Bench Test Procedure for Hydraulic Piston Pumps{5070} Caterpillar

Articulated Truck:

725 (S/N: WWA1-UP; B1L1-UP; AFX1-UP)

730 (S/N: WWB1-UP; AGF1-UP)

730 EJECTOR (S/N: B1M1-UP; B1W1-UP)

735 (S/N: WWC1-UP; B1N1-UP; AWR1-UP)

735B (S/N: L4D1-UP; T4P1-UP; E4R1-UP)

740 (S/N: WWD1-UP; AXM1-UP; B1P1-UP; DTX1-UP; AZZ1-UP)

740 EJECTOR (S/N: B1R1-UP)

740B (S/N: L4E1-UP; GLH1-UP; T4R1-UP; E4S1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

D250E Series II (S/N: 4PS1-UP)

D250E (S/N: 5TN1-UP)

D300E Series II (S/N: 5KS1-UP)

D300E (S/N: 7FN1-UP)

D350E Series II (S/N: 2XW1-UP)

D400E Series II (S/N: APF1-UP; 8PS1-UP)

Cold Planer:

PR-1000C (S/N: 5XC1-UP)

PR-750B (S/N: 8AC1-UP)

PR-750C (S/N: 7CK1-UP)

Engine:

3126 (S/N: 9ZR1-UP)

3516 (S/N: 29Z1-UP)

Excavator:

5130B (S/N: 4CS1-UP)

5230 (S/N: 7LL1-UP)

5230B (S/N: 4HZ1-UP)

Off-Highway Truck/Tractor:

784B (S/N: 5RK1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP; AP21-UP)

785D (S/N: DMC1-UP; MSY1-UP)

789 (S/N: 9ZC1-UP)

OEM POWERTRAIN (S/N: DTE1-UP)

Pipelayer:

PL83 (S/N: DLW1-UP; CB21-UP)

PL87 (S/N: TEC1-UP; ZAC1-UP)

Track-Type Tractor:

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

D11T (S/N: GEB1-UP; TPB1-UP; DDD1-UP; RAL1-UP)

Wheel Dozer:

844 (S/N: 2KZ1-UP)

Wheel Loader:

990 Series II (S/N: 4FR1-UP)

990 (S/N: 7HK1-UP)

Wheel Tractor-Scraper:

621F (S/N: 4SK1-UP)

621G (S/N: DBB1-UP; DXB1-UP; MSE1-UP; KLK1-UP; NEL1-UP; CEN1-UP; ALP1-UP; CEP1-UP; KJW1-UP; DBX1-UP; MEX1-UP)

621H (S/N: DBK1-UP)

623G (S/N: DBC1-UP; CES1-UP; ARW1-UP; CEW1-UP; DBY1-UP)

623H (S/N: DBF1-UP)

627G (S/N: DBD1-UP; AXF1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)

627H (S/N: DBW1-UP)

631E (S/N: 1AB1-UP)

631G (S/N: DFA1-UP; DXE1-UP; AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP; M1W1-UP)

637E (S/N: 1FB1-UP)

637G (S/N: CEH1-UP; CEJ1-UP; DFJ1-UP; AXT1-UP; DEX1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3583
00	New document.

© 2015 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 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 questions or additional information concerning this guideline, submit a feedback for in the Service Information System website. In Order to address an urgent need, please use the following to relay your request to Caterpillar Repair Process Engineering.

• Cat Dealer Technical Communicator

• Dealer Solution Network

• Cat Technical Representative

• Knowledge Network (on-line)

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. The test procedure should be used with the ""Test Specifications" " and the ""Tooling" " sections. Both sections are displayed toward the back 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

Table 2

References
Media Number	Title
REHS1761	Required Tooling for Bench Testing Hydraulic Components
SEBF8810	Hydraulic Pump, Motor, and Cylinder Bench Test Procedure Reference Manual
SEHS8892	Operating Instructions for Caterpillar 1U-9400 Series Hydraulic Test Center
NEHS0563	Tool Operating Manual for 9U-5000 Series Hydraulic Test Bench

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

Pump Illustrations

Illustration 7	g03875777
Port locations for pumps with rear-facing suction and discharge ports and a rear-mounted control. (49) Case drain port (50) Adjustment screw for the high-pressure cut (51) Discharge port (52) Case drain port (53) Suction port

Illustration 8	g03875778
Port locations for pumps with side-facing suction and discharge ports and a side-mounted control. (49) Case drain port (50) Adjustment screw for the high-pressure cut (51) Discharge port (52) Case drain port (53) Suction port

Illustration 9	g01380768

Pump Setup

1. Connect a one inch high pressure "XT-6 " rated hose from the pump discharge port (51) to the flow meter inlet on the test bench.

2. Connect a one inch high pressure "XT-6" rated hose from the flow meter outlet on the test bench back to the tank.

3. Connect the oil supply suction hose to pump inlet port (53) .

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 fitting.

5. Fill the pump case with oil before rotating. 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) or (52). 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 for proper rotation of the test bench.

Test Procedure

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

The contamination level of the hydraulic oil in the test bench should be 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)

Illustration 10	g01378800
Pump Characteristics (F) Discharge Flow (P) Discharge Pressure

Note: If the pump being tested has a control valve with two valves, always be sure the adjustment screw on the valve farthest from the pump is turned in completely. See Illustrations 7 and 8 for reference.

1. Start rotating the pump according to the RPM in Step 1 of the ""Test Specifications" ". Listen for abnormal noise and verify flow from the pump. Be sure that all connections are secure and not leaking. Check for leaky shaft seals and control valve connections.

2. Slowly increase the input RPM to the value in Step 2 of the ""Test Specifications" ". The pump may not be feasible if the actual flow is less than the value in Step 2 of the ""Test Specifications" ". The pump should be disassembled and inspected.

3. Increase the pump discharge pressure to the value in Step 3 of the ""Test Specifications" ". Compare the actual case drain value with the case drain value in Step 3 of the ""Test Specifications" ". This value is an indication of the pump efficiency. The pump may not be feasible if the case drain is more than the value in Step 3 of the ""Test Specifications" ". The pump should be disassembled and inspected.

4. Increase the pump discharge pressure to the value in Step 4 of the ""Test Specifications" ". Turn the adjustment screw for the high pressure cut (50) until the actual high-pressure cut value is equal to the value in Step 4 of the ""Test Specifications" ". Pump discharge flow should be 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. Cap and plug all ports.

Test Specifications

Table 3

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
105-4913	CCW	1	1000	0	71 (19)	-
		2	1500	0	106 (28)	-
		3	1500	9540 (1384)	106 (28)	6.2 (1.6)
		4	1500	10600±350 (1537±50)	0	-

Table 4

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
109-4197	CCW	1	1000	0	71 (19)	-
		2	1500	0	106 (28)	-
		3	1500	9540 (1384)	106 (28)	6.2 (1.6)
		4	1500	10600±350 (1537±50)	0	-

Table 5

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
131-5269	CCW	1	1000	0	28 (7)	-
		2	1500	0	42 (11)	-
		3	1500	13950±630 (2025±90)	42 (11)	3.0 (0.8)
		4	1500	15500±700 (2250±100)	0	-

Table 6

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
136-4631	Tandem Pumps, see 145-4878 (REHS9363) or 145-0771

Table 7

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
137-2550	Tandem Pumps, see 171-2949 (REHS1377) or 171-2950

Table 8

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
145-0771	CCW	1	1000	0	22 (6)	-
		2	1500	0	33 (9)	-
		3	1500	14850 (2154)	33 (9)	4.0 (1.0)
		4	1500	16500±350 (2395±50)	0	-

Table 9

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
152-2913	CCW	1	1000	0	18 (5)	-
		2	2000	0	36 (10)	-
		3	2000	18630±350 (2700±50)	36 (10)	1.6 (0.5)
		4	2000	20700±350 (3000±50)	0	-

Table 10

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
161-6743	CCW	1	1000	0	18 (5)	-
		2	1500	0	27 (7)	-
		3	1500	18900 (2741)	27 (7)	1.6 (0.5)
		4	1500	21000±350 (3045±50)	0	-

Table 11

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
171-2950	CCW	1	1000	0	18 (5)	-
		2	1500	0	27 (7)	-
		3	1500	18630 (2702)	27 (7)	1.6 (0.5)
		4	1500	20700±350 (3002±50)	0	-

Table 12

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
172-5636	CCW	1	1000	0	22 (6)	-
		2	1500	0	33 (9)	-
		3	1500	17550 (2545)	33 (9)	4.0 (1.0)
		4	1500	19500±350 (2828±50)	0	-

Table 13

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
172-9322	CW	1	1000	0	18 (5)	-
		2	1500	0	27 (7)	-
		3	1500	18630 (2702)	27 (7)	1.6 (0.5)
		4	1500	20700±350 (3002±50)	0	-

Table 14

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
177-0280	CW	1	1000	0	18 (5)	-
		2	1500	0	27 (7)	-
		3	1500	18630 (2702)	27 (7)	1.6 (0.5)
		4	1500	20700±350 (3002±50)	0	-

Table 15

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
187-9090	CCW	1	1000	0	18 (5)	-
		2	1500	0	27 (7)	-
		3	1500	18900 (2741)	27 (7)	1.6 (0.5)
		4	1500	21000±350 (3045±50)	0	-

Table 16

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
190-2279	CCW	1	1000	0	71 (19)	-
		2	1500	0	106 (28)	-
		3	1500	15822 (2295)	106 (28)	6 (1.6)
		4	1500	17580±345 (2550±50)	0	-

Table 17

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
202-1335	CCW	1	1000	0	18 (5)	-
		2	1500	0	27 (7)	-
		3	1500	14400 (2089)	27 (7)	1.6 (0.5)
		4	1500	16000±350 (2320±50)	0	-

Table 18

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
203-2790	CW	1	1000	0	18 (5)	-
		2	1500	0	27 (7)	-
		3	1500	14400 (2089)	27 (7)	1.6 (0.5)
		4	1500	16000±350 (2320±50)	0	-

Table 19

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
218-3686	CW	1	1000	0 (0)	18 (5)	-
		2	1500	0 (0)	27 (7)	-
		3	1500	21150 (3068)	27 (7)	1.6 (0.5)
		4	1500	23500±350 (3408±51)	0 (0)	-

Table 20

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
232-1835	CCW	1	1000	0 (0)	71 (19)	-
		2	1500	0 (0)	106 (28)	-
		3	1500	15822 (2295)	106 (28)	6 (1.6)
		4	1500	17580±345 (2550±50)	0 (0)	-

Table 21

Part Number	Pump Rotation	Step	Input Speed	Discharge Pressure kPa (psi)	Discharge Flow lpm (gpm)	Max. Case Drain Flow lpm (gpm)
432-6069	CW	1	1000	0 (0)	110 (29)	-
		2	1500	0 (0)	165 (43)	-
		3	1500	3600±225 (520±30)	165 (43)	12 (3)
		4	1500	4000±250 (580±40)	0	-

Tooling

Table 22

Tooling
Part Number	Adapter Plate	Drive Adapter	Suction Adapter	Split Flange	Flange Adapter	Case Drain Port
105-4913	1U-9128	1U-9834	1U-9873	1P-4577	9U-7444	7/8-14 STOR
109-4197	1U-9128	1U-9834	1U-9873	1P-4577	9U-7444	M22 X 1.5
131-5269	1U-9127	1U-9833	1U-9869	1P-4576	9U-7443	3/4-16 STOR
136-4631	Tandem Pumps, see 145-4878 (REHS9363) or 145-0771
137-2550	Tandem Pumps, see 171-2949 (REHS9363) or 171-2950
145-0771	1U-9127	4C-4088	1U-9870	1P-4577	9U-7444	7/8-14 STOR
152-2913	1U-9127	1U-9833	1U-9872	1P-4576	9U-7443	M16 X 1.5
161-6743	1U-9126	1U-9836	1U-9872	1P-4576	9U-7443	9/16-18 STOR
171-2950	1U-9126	1U-9836	1U-9872	1P-4576	9U-7443	9/16-18 STOR
172-5636	1U-9127	4C-4088	1U-9870	1P-4577	9U-7444	7/8-14 STOR
172-9322	1U-9127	1U-9833	1U-9872	1P-4576	9U-7443	9/16-18 STOR
177-0280	1U-9127	1U-9833	1U-9872	1P-4576	9U-7443	9/16-18 STOR
187-9090	1U-9127	1U-9833	1U-9872	1P-4576	9U-7443	9/16-18 STOR
190-2279	1U-9128	1U-9834	1U-9873	1P-4578	9U-7445	7/8-14 STOR
202-1335	1U-9126	1U-9836	1U-9872	1P-4576	9U-7443	9/16-18 STOR
203-2790	1U-9126	1U-9836	1U-9872	1P-4576	9U-7443	9/16-18 STOR
218-3686	1U-9126	1U-9836	1U-9872	1P-4576	9U-7438	9/16-18 STOR
232-1835	1U-9128	1U-9834	1U-9873	1P-4578	9U-7440	7/8-14 STOR
432-6069	1U-9126	1U-9394	1U-9869	6V-0397	9U-7445	1 1/16-12 STOR