Bench Test Procedure for Hydraulic Piston Pumps {5070} Caterpillar

Excavator

330D (S/N: RDA1-UP; KAB1-UP; GBC1-UP; PFC1-UP; NBD1-UP; R2D1-UP; GGE1-UP; NEF1-UP; B6H1-UP; EAH1-UP; LCJ1-UP; THJ1-UP; C5K1-UP; E4K1-UP; FFK1-UP; H3K1-UP; L2K1-UP; PCK1-UP; RDK1-UP; PEL1-UP; JJM1-UP; LEM1-UP; LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP; LDR1-UP; HAS1-UP; RAS1-UP; EDX1-UP; MEY1-UP; T2Y1-UP)

336D (S/N: PTB1-UP; SKE1-UP; J2F1-UP; JBF1-UP; PRF1-UP; LMG1-UP; MYG1-UP; KDJ1-UP; W3K1-UP; WRK1-UP; MPL1-UP; ZML1-UP; PPN1-UP; MYP1-UP; JER1-UP; JWR1-UP; DTS1-UP; MDS1-UP; NLS1-UP; JBT1-UP; KKT1-UP; M4T1-UP; WET1-UP; PGW1-UP; EMX1-UP)

336D2 (S/N: WBC1-UP; WDC1-UP; YCF1-UP; XBH1-UP; LAM1-UP; NBN1-UP; ELR1-UP; FAR1-UP; EFT1-UP; ZCT1-UP; TLY1-UP)

340D (S/N: JTN1-UP)

340D2 (S/N: HHK1-UP)

345B (S/N: CFM1-UP)

345B Series II (S/N: ALB1-UP; APB1-UP; CCC1-UP; ALD1-UP; AMD1-UP; FEE1-UP; AKJ1-UP; AMJ1-UP; CDJ1-UP; AMN1-UP; AYR1-UP; AGS1-UP; DET1-UP; DCW1-UP; AKX1-UP)

345C (S/N: TBA1-UP; FPC1-UP; MDC1-UP; SPC1-UP; ESD1-UP; MTE1-UP; WDE1-UP; TDG1-UP; GBH1-UP; GPH1-UP; TAJ1-UP; A3L1-UP; GCL1-UP; S5M1-UP; RFN1-UP; SCN1-UP; DHP1-UP; JAR1-UP; M2R1-UP; D3S1-UP; ELS1-UP; LYS1-UP; PJW1-UP; BWY1-UP)

365B (S/N: AGD1-UP; CFJ1-UP; CTY1-UP; 4XZ1-UP; 9PZ1-UP)

365B Series II (S/N: BTH1-UP)

365BL (S/N: 9TZ1-UP)

365BL Series II (S/N: JMB1-UP; PEG1-UP; SDL1-UP; DER1-UP)

365C (S/N: ELC1-UP; GWC1-UP; MEM1-UP; FEN1-UP; PAR1-UP; MCS1-UP; MCY1-UP)

374D (S/N: PJA1-UP; PAP1-UP; PAS1-UP; PAX1-UP)

385B (S/N: MYA1-UP; RCD1-UP; BKF1-UP; FDL1-UP; ANS1-UP; CLS1-UP; BKX1-UP; BLY1-UP)

385C (S/N: EDA1-UP; MMA1-UP; KGB1-UP; KBC1-UP; SBE1-UP; T2E1-UP; T2F1-UP; KKK1-UP; EAM1-UP; JCM1-UP; WAW1-UP; MNZ1-UP)

390D (S/N: WAG1-UP; BYP1-UP; WAP1-UP; WBT1-UP; KCZ1-UP)

5090B (S/N: CLD1-UP; SJY1-UP)

Hydraulic Shovel

6015B (S/N: FKD1-UP; HLD1-UP; MKE1-UP; PZE1-UP; LWN1-UP; WSN1-UP; ZEN1-UP; LWS1-UP)

6020B (S/N: D4R1-UP; DNR1-UP)

Landfill Compactor

836K (S/N: LWZ1-UP; TWZ1-UP)

Load Haul Dump

R1700 (S/N: KT41-UP)

Motor Grader

12H (S/N: 1251-UP; CBK1-UP; AMZ1-UP)

140H (S/N: 1261-UP; CCA1-UP; APM1-UP)

143H (S/N: APN1-UP)

14H (S/N: ASE1-UP)

160H (S/N: ASD1-UP; CCP1-UP)

163H (S/N: ARL1-UP)

16H (S/N: ATS1-UP)

Pipelayer

583T (S/N: CMX1-UP)

Rotary Drill

MD6250 (S/N: DN71-UP)

Telehandler

TH220B (S/N: SLA1-UP)

TH336C (S/N: MJR1-UP)

TH350B (S/N: SLD1-UP)

Track-Type Tractor

24 (S/N: E9Z1-UP; N9Z1-UP)

D10T (S/N: RJG1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; DDD1-UP; MDG1-UP; JEL1-UP; RAL1-UP; JNS1-UP)

D8T (S/N: J8B1-UP; KPZ1-UP)

D9T (S/N: TWG1-UP; RJS1-UP)

Wheel Dozer

814K (S/N: LW41-UP; T1Z1-UP)

834K (S/N: LWY1-UP; TWY1-UP)

844K (S/N: MBE1-UP; M4R1-UP; KLS1-UP; K4Y1-UP)

Wheel Loader

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)

Wheeled Excavator

M330D (S/N: KRE1-UP; MBR1-UP)

W345B Series II (S/N: ANJ1-UP; CDY1-UP)

W345C (S/N: R5K1-UP)

Introduction

© 2018 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. 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

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	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	g03867247
Port locations and adjustments (49) Case drain port (50) Adjustment screw for standby pressure (51) Suction port (52) Discharge port (53) Adjustment screw for high-pressure cut (54) Electrical connector for inverse proportional control

Illustration 8	g03867871
Hydraulic Schematic (49) Case drain port (50) Adjustment screw for standby pressure (51) Suction port (52) Discharge port (53) Adjustment screw for high-pressure cut (54) Electrical connector for inverse proportional control

Pump Pre-Test Set Up

Note: A power supply is required to operate the solenoid. The power supply should deliver 0 mA to 1500 mA with an infinite setting in that range.

1. Connect a1 inch high-pressure "XT-6" rated hose from the pump discharge port (52) to the flow meter inlet on the test bench.

2. Connect a 1 inch hydraulic hose from the flow meter outlet on the test bench back to the tank.

3. Connect the hydraulic oil suction line to the inlet port (51).

4. 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.

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

6. Connect an in-line flow meter to the case drain port (49). Direct the oil from the in-line flow meter back to the tank.

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.

Test Procedure

Note: The steps in the procedure correlate with the steps in the test specification tables 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 9	g00940246

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 to raise the temperature of the oil and purge the system of air.

2. Slowly increase the input RPM to the value in Step 2 of the test specifications. If the actual flow is less than the value in Step 2 of the test specifications, the pump may not be mechanically feasible. Internally inspect the pump.

3. Increase the pump discharge pressure to the value in Step 3 of the test specifications. Compare the actual value of the case drain with the values in Step 3 of the test specifications. This value is an indication of the pump efficiency. If the case drain is more than the value given in Step 3 of the test specifications, the pump may not be mechanically feasible. Internally inspect the pump.

4. Apply current to the value in Step 3 of the test specifications when applicable. Increase the pump discharge pressure to the value in Step 4 of the test specifications. If the value is not within the value in Step 4 of the test specifications, turn the adjustment screw for the high pressure cut (53) until the actual high-pressure cut value is equal to the value in Step 4 of the test specifications. The discharge flow should be zero when the high-pressure cut is reached.

5. Apply the solenoid current to the value in Step 5 of the test specifications. The discharge pressure should not reach above the value in Step 5 of the test specifications. This step will test the operation of the solenoid valve. This value should be used for reference only.

6. Increase the solenoid current to the value in Step 6 of the Test Specifications. This discharge pressure should drop to the value in Step 6 of the Test Specifications. This is the standby pressure setting. The discharge pressure should not be higher than the value in Step 6 of the Test Specifications. If the standby pressure setting is not correct, turn adjustment screw for standby pressure (50) until the value is within specifications.

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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