Service Training CTN Broadcast Handouts SEEV0S41 September 1991 CATERPILLAR’ STUDENT HANDBOOK VARIABLE DISPLACEMENT PUMP fo mr TO ACCOMPANY VIDEO TAPE SEVN1837 INTRODUCTION TO VARIABLE DISPLACEMENT PUMPS AND PUMP CONTROLS USED IN LS/PC HYDRAULIC SYSTEMSINTRODUCTION TO VARIABLE DISPLACEMENT PUMPS AND PUMP CONTROLS USED IN LS/PC HYDRAULIC SYSTEMS PROGRAM DESCRIPTION This 2 hour program Is part two of a four part series on Load Sensing/Pressure Compensated Hydraulies (LS/PC). It Is Intended for the Service Training Instructor mechanic, and those personnel who need a basic understanding of variable displacement pumps used in LS/PC hydraulic systems. We will study the ‘operation and testing procedures for variable displacement pumps used in 416-446 Backhoe Loaders, G-Series Motorgraders, D4H-D6H Track Type Tractors, and DSH-D8N Differential Steer Track Type Tractors. PROGRAM OBJECTIVES Upon completion of the broadcast the students will be able = ‘To Identify major components and explain thelr function. ‘To explain how the pump reacts to changes in flow requirements and and work port loads. To trace flow through the pumps and pump control valves for low pressure standby, upstroking, destroking, and high pressure stall. To locate the pumps on representative machines, and perform pressure tests for low pressure standby, ‘margin pressure, and maximum system pressure. PRE-REQUISITES ‘Students need a good working knowledge of hydraulics. If they were not able to participate in the first program of this series hold on May 11, 1990 on “introduction to Load Sensing/Pressure Compensated Hydraulics", then It Is suggested they review a tape of the broadcast. Note: Participants will watch the program on TV monitors, and will be able to ask the instructor questions during the presentation. Site co-ordinators will receive one set of handouts prior to the program to be duplicated and distributed to viewers prior to the start of the program. ABOUT THE HANDBOOK This handbook will help reinforce the Information being presented in this program. The student should complete the hadnbook as directed by the program instructor. A.quiz will be given upon completion of this program to assist the dealer Instructor in determining the ‘etfectiveness of the Instruction.STUDENT HANDOUT #1 LOAD SENSING / PRESSURE COMPENSATION a] came ENGINE | Ls VARIABLE DISPLACEMENT PUMP i = CLOSED pesceme ©‘! [><] CENTERED VALVE : CONTROL VALVE The pump control valve ________ pump output pressure and the work port pressure (signal pressure) to regulate the pump flow to maintain a fixed difference in pressure between pump supply and signal pressure called pressure. Two advantages of using a variable displacement pump: 1) Less 2) less horsepower from the engine, resulting in reduced fuel consumption. generated, giving longer componentlife, and‘STUDENT HANDOUT #2 LNdno dnd 4ddO diNnd ‘TWNOIS ON‘STUDENT HANDOUT #3 The Pressure Compensator limits Low Pressure Standby is always than or to Margin Pressure. The following are conditions which can result in upstroking of the pump. 1. An implement control valve is activated when the system is at low pressure standby, so more flow is needed. 2. The control valve directional stem is moved for additional flow. 3. An additional circuit is activated, so more flow is required. 4. Engine speed decreases so pump speed decreases, causing a loss in flow and pump supply pressure. The pump has to upstroke to maintain system flow requirements. The following are condi the pump. ns which can result in destroking of 1. All implement control valves are moved to the hold position, so no flow is needed. The pump returns to low pressure standby. 2. The control valve directional stem is moved to reduce flow. 3. An additional circuit is deactivated, so less flow is required. 4, Engine speed increases so pump speed increases.causing ian increase in flow. The pump destrokes to maintain system requirements.‘STUDENT HANDOUT #4 L = 1 = 1Ndino diind — TWNODIS ON 4dO diNWNdSTUDENT HANDOUT #5, Recommended Steps For Identifying a Pump Control Problem 1. Determine if a problem really exists. a) Take cycle times to determine if all components suffer from poor response. 2. Check Maximum System Pressure a) This will determine if a signal is getting to the pump control valve and if the machine can move its maximum loads. 3. Check Low Pressure Standby a) If at "mean" and cycle times were all good, then no flow compensator adjustments are required. b) If not at "mean", adjustment may be required to improve implement response if cycle times are to the low side (Challenger 65 is only exception). c) If adjustment made to Low Pressure Standby do a quick check of Margin Pressure to see if it falls within specification range. Note: Perform all tests at High Idle.STUDENT HANDOUT #6 4dO diNNd 104INV AFINI OL AUN TOU.LNOS LNAWS Td WOus‘STUDENT HANDOUT #7 LAB #1 For Lab #1 perform the following steps on a representative machine. Refer to the service manual for specifications and test port locations. Record readings. ‘SPEC. ACTUAL Check Maximum System Pressure Check Low Pressure Standby Check Margin Pressure LAB #2 For Lab #1 perform the following steps on the same representative machine. Refer to the service manual for cycle times. Make a chart to record cycle times and your pressure readings. Have your dealer instructor assist you. Back "flow compensator spool” out at least one full turn or until cycle times fall off Check cycle times Check Maximum System Pressure Check Low Pressure Standby and Margin Pressure Adjust Low Pressure Standby to "mean" Recheck Margin Pressure Recheck Cycle TimesPAGE 1 LS/PC HYDRAULICS VARIABLE DISPLACEMENT PUMPS AND PUMP CONTROLS QUIZ 1. The following are true or false. Enter T for true and F for false. If false, circle the word or words that make the statement false and replace with a word or words that make the statement correct. 1. The difference in pressure between pump supply pressure and signal pressure is called margin pressure. 2. Margin Pressure is usually higher than Low Pressure Standby. 3. The pressure compensator serves as a relief valve for the 416 Backhoe Loader. 4. Margin pressure is considered more critical than low- pressure standby in regards to motor graders. 5. You must install the special orifice in the tilt circuit of the 416 BHL to check margin pressure. 6. Besides a pressure compensator all 3 diff steer track-type Tractors have a system relief valve. 7. By stalling out your lift circuit on diff. steer machines you can reach max. system pressure across the pressure compensator. 8. To check maximum system pressure the engine should be at low idle. 9. If an implement is in stall there is no flow available for another implement.I. PAGE 2 Select the best answer. . Ifa D4H pump is at Low Pressure Standby: a. There is a signal being sent from the implements. b. The pump will signal itself by way of the signal network. c. There is no signal being sent from the implements. By adjusting the flow compensator screw we will effect: a. Margin pressure and maximum system pressure. b. Margin pressure and low pressure standby. c. Margin pressure only. By adjusting the pressure compensator screw we will effect: a, Maximum system pressure. b. Low pressure standby. c. Margin pressure. ‘The variable displacement pump in a 446 BHL will upstroke: a. If there is an increase in work port pressure but the flow requirements do not change. b. If the flow requirements increase but the highest work port pressure decreases. c. If the flow requirements do not change and the work port pressure stays the same. While an implement is activated on a D8N and the operator maintains a constant lever displacement, a drop in engine RPM will cause the pump: a. To Upstroke b. To Destroke c. Remain unchangedPAGE3 LNdLNo diwnd 4sdO diNnd ‘TWNOIS ON “smoue [age] “sjueuoduios Ajuep] ‘IIILS/PC HYDRAULICS VARIABLE DISPLACEMENT PUMPS AND PUMP CONTROLS ANSWER SHEET QUIZ I. True False _T__ 1. The difference in pressure between pump supply pressure and signal pressure is called margin pressure. __F__ 2. Margin Pressure, is usually LOWER than Low Pressure Standby. __T__ 3. The pressure compensator serves as a relief valve for the 416 Backhoe Loader. __F__ 4. Margin pressure is considered LESS critical than low- pressure standby in regards to motor graders. __F__ 5. You DON'T NEED the special orifice in the tilt circuit of the 416 BHL to check margin pressure. __T__ 6. Besides a pressure compensator all 3 diff steer track-type ‘Tractors have a system relief valve. __F_7. By stalling out your STEERING circuit on diff. steer machines you can reach max. system pressure across the pressure compensator. __F__ 8. To check maximum system pressure the engine should be at HIGH idle. __F__9. If an implement is in stall there IS flow available for another implement. Il. Answers yreye poe oo Ill, Label Components - Refer to Student Handout #2.