Bench Test Procedure for Hydraulic Piston Pumps{5070} Caterpillar

Excavator:

215B (S/N: 9YB1372-1704,1705-3158,3159-UP; 2XC1-UP; 4FC426-499,500-834,835-UP)

215C (S/N: 4HG1-UP)

215D (S/N: 9TF1-UP)

219 (S/N: 5CF1-UP)

219D (S/N: 5XG1-UP)

225 (S/N: 51U6258-6527,6528-UP; 76U5916-5931,5933-UP; 61X414-UP)

225B (S/N: 2ZD1-UP; 3YD1-UP)

225D (S/N: 6RG1-UP; 2SJ1-221,222-289,290-UP)

229 (S/N: 1GF1-UP; 1AG1-UP)

229D (S/N: 2LJ1-UP)

231D (S/N: 5WJ1-284,285-UP; 1NK1-UP)

Introduction

© 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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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 1	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 2	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 3	g01063314
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 4	g01093468
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 5	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 6	g01142939
Typical port locations and adjustments (49) Adjustment screw for constant power (50) Adjustment screw for the ramp angle (51) Adjustment screw for minimum angle (52) Pressure port for Summation (53) Discharge port (54) Suction port (55) Adjustment screw for maximum angle (56) Case drain port (57) Pressure port for the actuator (if equipped)

Pump Pre-Test Set Up

1. A 6V-3965 Quick Disconnect Fitting is needed for the summation pressure port (52) (refer to Illustration 1). Install a 8T-2353 Adapter into the summation pressure port (52). Install a 6V-3965 Quick Disconnect Fitting into 8T-2353 Adapter .

   Connect a 8T-0860 Pressure gauge to the pressure port for summation (52) .

2. Connect the discharge ports to the flow meter loops on the test bench.

3. Vent the pressure port for the actuator (57) (if equipped) to the atmosphere in order to prevent hydraulic lock.

4. Connect the pump suction port (54) to the test bench oil supply.

5. Carefully loosen the drain plug. This will release the case's air pressure in order to allow the case to fill with oil from the suction line.

6. Verify that the pump case is full of oil before rotating. Secure the drain plug (56).

7. 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 pump for proper rotation.

8. Measure the distance from the top of the locknut to the end of the adjustment screw for minimum angle (51). This distance should be 17 mm (0.6693 inch). Loosen the locknut and turn the adjustment screw for minimum angle (51) accordingly if the adjustment is not correct. Torque the locknut to 55 N·m (487 lb in) after adjusting.

Test Procedure

Note: The steps in the procedure correlate with the steps under the test specifications according to your specific part number.

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)

Illustration 7	g01013782

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. Increase the input RPM and the pump discharge pressure to the value in Step 2 of the test specifications.

   Adjust the adjustment screw for the maximum angle (55) if the discharge flow is not within specifications. Loosen the locknut and turn the adjustment screw for maximum angle (55) counterclockwise in order to increase the flow. Turn the adjustment screw for maximum angle (55) clockwise in order to decrease the flow.

3. Use the test bench to load one pump's discharge to the high (H) pressure value in Step 3. Load the other pump's discharge to the low (L) pressure value in Step 3 of the test specifications. Verify that the summation pressure is correct. The summation pressure is the average of the two discharge pressures. Replace the summing valve if the summation pressure is not equal to the value in Step 3 of the test specifications.

4. Use the test bench to load each pump's discharge to the value in Step 4 of the test specifications. Verify that the summation pressure is correct.

   This is the point of adjustment for constant power. The discharge flows should equal the value in Step 4 of the test specifications. The constant power adjustment screw (49) must be adjusted accordingly if the pump's discharge flow is not within specifications.

   Loosen the locknut on the constant power adjustment screw (49) in order to change the flow rate. (49). Turn the constant power adjustment screw (49) clockwise in order to increase the discharge flow to the value in Step 4 of the test specifications. Turn the constant power adjustment screw (49) counterclockwise in order to decrease the discharge flow to the value in the Step 4 of the test specifications.

5. Use the test bench to load each pump's discharge to the value in Step 5 of the test specifications. Verify that the summation pressure is correct.

   This is the point of adjustment for the ramp angle. The discharge flows should equal the value in Step 5 of the test specifications. The adjustment screw for the ramp angle (50) must be adjusted accordingly if the discharge flow is not within specifications.

   Loosen the locknut on the adjustment screw for the ramp angle (50) in order to change the flow rate. Turn the adjustment screw for the ramp angle (50) clockwise until the flow rates match the value in Step 4 of the test specifications. Turn the adjustment screw for the ramp angle (50) counterclockwise until the flow rates match the value in the Step 5 of the test specifications.

Note: If an adjustment is made during Step 5, Step 4 must be verified again.

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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

Tooling