330D, 336D and 340D Excavators Hydraulic System – Pump Control (Negative Flow) – Test – Stage 2 pump

This test measures individual pump flow at the pump while a fixed negative flow control pressure is sent to the main pump regulator. Each pump is tested individually for an output flow rate at a specified delivery pressure and a specified negative flow control pressure.

Drive Pump

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

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. Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply 276 to 414 kPa (40 to 60 psi). This procedure will pull a vacuum on the hydraulic system.

5. Install the following tools in accordance with the circuit diagram. Refer to Illustration 2.
   1. Disconnect delivery line (12) from drive pump (23) .
   2. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (12) by using bolts (46) and washers (47) .
   3. 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) .
   
   

   Illustration 4	g00669270
   Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

   4. Disconnect makeup line (4) from connector (2) at swing motor (1) .
   5. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1) .
   6. Install seal (30) and makeup line (4) to tee (3) .
   7. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at drive pump (23) and coupling (37) at the swing motor.
   8. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (16) for drive pump delivery pressure.
   9. Install multitach group (22) on engine (21). This is used to monitor engine speed.
   
   

   Illustration 5	g00670945
   Tool setup (6) Negative flow control line (drive pump) (7) 6V-9508 Face seal plug (13) Negative flow control line (idler pump) (14) Pressure tap (power shift pressure) (15) 8T-8902 Tee (18) 177-7860 Hose assembly (19) Idler pump regulator (20) 8T-0855 Pressure gauge (23) Drive pump (24) Idler pump (25) 6V-8397 O-Ring seal (27) 6V-9829 Cap (28) 3J-1907 O-Ring seal (41) 6V-3965 Fitting (43) 6V-4143 Coupler (44) Test hose (45) 6V-3989 Fitting

   10. 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) .
   11. Connect two tees (15) to the elbow at the negative flow signal pressure port of drive pump (23). Install cap (27) to tee (15) .
   12. Connect one end of test hose (18) to tee (15) .
   13. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
   14. Connect one end of test hose (44) to tee (15) .
   15. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
   16. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .

Idler Pump

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

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. Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply 276 to 414 kPa (40 to 60 psi). This procedure will pull a vacuum on the hydraulic system.

5. Install the following tools in accordance with the circuit diagram. Refer to Illustration 2.
   1. Disconnect delivery line (11) from idler pump (24) .
   2. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (11) by using bolts (46) and washers (47) .
   3. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) to idler pump (24) by using half flanges (48), bolts (46) and washers (47) .
   
   

   Illustration 7	g00669270
   Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

   4. Disconnect makeup line (4) from connector (2) at swing motor (1) .
   5. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1) .
   6. Install seal (30) and makeup line (4) to tee (3) .
   7. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at idler pump (24) and coupling (37) at the swing motor.
   8. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery pressure of the idler pump.
   9. Install multitach group (22) on engine (21). This is used to monitor engine speed.
   
   

   Illustration 8	g00670945
   Tool setup (6) Negative flow control line (drive pump) (7) 6V-9508 Face seal plug (13) Negative flow control line (idler pump) (14) Pressure tap (power shift pressure) (15) 8T-8902 Tee (18) 177-7860 Hose assembly (19) Idler pump regulator (20) 8T-0855 Pressure gauge (23) Drive pump (24) Idler pump (25) 6V-8397 O-Ring seal (27) 6V-9829 Cap (28) 3J-1907 O-Ring seal (41) 6V-3965 Fitting (43) 6V-4143 Coupler (44) Test hose (45) 6V-3989 Fitting

   10. 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) .
   11. Connect two tees (15) to the elbow at the negative flow signal pressure port of idler pump (24). Install cap (27) to tee (15) .
   12. Connect one end of test hose (18) to tee (15) .
   13. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
   14. Connect one end of test hose (44) to tee (15) .
   15. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
   16. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .

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

Illustration 9	g01321378
Monitor (A) Display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key (G) Back key (H) Home key (I) OK key (J) Menu key

3. Start Service Mode and input a fixed power shift pressure of 2550 kPa (370 psi).
   1. 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) .

   2. Press right key (F) in order to highlight “SERVICE” menu option.
   3. After the “SERVICE” option is highlighted, press OK key (I) .
   
   

   Illustration 10	g01148206

   4. After OK key (I) is pressed, the screen in Illustration 10 will be displayed. The password for the service menu is “FFF2”. The keys for direction are used to input the password. Press left key (D) or right key (F) in order to change the position of the flashing character. Press OK key (I) in order to enter the highlighted character.
   5. After entering the last letter of the password, the monitor will continue with the “SERVICE” screen.
   6. Repeatedly press down key (E) in order to highlight the “DEVICE TEST” line on the display.
   7. After the “DEVICE TEST” line is highlighted, press OK key (I) .
   8. Once the “DEVICE TEST” screen is displayed, press down key (E) until “POWER SHIFT PRES” appears on the display.
   9. When “POWER SHIFT PRES” is highlighted, press OK key (I) .
   10. Place the machine controls at the following settings: engine speed dial “10” and AEC switch OFF. Refer to Testing and Adjusting, “Engine Performance – Test (Engine Speed)” for engine rpm settings.

       Note: Press OK key (I) within 5 seconds after completion of Step 3.j in order to ensure high idle.

   11. The “POWER SHIFT PRES” will now be displayed. Line 4 of the display will now change to a numeric value. These characters represent the power shift pressure (kPa).
   12. 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 display. Pressing left key (D) decreases the power shift pressure. Pressing right key (F) increases the power shift pressure.

       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 kPa (370 psi) on the pressure gauge.

       Note: To prevent a change in power shift pressure during the main pump flow test, do not exit the “DEVICE TEST” screen and do not turn the engine start switch to the OFF position.

       Note: Refer to Systems Operation, “Monitoring System” for the machine for additional information on Service Mode.

Illustration 11	g00670500
Portable hydraulic tester (flow meter) (10) Portable hydraulic tester (flow meter) (22) Multitach (26) Valve

4. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is 6900 kPa (1000 psi).

5. Record the negative flow rate in Table 1.

Note: Specifications for flow rates are based on an engine speed of 1800 rpm. To get more accurate test results, measured flow should be corrected with the following calculation.

Flow measurements must be done in pressure rise.