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

Paving Compactor

CP-533F (S/N: C5Z1-UP)

CS-533F (S/N: C5X1-UP)

Vibratory Soil Compactor

CP-533E (S/N: BZG1-UP; TLH1-UP; ASM1-UP; DAM1-UP)

CP54 (S/N: C5Y1-UP)

CS-533E (S/N: BZE1-UP; TBE1-UP; DAK1-UP; ASL1-UP)

CS10 (S/N: T8F1-UP)

CS11 (S/N: RK81-UP)

CS12 (S/N: GCS1-UP)

CS54 (S/N: C5R1-UP; C5W1-UP)

Vibratory Utility Compactor

CB22B (S/N: 4191-UP)

CB24B (S/N: 4201-UP)

CB32B (S/N: 4221-UP)

CB34B (S/N: 4231-UP)

CB34B XW (S/N: 4251-UP)

CC24B (S/N: 4211-UP)

CC34B (S/N: 3241-UP)

Introduction

© 2019 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.

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

• Dealer Solution Network

• Cat Technical Representative

• Knowledge Network (online)

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

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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.

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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.

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 1	g01088926
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	g01088929
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	g01088930
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 4	g01088934
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 (33) "Flow meter 1" inlet (34) Auxiliary pump oil supply (35) "Flow meter 1" inlet

Illustration 5	g01088935
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	g01415991
Typical port locations and adjustments (49) Pressure override valve (50) Mechanical displacement lever (51) Adjustment screw for the Hydraulic Zero (52) Gauge ports for stroking pressure (53) Air purge port (54) Adjustment screws for mechanical stroke limiter (55) Case drain ports (56) Adjustment screw for high pressure cut out (57) Discharge ports (58) Inlet port for charge pressure (59) Adjustment screw for mechanical zero (60) Gauge ports for discharge pressure (61) Gauge port for charge pressure (62) Connector for the electric solenoid (63) Adjustment for charge pressure (64) Gauge port for brake release pressure

Illustration 7	g01414480
Hydraulic Schematic (52) Gauge ports for stroking pressure (55) Case drain ports (56) Adjustment screw for high pressure cut out (57) Discharge ports (58) Inlet port for charge pressure (60) Gauge ports for discharge pressure (61) Gauge port for charge pressure (63) Adjustment for charge pressure (64) Gauge port for brake release pressure

9U-5902 Rectifier Block

Illustration 8	g01416529
9U-5902 Rectifier Block Connections

Illustration 9	g01416530
9U-5902 Rectifier Block Schematic (65) High-pressure port "from pump discharge" (66) Outlet "to flow meter loop" (67) High-pressure port"from pump discharge" (68) Low-pressure return "from heat exchanger"

9U-5893 Heat Exchanger

Illustration 10	g01416528
9U-5893 Heat Exchanger Connections (69) Inlet "from flow meter loop" (70) Outlet "to rectifier block" (71) Water inlet (72) Water outlet

198-4240 Electric Pressure Gauge Group

Illustration 11	g01416532
198-4240 Electric Pressure Gauge Group (73) Pressure gauge (74) Red Transducer 34500 kPa (5000 psi) (75) Blue Transducer 3450 kPa (500 psi)

Note: Accuracy for mechanical and hydraulic zero position is crucial. The use of the 198-4240 Electric Pressure Gauge Group is Highly recommended.

Pump Setup

1. Mount the pump with a case drain port (55a) or (55b) facing upward.

2. Connect an auxiliary oil supply to the inlet port for charge pressure (58).

3. Connect the discharge ports (57a) and (57b) to the high-pressure ports (65) and (67) on the 9U-5902 Rectifier Block.

4. Connect the outlet port (66) on the rectifier block to an inlet port on a flow meter.

5. Connect the outlet port on the flow meter to the inlet port (69) on the 9U-5893 Heat Exchanger.

6. Connect the outlet port (70) on the heat exchanger to the inlet port (68) on the rectifier block. Connect the water inlet port (71) and the water outlet port (72) to a water supply.

7. Vent air purge port (53) to atmosphere

8. Fill the pump case with oil before rotating. Pour oil directly into a case drain port (55a) or (55b) until the case is full. Plug air purge port (53) once case is full.

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

Adjustment for Mechanical Zero Position

Note: Before performing the adjustment for the mechanical zero the pump must be mechanically sound. Start rotating the pump according to step 1 of the test specifications. Verify that all connections are tight. Listen for abnormal noise. Check for leaks around shaft seals. Check for leaks around the control valves. For pumps not equipped with a charge pump, be sure to sustain charge pump flow to port (58) in Step 1 through 4 on the mechanical zero adjustment.

1. Turn the load control on the test bench clockwise in order to control the pump discharge pressure. Start rotating the pump at the value in Step 1 of the test specifications. This unit is not equipped with a charge pump. Be sure to sustain charge pump flow to port (58) in Steps 1 through 4 of the mechanical zero adjustment. Vent the ports for the stroking pressure (52a) and (52b) to the atmosphere. This will equalize the pressure on the servo spool. If the mechanical zero adjustment is incorrect, a discharge pressure higher than the charge pressure may occur.

2. Turn the adjustment screw for the mechanical centering (59) clockwise. Continue to turn until a pressure of 1400 kPa (200 psi) above charge pressure is achieved. This pressure may be seen on the gauge for the system pressure B (60a) or gauge port for system pressure A (60b). Mark the position for the adjustment screw for the mechanical centering (59).

3. Turn adjustment screw for the mechanical centering (59) counterclockwise until pressure increases on gauge ports (60a) or (60b). Mark the position for the adjustment screw for the mechanical centering (59).

4. A mark should be placed halfway between position one and position two. Turn the adjustment for the mechanical centering (59) to the midpoint of both marks. There should be less than a 34.5 kPa (5 psi) pressure differential between gauge ports (60a) and (60b).

5. Stop rotating the pump. Turn the load control on the test for pump discharge pressure counterclockwise. Allow the discharge pressure of the pump to decrease. Disconnect pressure gauges from ports (60a) and (60b).

Adjustment for Hydraulic Zero Position

1. Connect two blue transducers 3450 kPa (500 psi) or connect two 6000 kPa (870 psi) 8T-0856 Pressure Gauges into both gauge ports for stroking pressure (52a) and (52b).

2. Start rotating the pump to the value listed in Step 1 of the test specifications. Turn the load control for the pump discharge pressure clockwise. This will allow pump discharge pressure to increase in the following steps.

3. Adjust the adjustment screw for hydraulic zero (51) until the pressure at the gauge ports for the stroking pressure (52a) and (52b) differ by less that 21 kPa (3 psi).

   Note: Do not turn the adjustment screw for hydraulic zero (51) more than 90 degrees in either direction.

4. Turn the load control for the pump discharge pressure counterclockwise. This will allow pump discharge pressure to decrease. Stop rotating the pump and allow pump pressure to dissipate. Disconnect the pressure gauges that are connected to the gauge ports for stroking pressure (52a) and (52b).

Test Procedure

The hydraulic oil in the test bench should meet an ISO rating of 16/13 or cleaner. 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. Slowly apply auxiliary flow to the inlet port for charge pressure (58) according to Step 1 of the test specifications. Check the gauge port for charge pressure (61). 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. In order to adjust the charge pressure, shims must be added or removed to the charge relief valve (63). 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 apply current to the electrical connector for solenoid (62) and increase the input RPM according to Step 2 of the test specifications. Shift the mechanical displacement lever (50) fully in either direction in order to acquire pump flow.

3. Slowly adjust the input RPM and discharge pressure to the values in Step 3 of the test specifications. Verify that the main discharge flow is within specifications. If the values are not within specifications, adjust the adjustment screws for maximum displacement (54a) or (54b). Adjust the appropriate setscrew clockwise in order to decrease flow. Adjust the appropriate setscrew counterclockwise in order to increase flow.

   Shift the mechanical displacement lever (50) in the opposite directions and repeat Step 3 of the test specifications.

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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 during adjustment of the high pressure relief valve if recommended hose maintenance practices are not followed. Escaping fluid under pressure can penetrate body tissue causing serious injury, and possible death. Adjustment of the high pressure cut or pressure override valve shall only be performed when the pump is operating at a zero discharge pressure condition. Continuation of the pump test procedure can be resumed when this high pressure adjustment is completed.

4. Increase the discharge pressure to the value in Step 4 of the test specifications. Turn the adjustment screw for the high pressure cut out (56) until the actual high pressure cut out value is equal to the value in Step 4 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.

Test Specifications

Test Bench Tooling