Bench Test Procedure for Hydraulic Piston Pumps {0599, 0738, 5050, 5070, 7000} Caterpillar

Material Handler

MH3024 (S/N: FM41-UP; FB51-UP)

Wheeled Excavator

M322F (S/N: M321-UP; FBW1-UP; F2Z1-UP)

Introduction

© 2016 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 questions or additional information concerning this guideline, submit a feedback form in the Service Information System website. 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

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) to view the latest version.

References

Connections for the Caterpillar Hydraulic Test Center

Illustration 2	g01178572
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	g01178573
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	g01178574
Connections for the test bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil supply

Illustration 5	g01178575
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 6	g01178576
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) Control for the auxiliary oil supply (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 7	g06127943
Port locations (49) Case drain port (50) Electrical connector for stroke limiter (51) Adjustment screw for stroke limiter (52) Pilot pressure port (53) Adjustment screw for pilot pressure (54) Gauge port for control pressure (55) Gauge port for discharge pressure (56) Adjustment screw for minimum displacement (57) Discharge port (58) Case drain port (59) Suction port (60) Cased drain port (61) Gauge port for stroking pressure (62) Adjustment screw for maximum displacement

Illustration 8	g06127948
Hydraulic Schematic (49) Case drain port (50) Electrical connector for stroke limiter (51) Adjustment screw for stroke limiter (52) Pilot pressure port (53) Adjustment screw for pilot pressure (54) Gauge port for control pressure (55) Gauge port for discharge pressure (56) Adjustment screw for minimum displacement (57) Discharge port (58) Case drain port (59) Suction port (60) Cased drain port (61) Gauge port for stroking pressure (62) Adjustment screw for maximum displacement

Pump Setup

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

2. Connect the suction port (59) to the test bench oil supply.

3. Connect a 1 inch high pressure "XT6" hose from the pump discharge port (57) 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 pilot oil supply line from the pilot pressure port (52) to a signal pressure supply on the test bench.

5. Fill the pump case with oil. Pour oil directly into case drain port (49) until the case is full.

6. 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.

7. Install flow meter to case drain port (49). Route the flow meter discharge back to tank.

8. Connect an electrical power supply to the electrical connector for stroke limiter (50)

Test Procedure

The hydraulic oil in the test bench should meet an ISO rating of 16/13. 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. This step will verify proper pump assembly.

   Increase solenoid current to the electrical connector for stroke limiter (50) according to Step 1 of the "Test Specifications". Start rotating the pump according to Step 1 of the "Test Specifications". Listen for abnormal noise. Verify that all the connections are not leaking. Check for leaks around the shaft seals and control valve.

2. This step will verify the minimum displacement setting of the pump and the start of the electrical stroke limiter function of the pump control.

   Slowly increase the input speed according to Step 2 of the "Test Specifications". Increase pump discharge pressure to the value in Step 2. Decrease solenoid current to the electrical connector for stroke limiter (50) according to Step 2 of the "Test Specifications". At this step, the pump should produce only a small amount of discharge flow. Verify that the discharge flow has decreased. If the pump discharge flow is not equal to the value given in the "Test Specifications", adjust the screw for minimum displacement (56) until the flow is within specification.

3. This step will verify the maximum displacement setting of the pump and the end of the electrical stroke limiter function of the pump control.

   Slowly increase solenoid current to the electrical connector for stroke limiter (50). Verify that pump discharge flow has increased to the value in Step 3 of the "Test Specifications". If the pump discharge flow is not equal to the value given in the "Test Specifications", adjust the screw for maximum displacement (62) until the flow is within specification.

   If the pump is not capable of producing flow according to Step3 of the "Test Specifications", the pump may not be mechanically feasible. The pump is to be internally inspected.

4. This step will verify the pilot pressure override function of the pump control.

   Increase pump discharge pressure to the value in Step 4 of the "Test Specifications". Increase pressure to the pilot pressure port (52). The pump should destroke and the discharge flow should equal the value in Step 4 of the "Test Specifications". If the discharge flow is not equal to the value given in the "Test Specifications", adjust the screw for pilot pressure (52) until the flow is within specification.

5. This step will verify the volumetric efficiency of the pump.

   Decrease pressure to the pilot pressure port (52) according to the value in Step 5 of the "Test Specifications". Slowly increase pump discharge pressure to the value given in Step 5 of the "Test Specifications". Compare the actual value from the case drain with the values in Step 5 of the "Test Specifications". This value is an indication of pump efficiency. If the case drain is more than the value given in Step 5 of the "Test Specifications", the pump may not be mechanically feasible. The pump is to be internally inspected.

Reduce all pressures, electrical current, and input speed to zero. Allow the components to cool. Remove the component from the test bench. Drain the component of oil. Cap or plug all open ports.

Test Specifications

Tooling