Bench Test Procedure for Hydraulic Piston Pumps {3203, 5070} Caterpillar

Paving Compactor

CB-214D (S/N: 1TZ1-UP)

CB-224D (S/N: 8RZ1-UP)

CB-225D (S/N: 9FZ1-UP)

CB-334D (S/N: DCZ1-UP; 3JZ1-UP; 4CZ1-UP)

CB-335D (S/N: D4E1-UP; BBW1-UP; 5PZ1-UP)

CB-335E (S/N: C5F1-UP; C5J1-UP)

Vibratory Soil Compactor

CB-334E (S/N: C4F1-UP; C4J1-UP; C4X1-UP)

CP-433E (S/N: CYE1-UP; CFK1-UP; ASN1-UP; BTY1-UP)

CP44 (S/N: MPC1-UP; M4P1-UP)

CS-423E (S/N: EAE1-UP)

CS-433E (S/N: MC21-UP; DAC1-UP; CFP1-UP; ASR1-UP; BTT1-UP)

CS433E (S/N: BWG1-UP; ASH1-UP; DCL1-UP; AST1-UP; CFX1-UP)

CS44 (S/N: M4C1-UP; M4S1-UP)

Introduction

© 2018 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 may be violation of intellectual property law. Information contained within this document is considered Caterpillar: Confidential Yellow

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 website. In order to address an urgent need, use the following to relay your request to Caterpillar Repair Process Engineering:

• Cat Dealer Technical Communicator

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Canceled Part Numbers and Replaced Part Numbers

This document may not include all 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

Illustration 1	g02139237

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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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Pump test pressures in this guideline may exceed the normal operating range of the hydraulic test hoses utilized when connecting the tested pump to the test bench. However, the order of magnitude of these pressures is significantly below the burst strength of the Caterpillar "XT6" product. High pressure oil can escape through improperly assembled hoses and fittings. High pressure oil can also escape through poorly maintained hoses and fittings. High pressure oil may also leak through hose that has become damaged over the life of the hose due to the pressure levels that occur during test bench operation. Personal injury or death can result from improper hose & fitting inspection or improper hose replacement procedures. Escaping fluid under pressure can penetrate body tissue causing serious injury, and possible death. Thoroughly inspect all testing hoses, fittings, and quick disconnects prior to any testing operation. Check the assembly date tag or hose assembly log date for a hose life indicator. Replace all Test Bench hoses at a minimum of every 2 years or earlier if the hose or fittings appear to be damaged.

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

Summary

This procedure is specific to the type of pump and the type of control. Refer to the test specifications and the tooling at the end of this document.

Note: A paper copy of this document may not be the latest version. Go to the Service Information System (SIS) in order to view the latest version.

References

Connections for the Caterpillar Hydraulic Test Center

Illustration 2	g01096874
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 3	g01096875
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 4	g01096876
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 5	g01096884
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 pump oil supply outlet (34) Auxiliary pump oil supply inlet (35) "Flow meter 1" inlet

Illustration 6	g01096885
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 7	g01147923
Typical port locations. (49) Manual displacement lever (50) Gauge Port for the Servo (51) Adjustment for pump neutral (52) Charge Pump Discharge (53) Gauge port for charge pressure (54) Charge pump suction port (55) Charge pump inlet port (56) Charge relief valve adjustment (57) Case drain (58) Discharge port (59) Discharge gauge port (60) Discharge port (61) Adjustment for control neutral

9U-5902 Rectifier Block

Illustration 8	g01096892
9U-5902 Rectifier Block Connections

Illustration 9	g01210239
9U-5902 Rectifier Block Schematic (62) High-pressure port "from pump discharge" (63) Outlet "to flow meter loop" (64) High-pressure port"from pump discharge" (65) Low-pressure return "from heat exchanger"

9U-5893 Heat Exchanger

Illustration 10	g01096895
9U-5893 Heat Exchanger Connections (66) Inlet "from flow meter loop" (67) Outlet "to rectifier block" (68) Water inlet (69) Water outlet

Pump Setup

1. Mount the pump with a case drain port (57) upward.

   Note: Step 2 is only to be used with tandem pumps.

2. Tandem pumps will require the discharge ports (58) and (60) that are not being tested to be connected to each other in order to isolate the rear pump. The rear pump will not be tested. Tandem pumps will also require the brake interlock valve supply port to be plugged. The brake interlock valve will require current in all the steps of the procedure according to the Test Specifications.

3. Connect pump discharge ports (58) and (60) to the 9U-5902 Rectifier Block high-pressure ports (62) and (64).

4. Connect the 9U-5902 Rectifier Block outlet (63) to the flow meter inlet of the test bench.

5. Connect the "flow meter outlet" to the 9U-5398 Heat Exchanger inlet (66).

6. Connect the 9U-5398 Heat Exchanger outlet (67) to the low-pressure return (65) on the 9U-5902 Rectifier Block.

7. Connect gauge port for charge pressure (53) to test bench. Connect charge pump suction port (54) to the test bench oil supply. Connect the charge pump discharge port (52) to the charge inlet port (55). Pumps without an internal charge pump will require an auxiliary oil supply. Connect the auxiliary oil supply to the charge inlet port (55).

8. Connect an in-line flow meter to the case drain port (57).

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

10. Fill the pump case with oil. Pour oil directly into a case drain port (57) until the case is full.

11. 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.

Pump Neutral Adjustment

1. Connect a hose between the gauge ports for the servo (50) in order to equalize the pressure on each side of the servo. Connect two 8T-0860 Pressure Gauges into the gauge ports for system pressure (59).

2. Slowly increase the input RPM to the value in Step 1 of the test specifications. Increase the discharge pressure. Loosen the locknut on adjustment screw (51) in order to adjust the pump neutral setting. Turn the set screw (51) until the gauge readings are equal. Turn the set screw (51) clockwise until there is a pressure increase in one of the pressure gauges. Record the position of the wrench.

3. Turn the set screw (51) counterclockwise until there is a pressure increase on the other pressure gauge. Record the position of the wrench. Turn the set screw (51) clockwise to the halfway point between the two previous points. Tighten locknut on adjustment screw (51).

4. Reduce discharge pressure and input RPM to zero.

Pump Control Neutral Adjustment

1. Connect two 8T-0860 Pressure Gauges into the gauge ports (50) of the servo.

2. Slowly increase the input RPM to the value in Step 1 of the test specifications. Increase the discharge pressure. Loosen the locknut on adjustment screw (61) in order to adjust the pump control neutral setting. Turn the set screw (61) until the gauges are equal. Turn the set screw (61) clockwise until there is a pressure increase in one of the pressure gauges. Record the position of the wrench.

3. Turn the set screw (61) counterclockwise until there is a pressure increase on the other pressure gauge. Record the position of the wrench at the point. Turn the set screw (61) clockwise to the halfway point between the two previous points. Tighten locknut on adjustment screw (61).

Test Procedure

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

The contamination level of the hydraulic oil in the test bench should be ISO 16/13 or better. 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)

1. Start rotating the pump according to Step 1 of the test specifications. Listen for abnormal noise. Verify flow from the charge pump. Verify that all connections are tight. Check for leaks around shaft seals. Check for leaks around the control valves. Check the gauge port for the charge pressure (53). Compare the charge pressure with the value in Step 1 of the test specifications. If the charge pressure is not within the test specifications, adjust accordingly. Turn the adjustment screw for charge pressure (56) clockwise in order to increase the pressure. Turn the adjustment screw for the charge pressure (56) counterclockwise in order to decrease the pressure.

2. Slowly shift the manual displacement lever (49) in one direction and increase the input RPM according to Step 2 of the test specifications. Slowly increase the discharge pressure according to Step 2 of the test specifications. If the actual flow is less than the value in Step 2 of the test specifications, the pump may not be mechanically feasible. Internally inspect the pump.

3. Slowly increase the pump discharge pressure to the value in Step 3 of the test specifications. Measure pump leakage. Calculate the total loss. If the total loss is higher than the allowable value in Step 3 of the test specifications, The pump may not be mechanically feasible.

   Subtract the discharge flow in Step 3 from Step 2. The result is your total loss.

   Example "Step 2 flow" 162 L/min (42.8 US gpm) - "Step 3 flow" 158 L/min (41.7 US gpm) = "total loss" 4 L/min (1.1 US gpm). The "max. allowable loss" is 7.2 L/min (1.9 US gpm).

   The pump in the example is acceptable because the actual total loss is less than the maximum allowable loss.

   Remove all the pressures. Shift the manual displacement lever in the other direction and repeat Steps 1 through 3.

   Tandem pumps will require Steps 1 through 3 to be repeated. Test the pump that was previously isolated.

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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 bench. Drain the oil from the pump. Plug all of the ports.

Test Specifications

Test Bench Tooling