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320 c info 320 c info Document Transcript

  • CONFIDENTIALTECHNICAL INFORMATION BULLETIN July 26, 2000EXCAVATORS 320C (ANB, BCB, BBC, BDB, BDC, ALF, BEF, AKH, BER, BPR, BRX,) EXCAVATORS COMPONENT CODE(S) xxxxSUBJECT: HYDRAULIC POWER TEST FOR AKASHI BUILT 320CPROBLEM:This is an optional pump flow test to measure hydraulichorsepower. This test was not available at first ship of the320C.SOLUTION:This test is performed by measuring the pump flow at theboom cylinders. This test measures the combined horsepowerlevel of the engine and the hydraulic systems. .Illustration 1 Illustration 2(1).Alarm lamp (3) Monitor(2).Electronic control module (4)Message displayNote: Before starting main pump flow tests, check messagedisplay (4) on monitor (3) and alarm lamp (1) on electroniccontrol module (2) for normal operation. If no faults arepresent, perform the operational checks. Refer to Testingand Adjusting, "Operational Checks".Page 1 of 1
  • Illustration 3 Flow meter tool layout(6) 6V-9746 O-Ringseal (7) Line (right boom cylinder head end) (8) Line (rightboom cylinder rod end) (9) Line (left boom cylinder rod end)(10) 4C-9910 Portable hydraulic tester (flow meter) (11)Line (left boom cylinder head end) (12) 6V-8716 Sealconnector (13) Left boom cylinder (14) Right boom cylinder(15) 6V-9832 Cap (31) 5P-0201 Hose (32) 5P-1010 Sleeve (33)4C-8767 Coupling (34) 7M-8485 O-Ring seal (35) 4C-6481Coupler assembly (36) 4C-6482 Nipple assembly (37) 4I-6141Coupling (38) 8C-9026 Adapter (39) 6K-6307 O-Ring seal (40)6V-9511, (41) 6V-9746Page 2 of 2
  • Illustration 4 Circuit diagram (5) Main control valve, (9)Line (left boom cylinder rod end), (10) 4C-9910 Portablehydraulic test (flow meter1) (11) Line (left boom cylinderhead end)(13) Left boom cylinder (14) Right boom cylinder(15) 6V-9832 Cap (17) Pressure tap (right pump deliverypressure) (18) Pressure tap (left pump delivery pressure)(19) Tap (power shift pressure) (20) 8T-0861 Pressure gauge(21) Engine (22) Multitach (23) Right pump (24) Left pump(42) 8T-0856 Pressure gaugeNote Care must be taken to ensure that fluids are containedduring performance of inspection, maintenance, testing,adjusting and repair of the product. Be prepared to collectthe fluid with suitable containers before openinganycompartment or disassembling any component containingfluids.Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.Page 3 of 3
  • Dispose of all fluids according to local regulations andmandates.1. Position the machine on level ground. Illustration 5 Illustration 6 (7) Line (right boom cylinder head end) (8) Line (right boom cylinder rod end) (9) Line left boom cylinder rod end) (11) Line left boom cylinder head end) 13 Left boom cylinder (14) Right boom cylinder2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to Illustration 5.3. Stop the engine.4. Release the pressure in the hydraulic system. Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".5. Install the following tools in accordance with the flow meter tool layout and the circuit diagram. Refer to Illustration 3 and Illustration 4. a. Disconnect lines (7), (8), (9), and (11) from boom cylinders (13) and (14).Page 4 of 4
  • Illustration 7 (15) 6V-9832 Cap b. Install caps (15) to the open end of the connectors at boom cylinders (13) and (14). c. Connect portable hydraulic tester (10), test hoses and fittings between line (9) and line (11). Line (11) must be connected to the inlet side of portable hydraulic tester (10). Line (9) must be connected to the outlet side of portable hydraulic tester (10). d. Plug lines (7) and (8) with plug (40) and seal (41).Illustration 8 (17) Pressure tap(right pump delivery pressure) (18)Pressure tap (left pump deliverypressure) (19) Pressure tap (powershift pressure) 23 Right pump (24) Leftpump e. Connect a 6000 kPa (870 psi) pressure gauge (20) to the power shift pressure tap (19). f. Connect a 60000 kPa (8700 psi) pressure gauge (20) to pressure tap (17) for right pump delivery pressure. g. Connect a 60000 kPa (8700 psi) pressure gauge (20) to pressure tap (18) for right pump delivery pressure.Page 5 of 5
  • h. Install multitach (22) on engine (21).6. Obtain a fuel sample and determine the fuel API rating. The fuel API rating will be used in order to calculate the corrected hydraulic horsepower. See Table 5. 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 comoponents 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.7. Start the engine.8. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing And Adjusting, "Engine Performance Test" for engine rpm settings.9. Place the hydraulic activation control lever in the UNLOCKED position.10. Increase the hydraulic oil temperature to the recommended temperature range. Refer to Table 1 and TablePage 6 of 6
  • 2 for the recommended operating temperatures of the hydraulic oil.11. Slowly move the joystick for the boom to the full BOOM RAISE position. Hold the joystick for the boom in this position until the pump flow test is completed.Illustration 9 Portablehydraulic tester (flow meter)12. Turn valve (26) on portable hydraulic tester (10) clockwise until the pressure gauge reads 15700 kPa (2300 psi). Record the pump flow at the pressure specification in Table 1 and Table 2.Table 1 Pump Flow Test At 15700 kPa (2300 psi)1Flow Measured Flow Meter(liter/min.Pump delivery Pumppressure (kPa)(1) The recommended hydraulic oil temperature for this pressure range is 50 to 55° (120 to 130°) . The hydraulic oil temperature will increase quickly during this test. Collection of data should begin when the temperature reaches 50° C (120°F)Page 7 of 7
  • Table 2Standard Pump Flow Test At 29400 kPa (4250 psi)2Flow Measured Flow Meter(liter/min.Pump delivery Pumppressure (kPa)(2) The recommended hydraulic oil temperature for this pressure range is 50 to 57° (120 to 135°) . The hydraulic oil temperature will increase quickly during this test. Collection of data should begin when the temperature reaches 50° C (120°F)13. Use the data in Table 1, the data in table 2 and the following formula in order to calculate the hydraulic horsepower.Case 1: Metric SystemKW = [(Pf + Pr)/2 _ Q/60000]_ Cr _ Cf _ Ca Cf = 1 - 0.004 _ (40 - Tf) Ca = 1 - 0.0014 _ (25 - Ta) KW : Hydraulic power Pf (kPa) : Pump pressure (front) Pr (kPa) : Pump pressure (rear) Q (Lpm) : Hydraulic oil flow rate Cr : Correction factor of fuel gravity (refer to the above table) Cf : Correction factor of fuel temperature Tf (C°) : Fuel temperature in fuel filter (Ambient temperature + 10) can be used. Ca : Correction factor of inlet air Ta (C°) : Air temperature at air cleaner inlet (Ambient temperature + 10) can be used.Page 8 of 8
  • Case 2: English SystemHP = [(Pf + Pr)/2 _ Q/1714] _ Cr _ Cf _ Ca Cf = 1 - 0.004 _ (40 - Tf) Ca = 1 - 0.0014 _ (25 - Ta) HP : Hydraulic horsepower Pf (psi) : Pump pressure (front) Pr (psi) : Pump pressure (rear) Q (gpm) : Hydraulic oil flow rate Cr : Correction factor of fuel gravity (refer to the above table) Cf : Correction factor of fuel temperature Tf (C°) : Fuel temperature in fuel filter (Ambient temperature + 10) can be used. Ca : Correction factor of inlet air Ta (C°) : Air temperature at air cleaner inlet (Ambient temperature + 10) can be used.Note: Be sure that all temperature data are indicated incentigrade (C).Table 3Specifications for Standard ConfigurationTest point / Pressure kPa KW HP(psi)First / 15700 (2300) 84.6 113.4Second / 29400 (4250) 72.8 97.6Table 4Specifications for High AmbientTest point / Pressure KW HPkPa (psi)First / 15700 (2300) 79.4 106.5Second / 29400 (4250) 67.7 90.7NOTE: Power specifications in the above table should read“Equal to or no less than” the values indicated.Page 9 of 9
  • Table 5Fuel Gravity (API)API Rating Correction Factor32 0.98733 0.99134 0.99535 1.00036 1.00537 1.01138 1.01739 1.02740 1.03141 1.03942 1.04743 1.05644 1.06614. Call your Service Engineering contact if the calculated hydraulic power values are below specifications. Your values can be compared with the factory data. It may be necessary to check the following items after the review.§ Individual pump flow test§ Main relief setting and line relief setting§ Power shift pressure calibration§ Engine boost§ Flow meter accuracyCOPYRIGHT 2000 CATERPILLARALL RIGHTS RESERVEDPage 10 of 10
  • P-Q CURVE - ENGLISH 60 50 40FLOW (GPM) 30 20 10 5 10 15 20 25 30 35 40 45 50 PRESSURE (PSI x 100)
  • P-Q CURVE - METRIC 250 200FLOW (L/min) 150 100 50 5 10 15 20 25 30 35 40 PRESSURE (kPa x 1000)
  • ELECTRONIC TECHNICIAN PC TO MACHINE/ENGINE CONNECTIONS ENGINE ELECTRONIC COMMUNICATION ADAPTER ICONTROL MODULE (ECM) 139-4166 7X1425 DATA LINK CABLE (18 FT) SERIAL CABLE (4 FT) LAPTOP PC SERIAL PORT COMPUTER SERVICE TOOL (COMM PORT) CONNECTOR CAT ELECTRONIC TECHNICIAN COMMUNICATION ADAPTER I 7X1700 (DISCONTINUED) ENGINE COMMUNICATION ADAPTER II ELECTRONICCONTROL MODULE (ECM) 160-0133 UNIVERSAL 160-0141 DATA LINK CABLE (2 FT) SERIAL CABLE (25 FT) LAPTOP OR 139-4166 PC SERIAL PORT COMPUTER SERVICE TOOL (ATA/CDL ONLY (COMM PORT) CONNECTOR COMMUNICATION DISCONTINUED) ADAPTER II CAT 171-4400 ELECTRONIC TECHNICIAN
  • COMMONALITY 8/30/00 COMMONALITY BETWEEN 320C AND 320CU Åõ ÅF Common with "B" Å¢ ÅF Similar to "B" Å~ ÅF Not common with "B" ÅF Common with "320C" 320C 320CU DIFFERENT from 320C ENGINE SYSTEM ENGINE AS BASIC Å¢ Å¢ MTG GP ENGINE Åõ Åõ MUFFLER Å¢ Å¢ LINES GP - AIR Å¢ Å¢ Air Line Routing FAN Å¢ Å¢ RADIATOR / OIL COOLER - BTB Å~ Å~ POWER TRAIN DRIVE GP - FINAL Åõ Åõ DRIVE GP - SWING Å~ Å~ FASTENER GP Å¢ Å¢ SWING BEARING Å¢ Å¢ UNDER CARRIAGE SPROCKET GP Åõ Åõ IDLER GP - FRONT Åõ Åõ RECOIL GP Å¢ Å¢ ROLLER AR - TRACK & Åõ Åõ TRACK GP Åõ Åõ HYDRAULICS PUMP GP Å~ Å~ MOTOR GP - SWING Åõ Åõ MOTOR GP - TRAVEL Åõ Åõ
  • COMMONALITY 8/30/00 VALVE GP - MANIFOLLD Å~ Å~ LINES GP - TRAVEL Å¢ Å¢ Tube & Hose Routing LINES GP - SWING Å¢ Å¢ Å™ LINES GP - FRONT Å¢ Å¢ Å™ LINES GP - RETURN & FIL Å~ Å¢ Å™ LINES GP - PUMP Å¢ Å¢ Å™ LINES GP - PILOT (A) Å¢ Å¢ Tube & Hose Routing LINES GP - PILOT (C) Å~ Å~ Tube & Hose RoutingÅAÇuÇÅÇåÇñÇÖ etc. CONTROL VALVE GP Å~ Å~ DRIFT RED. VALVE - BM Å¢ Å¢ DRIFT RED. VALVE - STK Å~ Å~ LOWERING CHECK V - BM Å~ Å~ SWIVEL JOINT Åõ Åõ TANK GP - FILTER & Å~ Å~ Return filter §Shape CYL GP - LINE & (BM) Åõ Åõ CYL GP - LINE & (STK) Åõ Åõ CYL GP - LINE & (BKT) Åõ Åõ Åõ ÅF Common with "B" Å¢ ÅF Similar to "B" Å~ ÅF Not common with "B" ÅF Common with "320C" 320C 320CU DIFFERENT from 320C BASE MACHINE SYSTEM FRONT LINKAGE BOOM AR Åõ Åõ ÇoÇâÇêe support STICK AR Åõ Åõ BUCKET AR Åõ Åõ IDLER LINK /POWER LINK Åõ Åõ MAIN STRUCTURE FRAME GP - UPPER Å~ Å¢ FRAME AS - U/C Åõ Åõ GUARD GP - TR MOTOR Å~ Å~ GUARD GP - TR GUIDE Å¢ Å¢
  • COMMONALITY 8/30/00 SHEETMETAL COUNTERWEIGHT Å~ Å~ PÇíÇÖÇìÇì formed shell & steel block BOTTOM GUARD Å¢ Å¢ Shape ENGINE HOOD Å~ Å~ Shape & installation UPPER & SIDE COVER Å~ Å~ Shape & installation HAND RAIL GP Å~ Å¢ Size & shape MIRRER GP Å~ Å¢ Location (same mirrer use) TANK GP -FUEL Å~ Å¢ Size & shape BOX GP - STRAGE Å~ Å~ New design CAB SYSTEM CAB GP - BASIC Å~ Å~ LINES GP - A/C Å¢ Å¢ MONITOR GP - MTG & Å~ Å~ CONSOLE GP - OPERATOR Å~ Å~ SEAT GP - BASIC Å~ Å~ CONDITIONER GP - CAB Å~ Å~ WIRING GP - CAB Å~ Å~ WIRING GP - CONSOLE Å~ Å~ ELECTRIC / ELECTRONIC CONTROLLER Å~ Å~ GOVERNER MOTOR Åõ Åõ CAB LIGHT Å¢ Å¢ ELEC. REFUEL PUMP Å¢ Å¢ WIRING GP - BATTERY & Å~ Å~ Relay boxÅABattery locationÅA Harness routing NEW CONTENTS IS ÇSÅì
  • 320C - 330C : PARTS COMMONALITY Jul.27, 2000 M.V.P.D. A Common with "B" B Similar to "B" C Not common with "B" _ Similar in "C" series _ Common in "C" series 320C 322C 325C 330C _HX121_ _HX122_ _HX123_ _HX124_ENGINE SYSTEM ENGINE AS BASIC B C C C HX121,HX122 : TIER _ MTG GP - ENGINE A B B C HX123,HX124 : TIER _ MUFFLER B B C C LINES GP - AIR B B C C FAN B C C C RADIATOR / OIL COOLER - BTB C C B B Larger ( power up ) RADIATOR / OIL COOLER - OCS B B C C Larger ,__you_ changePOWER TRAIN DRIVE GP - FINAL A C C C Drawbar pull increase (same as 322B) DRIVE GP - SWING B C C C Swing torque increase FASTENER GP C C C C SWING BEARING C C C CUNDER CARRIAGE SPROCKET GP A A A A IDLER GP - FRONT A A A A RECOIL GP B B B C Drawbar pull increase ROLLER AR - TRACK & A A A A TRACK GP B B B B
  • HYDRAULICS PUMP GP C C C C MOTOR GP - SWING A A A C MOTOR GP - TRAVEL A A A C VALVE GP - MANIFOLD A A A A LINES GP - TRAVEL B B B B LINES GP - SWING B B B B LINES GP - FRONT B B B B LINES GP - RETURN & FIL C C C C LINES GP - PUMP B B B B LINES GP - PILOT (A) C C C C LINES GP - PILOT (C) C C C C CONTROL VALVE GP C C C C New C service valve DRIFT RED. VALVE - BM C C C C DRIFT RED. VALVE - STK C C C C LOWERING CHECK V - BM C C C C SWIVEL JOINT A A A A TANK GP - FILTER & C C C C Suction system change CYL GP - LINE & (BM) A A A A CYL GP - LINE & (STK) A A B B Stroke is longer CYL GP - LINE & (BKT) A A A A ( HX123 & HX124 ) PUMP GP - OCS B B C C For TIER _ MOTOR GP - OCS B B C C For TIER _ELECTRIC / ELECTRONIC CONTROLLER C C C C GOVERNOR MOTOR A A C C CAB LIGHT B B B B ELEC. REFUEL PUMP B B B B WIRING GP - BATTERY & B B B B Battery location is changed
  • BASE MACHINE SYSTEM FRONT LINKAGE BOOM AR A A B C STK force increase STICK AR A A B C STK force increase BUCKET AR A A A A ( HX123 & HX124 ) IDLER LINK /POWER LINK A A A A MAIN STRUCTURE FRAME GP - UPPER C C C C FRAME AS - U/C A A A A GUARD GP - TR MOTOR B B B A GUARD GP - TR GUIDE B A B B SHEET METAL COUNTERWEIGHT C C C C New _ styling BOTTOM GUARD B B B B ENGINE HOOD C C C C New _ styling UPPER & SIDE COVER C C C C New _ styling HANDRAIL GP C C C C Height 800mm _ 900mm MIRROR GP C C C C TANK GP -FUEL C C C C BOX GP - STORAGE C C C C New _ stylingCAB SYSTEM CAB GP - BASIC C C C C New C cab LINES GP - A/C B B B B MONITOR GP - MTG & C C C C CONSOLE GP - OPERATOR C C C C SEAT GP - BASIC C C C C CONDITIONER GP - CAB C C C C WIRING GP - CAB C C C C WIRING GP - CONSOLE C C C C