- Excavator
- 320 (S/N: BR61-UP; EBB1-UP; DJH1-UP; ZBN1-UP; YBP1-UP; YCP1-UP; HEX1-UP)
- 320 GC (S/N: BR41-UP; DKJ1-UP; XBJ1-UP; KTN1-UP; ZBT1-UP)
- 323 (S/N: BR91-UP; DWF1-UP; ZBK1-UP; YBL1-UP; RAZ1-UP)
- 320 GC (S/N: BR41-UP; DKJ1-UP; XBJ1-UP; KTN1-UP; ZBT1-UP)
Introduction
Revision | Summary of Changes in M0081456 |
04 | Updated effectivity |
03 | Updated effectivity |
02 | Updated effectivity |
01 | Added part numbers 531-9885 Pump Gp and 531-9886 Pump Gp to document. |
© 2018 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 may 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 questions or additional information concerning this guideline, submit a feedback form in the Service Information System website. 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
Illustration 1 | g02139237 |
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. |
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. |
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
References | |
---|---|
Media Number | Title |
REHS1761 | "Required Tooling for Bench Testing Hydraulic Components" |
, SEBF8810 | "Hydraulic Pump, Motor, and Cylinder Bench Test Procedure Reference Manual" |
, SEHS8892 | "Operating Instructions for Caterpillar 1U-9400 Series Hydraulic Test Center" |
, NEHS0563 | "Tool Operating Manual for 9U-5000 Series Hydraulic Test Bench" |
Connections for the Caterpillar Hydraulic Test Center
Illustration 2 | g01178572 |
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 | g01178573 |
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 | g01178574 |
Connections for the test bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil supply |
Illustration 5 | g01178575 |
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 | g01178576 |
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) Control for the auxiliary oil supply (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 |
Pump Illustrations
Illustration 7 | g06184598 |
Port locations (49) Case drain port (50) Adjustment screw for min displacement setting on rear pump (if equipped) (51) Electrical connector for control solenoid of front pump (52) Electrical connector for control solenoid of rear pump (53) Discharge port for rear pump (54) Discharge port for front pump (55) Adjustment screw for min displacement setting on front pump (if equipped) (56) Adjustment screw for control of front pump (57) Suction port (58) Gauge port for discharge pressure of front pump (59) Alternate gauge port for discharge pressure of front pump (60) Gauge port for discharge pressure of rear pump (61) Case drain port (62) Adjustment screw for control of rear pump (63) Adjustment screw for max displacement setting on rear pump (64) Gauge port for destroking pressure of rear pump (65) Gauge port for destroking pressure of front pump (66) Adjustment screw for max displacement setting on front pump |
Illustration 8 | g06192097 |
Hydraulic schematic (49) Case drain port (50) Adjustment screw for min displacement setting on rear pump (if equipped) (51) Electrical connector for control solenoid of front pump (52) Electrical connector for control solenoid of rear pump (53) Discharge port for rear pump (54) Discharge port for front pump (55) Adjustment screw for min displacement setting on front pump (if equipped) (56) Adjustment screw for control of front pump (57) Suction port (58) Gauge port for discharge pressure of front pump (60) Gauge port for discharge pressure of rear pump (61) Case drain port (62) Adjustment screw for control of rear pump (63) Adjustment screw for max displacement setting on rear pump (64) Gauge port for destroking pressure of rear pump (65) Gauge port for destroking pressure of front pump (66) Adjustment screw for max displacement setting on front pump |
Pump Setup
- Mount the pump with case drain port (61) upward.
- Connect a suction hose from the test bench oil supply to suction port (57).
- Connect a 1 inch high pressure "XT6" hose from the pump discharge port (53) to a flow meter inlet on the test bench. Connect a 1 inch high pressure "XT6" hose from the flow meter outlet to the test bench reservoir.
- Connect a 1 inch high pressure "XT6" hose from the pump discharge port (54) to a flow meter inlet on the test bench. Connect a 1 inch high pressure "XT6" hose from the flow meter outlet to the test bench reservoir.
- Fill the pump case with oil. Pour oil directly into case drain port (61) until the case is full.
- Purge all air from the suction line. Carefully loosen the suction hose at the pump until oil leaks from the connection. Tighten the suction hose.
- Install flow meter to case drain port (61). Route the flow meter discharge back to tank.
- Connect an electrical power supply to the electrical connector for pump controls (51) and (52)
Test Procedure
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)
Test one pump at a time and leave the other in stand-by. Due to the function of the electronic control solenoid, the pumps will be in stand-by naturally until a signal current is applied. After testing one pump repeat the steps of the test procedure for the other pump.
- This step will verify proper pump assembly.
- Start rotating the pump according to Step 1 of the"Test Specifications".
Listen for abnormal noise. Verify that all the connections are not leaking. Check for leaks around the shaft seals and control valves.
- This step will verify the minimum displacement setting of the pump.
- Slowly increase the input speed according to Step 2 of the"Test Specifications".
- Increase pump discharge pressure to the value in Step 2.
At this step, the pump should produce minimum flow. Verify that the discharge flow is at minimum. If the pump discharge flow is not equal to the value given in the "Test Specifications", adjust the screw for minimum displacement (55) or (50) if equipped until the flow is within specification.
- This step will verify the start of the electronic control range.
- Slowly increase solenoid current to the electrical connector (51) or (52).
At this point, the pump should be on the verge of upstroke. Discharge flow may not be noticeable at this point.
- This step will verify the maximum displacement setting of the pump.
- Increase solenoid current to the value in Step 4 of the"Test Specifications".
At this step, the pump should produce maximum flow. Verify that the discharge flow is at maximum. If the pump discharge flow is not equal to the value given in the "Test Specifications", adjust the screw for maximum displacement (66) or (63) until the flow is within specification.
- This step will verify the volumetric efficiency of the pump.
- Slowly increase pump discharge pressure to the value given in Step 5 of the"Test Specifications".
Compare the actual value from the case drain with the values in Step 5 of the"Test Specifications". This value is an indication of pump efficiency. If the case drain is more than the value given in Step 5 of the "Test Specifications", the pump may not be mechanically feasible and should be internally inspected.
Once one pump has been tested, put it in standby by reducing solenoid current to 0 and discharge pressure to 0. Then repeat steps 1 through 5 for the second pump.
Once both pumps have been tested:
- Reduce electrical current to zero.
- Reduce discharge pressure to zero.
- Reduce input speed to zero.
- Allow the component to cool.
- Remove the component from the test bench mount.
- Drain the component of oil.
- Cap or plug all open ports.
Test Specifications
Part Number | ________________________________ |
||||
Pump Rotation | ________________________________ |
||||
Step | 1 | 2 | 3 | 4 | 5 |
Input Speed RPM | ____________ |
____________ |
____________ |
____________ |
____________ |
Discharge Flow lpm (gpm) | ____________ |
____________ |
- | ____________ |
____________ |
Discharge Pressure kPa (psi) | ____________ |
____________ |
____________ |
____________ |
____________ |
Solenoid Current mA | ____________ |
____________ |
____________ |
____________ |
____________ |
Max Case Drain Flow lpm (gpm) | - | - | - | - | ____________ |
Part Number | |||||
Pump Rotation | Clockwise | ||||
Step | 1 | 2 | 3 | 4 | 5 |
Input Speed RPM | 600 rpm | 1200 rpm | 1200 rpm | 1200 rpm | 1200 rpm |
Discharge Flow lpm (gpm) | 0 | 0(1) | - | |
|
Discharge Pressure kPa (psi) | 0 | |
|
|
|
Solenoid Current mA | 0 | 0 | 400 mA | 1700 mA | 1700 mA |
Max Case Drain Flow lpm (gpm) | - | - | - | - | |
(1) | This pump is not equipped with adjustment screws for minimum displacement (50) and (55). |
Part Number | |||||
Pump Rotation | Clockwise | ||||
Step | 1 | 2 | 3 | 4 | 5 |
Input Speed RPM | 600 rpm | 1200 rpm | 1200 rpm | 1200 rpm | 1200 rpm |
Discharge Flow lpm (gpm) | 0 | 0(1) | - | |
|
Discharge Pressure kPa (psi) | 0 | |
|
|
|
Solenoid Current mA | 0 | 0 | 400 mA | 1700 mA | 1700 mA |
Max Case Drain Flow lpm (gpm) | - | - | - | - | |
(1) | This pump is not equipped with adjustment screws for minimum displacement (50) and (55). |
Part Number | |||||
Pump Rotation | Clockwise | ||||
Step | 1 | 2 | 3 | 4 | 5 |
Input Speed RPM | 600 rpm | 1200 rpm | 1200 rpm | 1200 rpm | 1200 rpm |
Discharge Flow lpm (gpm) | 0 | 0(1) | - | |
|
Discharge Pressure kPa (psi) | 0 | |
|
|
|
Solenoid Current mA | 0 | 0 | 400 mA | 1700 mA | 1700 mA |
Max Case Drain Flow lpm (gpm) | - | - | - | - | |
(1) | This pump is not equipped with adjustment screws for minimum displacement (50) and (55). |
Part Number | |||||
Pump Rotation | Clockwise | ||||
Step | 1 | 2 | 3 | 4 | 5 |
Input Speed RPM | 600 rpm | 1200 rpm | 1200 rpm | 1200 rpm | 1200 rpm |
Discharge Flow lpm (gpm) | 0 | 0(1) | - | |
|
Discharge Pressure kPa (psi) | 0 | |
|
|
|
Solenoid Current mA | 0 | 0 | 400 mA | 1700 mA | 1700 mA |
Max Case Drain Flow lpm (gpm) | - | - | - | - | |
(1) | This pump is not equipped with adjustment screws for minimum displacement (50) and (55). |
Tooling
Tooling | ||||||
Part Number | Adapter Plate | Drive Adapter | Suction Adapter | Flange Adapter | Split Flange | Case Drain Port Adapter |
1 1/16-12 STOR | ||||||
1 1/16-12 STOR | ||||||
1 1/16-12 STOR | ||||||
1 1/16-12 STOR |