ASTM D7043 Standard Test Method for Indicating Wear Characteristics of Non-Petroleum and Petroleum Hydraulic Fluids in a Constant Volume Vane Pump
12. Procedure
12.1 Pump Cartridge Assembly - (See Fig. 8 and Fig. 7.)

NOTE 18 - Assembly is best done by assembling directly into the housing rather than on the bench. Components often become misaligned when a preassembled cartridge is inserted into the housing.

12.1.1 Wet all cartridge components with a thin film of test fluid and lay them out on a scrupulously clean surface.

12.1.2 Ensure that the pump body and head are clean.

NOTE 19 - Debris on the sealing surfaces between the bushings and the pump body and head faces (Surfaces A and B, Fig. 4) will contribute to internal leakage, causing poor flow from the pump.

12.1.3 Insert the inner bushing (2882-4C) into the pump body. Bottom it against the pump body and rotate it slightly in both directions to ensure it is properly seated. Align the hole in the bushing with the alignment pinhole in the pump body.

12.1.4 Insert the cam ring (2882-5) so that the larger diameter of the stepped hole will be toward the operator. Ensure that the ring has seated against the 2882-4C bushing and align the stepped hole in the ring with the alignment holes in the bushing and the pump body.
12.1.4.1 If used, the shim described in 8.3.5.2 is added while the ring is being inserted. After installation, the ring should have some free movement in the bore. If it has jammed, remove the ring and shim and reinstall.

12.1.5 Insert and bottom the alignment pin (2882-10). The large diameter end should be toward the operator and should be bottomed in the cam ring so that approximately 8 mm of the large diameter end is visible above the ring surface.

12.1.6 Insert the rotor (2882-1C) making certain that the rotor directional arrow points counterclockwise (Fig. 8, Fig. 7).

12.1.7 Insert the 2882-3 vanes into the rotor slots making certain that the chamfered edge will be in contact with the cam ring and will be the trailing edge when the rotor turns counterclockwise (Fig. 8, Fig. 7).
12.1.7.1 Ensure that the vanes move freely in the rotor slots when assembling. If the vanes do not move freely, remove the rotor and check for dirt or burrs in the rotor slots or on the vanes.

12.1.8 Insert the outer bushing (2882-4E) and engage the alignment pin. After installing the 2882-4E bushing, approximately 3 mm of the large diameter end of the alignment pin should be visible above the bushing surface.

12.2 Torquing the Pump:
12.2.1 Install the packing seal, pump head, and head bolts. Bring the head bolts to finger tight.

12.2.2 Close all drain valves. Open pump inlet and return line valves, if used (see Notes 9 and 10).

12.2.3 Pour enough test fluid into the reservoir to ensure that the pump case is full.

12.2.4 Use a torque wrench to tighten the eight head bolts (Fig. 9), a maximum of 1130 N-mm at a time, using the following sequence: top right (1), bottom left (2), right low (3), left high (4), then bolts (5), (6), (7), and (8). Slowly rotate the pump shaft by hand while tightening the bolts or at the end of each sequence. Record the final level of torque (usually about 4520 to 7910 N-mm. The pump should rotate with a slight drag on the shaft but there should be no binding.
12.2.4.1 Bind is characterized by a catch or tight spot in an otherwise smooth shaft rotation or complete seizure or stoppage, requiring abnormal hand effort to turn the shaft, or both.

12.2.4.2 If binding occurs at less than 3390 N-mm, there probably is a misalignment within the pump and it should be disassembled and all components checked.

NOTE 20 - To eliminate the drag of the motor while rotating the pump shaft, some users disconnect the pump to motor shaft coupling during torquing.

NOTE 21 - Some users have found that reversing the torquing sequence (that is, 2-1-4-3-6-5-8-7) every other sequence helps avoid binding and cocking of the pump head.

NOTE 22 - To get more even torquing, some users use brass washers under the head bolts to reduce tightening friction.

NOTE 23 - To ensure that the cartridge seats properly against the pump housing and head sealing faces (Planes A and B, Fig. 4), some users use feeler strips between the head and housing while torquing the head. This technique requires that the head and housing have parallel faces and shoulders (Planes A and C, B and D, Fig. 4) and accurate measurements have been made (Measurements W and X, Fig. 4). The gap (Z) that should be present when the cartridge has been properly seated will be equal to Y (cartridge thickness) + X - Y. Ensuring that the gap is consistent around the pump head during the torquing procedure will also guard against cocking the head, which may cause it to jam in the housing bore.

12.3 Test Startup and Operation:
12.3.1 If not already done, close all drain valves and open the reservoir outlet valve and return line valve.

12.3.2 Pour approximately 12 L of the test fluid into the reservoir.

12.3.3 Reduce the setting of the pressure control valve so that pressure will not be generated when flow starts, and turn off cooling water if not already done.

12.3.4 Jog the pump drive motor ON and OFF switches until fluid is returned to the reservoir.

12.3.5 Pour the remainder of the test fluid into the reservoir.

12.3.6 Start the pump and adjust the speed to 1200 r/min.

12.3.7 Observe the fluid in the reservoir to ensure that it is clear and does not contain noticeable amounts of entrained air before increasing pressure.

12.3.8 Adjust pump outlet pressure to 2.1 MPa (300 psi).

12.3.9 Warm up for 1 h in six 10 min steps, at increased pressure levels. The pressure levels are 2.1 MPa, 4.1 MPa, 6.2 MPa, 8.3 MPa, 10.3 MPa, and 12.4 MPa (300 psi, 600 psi, 900 psi, 1200 psi, 1500 psi, and 1800 psi). During this warm-up period, pump inlet temperature will be rising. When this temperature is within 3 °C (5 °F) of the control level, start to apply cooling through the heat exchanger system to minimize temperature override on the test fluid.

NOTE 24 - If pump vane noise (chatter) is heard during the warm-up, the pump can be shut down and the pump head bolts tightened in 560 N·mm increments, using the same tightening sequence as described in 12.2.4, in an effort to eliminate the noise.

12.3.10 Make certain that pump speed, pump inlet temperature, and flow are at test conditions, and adjust pump outlet pressure to exactly 13.8 MPa (2000 psi).

12.3.11 Do not start the test if the pressure gage shows evidence of unusual relief valve fluctuation or pulsations, or if unusual noise or vibration are present.

12.3.12 Measure and record fluid flow rate.

12.3.13 Record clock time or adjust test system timer to zero and consider this the start of the test.

NOTE 25 - It is advisable to monitor test conditions for at least the initial few hours of the test to ensure that conditions are stable. A continual drop in the flow rate indicates increasing internal leakage caused by bushing wear or improper seating of the cartridge.

12.3.14 Operate system at the following conditions uninterrupted for 100 h or until operating difficulties dictate test termination:
Pump outlet pressure: 13.8 MPa ± 0.3 MPa (2000 psi ± 40 psi)
Pump speed: 1200 r/min ± 60 r/min
Pump output: >15.0 L/min

Fluid temperature at pump inlet:
Water glycols, emulsions, and other water containing fluids: 66 °C ± 3 °C
Petroleums and synthetic fluids of ISO Grade 46 or lighter: 66 °C ± 3 °C
All other petroleum and synthetic fluids: 80 °C ± 3 °C

12.3.15 It is not acceptable to replace the ring or vanes during the test. The test should be terminated if flow drops to 15.0 L/min (4.0 gpm) or less, if system pressure cannot be maintained, or if there is excessive noise or leaking.

12.3.16 It is permissible to replace the bushings during the test if loss of flow has caused an early termination. Replace vanes in their original slots after such a rebuild. Report the bushing failure.

12.3.17 After the test has begun, it is not acceptable to add additional test fluid or water in order to make up for spillage or evaporation.

12.4 Test Shut-Down and Final Parts Inspection:
12.4.1 Reduce the pressure control valve setting and stop pump operation.

12.4.2 Stop the flow of the cooling water.

12.4.3 Observe and record the condition of the test fluid, noting any unusual appearance or odor.

12.4.4 Open all drain valves and drain the test system.

12.4.5 After the pump has cooled sufficiently, remove the pump head and carefully remove the test cartridge.

NOTE 26 - The use of a bent piano wire inserted through an inlet or outlet port to catch and hold the inner bushing or the use of needle nose pliers to grasp the outer bushing and the rotor hub, or both, facilitates removal of the cartridge.

12.4.6 Observe and record the condition of the reservoir surfaces, noting any deposits. System preparation for additional testing can now proceed.

12.4.7 Carefully disassemble the test cartridge and inspect the individual pump cartridge parts for signs of wear, deposit formation, or discoloration. Record any observations.

12.4.8 Demagnetize the cam ring and vanes.

12.4.9 Remove all deposits from the test cartridge cam ring and vanes by thorough nonabrasive cleaning. Rinse in precipitation naphtha (Warning - see 7.3) or other appropriate solvent (see 7.5) and air dry.

13. Calculation
13.1 Determine the mass (separately) of the used cam ring and the set of twelve used vanes to the nearest milligram. Record these two masses and their total.

13.2 Subtract the after-test total mass (cam ring plus twelve vanes) from the unused mass total to determine the mass loss sustained during the run.