312F and 313F Excavator Machine Systems Main Pump (Flow) - Test - Hydraulic Power Caterpillar


Main Pump (Flow) - Test - Hydraulic Power
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1.1. Specification
2.2. High-Power Mode
3.3. Hydraulic Power Conversion
4.1. Introduction
5.2. Preliminary Test
6.1. Required Tools
7.1. Machine Preparation
8.1. Test Procedure

Specification

High-Power Mode

Table 1
"Main Pump (Flow) - Test (Hydraulic Power)" 
Machine Settings  Engine Speed  Function 
Speed dial 10
AEC switch OFF
Boom Raise 
Measured Items  Measuring Points 
17000 ± 500 kPa (2466 ± 73 psi) 25000 ± 500 kPa (3626 ± 73 psi)
Drive Pump Pressure     
Idler Pump Pressure     
Average Pump Pressure     
Measured Flow L/min (US gpm)     
Hydraulic Power kW (hp)     
Oil temperature °C (°F)     
Specification for Hydraulic Power kW (hp)  New  52.8 ± 4 kW (70.8 ± 5.4 hp)  49.7 ± 4 kW (66.6 ± 5.4 hp) 
Service limit 44 kW (59.0 hp)  38 kW (51.0 hp) 
Equipped with 3rd pump open center valve package 
Specification for Hydraulic Power kW (hp)  New  52.0 ± 4 kW (69.7 ± 5.4 hp)  49.0 ± 4 kW (65.7 ± 5.4 hp) 
Service limit 44 kW (59.0 hp)  37 kW (49.6 hp) 
Equipped with 3rd pump load sense valve package 
Specification for Hydraulic Power kW (hp)  New  50.0 ± 4 kW (67.1 ± 5.4 hp)  47.0 ± 4 kW (63.0 ± 5.4 hp) 
Service limit 42 kW (56.3 hp)  36 kW (48.3 hp) 

Hydraulic Power Conversion

Table 2
Power (kW)  (Pump Pressure x Measured Flow)    Power (hp)  (Pump Pressure x Measured Flow) 
60000        1714 

Introduction

This test measures two pump flow to the boom cylinders at the boom foot. Both pumps are tested for output flow at specified pressures. If the results from this test are not within the specification, refer to Testing and Adjusting, "Pump Control (Output Flow) - Test (Two Pump Calibration)" to isolate any problem with the pumps.

Note: If the operational checks (cycle time) indicate that slow speed of an implement is common to the circuits of one pump, the problem is most likely in the hydraulic system. Then perform the pump flow tests. Refer to Testing and Adjusting, "Main Pump (Flow) - Test (Hydraulic Power)".

Note: The engine, the fuel, or the working altitude may be the problem if the operational checks indicate that slow speed of an implement is common to both pump circuits.

Preliminary Test

  • Testing and Adjusting, "Relief Valve (Pilot) - Test and Adjust"

  • Testing and Adjusting, "Relief Valve (Main) - Test and Adjust"

  • Testing and Adjusting, "Solenoid Valve (Proportional Reducing) - Calibrate (Power Shift Pressure)"

  • Testing and Adjusting, "Power Shift Pressure - Check"

Required Tools



Illustration 1g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp


Illustration 2g02535237
Tooling (C)


Illustration 3g03516921
100 US gpm flow meter setup

Table 3
Tool  Item  Qty  Part Number  Description 
  198-4240  Digital Pressure Indicator Gp 
  A1  198-4234  Indicator 
A2 198-4239  Pressure Sensor 41,368 kPa (6,000 psi) 
A3 198-4236  Extension Cable 
  348-5430  Multi-Tool Gp 
  C1  285-0908  Multi-Tool 
C2 6V-2198  Cable As 
C3 9U-5140  Photo Pickup 
C4 6V-3137  Base 
C5 1U-6605  Reflective Tape 
C6 6V-3138  Extension 
D1  436-8664  Portable hydraulic tester (flow meter) 
D3 8C-9029  Adapter 
D4 10  7M-8485  O-Ring Seal 
D5 4C-6482  Fitting 
D6 4C-6481  Coupler 
D7 4C-8767  Coupling 
D8 5P-1010  Sleeve 
D9 9X-2734  Hose 
D10 7I-0048  Connector 
D11 6V-9746  O-Ring Seal 
D12 6V-8943  Reducer 
D13 7J-9108  O-Ring Seal 
D14 6V-9510  Plug 
D15 6V-9831  Cap 
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.

Machine Preparation


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.




    Illustration 4g02280104

  1. Position the machine on level ground in the service position. Refer to Illustration 4.

  2. Stop the engine.

  3. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".

  4. 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.


    Illustration 5g06017998
    Pump compartment
    (1) Pressure tap (delivery pressure for drive pump)
    (2) Pressure tap (delivery pressure for idler pump)

  5. Connect 41,368 kPa (6,000 psi) pressure sensors to pressure tap (1) and pressure tap (2) for delivery pressure from both pumps.


    Illustration 6g03517018
    Flow meter tool layout at boom foot
    Tooling D
    (4) Connector (boom cylinder lines)
    (5) Boom cylinder
    (6) Line (boom cylinder head end)
    (7) Line (boom cylinder rod end)
    (8) Line (boom cylinder rod end)
    (9) Line (boom cylinder head end)

  6. Install the following tools in accordance with the flow meter tool layout. Refer to Illustration 6.

    1. Disconnect line (8) and line (9) from boom cylinder (5).

    2. Install O-ring seal (D13) and plug (D14) to the end of line (8) and line (9).

    3. Install cap (D15) on connector (4) for the boom cylinder lines.

    4. Disconnect line (6) and line (7) from boom cylinder (5).

    5. Install cap (D15) on connector (4) for the boom cylinder lines.

    6. Install O-ring seal (D13), reducer (D12), O-ring seal (D11), connector (D10), O-ring seal (D4), and coupler assembly (D5) to the end of line (6) and line (7).

    7. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.

    8. Connect portable hydraulic tester (D1) and the test hoses between coupler assembly (D5) on line (6) and coupler assembly (D5) on line (7).

      Note: To avoid damage to the flow meter, make sure that the direction of oil flow is correct. The proper direction of flow is from line (6) for the boom cylinder head end, through portable hydraulic tester (D1), and return through line (7) for the boom cylinder rod end.

Test Procedure

------ WARNING! ------

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.


------ WARNING! ------

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.


  1. Start the engine.

  2. Place the hydraulic activation control lever in the UNLOCKED position.

  3. Place the machine controls at the following settings: engine speed dial "1" and AEC switch OFF.

  4. Move the joystick for the boom to the full BOOM RAISE position. Hold the joystick for the boom in this position.

  5. Slowly increase engine speed to speed dial "10".

  6. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).


    Illustration 7g02599896
    Portable hydraulic tester (flow meter)
    (D1) Portable hydraulic tester (flow meter)
    (17) Valve

  7. Turn valve (17) on portable hydraulic tester clockwise. Record the following items for each measuring point in Table 1.

    • Drive Pump Pressure

    • Idler Pump Pressure

    • Measured Flow

    Note: Flow measurements must be done only during pressure rise.

  8. Return the joystick for the boom to the NEUTRAL position.

  9. Stop the engine.

  10. Calculate the hydraulic power using the average pump pressure and the measured flow. Refer to Table 2 for Metric (kW) and English (hp) calculations.

  11. Let the hydraulic oil cool to 55° ± 5°C (131° ± 9°F) and repeat the test.

    Note: If second test results differ from the first test, then run a third test.

    The following factors can affect the outcome of the test:

    • Engine

    • Hydraulic Oil Temperature

    • Calibrated Pressure Gauges

    • Calibrated Flow Meter

    • Working Altitude

  12. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".

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