Test Manual d9t

Connections for the Caterpillar Hydraulic Test Center
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Illustration 2 g01140178
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
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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

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Connections for the test bench
(26) Flow meter 1 loop and flow meter 2 loop
(27) Oil supply
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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
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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
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Typical port locations and pump adjustments
(49) Gauge port for stroking pressure

(50) Connector for electrical solenoid
(51) Adjustment screw for hydraulic zero
(52) Suction port for charge pump
(53) Pump discharge port

(55) Case drain port
(57) Adjustment screw for mechanical zero
(59) Return port for charge pump
(60) Adjustment screw for high-pressure cut
(61) Discharge port for charge pump
(62) Gauge port for discharge pressure

(64) Gauge port for charge pressure
(77 (Y)) Control pressure
(78) Flushing valve discharge port
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Typical port locations and pump adjustments for part numbers 417-9308 and 417-9312.





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Typical port locations and pump adjustments for part numbers 109-5752, 109-5754, 137-5787, 137-
5788, 146-1781, 156-7034, 162-9592, 180-0459, 194-3253, 198-5477, 199-1062, 199-1063, 199-
1064, 202-7850, 203-6568, 205-1823, 214-1093, 221-3667, 221-3668, 221-3669, 233-6702, 236-
4668, 236-4669, 236-4631, 243-0103, 254-1379, 261-3629, 261-3630, 264-3172, 269-3128, 325-
9773, 325-9788, 333-7827 and 6E-5845.




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3125, 269-3126, 269-3127, 280-3455, 285-3599 and 286-2477 .





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Typical port locations and pump adjustments for part number 288-5473.

(52) Suction port for charge pump (Charge supply for pumps without a charge pump)



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Typical port locations and pump adjustments for part numbers 264-5069 and 355-2401 .




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4989, 358-4990, and 358-4991 .




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Typical port locations and pump adjustments for part number 249-8600 .



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Typical port locations and pump adjustments for part number 351-8908 and 389-8424 .



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Typical port locations and pump adjustments for part number 261-3631 (does not have charge
pump), 261-3632, 289-6385, 289-6386, 289-6387, 289-6388, 289-6389, and 289-6390 .





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Typical port locations and pump adjustments for part numbers 417-9308 and 417-9312.




9U-5902 Rectifier Block

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9U-5902 Rectifier Block Connections
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9U-5902 Rectifier Block Schematic
(66) High-pressure port
(67) High-pressure outlet

(68) High-pressure port
(69) Low-pressure inlet
9U-5893 Heat Exchanger

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9U-5893 Heat Exchanger Connections
(70) Inlet from flow meter loop
(71) Outlet "to rectifier block"
(72) Water inlet
(73) Water outlet
198-4240 Electric Pressure Gauge Group

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198-4240 Electric Pressure Gauge Group Connections
(74) Pressure gauge
(75) Red transducer 34500 kPa (5000 psi)
(76) Blue transducer 3450 kPa (500 psi)
Note: The accuracy of the mechanical zero position and the hydraulic zero position
is crucial. The use of the 198-4240 Electric Pressure Gauge Group is Highly
recommended.
Pump Setup
Note: A power supply is required to operate the solenoid. The power supply should
be capable of delivering 0 mA to 1.2 A with an infinite setting in that range.
1. Install pressure taps in the following test ports:
2. Connect power supply to the connector for electric solenoid (50) or (56) .
3. Connect power supply to the connector for electric solenoid (65) if pump is
equipped with breaking valve.
4. Connect pump discharge ports (53) and (54) to the 9U-5902 Rectifier Block high-
pressure ports (66) and (68) .
5. Connect the 9U-5902 Rectifier Block outlet (67) to the flow meter inlet on the test
bench.
6. Connect the flow meter outlet to the 9U-5398 Heat Exchanger inlet (70) .
7. Connect the 9U-5893 Heat Exchanger outlet (71) to the low-pressure return (69)
on the 9U-5902 Rectifier Block .
8. Connect the red transducer 34500 kPa (5000 psi) (75) or 8T-0860 Pressure Gauge
to the pump's gauge ports for discharge pressure (62) and (63) .
9. Some pumps do not have internal charge pumps. Refer to the Test Specifications if
the pump that is being tested uses an internal charge pump or an external charge
pump. Connect the charge pump suction port (52) to the test bench oil supply for
pumps with an internal charge pump. Pumps without an internal charge pump will
require auxiliary charge flow supplied to the return port for the charge pump.
10. Some pumps require signal pressure at the Y port (77). Refer to the footnotes in
the Test Specifications to determine if the pump being tested requires the signal
pressure and to find the signal pressure values. Refer to Illustration 7, Illustration
13, Illustration 14, and Illustration 16.
11. For pumps without an internal charge pump connect auxiliary pump oil supply to
the return port for the charge pump (59) .
12. For pumps with flushing valves (see Illustrations 8 and 17), plug flushing valve
discharge port (78) .
13. Purge all air from the suction line. Loosen the suction hose at the pump until oil
leaks from the connection. Tighten the suction hose.
14. Fill the pump case with oil. Pour oil directly into case drain port (55) until the case
is full. Direct flow from case drain port (55) to test bench reservoir.
15. 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.
Adjustment for Mechanical Zero Position

1. Turn the load control on the test bench completely clockwise to control the pump
discharge pressure. Start rotating the pump at the value in Step 1 of the Test
Specifications. Be sure to sustain charge pump flow to port (59) in Steps 1 through
5 of the Test Specifications. Vent the ports for the stroking pressure (49) and (58)
to the atmosphere. This will equalize the pressure on the servo spool. Install
pressure gauges on ports (62) and (63). Turn the load control on the test bench
completely clockwise to control the pump discharge pressure. If the mechanical
zero adjustment is incorrect, a discharge pressure higher than the charge pressure
may occur.
Note: Increase signal current to solenoid (65) until braking valve is activated.
Note: If the mechanical zero is unable to be set correctly, the hydraulic zero may
be too far out of adjustment. In this case it will be necessary to set the hydraulic
zero within 300 kPa (43.5 psi) using the procedure ""Adjustment for Hydraulic Zero
Position" ". Try to set the mechanical zero again. This may need to repeated
several times to correctly achieve the mechanical zero adjustment. After the
mechanical zero is set, proceed to ""Adjustment for Hydraulic Zero Position" ". For
the final hydraulic zero adjustment, set the hydraulic zero within 21 kPa (3 psi)
Note: Some pumps require signal pressure at the Y port (77). Refer to the
footnotes in the Test Specifications to determine if the pump being tested requires
the signal pressure and to find the signal pressure values. Refer to Illustration 7
and Illustration 13.
2. Turn the adjustment screw for the mechanical centering (57) clockwise. Continue
to turn until a pressure of 200 psi above charge pressure is achieved. This
pressure may be seen on the gauge port for the system pressure B (62) or gauge
port for the system pressure A (63). Mark the position of the adjustment screw for
the mechanical centering (57) .
3. Turn adjustment screw for the mechanical centering (57) counterclockwise until
pressure increases on gauge ports (62) or (63). Mark the position of the adjustment
screw for the mechanical centering (57) .
4. A mark should be placed halfway between position one and position two. Turn the
adjustment screw for the mechanical centering (57) to the midpoint of both marks.
There should be less than a 34.5 kPa (5 psi) pressure differential between pump
gauge ports (62) and (63) .
5. Stop rotating the pump. Turn the load control on the test bench for pump discharge
pressure counterclockwise. Allow the discharge pressure of the pump to decrease.
Disconnect pressure gauges from ports (62) and (63) .
Adjustment for Hydraulic Zero Position

1. Connect two blue transducers 3450 (500 psi) or connect two 6000 kPa (870 psi)
8T-0856 Pressure Gauges into both gauge ports for stroking pressure (49) and
(58) .
2. Start rotating the pump to the value listed in Step 1 of the Test Specifications. Turn
the load control for the pump discharge pressure clockwise. This will allow pump
discharge pressure to increase in the following steps.
3. Adjust the adjustment screw for hydraulic zero (51) until the pressure at the gauge
ports for the stroking pressure (49) and (58) differ by less than 21 kPa (3 psi).
Note: Do not turn the adjustment screw for the hydraulic zero (51) more than 90
degrees in either direction.
4. Turn the load control for the pump discharge pressure counterclockwise. This will
allow pump discharge pressure to decrease. Stop rotating the pump and allow
pump pressure to dissipate. Disconnect the pressure gauges that are connected to
the gauge ports for stroking pressure (49) and (58) .
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)
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1. Start rotating the pump according to the RPM in Step 1 of the Test Specifications.
Pumps without a charge pump will require auxiliary charge flow according to the
value in Step 1 of the Test Specifications. Verify the flow rates and listen for
abnormal noise. Verify that all connections are secure. Verify that all connections
are tight. Check for leaks around shaft seals. Check for leaks around control
valves. Check the gauge port for the charge pressure (52). Compare the actual
charge pressure with the value in Step 1 of the Test Specifications. If the charge
pressure is not within the Test Specifications adjust the charge relief valve. Adjust
the charge relief valve by turning the adjustment screw (60) clockwise or
counterclockwise accordingly. Run the pump for at least five minutes in order to
raise the temperature of the oil and purge the system of air.
Note: The pump has two separate solenoids. Test one solenoid at a time then
repeat steps 2 through 5 of the Test Procedure in order to test the other solenoid.
2. Slowly increase the pump RPM to the value in Step 2 of the Test Specifications.
Increase the signal current to solenoid (50) or (56) according to the value in Step 2
of the Test Specifications. This is the point of upstroke of the pump. The pump
operation or the control of the signal pressure may not be operating properly if the
actual discharge flow is not correct.
Note: Some flow meters may not be able to read discharge flows at this level.
Slowly increase signal current to a value that is higher than the value in Step 2 of
the Test Specifications if the flow meter does not register the flow. Continue until
the flow begins to register.
3. Increase the signal current to (50) or (56) to the value in Step 3 of the Test
Specifications. The pump should be fully upstroked at this time. Record actual
pump flow. The pump or the control for the proportional solenoid valve may not be
mechanically feasible if the actual flow is not equal to the value in Step 3 of the
Test Specifications.
4. Increase pump discharge pressure to the value in Step 4 of the Test Specifications.
Measure pump leakage at this point. Calculate the total loss. The pump may not be
mechanically feasible if the total loss is higher than the allowable value in Step 4 of
the Test Specifications.
Subtract the discharge flow that was recorded in Step 4 of the Test Procedure from
the discharge flow that was recorded in Step 3 of the Test Procedure in order to
find the total loss.
Example: Step 5 flow 162 L/min (42.8 US gpm) - "Step 4 flow" 158 L/min (41.7 US
gpm) = "total loss" 4 L/min (1.1 US gpm). The "max. allowable loss" is 7.2 L/min
(1.9 US gpm).
The pump in the example is acceptable because the actual total loss is less than
the maximum allowable loss.
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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. Slowly increase the pumps discharge pressure to the value in Step 5 of the Test
Specifications. If the actual discharge pressure is not within the specification then
turn the adjustment screw for high pressure cut (60) 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.
Repeat Steps 2 through 5of the Test Procedure by connecting the power supply to
the opposite connector for electrical solenoid (50) or (56).
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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 all ports or plug all ports.
Note: Crossover relief valves are not preset from factory. If crossover relief valves
are replaced, they must be adjusted while installed on the machine. See Testing
and Adjusting manual for specific machine.
Table 23
Part Number 214-1093
Rotation Clockwise
Step 1 2 3 4 5
RPM 800 1000 1000 1000 600
Signal Current
0 400 1200 1200 1200
mA
Discharge
2750 2750 2750 22750 42100
Pressure kPa
(399) (1)
(399) (1)
(399) (1)
(3300) (6100)
(psi)
Discharge
Flow liter per 180 (47.6)
0 1 (0.26) 180 (47.6) 0
minute Max
(gpm)
Pump Loss
Subtract the actual step 3 Discharge Flow
Efficiency liter
from the actual step 4 Discharge Flow. This 7.2 (1.9) -
per minute
is the Total Loss.
(gpm)
Charge
2750 2750
Pressure kPa 2750 (399) 2750 (399) 2750 (399)
(399) (399)
(psi)
Charge Flow
liter per 31.8 (8.4) 39.8 (10.5) 39.8 (10.5) 39.8 (10.5) 23.8 (6.3)
minute (Internal) (Internal) (Internal) (Internal) (Internal)
(gpm)
(1)
Discharge pressure equals charge pressure

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Connections for the Caterpillar Hydraulic Test Center

(2) F3 Flow meter inlet

(5) F3 inlet for the flow meter with flow limiter

(6) F3 outlet for the flow meter with pressure control

(10) Return to tank

(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

(19) F3 discharge flow

(20) F4 discharge pressure gauge

(21) F4 discharge flow

(22) Auxiliary pump flow control

Connections for the Caterpillar Hydraulic Test Bench

(27) Oil supply

(29) Flow meter 1 loop

(30) Flow meter 2 outlet

(31) Signal pressure line

(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

(42) Auxiliary oil supply control

(43) Flow meter 2 discharge flow

(44) Discharge flow for auxiliary pump

(45) Flow meter 1 discharge flow

(49) Gauge port for stroking pressure

(54) Pump discharge port

(63) Gauge port for discharge pressure

(50) Connector for electrical solenoid

(52) Suction port for charge pump

(56) Connector for electrical solenoid

(62) Gauge port for discharge pressure

(64) Gauge port for charge pressure

(77 (Y)) Control pressure

(50) Connector for electrical solenoid

(54) Pump discharge port

(55) Case drain port

(57) Adjustment screw for mechanical zero

(59) Return port for charge pump

(60) Adjustment screw for high-pressure cut

(61) Discharge port for charge pump

(62) Gauge port for discharge pressure

(63) Gauge port for discharge pressure

(49) Gauge port for stroking pressure

(50) Connector for electrical solenoid

(52) Suction port for charge pump

(54) Pump discharge port

(55) Case drain port

(59) Return port for charge pump

(60) Adjustment screw for high-pressure cut

(63) Gauge port for discharge pressure

(50) Connector for electrical solenoid

(53) Pump discharge port

(56) Connector for electrical solenoid

(58) Gauge port for stroking pressure

(63) Gauge port for discharge pressure

(49) Gauge port for stroking pressure

(50) Connector for electrical solenoid

(54) Pump discharge port

(55) Case drain port

(58) Gauge port for stroking pressure