Testing&Adjusting PW140 160 180-7EO

8/10/2019 Testing&Adjusting PW140 160 180-7EO

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Test & Adjust PW140/ 160/ 180-7EO Page 1 (01/2008)

Testing & Adjusting PW140/ 160/ 180-7EO


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PW140-7/ PW160EO-7/ PW180EO-7

Testing & AdjustingHydraulic System


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PPC pressure portM10x1,25

Standard: 35 38 bar

PPC Pressure Check Port PW140-7


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PPC pressure port

M10x1,25

Standard: 35 38 bar

PPC Pressure Check Port PW160/ 180-7EO


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Port PA Pump

pressure

(M10x1,25 )

Port PLFC

LS pressure

(M10x1,25)

LS-EPCsolenoid valve

(V22)

PC-EPCsolenoid valve

(V21)

Pump and LS Pressure Check Ports


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PC ValveLS Valve

LS and PC Valve Position


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Procedure:

Disconnect CN V22 of the LS-EPC solenoid.

Start the engine with Auto Deceleration OFF and set fuel dial to MAX. rpm.

Lift the wheels off the ground by using undercarriage attachments and / or work equipment.

Select Hi travel speed.

(It is also possible to perform this test in Lo speed.)

Depress travel pedal fully.

Measure a LS differential pressure.

Adjust the LS valve if necessary.

Measure Work Equipment LS Differential Pressure


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Procedure :Start the engine and adjust the LS valve. Loosen lock nut (10) and adjust the LS differential

pressure by turning the adjustment screw (11).

If the adjusting screw is turned to the right, the differential pressure rises.

If the adjusting screw is turned to the left, the differential pressure falls.

1011

LS Valve Adjustment


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PC pressure check port PEN

M10 x 1.25mm

Perform the test in Pmode with arm in

relief and power MAX.

PC pressure is about

60% of pumppressure.

PC Pressure Check Port PW140-7


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PC pressure check port PEN

M10 x 1.25mm

Perform the test in Pmode with arm in

relief and power MAX.

PC pressure is about

60% of pumppressure.

PC Pressure Check Port PW160/ 180-7EO


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Procedure :Loosen lock nut (8) and adjust stall speed with the adjusting screw (9)

.Adjustable range :Maximum 1 turn to the left => Stall speed increases.

Maximum 1/2 turn to the right => Stall speed decreases.

PC Valve Adjustment


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5 Pump LS- EPC ValveDo not travel the machine.

2 LS EPC Valve FULL OFF OFF

Check Point - PSIG Creep

P Neutral Neutral

Creep 583mA

900mA

Arm Dump pump relieved 0mA

LS-EPC pressure port PSIG

10 x 1.25mm

LS EPC Pressure Check Port PW140-7


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5 Pump LS- EPC ValveDo not travel the machine.

2 LS EPC Valve FULL OFF OFF

Check Point - PSIG Creep

P Neutral Neutral

Creep 583mA

900mA

Arm Dump pump relieved 0mA

LS-EPC pressure port PSIG

10 x 1.25mm

LS EPC Pressure Check Port PW160/ 180-7EO


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5 Pump PC-EPC ValveDo not travel the machine.

1 PC EPC Valve OFF OFF

Check point - PM FULL

B

Value barOperation

Work

Neutral

Travel

LeverNeutral

Neutral

Max Equipment

Auto

Decel

E

L

Low

Working

Mode

P

Checking

item

Fuel

Dial

Power

PC-EPC pressure port PM

10 x 1.25mm

PC EPC Pressure Check Port PW140-7


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5 Pump PC-EPC ValveDo not travel the machine.

1 PC EPC Valve OFF OFF

Check point - PM FULL

B

Value barOperation

Work

Neutral

Travel

LeverNeutral

Neutral

Max Equipment

Auto

Decel

E

L

Low

Working

Mode

P

Checking

item

Fuel

Dial

Power

PC-EPC pressure port PM

10 x 1.25mm

PC EPC Pressure Check Port PW160/ 180-7EO


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Procedure :- Divide front and rear pump with the merge divider valve.

- Adjust high main pressure (385 bar) first, then low mainpressure (355 bar).

Lock nut Adjustingscrew for highmain pressure

(385 bar)

Adjustingscrew for lowmain pressure

(355 bar)

Lock nut

Main Relief Valve Adjustment


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S

B

T

A

G

MB X M1U

MA

LeftRight

G (Travel pressure)X (Creep speed)

A B

S

M1 (Servo pistonpressure)

ST

A,B

U

G

M1

MB, (MA)

T

MIN. angle stopper bolt

Pressure dependentange set (270bar)Left side

G und X : M14 x 1.5

MA und MB : M18 x 1.5

S : M27 x 2

M1: M10x 1Safety Valve Safety Valve

MAX. anglestopper bolt

420 bar

Travel Motor Ports


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PW140-7/ PW160EO-7/ PW180EO-7

Testing & Adjusting

Engine


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Measure Low Fuel Pressure

5.) Measure low fuel pressure circuit.

Read the Safety Instructions from the ShopManual.

Make sure all temperatures are within

working range.Remove plug (1) from the fuel filter bracketand install a test nipple (G1, G2).

Run the engine at low idle in P Mode andmeasure the fuel pressure.

Standard Value:


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Measure Return Fuel Pressure

6.) Measure return fuel pressure circuit.



working range.Remove plug (2) from the return fuel blockand install a test nipples (1 and 3).

Install a gauge and run the engine at low idleor crank it with the starter motor for no more

than 20 seconds.

Standard Value:


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Adjust Valve Clearance

7.) Adjust valve clearance

Read the Safety Instructions in the ShopManual.

Remove all valve cover (1).

Remove plate (2) and cap (3) from the flywheelhousing and install gear (B1).

Rotate the crankshaft in normal direction withgear (B1) to bring the stamped 1.6 TOP line(a) on the damper to the top and set the 1st.

cylinder to TDC.


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Adjust Valve Clearance

Adjust the valves marked with ().

Loosen lock nut (5) of adjustment screw (6)and adjust the clearance by inserting aclearance gauge (B2) between crosshead (4)and rocker arm (3) until the clearance gauge

becomes slightly movable.

After the adjustment rotate the crankshaftagain in normal direction with gear (B1) tobring the stamped 1.6 TOP line (a) on thedamper to the top.

Adjust the valves marked with ().

Valve clearance:Intake valve 0,25 mm

Exhaust valve 0,51 mm


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Injector Installation

8.) Please find the details in the extracted pages from the 107-1 Engine Shop Manual.

Click on the button to start start the pdf - pages.

Injector Installation


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Measure Fuel Supply Pump Rate

9.) Measure fuel supply pump rate.



working range.Disconnect fuel return hose (1) from the fuelsupply pump.

Connect the fuel return port of the supplypump to measuring cylinder (H4).

Run the engine at low idle or crank it with thestarter motor for no more than 20 secondsand measure the fuel return flow.

Standard Value:


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Measure Pressure Limiter Leakage

10.) Measure fuel pressure limiter leakage.



working range.Disconnect fuel return hose (2) from the fuelpressure limiter.

Connect the port of the pressure limiter tomeasuring cylinder (H4).

Run the engine at low idle and measure thefuel return flow.

Standard Value:


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Measure Fuel Injector Return Flow

11.) Measure fuel injector return flow.



working range.Disconnect fuel return hose (3) from the fuelinjectors.

Connect the return port of the fuel injectors tomeasuring cylinder (H4).

Run the engine at low idle or crank it with thestarter motor for no more than 20 secondsand measure the fuel return flow.

Standard Value:


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Bleeding Air from the Fuel Circuit

12.) Air bleeding from the fuel circuit.

Read the Safety Instructions from the Shop Manual.

The fuel circuit is a self bleeding circuit through the marked orifice in the fuel return line.

After replacement of components in the fuel circuit operate the fuel priming pump until theknob becomes hard to move.

Lock the knob of the fuel priming pump and start the engine.


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Testing&Adjusting PW140 160 180-7EO

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