2002/04/08 Gear Pump (Pilot) - Test (RENR6607)

SMCS - 5085 i01668724

Callout  Part Number and Part Description  Quantity 
3  6V-9839 Swivel Tee  1 
11  6V-9830 Cap As  1 
12  9X-8408 Connector  1 
13  6V-8398 O-Ring Seal  2 
14  6V-9746 O-Ring Seal  3 
15  4I-6140 Coupling  1 
16  7M-8485 O-Ring Seal  2 
17  4C-6482 Fitting  2 
  Laptop computer with electronic technician  1 
  171-4400 Communication Adapter Group  1 

Table 1

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, "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.

Illustration 1 g00864045
Flow meter tool layout
(1) Swing motor
(2) Connector
(3) 6V-9839 Swivel Tee
(4) Makeup line
(6) Pilot filter
(7) Setup of basic flow meter and hoses
(8) Valve
(9) Pilot line (oil delivery from pilot pump)
(10) Elbow
(11) 6V-9830 Cap As
(12) 9X-8408 Connector
(13) 6V-8398 O-Ring Seal
(14) 6V-9746 O-Ring Seal
(15) 4I-6140 Coupling
(16) 7M-8485 O-Ring Seal
(17) 4C-6482 Nipple assembly

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".

Illustration 2 g00861995
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(6) Pilot filter
(7) Flow meter
(9) Pilot line
(10) Elbow
(11) Cap
(24) Pilot pump
(25) Pressure gauge
(26) Engine

Illustration 3 g00862120

4. Install the following tools in accordance with the flow meter tool layout and the circuit diagram.

a. Assemble the basic flow meter and hoses.

Note: Refer to Testing and Adjusting, "Flow Meter and Hose Setup (Basic)" for the procedure to assemble these parts.

b. Disconnect pilot line (9) from connector (10) at pilot filter (6). Connect O-ring (13) and cap (11) to connector (10).

c. Disconnect makeup line (4) from connector (2) at swing motor (1).

d. Connect O-ring (14) and tee (3) to connector (2).

 e. Connect O-ring (14) and makeup line (4) to tee (3).

f. Connect flow meter (7) between pilot line (9) and tee (3).

g. Connect the laptop computer to the service tool connector. Refer to Special Publication, NEHS0758, "Communications Adapter II
Hardware and Software" for additional information.
Note: The service tool connector is located in the battery compartment.

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.

5. Start the engine.

6. Place the machine controls at the following settings: engine speed dial "10" and Low idle switch OFF. Refer to Testing And Adjusting,
"Engine Performance - Test" for engine rpm settings.

7. Place the hydraulic activation control lever in the UNLOCKED position.

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

Illustration 4 g00876235
Portable hydraulic tester (flow meter)
(7) Flow meter
(8) Valve

9. Slowly turn valve (8) on flow meter (7) clockwise until pressure gauge (25) on the flow meter shows a reading of 4100 ± 200 kPa
(595 ± 29 psi).

Pump Flow Test 

Oil temperature C° (F°)   
Engine speed (rpm)   
Flow measured liter/min (US gpm)   
Flow corrected liter/min (US gpm)   
New  24 ± 3 L/min (6.3 ± 0.8 US gpm) 
Specification for pump flow liter/min (US gpm) 
Service limit 16 L/min (4.2 US gpm) 

Table 2

Note: Specifications for pump flow are based on an engine speed of 1950 rpm. To get more accurate test results, measured flow should be
corrected by the following calculation.

Measured flow x 1950 rpm 

Corrected flow  = 
measured rpm

Table 3

Flow measurements must be done in pressure rise.

KJA1-UP, PCA1-UP, SNY1-UP

PPI-00011A92
2021/10/05
21:53:52-05:00
i01668724
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