| "Pump Control (Negative Flow) - Test" | |||
|---|---|---|---|
| Measured Items | Measuring Points | ||
| Machine Settings | Engine Speed | Engine speed dial "10"
AEC switch OFF |
|
| Power Shift Pressure | |
||
| Pump Pressure | No Load Standby Pressure | ||
| Pump Flow Limit Pressure | |
|
|
| Drive Pump Flow Measured L/min (US gpm) | |||
| Engine Speed (rpm) | |||
| Oil Temperature °C (°F) | |||
| Idler Pump Flow Measured L/min (US gpm) | |||
| Engine Speed (rpm) | |||
| Oil Temperature °C (°F) | |||
| Specification for negative flow rate L/min (US gpm) | |
|
|
| (1) | Negative Flow Control Adjustment |
| (2) | Minimum Output Flow Adjustment |
Note: Specifications for flow rates are based on an engine speed of 1800 rpm. To get more accurate test results, measured flow should be corrected with the following calculation.
| Corrected flow | = | Measured flow x 1800 rpm |
| Measured rpm |
Flow measurements must be done in pressure rise.
This test measures individual pump flow at the pump while a fixed negative flow control pressure is sent to the main pump regulator. Each pump is tested individually for an output flow rate at a specified delivery pressure and a specified negative flow control pressure.
- Set the pilot pressure to the specifications in Testing and Adjusting, "Relief Valve (Pilot) - Test and Adjust" for the machine.
- Calibrate the power shift pressure. Refer to Testing and Adjusting, "Solenoid Valve (Proportional Reducing) - Calibrate (Power Shift Pressure)" for the machine.
- Calibrate the proportional reducing valve for negative flow control. Refer to Testing and Adjusting, "Solenoid Valve (Proportional Reducing) - Calibrate (Negative Flow Control)" for the machine.
| |
| Illustration 1 | g02571852 |
|
Tooling (A) 198-4240 Digital Pressure Indicator Gp | |
| |
| Illustration 2 | g02726620 |
| |
| Illustration 3 | g02535237 |
|
Tooling (C) 348-5430 Multi-Tool Gp | |
| |
| Illustration 4 | g06256183 |
|
Tooling (D) (Flow meter tool layout) | |
| Tool | Item | Part
Number |
Description | Qty |
|---|---|---|---|---|
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 198-4234 | Indicator | 1 | |
| A2 | 198-4237 | Pressure Sensor
|
1 | |
| A2 | 198-4239 | Pressure Sensor
|
2 | |
| A3 | 198-4236 | Extension Cable | 3 | |
| C | 348-5430 | Multi-Tool Gp | ||
| C1 | 285-0908 | Multi-Tool | 1 | |
| C2 | 6V-2198 | Cable As | 1 | |
| C3 | 9U-5140 | Photo Pickup | 1 | |
| C4 | 6V-3137 | Base | 1 | |
| C5 | 1U-6605 | Reflective Tape | 1 | |
| C6 | 6V-3138 | Extension | 1 | |
| D | D1 | 436-8662 | Portable hydraulic tester (flow meter) | 1 |
| D2 | 6K-6307 | O-Ring Seal | 2 | |
| D3 | 8C-9026 | Adapter | 2 | |
| D4 | 7M-8485 | O-Ring Seal | 9 | |
| D5 | 4C-6482 | Fitting | 4 | |
| D6 | 4C-6481 | Coupler | 4 | |
| D7 | 4C-8767 | Coupling | 4 | |
| D8 | 5P-1010 | Sleeve | 4 | |
| D9 | 5P-0201 | Hose | 2 | |
| D10 | 499-1187 | Coupling As | 1 | |
| D11 | 8T-4185 | Bolt | 4 | |
| D12 | 8T-4121 | Hard Washer | 12 | |
| D13 | 8T-9403 | Half Flange | 2 | |
| D14 | 8T-4133 | Nut | 4 | |
| D15 | 1P-3702 | Rectangular Seal | 1 | |
| D16 | 122-1951 | Cover | 1 | |
| D17 | 4I-6141 | Adapter | 1 | |
| D18 | 5K-9090 | O-Ring Seal | 2 | |
| D19 | 6V-9840 | Swivel Tee | 1 | |
| D21 | 498-8395 | Coupling As | 1 | |
| D22 | 8T-4196 | Bolt | 4 | |
| D23 | 124-4287 | Split Flange | 2 | |
| D24 | 4J-5267 | O-Ring Seal | 1 | |
| F | 311-1362 | Vacuum Cap | 1 | |
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.
| 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.
| |
| Illustration 5 | g06259548 |
|
Pump compartment (1) Pressure tap (delivery pressure for drive pump) (2) Pressure tap (delivery pressure for idler pump) (3) Pressure tap (power shift pressure) (4) Delivery line for drive pump (5) Delivery line for idler pump (6) Negative flow control line (drive pump) (7) Negative flow control line (idler pump) | |
- 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.Show/hide table
Illustration 6 g06256396 Flow meter tool layout
Tooling (D)
( 4) Delivery line for drive pump
(5) Delivery line for idler pump
(10) Makeup line
(11) Seal
(12) Elbow - Install seal (D16) and blocking cover (D17) to the end of the delivery line.
- Refer to Illustration 6 and install tooling for the drive pump.
Show/hide table
Illustration 7 g03862377 Swing motor (top view)
(10) Makeup line
(11) Seal
(12) Elbow - Disconnect makeup line (10) from elbow (12) at the swing motor.
- Refer to Illustration 6 and install tooling on the swing motor.
- 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 or the idler 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. Attach a41,368 kPa (6,000 psi) pressure sensor to pressure tap (2) for delivery pressure of the idler pump.Show/hide table
Illustration 8 g06259574 Pump compartment
(6) Negative flow control line (drive pump)
(7) Negative flow control line (idler pump)
(15) Pressure tap (negative flow for drive pump)
(16) Pressure tap (negative flow for idler pump) - Attach a
3445 kPa (500 psi) pressure sensor to pressure tap (15) for negative flow control pressure for the drive pump. Attach a3445 kPa (500 psi) pressure sensor to pressure tap (16) for negative flow control pressure for the idler pump. - Install multitach group (C) on the engine. This will be used to monitor engine speed.
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
 |
|
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. |
- Start the engine.
- Increase the hydraulic oil temperature to
55° ± 5°C (131° ± 9°F) . - Enter the service mode.
- Input the password "9992".
- Select "Override Parameters".
- Override the "Desired Engine Speed" to 1800 rpm.
- Override the "Power Shift Pressure" to
0 kPa (0 psi) . - Override the "Flow Limit Pressure PRV" to the pump flow limit pressures listed in Table 1. Confirm the pump flow limit pressure at pressure tap (15) for the drive pump and pressure tap (16) for the idler pump.
Note: Override the pump flow limit pressure back to
0 kPa (0 psi) before attempting to enter a second override value.Show/hide table
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. The measuring point is listed in Table 1. Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the drive pump or use pressure tap (2) to monitor the delivery pressure of the idler pump.
Note: In order to perform flow measurements for either one of the pumps, the other pump must not be under load.
