Bench Test Procedure for Hydraulic Piston Pumps{5070} Caterpillar

Industrial Tractor:

TK371 (S/N: WBG1-UP)

TK381 (S/N: WBH1-UP)

Track Feller Buncher:

1090 Series II (S/N: BZJ1-UP)

1190 Series II (S/N: BZK1-UP)

1190T Series II (S/N: BZL1-UP)

1290T Series II (S/N: BZM1-UP)

1390 (S/N: B3F1-UP)

2491 (S/N: P5J1-UP)

2590 (S/N: P6B1-UP)

511B (S/N: F7A1-UP)

521B (S/N: F7B1-UP)

522B (S/N: F7C1-UP)

541 Series 2 (S/N: F7D1-UP)

552 Series 2 (S/N: F7G1-UP)

TK711 (S/N: 1011-UP)

TK721 (S/N: 1021-UP)

TK722 (S/N: 1031-UP)

TK732 (S/N: 1041-UP)

TK741 (S/N: 2021-UP)

TK751 (S/N: 3011-UP)

TK752 (S/N: 3021-UP)

Wheel Feller Buncher:

533 (S/N: CDR1-UP)

543 (S/N: ASJ1-UP)

HA770 (S/N: HAB1-UP)

HA771 (S/N: HAF1-UP)

HA870 (S/N: HAE1-UP)

HA871 (S/N: HAG1-UP)

TK370 (S/N: WBD1-UP)

TK380 (S/N: WBE1-UP)

Introduction

© 2013 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only. Unauthorized use of this document or the proprietary processes therein without permission bay be violation of intellectual property law.

This Special Instruction includes test procedures for piston pumps. This Special Instruction also provides specifications. The technician should have a good understanding of hydraulic piston pumps. The technician should be educated in the operation of the hydraulic test bench. The test benches in this document are available through the Caterpillar Service Tool Division. Gather all necessary tooling before you need to hook up the pump. Some of the required tooling appears in a table at the end of this document. There are many possible variations of tooling that could be used. Not every possible variation can be listed.

For questions or additional information concerning this guideline, submit a feedback form in the Service Information System web site. In order to address an urgent need, use the following to relay your request to Caterpillar Repair Process Engineering:

• Cat Dealer Technical Communicator

• Dealer Solution Network

• Cat Technical Representative

• Knowledge Network (online)

Canceled Part Numbers and Replaced Part Numbers

This document does not include Canceled part numbers and replaced part numbers. Use NPR on SIS for information about Canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Safety

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Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

References

Connections for the Caterpillar Hydraulic Test Center

Illustration 1	g01095334
Connections for the Test Center (1) Flow control for discharge (2) "F3" flow meter inlet (3) "F4" flow meter inlet (4) Oil supply from the auxiliary pump (5) "F3" inlet for the flow meter with flow limiter (6) "F3"outlet for the flow meter with pressure control (7) Load sensing pressure (8) Signal pressure (9) "F4" outlet for the flow meter (10) Return to tank (11) Connections for case drain (12) Oil supply

Illustration 2	g01095335
Control and Gauges for the Test Center (13) Meter for speed and torque (14) Gauge for signal pressure (15) Control for signal pressure (16) Pressure gauge for auxiliary pump (17) Auxiliary pump flow (18) "F3" discharge pressure gauge (19) "F3" discharge flow (20) "F4" discharge pressure gauge (21) "F4" discharge flow (22) Auxiliary pump flow control (23) "F3" margin pressure (24) "F3" Load control for discharge pressure (25) "F4" Load control for discharge pressure

Connections for the Caterpillar Hydraulic Test Bench

Illustration 3	g01095336
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 4	g01095337
Connections for the Test Bench (28) "Flow meter 2" loop (29) "Flow meter 1" loop (30) "Flow meter 2" outlet (31) Signal pressure line (32) "Flow meter 2" inlet (33a) "Flow meter 1" outlet (33b) Auxiliary oil outlet (34) Auxiliary oil inlet (35) "Flow meter 1" inlet

Illustration 5	g01095341
Control and Gauges for the Test Bench (36) Auxiliary pump pressure (37) Signal pressure (38) Control for signal pressure (39) "Flow meter 1" discharge pressure (40) Control for auxiliary pump pressure (41) "Flow meter 2" discharge pressure (42) Auxiliary pump flow control (43) "Flow meter 2" discharge flow (44) Discharge flow for auxiliary pump (45) "Flow meter 1" discharge flow (46) "Flow meter 1" load control (47) Speed and direction control (48) "Flow meter 2" load control

Port Locations

Illustration 6	g01095344
Typical port locations and adjustments for the Parker Series P2 Pump. (49) Discharge port (50) Pressure port for load sensing (51) Adjustment screw for maximum angle (52) Adjustment screw for margin pressure (53) Adjustment screw for high-pressure cut (54) Case drain port (55) Gauge port for discharge pressure (56) Suction port

4C-3582 Load Sensing Valve

Illustration 7	g01209679
4C-3582 Load Sensing Valve

Illustration 8	g01209684
4C-3582 Load Sensing Valve

Illustration 9	g01209687
Schematic for 4C-3582 Load Sensing Valve (57) Outlet port (58) Adjustment for the discharge flow (59) Inlet port (60) High Pressure Port (61) Adjustment for the discharge pressure (62) Low-pressure port (63) Pressure port for load sensing

Illustration 10	g01209736
4C-3582 Load Sensing Valve and 1U-5796 Pressure Differential Gauge (57) To the flow meter on the test bench (58) Adjustment knob for discharge flow (59) From the pump discharge port (60) To the high side of the differential gauge (61) Load control for pump discharge pressure (62) To the low side of the differential gauge (63) Pressure port for load sensing (64) Pressure differential gauge group (65) To the low side of the load sensing group (66) To the high side of the load sensing valve

Pump Set Up

1. Connect a 1 inch high pressure "XT5" hose from pump discharge port (49) to inlet port (59) on the 4C-3582 Load Sensing Valve .

2. Connect a 1 inch high pressure "XT5" hose from outlet port (57) on the 4C-3582 Load Sensing Valve to the flow meter inlet on the test bench.

3. Connect a 1 inch high-pressure hose from the flow meter outlet on the test bench back to the tank.

4. Connect a 6D-7726 Hose Assembly to the pressure port for load sensing (63). Connect the other end of 6D-7726 Hose Assembly to the pressure port for load sensing (50) on the pump.

   Note: Do not use 1U-5754 Hose Assembly or 1U-5755 Hose Assembly for load sensing signal lines. The flow rate through these hoses will not compensate for the possible leakage through the control valve. Erratic readings will result.

5. Connect the 1U-5796 Pressure Differential Gauge Group (64) to the high-pressure valve port (60) and low-pressure valve port (62) on the 4C-3582 Load Sensing Valve . The port marked "hi" (66) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "hi" (60) on the 4C-3582 Load Sensing Valve . The port marked "low" (65) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "low" (62) on the 4C-3582 Load Sensing Valve .

   Note: The ports marked "low" (62) and "sense line" (63) on the 4C-3582 Load Sensing Valve are reading the same pressure.

6. Purge all air from the suction line. Loosen the suction hose at the pump until oil leaks from the connection. Tighten the suction hose.

7. Fill the pump case with oil. Pour oil directly into a case drain port until the case is full.

8. Connect an in-line flow meter to the case drain port (54). Direct the oil from the in-line flow meter back to the tank.

9. Do not rotate the pump in the wrong direction. The correct direction of rotation will be stated on the pump. The correct direction of rotation will also be in the test specifications. The direction of rotation is viewed from the input shaft end. Visually check the pump for proper rotation.

Test Procedure

Note: The steps in the procedure correlate with the steps under the test specifications according to your specific part number.

The hydraulic oil in the test bench should meet an ISO rating of 16/13. The oil in the test bench should be one of the following.

• SAE 10W at 50 °C (122 °F) or

• Mobil DTE-11 at 46 °C (115 °F)

Illustration 11	g01095388
Load sensing and high-pressure cut characteristics (P) Discharge pressure (Q) Discharge flow

1. Start rotating the pump according to the RPM in Step 1 of the test specifications. Listen for abnormal noise. Verify flow from the pump. Verify that all connections are tight. Check for leaks around shaft seals. Check for leaks around the control valve.

   Run the pump for at least 5 minutes in order to raise the temperature of the oil and purge the system of air.

2. Slowly increase the input RPM to the value in Step 2 of the test specifications. If the actual flow is less than the value in Step 2 of the test specifications, turn the adjustment screw for the maximum angle (51) counterclockwise. If the actual flow is more than the value in Step 2 of the test specifications, turn the adjustment screw for the maximum angle (51) clockwise.

   Note: If the value of the discharge flow cannot be achieved, the pump may not be mechanically feasible. Internally inspect the pump.

3. Slowly increase the input RPM to the value in Step 3. The discharge flow is adjusted by using the 4C-3582 Load Sensing Valve . To adjust the discharge flow, turn the adjustment knob (58) accordingly. Bench circuitry will be used for flow limiting when using a 1U-9400 Test Center . Decrease the discharge flow according to the values in Step 3 of the test specifications. Increase the discharge pressure according to the values in Step 3 of the test specifications. Turn the adjustment screw for the margin pressure (52) until the actual value of the margin pressure is equal to the value in Step 3 of the test specifications. The margin pressure will be displayed on the 1U-5796 Pressure Differential Gauge (64).

   Note: The margin pressure may change as discharge pressure changes. Adjust margin pressure at Step 3 within operating conditions only.

4. Slowly decrease the input RPM to the value in Step 4. Increase the pump discharge pressure to the value in Step 4 of the test specifications. Compare the actual values of the case drain with the values in Step 4 of the test specifications. This value is an indication of the efficiency. If the case drain is more than the value in Step 4 of the test specifications, the pump may not be mechanically feasible. Internally inspect the pump.

5. Increase the pump discharge pressure to the value in Step 5 of the test specifications. Turn the adjustment screw for the high pressure cut (53) until the actual high-pressure cut value is equal to the value in Step 5 of the test specifications. The discharge flow should be zero when the high-pressure cut is reached.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

Reduce RPM and all pressures to zero. Remove the component from the test bench. Drain the oil from the pump. Plug all of the ports.

Test Specifications

Test Bench Tooling