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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the power train. |
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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| 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, "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. |
Introduction
The following tests are performed in order to determine if there is excessive wear of the following components:
- The charge pump
- The work tool pump (standard flow)
- The work tool pump (high flow)
Test Preparation
Note: The oil in the hydraulic system must be at an operating temperature of 50° ± 10°C (122° ± 18°F). This temperature range is specified for standard factory fill oil only. Use the Electronic Technician Software in order to monitor this temperature. Or refer to Testing and Adjusting, "Hydraulic Oil Temperature Test" for an alternate procedure.
Before any tests are performed, prepare the machine. Refer to Testing and Adjusting, "Machine Preparation". Before any tests are performed, visually inspect the complete hydraulic system for oil leaks and damaged parts. Refer to Testing and Adjusting, "Visual Inspection"
- Release the system pressure before attempting any adjustment. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release" for the proper procedure.
Charge Pump Test Procedure
Specifications
| System Requirements | |
| Test | Specification |
| Pump Outlet Pressure | 18000 ± 1000 kPa (2610 ± 145 psi) |
| Engine Speed | 2000 ± 10 RPM |
| Oil Temperature | 50° ± 10°C (122° ± 18°F) |
| Charge Pump | |
| Machine Model | Minimum Flow |
| All models | 36.8 L/min (9.72 US gpm) (Minimum) |
Required Tools
| Required Tools | |||
| Item | Part Number | Description | Qty |
| A | 9U-7400 | Multitach Tool Gp | 1 |
| B | 4C-9910 | Portable Hydraulic Tester | 1 |
Test Procedure
- Open the engine access door. Install the 9U-7400 Multitach Tool Gp in front of opening (1) in order to measure engine RPM. Use reflective tape on the pulley for the engine crankcase to measure the RPM.
Note: Caterpillar Electronic Technician Software may be used in order to monitor engine rpm, engine oil temperature, and engine coolant temperature. Refer to Illustration 2 for the "Status" screen display.
| Illustration 1 | g03387841 |
(1) Opening in the engine access cover | |
| Illustration 2 | g01372105 |
Typical example of ET screen (C) "Status icon" (D) "Engine status icon" (E) "Engine speed information" | |
- Stop the engine. Release the system pressure before attempting any adjustment. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release" for the proper procedure.
- Disconnect the hose assembly (2) from the fan motor inlet. Install tooling (B) . Connect the flow meter inlet to the hose assembly (2) . Connect the outlet of the flow meter to the fan motor inlet. The flow meter is installed in-line to the outlet of the charge pump.
Note: The flow meter valve must be fully open before installing the flow meter in-line.
Note: Damage to the pump and damage to the hoses may result from the high pressure that is created by the flow meter valve.
Note: Ensure that the outlet flow from the flow meter is returned to the fan motor inlet. This configuration will maintain charge flow to the hystat pump.
| Illustration 3 | g03387845 |
(2) Hose from the charge pump to the fan motor inlet | |
- Route the test lines and cables in order to avoid contact with the muffler. Secure the test instruments so that the test instruments are visible during the test.
- Fasten the seat belt. Lower the armrest.
- Start the engine. Run the engine at high idle.
Note: Caterpillar Electronic Technician Software may be used in order to monitor engine rpm, engine oil temperature, and engine coolant temperature. Refer to Illustration 2 for the "Status" screen display.
- Set the pump outlet pressure to 18000 ± 1000 kPa (2610 ± 145 psi) by slowly adjusting the load valve on the flow meter.
Note: Maintain the pump outlet pressure to 18000 ± 1000 kPa (2610 ± 145 psi) throughout the test.
- Set the engine speed to 2000 ± 10 RPM. Ensure that engine speed is maintained throughout the test.
Note: If necessary, readjust the pressure to 18000 ± 1000 kPa (2610 ± 145 psi).
- Refer to Table 2 for the flow specification. Replace the pump if the specification is not met.
- Unload the pump by adjusting the flow meter valve to the fully open position.
- Stop the machine. Remove the Multitach Tool Gp (A) and the Portable Hydraulic Tester (B) . Reconnect hydraulic lines.
Work Tool Pump (Standard Flow) Test Procedure
Specifications
| System Requirements | |
| Test | Specification |
| Pump Outlet Pressure | 18000 ± 1000 kPa (2610 ± 145 psi) |
| Engine Speed (all models) | 2000 ± 10 RPM |
| Oil Temperature | 50° ± 10°C (122° ± 18°F) |
| Standard Flow Work Tool Pump Output | |||
| Machine Model | WT Jumper | System Pressure | Minimum Flow |
| 236D, 242D, 257D, 259D, | - | 18000 ± 1000 kPa (2610 ± 145 psi) |
52 L/min (13.7 US gpm) |
| 246D, 262D, 272D, 277D, 279D, 287D, 289D, 297D, 299D | - | 18000 ± 1000 kPa (2610 ± 145 psi) |
61 L/min (16.1 US gpm) |
Required Tools
| Required Tools | |||
| Item | Part Number | Description | Qty |
| A | 9U-7400 | Multitach Tool Gp | 1 |
| B | 4C-9910 | Portable Hydraulic Tester | 1 |
Test Procedure
- Before any tests are performed, prepare the machine. Refer to Testing and Adjusting, "Machine Preparation". Before any tests are performed, visually inspect the complete hydraulic system for oil leaks and damaged parts. Refer to Testing and Adjusting, "Visual Inspection".
- Open the engine access door. Install the 9U-7400 Multitach Tool Gp in front of opening (1) in order to measure engine RPM. Use reflective tape on the pulley for the engine crankcase to measure the RPM.
Note: Caterpillar Electronic Technician Software may be used in order to monitor engine rpm, engine oil temperature, and engine coolant temperature. Refer to Illustration 2 for the "Status" screen display.
- Stop the engine. Release the system pressure before attempting any adjustment. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release" for the proper procedure.
- Install Tooling (B) between the "A2" coupling (4) and the "A1" coupling (6) . These couplings are located on the left-hand side lift arm. Completely unload the load valve on the 4C-9910 Portable Hydraulic Tester .
Note: Install the flow meter onto the machine so that the hydraulic oil flows out of the "A2" coupling (4) into the "A1" coupling (6) .
Note: The flow meter valve must be fully open before installing the flow meter in-line.
Note: Damage to the pump and damage to the hoses may result from the high pressure that is created by the flow meter valve.
| Illustration 4 | g03387446 |
Connector for the work tool harness. (1/2 Inch Coupler). (4) "A2" Coupling for the auxiliary hydraulic control. (5) "C2" Connector for the work tool harness. (6) "A1" Coupling for the auxiliary hydraulic control. | |
- Fasten the seat belt. Lower the armrest.
- Start the engine. Run the engine at 2000 ± 10 RPM.
Note: The hydraulic oil temperature rises quickly as engine starts.
- The oil in the hydraulic system must be at an operating temperature of 50° ± 10°C (122° ± 18°F) throughout test.
Note: Caterpillar Electronic Technician Software may be used in order to monitor engine rpm, engine oil temperature, and engine coolant temperature. Refer to Illustration 2 for the "Status" screen display.
- Disengage the parking brake. Roll the thumb wheel (7) fully upward in order to operate the high flow auxiliary circuit at the highest flow rate that is possible.
| Illustration 5 | g03387560 |
Right Hand electrohydraulic control (joystick) for the work tool (7) Thumb wheel for the auxiliary hydraulic control | |
- Set the pump outlet pressure to 18000 ± 1000 kPa (2610 ± 145 psi) by slowly adjusting the load valve on the flow meter.
Note: Maintain the pump outlet pressure to 18000 ± 1000 kPa (2610 ± 145 psi) and the engine speed to 2000 ± 10 RPM throughout the test.
- Refer to Table 5 for the flow specification. Troubleshoot the pump if the specification is not met.
- Unload the pump by adjusting the flow meter valve to the fully open position.
- Stop the machine. Remove the Multitach Tool Gp (A) and the Portable Hydraulic Tester (B) .
Work Tool Pump (High Flow) Test Procedure
Specifications
| System Pressure | |
|---|---|
| 236D, 242D, 257D, 259D, | 18000 ± 100 kPa (2610 ± 15 psi) |
| 246D, 262D, 272D, 277D, 279D, 287D, 289D, 297D, 299D | 10000 ± 345 kPa (1450 ± 50 psi) |
| High Flow Work Tool Pump Output | |||
| Machine Model | WT Jumper | RPM | Minimum Flow |
| 236D, 242D, 257D, 259D, | 377-5466 | 2000 ± 25 RPM | 78 L/min (21 US gpm) |
| 246D, 262D, 272D, 277D, 279D, 287D, 289D, 297D, 299D | - | 1800 ± 25 RPM | 57 L/min (15 US gpm) |
| 246D, 262D, 272D, 277D, 279D, 287D, 289D, 297D, 299D | 377-5466 | 1800 ± 25 RPM | 78 L/min (21 US gpm) |
| 272D XHP, 297D XHP, 299D XHP | - | 1800 ± 25 RPM | 57 L/min (15 US gpm) |
| 272D XHP, 297D XHP, 299D XHP | 377-5466 | 1800 ± 25 RPM | 96 L/min (25.3 US gpm) |
Required Tools
| Required Tools | |||
| Item | Part Number | Description | Qty |
| A | 377-5466 | Plug As Highflow Jumper |
1 |
| B | 4C-9910 | Portable Hydraulic Tester | 1 |
| Illustration 6 | g03387446 |
Connector for the work tool harness. (1/2 Inch Coupler). (4) "A2" Coupling for the auxiliary hydraulic control. (5) "C2" Connector for the work tool harness. (6) "A1" Coupling for the auxiliary hydraulic control. | |
Test Procedure
- Before any tests are performed, prepare the machine. Refer to Testing and Adjusting, "Machine Preparation". Before any tests are performed, visually inspect the complete hydraulic system for oil leaks and damaged parts. Refer to Testing and Adjusting, "Visual Inspection".
- Install Tooling (B) between the "A2" coupling (4) and the "A1" coupling (6) . These couplings are located on the left-hand side lift arm. Completely unload the load valve on the 4C-9910 Portable Hydraulic Tester .
Note: Install the flow meter onto the machine so that the hydraulic oil flows out of the "A2" coupling (4) into the "A1" coupling (6) .
- If required, install plug (A) into the connector (5) for the work tool harness that is located on the left-hand lift arm. Refer to Table 8 for use of the work tool plug (A) .
- Sit in the seat. Lower the armrest. Engage the parking brake.
- Start the engine. Refer to Table 8 for engine speed of model being tested.
- The oil in the hydraulic system must be at an operating temperature of 50° ± 10°C (122° ± 18°F) throughout test.
- Open the engine access door. Install the 9U-7400 Multitach Tool Gp in front of opening (1) in order to measure engine RPM. Use reflective tape on the pulley for the engine crankcase to measure the RPM.
Note: Caterpillar Electronic Technician Software may be used in order to monitor engine rpm, engine oil temperature, and engine coolant temperature. Refer to Illustration 2 for the "Status" screen display.
- Disengage the parking brake. Roll the thumb wheel (7) fully upward in order to operate the high flow auxiliary circuit at the highest flow rate that is possible.
| Illustration 7 | g03387560 |
Right Hand electrohydraulic control (joystick) for the work tool (7) Thumb wheel for the auxiliary hydraulic control | |
- Refer to Table 7 and adjust the load valve on the hydraulic tester so the pressure matches your machine specification. Refer to Table 8 and adjust the throttle so the engine RPM matches your machine specification. Ensure that the engine speed and the system pressure are both within the proper specification throughout the test. Record the flow from the hydraulic tester.
- Set the throttle to the LOW idle position and turn the ignition switch to the OFF position.
