General Information (Main Pump System) (KENR9994-05)

SMCS - 1400, 5070 i05285514

Main Hydraulic Pumps

The main hydraulic pumps consist of two variable displacement piston pumps that are connected in
series. The two main pumps are referred to as the front pump and the rear pump. The engine
directly powers the front pump through a mechanical connection to the engine flywheel. A splined
shaft inside the pump housing transfers the rotational power from the front pump to the rear pump.
The front pump and the rear pump are identical in construction and operation. The front pump and
the rear pump are equipped with a common charge pump that is located within the center of the
pump housing.

The front pump and the rear pump regulators are controlled by the electronic control system. A
pump control manifold contains two negative flow control PRV's and one power shift pressure PRV.
The proportional reducing valves send a hydraulic signal pressure to the pump regulators to control
the output flow of the pumps. By changing the NFC and PSP signal pressure that flows to the pump
regulators the output flow of the pump changes.

Note: Refer to the appropriate sections in this manual for more information.
 Electronic Control (Main Pump System) (KENR9994-05)

SMCS - 1400, 5070 i07390478

Electronic Control Module (ECM)

Illustration 1 g02612416
Machine ECM
(1) Controller
(2) J1 Connector
(3) J2 Connector
Illustration 2 g02613001
Connectors of Machine ECM
(2) J1 Connector
(3) J2 Connector
The output from the Machine ECM is based on input information from the sensors. The output
commands are based on the software programmed into the control module. After the Machine ECM
receives the input information, the ECM sends a corresponding response to the outputs. The inputs
and outputs of the ECM are connected to the machine harness by two 54-pin connectors (J1 and
J2). The inputs and outputs to the ECM can be viewed through the Caterpillar Electronic Technician
(Cat ET). Input and output information can also be viewed using the Operator Monitor.

The ECM also communicates with sensors and other control modules via the CAN Data Link. The
data link is bi-directional, allowing the Machine ECM to both receive and send information with the
Engine ECM. The Machine ECM also communicates to input and output components that are
directly connected to the Switch Panel. The Switch Panel is used to link input and output
components to the Machine ECM via the CAN Data Link.
Note: Only the complete ECM is serviced (no lower levels components). The ECM must be
replaced if the ECM is damaged. Replace the ECM if a failure is diagnosed.

Pin Locations
The Cat Data Link is used to provide a connection for the service tool for troubleshooting, testing,
and calibrations. The data link is bidirectional. The data link allows the ECM to receive information.
The data link also allows the ECM to send information.

Table 1

Machine ECM Connector J1 Contact Descriptions(1)

No. Type Pin Description
1 Power +Battery
2 Ground Ground
4 Input Front Pump Displacement Sensor
5 Input Rear Pump Displacement Sensor
8 Power Power Supply for Pump Displacement Sensors (12V)
16 Input Joystick LH-X
17 Input Joystick RH-X
18 Ground Analog Return
26 Input Joystick LH-Y
27 Power Power Supply for Sensor (8V)
34 Input Joystick RH-Y
35 Input Left Travel Pilot Pressure Sensor
36 Input Right Travel Pilot Pressure Sensor
53 Input Front Pump Pressure Sensor
54 Input Rear Pump Pressure Sensor
(1) Contacts that are not listed are not used.

Table 2
Machine ECM Connector J2 Contact Descriptions(1)
No. Type Pin Description
8 Output Power Shift Pressure PRV
35 Ground PRV Return
36 Input/Output Valve CAN Data Link +
37 Input/Output Valve CAN Data Link -
 43 Output Rear Pump NFC PRV
47 Input/Output CAN (J1939) Data Link +
48 Input/Output CAN (J1939) Data Link -
50 Input/Output Machine CAN Data Link +
51 Input/Output Machine CAN Data Link -
53 Output Front Pump NFC PRV
(1) Contacts that are not listed are not used.

Inputs
The inputs describe the status of the machine systems. Two types of inputs exist. The inputs can be
either a switch type or a sensor type. Switches provide an open, a ground, or a + battery signal to
the inputs of the controller. Sensors (frequency, PWM, or voltage) provide a changing signal to the
sensor inputs of the controller. The controller will recognize the following types of sensor signals:

Frequency - The sensor will produce an AC signal (sine wave or square wave) that varies in
frequency (Hz) as the condition changes.

Pulse Width Modulated - The sensor produces a digital signal and varies the duty cycle as the
condition changes. The frequency of the signal will remain constant.

In some cases the operator is provided a manual switch that can be used to change a condition of
the machine.

Sensors
Low Pressure Sensors
Illustration 3 g02263393
Note: The values in Table 3are for bench testing only. Values may not represent parameters for
machine systems specifications.

Table 3

Operating pressure 10 MPa

Supply Voltage +7V ~ +14V
Output signal 500 ± 100 Hz (PWM)
Output range 5% ~ 95%

Left Travel and Right Travel Pilot Pressure Sensor

The left travel and right travel pressure sensors are used as input signals to the machine ECM. The
machine ECM uses this pressure information to determine how much pump flow is required to meet
the flow demand of the travel circuits. The machine ECM can then adjust the PWM driver to the
pump control manifold PRV's.

High Pressure Sensors

Illustration 4 g02263513
Note: The values in Table 4are for bench testing only. Values may not represent parameters for
machine systems specifications.

Table 4
Operating Pressure 50 MPa
Supply Voltage +7V ~ +14V
Output Signal 500 ± 100 Hz (PWM)
Output Range 5% ~ 95%

Front Pump Pressure Sensor and Rear Pump Pressure Sensor

The front pump pressure sensor and rear pump pressure sensors are inputs to the machine ECM.
The front pump and rear pump pressure sensors are located on the main control valve. The front
pump pressure sensor monitors the pressure of the front pump oil in the front half of the main
control valve high-pressure passages. The rear pump pressure sensor monitors the rear pump oil
pressure in the rear half of the main control valve high-pressure passages.

The pressure sensors send a pulse width modulated (PWM) input to the machine ECM. This
pressure information is used for pump control and travel speed.

Pump Displacement Sensor

Illustration 5 g03235271
Illustration 6 g03235722
Note: The values in Table 5are for bench testing only. Values may not represent parameters for
machine systems specifications.

Table 5

Rotational Range ± 24.15° Angular Rotation

Output Signal 500 ± 100 Hz
Output PWM 8% - 92%
Rating + 7V ~ +12V DC

The pump displacement sensor is a hall effect type sensor and is used to measure the pump
swashplate angle. The machine ECM uses the pump displacement sensor input to determine the
output current that is sent to the pump control manifold PRV's. The negative flow control PRVs and
the power shift pressure PRV then change the angle of the swashplate to meet the required
hydraulic flow demands.

For more information on the pump regulators, refer to Systems Operation, "Pump Control (Main
Hydraulic)".

Outputs
The ECM responds to decisions by sending electrical signals to the outputs. The outputs can create
an action or the outputs can provide information to the operator or the service technician.

Proportional Reducing Solenoid Valve

Illustration 7 g02703776
Note: The values in Table 6are for bench testing only. Values may not represent parameters for
machine systems specifications.

Table 6
Current Range 0 mA ~ 700 mA
Coil Resistance 11.5 ± 0.5Ω (T=20° C)

Power Shift Pressure PRV

The machine ECM continually monitors all of the input signals. The input signals are processed by
the machine ECM and an output signal is sent to power shift pressure PRV at the pump control
manifold. The power shift pressure PRV assists in controlling the output flow of front pump and rear
pump.
For more information concerning the power shift pressure system, refer to Systems Operation,
"Solenoid Valve (Proportional Reducing) - Power Shift System".

Reverse Proportional Reducing Solenoid Valve

Illustration 8 g02304374
Valve cutaway, hydraulic schematic symbol, and electrical connector designation
Note: The values in Table 7are for bench testing only. Values may not represent parameters for
machine systems specifications.

Table 7
Current Range 0 mA ~ 700 mA
Coil Resistance 11.5 ± 0.5Ω (T=20° C)

Negative Flow Control PRV for the Front Pump and Negative Flow
Control PRV for the Rear Pump
Proportional reducing valves for negative flow control are used in order to control the amount of
NFC signal to the pump regulators. The machine ECM receives various input signals in order to
control the flow limitation from the main hydraulic pumps. When the NFC valves are energized by
the machine ECM, pilot oil pressure is directed to the main hydraulic pump regulators from the
pump control manifold. The pilot oil pressure causes the hydraulic pumps to destroke which reduces
hydraulic oil flow.

For more information concerning the negative flow control system, refer to Systems Operation,
"Negative Flow Control System".
Data Link
Cat Data Link
The Cat Data Link is an input/output of the ECM. The data link uses the connector for the service
port in order to communicate with the Caterpillar Electronic Technician. A data link connection is
provided for the product link.

Note: The control for the product link provides a global positioning system for the machine.

The data link is bidirectional. The bidirectional link allows the ECM to input information and output
information. The data link consists of the following parts: internal ECM circuits, the related harness
wiring, the service tool connector, and the connector for the product link. The Cat Data Link
connects to the ECM at contact J2-16 (wire 892-BR(Brown)) and contact J2-25 (wire 893-
GN(Green)).

The ECM receives commands from the Cat ET in order to change the operating modes. The
Cat ET will read the service codes that are stored in the memory of the ECM. The Cat ET will
clear the service codes that are stored in the memory of the ECM.

The ECM sends the input and the output information to the Caterpillar ET.

CAN Data Link

A Controller Area Network (CAN) Data Link allows communication between the Machine ECM,
Engine ECM, and the input and output devices of the switch panel. The CAN Data Link allows for bi-
directional electronic signals to be passed among the controllers and the switch panel. The data link
allows the Machine ECM to be connected to sensors and actuators connected to the switch panel.
The Machine ECM can also use the data link to communicate engine speed and/or torque
requirements to the Engine ECM.
 Main Hydraulic Pump (KENR9994-05)

SMCS - 5070 i05721949

Construction

Illustration 1 g03637843
Main pump
(1) Front pump regulator
(2) Rear pump regulator
(3) Front pump
(9) Rear pump
(13) Center manifold
(16) Negative flow control regulator
(17) Power shift pressure regulator
(18) Charge pump
(32) Minimum angle stop screw
(33) Maximum angle stop screw
(A) Outlet port (front pump)
(B) Outlet port (rear pump)
(CR (A)) Pump signal pressure from rear pump
(CR (B)) Pump signal pressure from front pump
(H3 (A)) Port (negative flow control signal pressure)
(H3 (B)) Port (negative flow control signal pressure)
(L5 (A)) Port (power shift pressure)
(L5 (B)) Port (power shift pressure)
(MA) Port (front pump pressure)
(MB) Port (rear pump pressure)
(M1A) Control signal pressure (front pump)
(M1B) Control signal pressure (rear pump)
(PA) Port (pilot pressure)
(PB) Port (pilot pressure)
(S) Inlet port
(T1) Case drain port
(T2) Case drain port
The main pumps consist of front pump (3) and rear pump (9). The pumps are connected in series by center manifold (13). Both pumps are
variable displacement piston pumps. The displacement is controlled by regulators (1) and (2). The front pump and the rear pump are identical in
construction and operation. The front pump and the rear pump are equipped with a common charge pump (18) that is located within center
manifold (13).

Charge pump (18) is a fixed displacement pump that consists of an impeller. Charge pump (18) draws oil from inlet port (S) in center manifold
(13). The charge pump delivers oil to the front pump and the rear pump. The front pump delivers oil through outlet port (A) in center manifold
(13). The rear pump delivers oil through outlet port (B) in center manifold (13).

The pump regulators (1) and (2) are mounted on center manifold (13). Both the front pump and the rear pump have a regulator as part of the
pump control system. The control system is identical for both pumps.

Two pressure inputs are supplied to each regulator. The pressure inputs to the regulators control the output of the pump. Power shift pressure
and negative flow control signal pressure are inputs to the regulators.

Each regulator consists of power shift pressure regulator (17) and negative flow control regulator (16). The power shift pressure signal flows
through port (L5 (A)) and port (L5 (B)) to each regulator. The negative flow control signal pressure flows to the regulators through port (H3 (A))
and port (H3 (B)). In addition, oil from the pilot pump is delivered to each of the front and rear pumps through port (PA) and port (PB).

Note: Pilot oil that is delivered to port (PA) and port (PB) are inputs for pump control. The pilot pressure is used when the system pressure is
lower than the pilot system pressure.

Operation
 Pump Control (Main Hydraulic) - Main Pump Regulator (KENR9994-05)

SMCS - 3222, 5070, 5086 i07384074

Operation
The regulators for the front pump and the rear pump are identical in construction and operation. The pump regulators are located on the sides of
the main pump housing. The following description is given for the front pump regulator. The rear pump regulator operation is identical to the front
pump regulator operation.

The pump regulators are controlled by the electronic control system. The machine ECM continually monitors various inputs. The machine ECM
sends a pulse width modulated (PWM) driver to the negative flow control (NFC) PRV for the front pump and the rear pump. NFC PRV controls
the output flow of the pumps by changing the hydraulic signal pressure that flows to the NFC power regulator in the pump regulators.

The machine ECM also sends a pulse width modulated (PWM) driver to the power shift pressure (PSP) PRV for the front pump and the rear
pump. Power shift pressure controls the constant torque curve of the pump. The power shift pressure controls the pump output flow whenever
the pumps are operating on the constant torque curve.

The machine ECM controls the PWM driver sent to the NFC PRV and the PSP PRV which determines the required pump flow based off the
following inputs.

Desired engine speed - Determined by the engine speed dial.

Actual engine speed - Determined by the engine speed pickup.

Hydraulic torque output - The hydraulic torque output varies depending on the engine speed dial setting.

Front pump displacement - Determined by the front pump swashplate angle sensor.

Rear pump displacement - Determined by the rear pump swashplate angle sensor.

Flow requested - Determined by the left-hand joystick position, right-hand joystick position, or the travel pilot pressure sensors.

Front pump delivery pressure - The front pump delivery pressure is measured by the front pump pressure sensor located on the main control
valve.

Rear pump delivery pressure - The rear pump delivery pressure is measured by the rear pump pressure sensor located on the main control
valve.
Illustration 1 g06303615
Partial schematic
(1) Unloading valve (front pump)
(2) NFC power regulator (front pump)
(3) Unloading valve (rear pump)
(4) NFC power regulator (rear pump)
(5) Minimum angle stops (front pump)
(6) Minimum angle stops (rear pump)
(7) Maximum angle stops (front pump)
(8) Maximum angle stops (rear pump)
(9) Negative flow control PRV 1 (front pump)
(10) Negative flow control PRV 2 (rear pump)
(11) Power shift pressure PRV
(12) Front pump
(13) Rear pump
(32) Pilot pump
(33) Swashplate angle sensor (front pump)
(38) Front pump pressure sensor
(39) Rear pump pressure sensor
(45) Swashplate angle sensor (rear pump)

Demanded pump flow is determined by the joysticks and/or travel levers/pedals. The joysticks send an X and Y position signal to the machine
ECM with the requested flow from the operator. The travel levers/pedals requested flow is determined by travel pilot pressure sensors (9) and
(10). The machine ECM receives the requested flow input from the joysticks or travel levers/pedals. The machine ECM then sends a PWM
driver to negative flow control PRV (2) and negative flow control PRV (3). Pilot oil is supplied to the pump control manifold block from the pilot
pump. The pilot oil flows through the NFC PRV's and to the pump regulators.

The pump swashplate moves to meet the flow demand. Front pump (5) and rear pump (6) are each equipped with a swashplate angle sensor.
The swashplate angle sensor sends a feedback control signal to the machine ECM. The NFC PWM driver from the machine ECM adjusts the
current command to the NFC PRVs if the actual flow does not meet the requested flow.
Note: A decrease in current causes an increase in NFC hydraulic pressure which is then sent to the pump regulators. This increase in NFC
pressure to the pump regulators causes the main hydraulic pumps to destroke, decreasing the flow.

Note: An increase in current to the negative flow control PRV causes a decrease in NFC hydraulic pressure to the pump regulators. This
decrease of NFC pressure to the pump regulators causes the main hydraulic pumps to upstroke, increasing the flow.

Illustration 2 g03400517
P-Q characteristic curve
(A) Pressure/flow point (destroke point)
(B) P-Q characteristic curve
(C) High torque
(D) Low torque
(E) Low-power shift pressure
(F) High-power shift pressure

The flow rate of each pump is represented on P-Q characteristic curve (B) from pressure/flow point (A). Each point on the P-Q characteristic
curve represents the flow rate and pressure when pump output horsepower is maintained at a constant rate.

The P-Q characteristic curve is determined by the machine ECM. The machine ECM adjust the power shift pressure to determine the required
P-Q characteristic curve (torque line) of the pump. When the machine ECM sends a low PSP (E) to the pump regulators, the pump can produce
high torque (C). When the machine ECM sends a high PSP (F) to the pump regulators, the pump produces low torque (D).

The output characteristic of each pump depends on the following inputs.

Desired engine speed

Actual engine speed

Hydraulic torque output

Front pump displacement

Rear pump displacement

Flow requested
 Front pump delivery pressure

Rear pump delivery pressure

Regulator Operation (Standby - Full De-stroke)

Illustration 3 g03637762
Front pump regulator (standby - full de-stroke position)
(1) Unloading valve (front pump)
(2) NFC power regulator (front pump)
(3) Unloading valve (rear pump)
(4) NFC power regulator (rear pump)
(5) Minimum angle stops (front pump)
(6) Minimum angle stops (rear pump)
(7) Maximum angle stops (front pump)
(8) Maximum angle stops (rear pump)
(9) Negative flow control PRV 1 (front pump)
(10) Negative flow control PRV 2 (rear pump)
(11) Power shift pressure PRV
(12) Front pump
(13) Rear pump
(14) Shuttle valve
(15) Actuator piston
(16) Actuator piston
(32) Pilot pump
(33) Swashplate angle sensor (front pump)
(38) Front pump pressure sensor
(39) Rear pump pressure sensor
(45) Swashplate angle sensor (rear pump)
Illustration 1 shows the pump regulator and swashplate in the de-stroked position. When all hydraulic control valves are in NEUTRAL position,
the pump swashplate is held in the STANDBY condition.
The machine ECM driver sends no PWM current to the front pump NFC PRV (9). This action allows full pilot pressure to flow to NFC power
regulator (2) which shifts the NFC power regulator to the left. Power shift pressure is high and rear pump pressure is low. The PSP pressure
acting on unloading valve (1) shifts the valve to the right.

Because pump pressure at standby is less than pilot oil pressure, pilot oil flows through shuttle valve (14). From shuttle valve (14) the pilot oil
pressure flows through NFC power regulator (2) and unloading valve (1). Pilot oil pressure now acts on actuator piston (16). Because the
surface area on actuator piston (16) is larger than the surface area on actuator piston (15), the swashplate moves towards the de-stroked or
standby position.