318B Excavator Hydraulic System

Número de medio -RENR1957- Fecha de publicación - Fecha de actualización -

01 01/12/1999 09/10/2001

i01245585

Piston Pump (Main) - Test

SMCS - 5070-081

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Illustration 1 g00304069
Electronic controller

(1) Alarm lamp

(2) Electronic controller

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Illustration 2 g00304070
Right console

(3) Right console

(4) Operator monitor panel

Note: Before starting main pump flow tests, check operator monitor panel (4) and alarm
lamp (1) on electronic controller (2) for normal operation. If no faults are present,
perform the operational checks. Refer to Testing And Adjusting, "Operational Checks".

Note: If the operational checks (cycle time) 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. Refer to Testing And Adjusting, "Piston Pump
(Main) - Test".

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.

Main Pump Constant Horsepower Control Test

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Illustration 3 g00389975
Flow meter tool layout

(1) Swing motor

(2) Connector at swing motor

(3) 6V-9839 Tee

(4) Makeup line

(6) Delivery line for front pump

(7) 6V-9511 Face seal plug

(8) 4C-9910 Portable hydraulic tester (flow meter)

(9) Negative flow control line (rear pump)

(10) 8T-0856 Pressure gauge

(11) Pressure tap (rear pump delivery pressure)

(12) 8T-0861 Pressure gauge

(13) Delivery line for rear pump

(14) Pressure tap (front pump delivery pressure)

(15) Pressure tap (power shift pressure)

(16) Front pump

(17) Negative flow control line (front pump)

(18) 9S-9508 Plug

(21) Rear pump

(23) 6K-6307 O-Ring seal

(24) 8C-9026 Adapter

(25) 7M-8485 O-Ring seal

(26) 4C-6482 Nipple assembly

(27) 4C-6481 Coupler assembly

(28) 4C-8767 Coupling

(29) 5P-1010 Sleeve

(30) 5P-0201 Hose

(32) 6V-9746 O-Ring seal

(33) 6V-3989 Unvalved nipple

(34) 6V-4143 Coupler assembly

(35) 6V-3014 Hose

(36) 6V-8397 O-Ring seal

(40) 6V-9853 O-Ring seal

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Illustration 4 g00390092
Circuit diagram

(1) Swing motor

(2) Connector

(3) Tee

(4) Makeup line

(5) Main Control Valves

(6) Delivery line from front pump

(7) 6V-9511 Plug

(8) 4C-9910 Portable hydraulic tester (flow meter)

(9) Negative flow control line (rear pump)

(10) 8T-0856 Pressure gauge

(11) Pressure tap (rear pump delivery pressure)

(12) 8T-0861 Pressure gauge

(13) Delivery line for rear pump

(14) Pressure tap (front pump delivery pressure)

(15) Pressure tap (power shift pressure)

(16) Front pump

(17) Negative flow control line (front pump)

(18) 9S-9518 Plug

(19) Engine

(20) Multitach

(21) Rear pump

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Illustration 5 g00451803
Swing motor

(2) Connector

(4) Makeup line

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Illustration 6 g00444610
Portable hydraulic tester (flow meter)

(8) Portable hydraulic tester (flow meter)

(20) Multitach

(22) Valve

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Illustration 7 g00451804
Pump compartment

(6) Delivery line for front pump

(14) Pressure tap (front pump delivery pressure)

(15) Pressure tap (power shift pressure)

(16) Front pump

(17) Negative flow control line (front pump)

Preparation

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.

Front Pump

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 flow meter tool layout and the
circuit diagram. Refer to Illustration 3 and Illustration 4.
a. Disconnect delivery line (6) from front pump (16) .

b. Install plug (7) to the end of delivery line (6) .

c. Disconnect makeup line (4) from connector (2) at swing motor (1) .

d. Install seal (32) and tee (3) to connector (2) .

e. Connect makeup line (4) to tee (3) .

f. Connect portable hydraulic tester (8) between front pump (16) and tee
(3) .

g. Connect 6000 kPa (870 psi) pressure gauge (10) to pressure tap (15).
This is used to measure power shift pressure.

h. Connect 60000 kPa (8700 psi) pressure gauge (12) to pressure tap (14).
This is used to measure front pump delivery pressure.

i. Install multitach group (20) on engine (19). This is used to monitor

engine speed.

j. Disconnect negative flow control line (17) from front pump (16). Install
seal (36) and plug (18) to the end of negative flow control line (17) .

Rear Pump

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Illustration 8 g00451806
Pump compartment

(9) Negative flow control line (rear pump)

(11) Pressure tap (rear pump delivery pressure)

(13) Delivery line for rear pump

(15) Pressure tap (power shift pressure)

(21) Rear pump

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 flow meter tool layout and the
circuit diagram. Refer to Illustration 3 and Illustration 4.
a. Disconnect delivery line (13) from rear pump (21) .

b. Install plug (7) and seal (30) to the end of delivery line (13) .

c. Disconnect makeup line (4) from connector (2) at swing motor (1) .
 d. Install seal (30) and tee (3) to connector (2) .

e. Connect makeup line (4) to tee (3) .

f. Connect portable hydraulic tester (8) between rear pump (21) and tee (3)
.

g. Connect 6000 kPa (870 psi) pressure gauge (10) to pressure tap (15).
This is used to measure power shift pressure.

h. Connect 60000 kPa (8700 psi) pressure gauge (12) to pressure tap (11).
This is used to measure rear pump delivery pressure.

i. Install multitach group (20) to engine (19). This is used to monitor

engine speed.

j. Disconnect negative flow control line (9) from rear pump (21). Install
seal (36) and plug (18) to the end of negative flow control line (9) .

Test
Note: Perform the test for the front pump and the test for the rear pump one at a time.

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.

1. Start the engine.

2. Place the machine controls at the following settings: Power Mode, engine speed
dial "10" and AEC switch OFF.
 Reference: Make reference to Testing And Adjusting, "Operational Checks" for
engine rpm settings.

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

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Illustration 9 g00301843
Operator monitor panel (right console)

(1) Controller display

(2) Button for boom priority mode

(3) Button for swing priority mode

(4) Button for fine control mode

(5) Button for user mode

(6) Travel alarm cancel switch

(7) Power mode switch

4. Start Service Mode and maintain power shift pressure at 2250 ± 50 kPa (325 ± 7
psi).
a. Depress the following three buttons on the operator monitor panel at the
same time: button for fine control (4), button for user mode (5) and travel
alarm cancel switch (6). Hold all three buttons down for at least three
seconds.

b. The controller display (1) will be "00 00 00".

Note: If more than ten seconds pass between pushing the buttons, the
controller display (1) will revert to the operation mode.

c. Input the service code "0E 32 3A". To increase the flashing character,
push the button for boom priority mode (2). To decrease the flashing
character, push the button for swing priority mode (3). To move the
flashing character to the right, push the button for fine control mode (4).
To move the flashing character to the left, push the button for user mode
(5) .

d. Once the correct service code is entered into the controller display (1),
the controller display (1) will change to "10 -- 1" within approximately
ten seconds.

e. This step is optional. Step 4.e may be substituted for Step 4.d. Once
the correct service code is entered into the controller display (1), depress
the following three buttons on the operator monitor panel at the same
time: button for fine control (4), button for user mode (5) and travel
alarm cancel switch (6). Hold all three buttons down for at least three
seconds. The controller display (1) will change to "10 -- 1".

f. On the operator monitor panel, enter a fixed power shift pressure of 2250
± 50 kPa (325 ± 7 psi) on the controller display (1). Adjust controller
display (1) in order to attain a power shift pressure of 2250 ± 50 kPa
(325 ± 7 psi) on the pressure gauge at pressure tap (15) .

g. Move the flashing character to the far left. Increase the "1" to a "6".

h. Move the flashing character to the right and increase the "0" to a "6".

i. Move the flashing character to the right. The last four characters on the
controller display (1) will begin flashing. These characters represent the
power shift pressure (kPa). Adjust the last four characters to "2250". To
increase the power shift pressure 10 kPa (1.5 psi), push the button for
boom priority mode (2). To decrease the power shift pressure 10 kPa (1.5
psi), push the button for swing priority mode (3). To increase the power
shift pressure 200 kPa (29 psi), push the button for boom priority mode
(2) and power mode switch (7) at the same time. To decrease the power
shift pressure 200 kPa (29 psi), push the button for swing priority mode
(3) and power mode switch (7) at the same time.
 Note: Always monitor the actual power shift pressure on pressure gauge
(10) at pressure tap (15). The actual power shift pressure must be 2250 ±
50 kPa (325 ± 7 psi) on the pressure gauge.

Note: Refer to Service Manual, "Engine And Pump Electronic Control

System" for additional information on Service Mode.

Note: To prevent a change in power shift pressure during line relief

valve adjustment, do not turn the engine OFF.

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

6. Turn valve (22) on portable hydraulic tester (8) clockwise. Record pump flow at
each of the following pressures in Table 1. Use pressure gauge (12) at pressure
tap (14) to monitor front pump delivery pressure or use pressure tap (11) to
monitor rear pump delivery pressure.

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Illustration 10 g00664635
P-Q characteristic curve

Table 1
 Pump Flow Test

Measuring Points

4900 11300 19600 23500 30900

kPa kPa kPa kPa kPa
(710 (1650 (2850 (3400 (4500
psi) psi) psi) psi) psi)

Front
Flow measured Pump
liter/min (US
gpm) Rear
Pump

Oil temperature °C (°F)

Engine speed (rpm)

Front
Flow corrected Pump
liter/min (US
gpm) Rear
Pump

149 ± 6 140 ± 8 104 ± 6 90 ± 5 71 ± 4

Specification for New
(39.0 ± (36.0 ± (27.0 ± (23.0 ± (18.0 ±
flow rate 1.6) 2.1) 1.6) 1.3) 1.0)
liter/min (US
gpm) Service
143 118 87 68 54
limit
(37) (31) (23) (18) (14)

Note: Specifications for flow rates are based on an engine speed of 2200 rpm. To attain
more accurate test results, measured flow should be corrected with the following
calculation.

Table 2
Measured flow x 2200 rpm
Corrected flow =
measured rpm

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

Note: The pump flow changes approximately 4.5 L/min (1.2 US gpm) for each 100 kPa
1 1 0
(14 psi) of power shift pressure.

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