Bench Test Procedure for Hydraulic Piston Pumps{5070} Caterpillar


Bench Test Procedure for Hydraulic Piston Pumps{5070}

Usage:

950G 2JS
Articulated Truck:
740 (S/N: DTX1-UP)
Asphalt Paver:
AP1000F (S/N: AC41-UP)
AP500F (S/N: 5031-UP; 4491-UP)
AP600F (S/N: AP61-UP; LR61-UP)
Landfill Compactor:
836G (S/N: BRL1-UP)
Integrated Toolcarrier:
IT62G (S/N: AKP1-UP; 6PS1-UP)
Off-Highway Truck/Tractor:
OEM POWERTRAIN (S/N: DTE1-UP)
Underground Articulated Truck:
AD55B (S/N: JNW1-UP)
Wheel Dozer:
834G (S/N: BPC1-UP; 6GZ1-UP)
Wheel Loader:
950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)
962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)
980G (S/N: 9CM1-UP; 2KR1-UP; 2SR1-UP)
988G Series RTCH (S/N: 1NZ1-UP)
988G (S/N: BNH1-UP; 2TW1-UP)
988H (S/N: A7A1-UP)
988H CUSTOM (S/N: BXY1-UP)

Introduction

Table 1
Revision     Summary of Changes in REHS3586    
00     New Document    

© 2015 Caterpillar All Right 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 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




Illustration 1g02139237

------ WARNING! ------

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.

----------------------

------ WARNING! ------

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

----------------------

------ WARNING! ------

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

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 2g01037439

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 3g01037451

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 4g01063314

Connections for the test bench

(26) Flow meter 1 loop and flow meter 2 loop

(27) Oil supply




Illustration 5g01063315

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 6g01046207

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 7g03872104

Port locations and adjustments.

(49) Case drain port

(50) Pressure port for load sensing

(51) Adjustment screw for margin pressure

(52) Adjustment screw for high-pressure cut

(53) Discharge port

(54) Suction port

(55) Adjustment screw for maximum angle




Illustration 8g03873705

Port locations and adjustments.

(49) Case drain port

(50) Pressure port for load sensing

(51) Adjustment screw for margin pressure

(52) Adjustment screw for high-pressure cut

(53) Discharge port

(54) Suction port

(55) Adjustment screw for maximum angle




Illustration 9g03871502

Hydraulic Schematic

(49) Case drain port

(50) Pressure port for load sensing

(51) Adjustment screw for margin pressure

(52) Adjustment screw for high-pressure cut

(53) Discharge port

(54) Suction port

Remote Control Pressure Relief Valve




Illustration 10g01267512

(56) 8T-0859 Pressure Gauge

(57) 8F-0024 Hose Assembly

(58) 5P-3501 Adapter

(59) 5P-6944 Straight Thread Adapter

(60) 120-9181 Valve Body

(61) 231-1286 Pressure Relief Valve

(62) 2D-7325 Pipe Tee

Pump Setup

  1. Connect the suction port (54) to the reservoir on the test bench.

  1. Connect a 1 inch high pressure "XT6" hose from the pump discharge port (53) to the flow meter inlet on the test bench.

  1. Connect a 1 inch high-pressure hose from the flow meter outlet on the test bench back to the tank.

  1. Connect a case drain port (49) back to the tank.

  1. Connect the pressure relief valve (61) to the valve body (60). Connect the valve body (60) to the straight thread adapter (59). Connect the straight thread adapter (59) to the adapter (58). Connect the adapter (58) to the pipe tee (62). Connect a pressure gauge (56) to the pipe tee (62). Connect a hose assembly (57) to the pipe tee (62). Do not connect the pressure relief valve assembly to the pump until specified.

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

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

  1. Do not rotate the pump in the wrong direction. The correct direction of rotation will be stated on the pump or in the test specifications. 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 11g01270927

Solid line Pressure Relief Valve set at discharge pressure minus margin pressure.

Dotted line Pressure Relief Valve set below discharge pressure minus margin pressure.

  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.

  1. Slowly adjust 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, turn the adjustment screw for maximum displacement (55) on the type 1 pump. If the pump is a type 2, the pump may not be mechanically feasible. The pump should be internally inspected.

  1. Connect the Hose Assembly (57) to the Pressure port for load sensing (50) on the pump. Connect the Pressure Relief Valve (61) back to the tank.

    Rotate the pump to the value in step 3 of the test specifications. Turn the Pressure Relief Valve (61) set screw clockwise until it is all the way in. Load the pump to the value for step 3 in the test specifications. Turn the Pressure Relief Valve set screw counterclockwise until the discharge flow begins to drop. Read the Pressure Gauge (56). Adjust the Adjustment screw for margin pressure (51) until the Pressure Gauge (56) reads the value of the "Pressure Relief Valve Pressure" in step 3 of the test specifications.

  1. Disconnect the Hose Assembly (57). Rotate the pump to the value in Step 4 of the test specifications. Increase the pump discharge pressure to the value in Step 4 of the test specifications. Compare the actual values from the case drain 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 specification, the pump may not be mechanically feasible. The pump should be internally inspected.

  1. Increase the pump discharge pressure to the value in Step 5 of the test specifications. Turn the adjustment screw for the high-pressure cut 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.

------ WARNING! ------

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

Table 3
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
152-7767     CCW     1     1000     0     45 (12)                
2 2400 0     108 (29)                
3 2400 9500 (1378)     104 (28)         7500 (1088)     2000±100 (290±15)    
4 1500 13150±315 (1907±46)     67 (18)     4 (1)            
5 1500 14600±350 (2118±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)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
152-7768     CCW     1     1000     0     45 (12)                
2 2400 0     108 (29)                
3 2400 15000 (2176)     104 (28)         13000 (1886)     2000±100 (290±15)    
4 1500 16065±315 (2330±46)     67 (18)     4 (1)            
5 1500 17850±350 (2589±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)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
162-3140     CCW     1     1000     0     45 (12)                
2 1500 0     67 (18)                
3 1500 11060 (1604)     64 (17)         8060 (1169)     3000±100 (435±15)    
4 1500 14220 (2062)     67 (18)     4 (1)            
5 1500 15800 (2292)     0                

Table 6
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
191-4612     CW     1     1000     0     45 (12)                
2 1500 0     67 (18)                
3 1500 11060 (1604)     64 (17)         8060 (1169)     3000±100 (435±15)    
4 1500 14220 (2062)     67 (18)     4 (1)            
5 1500 15800 (2292)     0                

Table 7
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
195-3577     CCW     1     1000     0     28 (7)                
2 1500 0     42 (11)                
3 1500 6370 (924)     38 (10)         4670 (677)     1700 (247)    
4 1500 8190 (1188)     42 (11)     3 (1)            
5 1500 9100 (1320)     0                

Table 8
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
196-3807     CW     1     1000     0     45 (12)                
2 1500 0     67 (18)                
3 1500 11060 (1604)     64 (17)         8060 (1169)     3000±100 (435±15)    
4 1500 14220 (2062)     67 (18)     4 (1)            
5 1500 15800 (2292)     0                

Table 9
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
206-3574     CW     1     1000     0     45 (12)                
2 1500 0     67 (18)                
3 1500 11060 (1604)     64 (17)         8060 (1169)     3000±100 (435±15)    
4 1500 14220 (2062)     67 (18)     4 (1)            
5 1500 15800 (2292)     0                

Table 10
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
215-5721     CCW     1     1000     0     45 (12)                
2 2400 0     108 (28)                
3 2400 15000 (2176)     103 (27)         12900 (1871)     2100±100 (305±15)    
4 1500 18900±315 (2741±46)     67 (18)     4 (1)            
5 1500 21000±350 (3046±51)     0                

Table 11
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
299-3879     CW     1     1000     0     45 (11.9)                
2 2350 0     105.6 (27.9)                
3 2350 14685 (2130)     101.8 (26.9)         12686 (1840)     2000 (290)    
4 1500 18890 (2740)     67.4 (17.8)     6.8 (1.8)            
5 1500 20995 (3045)     0                

Table 12
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
299-3895     CW     1     1000     0     45 (11.9)                
2 2350 0     105.6 (27.9)                
3 2350 15396 (2233)     101.8 (26.9)         13410 (1945)     2000 (290)    
4 1500 19788 (2870)     67.4 (17.8)     6.8 (1.8)            
5 1500 21995 (3190)     0                

Table 13
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
324-8219     CW     1     1000     0     45 (11.9)                
2 2000 0     90 (23.8)                
3 2000 15445 (2240)     86.3 (22.8)         13445 (1950)     2000 (290)    
4 1500 19850 (2870)     67.4 (17.8)     6.8 (1.8)            
5 1500 22000 (3200)     0                

Table 14
Part Number     Pump Rotation     Step     Input Speed     Discharge Pressure kPa (psi)     Discharge Flow lpm (gpm)     Max. Case Drain Flow lpm (gpm)     Pressure Relief Valve Pressure kPa (psi)     Margin Pressure kPa (psi)    
396-7174     CCW     1     1000     0     45 (11)                
2 2000 0     90 (23)                
3 2000 15400 (2234)     87 (22)         14000 (2030)     1400±100 (203±15)    
4 1500 18600±315 (2700±46)     67 (17)     5 (2)            
5 1500 20700±350 (3000±51)     0                

Test Bench Tooling

Table 15
Tooling    
Part Number     Adapter Plate     Drive Adapter     Suction Adapter     Split Flange     Flange Adapter     Pilot Pressure Port     Case Drain Port    
152-7767     1U-9127     1U-9833     1U-9870     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
152-7768     1U-9127     1U-9833     1U-9870     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
162-3140     1U-9128     1U-9834     1U-9873     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
191-4612     1U-9127     1U-9833     1U-9870     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
195-3577     1U-9127     1U-9833     1 5/8-12 STOR         1 1/16-12 STOR     7/16-20 STOR     3/4-16 STOR    
196-3807     1U-9127     1U-9833     1U-9870     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
206-3574     1U-9127     1U-9833     1U-9870     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
215-5721     1U-9127     1U-9833     1U-9870     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
299-3879     1U-9127     1U-9833     1U-9870     8C-3206     9U-7444     7/16-20 STOR     7/8-14 STOR    
299-3895     1U-9128     1U-9394     1U-9874     1P-5767     9U-7440     7/16-20 STOR     1 1/16-12 STOR    
324-8219     1U-9127     1U-9833     1U-9870     1P-4577     9U-7444     7/16-20 STOR     7/8-14 STOR    
396-7174     1U-9127     4C-4088     1U-9869     1P-4576     9U-7443     7/16-20 STOR     3/4-16 STOR    

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