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

Asphalt Paver:

AP-1000D (S/N: EAD1-UP)

AP-1055D (S/N: FAC1-UP; A6P1-UP)

AP-655C (S/N: CDG1-UP; AYP1-UP)

AP1000E (S/N: T1F1-UP; DKH1-UP)

AP1055E (S/N: TJF1-UP; TRS1-UP)

AP500E (S/N: JWK1-UP)

AP555E (S/N: A5D1-UP)

AP600D (S/N: TFM1-UP)

AP655D (S/N: GNN1-UP; MAT1-UP; GNZ1-UP)

BG-2255C (S/N: CKR1-UP)

BG-2455D (S/N: BNW1-UP; BXW1-UP)

BG-260D (S/N: BPW1-UP)

BG1000E (S/N: RTT1-UP)

BG1055E (S/N: FRR1-UP)

BG500E (S/N: B5E1-UP)

BG555E (S/N: B5P1-UP)

Reclaimer Mixer:

RM-300 (S/N: BWR1-UP)

Introduction

© 2012 Caterpillar All Rights Reserved. This guideline is for the use of Cat 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

• Caterpillar 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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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 1	g01063311
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	g01063312
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	g01063314
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 4	g01093468
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 supply outlet (34) Auxiliary oil supply inlet (35) "Flow meter 1" inlet

Illustration 5	g01063316
Control and Gauges for the Test Bench (36) Auxiliary oil supply pressure (37) Signal pressure (38) Control for signal pressure (39) "Flow meter 1" discharge pressure (40) Control for auxiliary oil supply pressure (41) "Flow meter 2" discharge pressure (42) Auxiliary oil supply 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

This piston pump is produced with the multiple types of housings. Port locations will vary. Match the correct illustration with the pump that is being worked on.

Illustration 6	g01180973
Typical port locations, adjustments, and hydraulic schematic for the type 1 pump (49) Suction port (50) Case drain port (51) Discharge port (52) Adjustment screw for high-pressure cut (53) Gauge port for discharge pressure

Illustration 7	g01182002
Typical port locations, adjustments, and hydraulic schematic for type 2 pumps (49) Suction port (50) Case drain port (51) Discharge port (52) Adjustment screw for high-pressure cut (53) Gauge port for discharge pressure

Illustration 8	g01182003
Typical port locations, adjustments, and hydraulic schematic for type 3 pumps (49) Suction port (50) Case drain port (51) Discharge port (52) Adjustment screw for high-pressure cut (53) Gauge port for discharge pressure

Pump Setup

1. Connect the pump suction port (49) to the test bench oil reservoir. Purge all air from the suction line. Loosen the suction hose at the pump until oil leaks from the connection. Tighten the suction hose.

2. Connect the discharge port (51) to a test bench flow meter.

3. Connect the test bench flowmeter outlet to tank with aa high-pressure hose.

4. Fill the pump case with oil. Pour oil directly into a case drain port (50) until the case is full.

5. 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.

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 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. Verify the maximum displacement of the pump. Record the discharge flow.

3. Slowly increase the discharge pressure according to Step 3 of the test specifications. Measure pump efficiency. 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.

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

4. Slowly increase the pump discharge pressure to the value in Step 4 of the test specifications. The pump discharge flow should decrease to the value in Step 4 of the test specifications.

   If the discharge flow does not decrease, then turn the adjustment screw for the high pressure cut (52) until the pump destrokes.

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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