Bench Test Procedure for Hydraulic Piston Pumps {5070} Caterpillar

Excavator

336D2 (S/N: MFA1-UP; MEH1-UP; NAH1-UP; LBX1-UP)

336E (S/N: RZA1-UP; SSL1-UP)

336F (S/N: TZA1-UP; RKB1-UP; YFD1-UP; KGH1-UP; NAJ1-UP; ZBJ1-UP; LCL1-UP; NBL1-UP; PFL1-UP; SSN1-UP; LTP1-UP; KFT1-UP; DSW1-UP; MTW1-UP; WTZ1-UP)

340F (S/N: XBD1-UP; YBF1-UP; WBX1-UP)

352F (S/N: XAL1-UP)

Introduction

© 2017 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 Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 5	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 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	g03389270
Port locations and adjustments (49) Electrical connector for swash plate sensor for drive pump (50) Discharge port for drive pump (51) Electrical connector for swash plate sensor for driven pump (52) Discharge port for drive pump (53) Gage port for discharge pressure for driven pump (54) Gage port for discharge pressure for drive pump (55) Electrical connector for solenoid for driven pump (56) Discharge port for auxiliary pump (57) Case drain (58) Adjustment screw for minimum displacement of driven pump (59) Adjustment screw for maximum displacement of driven pump (60) Suction port (61) Suction port for auxiliary pump (62) Adjustment screw for maximum displacement of drive pump (63) Electrical connector for solenoid for drive pump (64) Adjustment screw for minimum displacement of drive pump

Illustration 8	g03370043
Hydraulic schematic (49) Electrical connector for swash plate sensor for drive pump (50) Discharge port for drive pump (51) Electrical connector for swash plate sensor for driven pump (52) Discharge port for drive pump (53) Gage port for discharge pressure for driven pump (54) Gage port for discharge pressure for drive pump (55) Electrical connector for solenoid for driven pump (56) Discharge port for auxiliary pump (57) Case drain (58) Adjustment screw for minimum displacement of driven pump (59) Adjustment screw for maximum displacement of driven pump (60) Suction port (61) Suction port for auxiliary pump (62) Adjustment screw for maximum displacement of drive pump (63) Electrical connector for solenoid for drive pump (64) Adjustment screw for minimum displacement of drive pump

Pump Setup

Illustration 9	g03389284

1. Mount the pump with the suction port (60) downward. Use an adapter to connect the pump to the test bench oil supply.

2. Connect suction port (60) to the test bench oil supply. Connect the suction port for auxiliary pump (61) to the test bench oil supply. Connect the discharge port for auxiliary pump (56) according to Illustration 8. The use of a 120-9181 Valve Body, a 4C-4014 Relief Valve, a 8T-0856 Pressure Gaugeand a 8T-0454 Flow Meter will be required to perform the test procedure.

3. Connect discharge ports (50) and (52) to the flow meter inlets on the test bench. Connect flow meter outlets from the test bench back to tank.

4. Fill the pump case with oil. Pour oil directly into a case drain port (57) until the case is full.

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

6. Install the flow meter to case drain port (57).

7. Connect one end of the hose to the outlet of the flow meter and route the other end of the hose back to the tank.

8. Connect a power supply to the electrical connector for solenoid for driven pump (55) and to the electrical connector for solenoid for drive pump (63). The power supply should be able to deliver 0 V to 6.0 V with an infinite setting in that range.

9. Connect a multimeter to the electrical connector for swash plate sensor for drive pump (49). Connect a multimeter to the electrical connector for swash plate sensor for driven pump (51).

   Note: See the "Swash Plate Position Sensor Setup" section in this document.

Swash Plate Position Sensor Setup

Illustration 10	g03389272
146-4080 Digital Multimeter Gp (65) Common port (66) Voltage port

Illustration 11	g03581848
276-7273 Sensor Test Box (Position Sensor) (67) Positive voltage banana connector (68) Negative voltage banana connector (69) Four-pin Deutsch connector (70) Battery test momentary switch

Illustration 12	g03389275
Fabricated electrical adapter (71) Four-pin Deutsch connector (72) Three-pin Amp-seal connector

Illustration 13	g03389279
Schematic of swash plate position sensing setup (49) Electrical connector for swash plate sensor for drive pump (51) Electrical connector for swash plate sensor for driven pump (67) Positive voltage banana connector (68) Negative voltage banana connector (69) Four-pin Deutsch connector (70) Battery test momentary switch (71) Four-pin Deutsch connector (72) Three-pin Amp-seal connector

Illustration 14	g03389282
Swash plate position sensors (49) Electrical connector for swash plate sensor for drive pump (51) Electrical connector for swash plate sensor for driven pump

Note: This setup only needs to be performed prior to Step 6 of the Test Procedure.

1. Connect 276-7273 Sensor Test Box to 146-4080 Digital Multimeter Gp so that positive voltage banana connector (67) is inserted into voltage port (66) and negative voltage banana connector (68) is inserted into common port (65).

   Note: Use an electrical adapter to connect 276-7273 Sensor Test Box to the electrical connector for swash plate sensor (49) or (51) on the pump. This adapter may need to be fabricated. Refer to Illustration 13 for the schematic.

2. Connect four-pin Deutsch connector (69) into four-pin Deutsch connector (71).

3. Connect three-pin Amp-seal connector (72) to the electrical connector for swash plate sensor (49) or (51). The swash plate sensors will need to be tested one at a time.

4. Turn on 146-4080 Digital Multimeter Gp to read DC voltage. The battery power of the 276-7273 Sensor Test Box can be checked by holding in the battery test momentary switch (70) while the multimeter is on.

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 a contamination rating of 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)

1. Set the voltage from the power supply 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 connections are not leaking. Check for leaks around shaft seals and control valves.

   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 rotation and the discharge pressure according to Step 3 of the Test Specifications. Increase the voltage across each solenoid to the value in the Test Specifications. Verify the flow out of the discharge port for auxiliary pump (56). Adjust 4C-4014 Relief Valve to the auxiliary pump discharge pressure in Step 3 of the Test Specifications. If the main pump maximum flow is not within specifications adjust the adjustment screw for maximum angle (59) or (62). Loosen the locknut and turn the adjustment screw for maximum angle (59) or (62) counter-clockwise in order to increase the flow until the flow is within specifications. Loosen the locknut and turn the adjustment screw for the maximum angle (59) or (62) clockwise in order to decrease the flow until flow is within specifications. After adjustment, torque locknut to 177 N·m (131 lb ft).

3. Slowly decrease input voltage according to Step 3 of the Test Specifications. The minimum flow should read the value in Step 3 of the Test Specifications. If the discharge flow does not fall within the specified value adjustment of the adjustment screw for minimum displacement (58) or (64) is necessary. If the discharge flow is too high, loosen the locknut and slowly turn the adjustment screw for minimum displacement (58) or (64) counter-clockwise until the discharge flow is correct. If the discharge flow is too low, loosen the locknut and turn the adjustment screw for minimum displacement (58) or (64) clockwise until discharge flow is correct. After adjustment, torque the locknut to 177 N·m (131 lb ft).

4. This step will check the pump control function.

   Set the pump RPM, solenoid voltage, and discharge pressures according to Step 4 of the Test Specifications. The discharge flow should be the value in Step 4 of the Test Specifications as the voltage is adjusted from maximum voltage to minimum voltage and back to maximum voltage given in Step 4 of the Test Specifications.

5. This step will check the pump efficiency.

   The drive and driven pumps will be tested separately. Refer to footnote 3 in the Test Specifications.

   1. Set the RPM and discharge pressures according to Step 5a of the Test Specifications. Apply the solenoid voltage in Step 5a of the Test Specifications to the electrical connector for solenoid for drive pump (63). The max case drain of the drive pump should not be greater than the value given in Step 5a of the Test Specifications. If the max case drain is greater than this value, the pump may not be mechanically feasible.

   2. Set the RPM and discharge pressures according to Step 5b of the Test Specifications. Apply the solenoid voltage in Step 5b of the Test Specifications to the electrical connector for solenoid for driven pump (55). The max case drain of the driven pump should not be greater than the value given in Step 5b of the Test Specifications. If the max case drain is greater than this value, the pump may not be mechanically feasible.

6. This step will check the operation of the swash plate sensor.

   Set the pump RPM and discharge pressures according to Step 6 of the Test Specifications. Set the solenoid voltages to the minimum value in Step 5 of the Test Specifications. Read the voltages across the swash plate sensors (49) and (51) while the swash plate is at the minimum angle. Adjust the solenoid voltages to the maximum value in Step 5 of the Test Specifications. Read the voltages across the swash plate sensors (49) and (51) while the swash plate is at the maximum angle. The difference between the voltages at minimum and maximum angle should be equal to the value in Step 5 of the Test Specifications.

Test Specifications

Tooling