312F and 313F Excavator Machine Systems Pump Control (Output Flow) - Test - One Pump Calibration (Optional Test) Caterpillar

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.

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.

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Table 1
"Pump Control (Output Flow) - Test (One Pump Calibration)"
Measured Items		Measuring Points
Machine Settings	Engine Speed	Speed dial "10" AEC "OFF" (1500 ± 50 rpm)
	Power Shift Pressure	1500 ± 50 kPa (218 ± 7 psi)	2800 ± 50 kPa (406 ± 7 psi)
	Pump Pressure	10000 kPa (1450 psi)	12000 kPa (1740 psi)	17000 kPa (2466 psi)	23000 kPa (3336 psi)	30000 kPa (4351 psi)
Drive Pump Flow L/min (US gpm)
Engine speed (rpm)
Oil temperature °C (°F)
Drive Pump Corrected Flow L/min (US gpm)
Idler Pump Flow L/min (US gpm)
Engine speed (rpm)
Oil temperature °C (°F)
Idler Pump Corrected Flow L/min (US gpm)
Specification for flow rate L/min (US gpm)		111 ± 3 L/min (29.3 ± 0.8 US gpm)	91 ± 6 L/min (24.0 ± 1.6 US gpm)	75 ± 6 L/min (19.8 ± 1.6 US gpm)	58 ± 8 L/min (15.3 ± 2.1 US gpm)	45 ± 10 L/min (11.9 ± 2.6 US gpm)

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Illustration 1	g06014738

Note: Specifications for output flow rates are based on an engine speed of 1600 rpm. To attain more accurate test results, measured flow should be corrected with the following calculation.

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Table 2
Corrected flow	=	Measured flow x 1500 rpm
		measured rpm

Note: The output flow rate changes approximately 1.8 L/min (0.48 US gpm) for each 100 kPa (14 psi) of power shift pressure in the lower range of the constant horsepower control. The output flow rate changes approximately 0.8 L/min (0.21 US gpm) for each 100 kPa (14 psi) of power shift pressure in the higher range of the constant horsepower control.

Note: If the output flow rate of the pump is not within the specification, disconnect the negative flow control line from the pump that is being tested and perform the test again. The NFC port on the regulator should be left open to the atmosphere. Oil leakage from the regulator spool could cause pressure in the NFC port and affect the test results.

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

Introduction

This test is a single pump flow test with a fixed power shift pressure with the second pump at standby. For optimal performance and efficiency, set each pump to the target flow for the measuring points listed in Table 1.

Preliminary Test

Testing and Adjusting, "Main Pump (Flow) - Test (Hydraulic Power)"

Required Tools

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Illustration 2	g02571852
Tooling (A) 198-4240 Digital Pressure Indicator Gp

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Illustration 3	g02535237
Tooling (C)

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Illustration 4	g03531059
Tooling (D) (Flow meter tool layout)

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Table 3
Tool	Item	Qty	Part Number	Description
A			198-4240	Digital Pressure Indicator Gp
	A1	1	198-4234	Indicator
	A2	1	198-4237	Pressure Sensor 3447 kPa (500 psi)
	A2	2	198-4239	Pressure Sensor 41,368 kPa (6,000 psi)
	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	436-8664	Portable hydraulic tester (flow meter)
	D3	2	8C-9029	Adapter
	D4	10	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	2	4I-6140	Adapter
	D11	1	6V-9511	Plug
	D12	1	6V-9853	Elbow
	D14	4	6V-9746	O-Ring Seal
	D15	1	6V-9839	Swivel Tee
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.

Machine Preparation

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Illustration 5	g03531072
Flow meter tool layout Tooling (D) ( 4) Delivery line for drive pump (5) Delivery line for idler pump (6) Seal (7) Makeup line (8) Seal (9) Elbow

Drive Pump

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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.

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Illustration 6	g02793314
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

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 5.
1. Disconnect delivery line (4) from the drive pump.
2. Install seal (6) and plug (D11) to the end of the delivery line.
3. Assemble and install seals (D14), elbow (D12), adapter (D10), seal (D4), and fitting (D5) on the drive pump.
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  Illustration 7 g03524636
  
  Swing motor
  (7) Makeup line
  (8) Seal
  (9) Elbow
4. Disconnect makeup line (7) from elbow (9) at the swing motor.
5. Assemble and install seals (D14), tee (D15), adapter (D10), seal (D4), and fitting (D5) to elbow (9) at the swing motor.
6. Install seal (8) and makeup line (7) to tee (D15).
Remove 311-1362 Vacuum Cap and install the filler cap 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. Attach a 3447 kPa (500 psi) pressure sensor to pressure tap (3) for power shift pressure.
Install tooling (C) on the engine to monitor engine speed.

Idler Pump

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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.

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Illustration 8	g02793314
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

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 5.
1. Disconnect delivery line (5) from the idler pump.
2. Install seal (6) and plug (D16) to the end of the delivery line.
3. Assemble and install seal (D11), adapter (D10), seal (D4), and fitting (D5) on the idler pump.
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  Illustration 9 g03524636
  
  Swing motor
  (7) Makeup line
  (8) Seal
  (9) Elbow
4. Disconnect makeup line (7) from elbow (9) at the swing motor.
5. Assemble and install seals (D14), tee (D15), adapter (D13), seal (D4), and fitting (D5) to elbow (9) at the swing motor.
6. Install seal (8) and makeup line (7) to tee (D15).
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. Attach a 3447 kPa (500 psi) pressure sensor to pressure tap (3) for power shift pressure.
Install tooling (C) on the engine to monitor engine speed.

Test Procedure

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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.

Start the engine.
Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
Enter the Service Menu on the monitor.
1. Input the password "9992".
2. Select "Override Parameters".
Override "Desired Engine Speed" to 1500 rpm.
Override "Power Shift Pressure" to 1500 kPa (218 psi). Confirm the power shift pressure setting at pressure tap (3).
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Illustration 10 g02599896

Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve
Turn valve (17) on the flow meter clockwise. Record the following items for the first measuring point in Table 1.
- Drive Pump Flow or Idler Pump Flow
- Engine Speed
Note: Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the drive pump and use pressure tap (2) to monitor the delivery pressure of the idler pump.
Note: Flow measurements must be done only during pressure rise.
Turn valve (17) on the flow meter counterclockwise to the full open position.
Override "Power Shift Pressure" to 2800 kPa (406 psi). Confirm the power shift pressure setting at pressure tap (3).
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Illustration 11 g02599896

Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(17) Valve
Turn valve (17) on the flow meter clockwise. Record the following items for the last three measuring points in Table 1.
- Drive Pump Flow or Idler Pump Flow
- Engine Speed
Note: Use the pressure sensor at pressure tap (1) to monitor the delivery pressure of the drive pump and use pressure tap (2) to monitor the delivery pressure of the idler pump.
Note: Flow measurements must be done only during pressure rise.
Turn valve (17) on the flow meter counterclockwise to the full open position.
Stop the engine.