- Agricultural Tractor
- All
- Armored Face Conveyor
- All
- Articulated Truck
- All
- Asphalt Paver
- All
- Backhoe Loader
- All
- Beamed Stageloader
- All
- Challenger
- All
- Cold Planer
- All
- Combine
- All
- Compact Track Loader
- All
- Compact Wheel Loader
- All
- Continuous Haulage
- All
- Continuous Miner
- All
- Dragline
- All
- Earthmoving Compactor
- All
- Electric Rope Shovel
- All
- Excavator
- All
- Face Haulage
- All
- Feeder Breaker
- All
- Forest Products
- All
- Highwall Miner
- HW 300 (S/N: HWM1-UP)
- Hydraulic Shovel
- All
- Integrated Toolcarrier
- All
- Landfill Compactor
- All
- Load Haul Dump
- All
- Expanded Mining
- Mini Hydraulic Excavator
- All
- Motor Grader
- All
- Multi Terrain Loader
- All
- Off-Highway Truck/Tractor
- All
- Paving Compactor
- All
- Pipelayer
- All
- Plow
- All
- Road Reclaimer/Soil Stabilizer
- All
- Rock Feeder
- RF300 (S/N: RF41-UP)
- Rock Mover
- RM900 (S/N: RF31-UP)
- Roof Bolter
- All
- Roof Support Carrier
- All
- Roof Support
- All
- Rotary Drill
- All
- Scoop
- ALL
- Shearer
- All
- Skid Steer Loader
- All
- Telehandler
- All
- Track Drills
- All
- Track Feller Buncher
- Caterpillar
- Track-Type Loader
- All
- Track-Type Skidder
- All
- Track-Type Tractor
- All
- Underground Articulated Truck
- All
- Unit Rig Mining Truck
- All
- Wheel Dozer
- All
- Wheel Feller Buncher
- All
- Caterpillar Branded
- Wheel Loader
- All
- Wheel Skidder
- All
- Wheel Tractor-Scraper
- All
- Wheeled Excavator
- All
Introduction
Revision | Summary of Changes in REHS1761 |
10 | Updated values in Tables 8 and 9. |
09 | Updated Effectivity. |
Added new part number 502-5720 Pump and Motor Drive Gp. to document. | |
Added new part number 502-5721 Mounting Adapter Plate Gp. to document. | |
08 | Updated Off-Highway Truck/Tractor effectivity. |
07 | Included new part numbers within tables.
Added new Cat Expanded Mining effectivity. |
06 | Added "Canceled Part Numbers and Replaced Part Numbers" section to document. |
© 2017 Caterpillar All Rights 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 provides a list of tooling that is available for bench testing hydraulic pumps and motors. All the tooling in this document is available through Caterpillar Service Tool Division. The technician should have a good understanding of hydraulic pumps and motors. The technician should fully understand how to correctly and safely operate the specific test bench used. There are many possible variations of tooling that could be used. Not every possible variation can be listed.
For technical questions when using this document, work with your Dealer Technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
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.
Mounting and Drive Hardware
Illustration 1 | g01033096 |
Typical Pump Drive Adapters |
Illustration 2 | g01033097 |
|
- The drive adapters work with any size 27 drive shaft, which are standard on Aidco, Wolff, and Schroder benches. The drive adapters also work with 1U-9359 Adapter and can be used with the size 55 drive shaft on the Caterpillar Hydraulic Test Center.
Pump and Motor Drive Adapters | ||
Part Number | Spline Data | Remarks |
1U-9840 | 10T | Parallel Side Spline |
1U-9837 | 11T-12/24 | |
1U-9836 | 11T-16/32 | |
9U-5746 | 12T-20 DEG | JIS |
1U-9835 | 13T-8/16 | |
1U-9838 | 13T-12/24 | |
1U-9833 | 13T-16/32 | |
267-5713 | 14T-8/16 | |
1U-9841 | 14T-10/20 | |
1U-9834 | 14T-12/24 | |
9U-5747 | 14T-20 DEG | JIS |
131-6452 | N30X2X30X14X9g | DIN5480-14T |
9U-7519 | 15T-8/16 | |
9U-7520 | 15T-10/20 | |
9U-5744 | 15T-12/24 | |
4C-4088 | 15T-16/32 | |
9U-7063 | 16T-20 DEG | JIS |
9U-5276 | 16T B30X27X30 DEG | DIN 5482 MDL 1.75 |
9U-7521 | 17T-8/16 | |
131-6456 | 17T-10/20 | |
1U-9394 | 17T-12/24 | |
264-4491 | 17T-16/32 | |
9U-5748 | 17T-20 DEG | JIS |
246-1588 | 18T-8/16 | |
9U-5275 | N40X2X30X18X9g | DIN5480-18T |
1U-9842 | 19T-16/32 | |
4C-4385 | 19T-24/48 | |
136-3648 | 20T-8/16 | |
1U-9839/9U-5745 | 20T-12/24 | 1U9839 CRB 9U5745 |
9U-5230 | 20T-B40X36X30 DEG | DIN 5482 MDL 1.75 |
133-2329 | 21T-16/32 | |
9U-5277 | N45X2X30X21X9g | DIN 5480-21T |
326-4012 | W28X1.25X30X21X9H | |
457-2326 | R70X3X22X9g | DIN 5480 |
1U-9132 | 23T-16/32 | DIN 5480 |
1U-6433 | N50X2X30X24X9g | DIN 5480-24T |
453-5309 | R80X3X25X9g | DIN 5480 |
142-8576 | N55X2X30X26X9g | DIN5480-26T |
128-0794 | 27T-16/32 | SPL |
131-8620 | N60X2X30X28X9g | DIN 5480-28T |
453-5310 | R90X3X28X9g | DIN 5480 |
4C-4705 | 30T-16/32 | |
4C-4703 | 32T-16/32 | External Spline |
1U-9843 | 7/8 SAE B | Keyed Shaft |
265-3895 | 1 SAE B | Keyed Shaft |
1U-9844 | 1-1/4 SAE B | Keyed Shaft |
1U-9845 | 1-3/4 SAE B | Keyed Shaft |
502-5720 | 50 mm | Keyed Shaft |
1U-9846 | 1 Taper | Keyed Shaft |
1U-9847 | 1-1/16 Taper | Keyed Shaft |
1U-9848 | 1-1/4 Taper | Keyed Shaft |
9U-5743 | 1-3/8 Taper | Keyed Shaft |
136-3602 | 1-3/4 Taper | Keyed Shaft |
1U-9359 | Adapter Assembly | For Large Drive Shaft |
Stand Assembly and Adapter Plates
Illustration 3 | g01033104 |
|
- Use the adapter plates and stand assembly to mount hydraulic pumps and motors for bench testing. The use of clamps, chains, and turnbuckles is not necessary to secure test component to test bench bed.
- The adapter plates slide into 1U-9130 Stand Assembly. The adapter plates become a part of the stand assembly and the adapter plates create a sturdy fixture.
- 1U-9130 Stand Assembly can be used on any test bench bed with mounting rail centerline width of 37.5 inch and minimum rail slot width of 3/4 inch.
- The stand is designed to accommodate any horsepower rated pump or motor Caterpillar has in current production.
- The adapter plates hold pumps and motors that have SAE style mounting flanges. The adapter plates can accommodate two or four hole mountings.
Mounting Adapter Plates used with the 1U-9130 Stand Assembly | ||
Part Number | Pilot Diameter | Remarks |
1U-9126 | 84.15 (3.313) | SAE-A |
1U-9127 | 103.60 (4.079) | SAE-B |
1U-9128 | 128.55 (5.061) | SAE-C |
131-8683 | 153.00 (6.024) | |
502-5721 | 165 (6.496) | |
1U-9129 | 180.50 (7.106) | SAE-D-E-F |
4C-4702 | 191.00 (7.720) | |
131-8477 | 195.00 (7.677) | |
9U-5751 | 200.25 (7.884) | |
131-8476 | 200.25 (7.884) | |
128-0929 | 223.00 (8.780) | |
457-2325 | 245.00 (9.646) | |
130-1986 | 280.25 (11.033) | |
SAE Flywheel Adapter Plates | ||
9U-5750 | 511.18 (20.125) | SAE NO. 1 |
1U-5738 | 447.80 (17.630) | SAE NO. 2 |
4C-4622 | 409.58 (16.125) | SAE NO. 3 |
453-5312 | 405.00 (15.945) | |
4C-4623 | 361.95 (14.250) | SAE NO. 4 |
453-5311 | 320.00 (12.598) |
Motor Stall Adapters
Illustration 4 | g01033106 |
- Use the motor stall adapters to stall test hydraulic fluid motors.
Part Number | Spline |
4C-4679 | 32T-16/32 External |
4C-4680 | 19T-16/32 Internal |
4C-4681 | 13T-8/16 Internal |
Fittings
- The fittings are used to test various Caterpillar and competitive hydraulic components.
2-Bolt Flanges
Illustration 5 | g01033107 |
Refer to table 5 for part description. |
Part Number | Description |
2-Bolt Flanges | |
1U-9849 | Flange 1/2 inch Pipe X 1-7/8 inch BHC |
1U-9850 | Flange 1 inch Pipe X 2-1/2 inch BHC |
1U-9851 | Flange 1 inch Pipe X 1 inch BHC |
1U-9852 | Flange 1 inch Pipe X 2-1/2 inch BHC |
1U-9853 | Flange 1 inch Pipe X 2-5/8 inch BHC |
1U-9854 | Flange 1 inch Pipe X 2-3/4 inch BHC |
1U-9855 | Flange 1 inch Pipe X 2-7/8 inch BHC |
1U-9856 | Flange 1 inch Pipe X 3 inch BHC |
1U-9858 | Flange 1 inch Pipe X 3-1/4 inch BHC |
1U-9859 | Flange 1 inch Pipe X 3-3/7 inch BHC |
1U-9860 | Flange 1 inch Pipe X 3-5/8 inch BHC |
1U-9862 | Flange 1 inch Pipe X 3-3/4 inch BHC |
1U-9864 | Flange 1 inch Pipe X 4-1/2 inch BHC |
1U-9857 | Flange 1 inch 1/2 Pipe X 3 inch BHC |
1U-9861 | Flange 2 inch Pipe X 3-5/8 inch BHC |
1U-9863 | Flange 2 inch Pipe X 4 inch BHC |
1U-9865 | Flange 2-1/2 in Pipe X 4-1/2 in BHC |
4-Bolt Flanges
Illustration 6 | g01033109 |
Refer to table 6 for part description |
4-Bolt Flanges | |
Part Number | Description |
1U-9871 | Flange 3/4 inch Pipe |
1U-9872 | Flange 1 inch Pipe |
1U-9869 | Flange 1-1/4 inch Pipe |
1U-9870 | Flange 1-1/2 inch Pipe |
1U-9873 | Flange 2 inch Pipe |
1U-9874 | Flange 2-1/2 inch Pipe |
1U-9866 | Flange 3 inch Pipe |
1U-9867 | Flange 3-1/2 inch Pipe |
1U-9868 | Flange 4 inch Pipe |
457-2323 | Flange 5 inch Pipe |
Suction Fittings
Illustration 7 | g01033110 |
Refer to table 7 for part description. |
Item | Part Number | Description |
Camlock Fittings | ||
1 | 1U-9879 | Adapter 3 inch X 3 inch NPT Adapter |
1U-9880 | Adapter 4 inch X 4 inch NPT Adapter (Not Shown) | |
Suction Hose and Fittings | ||
1U-9875 | Coupler 3 inch X 3 inch Hose Barb (Not Shown) | |
2 | 1U-9876 | Coupler 4 inch X 4 inch Hose Barb |
1U-9881 | Hose 3 inch ID X 12 feet (Not Shown) | |
1U-9882 | Hose 4 inch ID X 12 feet (Not Shown) | |
Camlock Fittings | ||
3 | 1U-9877 | Adapter 3 inch Coupler X 4 inch |
4 | 1U-9878 | Adapter 3 inch X 4 inch Coupler |
Illustration 8 | g01037661 |
Illustration 9 | g01041110 |
Schematic for a |
- The valve is used to adjust the high-pressure cutout and margin pressures on load sensing pumps.
- The valve is a high-pressure manifold that has flow control, a relief valve, gauge ports, and flow ports. The flow control simulates the control valve on the vehicle. The relief valve simulates a load condition of the implement circuit.
- The flow capacity is
227 L/min (60 US gpm) . The adjustable pressure range is approximately344 to 41369 kPa (50 to 6000 psi) . - Use the 1U-5796 Differential Pressure Gauge with the 4C-3522 Load Sensing Valve to test margin pressure.
- Caterpillar Hydraulic Test Centers have a load sensing system that is incorporated in the hydraulics. The test centers do not require a 4C-3582 Valve.
Reference: Bench Testing Hydraulic Components, NEHT5000 and Hydraulic Pump, Motor and Cylinder Bench Test Procedure Reference Manual, SEBF8810 (under procedures for testing load sensing pumps)
Illustration 10 | g01033325 |
- A heat exchanger supplies cooled oil for easier testing and more accurate adjusting. This prevents overheating the oil and burning the pump.
- The heat exchanger is rated at
3447 kPa (500 psi) .
Pressure Relief Valve
Illustration 11 | g01033328 |
Illustration 12 | g01040342 |
Schematic for a Pressure Relief Valve |
- Use to set up external charge relief on closed loop pumps.
Part Number | Description | Gallons Per Minute | Pressure
(PSI) |
Control | Seal Material |
120-9181 | Body | 0-25 | |||
4C-4014 | Pressure Relief Cartridge | 0-25 | 25-800 | Screw Adjustment | Buna-N |
488-9456 | Pressure Relief Cartridge | 0-25 | 50-1500 | Screw Adjustment | Viton |
508-6713 | Pressure Relief Cartridge | 0-25 | 60-400 | Hex Head Screw with Locknut | Buna-N |
180-1129 | Pressure Relief Cartridge | 0-25 | 100-3000 | Screw Adjustment | Buna-N |
231-1286 | Pressure Relief Cartridge | 0-25 | 150-4500 | Handknob | Buna-N |
282-9420 | Pressure Relief Cartridge | 0-25 | 150-6000 | Screw Adjustment | Buna-N |
Illustration 13 | g01037656 |
Illustration 14 | g01046354 |
- A rectifier block eliminates improperly connected hoses. The rectifier block allows reversing pump flow without changing hoses.
In Line Flow Meters
Illustration 15 | g01039707 |
Refer to table 9 for part description. |
Part Number | Gallons per minute | Liters per minute | Ports |
4C-8688 | 0.1-2 | 0.4-7.5 | 3/4F-NPT |
4C-8689 | 0.5-5 | 1.9-19 | 3/4F-NPT |
6V-7788 | 2-20 | 7.5-76 | 3/4F-NPT |
8T-0454 | 5-50 | 20-200 | 1-1/4F-NPT |
8T-0456 | 10-150 | 50-550 | 1-1/4F-NPT |
490-2095 | 10-150 | 50-550 | 1-1/2F-STOR |
- Maximum pressure
20700 kPa (3000 psi)
Illustration 16 | g01039733 |
- Use the 1U-5796 Differential Pressure Gauge with the 4C-3522 Load Sensing Valve to test margin pressure.
- Maximum Line Pressure
52400 kPa (7500 psi) - Maximum Measurable Differential Pressure
3500 kPa (500 psi)
Illustration 17 | g01037672 |
Illustration 18 | g01040345 |
Schematic for |
- Pressure-compensating, cartridge-type, pressure-reducing valve. Has a locking hand knob to adjust outlet port pressure. The manifold has two test ports for reading inlet (supply) pressures and outlet (regulated) pressures.
- The valve is used to regulate pilot pressure or control pressure when bench testing hydraulic pumps.
- The valve automatically maintains specified signal pressure throughout the test.
- The 1U-6392 Pressure Reducing Valve includes a cartridge with a range of
517 to 10334 kPa (75 to 1500 psi) . The rated flow is18.9 lpm (5.0 gpm) . - The 9U-5892 Cartridge is also available with a range from
0 to 3447 kPa (0 to 500 psi) .
Flange Adapters
- Flange adapters are used to aid the technician during flow testing of various hydraulic systems.
Illustration 19 | g01033534 |
Refer to table 10 for part description. |
XT3 Fittings & Quick Disconnects
Working pressure 1 inch NPT female thread fitting end 1/2 to 1 1/2 inch nominal size flange |
|||
Item | Part Number | Type | Description |
(1) | 9U-7442 | Adapter | 1/2 inch Flange Adapter |
4J-5140 | Seal | O-Ring | |
1P-4574 | Split Flange | 1/2 inch Split Flange | |
9U-7443 | Adapter | 3/4 inch Flange Adapter | |
4J-5267 | Seal | O-Ring | |
1P-4576 | Split Flange | 3/4 inch Split Flange | |
9U-7444 | Adapter | 1 inch Flange Adapter | |
4J-0520 | Seal | O-Ring | |
1P-4577 | Split Flange | 1 inch Split Flange | |
9U-7445 | Adapter | 1-1/4 inch Flange Adapter | |
4J-0522 | Seal | O-Ring | |
1P-4578 | Split Flange | 1-1/4 inch Split Flange | |
9U-7446 | Adapter | 1-1/2 inch Flange Adapter | |
4J-0524 | Seal | O-Ring | |
1P-4579 | Split Flange | 1-1/2 inch Split Flange | |
7M-8485 | Seal | O-Ring for -16 STOR Threads | |
(2) | 1U-8300 | Fitting | 1 inch Pipe to -16 STOR Port -Straight |
(3) | 1U-8304 | Fitting | 1 inch Pipe to -16 STOR Port -45 Degrees |
(4) | 1U-8301 | Fitting | 1 inch Pipe to -16 STOR Port -90 degrees |
(5) | 8C-7544 | Nipple | 1 inch NPT Male QD |
(6) | 8C-7545 | Coupler | 1 inch NPT Female QD |
7X-7646 | Nipple | 1 inch NPT Female QD |
Illustration 20 | g01033654 |
Refer to table 11 for part description. |
XT-5 Fittings and Quick Disconnects
Working Pressure 1 5/16 inch STOR Male Thread 3/4 to 1 1/2 inch nominal size flange |
|||
Item | Part Number | Type | Description |
(7) | 9U-7438 | Adapter | 1/2 inch Flange Adapter |
1P-3702 | Seal | Rectangular | |
1P-5765 | Split Flange | 1/2 inch Split Flange | |
9U-7439 | Adapter | 3/4 inch Flange Adapter | |
1P-3703 | Seal | Rectangular | |
1P-5766 | Split Flange | 1 inch Split Flange | |
9U-7440 | Adapter | 1-1/4 inch Flange Adapter | |
1P-3704 | Seal | Rectangular | |
1P-5767 | Split Flange | 1-1/4 inch Split Flange | |
9U-7441 | Adapter | 1-1/2 inch Flange Adapter | |
1P-3705 | Seal | Rectangular | |
5P-8077 | Split Flange | 1-1/2 inch Split Flange | |
457-9869 | Adapter | ||
1P-3709 | Seal | Rectangular | |
228-7097 | Seal | O-Ring | |
6V-0402 | Split Flange | 2 inch Split Flange | |
7M-8485 | Seal | O-ring for -16 STOR Threads | |
(8) | 1U-8302 | Fitting(1) | -16 STOR port --16 STOR Thread-Straight |
(9) | 1U-8305 | Fitting(1) | -16 STOR Port --16 STOR Thread -45 Degrees |
(10) | 1U-8303 | Fitting(1) | -16 STOR Port --16 STOR Thread -90 Degrees |
(11) | 8C-9032 | Nipple | -16 STOR Non-Valved QD |
(12) | 8C-7544 | Coupler | 1 inch NPT Non-Valved Female QD |
8C-7545 | Nipple | 1 inch NPT Non-Valved Female QD |
(1) | Includes 9/16-18 STOR gauge tap |
Hose Assemblies and Quick Disconnects
- The hose assemblies and quick-disconnects can be used for pressure testing hydraulic systems with pressures up to
41,500 kPa (6000 psi) . - Use 6D-7726 for a signal pressure source for load sensing pumps. The pressure rating is
68,900 kPa (10,000 psi) .
Illustration 21 | g01033660 |
Illustration 22 | g01033661 |
Item | Part Number | Description | ID | Length | Connections |
(1) | 6V-3965 | Nipple | 9/16 SAE Male-Valved | ||
6V-3966 | Nipple | 1/4 inch NPT Male Valved | |||
6V-3866 | Nipple | 1/4 inch NPT Male Valved | |||
6V-3989 | Nipple | 1/8 inch NPT Female Non-Valved | |||
(2) | 6V-4143 | Coupler | 1/8 inch NPT Female Valved | ||
6V-4144 | Coupler | 1/4 inch NPT Female Valved | |||
(3) | 6D-7726 | Hose | |
|
1/4 inch NPT Male |
(4) | 1P-2375 | Nipple | 1/4 inch NPT Male Valved (68,900 kPa) | ||
(5) | 1P-2376 | Coupler | 1/4 inch NPT Female Valved (68,900 kPa) | ||
(6) | 177-7860 | Hose Assembly | |
|
1/8 inch NPT Male Both Ends |
177-7861 | Hose Assembly | |
|
1/8 NPT Both Ends | |
177-7862 | Hose Assembly | |
|
1/8 NPT Both Ends | |
1U-5757 | Hose Assembly | |
|
1/8 NPT by 7/16-20 X 37 degree JIC |
Test Port Adapters
- Three metric test port adapters each convert different-sized metric DIN 3852 port to SAE No. 6 (9/16 inch-18 thread) port.
- Each adapter requires corresponding seals.
- All three adapters will accept 6V-3965 Valved Quick Disconnect Nipple.
Adapter Part Number | Corresponding Seal | Description |
8C-6862 | 8C-5199 | M10 X 1 Thread to SAE No. 6 (9/16 inch-18 Thread) Port |
8C-6863 | 8C-5200 | M12 X 1.5 Thread to SAE No. 6 (9/16 inch-18 Thread) Port |
8C-6864 | 8C-5201 | M14 X 1.5 Thread to SAE No. 6 (9/16 inch-18 Thread) Port |
Standard and Certified Pressure Gauges
Illustration 23 | g01033665 |
- The gauge is a dual scale and a liquid filled pressure gauge in a brass case.
- All gauges are 1/4-18 NPTF
Dual Scale Pressure Gauges (Stem Connector) 2.50 inches | ||
Certified Part Number | Standard Part Number | Range kPa (psi) |
186-2601 | 8T-0853 | 0 to 400
(0 to 58) |
186-2602 | 8T-0854 | 0 to 1,000
(0 to 145) |
186-2604 | 8T-0855 | 0 to 4,000
(0 to 580) |
- | 212-7043 | 0 to 700
(0 to 100) |
186-2605 | 8T-0856 | 0 to 6,000
(0 to 870) |
186-2606 | 8T-0857 | 0 to 10,000
(0 to 1,450) |
186-2607 | 8T-0858 | 0 to 16,000
(0 to 2,300) |
186-2608 | 8T-0859 | 0 to 25,000
(0 to 3,600) |
186-2609 | 8T-0860 | 0 to 40,000
(0 to 5,800) |
186-2610 | 8T-0861 | 0 to 60,000
(0 to 8,700) |
186-2611 | 8T-0862 | -100 to 0 to 500
(-15 to 0 to 72) |
186-2612 | 8T-0863 | 0 to 250
(0 to 36) |
Dual Scale Pressure Gauges (Stem Connector) 4.00 in | ||
Certified Part Number | Standard Part Number | Range |
186-2613 | 8T-0820 | 0 to 70,000
(0 to 10,000) |
Dual Scale Pressure (Back Connector) 2.50 in | ||
Certified Part Number | Standard Part Number | Range |
186-2592 | 8T-0846 | 0 to 1,000
(0 to 145) |
186-2593 | 8T-0847 | -100 to 0 to 50
(-15 to 0 to 72) |
186-2594 | 8T-0848 | 0 to 400
(0 to 58) |
186-2595 | 8T-0849 | 0 to 2,000
(0 to 290) |
186-2596 | 8T-0850 | 0 to 4,000
(0 to 580) |
186-2597 | 8T-0851 | 0 to 16,000
(0 to 2,300) |
186-2598 | 8T-0852 | 0 to 40,000
(0 to 5,800) |