Bench Test Procedure for Hydraulic Piston Pumps{0599, 5070, 5070} Caterpillar

Introduction

© 2014 AVSpare 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 AVSpare: 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 AVSpare 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, please use the following to relay your request to AVSpare Repair Process Engineering:

• Cat dealer Technical Communicator

• Dealer Solution Network

• AVSpare 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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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 AVSpare "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.

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

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 AVSpare Hydraulic Test Center

Illustration 2	g01037439
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	g01037451
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 AVSpare 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	g01063315
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	g01046207
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

Pump Illustrations

This type of pump is manufactured in several different configurations. The suction port (49) and discharge port (50) may be facing toward the rear of the pump or toward the sides.

Illustration 7	g03715980
Pump port locations. (49) Suction Port (50) Discharge Port (51a) Case Drain Port (51b) Case Drain Port (52) Pressure Port for Load Sensing (53) Adjustment Screw for High Pressure Cut (54) Adjustment Screw for Margin Pressure

Illustration 8	g03715983
Hydraulic schematic. (49) Suction Port (50) Discharge Port (51a) Case Drain Port (51b) Case Drain Port (52) Pressure Port for Load Sensing (53) Adjustment Screw for High Pressure Cut (54) Adjustment Screw for Margin Pressure

4C-3582 Load Sensing Valve

Illustration 9	g01272623
4C-3582 Load Sensing Valve

Illustration 10	g01272625
4C-3582 Load Sensing Valve

Illustration 11	g01272628
Schematic for 4C-3582 Load Sensing Valve

Illustration 12	g01049615
4C-3582 Load Sensing Valve and 1U-5796 Pressure Differential Gauge (56) Outlet port (57) Adjustment for the discharge flow (58) Inlet port (59) High-pressure valve port (60) Adjustment for the discharge pressure (61) Low-pressure valve port (62) Pressure port for load sensing (63) Pressure differential gauge group (64) Low-pressure gauge port (65) High-pressure gauge port

1. Connect a 1 inch high pressure "XT6" hose from the pump discharge port to inlet port (59) on the 4C-3582 Load Sensing Valve .

2. Connect a 1 inch high pressure "XT6" hose from outlet port (56) on the 4C-3582 Load Sensing Valve to the flow meter inlet on the test bench.

3. Connect a 6D-7726 Hose Assembly to the pressure port for load sensing (62) on the 4C-3582 Load Sensing Valve 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.

4. Connect the 1U-5796 Pressure Differential Gauge Group (63) to the high-pressure port (58) and low-pressure port (61) on the 4C-3582 Load Sensing Valve . The port marked "hi" (65) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "hi" (58) on the 4C-3582 Load Sensing Valve . The port marked "low" (64) on the 1U-5796 Pressure Differential Gauge Group should be hooked up to the port marked "low" (61) on the 4C-3582 Load Sensing Valve .

   Note: The ports marked "low" (61) and "sense line" (62) on the 4C-3582 Load Sensing Valve are reading the same pressure.

Pump Setup

1. 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.

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

3. 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 under the test specifications 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)

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Illustration 13	g01054155

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. Verify that all connections are not leaking.

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 given in Step 2 of the test specifications, the pump may not be mechanically feasible. The pump should be internally inspected.

3. Slowly adjust discharge flow to the value in step 3 of the test specifications. The discharge flow is adjusted by using the 4C-3582 Load Sensing Valve's Adjustment knob for discharge flow (57). Bench circuitry will be used to limit flow when using a 1U-9400 Test Center . Adjust the discharge pressure according to the values in Step 3 of the test specifications. Adjust the screw for margin pressure (54) to the value in Step 3 of the test specifications. The margin pressure will be displayed on the 1U-5796 Pressure Differential Gauge (63).

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

   Note: In order to adjust the screw for margin pressure (54), remove the external hexagon screw first.

   Slowly adjust the discharge flow back to full flow. Use the Adjustment knob for discharge flow (57) on the Load Sensing Valve.

4. Slowly adjust the input RPM to the value in Step 4. Increase the pump discharge pressure to the value in Step 4 of the test specifications. Compare the actual values of the case drain (51) 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 in Step 4 of the test specifications, the pump may not be mechanically feasible. The pump should be internally inspected.

5. Increase the pump discharge pressure to the value in Step 5 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 5 of the test specifications. The 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. Plug all of the ports.

Test Specifications

Bench Test Tooling