349F and 352F Excavators Hydraulic System Main Pump (Flow) - Test - Constant Horsepower Flow Control Caterpillar


Main Pump (Flow) - Test - Constant Horsepower Flow Control
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1.1. Specification
2.1. Introduction
3.2. Preliminary Test
4.1. Required Tools
5.1. Machine Preparation
6.2. Drive Pump
7.2. Idler Pump
8.1. Test Procedure

Specification

Table 1
"Main Pump (Flow) - Test (Constant Horsepower Flow Control)" 
Machine Settings  Power Shift Pressure  Engine Speed 
2700 kPa (392 psi) Engine speed dial "10"
AEC switch OFF
(1800 rpm) 
  Measuring Points 
6000 kPa (870 psi) 16000 kPa (2320 psi)  23000 kPa (3335 psi)  30000 kPa (4350 psi)  33000 kPa (4785 psi) 
Flow measured liter/min (US gpm)  Drive Pump           
Idler Pump          
Oil temperature °C (°F)           
       
Engine speed (rpm)           
       
Flow corrected liter/min (US gpm)  Drive Pump           
Idler Pump          
Standard Configuration  New  383 ± 30 L/min (102 ± 7.9 US gpm)  341 ± 30 L/min (90 ± 7.9 US gpm)  292 ± 30 L/min (77 ± 7.9 US gpm)  250 ± 30 L/min (66 ± 7.9 US gpm)  239 ± 30 L/min (63 ± 7.9 US gpm) 
Service limit 323 L/min (85 US gpm)  236 L/min (62 US gpm)  207 L/min (55 US gpm)  167 L/min (44 US gpm)  156 L/min (41 US gpm) 
With Auxiliary Pump Configuration  New  383 ± 30 L/min (102 ± 7.9 US gpm)  339 ± 30 L/min (90 ± 7.9 US gpm)  290 ± 30 L/min (77 ± 7.9 US gpm)  249 ± 30 L/min (66 ± 7.9 US gpm)  238 ± 30 L/min (63 ± 7.9 US gpm) 
Service limit 323 L/min (85 US gpm)  234 L/min (62 US gpm)  205 L/min (54 US gpm)  166 L/min (44 US gpm)  155 L/min (41 US gpm) 


Illustration 1g02377942
P-Q characteristic curve

Note: Specifications for output flow rates are based on an engine speed of 1800 rpm. To attain more accurate test results, measured flow should be corrected with the following calculation.

Table 2
Corrected flow  Measured flow x 1800 rpm a 
measured rpm

Note: Specifications for output flow rates are based on a power shift pressure at the pump of 2700 kPa (392 psi). The output flow rate changes approximately 10 L/min (2.6 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 3 L/min (0.8 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.

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

Introduction

This test measures individual pump flow at the pump. Each pump is tested individually for output flow at specified pressures. The pump that is not being tested is not under load and the pump remains at low-pressure standby.

Preliminary Test

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

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

  • Testing and Adjusting, "Solenoid Valve (Proportional Reducing) - Calibrate (Negative Flow Control)"

Required Tools



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


Illustration 3g02535237
Tooling (C)


Illustration 4g06424742
Tooling (D) (Flow meter tool layout)

Table 3
Tool  Item  Qty  Part
Number 
Description 
  198-4240  Digital Pressure Indicator Gp 
  A1  198-4234  Indicator 
A2 198-4237  Pressure Sensor
3447 kPa (500 psi) 
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  436-8662  Portable hydraulic tester (flow meter) 
D2 6K-6307  O-Ring Seal 
D3 8C-9026  Adapter 
D4 7M-8485  O-Ring Seal 
D5 4C-6482  Fitting 
D6 4C-6481  Coupler 
D7 4C-8767  Coupling 
D8 5P-1010  Sleeve 
D9 5P-0201  Hose 
D10 9S-4191  O-Ring Plug 
D11 3J-1907  O-Ring Seal 
D12 1U-8303  Fitting 
D13 8T-4184  Bolt 
D14 8T-4223  Hard Washer 
D15 1P-5767  Half Flange 
D16 1U-8293  Adapter 
D17 1P-3704  Rectangular Seal 
D18 7I-7133  Blocking Cover 
D19 124-8333  Elbow 
D20 5K-9090  O-Ring Seal 
D21 6V-9840  Swivel Tee 
D22 6V-9508  Plug 
D23 6V-8397  O-Ring Seal 
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



Illustration 5g06424722
Flow meter tool layout
Tooling (D)
( 4) Delivery line for the drive pump
(5) Delivery line for the idler pump
(6) Bolt
(7) Washer
(8) Half flange
(9) Seal
(10) Makeup line
(11) Seal
(12) Elbow
(18) Negative flow control line (drive pump)
(19) Negative flow control line (idler pump)

Drive Pump


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, PERJ1017, "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 6g02145888
Pump compartment
(1) Pressure tap (delivery pressure for the drive pump)
(2) Pressure tap (delivery pressure for the idler pump)
(3) Pressure tap (power shift pressure)
(4) Delivery line for the drive pump
(5) Delivery line for the idler pump

  1. Position the machine on level ground.

  2. Stop the engine.

  3. Release 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.

  5. 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 (9), half flanges (8), and blocking cover (D18) to the end of the delivery line with bolts (6) and washers (7).

    3. Assemble and install seal (D17), adapter (D16), seals (D4), fitting (D12), seal (D11), plug (D10), and fitting (D5) on the drive pump by using half flanges (D15), bolts (D13), and washers (D14).

    4. Disconnect negative flow control line (18) from the drive pump. Install seal (D23) and plug (D22) to the end of negative flow control line (18).


      Illustration 7g02146948
      Right swing motor (top view)
      (10) Makeup line
      (11) Seal
      (12) Tee

    5. Disconnect makeup line (10) from tee (12) at the right swing motor.

    6. Assemble and install seals (D20), tee (D21), elbow (D19), seal (D4), and fitting (D5) to tee (12) at the swing motor.

    7. Install seal (11) and makeup line (10) to tee (D21).

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

  7. Connect portable hydraulic tester (D) and test hoses between coupling assembly at the drive pump and coupling assembly at the swing motor.

  8. Attach a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (1) for delivery pressure of the drive pump. Attach a 34,450 kPa (5000 psi) pressure sensor to pressure tap (3) for power shift pressure.


    Illustration 8g02404480
    Proportional reducing valves (negative flow control)
    (13) Connector
    (14) Connector
    (15) Proportional reducing valve for "NFC1"
    (16) Proportional reducing valve for "NFC2"

  9. Disconnect connector (13) from proportional reducing valve (15).

  10. Install tooling (C) on the engine to monitor engine speed.

Idler Pump


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, PERJ1017, "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 9g02145888
Pump compartment
(1) Pressure tap (delivery pressure for the drive pump)
(2) Pressure tap (delivery pressure for the idler pump)
(3) Pressure tap (power shift pressure)
(4) Delivery line for the drive pump
(5) Delivery line for the idler pump

  1. Position the machine on level ground.

  2. Stop the engine.

  3. Release 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.

  5. 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 (9), half flanges (8), and blocking cover (D18) to the end of the delivery line with bolts (6) and washers (7).

    3. Assemble and install seal (D17), adapter (D16), seals (D4), fitting (D12), seal (D11), plug (D10), and fitting (D5) on the idler pump by using half flanges (D15), bolts (D13), and washers (D14).

    4. Disconnect negative flow control line (19) from the idler pump. Install seal (D23) and plug (D22) to the end of negative flow control line (19).


      Illustration 10g02146948
      Right swing motor (top view)
      (10) Makeup line
      (11) Seal
      (12) Tee

    5. Disconnect makeup line (10) from tee (12) at the right swing motor.

    6. Assemble and install seals (D20), tee (D21), elbow (D19), seal (D4), and fitting (D5) to tee (12) at the swing motor.

    7. Install seal (11) and makeup line (10) to tee (D21).

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

  7. Connect portable hydraulic tester (D) and test hoses between coupling assembly at the idler pump and coupling assembly at the swing motor.

  8. Attach a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (2) for delivery pressure of the idler pump. Attach a 34,450 kPa (5000 psi) pressure sensor to pressure tap (3) for power shift pressure.


    Illustration 11g02404480
    Proportional reducing valves (negative flow control)
    (13) Connector
    (14) Connector
    (15) Proportional reducing valve for "NFC1"
    (16) Proportional reducing valve for "NFC2"

  9. Disconnect connector (14) from proportional reducing valve (16).

  10. Install tooling (C) on the engine to monitor engine speed.

Test Procedure

Note: Perform the test for the drive pump and the test for the idler pump one at a time.

------ 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.


Note: In some circumstances, oil may escape out of the open NFC regulator port. Take proper precautions to contain the oil and prevent injury from the release of oil. The port can not be capped because it may affect test results.

  1. Start the engine.

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

  3. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.

  4. Enter the service mode.

    1. Input the password "9992".

    2. Select "Override Parameters".


    Illustration 12g02377538

  5. Set the engine speed to 1800 rpm.

  6. Set the power shift pressure to 2700 kPa (392 psi). Confirm the power shift pressure setting at pressure tap (3).

  7. In order to perform flow measurements for either one of the pumps, the other pump must not be under load.


    Illustration 13g02599896
    Portable hydraulic tester (flow meter)
    (D1) Portable hydraulic tester (flow meter)
    (17) Valve

  8. Turn valve (17) on the portable hydraulic tester clockwise. Record pump flow at each of the following pressures 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.

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