarm cancel switch (36) and work mode switch
(7).
2. Character display (4) will display [012]. The "0" indicates that this is the first of 21 "ports" or
additional types of information. The "12" indicates the wiring harness code for the 312 Excavator. A "
9" indicates the wiring harness code for the 311 Excavator.
3. To sequence through the 21 "ports", first depress and hold alarm cancel switch (36) and then work
mode switch (7) until the character display reads the desired "port".
NOTE: This mode is capable of providing a total of 21 types of information. Nine of the 21
"ports" (additional types of information) are spares.
The following chart gives a listing of the 21 "ports" and their components:
NOTE: Ports "0" and "1" give no indication of "[ O n] or [ o F] on the character display.
Typical Examples:
[012] : Indicates the machine model of "312" excavator.
[0 9] : Indicates the machine model of "311" excavator.
[1 1] : Engine speed dial is in position "1".
[110] : Engine speed dial is in position "10".
[1Er] : There is a problem in engine speed dial or circuit between speed dial and controller. (Er:error)
[2On] : Travel pressure switch is ON.
[2oF] : Travel pressure switch is OFF.
NOTE: To check the travel pressure switch, activate the travel control with the pressure switch in the
ON position. If the character display does not read [2On], it is an indication of a possible problem in
the travel pressure switch and/or its circuit.
Output Control Display
Electronic Monitor Panel (Output Control Display)

(4) Character display. (32) Wiper 1 indicator.
When this function mode is selected, wiper 1 indicator (32) flashes. Character display (4) displays the
code that represents current pump output. The initial code displayed will be [L00] for a normal pump
output control. The character display code remains ON for 2 seconds with an interval of 0.5 seconds
between codes.
Typical Examples:
[L00] : Output control is normal.
[L A] : Pump output control when governor actuator feedback sensor is abnormal.
[L b] : Pump control under too low hydraulic oil temperature.
NOTE: [L b] is displayed only when one of the controls is activated.
NOTE: During "Output Control Display" function, the AEC system and one touch low idle do not
activate. The engine speed dial switch controls the engine speed only under a no load condition.
Reference: For more information on the pump output control, refer to module, "Systems Operation,
Electronic System", SENR6135.
Data M ode Stop Procedure
Electronic Monitor Panel (Stop Procedure)

(4) Character display. (36) Alarm cancel switch.
Use either of the following two methods.
1. Turn the engine start switch to the OFF position.
2. Keep alarm cancel switch (36) depressed at least 2 seconds until character display (4) displays the
engine speed dial position.
Calibration M ode
NOTE: The procedures for each function in "Calibration Mode" are independent of each other. The
engine does not need to be running for all the functions listed in the following chart. The following
chart lists the functions in "Calibration Mode" and whether the engine must be running for each of the
functions:
Calibration M ode Start-Up
Electronic Monitor Panel (Calibration Mode Start-Up)

(1) Engine coolant temperature gauge. (2) Fuel gauge. (3) Action lamp. (4) Character display. (6) Hydraulic oil
temperature gauge. (8) Air heater indicator. (9) Charge alarm indicator. (10) Engine coolant temperature alarm indicator.
(11) Hydraulic oil temperature alarm indicator. (12) Engine oil pressure alarm indicator. (13) Controller alarm indicator.
(14) Monitor alarm indicator. (37) Service switch.
NOTI CE
Before the Calibration M ode is started, the engine speed dial switch
should be set at dial position "1" and the engine start switch must be in
the OFF position.
1. Depress service switch (37) and start the engine. As shown in the chart above, the engine does not
need to be started to obtain information for certain functions in the "Calibration Mode".
2. Continue to depress service switch (37) until action lamp (3) comes ON and character display (4)
displays [12H] or [11H]. All the alarm indicators except character display (4) will turn OFF.
3. The "Calibration Mode" is now accessed and character display (4) displays the first of the 10
functions (machine and engine model numbers) as shown in the chart above. Action lamp (3) remains
ON during all calibration function modes.
NOTE: Activation of the "Calibration Mode" overrides the function of engine coolant temperature
gauge (1), fuel gauge (2), action lamp (3), hydraulic oil temperature gauge (6), air heater indicator (8),
charge alarm indicator (9), engine coolant temperature alarm indicator (10), hydraulic oil temperature
alarm indicator (11), engine oil pressure alarm indicator (12), controller alarm indicator (13), and
monitor alarm indicator (14).
Calibration M ode Function Selection
Electronic Monitor Panel (Function Selection)

(3) Action lamp. (4) Character display. (17) Power mode selector switch. (22) Light switch. (28) Travel speed control
switch. (31) AEC switch. (35) Wiper switch.
Power mode selector switch (17), light switch (22), AEC switch (31), wiper switch (35), and travel
speed control switch (28) are pushed each time to obtain one of the following ten function modes:
M achine And Engine M odel
Electronic Monitor Panel (Machine And Engine Model)

(4) Character display. (17) Power mode selector switch. (18) Power mode III indicator.
1. Start "Calibration Mode". See the section, "Calibration Mode Start-Up".
Upon accessing the "Calibration Mode", the machine and engine model is the first function accessed.
To obtain this function again after viewing or accessing any of the other functions, depress power
mode selector switch (17) until power mode III indicator (18) comes ON.
2. Character display (4) displays [12H] for a "312" excavator and displays [11H] for a "311"
excavator.
The first and second positions of character display (4) represents the model of the excavator. The third
position of character display (4) shows the code for an excavator with a backhoe configuration.
3. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration
Mode Stop Procedure".
NOTE: Activation of the "Calibration Mode" overrides the AEC function and keeps the power shift
pressure constant at a pressure level equivalent to a no-load condition. The engine speed dial switch
works normally.
Controller/M onitor Software Version
Electronic Monitor Panel (Controller/Monitor Software Version)

(4) Character display. (17) Power mode selector switch. (19) Power mode II indicator. (31) AEC switch.
2. Depress power mode selector switch (17) until power mode II indicator (19) comes ON.
3. Character display (4) displays [17C] for example. The "17" in the character display represents a
two digit numeral particular to the software for each machine mode. The "C" represents the controller.
4. To determine the software version for the monitor depress AEC switch (31). Character display (4)
displays [20P] for example. The "20" in the character display represents a two digit numeral particular
to the software for each machine mode. The "P" represents the software version.
NOTE: Each time AEC switch (31) is depressed, the character display will alternate between the two
software codes [17C] and [20P] for example.
works normally.
Error log
Electronic Monitor Panel (Error Log)

(4) Character display. (17) Power mode selector switch. (20) Power mode I indicator. (28) Travel speed control switch.
(31) AEC switch. (34) Washer switch.
2. Depress power mode selector switch (17) until power mode I indicator (20) comes ON.
3. Character display (4) displays [Hd]. This display indicates that the list of stored error codes can be
viewed. The controller has a continual self-diagnostic function during machine operation. The
controller will store error codes if a fault is detected, even an intermittent fault. The list of error codes
is stored in the error history on important systems until the memory is cleared.
4. The error codes are viewed on the character display either in ascending or descending order. Each
time AEC switch (31) is depressed, the ascending sequential list of stored error codes are displayed as
shown in the following example:
[Hd]
[F 6]
[F10]
[F40]
[F41]
[End]
5. Each time washer switch (34) is depressed, the descending sequential list of stored error codes are
displayed as shown in the following example:
[End]
[F41]
[F40]
[F10]
[F 6]
[Hd]
NOTE: A "F" in the first position of character display (4) represents a stored error code (error
history). An "E" in the first position of character display (4) represents a real time error code.
6. To clear the error codes and error history, push and hold in sequence for approximately three
seconds the following three buttons:
* AEC switch (31)

* Power mode selector switch (17)
* Travel speed control switch (28)
7. The error codes are cleared from the error history memory when character display (4) displays
[CLr] and then returns to display [Hd].
Reference: For a listing of error codes, see the section in this module "Data Mode, Real Time Errors
Codes".
NOTE: Information about a problem is stored by this function mode until the correct clearing
procedure is completed. Always clear the error history after the problem has been corrected.
NOTE: Activation of the error log mode overrides the function of the AEC system and keeps the
power shift pressure constant at the no load pressure level. The engine speed dial works normally.
NOTE: The following error log codes are not displayed on the character display during activation of
this calibration mode. F1 to F5, F7, F9, F12, F15, F32, F34, F37, F38, F39, and F48.
works normally.
Digital Output Test
Electronic Monitor Panel (Digital Output Test)
(4) Character display. (22) Light switch. (23) Light 1 indicator. (29) AEC indicator. (31) AEC switch. (33) Washer
indicator. (34) Washer switch. (36) Alarm cancel switch.
2. Depress light switch (22) until light 1 indicator (23) comes ON.
3. Character display (4) displays [0oF] which represents the first of 10 components that can be tested.
There are 16 "ports" available of the electrical connections for various controller output components
(similar to the "Digital Input" information accessed in "Data Mode"). Six of the "ports" are spares.
The code in the first position of the character display represents the particular "port" of each
component.
The "ports" and their components are shown in the following chart:
4. Each time AEC switch (31) is pushed, a different port code appears in character display (4) in an
ascending order. Press washer switch (34) to view the ports in descending order.
5. Press alarm cancel switch (36) to turn the component for each port, either ON or OFF. Character
display (4) displays as shown in the chart above as each port is turned ON or OFF. If an over current
occurs at a component, the character display (4) displays [0Er].
works normally.
Proportional Reducing Valve Sweep Test
Test Preparation
Pilot Oil Manifold Compartment

(39) Connector.
1. Stop the engine and disconnect connector (39) from the proportional reducing valve.
2. Connect the test harness to connector (39).
Pump Compartment
(40) Power shift pressure tap.
3. Install a 4850 kPa (700 psi) pressure gauge at power shift pressure tap (40).
4. The pump backup switch must be in the "AUT" position.
NOTE: The engine must be running to obtain accurate information for this test.
6. Warm the hydraulic oil to normal operating temperature.
7. Run the engine at maximum no-load rpm.
8. All controls must be in the NEUTRAL position.
Electronic Monitor Panel (Proportional Reducing Valve Sweep Test)

(4) Character display. (22) Light switch. (24) Light 2 indicator.
9. Start the "Proportional Reducing Valve Sweep Test" as follows:
a. Depress light switch (22) until light 2 indicator (24) comes ON.
b. The left column of character display (4) displays the letter "P". The "P" in the first column
indicates that the proportional reducing valve is being tested.
NOTE: The purpose of this function is to check whether the proportional reducing valve is activating
with a current signal from the controller. When this function is selected, the second and third column
in character display (4) changes in an ascending number sequence from of 0 to 32. One cycle range
from 0 to 32 takes about five seconds. The character display (4) sequences form [P 0] to [P32].
10. As the "PRV Sweep Test" is being performed, monitor the multimeter and the that the first
calibration point has been accessed and the "0" indicates that the middle step of the 19 individual
calibration steps has been accessed. Each step will change the power shift pressure by approximately
50 kPa (8 psi).
NOTE: During the "PRV Sweep Test" the multimeter and pressure gauge readings should cycle at a
uniform rate of increase or decrease (no "spike" or quick changes). Also, during activation of this
function mode, AEC functions do not activate, but speed dial activates as normal.
11. Stop "Calibration Mode" (unless another function selection is desired). See the section,
"Calibration Mode Stop Procedure".
Engine Speed Change
NOTE: This test is useful to measure no load engine speeds in increments of 20 to 30 rpm, from the
factory preset LOW IDLE to HIGH IDLE positions of the governor speed dial switch. This test is
suitable for noise level measurement tests.
Electronic Monitor Panel (Engine Speed Change)

(4) Character display. (29) AEC indicator. (31) AEC switch. (32) Wiper 1 indicator. (33) Washer indicator. (34) Washer
switch. (35) Wiper switch.
2. Depress wiper switch (35) until wiper 1 indicator (32) comes ON.
3. Put the governor speed dial switch in the best position for the test requirement (the position that
comes closest to the desired engine rpm setting).
4. Depress AEC switch (31) to increase the engine rpm, and depress washer switch (34) to decrease
engine rpm. Each time AEC switch (31) is depressed, AEC indicator (29) comes ON. Each time
washer switch (34) is depressed, washer indicator (33) comes ON.
5. Character display (4) will increment by 1 (10 rpm).
Fixed Power Shift Pressure
NOTE: This test allows the power shift pressure command signal to remain constant at a desired
pressure level. The constant power shift pressure command signal is necessary to allow testing and
adjusting procedures to be performed to line relief valves and also perform pump "P-Q" tests.
Electronic Monitor Panel (Fixed Power Shift Pressure)
(4) Character display. (25) Wiper 2 indicator. (31) AEC switch. (34) Washer switch. (35) Wiper switch. (36) Alarm cancel
switch.
2. Depress wiper switch (35) until wiper 2 indicator (25) comes ON.
3. Character display (4) will display "P" in the first position and the selected power shift pressure in
the second and third positions. As a example the value shown in character display (4) of [P25] is in
kgf/cm2. To convert kgf/cm2 to kPa, multiply the value shown in character display (4) by 98. The
resultant power shift pressure is 2450 kPa (355 psi)
4. Depress AEC switch (31) to increase the power shift pressure command signal by 1 kgf/cm2.
5. Depress washer switch (34) to decrease the power shift pressure command signal by 1 kgf/cm2.
NOTE: Depressing alarm cancel switch (36) causes character display (4) to display alternately
between the power shift pressure and the engine rpm.
NOTE: Refer to "Engine Speed Change" to determine the value of engine speed displayed on
character display (4).
Engine Speed Dial Setting Check
NOTE: This test is used to verify that the selected engine speed dial switch position value is meeting
the factory engine speed setting value.
Electronic Monitor Panel (Engine Speed Dial Setting Check)

(4) Character display. (26) Travel speed HIGH (Rabbit) indicator. (28) Travel speed control switch.
2. Depress travel speed control switch (28) until travel speed HIGH (Rabbit) indicator (26) comes
ON.
3. Character display (4) displays the engine rpm value characteristic to the setting of the engine speed
dial switch position.
works normally.
Automatic Governor Actuator (G/A) Calibration
NOTI CE
The hydraulic oil temperature must be at the normal operating

temperature before this calibration procedure is performed.
NOTE: This procedure must be performed any time the governor actuator or controller has been
replaced or reinstalled.
Electronic Monitor Panel (Automatic Governor Actuator Calibration)

(4) Character display. (26) Travel speed HIGH (Rabbit) indicator. (28) Travel speed control switch. (31) AEC switch. (34)
Washer switch. (36) Alarm cancel switch.
2. Depress travel speed control switch (28) until travel speed HIGH (Rabbit) indicator (26) comes
ON.
3. Depress and hold AEC switch (31) then depress and hold washer switch (34). Character display (4)
displays [AC] in a flashing mode.
4. While still depressing AEC switch (31) and washer switch (34), depress alarm cancel switch (36)
until character display (4) stops flashing and changes to [ACP]. The automatic calibration mode is
now started and the governor actuator motor has moved to the initial high idle stop position. The
governor actuator is now calibrated to the factory engine rpm setting designated for position "10" of
the engine speed dial switch.
NOTE: Check to be sure that the governor lever is in contact with the high idle stop.
5. Once character display (4) displays [ACt], the calibration procedure can be completed.
6. Depress AEC switch (31) and washer switch (34) in sequence until character display (4) displays
[AC1]. The calibration procedure for the factory engine rpm setting designated for positions "1"
through "10" of the engine speed dial switch is now started. The calibration procedure from this point
takes approximately two minutes. Character display (4) will change as follows:
* [AC1]
* [AC2]
* [AC3]
* [AC4]
* [AC5]
* [AC6]
* [AC7]
* [AC8]
* [AC0]
When [AC0] appears in character display (4), the calibration procedure is complete.
NOTE: If the data is not correct or within specified limits, character display (4) will indicate an error
code as shown in the following chart:
NOTE: If character display (4) displays [AC2] and [-*] (*:error code shown in the following chart)
alternately during Automatic G/A Calibration procedure, it is an indication of the following possible
problems. Have necessary repairs made. If character display (4) displays [AC0] after taking corrective
action, is an indication that the automatic governor actuator calibration has been completed correctly.
NOTE: If the error code [- 1], [- 2], [- 3], [-15], or [-16] is indicated on character display (4), readjust
the accelerator/decelerator cables. See the section "Adjustment After Replacement Of Major
Components".
NOTE: If the error code [- 4] through [-12] or [-14] is indicated on character display (4), check the
corresponding checking procedure in the section "Checking Procedures (Electronic Control System)".
NOTE: When character display (4) displays [-13], return all controls to the NEUTRAL position. If
the error code still exists, check the pressure switches and circuits.
NOTE: Even if any of error codes [-51], [-52], or [-53] appears after character display (4) has
displayed [AC0], the machine does not need to be stopped immediately, but can continue to be used
for the time being. However, since these three codes indicate that the accelerator cable needs further
readjustment, it is recommended to make readjustment to the accelerator cable at your convenience,
using the following procedure:
a. If [-51] is displayed for two seconds, readjust the accelerator cable. See the section
"Adjustment After Replacement Of Major Components".
b. If character display (4) alternates between [-52] and [ 10], for example, in two second
intervals, decreases the tension by loosening the adjusting nut of the accelerator cable by one
turn. (If [ 15] is indicated, then loosen the nut one and a half turns.)
c. If character display (4) alternates between [-53] and [ 10], for example, in two second
intervals, increase the tension by tightening the adjusting nut of the accelerator cable by one
turn.
NOTE: The character display reading [-53] will change to another code as a guidance to adjust the
accelerator cable screw. When the code [ 10] is displayed, the "1" position represents the number of
turns to rotate the adjusting screw to tighten the accelerator cable.
Calibration Of Proportional Reducing Valve
NOTE: This calibration procedure must be performed when either the proportional reducing valve
and/or the controller has been replaced. This procedure is made at two power shift pressure points of 5
kgf/cm2 [490 kPa (71 psi)] and 25 kgf/cm2 [2450 kPa (355 psi).
Pump Compartment
(40) Power shift pressure tap.
1. Stop the engine and install a 4850 kPa (700 psi) pressure gauge to power shift pressure tap (40).
2. Make sure that the pump control backup switch is in the "AUT" position.
3. Start the "Calibration Mode". Refer to the section "Calibration Mode Start-Up".
NOTE: The engine must be running and have a hydraulic oil temperature of approximately 50°C
(122°F) to perform this calibration procedure.
4. Run the engine with engine speed dial switch at position "10".
NOTE: Activation of this calibration mode overrides the AEC function. If the engine speed dial
switch is not at position "10" character display (4) will show an "E" in the first column. The engine
speed must be corrected within specifications to continue the calibration procedure.
Electronic Monitor Panel (Calibration Of Proportional Reducing Valve)

(4) Character display. (27) Travel speed LOW (tortoise) indicator. (28) Travel speed control switch. (31) AEC switch. (34)
Washer switch. (36) Alarm cancel switch.
5. Depress travel speed control switch (28) until travel speed LOW (tortoise) indicator (27) comes
ON.
6. Character display (4) now displays [1 0]. The "1" indicates that the first calibration point has been
accessed and the "0" indicates that the middle step of the 19 individual calibration steps has been
accessed. Each step will change the power shift pressure by approximately 50 kPa (8 psi).
7. To change the power shift pressure:
a. To increase the power shift pressure, depress AEC switch (31) once. This will change character
display (4) to [1 1]. Each time AEC switch (31) is depressed, character display (4) increases by one
until character display (4) displays [1 9]. Also, the pressure reading at power shift pressure tap (40)
increases by approximately 50 kPa (8 psi) for each increase. The following is an example of character
display (4) readings in an increasing order:
* [1-9]
* [1-8]
* [1-7]
* [1-6]
* [1-5]
* [1-4]
* [1-3]
* [1-2]
* [1-1]
* [1 0] = Middle Step
* [1 1]
* [1 2]
* [1 3]
* [1 4]
* [1 5]
* [1 6]
* [1 7]
* [1 8]
* [1 9]
b. To decrease the power shift pressure, depress washer switch (34) once to lower the value displayed
in character display (4). Each time washer switch (34) is depressed, character display (4) decreases by
one in descending order until character display (4) displays [1-9]. Also, the pressure reading at power
shift pressure tap (40) decreases by 50 kPa (8 psi) for each decrease. The following is an example of
character display (4) readings in decreasing order:
* [1 9]
* [1 8]
* [1 7]
* [1 6]
* [1 5]
* [1 4]
* [1 3]
* [1 2]
* [1 1]
* [1 0] = Middle Step
* [1-1]
* [1-2]
* [1-3]
* [1-4]
* [1-5]
* [1-6]
* [1-7]
* [1-8]
* [1-9]
8. To set "Calibration Point No. 1", perform the following steps:
a. Depress washer switch (34) until the pressure reading at tap (40) is less than 490 kPa (71 psi).
b. Depress AEC switch (31) until the pressure reading at tap (40) increases to approximately 490 kPa
(71 psi).
NOTE: Pressure adjustments must always be made as the pressure is being increased.
c. Depress alarm cancel switch (36) to store the data in the controller.
d. Once the data is stored in the controller, display (4) changes to [2 0], which indicates that the first
calibration point has been accepted and the second calibration point can be performed.
9. To set "Calibration Point No. 2", perform the following steps:
a. Depress washer switch (34) until the pressure reading at tap (40) is less than 2450 kPa (355 psi).
b. Depress AEC switch (31) until the pressure reading at tap (40) increases to approximately 2450
kPa (355 psi).
NOTE: Pressure adjustments must always be made as the pressure is being increased.
c. Depress alarm cancel switch (36) to store the data in the controller.
d. Once the data is stored in the controller, display (4) will change to [1 0], which indicates that the
second calibration point has been accepted and the controller has reset to the first calibration point.
10. Stop "Calibration Mode" (unless another function selection is desired). See the section,
"Calibration Mode Stop Procedure".
Calibration M ode Stop Procedure
Electronic Monitor Panel (Stopping Calibration Mode)

(4) Character display. (37) Service switch.
Use either of the following two methods:
1. Place engine in LOW IDLE position and turn the engine start switch to the OFF position.
2. Depress service switch (37) for a minimum of two seconds until character display (4) changes from
"Calibration Mode" to engine speed dial position.
Adjustment After Replacement Of M ajor Components

When major components of the electronic control system have been replaced, adjustment is required.
The major components include:
* Governor actuator
* Proportional reducing valve
* Engine speed sensor
* Controller
Governor Actuator
Pump Compartment (9LJ1-UP, 2KM1-UP, And 6GK1-UP)

(1) Accelerator cable. (2) Governor actuator. (3) Decelerator cable. (4) Connector.
Pump Compartment (6BL1-UP)

(1) Accelerator cable. (2) Governor actuator. (3) Decelerator cable. (4) Connector.
Engine Compartment (9LJ1-UP, 2KM1-UP, And 6GK1-UP)

(1) Accelerator cable. (3) Decelerator cable. (5) Seal. (6) Nut. (7) Support. (8) Locknut. (9) Inner wire. (10) Nut. (11)
Locknut. (12) Outer wire. (13) Pulley.
Engine Compartment (6BL1-UP)

(9) Inner wire. (12) Outer wire. (13) Pulley.
Installation Of Accelerator And Decelerator Cables

(1) Accelerator cable. (3) Decelerator cable. (6) Nut. (7) Support. (8) Locknut. (9) Inner wire. (10) Nut. (11) Locknut. (12)
Outer wire. (13) Pulley. (14) Slot.
I nitial Setting Of Governor Actuator
1. Connect the harness of governor actuator (2) to connector (4).
2. Determine the HIGH IDLE position "10" (initial setting) by activating the automatic actuator
calibration mode. See the section in this module "Calibration Mode", Automatic Governor Actuator
(G/A) Calibration"
NOTE: The accelerator cable is a part of the governor actuator assembly. When installing a new
governor actuator and accelerator cable, the initial setting of the governor actuator is not necessary.
However, if the accelerator cable end position is changed from the factory setting by activating the
engine speed dial, for example, before the new governor actuator and accelerator cable have correctly
been installed in position the governor actuator needs to be calibrated to the initial (factory) engine
rpm setting designated for dial position "10" of the engine speed dial. Also, if current accelerator
cable was disconnected from the governor lever, the initial calibration is required. See the section in
this module, "Calibration Mode, Automatic Governor Actuator Calibration".
Adjustment Of Accelerator Cable
1. Accelerator cable (1) is identified by a blue seal (5). Turn nut (6) and locknut (8) of accelerator
cable (1) counterclockwise until they are as far apart as possible.
NOTE: If blue identification seal is missing, accelerator cable (1) is the upper cable when viewed
from the governor actuator (2).
2. Place inner wire (9) into the inner groove (groove closest to the engine) of pulley (13).
3. Wrap inner wire (9) around (counterclockwise as viewed from the front of the machine) pulley
(13).
4. Put the "T" end of inner wire (9) into slot (14). Make sure the "T" end of inner wire (9) is in line
with the inner groove (groove closest to the engine) after installation.
5. Put the threaded portion of accelerator cable (1) in the lower notch of support (7).
6. Turn pulley (13) clockwise (as viewed from the front of the machine) to the HIGH IDLE STOP
position (FULL ROTATION position).
7. Hold pulley (13) against the HIGH IDLE STOP position and turn nut (6) clockwise until the slack
is removed from inner wire (9). Tighten nut (6) approximately an additional two turns by hand.
8. Torque (standard torque) locknut (8) against support (7).
Adjustment Of Decelerator Cable
1. Turn nut (10) and locknut (11) of decelerator cable (3) counterclockwise until they are as far apart
as possible.
2. Place outer wire (12) into the outer groove (groove farthest from the engine) of pulley (13).
3. Wrap outer wire (12) around (clockwise as viewed from the front of the machine) pulley (13).
4. Put the "T" end of outer wire (12) into slot (14). Make certain the "T" end of outer wire (12) is in
line with outer groove (groove farthest from the engine) after installation.
5. Put the threaded portion of decelerator cable (3) in the upper notch of support (7). Make certain
outer wire (12) remains in outer groove of pulley (13).
6. Finger tighten nut (10) against support (7).
7. Loosen nut (10) approximately two turns to provide slack in outer wire (12).
8. Torque (standard torque) locknut (11) against support (7). Make certain nut (10) remains in
position of threaded portion of decelerator cable (3) while tightening locknut (11) against support (7).
9. Reinstall clamps to decelerator cable (3) and accelerator cable (1). Do not allow the cables to twist.
NOTE: Check to be sure that the governor lever is in contact with the high idle stop lever. Also make
sure nuts (10) and (6) are correctly tightened so that accelerator cable (1) is under tension and
decelerator cable (3) has a small amount of slack. Failure to do so could result in incorrect engine
speed setting, or overload the governor actuator. Governor actuator (2) must not be operated until the
calibration procedure is complete. If actuator (2) is operated before the calibration procedure is
complete, recalibrate.
Calibration Of Governor Actuator
Reference: Make reference to the section in this module, "Calibration Mode", "Automatic Governor
Actuator Calibration".
1. Start the engine and perform the "Automatic Governor Actuator Calibration" by activating
"Calibration Mode Start-Up".
2. After correctly calibrated, clear the error log information.
Reference: Make reference to the section in this module, "Calibration Mode", "Error Log".
Proportional Reducing Valve
1. Calibrate the proportional reducing valve.
Reference: See the section of this module, "Calibration Of Proportional Reducing Valve" in
"Calibration Mode".
2. After the proportional reducing valve is correctly calibrated, clear the error log information.
Reference: See the section of this module, "Error Log" in "Calibration Mode".
Engine Speed Sensor (M agnetic Pickup)
Installation Of Engine Speed Sensor

(1) Speed sensor. (2) Locknut. (3) Magnetic core. (4) Gear. (5) Flywheel housing.
NOTI CE
The engine must not be running prior to adjustment of the engine

speed sensor.
1. With the engine stopped, slowly tighten speed sensor (1) into flywheel housing (5) until magnetic
core (3) is in contact with gear (4).
2. Back out speed sensor (1) 3/4 turn and temporarily tighten locknut (2).
3. With the engine speed dial switch set at position "1" (LOW IDLE position) start the engine.
4. Start service program "Data Mode" and select the engine speed display function.
Reference: Make reference to the section in this module, "Data Mode"-Engine Speed.
5. The character display should read a speed of approximately 700 rpm.
6. If the character display does not read correct rpm, gradually tighten speed sensor (1). Do not turn
more than 120°.
7. If satisfactory, stop the engine and tighten locknut (2) to a torque of 44 N·m (33 lb ft).
8. After the speed sensor calibration is correct, clear the error log information.
Reference: See the section in this module, "Error Log" in "Calibration Mode".
Controller
1. Before removal/installation of the controller, be sure to turn the disconnect switch to the OFF
position.
2. Perform the automatic governor calibration procedure.
Reference: See the section in this module, "Automatic Governor Actuator Calibration" in
"Calibration Mode".
3. Perform the proportional reducing valve calibration procedure.
Reference: See the section in this module, "Calibration Of Proportional Reducing Valve" in
"Calibration Mode".
Controller I nput And Output Schematic (Voltage Signals I n Normal Operating

Condition)
312 Excavator Input And Output Schematic
311 Excavator Input And Output Schematic
Terminal (Pin) Numbers Of Controller Connection And Voltage Specifications
Terminal (Pin) Numbers Of Controller Connectors
Voltage Specifications
Checking Procedures
Harness And Wire I dentification
The colors and sizes of wires shown in the Electric Circuit Diagram are identified as described in the
following chart:
Example; [308] - BK - (18)
[308] = Circuit identification code.
BK = Wire color.
(18) = Wire size specified by AWG (American Wiring Gauge). If not indicated, wire size is AWG
NO.16.
I dentification Of Electric Components, Connectors, And

Harnesses
This section includes the charts and views that show the location of the electric components,
connectors, and harnesses.
NOTE: The material in this module is intended to be used with the separate module, "Electrical
Schematic", SENR6129.
NOTE: Each of CONN3, 5, 6, 8 and 9 located in area D has 10 poles with a different number of
plugs, as shown below. The following chart will help to identify them.
NOTE: Harnesses in partial electric schematics given in the "Checking Procedures" are identified by
A, B, and C, which are also indicated in the general and area views.
Typical Example Of Partial Electric Schematic

(1) Harness A. (2) Harness L.
NOTE: Material in this module is intended to be used with the separate module, "Electrical
Schematic", SENR6129.
Checking Procedures (Electronic Control System)

I ntroduction
Example Chart
Electronic Control System Checking Procedure Chart

(2) Preparations. (3) Problem description. (4) Error code on character display. (5) Check items. (6) Probable causes. (7)
Solution.
NOTE: In each checking procedure, the engine operation is considered to be normal unless otherwise
specified.
NOTE: The character display on the monitor panel indicates error code on character display (4)
assigned for the real time errors and error log, if problem(s) occurs. The charts that follow should be
used to troubleshoot problems indicated by error code on character display (4).
Connector information located at the top of each chart provides information on the connectors or
components that should be checked before troubleshooting. Check the connectors specified for
improper connections. Loose contact of connectors is often due to water drops collected in the
connectors.
Preparations (2) provide information on the preliminary arrangements that have to be made before
troubleshooting.
Problem description (3) in the chart states various problems indicated by the character display on the
electronic monitor panel.
Character display (4) on the electronic monitor indicates specific codes for real time errors and error
log. The display pattern of the character display is determined by what service program has been
selected.
Check items (5) list items that need to be checked with a multimeter.
(a) In the check items (5), "0 Ohms" means "there is continuity" and "infinite Ohms" means
that "there is no continuity".
(b) The connector check information - [other than ( )] : 0 Ohms.
NOTE: [Other than ( )] means all the terminals or pins of the connector except the one specified in
( ).
The following is an explanation of the terms in "Check Items (5)".
Example; (1)-(2) of CONN56M
(1) = Pin number.
(2) = Short circuit indication.
CONN56 = Connector number.
M = The male (M) or female (F) half of the connector.
Probable causes (6) shows probable cause(s) of trouble or problem.
Solution (7) shows the corrective action that should be taken to solve a particular problem. The
statement "Replace" is includes "Repair if possible".
When a continuity check is to be performed, "turn the starter switch to the OFF position". This stops
the power supply to prevent damage to the tester or short-circuiting the power supply.
When a voltage check is to be made, "turn the starter switch to the ON position" to allow power
supply. The engine should be in operation unless otherwise specified. Stable inputs and outputs
cannot be obtained without running the engine.
NOTI CE
To avoid damage to electrical components when the power supply is

ON, make sure disconnected connectors and wires do not come in
contact with the machine.
[Elec #1] Controller Self-Diagnostic LED Display
Controller Compartment
(1) LED lamp. (2) Controller.
[Elec #1-1] Normal
Normal: Green LED lamp (1) comes ON.
[Elec #1-2] Yellow And Green LED Lamp ON
Problem:
Problem in communication line between controller and monitor causes the yellow and green LED
lamps come ON.
Solution:
Check problem according to "[Elec #10-1] and [Elec #10-2.]"
[Elec #1-3] Green And Red LED Lamp ON
Problem:
Problem in controller causes the green LED lamp and red LED lamps to come ON in continuous
lighting mode. In some cases, the yellow LED lamp may come ON.
Solution:
Replace the controller.
[Elec #1-4] No Power To Controller And LED Lamps ON
Problem:
No power supply to controller causes LED lamps to come ON.
Solution:
Check problem according to "[Elec #1-5]".
[Elec #1-5] No Power To Controller
Problem:
No power supply to controller.
Solution:
Check to ensure that CONN1, 3, and 24 are properly connected. If the problem still exists,
troubleshoot according to the following sequence chart.
[Elec #2-1] PRV Circuit I s Open
Problem:
Proportional reducing valve circuit is open.
Solution:
Check to ensure that CONN56, 8, 1, and 17 are properly connected. If the problem still exists,
[Elec #2-2] PRV Circuit I s Shorted To Body Ground
Problem:
Proportional reducing valve circuit is shorted to body ground.
Solution:
Check to ensure that CONN56, 8, 1, and 17 are properly connected. If problem still exists,
[Elec #2-3] PRV Circuit I s Shorted To Battery Voltage
Problem:
Proportional reducing valve circuit is shorted to battery voltage.
Solution:
[Elec #3] Engine Speed Sensor I s Open Or Not I nstalled Correctly
Problem:
Engine speed sensor (magnetic pickup) circuit is open or speed sensor is not installed correctly.
Solution:
[Elec #4-1] Travel Pressure Switch Circuit I s Open Or Shorted To Body Ground
Problem:
Travel pressure switch circuit is open or shorted to body ground.
Solution:
Check to ensure that CONN52, 10, and 2 are properly connected. Check to ensure orifice in signal
passage to pressure switch is not blocked. If the problem still exists, troubleshoot according to the
following sequence chart.
[Elec #4-2] I mplement/Swing Pressure Switch Circuit I s Open Or Shorted to

Body Ground
Problem:
Implement/swing pressure switch circuit is open or shorted to body ground.
Solution:
[Elec #4-3] Boom Raise Pressure Switch Circuit I s Open Or Shorted To Body
Ground
Problem:
Boom raise pressure switch circuit is open or shorted to body ground.
Solution:
[Elec #5] Controller Receives Signal Of Engine Speed Other Than Specified "10"
Problem:
Controller receives signal of engine speed other than specified "10" from engine speed dial.
Solution:
[Elec #6-1] Governor Actuator Feedback Sensor Circuit I s Open Or Shorted To

Battery Voltage
Problem:
Governor actuator feedback sensor circuit is open or shorted to battery voltage.
Solution:
Check to ensure that CONN44, 10, 6, 9, and 2 are properly connected. If the problem still exists,
[Elec #6-2] Governor Actuator Feedback Sensor Circuit I s Shorted To Body

Ground
Problem:
Governor actuator feedback sensor circuit is shorted to body ground.
Solution:
[Elec #6-3] Governor Actuator M otor Circuit I s Shorted To Body Ground.
Problem:
Governor actuator motor circuit is shorted to body ground.
Solution:
[Elec #6-4] Governor Actuator M otor Does Not Rotate Or Governor Actuator
M otor Circuit I s Shorted To Battery Voltage
Problem:
Governor actuator motor does not rotate or governor actuator motor circuit is shorted to battery
voltage.
Solution:
Check to ensure that CONN44, 8, 1, and 18, and the circuits of speed change switch and governor
backup switch are properly connected. If the problem still exists, troubleshoot according to the
[Elec #6-5] Governor Actuator M otor Circuit I s Open Or Governor Backup

Switch I s I n "M AN" Position.
Problem:
Governor actuator motor circuit is open or governor backup switch is in "MAN" position.
Solution:
[Elec #6-6] Governor Actuator Remains Deactivated An Elapse Time Of 2.5

Seconds After Engine Speed Dial Has Been Set
Problem:
Governor actuator remains deactivated an elapse time of 2.5 seconds after engine speed dial has been
activated.
Solution:
Troubleshoot according to the following chart.
[Elec #7] Low I dle Switch Circuit I s Open Or Shorted To Body Ground
Problem:
Low idle switch circuit is open or shorted to body ground.
Solution:
Check to ensure that CONN26, 25 and 1 are properly connected. If the problem still exists,
[Elec #8-1] Solenoid Valve Return Circuit I s Shorted To Battery Voltage
Problem:
Solenoid valve return circuit is shorted to battery voltage.
Solution:
[Elec #8-2] Battery Voltage Cable Of Solenoid Valve Circuit I s Shorted To Body
Ground
Problem:
Battery voltage cable of solenoid valve circuit is shorted to body ground.
Solution:
Check to ensure that CONN53, 54, 10, 4, and 2 are properly connected. If the problem still exists,
[Elec #8-3] Solenoid Valve Circuit I s Open
Problem:
Solenoid valve circuit is open.
Solution:
Check to ensure that CONN53, 54, 10, 4, and 2 are properly connected. If problem still exists,
[Elec #9-1] Travel Speed Solenoid Valve Return Circuit I s Shorted To Battery
Voltage
Problem:
Travel speed solenoid valve return circuit is shorted to battery voltage.
Solution:
[Elec #9-2] Battery Voltage Of Travel Speed Solenoid Valve Circuit I s Shorted To
Body Ground
Problem:
Battery voltage of travel speed solenoid valve circuit is shorted to body ground.
Solution:
[Elec #9-3] Travel Speed Solenoid Valve Circuit I s Open
Problem:
Travel speed solenoid valve circuit is open.
Solution:
[Elec #10-1] No Power Supply To M onitor
Problem:
No power supply to monitor.
Solution:
Check to ensure that CONN6, 14 and 30 are properly connected. If the problem still exists,
[Elec #10-2] Communication Line Between Controller And M onitor I s Abnormal
Problem:
Communication line between controller and monitor is abnormal.
Solution:
[Elec #11-1] Chassis Light System Problem
Problem:
Chassis light system problem.
Solution:
Check to ensure that CONN4, 3, and 1 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
[Elec #11-2] Chassis Light Return Circuit I s Shorted To Battery Voltage
Problem:
Chassis light return circuit is shorted to battery voltage.
Solution:
Check to ensure that CONN3 and 1 are properly connected. If the problem still exists, troubleshoot
[Elec #11-3] Boom Light System Problem
Problem:
Boom light system problem.
Solution:
[Elec #11-4] Boom Light Return Circuit I s Shorted To Battery Voltage
Problem:
Boom light return circuit is shorted to battery voltage.
Solution:
312 TRACK-TYPE EXCAVATOR 6GK00001-UP (MACHINE) POWERED BY... Página 100 de 202
[Elec #12-1] Wiper System Problem (9LJ1-Up, 2KM 1-Up, And 6GK1-Up)
Problem:
Wiper system problem.
Solution:
Check to ensure that CONN32, 28, 13, 6, 3, and 1 are properly connected. If the problem still exists,
[Elec #12-1] Wiper System Problem (6BL1-Up)
Problem:
Wiper system problem.
Solution:
Check to ensure that CONN32, 28, 13, 6, 3, and 1 are properly connected. If the problem still exists,
[Elec #12-2] Wiper Return Circuit I s Shorted To Battery Voltage
Problem:
Wiper return circuit is shorted to battery voltage.
Solution:
[Elec #12-3] Washer System Problem
Problem:
Washer system problem.
Solution:
[Elec #12-4] Washer Return Circuit I s Shorted To Battery Voltage
Problem:
Washer return circuit is shorted to battery voltage.
Solution:
[Elec #13] Engine Oil Pressure Switch Circuit I s Open
Problem:
Engine oil pressure switch circuit is open.
Solution:
[Elec #14-1] Action Alarm Buzzer Circuit I s Open
Problem:
Action alarm buzzer circuit is open.
Solution:
[Elec #14-2] Action Alarm Buzzer Circuit I s Shorted To Body Ground
Problem:
Action alarm buzzer circuit is shorted to body ground.
Solution:
[Elec #14-3] Action Alarm Buzzer Return Circuit I s Shorted To Battery Voltage
Problem:
Action alarm buzzer return circuit is shorted to battery voltage.
Solution:
[Elec #15-1] Engine Coolant Temperature Sensor Circuit I s Open Or Shorted To

Battery Voltage
Problem:
Engine coolant temperature sensor circuit is open or shorted to battery voltage.
Solution:
[Elec #15-2] Engine Coolant Temperature Sensor Circuit I s Shorted To Body

Ground
Problem:
Engine coolant temperature sensor circuit is shorted to body ground.
Solution:
[Elec #16-1] Hydraulic Oil Temperature Sensor Circuit I s Open Or Shorted To

Battery Voltage
Problem:
Hydraulic oil temperature sensor circuit is open or shorted to battery voltage.
Solution:
[Elec #16-2] Hydraulic Oil Temperature Sensor Circuit I s Shorted To Body

Ground
Problem:
Hydraulic oil temperature sensor circuit is shorted to body ground.
Solution:
[Elec #17-1] Fuel Level Sensor Circuit I s Open Or Shorted To Battery Voltage
Problem:
Fuel level sensor circuit is open or shorted to battery voltage.
Solution:
[Elec #17-2] Fuel Level Sensor Circuit I s Shorted To Body Ground
Problem:
Fuel level sensor circuit is shorted to body ground.
Solution:
[Elec #18-1] Battery Voltage I s Abnormal
Problem:
Battery voltage is abnormal (not within 23 to 32V).
Solution:
Check to ensure that CONN9, 3, 2, and 1, and terminals of alternator, breaker and terminal block are
properly connected. If the problem still exists, troubleshoot according to the following sequence chart.
[Elec #18-2] Alternator Terminal P Circuit I s Open
Problem:
Alternator terminal P circuit is open.
Solution:
Check to ensure that CONN11, 9, and 2, and terminal P are properly connected. If the problem still
exists, troubleshoot according to the following sequence chart.
[Elec #19] Diagnosis Of Backup Switches And Starter Switch.
Disconnect all harnesses from backup switches and starter switch. Check for continuity across
terminals of each of the above switches. Any results other than given below indicate that the switch
has loose contacts.
[Elec #19-1] Pump Backup Switch
[Elec #19-2] Governor Backup Switch
[Elec #19-3] Engine Speed Change Switch
[Elec #19-4] Starter Switch
[Elec #20] Heater Signal I s Shorted To Battery Voltage (9LJ1-UP, 2KM 1-UP,
And 6GK1-UP)
Problem:
Heater signal is shorted to battery voltage.
Solution:
Check to ensure that CONN1 and 3, and terminals of heater relay, terminal block and air heater are
[Elec #20] Heater Signal I s Shorted To Battery Voltage (6BL1-UP)
Problem:
Heater signal is shorted to battery voltage.
Solution:
Check to ensure that CONN1 and 3, and terminals of heater relay, terminal block and air heater are
[Elec #21] Governor Actuator Feedback Sensor Voltage I s Too Low Or Not
Stable
Problem:
Governor actuator feedback sensor voltage is too low ([E 9]) or not stable ([E12]).
Solution:
With the AEC switch in the OFF position, place the engine speed dial at position "10". Check to see if
the voltage between terminal 21 of controller connector B and ground is 6.3 to 6.7 V. If the voltage is
within 6.3 to 6.7, it is normal. If not, check or replace the governor actuator, as necessary.
NOTE: To check voltages, see in this module, "Controller Connector Terminal Voltage".
[Elec #22] Engine Coolant Temperature I s Too High
Problem:
Engine coolant temperature is too high.
Solution:
Troubleshoot according to the following sequence chart.
[Elec #23] Engine Oil Pressure I s Too Low
Problem:
Engine oil pressure is too low.
Solution:
[Elec #24] Hydraulic Oil Temperature I s Too High
Problem:
Hydraulic oil temperature is too high.
Solution:
[Elec #25] There I s M ore Than 100 rpm Difference Between Engine Speed Dial
Setting And Actual Speed
Problem:
There is more than 100 rpm difference between engine speed dial setting (speed calculated from
governor actuator feedback signal) and actual speed.
Solution:
[Elec #26] M onitor Takes At Least One Second To Respond To Controller's

Signal
Problem:
Monitor takes at least one second to respond to controller's signal.
Solution:
[Elec #27] M onitor RAM I s Not Normal
Problem:
Monitor RAM (Random Access Memory) is not normal.
Solution:
[Elec #28] Controller I s I nformed Of I ts Error Signal By M onitor
Problem:
Controller is informed of its error signal by monitor.
Solution:
[Elec #29] Controller Detects I ts Error Signal By I tself
Problem:
Controller detects its error signal by itself.
Solution:
[Elec #30] Error I n Controller M emory
Problem:
Error in controller memory.
Solution:
[Elec #31] A Controller For A Different M achine I s I nstalled Or Harness Code

Problem (312 Excavator)
Problem:
A controller for a different machine is installed or harness code problem.
Solution:
[Elec #31] A Controller For A Different M achine I s I nstalled Or Harness Code

Problem (311 Excavator)
Problem:
A controller for a different machine is installed or harness code problem.
Solution:
[Elec #32] Engine Stalls
Problem:
Engine stalls.
Solution:
Hydraulic System Checking Procedures

(Hyd #1) Hydraulic Oil Supply
Reference: Refer to "Operation and Maintenance Manual",. SEBU6724.
(Hyd #2) Suction Filter Cleaning
Reference: Refer to "Operation and Maintenance Manual", From No. SEBU6724.
(Hyd #3) Adjustment Of Pressure And Flow
Reference: Refer to the section in this module, "Hydraulic System Testing And Adjusting, Pressure
Adjustment".
Reference: Refer to the section in this module, "Hydraulic System Testing And Adjusting, Pump
Flow Tests".
(Hyd #4) Check Of Pilot Pressure To M ain Control Valves
Main Control Valve Compartment (Viewed From Machine Rear)

(1) Pilot line (stick I IN). (2) Pilot line (swing RIGHT). (3) Pilot line (FORWARD LEFT travel). (4) Pilot line
(FORWARD RIGHT travel). (5) Pilot line (boom I RAISE). (6) Pilot line (bucket CLOSE).
1. To check the pilot pressure at each inlet port of the main control valves, connect a tee between each
pilot line and its control valve.
2. Attach a 0 kPa (700 psi) pressure gauge to the tee.
3. With the hydraulic activation control lever in the UNLOCKED position, operate the pilot control
lever for each function.
(Hyd #5) Swing M otor Performance Problem (M achines With Swing Pin)
(M easurement Of Case Drain Oil)
Swing Motor Compartment

(1) Case drain hose. (2) Case drain hose.
To check the swing motor performance, measure the amount of swing motor case drain oil as follows:
1. Disconnect case drain hose (1) from the swing motor.
2. Install a plug in the end of case drain hose (1) and a cap in the open port of the swing motor.
3. Disconnect case drain hose (2) from the swivel.
4. Install a cap in the open port of the swivel.
5. Put the open end of drain hose (2) into a suitable measuring container.
6. With the swing pin in the LOCKED position, operate the swing control for one minute.
7. Measure the amount of swing motor case drain oil.
NOTE: The maximum case drain oil with a swing relief pressure setting of 23 000 ± 980 kPa (3350 ±
140 psi) must be:
For a New swing motor ... 15 liter/min (4.0 U.S. gpm)
For a Rebuilt swing motor ... 17 liter/min (4.5 U.S. gpm)
(Hyd #5) Swing M otor Performance Problem (M achines Without Swing Pin)
(M easurement Of Case Drain Oil)

(1) Drain line. (2) Tee. (3) Drain line.
In Front Of Main Control Valves

(4) Pilot line. (5) Elbow.
To check the swing motor performance, measure the amount of swing motor case drain oil as follows:
1. Stop the engine. Release the pressure in the hydraulic system. See the section in this module,
"Release Of Pressure In The Hydraulic System".
2. Disconnect case drain line (3) from tee (2) on the swing motor.
3. Install a plug (3/4-16UN) in the end of case drain line (3) and a cap (3/4-16UN) in the open end of
tee (2).
4. Disconnect case drain line (1) from the swivel. Put the open end of case drain line (1) into a
suitable measuring container.
5. Install a cap (3/4-16UN) in the open port of the swivel.
6. Engage the swing parking brake as follows:
a. Disconnect pilot line (4) from elbow (5).
b. Install a cap (7/16-20UN) on elbow (5). Leave the end of pilot line (4) open to the air.
7. Start and run the engine at high idle speed of 1890 ± 80 rpm. Place the power mode switch in
MODE III position.
8. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).
9. Operate the swing control for one minute. Measure the amount of swing motor case drain oil and
record the measurement.
NOTE: Check to be sure that the swing parking brake is correctly engaged while the swing control is
being activated.
10. Disengage the swing parking brake as follows;
a. Stop the engine and release the pressure in the hydraulic system. See the section in this module,
b. Remove cap (7/16-20UN) from elbow (5).
c. Connect pilot line (4) to elbow (5).
11. Operate the swing control to place the swing motor barrel at a new position.
12. Repeat steps 1 through 9. Take three measurements.
NOTE: The maximum acceptable case oil with a swing relief pressure setting of 23 000 ± 980 kPa
(3350 ± 140 psi) must be:
For a New swing motor ... 15 liter/min (4.0 U.S. gpm)
For a Rebuilt swing motor ... 17 liter/min (4.5 U.S. gpm)
(Hyd #6) Travel M otor Performance Problem (M achines With Swing Pin)
(M easurement Of Case Drain)
Travel Motor
(1) Connector. (2) Drain hose.
To check the travel motor performance, measure the amount of case drain oil as follows:
1. Disconnect drain hose (2) from connector (1). Install a plug in the open end of drain hose (2).
2. Connect one end of the vinyl hose to connector (1) and put the other end of the vinyl hose into a
3. With the track blocked, operate the travel control for one minute.
4. Measure the amount of case drain oil.
5. Remove the track block, and move the machine forward to place the travel motor barrel in a new
position.
6. Repeat steps 1 through 4.
NOTE: The maximum case drain oil with a main relief pressure of 34 300 ± 490 kPa (5000 ± 72 psi)
must be:
For a New travel motor ... 20 liter/min (5.3 U.S. gpm)
For a Rebuilt travel motor ... 23 liter/min (6.1 U.S. gpm)
(Hyd #6) Travel M otor Performance Problem (M achines Without Swing Pin)
(M easurement Of Case Drain)
Travel Motor
(1) Connector. (2) Drain line.
Travel Motor (6BL825-UP)

(1) Connector. (2) Drain line.
To check the travel motor performance, measure the amount of case drain oil as follows:
1. Stop the engine. Release the pressure in the hydraulic system. See the section in this module,
2. Disconnect drain line (2) from connector (1). Install a plug (9/16-18UN) in the open end of drain
line (2).
3. Connect one end of the vinyl hose to connector (1) and put the other end of the vinyl hose into a
4. Start and run the engine at high idle speed of 1980 ± 80 rpm. Place the power mode selector switch
in MODE III position.
6. With the track blocked, operate the travel control for one minute.
7. Measure the amount of case drain oil.
8. Remove the track block, and move the machine forward to place the travel motor barrel in a new
position.
9. Repeat steps 1 through 7. Take three measurements.
NOTE: The maximum acceptable case drain oil with a main relief pressure of 34 300 ± 0 kPa (4950 ±
215 psi) must be:
For a New travel motor ... 20 liter/min (5.3 U.S. gpm)
For a Rebuilt travel motor ... 23 liter/min (6.1 U.S. gpm)
Hydraulic System
I ntroduction
M achines With Swing Lock Pin
Hydraulic oil pressure can remain in the hydraulic systems on this

machine after the engine and pump have been stopped. Serious injury
can be caused if this pressure is not released before any service is done
on the hydraulic systems. To prevent possible injury, refer to section,
Release Of Pressure I n The Hydraulic System, before any fitting, hose
or component is loosened, tightened, removed or adjusted.
When possible, the bucket must always be lowered to the ground before
service is started. When it is necessary for the boom to be in the raised
position while tests or adjustments are done, be sure that boom, stick
and bucket have correct support.
Swing lock must be engaged before service is started.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
During diagnosis of the hydraulic system, remember that correct oil temperature, flow, and pressure
are necessary for correct operation. Pump output (oil flow) is a function of engine speed (rpm). Oil
pressure is caused by resistance to the flow of oil.
M achines Without Swing Lock Pin
Hydraulic oil pressure can remain in the hydraulic systems on this

machine after the engine and pump have been stopped. Serious injury
can be caused if this pressure is not released before any service is done
on the hydraulic systems. To prevent possible injury, refer to section,
Release Of Pressure I n The Hydraulic System, before any fitting, hose
or component is loosened, tightened, removed or adjusted.
When possible, the bucket must always be lowered to the ground before
service is started. When it is necessary for the boom to be in the raised
position while tests or adjustments are done, be sure that boom, stick
and bucket have correct support.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
During diagnosis of the hydraulic system, remember that correct oil temperature, flow, and pressure
are necessary for correct operation. Pump output (oil flow) is a function of engine speed (rpm). Oil
pressure is caused by resistance to the flow of oil.
Visual Checks
A visual inspection of the system is the first step when troubleshooting a problem. Make the
inspection with the engine off and the implements lowered to the ground.
1. Check the level of the oil in the hydraulic tank. Slowly loosen the hydraulic tank air vent plug and
release the pressure before the filler cap is removed.
2. Remove the filter element and check it for material that would give an indication of damage to a
component.
3. Inspect all lines and connections for damage or leaks.
4. Inspect control linkage for bent, broken, or damaged components.
Checks During Operation

The checks during operation can be used to find leakage in the system. They can also be used to find a
valve, pump, motor, or cylinder that is not working correctly. The speed of rod movement or the
torque on a motor can be used to check the condition of the cylinders, motors, and pumps.
Operational Tests
NOTE: For specifications given in "Operational Tests", a "NEW" specification is the performance
that can be expected for a new machine. A "REBUILD" specification is the performance target to use
after rebuilding the components of a system. A machine that performs beyond "Service Limit"
specifications should be checked for improper maintenance or adjustment, component wear, or

failure.
Specifications given in charts for the 312 Excavator are for a machine equipped with 4650 mm (15 ft
3 in) boom, 2500 (8 ft 2 in) stick, and SAE 0.52 m3 (5/8yd3) bucket.
Specifications given in charts for the 311 Excavator are for a machine equipped with 4300 mm (14 ft
1 in) boom, 2250 mm (7 ft 4 in) stick, and SAE 0.45 m3 (5/8yd3) bucket.
NOTE: The power mode selector switch must be placed at Mode III position, unless otherwise
specified, during tests.
Operational Test Preparations
1. Engine speed:
312 Excavator with no load at high idle, 1980 ± 80 rpm
311 Excavator with no load at high idle, 1880 ± 80 rpm
2. Hydraulic oil temperature: 55 ± 5°C (130 ± 9°F)
NOTE: Fully move the stick in and out several times until the normal hydraulic oil temperature
is reached.
3. Relief valve pressure settings are set according to specification.
Reference: Make reference to the section in this module "Relief Valves", "Specifications".
Travel Test On Level Ground
Test Preparation:
1. Set engine speed and increase the hydraulic oil to normal operating temperature.
Reference: Make reference to the section "Operation Tests Preparation"
2. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft) long.
4. Draw a 25 m (82.5 ft) straight line on travel test ground as a reference line.
5. Position the machine so that one track is in line (parallel) with the reference line. Put the machine
in the travel test position as shown in the illustration.
6. The bucket must be empty.
Test Procedure:
1. Start the engine and place the power mode selector switch in mode III position. Place the engine
speed dial at position "10" and the travel speed switch in HIGH (rabbit) position. Move the machine
by operating both travel levers at the same time.
2. The first 5 m (16.5 ft) are for a preliminary run. Measure the time required for the machine to travel
the remaining 20 m (66 ft) in each direction (FORWARD and REVERSE).
3. Measure the travel deviation from the reference line.
4. Repeat the above procedure with the travel speed switch in LOW (turtle) position.
NOTE: The following chart represents the time (in seconds) it should take to complete the 20 m (66
ft) test run:
NOTE: The following chart represents the travel deviation from the reference line:
Travel On Level Ground (Optional Test)
NOTE: If suitable ground (as stated in Step No.2 in "Test Preparation" for "Travel On Level
Ground") cannot be found, the following test should be done as a substitute.
Test Preparation:
2. Place the machine on level ground.
3. Raise a track for the test as shown in the illustration.
4. Put a mark on a shoe of the raised track.
Test Procedure:
1. Start the engine and place the power mode selector switch in power Mode III position. Run the
raised track with the engine speed dial at position "10" (HIGH IDLE) and the travel speed switch in
HIGH (rabbit) position.
2. Measure the time required for the track to make three complete turns (revolutions) in each direction
(FORWARD and REVERSE).
3. Repeat the above procedure with the travel speed switch in LOW (turtle) position.
Drift On Slope
Measuring the amount of drift of the machine on a slope will determine if there is a need to check the
travel brake.
Test Preparation:
1. Place the machine on a slope of 12°. The slope surface must be hard and smooth.
2. Put the implements in the position shown in the illustration.
3. Bucket should be empty.
Test Procedure:
1. Put marks on both track and ground to indicate its relative position to the slope.
2. Stop the engine and time three minutes (using a stopwatch).
3. Measure (with a scale) the distance the tracks have moved on the slope.
Swing Speed And Over Swing (On Level Ground)
Measuring the swing speed and over swing of the machine will determine if there is a need to check
the swing motor and/or anit-reaction valve.
Test Preparation:
2. Place the machine on level ground as shown in the illustration.
3. Put marks on both inner and outer races of the swing bearing to indicate relation of two positions.
4. The bucket should be empty.
Test Procedure (Over Swing):
1. Start the engine and place the power mode selector switch in power Mode III position. Place the
engine speed dial at position "10" (HIGH IDLE).
2. Move the swing control lever to the RIGHT or LEFT until the machine completes a 180° swing
operation. Return the swing control lever to the NEUTRAL position at the end of the 180° swing
operation and measure the amount of over swing by measuring the distance between the marks on the
swing bearing.
NOTE: Use a reference point that is visible from the operator's seat as a indicator of when to stop the
180° rotation.
Test Procedure (Speed):
Move the swing control lever to the LEFT or RIGHT and measure the time it takes to complete a 180°
swing operation.
Swing Speed And Drift (On A Slope)
Measuring the swing speed on a slope will determine if there is a need to check the swing motor
and/or anti-reaction valve. Measuring the swing drift on a slope will determine if there is a need to
check the swing parking brake.
Test Preparation:
1. Place the machine on a 12° slope.
2. Place the implements at maximum reach and fill the bucket with soil. The bucket should be
positioned above the ground to clear any obstructions.
Test Procedure (Speed):
1. Stop the machine on a slope of 12°. Place the upper structure at a 90° angle to the lower structure as
shown in the illustration.
2. Measure the time needed to swing the upper structure 90° counterclockwise. Do the same for a 90°
swing clockwise.
Test Procedure (Drift):
1. Stop the machine on a slope of 12°.
2. Place the upper structure at a 90° angle to the tracks as shown in the illustration.
3. Put marks on the inner and outer races of the swing bearing.
4. Stop the engine.
5. Leave the machine in this position for three minutes, and measure swing drift on the circumference
of the swing bearing.
6. Rotate the upper structure 180° from the original position as described in Step 1.
7. Repeat Steps 2 through 5.
Cylinder Drift
Test Preparation:
2. Place the machine on level ground as shown in the illustration.
3. Fill the bucket with soil.
Test Procedure (For Boom And Stick Cylinders):
1. Fully extend the bucket cylinder.
2. Fully retract the stick cylinder.
3. Raise the boom until its upper surface becomes parallel to the ground.
4. Measure each cylinder's length from pin to pin.
5. Stop the engine.
6. Leave the machine in this position for three minutes, then measure each cylinder's length from pin
to pin for drift.
Test Procedure (For Bucket Cylinder):
1. Fully extend the bucket cylinder.
2. Raise the boom high enough until the stick is perpendicular to the ground.
3. Measure each cylinder's length from pin to pin.
4. Stop the engine.
5. Leave the machine in this position for three minutes, then measure each cylinder's length from pin
to pin for drift.
Cylinder Operating Speed
Test Preparation:
1. Place the machine on level ground.
2. Bucket must be empty.
Test Procedure (Boom Cylinders):
1. Fully retract bucket and stick cylinders.
Extension test;
Measure the time required for the boom cylinders to reach full extension position starting with the
bucket on the ground.
Retraction test;
Measure the time required for the bucket to come in contact with the ground from the full extension
position of the boom cylinders.
Test Procedure (Stick Cylinder):
1. Position the upper surface of the boom parallel to the ground and fully extend the bucket cylinder.
Extension test;
Measure the time required for the stick cylinder to reach full extension position from full retraction
position.
Retraction test;
Measure the time required for the stick cylinder to reach full retraction position from full extension
position.
Test Procedure (Bucket Cylinder):
1. Position the upper surface of the boom parallel and the stick perpendicular to the ground.
Extension test;
Measure the time required for the bucket cylinder to reach full extension position from full retraction
position.
Retraction test;
Measure the time required for the bucket cylinder to reach full retraction position from full extension
position.
Release Of Pressure I n The Hydraulic System

Release the pressure in the implement hydraulic circuits (boom, stick, and bucket) before any
hydraulic lines or components are disconnected or removed.
1. Fully retract the stick cylinder rod.
2. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.
3. Lower the boom until the bucket is flat on the ground.
4. Shut off the engine and put the hydraulic activation control lever in the UNLOCK position.
5. Move the control levers for boom, stick, and swing to all full stroke positions. This will release any
pressure that might be present in the pilot system.
6. Slowly loosen the air vent plug on the hydraulic tank and release the pressure.
7. Tighten the air vent plug on the hydraulic tank.
8. The pressure in the hydraulic system has been released and lines and components can be removed.
Release Of Air From M ain Pumps

When the main pumps have been serviced or the hydraulic oil replaced, remove air from the hydraulic
system as follows:
NOTI CE
No attempt should be made to start the engine until the main pumps
have been filled with hydraulic oil, or serious damage can be caused to
hydraulic components.
Pump Compartment
(1) Air vent plug.
1. With the engine stopped, remove air vent plug (1) from the top of the main pump. Leave the plug
out for several minutes until the main pumps are filled with oil. Install the air vent plug (1) to the top
of the main pumps and start the engine in low idle and fully raise the boom and hold it in this position.
2. Stop the engine and slowly lower the boom until the bucket is on the ground. This pressurizes the
hydraulic tank.
3. Slowly loosen air vent plug (1) until oil flows out of the plug opening. This is an indication that the
air has been released from the pump.
4. Tighten the air vent plug to the specified torque.
Pressure Adjustment
Specifications
NOTE: A new or rebuilt machine must perform according to New or Rebuild specifications. A
machine that performs beyond Service Limit specifications must be checked for improper adjustment,
wear, or damage of relief valves or pumps.
Hydraulic Component Layout

(1) Right travel motor. (2) Pilot oil manifold. (3) Main control valves. (4) Swing motor. (5) Boom. (6) Cab. (7) Left travel
motor.
Adjustment Procedures
NOTE: Values given above are approximate. Use a pressure gauge for adjustment.
Pilot Relief Valve Adjustment
Preparation
Pump Compartment
(1) Tap (power shift pressure). (2) Tap (rear pump). (3) Tap (front pump).

(25) Pilot relief valve. (26) Tap. (27) Screw. (28) Locknut.
1. Place the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".
3. Connect a 49 000 kPa (7100 psi) pressure gauge to either the main pump tap (2) or tap (3).
4. Connect a 4750 kPa (700 psi) pressure gauge to tap (1).
5. Start the engine and move the stick IN and OUT to its full travel position. Do this operation several
times until the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).
6. Place the power mode selector switch in Mode III position.
7. Place the engine speed dial at position "10". Check that engine speed under no load is at specified
rpm with AEC switch in the OFF position. (Read rpm 3 seconds after the speed dial switch has been
placed in position "10".)
NOTE: See the section, "Operational Test Preparations" for the specified engine rpm for dial position
"10".
NOTE: Normal operations (see characteristic curve) of the engine and pumps are necessary for the
pressure adjustment. If the results of the pressure adjustment are not correct, then the engine and
pump characteristic curve needs to be checked.
Adjustment Procedure
1. Loosen locknut (28) of pilot relief valve (25).
2. Turn screw (27) until the pressure gauge at tap (26) reads 3450 +200 -0 kPa (500 +30 -0 psi)
Reference: Turning screw (27) clockwise increases the pressure and turning screw (27)
counterclockwise decreases the pressure.
Tighten locknut (28) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).
NOTE: Always make final pressure adjustments on pressure rise.
Temporary Setting Of The M ain Relief Valve Pressure
NOTE: The purpose for "Temporary Setting Of The Main Relief Pressure" is done so implement line
relief valves and travel relief valves can be adjusted.
Top Of Main Control Valves

(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.
1. Place the machine on level ground and stop the engine. Release the pressure in the hydraulic
system. See the section, "Release Of Pressure In The Hydraulic System".
2. Slowly move the bucket control lever to the bucket open position (full cylinder rod retraction).
3. Check to be sure the main relief valve pressure setting is 27 500 ± 490 kPa (4000 ± 71 psi).
4. Loosen locknut (5) and turn plunger (4) clockwise until it bottoms out. Tighten locknut (5).
5. Loosen locknut (7) and turn adjuster (6) clockwise a quarter turn. Tighten locknut (7).
Swing Crossover Relief Valve Pressure Check (M achines With Swing Pin)

(21) Crossover relief valve (right swing). (22) Crossover relief valve (left swing).
Preparation
Hydraulic System".
2. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (2).
3. Start the engine and place the engine speed dial at position "10" with the power mode selector
switch at Mode III position.
5. Place the swing lock pin in the LOCKED position.
Check Procedure
1. To check the crossover relief pressure for right swing, slowly move the swing control lever for a
full RIGHT swing operation and check the pressure of crossover relief valve (21) at tap (2).
2. If pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new crossover relief
valve.
3. To check the crossover relief pressure for left swing, slowly move the control lever to a full LEFT
swing operation and check the pressure of crossover relief valve (22) at tap (2).
4. If pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new crossover relief
valve.
Swing Crossover Relief Valve Pressure Check (M achines Without Swing Pin)

(21) Crossover relief valve (right swing). (22) Crossover relief valve (left swing).
Main Control Valve Compartment

(23) Pilot line (swing parking brake). (24) Elbow.
Preparation
1. Place the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure
In The Hydraulic System".
4. Engage the swing parking brake as follows;
a. Disconnect pilot line (23) from elbow (24).
b. Install a cap (7/16-20UN) on elbow (24). Leave the end of pilot line (23) open to the air.
5. Start and run the engine at high idle speed of 1980 ± 80 rpm. Place the power mode selector switch
at MODE III position.
Check Procedure
1. Slowly move the swing pilot control lever to the full RIGHT swing position and check the pressure
of relief valve (21) at tap (2).
NOTE: Check to be sure that the swing parking brake is correctly engaged while the swing control is
being activated.
2. If the pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new relief valve.
3. To check the relief valve for left swing, slowly move the swing pilot control lever to the full LEFT
position and check the pressure of relief valve (22) at tap (2).
4. If the pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new relief valve.
5. After pressure check, disengage the swing parking brake as follows;
a. Stop the engine and release the pressure in the hydraulic system. See the section in this module,
b. Remove the cap (7/16-20UN) from elbow (24).
c. Connect pilot line (23) to elbow (24).
Adjustment Of Line Relief Valve Pressure
Preparation
1. Start the service program "Calibration Mode" and keep the power shift pressure constant at 2250
kPa (325 psi). Read the pressure gauge attached at tap (1) to monitor the power shift pressure.
NOTE: For further information of "Calibration Mode", see the section in this module "Calibration
Mode".
NOTE: During line relief adjustment, do not turn the engine OFF to prevent a change in power shift
pressure.
2. Use the pressure gauge at tap (3) to read the line relief pressure for boom and bucket circuits. Use
the pressure gauge at tap (2) to read the line relief pressure for stick circuit. For line relief pressure
settings for the implement circuits see the section, "Relief Valves, Specifications".
NOTE: After adjustment of the line relief valves, return the main relief pressure to its normal setting.
Main Control Valve Compartment (Viewed From Machine Rear)

(9) Screw. (10) Locknut. (11) Line relief valve (boom cylinder head end). (12) Line relief valve (bucket cylinder head
end). (13) Line relief valve (stick cylinder rod end). (14) Line relief valve (stick cylinder head end).
NOTE: Rod end line relief valves of boom and bucket are located under the main control valves.
Adjustment (Stick Cylinder)
1. To adjust the pressure in the stick cylinder rod end, move the stick control lever to full stick OUT
(rod retracted) position. Check the pressure in the stick cylinder rod end at tap (2).
2. Return the stick control lever to the NEUTRAL position. Loosen locknut (10) and turn screw (9)
until line relief valve pressure at tap (2) reads 31 400 ± 1475 kPa (4550 ± 215 psi). Turning screw (9)
clockwise increases the pressure and turning screw (9) counterclockwise decreases the pressure.
3. To adjust the pressure in the stick cylinder head end, move the stick control lever to full stick IN
(rod extended) position. Check the pressure at tap (2).
4. Return the stick control lever to the NEUTRAL position. Adjust the line relief valve pressure in the
same manner as the stick rod end.
NOTE: Always make final pressure adjustment on pressure rise.
Adjustment (Bucket Cylinder)
1. To adjust the pressure in the bucket cylinder head end, move the bucket control lever to full bucket
CLOSE (rod extended) position. Check the pressure in the bucket cylinder head end at tap (3).
2. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve pressure in
the same manner as described for the stick cylinder.
3. To adjust the pressure in the bucket cylinder rod end, move the bucket control lever to full bucket
OPEN (rod retracted) position. Check the pressure at tap (3).
4. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve pressure to
31 400 ± 1475 kPa (4550 ± 215 psi) on 312 Excavators, or 26 000 ± 1475 kPa (3750 ± 215 psi) on
311 Excavators using the same procedure as that described for the stick cylinder.
Adjustment (Boom Cylinder)
1. To adjust the pressure in the boom cylinder head end, move the boom control lever to full boom
RAISE (rod extended) position. Check the pressure in the boom cylinder head end at tap (3).
2. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve pressure in
the same manner as described for the stick cylinder.
3. To adjust the pressure in the boom cylinder rod end, move the boom control lever to full boom
DOWN (rod retracted) position. Check the pressure at tap (3).
4. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve pressure to 31
400 ± 1475 kPa (4550 ± 215 psi) using the same procedure as that described for the stick cylinder.
NOTE: If an appropriate location is not available for full retraction of the boom cylinder, reverse the
line relief valves of the head end and rod end by switching the valves. Adjust the pressure of the line
relief valve now attached in the head end. Once adjusted, return the respective relief valves to their
original positions and cancel the function of the service program "Calibration Mode". Refer to the
section in this module, "Calibration Mode Stop Procedure".
Travel Crossover Relief Valve Adjustment
Sprocket (Left Track) (Typical Example)

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

(17) Screw. (18) Locknut. (19) Crossover relief valve (reverse left travel). (20) Crossover relief valve (forward left travel).
Travel Brake Valve (Left Track) (6BL825-UP)

(17) Screw. (18) Locknut. (19) Crossover relief valve (reverse left travel). (20) Crossover relief valve (forward left travel).
Pump Compartment
Preparation
1. Start Service Program "Calibration Mode" and maintain power shift pressure at 2250 kPa (325 psi).
Read the pressure gauge at tap (1) for the power shift pressure settings.
NOTE: During this test, to prevent a change in power shift pressure do not turn the engine start
switch to OFF position.
2. Block forward left travel, by putting stopper (16) in position on the gear of sprocket (15), as shown
above.
1. Slowly move the left travel control lever to full FORWARD position and check the pressure of
crossover relief valve (20) at tap (2).
2. Return the control lever to the NEUTRAL position and adjust relief valve pressure to 36 300 ±
1475 kPa (5250 ± 215 psi). To adjust crossover relief valve (20), loosen locknut (18) and turn screw
(17) until the pressure gauge at tap (2) reads 36 300 ± 1475 kPa (5250 ± 215 psi).
3. Tighten locknut (18) on 312 Excavator (6GK1-UP and (6BL1-6BL824) to a torque of 44 ± 5 N·m
(33 ± 4 lb ft). Tighten locknut (18) on 312 Excavator (6BL825-UP) to a torque of 20 ± 2 N·m (15 ±
1.5 lb ft). Tighten locknut (18) on 311 Excavator to a torque of 39 ± 5 N·m (29 ± 4 lb ft).
4. Position stopper (16) to block reverse left travel.
5. Slowly move the left travel control lever to full REVERSE position and check the pressure of
crossover relief valve (19) at tap (2). Adjust the pressure of crossover relief valve (19) in the same
manner as described for crossover relief valve (20).
6. Adjust the pressure of crossover relief valves of right travel motor in the same manner as described
for the left travel motor. Use the pressure gauge at tap (3) to read the pressure.
7. After completion of adjustment, stop the function of the service program "Calibration Mode". Refer
to the section "Calibration Mode Stop Procedure".
M ain Relief Valve Adjustment
NOTE: Pressure adjustments to the main relief valve should be done by first adjusting the travel
operation of the main relief valve and then adjusting the implement operation of the main relief valve.
Any adjustment to the travel operation of the main relief valve will change the pressure setting to the
implement operation of the main relief valve.
Preparation
Hydraulic System".
3. Start the engine and place the engine speed dial at position "10" with the power mode selector
switch at Mode III position.
Adjustment Procedure (I n Travel Operation)
Top Of Main Control Valves

(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.

1. Block forward left travel by putting stopper (16) in position on the gear of sprocket (15).
Pump Compartment
2. Slowly move the left travel control lever to full FORWARD position and check main relief valve
pressure at tap (2).
3. Return the control lever to the NEUTRAL position.
4. Loosen locknut (7) and turn adjuster (6) until the pressure gauge at tap (2) reads 34 300 ± 490 kPa
(5000 ± 71 psi). Tighten locknut (7) to a torque of 29 ± 2 N·m (22 ± 1 lb ft).
Reference: Turning adjuster (6) clockwise increases the pressure. Turning adjuster (6)
Adjustment Procedure (I mplement Operation)
1. Slowly move the control lever to full bucket OPEN (bucket cylinder full retraction) position and
check the main relief valve pressure at tap (3).
2. Return the control lever to the NEUTRAL position and adjust main relief valve pressure to 27 500
± 490 kPa (4000 ± 71 psi).
3. To adjust, loosen locknut (5) and turn plunger (4) until the pressure gauge at tap (3) reads 27 500 ±
490 kPa (4000 ± 71 psi). Tighten locknut (5) to a torque of 29 ± 2 N·m (22 ± 1 lb ft).
Reference: Turning plunger (4) clockwise increases the pressure. Turning plunger (4)
Adjustment Of Automatic Travel Speed Travel Change Valve
Preparation
1. Reset main relief valves. Refer to the section, "Main Relief Valve Adjustment".
Hydraulic System".
Pump Compartment
(1) Tap (rear pump).
3. Install 49 000 kPa (7100 psi) pressure gauge at tap (1) of the rear pump.

(2) Tap.
3. Install 4750 kPa (700 psi) pressure gauge at tap (2).
Travel Motor (Left Track)

(3) Signal line (two speed travel).
Travel Motor (Left Track) (6BL825-UP)

(3) Signal line (two speed travel).
4. Disconnect signal line (3) from the travel motor. Install a tee on the port that the signal line was
removed from and connect signal line (3) to tee. Attach a 4750 kPa (700 psi) pressure gauge to the
tee.
5. Start the engine and raise the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).
6. Place the power mode selector switch in power Mode III position and maintain the maximum no
load speed on the 312 Excavator at 1980 ± 80 rpm with AEC switch OFF. On the 311 Excavator
maintain the maximum no load speed at 1880 ± 80 rpm with the AEC switch off and the power mode
selector switch in power Mode III position.

7. Block the forward left travel by putting stopper (5) in position on the gear of sprocket (4), as shown
above.
8. Place the travel speed control switch in HIGH (rabbit) position.
9. The pressure gauge at tap (2) should read 3450 kPa (500 psi).

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

(6) Automatic travel speed change valve. (7) Screw. (8) Locknut.
1. While reading the pressure gauges connected to the tee in signal line (3) and to tap (1), slowly
move the left travel control lever/pedal to the FORWARD position. When the pressure at tap (1) reads
31 700 ± 980 kPa (4600 ± 140 psi), the pressure gauge connected to signal line (3) should reduce to 0
kPa (0 psi).
NOTE: These pressures indicate that the automatic travel speed change valve has caused the travel
motor to shift to LOW (turtle) speed.
2. Slowly return the left travel control lever/pedal to the NEUTRAL position.
3. If the pressure gauge connected to signal line (3) does not read 0 kPa (0 psi) at the time the system
pressure at tap (1) reads 31 700 ± 980 kPa (4600 ± 140 psi), then adjust automatic travel speed change
valve (6) as follows:
a. Loosen locknut (8) and turn screw (7) until the pressure gauge connected to line (3) reads 0 kPa (0
psi) when the pressure gauge at tap (1) reads 31 700 ± 980 kPa (4600 ± 140 psi).
b. Tighten locknut (8) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).
NOTE: Turning screw (7) clockwise increases the pressure. Turning screw (7) counterclockwise
decreases the pressure.
4. Repeat Step 1.
5. Slowly move the travel control lever/pedal towards the NEUTRAL position until the pressure
gauge at tap (1) decreases to 18 600 ± 490 kPa (2700 ± 71 psi). Now the pressure gauge connected to
signal line (3) will read 3450 kPa (500 psi).
NOTE: These pressures indicate when the automatic travel speed change valve causes the travel
motor to shift to HIGH (rabbi)) speed.
Pump Flow Tests
Controller Compartment
(1) Controller alarm lamp. (2) Controller.
Right Console
(3) Monitor. (4) Monitor panel.
NOTE: Before starting pump flow tests, check the action alarm indicators on controller (2) and
monitor panel (4). If they indicate normal, then perform the operational tests.
NOTE: If operational tests (for example, cycle times) indicates that a slow implement problem is
common to the circuits of one pump, then the problem is most likely in the hydraulic system. Then
perform the "Pump Flow Tests".
NOTE: If the operational tests indicate a implement speed problem common to both pump circuits,
then the engine, fuel, or working altitude may be the problem.
M ain Pump Constant Horsepower Control Test
Illustration Of Flow Meter Tool Layout (Constant Horsepower Control Test) (Main Pump)
(1) Portable hydraulic tester. (2) O-ring. (3) Adapter block. (4) O-ring. (5) Nipple. (6) Coupler. (7) Reusable coupling. (8)
Sleeve. (9) XT-5 hose. (10) Elbow. (11) O-ring. (12) Plug. (13) Tee. (14) Front pump. (15) Rear pump. (16) Delivery line
(front pump). (17) Delivery line (rear pump). (18) Return line. (19) Swing motor.
Preparation (Front Pump)
Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Front Pump)
(1) Portable hydraulic tester (flow meter). (9) Hose. (12) Plug (front pump delivery line). (14) Front pump. (15) Rear
pump. (16) Delivery line (front pump). (17) Delivery line (front pump). (18) Return line. (19) Swing motor. (20)
Multitach. (21) Main control valves. (22) Pressure gauge. (23) Tap (front pump). (24) Tap (power shift pressure). (25) Tap
(rear pump). (26) Engine.
Pump Compartment
(9) Hose (front pump charge line). (12) Plug (front pump delivery line). (14) Front pump. (15) Rear pump. (16) Delivery
line (front pump). (23) Tap (front pump). (24) Tap (power shift pressure). (25) Tap (rear pump).
Flow Meter
(1) Portable hydraulic tester (flow meter). (9) Hose (front pump charge line). (20) Multitach. (27) Valve (flow meter).

(9) Hose (return line from flow meter). (13) Tee. (18) Return line. (19) Swing motor.
To prevent personal injury or equipment damage from failure of the

flow meter or associated circuit components because of blocked pump
flow, make sure before starting the engine that the flow meter valve is
fully open (turned counterclockwise).
1. Position the machine on level ground and stop the engine.
Hydraulic System".
3. Install the following tools in accordance with flow meter tool layout illustration and circuit
diagram.
a. Disconnect delivery hose (16) from front pump (14).
b. Install plug (12) and seal (11) to the end of delivery hose (16).
c. Disconnect return line (18) from swing motor (19).
d. Install tee (13) and two seals (11) to the swing motor (19) return port. Connect return line (18) to
tee (13).
e. Connect flow meter (1) between front pump (14) and return line (18).
f. Install pressure gauge (22) at power shift pressure tap (24) and at front pump tap (23). [A 49 000
kPa (7100 psi) pressure gauge can be used in place of pressure gauge (22).] Tap (24) is used to
measure the power shift pressure. Taps (23) and (25) are used to measure the front pump and rear
pump delivery pressure.
g. Install multitach group (20) on engine (26). This is used to read engine speed.
4. Start the engine and place the power mode selector switch in Mode III position.
5. Place the engine speed dial at position "10" and maintain the maximum no load speed at 1980 ± 80
rpm (for 312 Excavator) or 1880 ± 80 rpm (for 311 Excavator) with the AEC switch OFF. (Read the
rpm three seconds elapsed time after the engine speed dial has been placed in position "10").
6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil temperature,
move the stick IN and OUT its full travel several times.
Preparation (Rear Pump)
Pump Compartment
(9) Hose (rear pump charge line). (12) Plug (rear pump delivery line). (15) Rear pump. (17) Delivery line (rear pump).
(25) Tap (rear pump).
Perform the same preparation as that described for the front pump flow test under constant
horsepower control except Step 3. Use the following procedure in replacement for Step 3, for the rear
pump (15).
a. Disconnect delivery hose (17) from rear pump (15).
tee (13).
e. Connect flow meter (1) between rear pump (15) and return line (18).
f. Install pressure gauge (22) at power shift pressure tap (24) and at rear pump tap (25). [A 49 000 kPa
(7100 psi) pressure gauge can be used in place of pressure gauge (22).] Tap (24) is used to measure
the power shift pressure. Taps (23) and (25) are used to measure the front pump and rear pump
delivery pressure.
Test Procedure
NOTE: Perform the front and rear pump flow tests one at a time.

flow, make sure before starting the engine that the flow meter valve (27)
is fully open (turned counterclockwise).
To prevent personal injury and/or equipment damage from failed lines

or components while the flow meter is returned to the open flow
position after a flow test, slowly open the flow meter valve and monitor
pump flow at the same time to make sure flow increases. I f pump flow
does not increase as the flow meter is opened, shut the engine off and
determine what is causing the pump not to upstroke.
1. With the engine running, start the service program "Calibration Mode" and maintain the power shift
pressure at a constant pressure of 1780 ± 50 kPa (260 ± 8 psi). The power shift pressure is read at tap
(24), using pressure gauge (22).
NOTE: During this test, do not turn the starter switch to the OFF position to prevent any change in
power shift pressure. See the section in this module "Calibration Mode Stop Procedure".
NOTE: To start service program "Calibration Mode" see the section in this module "Calibration
Mode Start-Up".
2. Slowly turn valve (27) of portable hydraulic tester (1) clockwise and record pump flow at each of
the following pressure points. Use pressure gauge (22) at tap (24) for this pressure reading.
312 Excavator P-Q Characteristic Curve
311 Excavator P-Q Characteristic Curve
NOTE: Flow specifications given above are based on an engine speed of 1800 rpm for the 311
Excavator and 1900 rpm for the 312 Excavator. To get more accurate test results, each of
measurements should be corrected by calculating as follows.
Flow corrected (312 Excavator) = (Flow measured × 1900) ÷ rpm measured
Flow corrected (311 Excavator) = (Flow measured × 1800) ÷ rpm measured
1. Any flow readings must be done only in upstroke.

2. The pump flow changes approximately 5 liter/min. (1.3 U.S. gpm) for each 98 kPa (15.5 psi)
of power shift pressure.
Negative Flow Control Test
Illustration Of Flow Meter Tool Layout (Negative Flow Control Test) (Main Pump)
(1) Portable hydraulic tester. (2) O-ring. (3) Adapter block. (4) O-ring. (5) Nipple. (6) Coupler. (7) Reusable coupling. (8)
Sleeve. (9) XT-5 hose. (10) Elbow. (11) O-ring. (12) Plug. (13) Tee. (14) Front pump. (15) Rear pump. (16) Delivery line
(front pump). (17) Delivery line (rear pump). (18) Return line. (19) Swing motor.
Preparation (Front Pump)
Circuit Diagram For Negative Flow Control Test (Front Pump)

(1) Portable hydraulic tester (flow meter). (9) Hose. (12) Plug (front pump delivery line). (14) Front pump. (15) Rear
pump. (16) Delivery line (front pump). (17) Delivery line (front pump). (19) Swing motor. (20) Main control valves. (21)
Negative flow control line. (22) Pressure gauge. (23) Tap (front pump). (24) Pilot oil manifold. (25) Tap (rear pump). (26)
Tap. (27) Tee. (28) Test hose. (29) Plug. (30) Pressure gauge. (31) Engine. (32) Multitach. (33) Negative flow control line.
Pump Compartment
(9) Hose (front pump charge line). (12) Plug (front pump delivery line). (14) Front pump. (21) Negative flow control line.
(23) Tap (front pump).
Illustration Of Tool Layout (Negative Flow Control Test)(Main Pump)

(24) Pilot manifold. (26) Tap. (27) Tee. (28) Hose. (29) Plug. (30) Pressure gauge. (36) Coupler. (37) Nipple. (38) O-ring.
(39) Coupler. (40) Elbow (to negative flow control port).
Flow Meter
(1) Portable hydraulic tester (flow meter). (9) Hose (front pump charge line). (32) Multitach. (34) Valve (flow meter).

(9) Hose (return line from flow meter). (13) Tee. (18) Return line. (19) Swing motor.

(24) Pilot oil manifold. (26) Tap. (35) Pilot relief valve.
1. Position the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. See the section in this module "Release Of Pressure In
The Hydraulic System".
3. Install the following tools in accordance with flow meter tool layout illustration and circuit
diagram.
a. Disconnect delivery hose (16) from front pump (14).
tee (13).
e. Connect flow meter (1) between front pump (14) and return line (18).
f. Install pressure gauge (22) at front pump tap (23). [A 49 000 kPa (7100 psi) pressure gauge can be
used in place of pressure gauge (22).] Tap (23) is used to measure the front pump delivery pressure.
h. Disconnect negative flow control line (21) from front pump (14) and install plug (29).
i. Install test hose (28) to front pump negative flow control port.
j. Install tee (27) and pressure gauge (30) on pilot oil manifold tap (26). Connect test hose (28) to tee
(27).
4. Start the engine and place the power mode selector switch in Mode III position.
5. Place the engine speed dial at position "10" and maintain the maximum no load speed at 1980 ± 80
rpm (for 312 Excavator) or 1880 ± 80 rpm (for 311 Excavator) with the AEC switch OFF. (Read the
rpm three seconds elapsed time after the engine speed dial has been placed in position "10").
6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil temperature,
move the stick IN and OUT its full travel several times.
Preparation (Rear Pump)
Pump Compartment
(9) Hose (rear pump charge line). (12) Plug (rear pump delivery line). (15) Rear pump. (25) Tap (rear pump). (33)
Negative flow control line.
Perform the same preparation as that described for the front pump flow test under constant
horsepower control except Step 3. Use the following procedure in replacement for Step 3, for the rear
pump (15).
a. Disconnect delivery hose (17) from rear pump (15).
tee (13).
e. Connect flow meter (1) between rear pump (15) and return line (18).
f. Install pressure gauge (22) at rear pump tap (25). [A 49 000 kPa (7100 psi) pressure gauge can be
used in place of pressure gauge (22).] Tap (25) is used to measure the rear pump delivery pressure.
h. Disconnect negative flow control line (33) from rear pump (15) and install plug (29).
i. Install test hose (28) to rear pump negative flow control port.
j. Install tee (27) and pressure gauge (30) on pilot oil manifold tap (26). Connect test hose (28) to tee
(27).
Test Procedure
NOTE: Perform the front and rear pump negative flow control tests one at a time.

flow, make sure before starting the engine that the flow meter valve (27)
is fully open (turned counterclockwise).
To prevent personal injury and/or equipment damage from failed lines

or components while the flow meter is returned to the open flow
position after a flow test, slowly open the flow meter valve and monitor
pump flow at the same time to make sure flow increases. I f pump flow
does not increase as the flow meter is opened, shut the engine off and
determine what is causing the pump not to upstroke.
1. Slowly turn valve (34) of portable hydraulic tester (1) clockwise until the pump delivery pressure
setting is 6900 kPa (1000 psi).
2. Adjust pilot relief valve (35) of pilot oil manifold (24) until pressure gauge (30) connected to tee
(27) reads 2350 kPa (340 psi).
3. Record the negative control flow at each of the following pressure points.
NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To get more
accurate test results, measured flow should be corrected by calculating as follows:
Flow corrected for 312 Excavator = (Flow measured × 1900) ÷ rpm measured
Flow corrected for 311 Excavator = (Flow measured × 1800) ÷ rpm measured
P-Q Characteristic Curve [Negative Flow Control at 6900 kPa (1000 psi) Pump Delivery Pressure]
Pump Flow Adjustment

Flow Adjustment Under Constant Horsepower Control
Main Pump
(1) Setscrew. (2) Locknut. (3) Setscrew. (4) Locknut. (5) Locknut. (6) Setscrew. (7) Setscrew. (8) Setscrew. (9) Setscrew.
Flow adjustment procedure for the front and rear pumps under constant horsepower control is the
same. Setscrew (3) and (8) are for the lower pressure range where the first stage spring in each pump
regulator activates. Setscrews (1) and (9) are for the higher pressure range where the second stage
spring in each regulator activates.
Front Pump Adjustment
1. Loosen locknut (4).
2. Turn setscrew (3) until adjusted to the correct specification.
312 Excavator: Turning setscrew (3) 1/4 turn clockwise increases the flow rate approximately 9.7
liter/min (2.6 U.S.gpm) at a system pressure of 13 750 kPa (2000 psi) and 17 700 kPa (2550 psi)
where the first stage spring activates.
where the first stage spring activates.
3. Tighten locknut (4) to a torque of 155 ± 20 N·m (115 ± 15 lb ft).
where the second stage spring activates.
where the second stage spring activates.
Rear Pump Adjustment
To adjust the rear pump flow under constant horsepower control do the same as that described above
using setscrews (8) and (9) in place of setscrews (1) and (3).
M aximum Flow Adjustment
Maximum flow adjustment procedure for front and rear pumps is the same. Use setscrew (6) for the
front pump and setscrew (7) for the rear pump.
2. Turn setscrew (6) until adjusted to the correct specification. Turning the setscrew 1/4 turn
clockwise decreases flow rate approximately 3.0 liter/min (.8 U.S.gpm).
Negative Flow Control Adjustment
Pump Compartment
(13) Setscrew. (14) Locknut.
Rear Pump (Viewed From Drive Shaft Side)

(15) Setscrew.
Negative flow control adjustment procedure for front and rear pumps is the same. Use setscrew (15)
for the front pump and setscrew (13) for the rear pump.
312 Excavator: Turning the setscrew 1/4 turn clockwise increases the flow rate approximately 7.1
liter/min (1.9 U.S.gpm) at a negative control pressure of 2450 kPa (355 psi).
311 Excavator: Turning the setscrew 1/4 turn clockwise increases the flow rate approximately 6.7
liter/min (1.8 U.S.gpm) at a negative control pressure of 2450 kPa (355 psi).
Copyright 1993 - 2023 Caterpillar Inc. Mon Feb 13 23:24:01 UTC-0400 2023
Todos los derechos reservados.
Red privada para licenciados del SIS.

312A Pump

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312 TRACK-TYPE EXCAVATOR 6GK00001-UP (MACHINE) POWERED BY 306...

Testing and Adjusting

1. Electronic System Testing And Adjusting

Electronic Control System

Electronic Monitor Panel

* Power shift pressure.

Data M ode Start-Up

Electronic Monitor Panel

Data M ode Function Selection

Electronic Monitor Panel (Data Mode Function Selection)

Power Shift Pressure

Electronic Monitor Panel (Power Shift Pressure)

Electronic Monitor Panel (Engine Speed)

Engine Coolant Temperature

Electronic Monitor Panel (Engine Coolant Temperature)

Hydraulic Oil Temperature

Electronic Monitor Panel (Hydraulic Oil Temperature)

A/D (Analog/Digital) Conversion

Electronic Monitor Panel (A/D Conversion)

Real Time Error Codes

Electronic Monitor Panel (Real Time Error Codes)

Electronic Monitor Panel (Digital Input)

[012] : Indicates the machine model of "312" excavator.

[0 9] : Indicates the machine model of "311" excavator.

[1 1] : Engine speed dial is in position "1".

[110] : Engine speed dial is in position "10".

[2On] : Travel pressure switch is ON.

[2oF] : Travel pressure switch is OFF.

Output Control Display

Electronic Monitor Panel (Output Control Display)

[L00] : Output control is normal.

[L A] : Pump output control when governor actuator feedback sensor is abnormal.

[L b] : Pump control under too low hydraulic oil temperature.

NOTE: [L b] is displayed only when one of the controls is activated.

Data M ode Stop Procedure

Electronic Monitor Panel (Stop Procedure)

Use either of the following two methods.

1. Turn the engine start switch to the OFF position.

Calibration M ode Start-Up

Electronic Monitor Panel (Calibration Mode Start-Up)

Calibration M ode Function Selection

Electronic Monitor Panel (Function Selection)

M achine And Engine M odel

Electronic Monitor Panel (Machine And Engine Model)

1. Start "Calibration Mode". See the section, "Calibration Mode Start-Up".

Controller/M onitor Software Version

Electronic Monitor Panel (Controller/Monitor Software Version)

1. Start "Calibration Mode". See the section, "Calibration Mode Start-Up".

Electronic Monitor Panel (Error Log)

1. Start "Calibration Mode". See the section, "Calibration Mode Start-Up".

* AEC switch (31)

Digital Output Test

Electronic Monitor Panel (Digital Output Test)

1. Start "Calibration Mode". See the section, "Calibration Mode Start-Up".

Proportional Reducing Valve Sweep Test

Pilot Oil Manifold Compartment

2. Connect the test harness to connector (39).

4. The pump backup switch must be in the "AUT" position.

5. Start "Calibration Mode". See the section, "Calibration Mode Start-Up".

6. Warm the hydraulic oil to normal operating temperature.

7. Run the engine at maximum no-load rpm.

8. All controls must be in the NEUTRAL position.

Electronic Monitor Panel (Proportional Reducing Valve Sweep Test)