Required Tooling for Bench Testing Hydraulic Components {0784, 4000, 4005, 4129, 4250, 4300, 5050} Caterpillar

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

Table 1

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
1U-9359 Adapter Assembly

• 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.

Table 2

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
1U-9130 Stand Assembly with the 1U-9128 Adapter Plate

• 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.

Table 3

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.

Table 4

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.

Table 5

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

(BHC) Bolt Hole Center

4-Bolt Flanges

Illustration 6	g01033109
Refer to table 6 for part description

Table 6

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.

Table 7

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

Miscellaneous

4C-3582 Load Sensing Valve

Illustration 8	g01037661

Illustration 9	g01041110
Schematic for a 4C-3582 Load Sensing Valve

• 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 approximately 344 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)

9U-5893 Heat Exchanger

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.

Table 8

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

9U-5902 Rectifier Block

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.

Table 9

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)

1U-5796 Differential Pressure Gauge Group

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)

1U-6392 Pressure Reducing Valve

Illustration 17	g01037672

Illustration 18	g01040345
Schematic for 1U-6392 Pressure Reducing Valve

• 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 is 18.9 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.

Table 10

XT3 Fittings & Quick Disconnects Working pressure 27,560 kPa (4000 psi) 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.

Table 11

XT-5 Fittings and Quick Disconnects Working Pressure 41,340 kPa (6000 psi) 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

Table 12

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	6 mm (.23 in)	3505 mm (11.5 ft)	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	2 mm (.080 in)	3050 mm (10 ft)	1/8 inch NPT Male Both Ends
	177-7861	Hose Assembly	2 mm (.080 in)	4270 mm (14 ft)	1/8 NPT Both Ends
	177-7862	Hose Assembly	2 mm (.080 in)	5486 mm (18 ft)	1/8 NPT Both Ends
	1U-5757	Hose Assembly	2 mm (.080 in)	1830 mm (6 ft)	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.

Table 13

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

Table 14

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)

Table 15

Dual Scale Pressure Gauges (Stem Connector) 4.00 in
Certified Part Number	Standard Part Number	Range kPa (psi)
186-2613	8T-0820	0 to 70,000 (0 to 10,000)

Table 16

Dual Scale Pressure (Back Connector) 2.50 in
Certified Part Number	Standard Part Number	Range kPa (psi)
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)