330C Excavator Hydraulic System.pdf

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Cerrar SIS Pantalla anterior Producto: EXCAVATOR Modelo: 330C L EXCAVATOR DKY00772 Configuración: 330C L Excavator DKY00001-UP (MACHINE) POWERED BY C-9 Engine

Pruebas y Ajustes 330C Excavator Hydraulic System Número de medio -RENR5435-07

Fecha de publicación -01/03/2011

Fecha de actualización -18/03/2011

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Main Pump (Flow) - Test - Constant Horsepower Flow Control SMCS - 5070-081-FW 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.

Illustration 1

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The electronic control module is located in the compartment behind the cab. (1) Alarm lamp (2) Electronic control module

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Illustration 2

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(3) Monitor (4) Message display

Note: Before starting main pump flow tests, check message display (4) on monitor (3) and alarm lamp (1) on electronic control module (2) for normal operation. Lamp (1) should be green. If no faults are present, perform the operational checks. Refer to Testing and Adjusting, "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. Refer to Testing and Adjusting, "Main Pump (Flow) - Test". Note: If the operational checks indicate that slow speed of an implement is common to both pump circuits, the problem may be in the engine, the fuel, or the working altitude.

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Illustration 3

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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)

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(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

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Illustration 4

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Circuit diagram (1) Swing motor (2) Connector (3) Tee (4) Makeup line (5) Main control valve (8) Pressure tap (idler pump delivery pressure) (9) 8T-0861 Pressure gauge (10) 4C-9910 Portable hydraulic tester (flow meter)

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(11) Delivery line for idler pump (12) Delivery line from drive pump (16) Pressure tap (drive pump delivery pressure) (17) 7I-7133 Blocking cover (20) 8T-0856 Pressure gauge (21) Engine (22) Multitach (23) Drive pump (24) Idler pump (40) Elbow (50) Pressure tap (power shift pressure)

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, 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.

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

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Illustration 5

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Pump compartment (6) Negative flow control line (drive pump) (8) Pressure tap (idler pump delivery pressure) (12) Delivery line for drive pump (16) Pressure tap (drive pump delivery pressure) (23) Drive pump (24) Idler pump (50) Pressure tap (power shift pressure)

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 (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) .

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Illustration 6

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Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

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 4900 kPa (700 psi) pressure gauge (20) to tap (50) for power shift pressure. 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. 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) .

Idler Pump 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, "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.

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

Illustration 7

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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)

1. Position the machine on level ground. 2. Stop the engine.

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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 (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) on idler pump (24) by using half flanges (48), bolts (46) and washers (47) .

Illustration 8

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Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

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.

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h. Connect 4900 kPa (700 psi) pressure gauge (20) to pressure tap (50) for power shift pressure. 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. 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) .

Test Note: Perform the test for the drive pump and the test for the idler 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: 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).

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Illustration 9

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Monitor (A) Message display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key (G) Cancel key (H) Set key

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(I) OK key (J) Menu key

4. Start Service Mode and input a fixed power shift pressure of 2550 ± 50 kPa (370 ± 10 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 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 2550 ± 50 kPa (370 ± 10 psi) 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. In order to perform flow measurements for either one of the pumps, the other pump must not be under load.

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Illustration 10

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Portable hydraulic tester (flow meter) (10) Portable hydraulic tester (flow meter) (22) Multitach (26) Valve

6. Turn valve (26) on portable hydraulic tester (10) clockwise. Record pump flow at each of the following pressures in Table 1. Use pressure gauge (9) at pressure tap (16) to monitor drive pump delivery pressure or use pressure tap (8) to monitor idler pump delivery pressure.

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Illustration 11

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P-Q characteristic curve

Table 1 Pump Flow Test Measuring Points

9800 kPa (1420 psi)

Flow measured liter/min (US gpm)

15700 kPa (2275 psi)

19600 kPa (2845 psi)

25500 kPa (3700 psi)

29400 kPa (4250 psi)

Drive Pump Idler Pump

Oil temperature °C (°F)

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Engine speed (rpm) Drive Pump

Flow corrected liter/min (US gpm)

Idler Pump

New Specification for flow rate liter/min (US gpm) Service limit

231 ± 15 (61.0 ± 4.0)

200 ± 15 (52.8 ± 4.0)

184 ± 15 (48.6 ± 4.0)

160 ± 15 (42.3 ± 4.0)

147 ± 15 (38.8 ± 4.0)

189 (49.9)

164 (43.3)

150 (39.6)

119 (31.4)

106 (28.0)

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 Measured flow x 1800 rpm Corrected flow

= measured rpm

Note: Specifications for output flow rates are based on a power shift pressure at the pump of 2550 ± 50 kPa (370 ± 10 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 upper range of the constant horsepower control. The output flow rate changes approximately 6 L/min (1.6 US gpm) for each 100 kPa (14 psi) of power shift pressure in the higher range of the constant horsepower control. Note: Flow measurements must be done only during pressure rise. Copyright 1993 - 2013 Caterpillar Inc.

Thu Apr 11 10:05:46 CDT 2013

Todos los derechos reservados. Red privada para licenciados del SIS.

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