Note: Only perform this procedure if the Testing and Adjusting, "Main Pump (Flow) - Test (Hydraulic Power)" is not within specification.
Note: The flow specifications in Table 1 are target adjustments for setting the main hydraulic pump installed on the machine.
Note: The two pump calibration is the recommended procedure for making pump adjustments. The optional one pump calibration can be used when the two pump calibration is not applicable.
Note: The one pump calibration may not be as accurate as the two pump calibration procedure.
| "Pump Control (Output Flow) - Test (One Pump Calibration (Optional Test))" | |||||
|---|---|---|---|---|---|
| Measured Items | Measuring Points | ||||
| Machine Settings | Engine Speed | 1500 rpm | |||
| Pump Pressure | |
||||
| Swashplate Angle | 0% | 40% | 60% | 100% | |
| Amp / Flow rate | 0 Amps | |
|
2 Amps | |
| Drive Pump Flow L/min (US gpm) | |||||
| Engine speed (rpm) | |||||
| Hydraulic oil temperature °C (°F) | |||||
| Drive Pump Corrected Flow L/min (US gpm) | |||||
| Idler Pump Flow L/min (US gpm) | |||||
| Engine speed (rpm) | |||||
| Hydraulic oil temperature °C (°F) | |||||
| Idler Pump Corrected Flow L/min (US gpm) | |||||
| Specification for flow rate L/min (US gpm) | |
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| (1) | Load applied to flow meter. |
| (2) | The pump that is not being tested should be at low-pressure standby |
This test procedure measures individual pump flow at the pump outlets. Each pump is tested individually with the second pump at low-pressure standby.
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| Illustration 1 | g02571852 |
|
Tooling (A) 198-4240 Digital Pressure Indicator Gp | |
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| Illustration 2 | g02535237 |
|
Tooling (C) | |
| |
| Illustration 3 | g03681491 |
|
Tooling (D) (Flow meter tool layout) | |
| Tool | Item | Qty | Part
Number |
Description |
|---|---|---|---|---|
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 1 | 198-4234 | Indicator | |
| A2 | 1 | 198-4238 | Pressure Sensor
|
|
| A2 | 2 | 198-4239 | Pressure Sensor
|
|
| A3 | 3 | 198-4236 | Extension Cable | |
| C | 348-5430 | Multi-Tool Gp | ||
| C1 | 1 | 285-0908 | Multi-Tool | |
| C2 | 1 | 6V-2198 | Cable As | |
| C3 | 1 | 9U-5140 | Photo Pickup | |
| C4 | 1 | 6V-3137 | Base | |
| C5 | 1 | 1U-6605 | Reflective Tape | |
| C6 | 1 | 6V-3138 | Extension | |
| D | D1 | 1 | 436-8662 | Portable hydraulic tester (flow meter) |
| D2 | 2 | 6K-6307 | O-Ring Seal | |
| D3 | 2 | 8C-9026 | Adapter | |
| D4 | 9 | 7M-8485 | O-Ring Seal | |
| D5 | 4 | 4C-6482 | Fitting | |
| D6 | 4 | 4C-6481 | Coupler | |
| D7 | 4 | 4C-8767 | Coupling | |
| D8 | 4 | 5P-1010 | Sleeve | |
| D9 | 2 | 9X-2734 | Hose | |
| D10 | 1 | 9S-4191 | O-Ring Plug | |
| D11 | 1 | 3J-1907 | O-Ring Seal | |
| D12 | 1 | 1U-8303 | Fitting | |
| D13 | 1 | 1U-8293 | Adapter | |
| D14 | 1 | 1P-3704 | Rectangular Seal | |
| D15 | 1 | 5P-0048 | Cover | |
| D16 | 1 | 4I-6141 | Adapter | |
| D17 | 2 | 5K-9090 | O-Ring Seal | |
| D18 | 1 | 6V-9840 | Swivel Tee | |
| D19 | 2 | 1P-5767 | Half Flange | |
| D20 | 4 | 7X-2550 | Bolt | |
| D21 | 4 | 8T-4223 | Hard Washer | |
| F | 1 | 311-1362 | Vacuum Cap | |
Reference: Refer to Tool Operating Manual, NEHS1087 for operating instructions for the 348-5430 Multi-Tool Gp.
Note: Use Software License Card, NETG5049 with part number 348-5430 Multi-Tool Gp.
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| Illustration 4 | g03785821 |
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Flow meter tool layout Tooling (D) ( 3) Delivery line for drive pump (4) Delivery line for idler pump (6) Bolt (7) Washer (8) Half flange (10) Makeup line (11) Seal (12) Elbow | |
| NOTICE |
|---|
|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
- Position the machine on level ground.
- Stop the engine.
- Release pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".
- Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply
276 to 414 kPa (40 to 60 psi) . This procedure will pull a vacuum on the hydraulic system. - Install the following tools in accordance with the flow meter tool layout. Refer to Illustration 4.
- Disconnect delivery line (3) from the drive pump.
- Install cover (D15) and seal (D14) to the end of the delivery line (3) by using half flanges (D19), bolts (D20), and washer (D21).
- Assemble and install seal (D14), adapter (D13), seals (D4), fitting (D12), seal (D11), plug (D10), and fitting (D5) on the drive pump by using existing half flanges (8), bolts (6), and washers (7).
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Illustration 6 g03785230 Swing motor (top view)
(10) Makeup line
(11) Seal
(12) Elbow - Disconnect makeup line (10) from elbow (12) at the swing motor.
- Assemble and install seals (D17), tee (D18), adapter (D16), seal (D4), and fitting (D5) to elbow (12) at the swing motor.
- Install seal (11) and makeup line (10) to tee (D18).
Show/hide table
Illustration 5 g03751958 Pump compartment
(1) Pressure tap (delivery pressure for drive pump)
(2) Pressure tap (delivery pressure for idler pump)
(3) Delivery line for drive pump
(4) Delivery line for idler pump - Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
- Connect portable hydraulic tester (D) and test hoses between coupling assembly at the drive pump and coupling assembly at the swing motor.
- Attach a
41,368 kPa (6,000 psi) pressure sensor to pressure tap (1) for delivery pressure of the drive pump. - Install tooling (C) on the engine to monitor engine speed.
| NOTICE |
|---|
|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
- Position the machine on level ground.
- Stop the engine.
- Release pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".
- Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply
276 to 414 kPa (40 to 60 psi) . This procedure will pull a vacuum on the hydraulic system. - Install the following tools in accordance with the flow meter tool layout. Refer to Illustration 4.
- Disconnect delivery line (4) from the idler pump.
- Install cover (D15) and seal (D14) to the end of the delivery line (4) by using half flanges (D19), bolts (D20), and washer (D21).
- Assemble and install seal (D14), adapter (D13), seals (D4), fitting (D12), seal (D11), plug (D10), and fitting (D5) on the idler pump by using existing half flanges (8), bolts (6), and washers (7).
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Illustration 8 g03785230 Swing motor (top view)
(10) Makeup line
(11) Seal
(12) Elbow - Disconnect makeup line (10) from elbow (12) at the swing motor.
- Assemble and install seals (D17), tee (D18), adapter (D16), seal (D4), and fitting (D5) to elbow (12) at the swing motor.
- Install seal (11) and makeup line (10) to tee (D18).
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Illustration 7 g03751958 Pump compartment
(1) Pressure tap (delivery pressure for drive pump)
(2) Pressure tap (delivery pressure for idler pump)
(3) Delivery line for drive pump
(4) Delivery line for idler pump - Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
- Connect portable hydraulic tester (D) and test hoses between coupling assembly at the idler pump and coupling assembly at the swing motor.
- Attach a
41,368 kPa (6,000 psi) pressure sensor to pressure tap (2) for delivery pressure of the idler pump. - Install tooling (C) on the engine to monitor engine speed.
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
 |
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To prevent personal injury or equipment damage from failure of the hydraulic test equipment or associated circuit components because of blocked pump flow, make sure that the test equipment valves are fully open before starting the engine. |
|
|
To prevent personal injury and/or equipment damage from failed lines or components while the hydraulic test equipment is returned to the open flow position, slowly open the hydraulic test equipment valve while monitoring the pump flow. If pump flow does not increase as the valve is opened, shut the engine off and determine what is preventing the pump from upstroking. |
100% Swashplate Angle (Maximum Output Flow)
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Pump #1 Cont Spool Sol" to "2 Amps" to set drive pump to maximum displacement.
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Illustration 9 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until drive pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Drive Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the drive pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.
0% Swashplate Angle (Minimum Output Flow)
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Pump #1 Cont Spool Sol" to "0 Amps" to set drive pump to minimum displacement.
Show/hide table
Illustration 10 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until drive pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Drive Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the drive pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Des Pump #1 Flow Rate" to
179.4 L/min (47.39 US gpm) to set drive pump to 60% displacement.Show/hide table
Illustration 11 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until drive pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Drive Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the drive pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Des Pump #1 Flow Rate" to
131.1 L/min (34.63 US gpm) to set drive pump to 40% displacement.Show/hide table
Illustration 12 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until drive pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Drive Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the drive pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.
100% Swashplate Angle (Maximum Output Flow)
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Pump #2 Cont Spool Sol" to "2 Amps" to set idler pump to maximum displacement.
Show/hide table
Illustration 13 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until idler pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Idler Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (2) to monitor the delivery pressure of the idler pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.
0% Swashplate Angle (Minimum Output Flow)
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Pump #2 Cont Spool Sol" to "0 Amps" to set idler pump to minimum displacement.
Show/hide table
Illustration 14 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until idler pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Idler Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (2) to monitor the delivery pressure of the idler pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Des Pump #2 Flow Rate" to
179.4 L/min (47.39 US gpm) to set idler pump to 60% displacement.Show/hide table
Illustration 15 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until idler pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Idler Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (2) to monitor the delivery pressure of the idler pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Enter password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to "1500 rpm".
- Override "Des Pump #2 Flow Rate" to
131.1 L/min (34.63 US gpm) to set idler pump to 40% displacement.Show/hide table
Illustration 16 g02599896 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve - Turn valve (17) on the portable hydraulic tester clockwise until idler pump pressure is
10000 kPa (1450 psi) . Record the following items in Table 1.- Idler Pump Pressure
- Engine Speed
- Hydraulic Oil Temperature
Note: Use the pressure sensor at pressure tap (2) to monitor the delivery pressure of the idler pump.
Note: Flow measurement must be done only during pressure rise.
Note: To measure flow for either pump individually, the other pump must not be under load.