Bench Test Procedure for Hydraulic Piston Pumps {3203, 5070} Caterpillar

Forwarder

564 (S/N: KBN1-UP)

574B (S/N: RLS1-UP; CZZ1-UP)

Industrial Engine

C0.5 (S/N: C621-UP)

Pipelayer

572R (S/N: AAC1-UP; 2HZ1-UP)

572R Series II (S/N: DSC1-UP)

Rotary Drill

MD6240 (S/N: DN21-UP; DR21-UP; DT41-UP; DS61-UP)

MD6290 (S/N: DN31-UP; DR31-UP; DS31-UP; DS51-UP; DT81-UP)

MD6420 (S/N: DR41-UP; DT71-UP; DT91-UP)

Track-Type Tractor

D6H (S/N: 3ZF1-UP; 5HF1-UP; 6CF1-UP; 3YG1-UP)

D6H Series II (S/N: 9KJ1-UP; 6CK1-UP; 9LK1-UP; 1YL1-UP)

D6R (S/N: A6M1-UP; EMM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; JEN1-UP; 3ZN1-UP; 5LN1-UP; 7KN1-UP; 9MN1-UP; 9PN1-UP; DMP1-UP; 7GR1-UP; S6T1-UP; 1RW1-UP; S6X1-UP; S6Y1-UP)

D6R Series II (S/N: BNC1-UP; ADE1-UP; DAE1-UP; AFM1-UP; BPM1-UP; AEP1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP)

D6R Series III (S/N: WCB1-UP; HDC1-UP; RFC1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; MRT1-UP; EXW1-UP)

D7H (S/N: 5BF1-99999; 4FG1-99999)

D7R (S/N: R7B1-UP; R7C1-UP; DSH1-UP; R7H1-UP; DLN1-UP; 2EN1-UP; 3DN1-UP; DJR1-UP; 5KZ1-UP)

D7R Series II (S/N: AEC1-UP; ABJ1-UP; AGN1-UP)

D8N (S/N: 9TC1-99999; 1XJ1-99999)

Wheel Loader

980K (S/N: W7K1-UP; GTZ1-UP)

980L (S/N: D8Z1-UP)

980M (S/N: MK21-UP; MGD1-UP; KRS1-UP; N8T1-UP)

982M (S/N: MK61-UP; F9A1-UP; WMD1-UP; LRS1-UP; K1Y1-UP)

Introduction

© 2018 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 Dealer Service Tools. 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	g01067335
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" outlet for the flow meter with flow limiter (6) Oil supply (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	g01067338
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	g01067339
Connections for the Test Bench (26) "Flow meter 1" loop and "Flow meter 2" loop (27) Oil Supply

Illustration 5	g01067341
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 (33) Auxiliary pump oil supply (34) "Flow meter 1" outlet (35) "Flow meter 1" inlet

Illustration 6	g01067342
Control and Gauges for the Test Bench (36) Auxiliary pump pressure (37) Signal pressure (38) Control for signal pressure (39) "Flow meter 1" discharge pressure (40) Control for auxiliary pump pressure (41) "Flow meter 2" discharge pressure (42) Auxiliary pump flow 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	g01281485
Typical port locations and adjustment locations for single pump (49) Adjustment screw for margin pressure (50) Adjustment screw for high-pressure cut (51) Pressure port for load sensing (52) Case drain port (53) Suction port (54) Discharge port

Illustration 8	g01271436
Hydraulic Schematic for single pump (49) Adjustment screw for margin pressure (50) Adjustment screw for high-pressure cut (51) Pressure port for load sensing (52) Case drain port (53) Suction port (54) Discharge port

Illustration 9	g02522901
Typical port locations and adjustment locations for double pump (49) Adjustment screw for margin pressure (50) Adjustment screw for high-pressure cut (51) Pressure port for load sensing (52) Case drain port (53) Suction port (54) Discharge port

Illustration 10	g02522917
Hydraulic Schematic for double pump (49) Adjustment screw for margin pressure (50) Adjustment screw for high-pressure cut (51) Pressure port for load sensing (52) Case drain port (53) Suction port (54) Discharge port

4C-3582 Load Sensing Valve

Illustration 11	g01213586
4C-3582 Load Sensing Valve

Illustration 12	g01213587
4C-3582 Load Sensing Valve

Illustration 13	g01082036
Schematic for 4C-3582 Load Sensing Valve

Illustration 14	g01271677
4C-3582 Load Sensing Valve and 1U-5796 Pressure Differential Gauge (55) Outlet port (56) Adjustment for the discharge flow (57) high-pressure port (58) Inlet port (59) Adjustment for the discharge pressure (60) low-pressure port (61) Pressure port for load sensing (62) Pressure differential gauge group (63) low-pressure gauge port (64) high-pressure gauge port

Pump Setup

Illustration 15	g02529936
Tee Assembly required for double pump test (65) 8C-9032 Quick Disconnect Nipple (66) 7M-8485 O-Ring (67) 369-6833 Tee

Illustration 16	g02530476
Plumbing for double pump using the Tee Assembly (54) Discharge port

Note: For double pump, both discharge ports must be connected together using XT-6 hoses with a 369-6833 Tee. The remaining outlet on the 369-6833 Tee will be the discharge port throughout the Pump Setup and the Test Procedure when testing a double pump. See Illustration 15 for Tee Assembly. See Illustration 16 for plumbing the double pump with the Tee Assembly. See Test Specifications for designation of double pump.

Note: Due to the limited spacing between the discharge ports on the double pump, a 1U-8303 Elbow must be used on one of the 9U-7440 Flange Adapters to allow clearance for the quick disconnects. The 1U-8303 Elbow requires a 360-3692 Plug and a 3J-1907 O-Ring to seal the 9/16-18 STOR port. A 7M-8485 O-Ring is required between the 9U-7440 Flange Adapter and the 8C-9032 Quick Disconnect Nipple.

1. Connect a 1 inch high-pressure "XT6" hose from the pump discharge port (54) to inlet port (58) on the 4C-3582 Load Sensing Valve.

2. Connect a 1 inch high-pressure "XT6" hose from outlet port (55) 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 flow meter outlet on the test bench back to the tank.

4. Connect a 6D-7726 Hose Assembly to the pressure port for load sensing (61). Connect the other end of 6D-7726 Hose Assembly to the pressure port for load sensing (51) 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 (62) to the high-pressure valve port (57) and low-pressure valve port (60) on the 4C-3582 Load Sensing Valve. The port marked "hi" (64) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "hi" (57) on the 4C-3582 Load Sensing Valve. The port marked "low" (63) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "low" (60) on the 4C-3582 Load Sensing Valve.

   Note: The ports marked "low" (60) and "sense line" (61) on the 4C-3582 Load Sensing Valve are reading the same pressure.

6. Connect suction port (53) to the oil reservoir. 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 case drain port (52) until the case is full.

8. Direct a line from case drain port (52) to the test bench reservoir.

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

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 17	g01172757
Load sensing and high-pressure cut characteristics (P) Discharge pressure (Q) Discharge flow

1. Start rotating the pump according to Step 1 of the Test Specifications. Listen for abnormal noise. Verify flow from the pump. Verify that all connections are not leaking. Check for leaks around shaft seals. Check for leaks around the control valve.

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. The pump is to be internally inspected.

3. The discharge flow is adjusted by using the 4C-3582 Load Sensing Valve adjustment for discharge flow (56). Adjust the discharge flow 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 adjustment screw for margin pressure (49) to the value in Step 3 of the Test Specifications. The margin pressure will be displayed on 1U-5796 Pressure Differential Gauge (62).

   Note: The margin pressure may change as discharge pressure changes. Adjust margin pressure at Step 3 of the Test Procedure within operating conditions only.

   Return the pump to full flow by adjusting discharge flow (56).

4. Adjust the pump discharge pressure to the value in Step 4 of the Test Specifications. Compare the actual case drain values with the values in Step 4 of the Test Specifications. This value is an indication of the efficiency. If the case drain is more than the value given in Step 4 of the Test Specifications, the pump may not be mechanically feasible. The pump is to be internally inspected.
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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 during adjustment of the high pressure relief valve if recommended hose maintenance practices are not followed. Escaping fluid under pressure can penetrate body tissue causing serious injury, and possible death. Adjustment of the high pressure cut or pressure override valve shall only be performed when the pump is operating at a zero discharge pressure condition. Continuation of the pump test procedure can be resumed when this high pressure adjustment is completed.

5. Adjust the pump discharge pressure to the value in Step 5 of the Test Specifications. If the high-pressure cut is not within the test specifications, use the adjustment screw for the high pressure cut (50) until the actual high-pressure cut value is equal to the value in Step 5 of the Test Specifications. The discharge flow should be near zero when the high-pressure cut is reached.

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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