2003/05/19 Additional Information for Testing and Adjusting , "Pump Flow - Test" on the Wheel Skidders {4268, 5070} Caterpillar


Additional Information for Testing and Adjusting , "Pump Flow - Test" on the Wheel Skidders {4268, 5070}
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2003/05/19 [SEPD0683]
HYDRAULIC SYSTEM
PUMP GP
2003/05/19 Additional Information for Testing and Adjusting , "Pump Flow - Test" on the Wheel Skidders {4268, 5070}
Wheel Skidders:
515 (S/N: 4LR1-UP)
525 (S/N: 1DN1-UP)
525B (S/N: 3KZ1-UP)
535B (S/N: AAE1-UP)
545 (S/N: 2FZ1-UP)
Systems Operation/Testing and Adjusting, SENR6696, "515 Wheel Skidder and 525 Wheel Skidder Hydraulic and Steering System", "Pump Flow - Test". The module is part of Service Manual, SENR6680.Systems Operation/Testing and Adjusting, RENR4341, "525B Wheel Skidder and 535B Wheel Skidder Braking System", "Pump Flow - Test". The module is part of Service Manual, RENR4330.Testing and Adjusting, RENR4339, "525B Wheel Skidder and 535B Wheel Skidder Hydraulic and Steering System", "Pump Flow - Test". The module is part of Service Manual, RENR4330.Systems Operation/Testing and Adjusting, RENR3051, "545 Wheel Skidder Braking System", "Pump Flow - Test". The module is part of Service Manual, RENR3040.Testing and Adjusting, RENR3049, "545 Wheel Skidder Hydraulic and Steering System", "Pump Flow - Test". The module is part of Service Manual, RENR3040.

Replace the information in the Testing and Adjusting, "Pump Flow - Test" in the modules that are reference above with the following information.

This test is designed to determine whether a pump is operating within design parameters.

For any pump test, the pump flow at 690 kPa (100 psi) will be larger than the pump flow at 6900 kPa (1000 psi) if the pump is operating at the same rpm. The pump flow is measured in L/min (US gpm).

Note: The values in the examples are not set values for any specific pump or for any specific pump condition. See the Specification for the pump flow of a new pump at 690 kPa (100 psi) and at 6900 kPa (1000 psi).

The difference between the pump flow of two operating pressures is the flow loss.

Method of determining flow loss

Table 1
Method for determining flow loss (1)    
Pump flow at
690 kPa (100 psi)    

217.6 L/min (57.5 US gpm)    
Pump flow at
6900 kPa (1000 psi)    

196.8 L/min (52.0 US gpm)    
Flow loss    
20.8 L/min (5.5 US gpm)    
( 1 ) Values in the formula are not values for any specific pump, or for any specific pump condition. See the specifications for the actual pump flow of a new pump at 690 kPa (100 psi) and at 6900 kPa (1000 psi).

Table 2
    Pump flow at
690 kPa (100 psi)    
   
-     Pump flow at
6900 kPa (1000 psi)    
   
    Flow loss        

Example of determining flow loss

Table 3
   
217.6 L/min (57.5 US gpm)    
   
-    
196.8 L/min (52.0 US gpm)    
   
   
20.8 L/min (5.5 US gpm)    
   

Flow loss that is expressed as a percentage of pump flow is used as a measure of pump performance.

Method of determining the percent of flow loss

Table 4
Flow loss (L/min or US gpm)     ×     100     =     Percent of flow loss    
Pump flow at
690 kPa (100 psi)    

Example of determining the percent of flow loss

Table 5

20.8 L (5.5 US gal)    
×     100     =     9.5%    

217.6 L/min (57.5 US gpm)    

Note: The values in the examples are not set values for any specific pump or for any specific pump condition. See the Specification for the pump flow of a new pump at 690 kPa (100 psi) and at 6900 kPa (1000 psi).

Acceptable flow loss for the new piston pump is 6% of the total pump output. When flow loss reaches 16%, the pump should be inspected for damage or wear. The pump should then be repaired or replaced.

Machine Test (Case Drain Flow of the Implement Pump)

The test is for measuring the case drain flow of the 6E-6012 Piston Pump and the 161-5715 Piston Pump on Wheel Skidders.

Table 6
Materials that are Required    
Part Number     Description     Quantity    
030-8193     Connector     1    
124-1954     Permanent Coupling     1    
122-6889     Hydraulic Hose     (1)    
7C-6466     Protection Cap     1    
-     Container (2)     1    
-     Stopwatch     1    
( 1 ) Obtain hose by the foot. You may need more than eight feet of hose depending on the specific application.
( 2 ) This container should be at least a five gallon capacity. If you plan to reuse the oil after the test, ensure that the container is thoroughly cleaned. Also ensure that you have completely dried the container prior to use.

Note: The following test should be performed on the machine as a first step in order to diagnose the cause of the suspected problem.




    Illustration 1g00999366



    Illustration 2g00999386



    Illustration 3g00999394

  1. Clean the area around the pump case drain line. Clean the fitting and the top of the hydraulic tank in order to ensure that no debris will enter the hydraulic system during this procedure.

    • Refer to illustration 1 for 515 4LR1-UP, 525 1DN1-UP and 545 2FZ1-295 Wheel Skidders.

    • Refer to illustration 2 for 525B 3KZ1-795, 535B AAE1-582 and 545 2FZ296-432, 434-437 Wheel Skidders.

    • Refer to illustration 3 for 525B 3KZ796, 875-UP, 535B AAE583-UP and 545 2FZ433, 438-UP Wheel Skidders. These machines have hydraulic filters that are spin-on filters.

  1. Start the machine and warm the hydraulic oil to operating temperature. The normal hydraulic oil operating temperature is between 60 °C (140 °F) and 70 °C (160 °F). Warm up the hydraulic circuits by raising and lowering the decking blade continuously with the engine at 2200 rpm. The normal operating temperature will be reached in several minutes.

    Note: The normal temperature for a new pump that is using SAE 10 hydraulic oil is approximately 60 °C (140 °F).

  1. Relieve the hydraulic tank pressure prior to disconnecting case drain line that is located on the hydraulic tank.

    Reference: For more information about releasing the system pressure, refer to Testing and Adjusting, "System Pressure - Release".

  1. Disconnect the case drain line. Place one 7C-6466 Protection Cap onto the threads of the fitting.

  1. Assemble a hydraulic test hose by combining the following components: 030-8193 Connector, 124-1954 Permanent Coupling and 122-6889 Hydraulic Hose .

  1. Install the hydraulic test hose onto the open case drain line.

    Note: Ensure that the open end of the hose is routed into a suitable five gallon container prior to performing this test.

    Note: The remainder of the procedure requires two people.

  1. One person must operate the machine, and another person should be positioned at the hydraulic hose in order to time the flow rate.

  1. Start the engine and immediately place the pump into a high pressure cutoff condition by raising the blade to the maximum height. Hold this position. At the same time, begin timing the flow from the case drain port with the stopwatch. Hold this position for 30 seconds.

  1. After 30 seconds have passed, immediately release the control lever. Turn off the machine at the same time.

    Note: If the container that is used for the measurement of flow is completely filled prior to 30 seconds, immediately turn off the machine and stop timing. Record the time that elapsed in order to fill the container.

  1. Measure the amount of oil that is in the container. Write the measurement into the formula that is given in Table 7.

  1. Calculate the flow rate of the case drain by using the following formula:

    Table 7
    Amount of oil that is in the container (gallons)     ×     60 (seconds)     =     Case drain flow (GPM)    
    Time that is recorded on the stopwatch (seconds)     1 (minute)

    The acceptable flow rate of the case drain for the piston pump is 15 L/min (4 US gpm) or less at the pressure cutoff (21000 kPa (3050 psi)). This measurement is for a new pump when the pump is first installed on a machine.

    When the piston pump reaches 30 L/min (8 US gpm) of case drain flow, the pump should be inspected for damage or wear. The pump should be repaired or replaced.

  1. Return the machine to the operating configuration by removing the hydraulic test hose.

  1. Remove the 7C-6466 Protection Cap from the fitting.

  1. Install the pump case drain line onto the fitting.

Bench Test

If the bench test can be run at 6900 kPa (1000 psi) and at full pump rpm, determine the percent of flow loss by using the formula in Table 8.

Note: Prior to starting the following test, connect the pump load sense line to the pump discharge port. The pressure at the pump load sense line will be equal to the discharge pressure. A signal must then be given to the pump in order to get the pump to upstroke properly.

If the bench test can not be run at 6900 kPa (1000 psi) and at full pump rpm, the pump can be tested at a lower speed. If the pump must be tested at a lower speed, you must ensure that the speed of the pump does not change during the test. This will help in order to ensure accurate readings. Measure the pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi). Use these values in the top portion of the following formula. Measure the pump flow at 690 kPa (100 psi). Use this value for the bottom portion of the following formula.

Table 8
    Pump flow at
690 kPa (100 psi)    
               
-     Pump flow at
6900 kPa (1000 psi)    
×     100     =     Percent of flow loss    
    Pump flow at
690 kPa (100 psi)    

Note: The limits for case drain flow that are shown may be used for bench testing if the pump is installed on a test bench. If a flow meter is used, ensure that the flow meter is accurate at low flow conditions. If you are unsure of the accuracy of the flow meter, use the procedure above.

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