Usage:
The 5P3600 Hydraulic Flow Meter Group is the replacement for the former 9S2000 Flow Meter Group in all applications.
5P3600 Hydraulic Flow Meter Group.
1. 5P7365 Cable Assembly 2. 7N4154 Lamp 3. 9S6341 Safety Disc [4300 psi (27500 kPa)-.010" (0.25 mm) thick] also 1P7411 Safety Disc [6200 psi (44900 kPa-.013" (0.33 mm) thick] 4. 7N4153 Lamp 5. 5P7363 Hose Assembly 6. 5P7366 Power Cable Assembly 7. 5P7362 Tachometer Cable Assembly 8. 5P7360 Tachometer Generator Assembly 9. 5P7372 Meter-RPM and Temperature 10. 5P7368 Meter-GPM 11. Flow Block 12. Control Unit.
Former 9S2000 Flow Meter Group installed on a 988B Loader.
The most important improvements on the new flow meter group are that all of the controls, gauges and meters are in the control unit and the control unit can be used approximately 18 ft (5.5 m) from the hydraulic line connections. On all Caterpillar machines, the control unit can be put at the operators seat during tests. This is important because it permits one serviceman to test the hydraulic system. The only connections between the control unit and the flow block at the hydraulic line connections are an electric cable and a small hydraulic oil pressure hose. Since the hydraulic hoses do not need to be near the serviceman during the tests, the flow meter is safer for the serviceman if there is ever a failure of a hydraulic hose or connection.
New 5P3600 Hydraulic Flow Meter Group installed on a 988B Loader.
The new flow meter does not need as many hoses for installation as the former flow meter. Only one hose is needed for the D7, D8 and D9 Tractors, all loaders except the 992 Loaders, all excavators and all earlier tractor-scrapers. All other models except the 992 Loaders with a ROPS cab need only two hoses. The method of installation and the necessary parts for each model will be shown in the Service Manuals.
Because of the reduction in the number of parts needed, the total cost of both the new and former flow meters has been decreased. Formerly, a few of the parts were shown separately in the tool charts. These same parts were also in assemblies that were shown in the chart. Since the assemblies can easily be disassembled to use the parts, the separate parts are not needed and have been removed from the tool charts.
Also, some of the parts, which were used on only a small number of machines, have been changed on the tool charts from "recommended" to "available if needed".
All of the fittings on the tool charts are now high pressure fittings. A complete list of all the parts needed to use the flow meters is given in Tool Announcement, Form No. SENS6196. This list will be added to the Tool Guide at a later date.
With the new flow meter, the hydraulic oil flow can be measured to 200 gpm (760 litre/min), the engine RPM can be measured to 5000 RPM and the hydraulic oil pressure can be measured to 6000 psi (41500 kPa). These measurements are all higher than was possible on the former flow meter.
A measurement of the percent of flow loss can be made with the new flow meter. Formerly, it was necessary to calculate (use mathematics) to get the percent of flow loss.
The temperature of the hydraulic oil in the circuit that is being checked can be measured on the control unit. Also, the control unit has a temperature connection so other temperature measurements can be made by the connection of a temperature sender.
The meters in the control unit have a high resistance to damage from shock and will give a long service life.
The new flow meter uses electricity for the control unit from the machine's electric system. The former flow meter used batteries which needed replacement when discharged. Either of the clamp connectors for the power cable can be put on the positive (+) post of the machine battery. The other clamp connector must be connected to the machine chassis. The control unit will operate correctly on any direct current source with a voltage of 12 to 28.8 Volts. The new flow meter does not need an adjustment of the voltage for accuracy as was needed on the former flow meter.
Control Unit
1. Pressure Gauge 2. Temperature Connection 3. RPM Cable Connection 4. RPM-Temperature Meter 5. RPM-Temperature Selector Switch 6. RPM Scale Selector Switch 7. Caution Lamp 8. Valve Controller Knob 9. Safety Reset Button 10. GPM-% Flow Loss Selector Switch 11. GPM-% Flow Loss Meter 12. Stall Lamp 13. Serial Number and Calibration Data Plate 14. Percent Adjust Knob.
Connect either clamp connector for the power cable to the positive (+) post of the battery and the other clamp connector to the machine chassis.
TS4 Pulse Generator.
The control unit can be calibrated (adjusted) with a TS4 Pulse Generator made by Flo-tech, Inc., 403 Washington Blvd., Mundelein, Illinois 60060, or a similar pulse generator. To calibrate the unit, remove the plate on the end of the control unit opposite the handle.
All of the components of the new flow meter except the flow block can be put in the lid for the control unit when the flow meter is not used. With the components in the lid and the lid installed on control unit, the new flow meter is compact (in a small package) and portable (can be moved around by hand).
The 5P7360 Tachometer Generator Assembly is the replacement for the former 9S3047 Tachometer Generator Assembly. The former tachometer generator was connected to ground through its housing, while the new tachometer generator is not connected to ground. The new tachometer generator has a black color.
NOTE: Do not use the former 9S3047 Tachometer Generator Assembly with the 5P3600 Hydraulic Flow Meter Group.
Plate removed on end of control unit to make calibration.
Components of flow meter installed in lid for control unit.
5P3600 Hydraulic Flow-Meter Group ready to be moved.
The flow valve in the flow block is controlled at the control unit. The flow valve will automatically open if the engine is stopped. It will also automatically open during installation of the flow meter when the electric cables are connected. The valve in the former flow meter was operated manually. If the flow valve sticks (will not operate), remove the rubber plug in the end of the flow block. Turn the valve shaft with a wide blade screwdriver.
The flow block has a 9S6341 Safety Disc.
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Always be sure the correct safety disc is used in the flow block. When testing machines with relief valve pressures above 3000 psi (20700 kPa), install a 1P7411 Safety Disc in the flow block. When testing machines with relief valve pressures below 3000 psi (20700 kPa), install a 9S6341 Safety Disc in the flow block.
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Arrow gives location of rubber block in flow block.
The flow block has a check valve for the small pressure hose to the control unit. The check valve will keep leakage to a minimum if the small pressure hose breaks or if a connection leaks. The inlet and outlet connections for the hydraulic lines in the flow block have 1 5/8"-12 threads. The connections are more compact than on the former flow meter. Also, the connections can be fastened faster and easier than on the former flow meter.
Installation Procedure
1. Turn the machine disconnect switch to the "OFF" position. Install the flow block with the correct hoses, fittings and blocks as shown in the Service Manual "Testing Hydraulic Systems and Components".
2. Install the electric cable and small pressure hose to the flow block and to the control unit.
3. Install the cable to the tachometer generator and to the control unit.
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Always be sure the tachometer generator will operate correctly. The flow valve in the flow block will not open automatically when the engine is stopped if the tachometer generator does not operate correctly.
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4. Fasten one of the clamp connectors of the power cable to the positive (+) terminal of the machine batteries. Install the other clamp connector to the machine chassis.
5. Connect the power cable to the control unit.
Operation Procedure
1. Turn the RPM-Temperature selection switch to the °F-°C position. Turn the machine disconnect switch to the "ON" position. The needle on the RPM-temperature meter will move. This is an indication that the control unit has an electric supply.
2. When the caution lamp stops flashing (goes on and off), turn the RPM temperature selector switch to the RPM position and the GPM-% flow loss selector switch to the "B" position. Start the engine.
3. Turn the valve controller knob to the "5" position and push the safety reset button.
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Do not turn the valve controller knob higher than the "5" position until the pressure gauge is stabilized (stops moving). Turning the knob higher than the "5" position can cause excessive (too much) pressure in the hydraulic system. The excessive pressure can cause a failure in the hydraulic system and leakage of high pressure hydraulic oil.
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4. Make the test of the hydraulic system as shown in the Service Manual "Testing Hydraulic Systems and Components".
5. To find the percent of flow loss, turn the valve controller knob until the pressure gauge shows 100 psi. Turn the GPM-% flow loss selector switch to the "%" position. Turn the percent adjust knob until the GPM-% flow loss meter shows zero. Turn the valve controller knob until the pressure gauge shows the correct test pressure of 1000 psi. The engine RPM must be constant while the pressure is increased. The GPM-% flow loss meter will show the percent of flow loss. Also, the actual rate of flow can be seen on the GPM-% flow loss meter if the GPM -- % flow loss meter selector switch is turned to either the "A" or "B" position.
NOTE: Do not connect or disconnect the power cable, tachometer cable, pressure gauge hose, or flow block cable while the engine is running.