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


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

Usage:

320D3 ESX
Excavator
320D3 (S/N: ESX1-UP)
323D3 (S/N: FEY1-UP)

Introduction

Table 1
Revision  Summary of Changes in M0095641 
00  New document. 

© 2018 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 CaterpillarService 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

------ 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) in order 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 1g01093916
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 2g01063312
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 3g01063314
Connections for the Test Bench
(26) "Flow meter 1" loop and "Flow meter 2" loop
(27) Oil Supply


Illustration 4g01063315
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) Auxiliary pump oil supply
(34) "Flow meter 1" inlet
(35) "Flow meter 1" inlet


Illustration 5g01063316
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 6g06320724
Typical port locations and adjustments
(49) Case drain ports
(50) Gauge port for discharge pressure "front pump"
(51) Gauge port for power shift pressure downstream of solenoid
(52) Gauge port for discharge pressure "rear pump"
(53) Discharge port "front pump"
(54) Discharge port "rear pump"
(55) Port for power shift pressure
(56) Port for negative flow control pressure "front pump"
(57) Port for negative flow control pressure "rear pump"
(58) Adjustment screw for minimum displacement "front pump"
(59) Adjustment screw for maximum displacement "front pump"
(60) Adjustment screw for maximum displacement "rear pump"
(61) Adjustment screw for minimum displacement "rear pump"
(62) Suction port
(63) Electrical connection for power shift solenoid
(64) Adjustment screw for negative flow control "front pump"
(65) Adjustment screw for negative flow control "rear pump"
(66) Adjustment screw for power shift "front pump"
(67) Adjustment screw for power shift "rear pump"
(68) Pilot pump discharge port
(69) Pilot pump suction port
(70) Adjustment screw for pilot pump relief valve
(71) Gauge port for pilot pump discharge pressure


Illustration 7g06327054
Hydraulic schematic
(49) Case drain ports
(50) Gauge port for discharge pressure "front pump"
(51) Gauge port for power shift pressure downstream of solenoid
(52) Gauge port for discharge pressure "rear pump"
(53) Discharge port "front pump"
(54) Discharge port "rear pump"
(55) Port for power shift pressure
(56) Port for negative flow control pressure "front pump"
(57) Port for negative flow control pressure "rear pump"
(58) Adjustment screw for minimum displacement "front pump"
(59) Adjustment screw for maximum displacement "front pump"
(60) Adjustment screw for maximum displacement "rear pump"
(61) Adjustment screw for minimum displacement "rear pump"
(62) Suction port
(63) Electrical connection for power shift solenoid
(64) Adjustment screw for negative flow control "front pump"
(65) Adjustment screw for negative flow control "rear pump"
(66) Adjustment screw for power shift "front pump"
(67) Adjustment screw for power shift "rear pump"
(68) Pilot pump discharge port
(69) Pilot pump suction port
(70) Adjustment screw for pilot pump relief valve
(71) Gauge port for pilot pump discharge pressure

Pump Setup

  1. Install quick disconnect fittings in the following ports.

    • (55) Port for power shift pressure

    • (56) and (57) Port for negative flow control

  2. Mount the pump to the test bench with the pump controls facing up.

  3. Connect the suction ports (62) and (69) to the test bench oil supply. Purge all air from the suction line. Loosen the suction hose at the pump until oil leaks from the connection. Tighten the suction hose.

  4. Connect 1 inch high pressure “XT6” hoses from both discharge ports (53) and (54) to the flow meter inlets on the test bench. Direct flow meter outlets to test bench reservoir.

  5. Connect a hose from pilot pump discharge port (53) to and in-line flow meter and direct the discharge back to the test bench reservoir.

  6. Connect the auxiliary pressure from the test bench to port for power shift pressure (55). Vent both negative flow control ports (56) and (57) to atmosphere.

  7. Fill the pump case with oil. Pour oil directly into a case drain port (49) until the case is full and the rotating groups of the pump are submersed in oil. Direct a line from the case drain port (49) to the test bench reservoir.

  8. Connect an electrical power supply capable of delivering up to 1000mA to the electrical connector for power shift solenoid (63).

  9. Do not rotate the pump in the wrong direction. The correct direction of rotation will be stated on the pump. The correct direction of rotation will also be in the test specifications. 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)

Perform Steps 1 through 3 of the Test Procedure for the front pump while the rear pump is in standby. After the front pump is tested, repeat Steps 1 through 3 of the Test Procedure for the rear pump while the front pump is in standby.

  1. This step will verify 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 valves. Verify flow from the main pump and the pilot pump.

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

  2. This step will verify the maximum displacement setting and the setting of the power shift control.

    Ensure that the auxiliary pressure supply hose is connected to power shift pressure port (55). Ensure that negative flow control pressure ports (56) and (57) are vented to atmosphere. Slowly increase input speed to the value in Step 2 of the Test Specifications.

    1. Slowly increase discharge pressure to the value in Step 2a of the Test Specifications. Verify that discharge flow equals the value in Step 2a of the Test Specifications. If the discharge flow is not correct, turn the adjustment screw for maximum displacement (59) or (60) until the flow is within specification.

    2. Increase auxiliary pressure to the power shift pressure port (55) according to Step 2b of the Test Specifications. Increase electrical current to the electrical connector for power shift solenoid (65) according to Step 2b of the Test Specifications. Slowly increase discharge pressure to the value in Step 2b of the Test Specifications. Verify that discharge flow decreases to the value in Step 2b of the Test Specifications. If the discharge flow is not correct, turn the large/outer adjustment screw for power shift (66) or (67) until the flow is within specification. Turn clockwise to increase flow. Turn counterclockwise to decrease flow.

    3. Slowly increase discharge pressure to the value in Step 2c of the Test Specifications. Verify that discharge flow decreases to the value in Step 2c of the Test Specifications. If the discharge flow is not correct, turn the small/inner adjustment screw for power shift (66) or (67) until the flow is within specification. Turn clockwise to increase flow. Turn counterclockwise to decrease flow.

    4. Slowly increase discharge pressure to the value in Step 2d of the Test Specifications. Verify that discharge flow decreases to the value in Step 2d of the Test Specifications. If the discharge flow is not correct, turn the inner small/inner adjustment screw for power shift (66) or (67) until the flow is within specification. Turn clockwise to increase flow. Turn counterclockwise to decrease flow.

  3. This step will verify setting of the negative flow control.

    decrease discharge pressure to zero. Decrease auxiliary pressure to power shift pressure port (55) to zero. Connect the auxiliary pressure supply hose to negative flow control pressure port (56) or (57). Vent power shift pressure port (55) to atmosphere. Increase discharge pressure to the value in Step 3 of the Test Specifications.

    1. Increase auxiliary pressure to negative flow control pressure port (56) or (57). Verify discharge flow equals the value in Step 3a of the Test Specifications. If the discharge flow is not within specification, turn the adjustment screw for negative flow control (64) or (65) until the discharge flow is within specification.

    2. Increase auxiliary pressure to negative flow control pressure port (56) or (57). Verify discharge flow equals the value in Step 3a of the Test Specifications. If the discharge flow is not within specification, turn the adjustment screw for negative flow control (64) or (65) until the discharge flow is within specification.

One the test has been completed for the front pump. Repeat Steps 1 through 3 for the rear pump.

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

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


Once both pumps have been tested, reduce all pressures, electrical current, and input speed to zero. Allow the component to cool. Drain the component of oil. Cap or plug all of the ports. Remove the component from the test bench.

Table 3
Part Number  524-2648 
Pump Rotation  Clockwise 
Step  1  2a  2b  2c  2d  3a  3b 
RPM  600  1200  1200  1200  1200  1200  1200 
Power Shift Pressure kPa (psi)  1300 (190)  Vent port (55) to atmosphere 
Power Shift Solenoid Current mA  500  500  500 
Negative Flow Control Pressure kPa (psi)  Vent ports (56) and (57) to atmosphere  1100 (160)  3660 (530) 
Discharge Pressure kPa (psi)  19500 (2830)  24500 (3550)  34500 (5000)  7000 (1015) 
Discharge Flow lpm (gpm)  70 (18)  140±3 (36±1)  88±6 (23±2)  67±6 (17±2)  42±6 (11±2)  140±3 (36±1)  21±3 (5.5±1) 
Standby Pump Negative Flow Control Pressure kPa (psi) 
Standby Pump Discharge Pressure kPa (psi) 
Standby Pump Discharge Flow lpm (gpm)  70 (18)  140 (36) 
Pilot Pump Discharge Flow lpm (gpm)  6 (1.6)  12 (3.2)  12 (3.2)  12 (3.2)  12 (3.2)  12 (3.2)  12 (3.2) 

Test Bench Tooling

Table 4
Part Number  Mounting Flange  Drive Adapter  Suction Adapter  Split Flange  Flange Adapter  Power shift Port  Negative Flow Ports  Case Drain Port 
524-2648  131-8477  131-6456  1U-9874  8T-9403  9U-7438  9/16-18 STOR  9/16-18 STOR  1 1/16-12 STOR 

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