Note: This procedure should only be performed 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.
| "Pump Control (Output Flow) - Test (One Pump Calibration)" | ||||
|---|---|---|---|---|
| Measured Items | Measuring Points | |||
| Machine Settings | Engine Speed | Speed dial "10"
AEC switch OFF (1550 rpm) |
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| Power Shift Pressure | |
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| Pump Pressure | |
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| Front Pump Flow L/min (US gpm) | ||||
| Rear Pump Flow L/min (US gpm) | ||||
| Engine speed (rpm) | ||||
| Oil temperature °C (°F) | ||||
| Front Pump Corrected Flow L/min (US gpm) | ||||
| Rear Pump Corrected Flow L/min (US gpm) | ||||
| Specification for flow rate L/min (US gpm) | |
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| Illustration 1 | g03825584 |
|
One Pump Flow P-Q characteristic curve (Power shift pressure at | |
Note: Specifications for output flow rates are based on an engine speed of 1550 rpm. To attain more accurate test results, measured flow should be corrected with the following calculation.
| Corrected flow | = | Measured flow x 1550 rpm |
| measured rpm |
Note: Flow measurements must be done only during pressure rise.
Note: The pump flow changes approximately
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| Illustration 2 | g02571852 |
|
198-4240 Digital Pressure Indicator Gp | |
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| Illustration 3 | g02535237 |
|
348-5430 Multi-Tool Gp | |
| |
| Illustration 4 | g03681086 |
| (D1) 210 gpm Portable hydraulic tester (flow meter) | |
| Tool | Item | Qty | Part
Number |
Description |
|---|---|---|---|---|
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 1 | 198-4234 | Indicator | |
| A2 | 1 | 198-4237 | 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 | 9U-5229 | Adapter | |
| D4 | 9 | 2S-4078 | O-Ring Seal | |
| D5 | 4 | 4C-5093 | Fitting | |
| D6 | 4 | 4C-5094 | Coupler | |
| D7 | 4 | 4C-6461 | Coupling | |
| D8 | 4 | 5P-0477 | Sleeve | |
| D9 | 2 | 9X-2735 | Hose | |
| D10 | 2 | 9S-4191 | Plug | |
| D11 | 2 | 3J-1907 | O-Ring Seal | |
| D12 | 2 | 174-4360 | Elbow | |
| D13 | 4 | 8T-4193 | Bolt | |
| D14 | 2 | 5P-8077 | Half Flange | |
| D15 | 1 | 174-4356 | Adapter | |
| D16 | 1 | 1P-3705 | Rectangular Seal | |
| D17 | 4 | 8T-4196 | Bolt | |
| D18 | 2 | 1P-4578 | Half Flange | |
| D19 | 1 | 7X-2470 | Adapter | |
| D20 | 1 | 7M-8485 | O-Ring Seal | |
| D21 | 1 | 9U-7446 | Adapter | |
| D22 | 1 | 4J-0522 | Rectangular Seal | |
| D23 | 1 | 7I-7132 | Cover | |
| 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 5 | g03655907 |
| 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, PERJ1017, "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 front pump and the test for the rear pump one at a time.
- Position the machine on level ground.
- Stop the engine.
- Release the 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 tools in accordance with the tool layout. Refer to Illustration 5.
- Disconnect delivery line (7) from the rear pump.
- Install blocking cover to the end of delivery line.
- Assemble and install seal (D16), adapter (D15), seal (D4), elbow (D12), seal (D11), plug (D10), and fitting (D5) on the rear pump by using existing half flanges (10), bolts (8) and washers (9).
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Illustration 7 g03682272 Main Control Valve
(11) Cover (auxiliary return) - Remove cover (11) and bolts.
- Assemble and install seal (D22), adapter (D21), seal (D20), adapter (D19), seal (D4), elbow (D12), seal (D11), plug (D10), and fitting (D5) to auxiliary return.
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Illustration 6 g03681897 Pump compartment
(1) Pressure tap (delivery pressure for front pump 1)
(2) Pressure tap (delivery pressure for rear pump 2)
(3) Pressure tap (power shift pressure)
(4) Pressure tap (front pump 1 negative flow)
(5) Pressure tap (rear pump 2 negative flow)
(6) Delivery line (front pump)
(7) Delivery line (rear pump) - Remove 311-1362 Vacuum Cap and install the hydraulic cap for the hydraulic tank.
- Connect portable hydraulic tester (D) and test hoses between coupling assembly at the front pump and the coupling assembly at the auxiliary return.
- Attach a
41,368 kPa (6,000 psi) pressure sensor to pressure tap (2) for delivery pressure of the rear pump. - Attach a
3,447 kPa (500 psi) pressure sensor to pressure tap (3) to monitor power shift pressure. - 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, PERJ1017, "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 front pump and the test for the rear pump one at a time.
- Position the machine on level ground.
- Stop the engine.
- Release the 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 tools in accordance with the tool layout. Refer to Illustration 5.
- Disconnect delivery line (6) from the front pump.
- Install blocking cover to the end of delivery line.
- Assemble and install seal (D16), adapter (D15), seal (D4), elbow (D12), seal (D11), plug (D10), and fitting (D5) on the front pump by using existing half flanges (10), bolts (8) and washers (9).
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Illustration 9 g03682272 Main Control Valve
(11) Cover (auxiliary return) - Remove cover (11) and bolts.
- Assemble and install seal (D22), adapter (D21), seal (D20), adapter (D19), seal (D4), elbow (D12), seal (D11), plug (D10), and fitting (D5) to auxiliary return.
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Illustration 8 g03681897 Pump compartment
(1) Pressure tap (delivery pressure for front pump 1)
(2) Pressure tap (delivery pressure for rear pump 2)
(3) Pressure tap (power shift pressure)
(4) Pressure tap (front pump 1 negative flow)
(5) Pressure tap (rear pump 2 negative flow)
(6) Delivery line (front pump)
(7) Delivery line (rear pump) - Remove 311-1362 Vacuum Cap and install the hydraulic cap for the hydraulic tank.
- Connect portable hydraulic tester (D) and test hoses between coupling assembly at the front pump and the coupling assembly at the auxiliary return.
- Attach a
41,368 kPa (6,000 psi) pressure sensor to pressure tap (1) for delivery pressure of the front pump. - Attach a
3,447 kPa (500 psi) pressure sensor to pressure tap (3) to monitor power shift pressure. - Install tooling (C) on the engine to monitor engine speed.
 |
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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. |
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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. |
- Insert track block in both tracks to block forward travel.
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Input the password "9992".
- Select "Override Parameters".
- Override "Pump #1 Solenoid Current" to 0 mA.
- Override "Pump #2 Solenoid Current" to 700 mA.
- Override "Power Shift Pressure" to
3200 kPa (464 psi) . Confirm the power shift pressure setting at pressure tap (3). - Place the hydraulic activation lever in the UNLOCKED position.
- Move right travel lever to full forward position.
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Illustration 10 g03684087 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(12) Valve - Turn valve (12) on the flow meter clockwise. Record the following items for each measuring point in Table 1.
- Rear Pump Flow
- Engine Speed
Note: Use the pressure sensor at pressure tap (2) to monitor the delivery pressure of the rear pump.
Note: Flow measurements must be done only during pressure rise.
- Return the right travel lever to the neutral position.
- Stop the engine.
- Insert track block in both tracks to block forward travel.
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the Service Menu on the monitor.
- Input the password "9992".
- Select "Override Parameters".
- Override "Pump #1 Solenoid Current" to 700 mA.
- Override "Pump #2 Solenoid Current" to 0 mA.
- Override "Power Shift Pressure" to
3200 kPa (464 psi) . Confirm the power shift pressure setting at pressure tap (3). - Place the hydraulic activation lever in the UNLOCKED position.
- Move left travel lever to full forward position.
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Illustration 11 g03684087 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(12) Valve - Turn valve (12) on the flow meter clockwise. Record the following items for each measuring point in Table 1.
- Front Pump Flow
- Engine Speed
Note: Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the front pump.
Note: Flow measurements must be done only during pressure rise.
- Return the left travel lever to the neutral position.
- Stop the engine.