 |
Personal injury can result from contact with hot hydraulic oil and from contact with hydraulic oil that is under high pressure. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. The hydraulic oil pressure must be released before any service on the hydraulic system is performed or serious personal injury could occur. Verify that all of the work tools have been completely lowered to the ground. Release the hydraulic oil pressure at the hydraulic tank through the breaker relief valve when the breaker relief valve is cool enough to touch with your bare hand. Verify that the hydraulic oil is cool before you begin to remove any hydraulic components or hydraulic lines. |
 |
|
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 off and determine what is preventing the pump from upstroking. |
|
| 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, "Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids. Dispose of all fluids according to local regulations and mandates. |
Note: Before you start the main pump flow tests, check the operator monitor panel for normal operation. If no faults are present, perform the operational checks.
Note: If the operational checks 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.
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.
Note: Perform the test for the travel pump and the test for the implement pump one at a time.
Preparation
 | |
| Illustration 1 | g01229235 |
Flow meter tool layout (typical example) (travel pump) (1) Hydraulic tank (2) Filter cover (3) 148-8323 Connector Gp (4) 148-8352 Elbow Gp (5) 7X-1452 Collet Stem and 5P-1010 Sleeve (6) 5P-0201 Hose (7) 8C-3323 Connector (8) 4C-9910 Portable Hydraulic Tester (flow meter) (9) 3E-6820 Collet Stem and 5P-1010 Sleeve (10) 1P-5767 Half Flange (11) Travel pump | |
Implement Pump
 | |
| Illustration 2 | g01389252 |
Circuit diagram for the travel pump (1) Hydraulic tank (2) Filter cover (3) 148-8352 Elbow Gp and 148-8323 Connector Gp (4) Implement control valve (5) Delivery line from the implement pump (6) Load sensing control line (7) Travel pump (8) Engine (9) Implement pump (10) Pilot pump (11) Hose assembly from the flow meter to the hydraulic tank (12) 4C-9910 Portable Hydraulic Tester (flow meter) (13) Hose assembly from the right pump to the flow meter (14) 6V-9508 Plug for the load sensing line (15) 1P-5767 Half Flange with block plate on the delivery line (16) Load sensing port on the implement pump (17) Pressure tap (delivery pressure) (implement pump) | |
 | |
| Illustration 3 | g01389903 |
Right pump (typical example) (6) Load sensing control line (9) Implement pump (17) Pressure tap (delivery pressure) (implement pump) | |
- Position the machine on level ground.
- Open the hood for the engine compartment.
 | |
| Illustration 4 | g01162081 |
The switch for the hood | |
 | |
| Illustration 5 | g01069398 |
- Shut off the engine.
- Release the pressure in the hydraulic system. Refer to Testing And Adjusting, "System Pressure - Release".
- Remove the hydraulic tank breaker relief valve from the hydraulic tank. Install a tee. Attach an air hose in order to create a vacuum.
 | |
| Illustration 6 | g01071140 |
- Install the following parts in accordance with the circuit diagram. Refer to Illustration 2.
- Disconnect delivery line (5) from right pump (12) .
Show/hide table
Illustration 7 g01389278
- Install 1P-5767 Half Flange (15) with a block plate onto the end of delivery line (5) . Install hose assembly (13) onto implement pump (9) .
- Remove the cover that is on top of the machine in order to access the filter cover.
Show/hide table
Illustration 8 g01049755
- Remove filter cover (2) .
Show/hide table
Illustration 9 g01071038
(2) Filter cover.
- Remove the filter bypass valve and the spring from the hydraulic tank. Reinstall filter cover (2) .
Show/hide table
Illustration 10 g01071040
- Remove the plug from filter cover (2) . Install the 148-8323 Connector Gp onto filter cover (2) . Connect 148-8352 Elbow Gp (3) onto the connector on filter cover (2) . Connect hose assembly (11) to 148-8352 Elbow Gp (3) .
Show/hide table
Illustration 11 g01389288
- Connect portable hydraulic tester (12) to hose assembly (11) . Connect hose assembly (13) from implement pump (9) to portable hydraulic tester (12) .
Show/hide table
Illustration 12 g01389290
- Disconnect load sensing control line (6) from implement pump (9) . Install 6V-9508 Plug in load sensing control line (6) . Install 6V-9829 Cap As on load sensing port (16) .
- Install a hose assembly on the pressure tap of load sensing port (16) . Install the unconnected end to pressure tap (17) on implement pump (9) .
Travel Pump
 | |
| Illustration 13 | g01390189 |
Circuit diagram for the travel pump (1) Hydraulic tank (2) Filter cover (3) Connector (4) Hose assembly from the flow meter (5) Travel control valve (6) Load sensing control line (travel pump) (7) Delivery line for the travel pump (8) Blank flange (9) 4C-9910 Portable hydraulic tester (flow meter) (10) Hose assembly (11) Pressure tap (delivery pressure) (travel pump) (12) 6V-9508 Plug for the load sensing line (13) Travel pump (14) Pressure tap (load sensing) (15) Delivery line for the travel pump (16) Engine (17) Pilot pump (18) Implement pump | |
 | |
| Illustration 14 | g01389967 |
Travel Pump (typical example) (6) Load sensing control line for the travel pump. (11) Pressure tap (delivery pressure) (travel pump). (13) Travel pump. | |
- Position the machine on level ground.
- Open the hood for the engine compartment.
| | |
| Illustration 15 | g01162081 |
The switch for the hood | |
| | |
| Illustration 16 | g01069398 |
- Shut off the engine.
- Release the pressure in the hydraulic system. Refer to Testing And Adjusting, "System Pressure - Release".
- Remove the hydraulic tank breaker relief valve from the hydraulic tank. Install a tee. Attach an air hose in order to create a vacuum.
| | |
| Illustration 17 | g01071140 |
- Install the following parts in accordance with the circuit diagram. Refer to Illustration 13.
- Disconnect delivery line (7) and (15) from travel pump (13) .
- Install a seal and blank flange (8) to the end of delivery line (6) . Install a cap on the fitting of the pump. Install a plug and seal in delivery line (15) .
- Remove the cover that is on top of the machine in order to access the filter cover.
Show/hide table Illustration 18 g01049755
- Remove filter cover (2) .
Show/hide table Illustration 19 g01071038
(2) Filter cover.
- Remove the filter bypass valve and the spring from the hydraulic tank. Reinstall filter cover (2) .
Show/hide table Illustration 20 g01071040
- Remove the plug from filter cover (2) . Install connector (3) onto filter cover (2) . Connect the hose assembly (4) to connector (3) on filter cover (2) .
Show/hide table
Illustration 21 g01390201
- Connect portable hydraulic tester (9) onto travel pump (13) with hose assembly (10) . Connect portable hydraulic tester (9) to hose assembly (4) .
Show/hide table
Illustration 22 g01390198
- Disconnect load sensing control line (6) from travel pump (13) . Install a 6V-9508 Plug into load sensing control line (6) . Install a 6V-9829 Cap As onto the tee at load sensing port (14) .
- Install a hose assembly on pressure tap (11) on travel pump (13) . Install the unconnected end of the hose assembly to the tee at load sensing port (14) .
Test
Note: Perform the test for the implement pump and the test for the travel pump one at a time.
The test procedure requires two people.
- Remove the air line and the tee from the hydraulic tank. Reinstall the hydraulic tank breaker relief valve.
- Start the engine.
- Move the engine speed dial to high idle.
- Monitor the engine speed on the IQAN display inside the cab.
- Increase the hydraulic oil temperature to 45° C (113° F) to 60° C (140° F).
- Turn the valve on the portable hydraulic tester (flow meter) clockwise. Record pump flow at each of the following pressures in Table 1. Use the pressure gauge on the flow meter to monitor delivery pressure from the implement pump. Use the pressure gauge on the flow meter in order to monitor delivery pressure from the travel pump.
 | |
| Illustration 23 | g01078357 |
| Pump Flow Test | |||
|---|---|---|---|
| Measuring Points at Maximum Displacement | |||
3450 kPa (500 psi) |
29000 kPa (4200 psi) |
||
| Flow measured liter/min (US gpm) | Implement Pump | ||
| Travel Pump | |||
| Oil temperature °C (°F) | |||
| Engine speed (rpm) | |||
| Flow corrected liter/min (US gpm) | Implement Pump | ||
| Travel Pump | |||
| Specification for flow rate liter/min (US gpm) | New | 400 ± 20 L/min (106 ± 5.3 US gpm) |
345 ± 20 L/min (91 ± 5.2 US gpm) |
Note: Specifications for flow rates are based on an engine speed of 2100 rpm. To attain more accurate test results, measured flow should be corrected with the following calculation.
| Corrected flow | = | Measured flow x 2100 rpm | |||
| measured rpm | |||||
Note: Flow measurements must be done only during pressure rise.
If the pump flow is not within the specifications go to the Testing and Adjusting, "Pump Control (Output Flow) - Adjust" in order to adjust the flow.