Bench Test Procedure for Vane Pumps {5055} Caterpillar

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Introduction

© 2016 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 vane pumps. The technician should have a good understanding of hydraulic vane pumps. The technician should be educated in the operation of the hydraulic test bench. All the necessary tooling should be gathered before you begin to test the pump. 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 (on-line)

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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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 not specific to any one vane pump. The information in the document should prepare a technician to properly bench test most types of vane pumps after a rebuild. Specific specifications are not given. This procedure validates a vane pump by volumetric efficiency, which is discussed later.

References

Mounting and Drive Configurations

There are many possibilities for mounting a vane pump. Caterpillar has two bolt and four bolt mounting plates. The mounting plates fit pumps with SAE A, B, C, D, E, or F mounting flanges. Refer to Special Instruction, REHS1761, "Required Tooling for Bench Testing Hydraulic Components" in order to see the available mounting plates. Many other mounting plates will need to be fabricated. Fabricated tooling will need to be built according to the mounting flange of the pump that will be tested.

There are several types of drive shafts that can be used on vane pumps. On pumps with spline shafts, taper shafts, and keyed shafts, refer to Special Instruction, REHS1761, "Required Tooling for Bench Testing Hydraulic Components" for the required drive shaft adapter. A drive adapter must be fabricated for tang type shafts.

Multiple Pump Suctions

Many times multiple vane pumps are stacked in the same housing. A suction manifold may be required to supply oil to all the pump inlets. Because of the tremendous amount of possible variations, Caterpillar does not offer a suction manifold. The dealer must fabricate a suction manifold in order to accommodate the specific vane pump.

Test Instructions

Generic Test Instructions

The hydraulic oil contained in the test bench should meet an ISO cleanliness rating of 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 at 600 RPM. Listen for abnormal noise. Verify that all connections are not leaking. Check for leaks around shaft seals.

   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 pump to 2000 RPM over a 2 minute period.

3. Rotate the pump at 2000 RPM. Load the pump to 100 psi. Record the flow rate of the pump.

4. Rotate the pump at 2000 RPM. Load the pump to 1000 psi. Record the flow rate of the pump.

5. Divide the flow rate at Step 4 by the flow rate at Step 3 and multiply this number by 100. This is the volumetric efficiency of the pump.

   No more than 10% volumetric loss is acceptable for vane pumps. Pumps with an output equal to or less than 20 gpm at 2000 RPM are allowed up to 15% volumetric loss.

Limited Horsepower Instructions

Note: This procedure is for test benches that cannot rotate the tested pump at 2000 RPM with a 1000 psi load.

1. Start rotating the pump at 1000 RPM. Listen for abnormal noise. Verify that all connections are not leaking. Check for leaks around shaft seals.

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

2. Rotate the pump at 1000 RPM. Load the pump to 100 psi. Record the flow rate out of the pump.

3. Rotate the pump at 1000 RPM. Load the pump to 1000 psi. Record the flow rate out of the pump.

4. Rotate the pump at 2000 RPM. Load the pump to 100 psi. Record the flow rate out of the pump.

5. Use the following formula to calculate the volumetric loss.

Illustration 1	g01046377