Main Pump (Flow) - Test: Shutdown SIS

304 C CR Mini Hydraulic Excavator FPK00001-UP (MACHINE) POWERED BY S...
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Shutdown SIS
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Product: MINI HYD EXCAVATOR

Model: 304C CR MINI HYD EXCAVATOR FPK
Configuration: 304 C CR Mini Hydraulic Excavator FPK00001-UP (MACHINE)
POWERED BY S4Q2T Engine
Testing and Adjusting

304C CR and 305C CR Mini Hydraulic Excavators Hydraulic System
Media Number -RENR9635-03 Publication Date -01/08/2008 Date Updated -29/08/2008
i03247256
Main Pump (Flow) - Test

SMCS - 5070-081-FW
Table 1
Required Tools
Pt. No. Description Qty
1U-5796 Pressure Differential Gauge Group 1
4C-9910 Portable hydraulic tester (flow meter) 1
8T-0860 Pressure gauge (40000 kPa (5800 psi)) 1
Note: Before starting main pump flow tests, check the alarm indicators on the operator monitor panel 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 times) indicate that slow speed of an implement is common to all circuits of
the pump, the problem is most likely in the pump system. Then perform the pump flow tests. Refer to Testing and
Adjusting, "Main Pump (Flow) - Test".
Main Pump (Load Sensing Set)
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 Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Position the machine on level ground.
2. Stop the engine.
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304 C CR Mini Hydraulic Excavator FPK00001-UP (MACHINE) POWERED BY S... Strona 2 z 32
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 layout. Refer to Illustration 1.
Illustration 1 g01648601
(5) 6V-3965 Nipple
(6) 3J-1907 O-ring seal
(11) 6V-9853 Elbow
(14) Main pump
(22) Main control valve
(25) 6V-3989 Fitting
(26) 6V-4143 Coupler
(27) Test hose
(37) Sensing line for pump load
(39) 6V-9001 Elbow
(41) 6V-8397 O-ring seal
(42) 8T-8902 Swivel tee
(43) Pressure tap
(44) 8T-0860 Pressure gauge (40000 kPa (5800 psi))
(45) 8C-8431 Tee
(48) 1U-5793 Pressure differential gauge
(49) 6V-0484 Adapter
a. Disconnect load sensing line (37) from elbow (39) at the main pump (14) .
b. Assemble and install seal (41), swivel tee (42), seal (6) and nipple (5) to elbow (39) at the main pump
(14) .
c. Connect load sensing line (37) to swivel tee (42) .
d. Connect test hose (27) on the low pressure side of pressure differential gauge (48) to nipple (5) in
order to measure the pressure in the load sensing line (37) .
e. Connect test hose (27) on the high pressure side of pressure differential gauge (48) to pressure tap (43)
in order to measure the pump pressure.
ReferenceRefer to Special Instructions, SEHS8979 for more information in using 1U-5796 Pressure
Differential Gauge Group .
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.
5. Start the engine.
6. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
Typical example
7. Position the machine with the blade at the rear, and the bucket flat on the ground and the stick in a vertical
position. Raise the machine with the boom and blade functions. Make sure that the tracks are clear of the
ground for the entire length of the tracks. Refer to Illustration 2.
8. Place the machine controls at the high speed position for engine speed with load. Refer to Testing and
Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
9. Operate the LEFT TRAVEL and RIGHT TRAVEL circuits at full speed in the same direction, while the
travel speed is in TORTOISE MODE. Measure the pressure from the load sensing line (37) and from
pressure tap (43) once the speed of the TRAVEL functions have stabilized. Record the pressure from
differential pressure gauge (48) in Table 2.
Table 2
Load Sensing Specifications
Margin pressure
Specification for margin pressure kPa (psi)

1400 ± 200 (203 ± 29)
If the margin pressure is not within the allowable specification, then complete the necessary adjustments below.
Adjustment screw for main pump flow
(14) Main pump
(46) Adjustment screw
Adjustments to the load sensing valve can be made by turning the adjustment screw (46) left or right. Turn the
adjustment screw (46) to the RIGHT to INCREASE margin pressure. Turn the adjustment screw (46) to the LEFT
to DECREASE margin pressure.
Repeat Step 9 until the margin pressure is within the specification.
Main Pump (Minimum Flow)
NOTICE
containing fluids.

Illustration g01357406
Flow meter tool layout
(1) 4C-6482 Nipple assembly
(2) 7M-8485 O-ring seal
(3) 4I-6140 Adapter
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(8) 4C-6481 Coupler assembly
(9) 6V-9511 Plug
(10) Delivery line for main pump
(11) 6V-9853 Elbow
(12) 4C-8767 Hose coupling
(13) 5P-1010 Sleeve
(14) Main pump
(15) 5P-0201 Hose
(16) 8C-9026 Adapter
(17) 6K-6307 O-ring seal
(18) 4C-9910 Portable hydraulic tester (flow meter)
(19) 6V-9839 Swivel tee
(20) Return line assembly
(21) 2T-2991 Adapter
(23) Oil cooler
Circuit diagram
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(14) Main pump
(15) 5P-0201 Hose
(23) Oil cooler
(28) Hydraulic tank
(29) 9U-7400 Multitach Tool Group
(30) Engine
2. Stop the engine.
Release".
4. Install the following tools in accordance with the flow meter tool layout and the circuit diagram. Refer to
Illustration 4 and Illustration 5. A more detailed view of the installation at the pump and main control valve
can be seen in Illustration 6 and Illustration 7.
Pump compartment
304 C CR Mini Hydraulic Excavator FPK00001-UP (MACHINE) POWERED BY... Strona 10 z 32
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(11) 6V-9853 Elbow
(14) Main pump
a. Disconnect delivery line (10) from elbow (11) at main pump (14) .
b. Install seal (4) and plug (9) in the open end of delivery line (10) .
c. Assemble and install nipple assembly (1), seal (2), adapter (3), seal (4), tee (7), seal (6) and nipple (5)
to elbow (11) at the main pump (14) .
d. Connect delivery line (11) to tee (7) .
Oil cooler and main control valve (side view)
(23) Oil cooler
e. Disconnect return line (20) from adapter (21) at main control valve (22) .
f. Assemble and install seal (4), swivel tee (19), adapter (3), seal (2) and nipple assembly (1) to adapter

g. Install seal (4) and return line (20) to swivel tee (19) .
h. Connect portable hydraulic tester (18) and the test hoses between nipple assembly (1) at the main
pump (14) and nipple assembly (1) at the main control valve (22) .
5. Install multitach group (29) on engine (30). This is used to monitor engine speed.


(18) 4C-9910 Portable Hydraulic Tester (flow meter)
(31) Valve
9. Record the pump flow and the engine speed in the following appropriate table.
Specifications for Minimum Pump Flow for 304C CR

Table 3
Minimum Pump Flow Test for 304C CR
Flow measured liter/min (US gpm)
Oil temperature °C (°F)
Engine speed (rpm)
Flow corrected liter/min (US gpm)
Specification for flow rate liter/min (US gpm)

20 ± 3.0 (5.3 ± 0.8)
Note: Specifications for flow rates are based on an engine speed of 2400 rpm. To attain more accurate test results,
measured flow should be corrected with the following calculation.
Table 4
Measured flow x 2400 rpm
Corrected flow =
measured rpm
Specifications for Minimum Pump Flow for 305C CR

Table 5
Engine speed (rpm)

31 ± 3.0 (8.2 ± 0.8)
Table 6
Corrected flow =
measured rpm
Main Pump (Maximum Flow)
NOTICE


containing fluids.

(3) 4I-6140 Adapter
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(11) 6V-9853 Elbow
(13) 5P-1010 Sleeve
(14) Main pump
(15) 5P-0201 Hose
(23) Oil cooler
(27) Test hose
(32) 6V-9508 Plug
(34) 6V-9507 Plug
(36) Sensing line for the pump pressure
(38) 8T-0164 Elbow
(39) 6V-9001 Elbow
Circuit diagram
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(14) Main pump
(15) 5P-0201 Hose
(23) Oil cooler
(27) Test hose
(28) Hydraulic tank
(30) Engine
(32) 6V-9508 Plug
(34) 6V-9507 Plug
Position the machine on level ground.
2. Stop the engine.
Release".
Illustration 9 and Illustration 10. A more detailed view of the installation at the pump and main control valve
can be seen in Illustration 11 and Illustration 12.
Pump compartment
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(11) 6V-9853 Elbow
(14) Main pump
(32) 6V-9508 Plug
(34) 6V-9507 Plug
(36) Sensing line for pump pressure
(38) 8T-0164 Elbow
(39) 6V-9001 Elbow
e. Disconnect sensing line for pump pressure (36) from elbow (38) at the main pump (14) .
f. Install seal (35) and plug (34) in the open end of sensing line for pump pressure (36) .
g. Remove elbow (38) and replace the elbow with nipple (5) and seal (6) .
h. Disconnect load sensing line (37) from elbow (39) at the main pump (14) .
i. Install seal (33) and plug (32) in the open end of load sensing line (37) .
j. Remove elbow (39) and replace the elbow with nipple (5) and seal (6) .
k. Connect test hose (27) to nipples (5) at the load sensing port and the sensing port for pump pressure.
Note: By connecting the load sensing port and the sensing port for pump pressure with test hose (27),
the pump's swashplate will remain at the maximum angle.
(23) Oil cooler
l. Disconnect return line (20) from adapter (21) at main control valve (22) .
m. Assemble and install seal (4), swivel tee (19), adapter (3), seal (2) and nipple assembly (1) to adapter
(21) at main control valve (22) .
n. Install seal (4) and return line (20) to swivel tee (19) .
o. Connect portable hydraulic tester (18) and the test hoses between nipple assembly (1) at the main


(31) Valve
Specifications for Maximum Pump Flow for 304C CR

Table 7
Engine speed (rpm)

119.0 ± 3.0 (31.4 ± 0.8)
Table 8
Corrected flow =
measured rpm
Specification for Maximum Pump Flow for 305C CR

Table 9
Engine speed (rpm)

130.0 ± 3.0 (34.3 ± 0.8)
Note:

Specifications rates
for flow !!" # on
are based #"$#%
an engine speed of
Table 10
Corrected flow =
measured rpm
Main Pump Flow (Constant Power Control)
NOTICE
containing fluids.

(3) 4I-6140 Adapter
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(11) 6V-9853 Elbow
(13) 5P-1010 Sleeve
(14) Main pump
(15) 5P-0201 Hose
(23) Oil cooler
(25) 6V-3989 Fitting
(27) Test hose
(32) 6V-9508 Plug
(34) 6V-9507 Plug
(36) Sensing line for the pump pressure
(38) 8T-0164 Elbow
(39) 6V-9001 Elbow
Circuit diagram
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(14) Main pump
(15) 5P-0201 Hose
(23) Oil cooler
(27) Test hose
(28) Hydraulic tank
(30) Engine
(32) 6V-9508 Plug
(34) 6V-9507 Plug
2. Stop the engine.
Release".
Illustration 14 and Illustration 15. A more detailed view of the installation at the pump and main control
valve can be seen in Illustration 16 and Illustration 17.
&'
Illustration g01357415
Pump compartment
(5) 6V-3965 Nipple
(7) 7X-0873 Tee
(9) 6V-9511 Plug
(11) 6V-9853 Elbow
(14) Main pump
(32) 6V-9508 Plug
(34) 6V-9507 Plug
(36) Sensing line for pump pressure
(38) 8T-0164 Elbow
(39) 6V-9001 Elbow
e. Connect pressure gauge (24) to pressure tap (5) on tee (7) that is in line with the main pump delivery
line (11) for the main pump delivery pressure.
f. Disconnect sensing line for pump pressure (36) from elbow (38) at the main pump (14) .
g. Install seal (35) and plug (34) in the open end of sensing line for pump pressure (36) .
h. Remove elbow (38) and replace the elbow with nipple (5) and seal (6) .
i. Disconnect load sensing line (37) from elbow (39) at the main pump (14) .
j. Install seal (33) and plug (32) in the open end of load sensing line (37) .
k. Remove elbow (39) and replace the elbow with nipple (5) and seal (6) .
l. Connect test hose (27) to nipples (5) at the load sensing port and the sensing port for pump pressure.
Note: By connecting the load sensing port and the sensing port for pump pressure with test hose (27),
the pump's swashplate will remain at the maximum angle.
(23) Oil cooler
m. Disconnect return line (20) from adapter (21) at main control valve (22) .
n. Assemble and install seal (4), swivel tee (19), adapter (3), seal (2) and nipple assembly (1) to adapter
(21) at main control valve (22) .
o. Install seal (4) and return line (20) to swivel tee (19) .
p. Connect portable hydraulic tester (18) and the test hoses between nipple assembly (1) at the main


(31) Valve
9. Slowly turn valve (31) on portable hydraulic tester (18) clockwise until the reading on the pressure gauge
(24) at pressure tap (5) for main pump delivery pressure is at the first measuring point. Refer to the
following appropriate tables below for the measuring points.
11. Repeat Step 9 through Step 10 for all of the measuring points in the following appropriate tables.
Pump Flow Specifications and Adjustments for 304C CR
Table 11
Pump Flow Test for 304C CR
Measuring Points
0 kPa (0 10100 kPa 13000 kPa 15600 kPa 24500 kPa

psi) (1465 psi) (1885 psi) (2263 psi) (3553 psi)
Flow measured liter/min (US

gpm)
Engine speed (rpm)
Flow corrected liter/min (US

gpm)
Specification for flow rate

119.3
liter/min (US gpm) 115.7 (30.6) 90.0 (23.8) 67.6 (17.9) 34.9 (9.2)
(31.5)
Table 12
Corrected flow =
measured rpm
Note: Flow measurements must be done only during pressure rise.
(14) Main pump
()* +,-./012)0/ 03 042 5.15 6738 9+) :2 1+,2 :* 0.;)<)= 042 +,-./012)0 /9;28 >?@A 7260 3; ;<=40B C.;) 042
adjustment screw (40) to the RIGHT to INCREASE pump flow. Turn the adjustment screw (40) to the LEFT to
DECREASE pump flow.
Repeat Steps 9 and 11 until the pump flow is within the specification.
Pump Flow Specifications and Adjustments for 3

DEF FG
Table 13
Pump Flow Test for 305C CR
Measuring Points
0 kPa (0 10500 kPa 13500 kPa 16700 kPa 24500 kPa

psi) (1523 psi) (1960 psi) (2422 psi) (3553 psi)
Flow measured liter/min (US

gpm)
Engine speed (rpm)
Flow corrected liter/min (US
gpm)
Specification for flow rate

129.6
liter/min (US gpm) 127.0 (33.5) 101 (26.7) 73.9 (19.5) 44.3 (11.7)
(34.2)
Table 14
Corrected flow =
measured rpm
Note: Flow measurements must be done only during pressure rise.
(14) Main pump
Any adjustments to the pump flow can be made by turning the adjustment screw (40) left or right. Turn the
adjustment screw (40) to the RIGHT to INCREASE pump flow. Turn the adjustment screw (40) to the LEFT to
DECREASE pump flow.
Repeat Steps 9 and 11 until the pump flow is within the specification.
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304 C CR Mini Hydraulic Excavator FPK00001-UP (MACHINE) POWERED BY S...

Product: MINI HYD EXCAVATOR

Testing and Adjusting

Main Pump (Flow) - Test

Pt. No. Description Qty

1U-5796 Pressure Differential Gauge Group 1

4C-9910 Portable hydraulic tester (flow meter) 1

8T-0860 Pressure gauge (40000 kPa (5800 psi)) 1

Main Pump (Load Sensing Set)

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Dispose of all fluids according to local regulations and mandates.

1. Position the machine on level ground.

2. Stop the engine.

(5) 6V-3965 Nipple

(6) 3J-1907 O-ring seal

(11) 6V-9853 Elbow

(14) Main pump

(22) Main control valve

(25) 6V-3989 Fitting

(26) 6V-4143 Coupler

(27) Test hose

(37) Sensing line for pump load

(39) 6V-9001 Elbow

(41) 6V-8397 O-ring seal

(42) 8T-8902 Swivel tee

(43) Pressure tap

(44) 8T-0860 Pressure gauge (40000 kPa (5800 psi))

(45) 8C-8431 Tee

(47) 6V-4144 Coupler

(48) 1U-5793 Pressure differential gauge

(49) 6V-0484 Adapter

c. Connect load sensing line (37) to swivel tee (42) .

To prevent personal injury or equipment damage from failure of the

To prevent personal injury and/or equipment damage from failed lines

5. Start the engine.

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

Load Sensing Specifications

Specification for margin pressure kPa (psi)

(14) Main pump

(46) Adjustment screw

Repeat Step 9 until the margin pressure is within the specification.

Main Pump (Minimum Flow)

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Dispose of all fluids according to local regulations and mandates.

(1) 4C-6482 Nipple assembly

(2) 7M-8485 O-ring seal

(3) 4I-6140 Adapter

(4) 6V-9746 O-ring seal

(5) 6V-3965 Nipple

(6) 3J-1907 O-ring seal

(7) 7X-0873 Tee

(8) 4C-6481 Coupler assembly

(9) 6V-9511 Plug

(10) Delivery line for main pump

(11) 6V-9853 Elbow

(12) 4C-8767 Hose coupling

(13) 5P-1010 Sleeve

(14) Main pump

(15) 5P-0201 Hose

(16) 8C-9026 Adapter

(17) 6K-6307 O-ring seal

(18) 4C-9910 Portable hydraulic tester (flow meter)

(19) 6V-9839 Swivel tee

(20) Return line assembly

(21) 2T-2991 Adapter

(22) Main control valve

(23) Oil cooler

(7) 7X-0873 Tee

(9) 6V-9511 Plug

(10) Delivery line for main pump

(14) Main pump

(15) 5P-0201 Hose

(18) 4C-9910 Portable hydraulic tester (flow meter)

(19) 6V-9839 Swivel tee

(20) Return line assembly

(21) 2T-2991 Adapter