Bench Test Procedure for Hydraulic Piston Pumps {0784, 5070} Caterpillar

Asphalt Paver

AP1000E (S/N: T1F1-UP)

AP1055E (S/N: TJF1-UP)

AP555F (S/N: M451-UP; RBM1-UP)

AP600F (S/N: AP61-UP; LR61-UP)

AP655F (S/N: 4801-UP; 4521-UP; 4531-UP; P651-UP; 6551-UP; MH61-UP; ML61-UP; 4791-UP)

AP655F L (S/N: AC61-UP)

BG1000E (S/N: RTT1-UP)

BG1055E (S/N: FRR1-UP)

BG500E (S/N: B5E1-UP)

BG555E (S/N: B5P1-UP)

Hydraulic Shovel

6020B (S/N: D4R1-UP; DNR1-UP; D4Y1-UP; DNY1-UP)

6040 (S/N: DHJ1-UP)

6040 FS (S/N: DHX1-UP)

Mini Hydraulic Excavator

307.5 (S/N: GW71-UP)

308 (S/N: GG81-UP; GK81-UP; GW81-UP; GX81-UP)

308.5 (S/N: GZ81-UP)

309 (S/N: GG91-UP; GW91-UP)

310 (S/N: GWT1-UP)

Wheel Loader

966M Series XE (S/N: P6C1-UP; B8P1-UP)

972M Series XE (S/N: M5S1-UP; EDW1-UP)

Introduction

© 2017 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. Information contained in 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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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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) to view the latest version.

References

Connections for the Caterpillar Hydraulic Test Center

Illustration 2	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 3	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 4	g01063314
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 5	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 6	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

Illustration 7	g02149881
Port locations, adjustments, and hydraulic schematic. (49) "L1" Case drain (50) "L" Case drain (51) Solenoid valve (52) "B" Discharge port (53) Standby pressure adjustment screw (54) high-pressure cut adjustment screw (55) "S" Suction port (56) "L2" Case drain (57) "MB" Gauge port discharge pressure

Pump Setup

Note: A power supply will be required to operate the solenoid on this pump. The power supply must deliver 0 mA to 660 mA with an infinite setting in that range.

1. Mount the pump with the control on top. Connect the oil supply suction hose to suction port (55).

2. Connect one end of a high-pressure "XT6" hose to discharge port (52). Connect the other end of the high-pressure "XT6" hose to the flow meter inlet on the test bench.

3. Connect one end of a high-pressure "XT6" hose to the flow meter outlet on the test bench. Connect the other end of the high-pressure "XT6" hose to the tank.

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

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

6. Connect an in-line flow meter to case drain port (50). Direct the oil from the in-line flow meter back to the tank.

7. Connect a 8T-0855 Pressure Gauge to gauge port (57). Be sure to remove the gauge prior to testing the high-pressure cut to avoid damage to the gauge.

8. Connect a power supply to the electrical connector for solenoid valve (51) to operate the solenoid valve.

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

Test Procedure

Note: The steps in the procedure correlate with the steps in 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)

1. Start rotating the pump according to the RPM in Step 1 of the test specifications. Increase the signal current to solenoid valve (51) to the value in Step 1 of the test specifications. Increase the discharge pressure according to Step 1 of the test specifications. Listen for abnormal noise. Verify flow from the pump. Verify that all the connections are not leaking. Check for leaks around shaft seals and control valves.

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

2. Slowly increase the pump RPM according to Step 2 of the test specifications. Keep the signal current at the value in Step 2 of the test specifications. Keep the discharge pressure at the value in Step 2 of the test specifications. Verify that the discharge flow matches the value in Step 2 of the test specifications. The pump may not be mechanically feasible if the discharge flow values do not match.

3. Step 3 of the test specifications will check the standby pressure setting. Reduce the discharge pressure to the value in Step 3 of the test specifications. Keep the signal current at the value in Step 3 of the test specifications to ensure the pump is at maximum displacement. The case drain and the discharge flow should be the values in Step 3 of the test specifications. Slowly increase the discharge pressure until the discharge flow quickly rises and the case drain flow stops. This setting is the pressure at which the standby pressure is set. If the value of the standby pressure is different than the value in Step 3 of the test specifications, the standby pressure must be adjusted. To increase the standby pressure, turn adjustment screw (53) clockwise. To decrease the standby pressure, turn adjustment screw (53) counterclockwise.

   Note: Before adjusting the standby pressure, reduce the discharge pressure completely. Make the adjustment. Slowly increase the discharge pressure while watching the 8T-0855 Pressure Gauge closely. Do this step each time any standby pressure adjustments are made.

   Note: Before proceeding to Step 4, do the following in order. Set the signal current to the value in Step 3 of the test specifications. Set the discharge pressure to the value in Step 4 of the test specifications to ensure that the pump has sufficient control pressure. Leave the load control in this position during Step 4. Now decrease the signal current to 0 mA. The discharge flow should be 0 L/min (0 US gpm).

4. Be sure to follow the above note before proceeding. Increase the input current to the value in Step 4 of the test specifications. Keep the load control in the same position. This amperage is the starting point of upstroke for the pump.

   Note: Some flow meters may not be able to read discharge flows at this level. If the flow meter does not register the flow, slowly increase the signal current to a value that is higher than the value in Step 4 of the test specifications . Continue increasing the signal current until the flow begins to register. When flow is detected, the discharge pressure should be approximately the value in Step 4 of the test specifications.

5. Increase the signal current to the value in Step 5 of the test specifications. The pump or the control for the proportional solenoid valve (51) may not be mechanically feasible if the actual discharge flow is not equal to the value in Step 5 of the test specifications.

6. Increase the signal current to the value in Step 7 of the test specifications. The pump should be at maximum displacement. The pump or the control for the proportional solenoid valve (51) may not be mechanically feasible if the actual discharge flow is not equal to the value in Step 7 of the test specifications. Any increase in signal current above the value in Step 7 of the test specifications should not increase pump flow.

   Note: Reduce discharge pressure and remove the 8T-0855 Pressure Gauge before proceeding to avoid damage to the gauge.

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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.

7. Increase the signal current to the value in Step 7 of the test specifications. Increase the pump discharge pressure to the value in Step 7 of the test specifications. Measure the case drain using the in-line flow meter. The pump may not be mechanically feasible if the total loss is higher than the allowable value in Step 7 of the test specifications.

8. This step will test the high-pressure cut. Increase the discharge pressure to the value in Step 8 of the test specifications. Turn adjustment screw for the high-pressure cut (54) until the actual high-pressure cut value is equal to the value in Step 8 of the test specifications. Turn adjustment screw for the high-pressure cut (54) clockwise to increase the high-pressure cut. Turn adjustment screw for the high-pressure cut (54) counterclockwise to decrease the high-pressure cut. The pump 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 all pressures, amperage, and RPM to zero.

Test Specifications

Tooling