Bench Test Procedure for Hydraulic Piston Pumps{1387, 4306, 5070} Caterpillar

Integrated Toolcarrier:

IT38H (S/N: JNJ1-UP)

Wheel Loader:

938H (S/N: MCC1-UP; MJC1-UP; JKM1-UP; LKM1-UP)

966K (S/N: PBG1-UP; TFS1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

Introduction

© 2014 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 bay 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 web site. 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

• Caterpillar 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

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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 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

Connections for the Caterpillar Hydraulic Test Center

Illustration 2	g01063311
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	g01063312
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	g01063314
Connections for the Caterpillar Hydraulic Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 5	g01093468
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 6	g01063316
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

Port Locations

Illustration 7	g01450821
Typical port locations and adjustment (49) Discharge port (50) Case drain port (51) Stage two adjustment screw for the torque control (52) Stage one adjustment screw for the torque control (53) Adjustment screw for maximum displacement (54) Pressure port for load sense signal pressure (55) Pressure port for power shift (56) Adjustment screw for margin pressure (57) Case drain port (58) Suction port

Illustration 8	g01450740
Hydraulic schematic (49) Discharge port (50) Case drain port (54) Pressure port for load sense signal pressure (55) Pressure port for powershift (57) Case drain port (58) Suction port

Installation for the 4C-3582 Load Sensing Valve

Illustration 9	g01451543
4C-3582 Load Sensing Valve

Illustration 10	g01451546
4C-3582 Load Sensing Valve

Illustration 11	g01451549
Schematic for 4c-3582 Load Sensing Valve (59) Outlet port (60) Adjustment for the discharge flow (61) Inlet port (62) High-pressure port (63) Adjustment for the discharge pressure (64) Low-pressure port (65) Pressure port for load sensing

Illustration 12	g01451664
4C-3582 Load Sensing Valve and 1U-5796 Pressure Differential Gauge (59) Line to the flow meter on the test bench (60) Adjustment knob for discharge flow (61) Line from the pump discharge port (62) To the high side of the differential gauge (63) Load control for pump discharge pressure (64) Line to the low side of the differential gauge (65) Pressure port for load sensing (66) Pressure differential gauge group (67) Line to the low side of the load sensing group (68) Line to the high side of the load sensing group

Note: A sense pressure line from the pump should be connected to the load sensing pressure port (7) when you use the Caterpillar Hydraulic Test Center. A sense pressure line from the pump should be connected to the pressure port for load sensing (65) on the 4C-3582 Load Sensing Valve when using the Caterpillar Hydraulic Test Bench.

1. Connect a 1 inch high pressure "XT6" hose from the pump discharge port (49) to inlet port (61) on the 4C-3582 Load Sensing Valve .

2. Connect a 1 inch high pressure "XT6" hose from outlet port (59) on the 4C-3582 Load Sensing Valve to the flow meter inlet on the test bench.

3. Connect a 1 inch high-pressure hose from the outlet of the flow meter on the test bench back to the tank.

4. Connect a 6D-7726 Hose Assembly to the pressure port for load sensing (65). Connect the other end of 6D-7726 Hose Assembly to the pressure port for load sensing (54) on the pump.

   Note: Do not use 1U-5754 Hose Assembly or 1U-5755 Hose Assembly for load sensing signal lines. The flow rate through these hoses will not compensate for the possible leakage through the control valve. Erratic readings will result.

5. Connect the 1U-5796 Pressure Differential Gauge Group (66) to the high-pressure valve port (62) and low-pressure valve port (64) on the 4C-3582 Load Sensing Valve . The port marked "hi" (68) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "hi" (62) on the 4C-3582 Load Sensing Valve . The port marked "low" (67) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "low" (64) on the 4C-3582 Load Sensing Valve .

   Note: The ports marked "low" (64) and "sense line" (65) on the 4C-3582 Load Sensing Valve are reading the same pressure.

Pump Setup

1. Connect a 1U-8303 Fitting to the pump discharge port (49) .

2. Attach a quick disconnect fitting to the 1U-8303 Fitting .

3. Connect a 1 inch high pressure "XT6" hose from the pump discharge port (49) to the flow meter inlet on the test bench.

4. Connect a 1 inch high pressure "XT6" hose to the flow meter outlet. Direct flow meter outlet to the sump.

5. Install quick disconnect fittings in the following ports.
   • (54) Pressure port for load sense signal pressure

   • (55) Pressure port for powershift

6. Purge all air from the suction line. Loosen the suction hose at the pump until oil leaks from the connection. Tighten the suction hose.

7. Fill the pump case with oil. Pour oil directly into a case drain port until the case is full.

8. Connect an in-line flow meter to the case drain port (50) or (57). Direct the oil from the in-line flow meter back to the tank.

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 in the Test Specification Tables 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)

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Illustration 13	g01474272

1. Start rotating the pump according to the RPM in Step 1 of the Test Specifications. Listen for abnormal noise. Verify flow from the pump. 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 in order to raise the temperature of the oil and purge the system of air.

2. Step 2 will verify maximum displacement. Slowly increase the input RPM to the value in Step 2 of the Test Specifications. This step is a reference point. No adjustment will be made at this time. The adjustment will be made in Step 4.a of the Testing Procedure.

Note: Step 3 will require a different pump step up. Refer to the installation of the 4C-3582 Load Sensing Valve section of the bench test procedure. Follow Steps 1 through 5 in the ""Installation for the 4C-3582 Load Sensing Valve " " section for the correct setup.

3. The discharge flow is adjusted by using the 4C-3582 Load Sensing Valve . Bench circuitry will be used for flow limiting when you use a 1U-9400 Test Center .

   Increase the rpm input to the value listed in Step 3 of the Test Specifications. Decrease the discharge flow by turning adjustment for discharge flow (60) according to the values in Step 3 of the Test Specifications. Adjust the discharge pressure according to the values in Step 3 of the Test Specifications. Adjust the screw for margin pressure (56) to the value in Step 3 of the Test Specifications. The margin pressure will be displayed on the 1U-5793 Pressure Differential Gauge (65) .

   Note: The margin pressure may change as discharge pressure changes. Adjust margin pressure in Step 3 only.

Note: After Step 3 of the Test Procedure the 4C-3582 Load Sensing Valve must be disconnected. After removing the 4C-3582 Load Sensing Valve from the test bench circuit connect a 1 inch high pressure "XT6" hose from the pump discharge port (49) to the flow meter inlet on the test bench. Connect a 177-7860 Hose Assembly to the 1U-8303 Fitting on discharge port (49). Connect the other end of the 177-7860 Hose Assembly to the pressure port for load sense signal pressure (54). This will isolate the torque control valve for testing. Refer to illustration 14 for the correct pump setup.

4. The following steps will verify the torque control.
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   Illustration 14	g02698339
   Hydraulic schematic

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   Illustration 15	g01488213
   Adjustments of torque control (51) Stage two adjustment screw for the torque control (52) Stage one adjustment screw for the torque control (69) Stage two locknut (70) Stage one locknut

   1. Adjust the input RPM to the value in Step 4.a of the Test Specifications. Increase the discharge pressure to the value in Step 4.a of the Test Specifications. Compare the flow rate with Step 4.a of the Test Specifications. If the pump flow is not within specifications, adjust the adjustment screw for maximum displacement (53). Loosen the locknut and turn the adjustment screw for maximum displacement (53) counter clockwise in order to increase the flow. Increase the flow until the flow is within specifications. Loosen the locknut and turn the adjustment screw for maximum displacement (53) clockwise in order to decrease the flow until flow is within specifications.

   2. Adjust the discharge pressure to the value in Step 4.b of the Test Specifications. Compare the flow rate with Step 4.b of the Test Specifications. Loosen the stage one locknut (70) on the adjustment screw for torque control in order to adjust the torque control. Turn the stage one adjustment screw for the torque control (52) if the flow rate is not within specifications. Adjust the stage one adjustment screw for the torque control (52) until flow equals the specifications in Step 4.b of the Test Specifications. Tighten the stage one locknut (70) .

   3. Adjust the discharge pressure to the value in Step 4.c of the Test Specifications. Compare the flow rate with Step 4.c of the Test Specifications. Loosen stage two locknut (69) on the adjustment screw for torque control in order to adjust the torque control. Turn the stage two adjustment screw for the torque control (51) if the flow rate is not within specifications. Adjust the stage two adjustment screw for the torque control (51) until flow equals the specifications in Step 4.c of the Test Specifications. Tighten the stage two locknut (69) .

Note: For 319-6309 Piston Pump Gp skip Steps 5, 5.a, and 5.b of the Test Procedure. Proceed to Step 6 of the Test Procedure.

5. The following steps will verify the power shift pressure characteristics.

   Note: Connect the pressure port for power shift (55) to the signal pressure from the test bench.

   1. Adjust the discharge pressure to the value in Step 5.a of the Test Specifications. Increase the signal pressure from the bench to the pressure port for power shift (54) to the value listed in Step 5.a of the Test Specifications. Compare the flow rate with Step 5.a of the Test Specifications. If the actual flow is less than the value in Step 5.a of the Test Specifications, the pump may not be mechanically feasible. Internally inspect the pump.

   2. Adjust the discharge pressure to the value in Step 5.b of the Test Specifications. Compare the flow rate with Step 5.b of the Test Specifications. If the actual flow is less than the value in Step 5.b of the Test Specifications, the pump may not be mechanically feasible. Internally inspect the pump.

6. Adjust the pump discharge pressure to the value in Step 6 of the Test Specifications. Compare the actual values of the case drain (50) or (57) with the values in Step 6 of the Test Specifications. This value is an indication of the efficiency. If the case drain is more than the value in Step 6 of the Test Specifications, the pump may not be mechanically feasible. Internally inspect the pump.

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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

Test Bench Tooling