SMCS - 3222-081-FW
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.
Cerrar SIS
Pantalla anterior
Producto: NO SE HA ESCOGIDO NINGUN EQUIPO Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO
Número de medio -RENR5435-03 Fecha de publicación -01/10/2004 Fecha de actualización -29/10/2004 i01957742
Illustration 1 g
Flow meter tool layout (1) Swing motor
(2) Connector at swing motor (3) 6V-9840 Swivel tee (4) Makeup line (swing motor)
(6) Negative flow control line (drive pump) (7) 6V-9508 Plug
(10) 4C-9910 Portable hydraulic tester (flow meter) (11) Delivery line (idler pump)
(12) Delivery line (drive pump)
(13) Negative flow control line (idler pump) (17) 7I-7133 Blocking cover
(23) Drive pump (24) Idler pump
(25) 6V-8397 O-Ring Seal (29) 1U-8303 Fitting (30) 5K-9090 O-Ring seal (31) 5P-0201 Hose (32) 5P-1010 Sleeve (33) 4C-8767 Coupling (34) 7M-8485 O-Ring seal (35) 4C-6481 Coupler assembly (36) 4C-6482 Nipple assembly (37) 4I-6141 Coupling (38) 8C-9026 Adapter (39) 6K-6307 O-Ring seal (40) 6V-9854 Swivel elbow (42) 1P-3704 Rectangular seal (46) 8T-4194 Bolt
(47) 8T-4223 Hard washer (48) 1P-5767 Half flange (49) 1U-8293 Adapter
Illustration 2 g00846402
Circuit diagram (1) Swing motor (2) Connector (3) Tee
(4) Makeup line (5) Main control valves
(6) Negative flow control line (drive pump) (7) Plug
(8) Pressure tap (idler pump delivery pressure)
Drive Pump
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
(9) Pressure gauge
(10) Portable hydraulic tester (flow meter) (11) Delivery line (idler pump)
(12) Delivery line (drive pump)
(13) Negative flow control line (idler pump) (15) Tees
(16) Pressure tap (drive pump delivery pressure) (17) Blocking cover
(18) Test line (20) Pressure gauge (21) Engine
(22) Multitach group (23) Drive pump (24) Idler pump (40) Elbow
(50) Pressure tap (power shift pressure)
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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Position the machine on level ground.
2. Stop the engine.
3. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".
4. Install the following tools in accordance with the circuit diagram. Refer to Illustration 2.
a. Disconnect delivery line (12) from drive pump (23) .
b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (12) by using bolts (46) and washers (47) .
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on drive pump (23) by using half flanges (48), bolts (46) and washers (47) .
Illustration 3 g00843698
Pump compartment
(6) Negative flow control line (drive pump) (8) Pressure tap (idler pump delivery pressure) (12) Delivery line (drive pump)
(16) Pressure tap (drive pump delivery pressure) (23) Drive pump
(24) Idler pump
(50) Pressure tap (power shift pressure)
d. Disconnect makeup line (4) from connector (2) at swing motor (1) .
e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1) .
f. Install seal (30) and makeup line (4) to tee (3) .
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at drive pump (23) and coupling (37) at the swing motor.
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (16) for drive pump delivery pressure.
i. Install multitach group (22) on engine (21). This is used to monitor engine speed.
Illustration 4 g00669270
Swing motor (top view) (1) Swing motor (2) Connector (3) Tee
(4) Makeup line (40) Elbow
Illustration 5 g00846401
Tool setup
(6) Negative flow control line (drive pump) (7) 6V-9508 Face seal plug
(13) Negative flow control line (idler pump) (15) 8T-8902 Tee
(18) 177-7860 Hose assembly (19) Pump regulator
(20) 8T-0855 Pressure gauge (23) Drive pump
j. Disconnect negative flow control line (6) from drive pump (23). Install seal (25) and plug (7) to the end of negative flow control line (6) .
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of drive pump (23). Install cap (27) to tee (15) .
l. Connect one end of test hose (18) to tee (15) .
m. Connect the other end of test hose (18) to pressure tap (50) for the power shift pressure.
n. Connect one end of test hose (44) to tee (15) .
o. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .
Idler Pump
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
(24) Idler pump
(25) 6V-8397 O-Ring seal (27) 6V-9829 Cap (28) 3J-1907 O-Ring seal (41) 6V-3965 Fitting (43) 6V-4143 Coupler (44) Test hose (45) 6V-3989 Fitting
(50) Pressure tap (power shift pressure)
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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Position the machine on level ground.
2. Stop the engine.
3. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".
4. Install the following tools in accordance with the circuit diagram. Refer to Illustration 2.
a. Disconnect delivery line (11) from idler pump (24) .
b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (11) by using bolts (46) and washers (47) .
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) to idler pump (24) by using half flanges (48), bolts (46) and washers (47) .
Illustration 6 g00843712
Pump compartment
(8) Pressure tap (idler pump delivery pressure) (11) Delivery line for idler pump
(13) Negative flow control line (idler pump) (16) Pressure tap (drive pump delivery pressure) (23) Drive pump
(24) Idler pump
(50) Pressure tap (power shift pressure)
d. Disconnect makeup line (4) from connector (2) at swing motor (1) .
e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1) .
f. Install seal (30) and makeup line (4) to tee (3) .
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at idler pump (24) and coupling (37) at the swing motor.
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for idler pump delivery pressure.
i. Install multitach group (22) on engine (21). This is used to monitor engine speed.
Illustration 7 g00669270
Swing motor (top view) (1) Swing motor (2) Connector (3) Tee
(4) Makeup line (40) Elbow
Illustration 8 g00846401
Tool setup
(6) Negative flow control line (drive pump) (7) 6V-9508 Face seal plug
(13) Negative flow control line (idler pump) (15) 8T-8902 Tee
(18) 177-7860 Hose assembly (19) Pump regulator
(20) 8T-0855 Pressure gauge (23) Drive pump
j. Disconnect negative flow control line (13) from idler pump (24). Install seal (25) and plug (7) to the end of negative flow control line (13) .
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of idler pump (24). Install cap (27) to tee (15) .
l. Connect one end of test hose (18) to tee (15) .
m. Connect the other end of test hose (18) to pressure tap (50) for the power shift pressure.
n. Connect one end of test hose (44) to tee (15) .
o. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .
Test
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
(24) Idler pump
(25) 6V-8397 O-Ring seal (27) 6V-9829 Cap (28) 3J-1907 O-Ring seal (41) 6V-3965 Fitting (43) 6V-4143 Coupler (44) Test hose (45) 6V-3989 Fitting
(50) Pressure tap (power shift pressure)
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
1. Start the engine.
2. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.
3. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
off and determine what is preventing the pump from upstroking.
Illustration 9 g00672009
Monitor
(A) Message display (B) Keypad
4. Start Service Mode and input a fixed power shift pressure of 2350 kPa (340 psi).
a. Press menu key (J) .
Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu mode will be cancelled and the previous display will be restored to message display (A) .
b. Press down key (E) in order to highlight the second menu item "SERVICE OPTIONS"
on the message display. Press OK key (I) .
c. Input the password "FFF2". Press left key (D) or right key (F) in order to change the position of the flashing character. Press up key (C) or press down key (E) in order to change the value of the flashing character. Press OK key (I) after the correct password is displayed.
d. Press down key (E) once in order to highlight the second line on the message display.
e. Press right key (F) repeatedly until "DEVICE TEST" appears on the message display.
f. Press down key (E) in order to move down one line on the message display.
g. Press right key (F) until the "PS PRV - FIXED" appears on the message display.
h. Press down key (E) .
i. Press OK key (I). The display on line 4 of the message display will now change to a numeric value. These characters represent the power shift pressure (kPa).
j. Press left key (D) or right key (F) in order to increase or decrease the numeric value that is displayed on line 4 of the message display. Pressing left key (D) one time decreases the power shift pressure 10 kPa (1.5 psi). Pressing right key (F) one time increases the power shift pressure 10 kPa (1.5 psi).
Note: The value for power shift pressure on the monitor may not always match the pressure reading on the pressure gauge. Adjust the value on the monitor until the desired power shift pressure is attained on the pressure gauge that is connected to the pressure tap for power shift pressure. The actual power shift pressure must be 2350 kPa (340 psi)
(C) Up key
on the pressure gauge.
Note: To prevent a change in power shift pressure during the pump flow test, do not turn the engine start switch to the OFF position.
Note: Refer to Service Manual, "Engine and Pump Electronic Control System" for additional information on Service Mode.
5. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is 6850 kPa (1000 psi).
6. Record the negative flow rate in Table 1.
Illustration 10 g00670500
Portable hydraulic tester (flow meter) (10) Portable hydraulic tester (flow meter) (22) Multitach
(26) Valve
Illustration 11 g00846164 Pressure/Flow characteristic curve
Table 1
Negative Flow Control at 2350 kPa (340 psi)
Oil Temperature °C (°F)
Drive pump
Idler pump
Engine Speed (rpm)
Drive pump
Idler pump
Flow measured liter/min (US gpm)
Drive pump
Idler pump
Flow corrected liter/min (US gpm)
Drive pump
Idler pump
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.
Flow measurements must be done in pressure rise.
Specification for negative flow rate liter/min (US gpm)
New 147 ± 10 (38.8 ± 2.6)
Service limit
120 (31.7)
Table 2 Corrected flow =
Measured flow x 1800 rpm Measured rpm
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Wed Jul 26 11:15:07 EST 2006
Pruebas y Ajustes
330C Excavator Hydraulic System