Test Bench Procedure for Hydraulic Piston Pumps{3203, 5070} Caterpillar

Asphalt Paver:

AP-1000 (S/N: 1HD1-45,46-UP)

AP-1050 (S/N: 1JG1-UP)

AP-1200 (S/N: 2JD1-UP)

AP-800 (S/N: 1BF1-UP)

AP-800B (S/N: 1BF1-UP)

AP-800C (S/N: 1PM1-UP)

AP-800D (S/N: A5P1-UP)

AP-900B (S/N: AGJ1-152,153-UP)

BG-230 (S/N: 9AL1-279,280-UP)

BG-230D (S/N: B4G1-UP)

BG-240B (S/N: 7RL1-UP)

BG-240C (S/N: AGL1-232,233-UP)

BG-260B (S/N: 4AL1-UP)

Paving Compactor:

CP-433C (S/N: 2JM1-572)

CP-563C (S/N: 5JN1-UP)

CS-433C (S/N: 3TM1-UP)

CS-563 (S/N: 8XF955-UP)

CS-563C (S/N: 4KN1-UP)

Vibratory Soil Compactor:

CP-563 (S/N: 1YJ413-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS2465
03	Added ""Canceled Part Numbers and Replaced Part Numbers" " section to document.
	Added REHS1761 "Required Tooling for Bench Testing Hydraulic Components" to ""References" " section of document.

© 2012 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 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. 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

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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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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.

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

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 1	g01121900
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 2	g01121898
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 3	g01121894
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 4	g01121892
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 outlet (34) Auxiliary oil inlet (35) "Flow meter 1" inlet

Illustration 5	g01121888
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

This piston pump is produced with multiple types of housings. Port locations will vary. Match the correct illustration with the pump that is being worked on.

Illustration 6	g01121772
Typical port locations and adjustments for the type 1 pumps. (49) Case drain port (50) Discharge ports (51) Charge pump suction port (52) Crossover relief valves (53) Gauge ports for servo pressure (54) Adjustment for the charge pressure (55) Gauge port for system pressure (56) Outlet for charge filter (57) Inlet for charge filter (58) Solenoid (59) Adjustment screw for swashplate neutral (60) Adjustment screw for displacement limiters

Illustration 7	g01122673
Typical port locations and adjustments for the type 2 pumps. (49) Case drain port (50) Discharge ports (51) Charge pump suction port (52) Crossover relief valves (53) Gauge ports for servo pressure (54) Adjustment for the charge pressure (55) Gauge port for system pressure (56) Outlet for charge filter (57) Inlet for charge filter (58) Solenoid (59) Adjustment screw for swashplate neutral

9U-5902 Rectifier Block

Illustration 8	g01121880
9U-5902 Rectifier Block Connections

Illustration 9	g01121883
9U-5902 Rectifier Block Schematic (61) High-pressure port "from pump discharge" (62) Outlet "to flow meter loop" (63) High-pressure port "from pump discharge" (64) Low-pressure return "from heat exchanger"

9U-5893 Heat Exchanger

Illustration 10	g01121877
9U-5893 Heat Exchanger Connections (65) Inlet "from flow meter loop" (66) Outlet "to rectifier block" (67) Water inlet (68) Water outlet

Connections for the Solenoid

Illustration 11	g01125996
Connectors used on type 1 and type 2 pumps. (69) Ms connector (70) two pin connectors (71) Packard connector

There are several different connectors that are used for supplying current to the solenoids. Three different types of connectors are used for the electronic displacement control. Refer to Illustration 11 for your specific type of connector. The dual coil solenoids use either a four pin Packard connector (71) or a ms connector (69). The single coil solenoids use a two pin connector (70).

Test the pumps with dual coil solenoids (58) by first applying current from the power supply to terminals A and C on the connector. After testing of A and C terminals is complete, feed current to the B and D terminals to test the pump in the opposite direction.

Test the pumps with single coil solenoids (58) by first applying current to the A terminal with the B terminal as the ground. This setup will operate the pump in one direction. Test the pump in the opposite direction by applying current to B terminal and use A terminal as the ground.

Pump Pre-Test Setup

Note: Only test one pump at a time on tandem pumps. Isolate one of the pumps by connecting a hose between the discharge ports (50a) or (50b) on the pump that is not being tested.

1. Mount the pump with the case drain port (49) facing upward.

2. Connect pump discharge port (50a) to the 9U-5902 Rectifier Block high-pressure port (61). Connect pump discharge port (50b) to the 9U-5902 Rectifier Block high-pressure port (63) .

3. Connect the 9U-5902 Rectifier Block outlet (62) to the flow meter inlet on the test bench.

4. Connect the "flow meter outlet" to the 9U-5398 Heat Exchanger inlet (65) .

5. Connect the 9U-5398 Heat Exchanger outlet (66) to the low-pressure return (64) on the 9U-5902 Rectifier Block .

6. Some pumps have internal charge pumps. Some pumps do not have internal charge pumps. Refer to the test specifications if the pump that is being tested uses an internal charge pump or an external charge pump. Use Step 6.a or 6.b for correct setup.

   1. Connect the charge pump suction port (51) to the test bench oil supply for pumps with an internal charge pump. Connect a hose between the inlet for the charge filter (57) and the outlet for the charge filter (56) on pumps with an internal charge pump. Proceed to Step 7.

   2. Connect a hose from the inlet for the charge filter (57) to the auxiliary oil outlet on the test bench for pumps without a charge pump.

7. Connect an in-line flow meter to the case drain port (49) .

8. 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.

9. Fill the pump case with oil before rotating. Pour oil directly into a case drain port (49) until the case is full.

10. Connect a power supply to the solenoid (58) in order to operate the solenoid valve. Refer to Illustration 11 for the correct way to connect the power supply to the solenoid (58). The power supply should be able to deliver 0 mA to 1.5 A with an infinite setting in that range.

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

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)

Illustration 12	g01126432

1. The following steps verify the operation of the charge pump and the operation of the charge relief valve.

   1. Start rotating the pump according to Step 1.a of the test specifications. Listen for abnormal noise. Verify flow from the charge pump. Verify that all connections are tight. Check for leaks around shaft seals. Check for leaks around the control valves.

   2. Increase the input RPM to the value in Step 1.b of the test specifications. Check the charge pressure. Compare the actual charge pressure value with the value in Step 1.b of the test specifications. Adjust the charge pressure if the charge pressure is not within the test specifications. Remove the plug for the charge relief valve (54) in order to adjust the shims. Add shims to the charge relief valve (54) in order to increase the charge pressure. Remove shims from the charge relief valve (54) in order to decrease the charge pressure.

2. The following steps will verify the operation of the electronic displacement control and the initial point of the pump's stroke.

   1. Remove the current from the solenoid (58). Connect a hose between the gauge ports for the servo pressure (53) in order to equalize servo pressure on each side of the stroking servo. Connect 8T-0860 Pressure gauge into both of the gauge ports for system pressure (55). Increase load valve value in order to allow an increase in discharge pressure. Loosen the locknut on the adjustment screw for swashplate neutral (59). Turn the set screw (59) clockwise until there is a pressure increase in one of the pressure gauges. Record the position of the wrench. Turn the set screw (59) clockwise until there is a pressure increase on the other pressure gauge. Record the position of the wrench. Turn the set screw (59) clockwise to the halfway point between the two previous points.

   2. Slowly increase the input RPM and the current to the solenoid (58) to the values in Step 2.b of the test specifications. This is the beginning of the pump's stroke. Both directions of operation for the pump must be tested. Some flow meters may not be able to read discharge flows at the initial or low flow rates. Slowly increase the solenoid current until the flow meter can read the discharge flow. Increase the discharge pressure to 3450 kPa (500 psi). Remove the solenoid current to the solenoid in order to ensure that the pump is not flowing. Slowly increase the solenoid current at a steady rate. Visually check the discharge pressure until the pressure starts to rise above the charge pressure. This is the initial point of pump stroke.

3. Slowly increase the input RPM according to Step 3 of the test specifications. Slowly increase the current to the solenoid (58) to the value in Step 3 in the test specifications. The pump must be operated in both directions in order to verify operation in either direction. Displacement limiters (60) are options. Maximum pump flows may be adjusted with this option. The pump should be internally inspected if the discharge flow is unable to match the value in Step 3 of the test specifications. Adjust the displacement limiters (60) if the actual flow rates do not match the value in Step 3 of the test specifications.

4. Slowly increase the pump discharge pressure to the value in Step 4 of the test specifications. Measure pump leakage. Calculate the total loss. If the total loss is higher than the allowable value in Step 4 of the test specifications, The pump may not be mechanically feasible.

   Subtract the discharge flow in Step 4 from Step 3. This is the total loss.

   Example "Step 3 flow"162 L/min (42.8 US gpm) - "Step 4 flow"158 L/min (41.7 US gpm) ="total loss" 4 L/min (1.1 US gpm). The "max. allowable loss" is 7.2 L/min (1.9 US gpm).

   The pump in the example is acceptable because the actual total loss is less than the maximum allowable loss.

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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 RPM and all pressures to zero. Remove the component from the test bench. Drain the oil from the pump. Plug all of the ports.

Test Specifications

Table 3

Part Number	8C-7616
Pump Rotation	CCW
Canceled replaced by 143-2872

Table 4

Part Number	109-1360
Pump Rotation	CCW
Canceled replaced by 143-2872

Table 5

Part Number	112-9561
Pump Rotation	CCW
Step	1a	1b	2a	2b	3	4
RPM	500	1500	1500	1500	2000	2000
Solenoid Current mA	0	0	0	16 ± 5	90 ± 12	90 ± 12
Discharge Pressure kPa (psi)	2620 (380) (1)	2620 (380) (1)	2620 (380) (1)	2620 (380) (1)	2620 (380) (1)	17000 (2500)
Discharge FlowLpm (gpm)	0	0	0	1 (.26)	76 (20)	76 (20)
Pump LossLpm (gpm)	Subtract the actual measured discharge flow in Step 3 from the actual discharge flow in Step 4. This is the Total Loss.					4 (1)
Charge Pump FlowLpm (gpm)	10 (2.5) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)
Charge Relief Valve kPa (psi)	2620 (380)	2620 (380)	2620 (380)	2620 (380)	2620 (380)	2620 (380)

( 1 )

Discharge pressure equals charge pressure

Table 6

Part Number	120-6022
Pump Rotation	CCW
Step	1a	1b	2a	2b	3	4
RPM	500	1500	1500	1500	2000	2000
Solenoid Current mA	0	0	0	16 ± 5	90 ± 12	90 ± 12
Discharge Pressure kPa (psi)	2620 (380) (1)	2620 (380) (1)	2620 (380) (1)	2620 (380) (1)	2620 (380) (1)	17000 (2500)
Discharge FlowLpm (gpm)	0	0	0	1 (.26)	92 (24)	92 (24)
Pump LossLpm (gpm)	Subtract the actual measured discharge flow in Step 3 from the actual discharge flow in Step 4. This is the Total Loss.					4.5 (1)
Charge Pump FlowLpm (gpm)	10 (2.5) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)
Charge Relief Valve kPa (psi)	2620 (380)	2620 (380)	2620 (380)	2620 (380)	2620 (380)	2620 (380)

( 1 )

Discharge pressure equals charge pressure

Table 7

Part Number	121-4879
Pump Rotation	CCW
Step	1a	1b	2a	2b	3	4
RPM	500	1500	1500	1500	2000	2000
Solenoid Current mA	0	0	0	16 ± 5	90 ± 12	90 ± 12
Discharge Pressure kPa (psi)	2200 (320) (1)	2200 (320) (1)	2200 (320) (1)	2200 (320) (1)	2200 (320) (1)	17000 (2500)
Discharge FlowLpm (gpm)	0	0	0	1 (.26)	76 (20)	76 (20)
Pump Loss Lpm (gpm)	Subtract the actual measured discharge flow in Step 3 from the actual discharge flow in Step 4. This is the Total Loss.					4 (1)
Charge Pump Flow Lpm (gpm)	8 (2) (Internal)	21 (5.5) (Internal)	21 (5.5) (Internal)	21 (5.5) (Internal)	28 (7) (Internal)	28 (7) (Internal)
Charge Relief Valve kPa (psi)	2200 (320)	2200 (320)	2200 (320)	2200 (320)	2200 (320)	2200 (320)

( 1 )

Discharge pressure equals charge pressure

Table 8

Part Number	122-0595 (2)
Pump Rotation	CCW
Step	1a	1b	2a	2b	3	4
RPM	500	1500	1500	1500	2000	2000
Solenoid Current mA	0	0	0	16 ± 5	90 ± 12	90 ± 12
Discharge Pressure kPa (psi)	2930 (425) (1)	2930 (425) (1)	2930 (425) (1)	2930 (425) (1)	2930 (425) (1)	17000 (2500)
Discharge FlowLpm (gpm)	0	0	0	1 (.26)	85 (22.5)	85 (22.5)
Pump LossLpm (gpm)	Subtract the actual measured discharge flow in Step 3 from the actual discharge flow in Step 4. This is the Total Loss.					4 (1)
Charge Pump FlowLpm (gpm)	10 (2.5) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)	28 (7) (External)
Charge Relief Valve kPa (psi)	2930 (425)	2930 (425)	2930 (425)	2930 (425)	2930 (425)	2930 (425)

( 2 )	Equipped with displacement limiters
( 1 )	Discharge pressure equals charge pressure

Table 9

Part Number	140-9890
Pump Rotation	CCW
Step	1a	1b	2a	2b	3	4
RPM	500	1500	1500	1500	2000	2000
Solenoid Current mA	0	0	0	23 ± 6	132 ± 18	132 ± 18
Discharge Pressure kPa (psi)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	17000 (2500)
Discharge FlowLpm (gpm)	0	0	0	1 (.26)	92 (24.5)	92 (24.5)
Pump LossLpm (gpm)	Subtract the actual measured discharge flow in Step 3 from the actual discharge flow in Step 4. This is the Total Loss.					5 (1.5)
Charge Pump FlowLpm (gpm)	12 (3) (Internal)	35 (9) (Internal)	35 (9) (Internal)	35 (9) (Internal)	46 (12) (Internal)	46 (12) (Internal)
Charge Relief Valve kPa (psi)	1950 (283)	1950 (283)	1950 (283)	1950 (283)	1950 (283)	1950 (283)

( 1 )

Discharge pressure equals charge pressure

Table 10

Part Number	140-9891
Pump Rotation	CCW
Step	1a	1b	2a	2b	3	4
RPM	500	1500	1500	1500	2000	2000
Solenoid Current mA	0	0	0	23 ± 6	132 ± 18	132 ± 18
Discharge Pressure kPa (psi)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	17000 (2500)
Discharge FlowLpm (gpm)	0	0	0	1 (.26)	92 (24.5)	92 (24.5)
Pump LossLpm (gpm)	Subtract the actual measured discharge flow in Step 3 from the actual discharge flow in Step 4. This is the Total Loss.					5 (1.5)
Charge Pump FlowLpm (gpm)	12 (3) (Internal)	35 (9) (Internal)	35 (9) (Internal)	35 (9) (Internal)	46 (12) (Internal)	46 (12) (Internal)
Charge Relief Valve kPa (psi)	1950 (283)	1950 (283)	1950 (283)	1950 (283)	1950 (283)	1950 (283)

( 1 )

Discharge pressure equals charge pressure

Table 11

Part Number	143-2872
Pump Rotation	CCW
Step	1a	1b	2a	2b	3	4
RPM	500	1500	1500	1500	2000	2000
Solenoid Current mA	0	0	0	23 ± 6	132 ± 18	132 ± 18
Discharge Pressure kPa (psi)	1950 (283)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	1950 (283) (1)	17000 (2500)
Discharge FlowLpm (gpm)	0	0	0	1 (.26)	92 (24.5)	92 (24.5)
Pump Loss Lpm (gpm)	Subtract the actual measured discharge flow in Step 3 from the actual discharge flow in Step 4. This is the Total Loss.					5 (1.5)
Charge Pump FlowLpm (gpm)	12 (3) (Internal)	35 (9) (Internal)	35 (9) (Internal)	35 (9) (Internal)	46 (12) (Internal)	46 (12) (Internal)
Charge Relief Valve kPa (psi)	1950 (283)	1950 (283)	1950 (283)	1950 (283)	1950 (283)	1950 (283)

( 1 )

Discharge pressure equals charge pressure

Tooling

Table 12

Part Number	Mounting Plate	Drive Adapter	Suction Port	Charge Pressure Inlet	Charge Pressure Outlet	Discharge Port	Case Drain
8C-7616	Canceled replaced by 143-2872
109-1360	Canceled replaced by 143-2872
112-9521	1U-9127	1U-9846	1 5/16-12 STOR	7/8-14 STOR	7/8-14 STOR	1 5/16-12 STOR	1 1/16-12 STOR
120-6022	1U-9127	1U-9846	1 5/16-12 STOR	7/8-14 STOR	7/8-14 STOR	1 5/16-12 STOR	1 1/16-12 STOR
121-4879	1U-9127	1U-9846	1 5/16-12 STOR	7/8-14 STOR	7/8-14 STOR	1 5/16-12 STOR	1 1/16-12 STOR
122-0595	1U-9127	1U-9833	1 5/16-12 STOR	7/8-14 STOR	7/8-14 STOR	1 5/16-12 STOR	1 1/16-12 STOR
140-9890	1U-9127	4C-4088	1 5/8-12 STOR	7/8-14 STOR	7/8-14 STOR	1 5/16-12 STOR	1 1/16-12 STOR
140-9891	1U-9127	4C-4088	1 5/8-12 STOR	7/8-14 STOR	7/8-14 STOR	1 5/16-12 STOR	1 1/16-12 STOR
143-2872	1U-9127	4C-4088	1 5/8-12 STOR	7/8-14 STOR	7/8-14 STOR	1 5/16-12 STOR	1 1/16-12 STOR