Bench Test Procedure for Hydraulic Piston Pumps {5070} Caterpillar


Bench Test Procedure for Hydraulic Piston Pumps {5070}

Usage:

336 DKS
Excavator
330 (S/N: WCH1-UP; KEL1-UP; PFN1-UP; LHW1-UP)
330 GC (S/N: NDH1-UP; FEK1-UP; GDW1-UP)
336 (S/N: SP91-UP; JHD1-UP; TPK1-UP; FEL1-UP; YBN1-UP; DKS1-UP; ZBS1-UP; GDY1-UP; HBY1-UP)
336 GC (S/N: GSF1-UP; EBJ1-UP; HFJ1-UP; JFW1-UP)
340 (S/N: TYH1-UP; TMK1-UP; WDN1-UP; SZT1-UP)
345 GC (S/N: KEF1-UP)
349 (S/N: LKG1-UP; RYG1-UP; RBY1-UP)
352 (S/N: MGR1-UP; KZY1-UP)

Introduction

Table 1
Revision  Summary of Changes in M0094263 
04  Updated Effectivity. 
03  Updated effectivity and pump 566-8632 Piston Pump Gp to the document. 
02  Updated Effectivity. 
01  Updated Effectivity. 
00  New document. 

© 2019 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 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 1g02139237

------ WARNING! ------

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.


------ WARNING! ------

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


------ WARNING! ------

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

Table 2
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 2g01063311
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 3g01063312
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 4g01063314
Connections for the Test Bench
(26) "Flow meter 1" loop and "Flow meter 2" loop
(27) Oil Supply


Illustration 5g01093468
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 6g01063316
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

Pump Illustrations



Illustration 7g06312013
Port locations and adjustments
(49) Minimum displacement adjustment screw for front pump
(50) Case drain port
(51) Adjustment screw for rear pump control
(52) Suction port
(53) Pilot pressure port
(54) Gauge port for case drain
(55) Case drain port
(56) Gauge port for discharge pressure for rear pump
(57) Gauge port for discharge pressure for rear pump
(58) Discharge port for rear pump
(59) Discharge port for front pump
(60) Gauge port for discharge pressure for front pump
(61) Gauge port for discharge pressure for front pump
(62) Minimum displacement adjustment screw for rear pump
(63) Gauge port for control pressure for rear pump
(64) Electrical connector for rear pump solenoid
(65) Maximum displacement adjustment screw for rear pump
(66) Maximum displacement adjustment screw for front pump
(67) Adjustment screw for front pump control
(68) Electrical connector for front pump solenoid
(69) Gauge port for control pressure for front pump
(70) Gauge port for case drain
(71) Case drain port
(72) Case drain port


Illustration 8g06312090
Port locations and adjustments
(50) Case drain port
(51) Adjustment screw for rear pump control
(52) Suction port
(53) Pilot pressure port
(54) Gauge port for case drain
(55) Case drain port
(56) Gauge port for discharge pressure for rear pump
(57) Gauge port for discharge pressure for rear pump
(58) Discharge port for rear pump
(59) Discharge port for front pump
(60) Gauge port for discharge pressure for front pump
(61) Gauge port for discharge pressure for front pump
(63) Gauge port for control pressure for rear pump
(64) Electrical connector for rear pump solenoid
(67) Adjustment screw for front pump control
(68) Electrical connector for front pump solenoid
(69) Gauge port for control pressure for front pump
(70) Gauge port for case drain
(71) Case drain port
(72) Case drain port

Pump Setup

  1. Mount the pump with discharge ports (58) and (59) facing downward.

  2. Connect a suction hose from the test bench oil supply to suction port (52) on the pump.

  3. Connect a 1 inch high pressure "XT6" hose from the pump discharge port (58) 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.

  4. Connect a 1 inch high pressure "XT6" hose from the pump discharge port (59) 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.

  5. Connect a 6D-7726 Hose As from an auxiliary pressure supply on the test bench to pilot pressure port (53).

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

  7. Install flow meter to case drain port (72). Route the flow meter discharge back to tank.

  8. 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.

  9. Connect an electrical power supply to the electrical connector for pump control solenoids (64) and (68)

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)

Only test one pump at a time. Perform Steps 1 through 4 for one pump and then repeat Steps 2 through 4 for the other pump.

  1. This step will validate the pump rebuild.

    Start rotating the pump according to Step 1 of the Test Specifications. Listen for abnormal noise. 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 to raise the temperature of the oil and purge the system of air.

  2. This step will verify the minimum displacement setting of the pump.

    Slowly increase input speed to the value in Step 2 of the Test Specifications. Verify the discharge flow is at minimum according to Step 2 of the Test Specifications. If the discharge flow is not within specification, turn the adjustment screw for minimum displacement (49) or (62) until the discharge flow is within specification.

  3. This step will verify operation of the pump control valve, solenoid, and maximum displacement setting of the pump.

    Slowly increase pilot pressure to the pilot pressure port (53) according to Step 3 of the Test Specifications. Slowly increase control current to the electrical connector for pump solenoid (64) or (68) according to Step 3 of the Test Specifications. Discharge flow should increase to the value in Step 3 of the Test Specifications. If the discharge flow is not within specification, turn the adjustment screw for maximum displacement (65) or (66) until discharge floe is within specification.

  4. This step will verify pump efficiency.

    Slowly increase discharge pressure to the value in Step 4 of the Test Specifications. Verify that case drain flow does not exceed the value given in Step 4 of the Test Specifications. If the case drain exceeds the specifications, the pump is not efficient and may need to be internally inspected.

Slowly reduce all pressures, electrical currents, and input speed to zero. Repeat steps 2 through 4 for the other pump. Once finished, allow the component to cool. Drain the component of oil. Cap or plug all ports and remove from the test bench.

Test Specifications

Table 3
Part Number  505-0527 
Pump Rotation  CW 
Step  1  2  3  4 
Input Speed  800 rpm  1200 rpm  1200 rpm  1200 rpm 
Discharge Pressure kPa (psi)  34470 kPa (5000 psi) 
Discharge Flow lpm (gpm)  15 L/min (3.9 US gpm)  22 L/min (5.8 US gpm)  216 L/min (57 US gpm)  216 L/min (57 US gpm) 
Pilot Pressure kPa (psi)  2700 kPa (392 psi)  2700 kPa (392 psi) 
Displacement Control Current mA  1700 mA  1700 mA 
Case Drain Flow  16 L/min (4.2 US gpm) 

Table 4
Part Number  505-0529 
Pump Rotation  CW 
Step  1  2  3  4 
Input Speed  800 rpm  1200 rpm  1200 rpm  1200 rpm 
Discharge Pressure kPa (psi)  34470 kPa (5000 psi) 
Discharge Flow lpm (gpm)  14 L/min (3.7 US gpm)  21 L/min (5.5 US gpm)  192 L/min (50.7 US gpm)  192 L/min (50.7 US gpm) 
Pilot Pressure kPa (psi)  2700 kPa (392 psi)  2700 kPa (392 psi) 
Displacement Control Current mA  1700 mA  1700 mA 
Case Drain Flow  14 L/min (3.7 US gpm) 

Table 5
Part Number  516-9843 
Pump Rotation  CW 
Step  1  2  3  4 
Input Speed  800 rpm  1200 rpm  1200 rpm  1200 rpm 
Discharge Pressure kPa (psi)  34470 kPa (5000 psi) 
Discharge Flow lpm (gpm)  14 L/min (3.7 US gpm)  21 L/min (5.5 US gpm)  192 L/min (50.7 US gpm)  192 L/min (50.7 US gpm) 
Pilot Pressure kPa (psi)  2700 kPa (392 psi)  2700 kPa (392 psi) 
Displacement Control Current mA  1700 mA  1700 mA 
Case Drain Flow  14 L/min (3.7 US gpm) 

Table 6
Part Number  550-4341 
Pump Rotation  CW 
Step  1  2  3  4 
Input Speed  800 rpm  1200 rpm  1200 rpm  1200 rpm 
Discharge Pressure kPa (psi)  34470 kPa (5000 psi) 
Discharge Flow lpm (gpm)  15 L/min (3.9 US gpm)  22 L/min (5.8 US gpm)  216 L/min (57 US gpm)  216 L/min (57 US gpm) 
Pilot Pressure kPa (psi)  2700 kPa (392 psi)  2700 kPa (392 psi) 
Displacement Control Current mA  1700 mA  1700 mA 
Case Drain Flow  16 L/min (4.2 US gpm) 

Table 7
Part Number  550-4342 
Pump Rotation  CW 
Step  1  2  3  4 
Input Speed  800 rpm  1200 rpm  1200 rpm  1200 rpm 
Discharge Pressure kPa (psi)  34470 kPa (5000 psi) 
Discharge Flow lpm (gpm)  14 L/min (3.7 US gpm)  21 L/min (5.5 US gpm)  192 L/min (50.7 US gpm)  192 L/min (50.7 US gpm) 
Pilot Pressure kPa (psi)  2700 kPa (392 psi)  2700 kPa (392 psi) 
Displacement Control Current mA  1700 mA  1700 mA 
Case Drain Flow  14 L/min (3.7 US gpm) 

Table 8
Part Number  551-1122 
Pump Rotation  CW 
Step  1  2  3  4 
Input Speed rpm  800 rpm  1200 rpm  1200 rpm  1200 rpm 
Discharge Pressure kPa (psi)  34470 kPa (5000 psi) 
Discharge Flow lpm (gpm)  14 L/min (3.7 US gpm)  21 L/min (5.5 US gpm)  192 L/min (50.7 US gpm)  192 L/min (50.7 US gpm) 
Pilot Pressure kPa (psi)  2700 kPa (392 psi)  2700 kPa (392 psi) 
Displacement Control Current mA  1700 mA  1700 mA 
Case Drain Flow  14 L/min (3.7 US gpm) 

Table 9
Part Number  566-8632 
Pump Rotation  CW 
Step  1  2  3  4 
Input Speed rpm  800 rpm  1200 rpm  1200 rpm  1200 rpm 
Discharge Pressure kPa (psi)  34470 kPa (5000 psi) 
Discharge Flow lpm (gpm)  11.2 L/min (2.9 US gpm)  21 L/min (5.5 US gpm)  283 L/min (74.7 US gpm)  283 L/min (74.7 US gpm) 
Pilot Pressure kPa (psi)  2700 kPa (392 psi)  2700 kPa (392 psi) 
Displacement Control Current mA  1700 mA  1700 mA 
Case Drain Flow  20 L/min (5.3 US gpm) 

Tooling

Table 10
Part Number  Mounting Plate  Drive Adapter  Suction Adapter  Split Flange  Flange Adapter  Pilot Pressure Port  Gauge Port for Control Pressure  Case Drain Port 
505-0527  9U-5751  9U-7519  1U-9867  1P-5767  9U-7440  9/16-18 STOR  9/16-18 STOR  1-1/16-12 STOR 
505-0529  9U-5751  9U-7519  1U-9867  1P-5767  9U-7440  9/16-18 STOR  9/16-18 STOR  1-1/16-12 STOR 
516-9843  9U-5751  9U-7519  1U-9867  1P-5767  9U-7440  9/16-18 STOR  9/16-18 STOR  1-1/16-12 STOR 
550-4341  9U-5751  9U-7519  1U-9867  1P-5767  9U-7440  9/16-18 STOR  9/16-18 STOR  1-1/16-12 STOR 
550-4342  9U-5751  9U-7519  1U-9867  1P-5767  9U-7440  9/16-18 STOR  9/16-18 STOR  1-1/16-12 STOR 
551-1122  9U-5751  9U-7519  1U-9867  1P-5767  9U-7440  9/16-18 STOR  9/16-18 STOR  1-1/16-12 STOR 
566-8632  9U-5751  9U-7519  1U-9867  1P-5767  9U-7440  9/16-18 STOR  9/16-18 STOR  1-1/16-12 STOR 

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