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 two pump calibration will provide a more accurate pump setting than the one pump calibration.
| "Pump Control (Output Flow) - Test (Two Pump Calibration)" | |||||
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| Measured Items | Measuring Points | ||||
| Machine Settings | Engine Speed | Speed dial "10"
AEC switch OFF (1500 rpm) |
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| Power Shift Pressure | |
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| Pump Pressure | |
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| Drive Pump Flow L/min (US gpm) | |||||
| Idler Pump Flow L/min (US gpm) | |||||
| Engine speed (rpm) | |||||
| Oil temperature °C (°F) | |||||
| Drive Pump Corrected Flow L/min (US gpm) | |||||
| Idler Pump Corrected Flow L/min (US gpm) | |||||
| Specification for flow rate L/min (US gpm) | |
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| Illustration 1 | g06014793 |
Note: Specifications for output flow rates are based on an engine speed of 1500 rpm. To attain more accurate test results, measured flow should be corrected with the following calculation.
| Corrected flow | = | Measured flow x 1500 rpm |
| measured rpm |
Note: Specifications for output flow rates are based on a power shift pressure at the pump of
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.
This test is a two pump calibration with a fixed power shift pressure. For optimal performance and efficiency, set each pump to the target flow for the measuring points listed in Table 1.
- Testing and Adjusting, "Main Pump (Flow) - Test (Hydraulic Power)"
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| Illustration 2 | g02571852 |
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Tooling (A) 198-4240 Digital Pressure Indicator Gp | |
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| Illustration 3 | g02535237 |
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Tooling (C) | |
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| Illustration 4 | g03531059 |
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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 | 198-4237 | Pressure Sensor
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| A2 | 2 | 198-4239 | Pressure Sensor
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| 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) |
| D2 | 1 | 436-8663 | Portable hydraulic tester (load valve) | |
| D3 | 4 | 8C-9029 | Adapter | |
| D4 | 20 | 7M-8485 | O-Ring Seal | |
| D5 | 8 | 4C-6482 | Fitting | |
| D6 | 8 | 4C-6481 | Coupler | |
| D7 | 8 | 4C-8767 | Coupling | |
| D8 | 8 | 5P-1010 | Sleeve | |
| D9 | 4 | 9X-2734 | Hose | |
| D10 | 4 | 4I-6140 | Adapter | |
| D11 | 2 | 6V-9511 | Plug | |
| D12 | 2 | 6V-9853 | Elbow | |
| D14 | 8 | 6V-9746 | O-Ring Seal | |
| D15 | 2 | 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.
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| Illustration 5 | g06014813 |
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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 | |
| NOTICE |
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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. |
- 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.
- Disconnect delivery line (4) from the drive pump.
- Install seal (6) and plug (D11) to the end of the delivery line.
- Assemble and install seals (D14), elbow (D12), adapter (D10), seal (D4), and fitting (D5) on the drive pump.
- Disconnect delivery line (5) from the idler pump.
- Install seal (6) and plug (D11) to the end of the delivery line.
- Assemble and install seals (D14), elbow (D12), adapter (D10), seal (D4), and fitting (D5) on the idler pump.
Show/hide table
Illustration 7 g03524636 Swing motor
(7) Makeup line
(8) Seal
(9) Elbow - Disconnect makeup line (7) from elbow (9) at the swing motor.
- Assemble and install seals (D14), tee (D15), adapter (D10), seal (D4), and fitting (D5) to elbow (9) at the swing motor.
- Install seal (8) and makeup line (7) to tee (D15).
Show/hide table
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 - Remove 311-1362 Vacuum Cap and install the filler cap for the hydraulic tank.
- Connect portable hydraulic tester (D1) and test hoses between coupling assembly at the drive pump and coupling assembly at the swing motor.
- Connect portable hydraulic tester (D2) 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 (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. - 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.
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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.
- Input the password "9992".
- Select "Override Parameters".
- Override "Desired Engine Speed" to 1500 rpm.
- Override "Power Shift Pressure" to
1500 kPa (217.6 psi) . Confirm the power shift pressure setting at pressure tap (3).Show/hide table
Illustration 8 g03517568 Portable hydraulic tester (flow meter)
(D1) Portable hydraulic tester (flow meter)
(D2) Portable hydraulic tester (load valve)
(17) Valve - Turn valve (17) on both flow meters clockwise. Record the following items for each measuring point in Table 1.
- Drive Pump Flow
- 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.
- Stop the engine.
