9U-5000 Series Hydraulic Test Bench {0599, 0738} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

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Think Safety

European Union Compliant, ICE marked

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DUST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

Safety

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause 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. Always use a board or cardboard when checking for a leak.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills.

Repair and Maintenance

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Unless instructed differently, perform all maintenance as follows:

• Ensure that protective locks or controls are in the applied position.

• Do not attempt repairs you do not understand.

• Use proper tools and replace or repair broken or damaged equipment.

• Start the test center from the operators station.

Inspection

Check for the following:

• End fittings that are damaged, leaking, or displaced.

• Chafed or cut, outer covering and exposed wire reinforcing exposed.

• Outer covering ballooning in at spots.

• Evidence of kinking or crushing of the flexible part of the hose.

General Information

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9U-5000 Series Hydraulic Test Bench

Introduction

The Caterpillar 9U-5000 Series Hydraulic Test Bench is a low-cost alternative used to test many Caterpillar hydraulic components. Hydrostatic and Power shift transmissions, hydraulics pumps and motors, cylinders, and valves are a few.

The 9U-5000 Series Hydraulic Test Bench will test any component requiring input of up to 115 hp at 1250 rpm with a maximum of 2500 rpm. Many larger components can be tested using derated values. Testing hydraulic components assures good working order and proper adjustment before they are installed on/in a machine.

Cat dealers, or anyone else, can save themselves and their customers money by investing in specialized equipment to test hydraulic components after repair. Using the 9U-5000 Series Hydraulic Test Bench can provide dealers, and their customers, with the knowledge that only properly adjusted and working hydraulic components are leaving the rebuild shop. Therefore, re-servicing or additional downtime can be avoided.

he Caterpillar 9U-5000 Series Hydraulic Test Bench is a carefully designed, ruggedly built, piece of testing machinery. Each test bench provides excellent service with minimum maintenance, as long as it is properly operated and maintained.

In addition to this Tool Operating Manual, FORM NEHT5000 Bench Testing Hydraulic Components will provide the necessary information for testing Caterpillar hydraulic components.

Additional Contact Information

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at:

USA: 1-800-542-8665, Option 1International:: 1-309-578-7372

Basic Capabilities

Illustration 5	g02790049

Listed below are the testing capabilities of the 9U-5000 Series Hydraulic Test Bench .

• Hook-up and wide-range testing of transmissions, hydraulic pumps and motors, cylinders and valves.

• Drive power of up to 115 hp at 1250 rpm for rotating transmissions and pumps.

• 2500 maximum rpm.

• Oil flow to test components requiring a controlled flow and/or pressure.

• Oil flow for pump testing requiring positive head pressure.

• Oil flow rate and pressure metering from component through one of two digital flow meter circuits. One meter provides pressure testing using a variable supply of oil to a component, and can be used as a flow meter loop. The other meter provides a loop for reading only flow rates and pressures. Both circuits have reverse flow loading capabilities.

Main Systems of the Test Bench

The 9U-5000 Series Hydraulic Test Bench consists of three main systems: the hydrostat system, the oil flow out system, and the sum pump return to tank system.

1. The Hydrostat System: Consists of a 125 hp electric motor which drives two hydraulic pumps. The hydrostatic pump supplies oil to the hydrostat motor. Hoses connecting the pump to the hydrostat motor provide oil flow to the motor which supplies rotary mechanical power. This mechanical power in turn provides the output used to drive transmissions or pumps.

   A charge pump supplies make-up oil lost into either the hydrostat pump or motor cases. The pump and motor are self-contained in a closed-loop hydraulic system, fed by a 225 L (59.5 US gal) reservoir.

   Controls on the test bench enable the operator to vary the output speed from 0 to 2500 rpm, either in a clockwise (CW) or counterclockwise (CCW) rotation. The closed loop hydrostat system on this test bench provides a reliable, easily maintained source of power.

2. The Oil Flow Out System: Oil maybe supplied from any one of these three sources to a component being tested. Pressurized oil can supplied from a 200 L/min (52.8 US gpm) gear pump (main oil supply), a 102 mm (4.0 inch) suction line (pump supply), and a 13 L/min (3.4 US gpm) lube circuit. Depending on the oil source, the test bench provides all the test requirements for proper testing of hydraulic components.

3. The Sump Pump Return to Tank System: Oil used in the testing of components is directed to a sump pump under the work support table. Oil is then returned, through a series of filters, to a main 750 L (198.2 US gal) reservoir by sump pumps located on the end of the work support table. Also any leakage or spillage of oil on the work support table drains into the pump.

   Two sump pumps work in combination to return oil to the main reservoir. Both pumps are controlled by a three-position float switch. At "low level," both pumps are OFF. During testing, as the oil level rises to an "intermediate level" sump pump 1 comes ON. Finally, if the oil level reaches "high level" sump pump 2 is turned ON, and both pumps remain ON until the "low level" setting shuts them OFF.

Features and Specifications

• Primary Drive System

A main electric motor drives the hydrostat system and a 200 L/min (52.8 US gpm) gear pump.

50 Hertz - 125 hp at 1450 rpm

60 Hertz - 125 hp at 1755 rpm

Test bench electric motors are available for standard commercial power, from 208 to 575 Volt, 3 phase, 50 or 60 Hertz.

• Hydrostat System (Main Drive)

Consists of a variable displacement piston pump, charge pump, and hydrostat motor capable of 2500 rpm, 38000 kPa (5511.5 psi) with a maximum of 781 N·m (6912.4 lb in) output torque.

• Pump Control

Provided by a bi-directional control valve. The control valve is infinitely variable through the full range to a maximum 1250 rpm in CW or CCW rotation.

• Motor Speed Control

Provided by a variable control valve. The valve controls rpm of hydrostat motor from 1250 to 2500 rpm. Motor speed control increases rpm, while decreasing motor torque.

• Oil Flow Out Systems

A gear pump provides 0 to 21000 kPa (0 to 3045.8 psi) main oil supply up to 200 L/min (52.8 US gpm) for general purpose testing.

A lube flow circuit provides 0 to 3000 kPa (0 to 435.1 psi) oil flow up to 13 L/min (3.4 US gpm) for bearing/bushing lubrication or component control.

A pump supply system provides a positive head of oil using gravity flow from main reservoir through a 101 mm (4.0 inch) line of the inlet of pump being tested.

• Oil Flow and Pressure Metering Loops

Two flow and pressure metering loops are available for testing components. Each loop can return oil to sump.

One flow metering loop has an added pressurized oil supply of 200 L/min (52.8 US gpm).

Both loops are capable of metering 475 L/min (125.5 US gpm) with a maximum pressure of 47000 kPa (6816.9 psi). Reverse flow loading can be performed with both loops.

• Sump Pump System

Two 225 L/min (59.4 US gpm) sump pumps work in combination to return oil from work support sump back to main reservoir.

• Filtration

Four 10 micron absolute filters clean oil returning from sump to main reservoir.

One 13 micron absolute charge pump filter cleans oil from hydrostat charge pump.

One 10 micron absolute case-drain filter cleans oil from the hydrostat system case drains.

One 12 micron absolute main oil supply filter cleans oil from gear pump.

Two 10 micron absolute by-pass filters clean oil from main reservoir heat exchanger.

• Oil Temperature

Each oil reservoir is cooled by separate heat exchangers with automatic temperature control. Cooling water for heat exchangers can be supplied from a municipal water source or a closed water cooling system.

Oil temperature in main 750 L (198.2 US gal) reservoir is controlled by an oil-to-water heat exchanger and an in-line heater. With the use of Mobile DTE 11 oil, temperature in main reservoir is controlled at 46° to 70°C (115.0° to 125.0°F) to simulate oil viscosity under field conditions.

Note: For additional information on the recommended use of Mobil DTE 11 and DTE 26 oil, contact your Caterpillar Service Technology representative.

Oil Specifications

The recommended oil for the 750 L (198.2 US gal) main reservoir is Mobil DTE 11 hydraulic oil. During component testing, DTE 11 oil runs at a cooler temperature than regular hydraulic oil and still closely matches oil viscosity under field conditions. Using DTE 11 oil adds a measure of protection for the operator because oil temperatures only run 46° to 70°C (115.0° to 125.0°F).

For a 225 L (60.0 US gal) hydrostat system reservoir, Mobile DTE 26 oil, 10 to 30 weight is acceptable. Using DTE should extend the service life of the hydrostat system components.

Note: If additional information is required for this oil, contact your Caterpillar Service Technology representative.

Dimensions and Capabilities

Test Stand

• Main reservoir: 750 L (198.2 US gal)

• Length: 1829 mm (72.0 inch)

• Width: 1359 mm (54.0 inch)

• Height: 1700 mm (67.0 inch)

Work Support Sump

• Sump reservoir: 225 L (59.5 US gal)

• Length: 3750 mm (147.6 inch)

• Width: 1753 mm (69.0 inch)

• Height: 280 mm (11.0 inch)

• Height with drive mast support: 2375 mm (93.5 inch)

Control Console

• Length: 914 mm (36.0 inch)

• Width: 711 mm (28.0 inch)

• Height: 1346 mm (53.0 inch)

Installation

Each test bench comes factory tested and ready to install. Installation requires a main electrical service, water supply, and several test bench electrical and hydraulic connections. The installation procedure is described in detail in the following steps.

1. After unpacking, set the three major components of the test bench in position. Figure 41 at the end of this Tool Operating Manual provides general installation dimensions. The test bench should be mounted on a concrete, or other stable foundation. The exact location of three major test bench components can be adjusted to customer requirements.

2. Bolt work support sump to floor.

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Illustration 6	g02790055
(1) Oil Drain Line - Console Fitting (2) Control Pressure Line Connection Fitting (3) Main Oil Supply Line Connection Fitting

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Illustration 7	g02790057
(4) Control Pressure Line (5) Main Oil Supply Line

3. The main oil supply line (5) is shipped separately. Connect line (5) to main oil supply filter and to fitting (3) on console. Connect control pressure line (4) to fitting (2). Both hoses are routed from gear pump behind hydrostat reservoir and over to upper right-hand corner of control console. Also hook-up route oil drain line (1) to work support sum pump fitting (6) .

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Illustration 8	g02790091
(6) Oil Drain Line, Sump Fitting

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Illustration 9	g02790093
(7) Hydrostat Motor Supply Lines (8) Control Pressure Line (9) Case Drain

4. Hook up two hydrostat motor supply lines (7), control pressure line (8), and case drain line (9) from test stand.

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Illustration 10	g02790100
(6) Oil Drain Line (10) Sump Pump Line (19) Magnetic Pick-up

5. Hook up sump pump line (10) from sump pump filter manifold. Plug in magnetic pick-up connector (19) and secure with screw. Magnetic pick-up is mounted on drive shaft cover.

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Illustration 11	g02790103
(11) Water Inlet (12) Water Outlet (20) Control Console Connection (21) Work Table Sump Connection

6. Hook up water supply inlet (11) and outlet (12) for heat exchangers. For dimensional location of inlet and outlet, refer to Figure 41.

7. Make control wiring connections (20) from control console and from work table sump (21) to side of electrical enclosure. Engage connectors by pushing in on the socket and lock into position with cam lock lever.

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Illustration 12	g02790108
(22) Electrical Connecting Lugs

8. Hook up main incoming electrical service to three connecting lugs (22), located on the motor starter in the upper right corner of the electrical panel. The test bench requires the main power to be run through a customer-supplied fused disconnect.

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Illustration 13	g02790109
(17) Main Pump Control Cable (18) Motor Speed Control Cable

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Illustration 14	g02790114

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Illustration 15	g02790115
(17) Main Pump Control Cable (18) Motor Speed Control Cable

9. Hook up main pump electrical control cable (17) and motor speed control cable (18) to the connections inside the control console. Make similar cable connections to corresponding main pump and fluid motor controls.

Note: When control console pump control lever is in neutral, make sure that the main pump stroking lever is straight up and is in neutral. This can be identified by checking for continuity across terminals #4 and #7 inside the electrical panel. When in neutral, continuity must be present.

Control Console Gauges and Controls

Illustration 16	g02790111

(1) Control Pressure Gauge - #7: Indicates the pressure setting of control pressure valve #7. The gauge reads 0 to 4000 kPa (0 to 580.2 psi).

(2) Control Pressure Valve - #7: A pressure reducing valve supplying regulated oil pressure for bearing lube or component control. Output pressure can be varied from 0 to 3000 kPa (0 to 435.1 psi).

(3) Main Oil Supply Gauge #6: Indicates the pressure relief setting of the gear pump relief valve. The gauge reads from 0 to 21000 kPa (0 to 3045.8 psi).

(4) Main Oil Supply Valve - #6: Relief pilot oil for remote control of the gear pump pressure relief valve. The pressure relief valve in turn determines the volume of oil going to the main oil supply line. Flow can be adjusted from 200 L/min (52.8 US gpm).

(5) Flow Port #1 Pressure Gauge - #12: Indicates pressure in flow meter #1 loop. The gauge reads 0 to 7000 kPa (0 to 1015.3 psi). The gauge is protected by an in-line gauge above 0 to 7000 kPa (0 to 1015.3 psi). Pressure greater than 0 to 7000 kPa (0 to 1015.3 psi) can then be read on the gauge in flow meter #1.

(6) Supply Flow Lever - #8: Opens or closes the flow of oil from main oil supply gear pump through flow meter #1. (In the horizontal position, valve is closed.)

See Figure 17.

Illustration 17	g02790116
Control Console Gauges and Ports

(7) Flow Meter - #1: A digital display read-out indicates oil flow through the flow loop in LPM, US gpm, and Imperial gpm. The display also indicates temperature in degrees Fahrenheit, or degrees Centigrade. A built-in pressure gauge reads pressure from 0 to 55000 kPa (0 to 7977.2 psi). An external tachometer and flow meter can also be hooked up to the flow meter electrical sockets. The flow meter #1 loop is the main oil supply circuit and can be used as a metering loop, which has reverse flow loading capability.

(8) Load Valve - #9: A reverse-flow loading valve, which gives positive shut off and flow control in both directions of oil flow. The valve controls the flow of oil thorough the flow meter #1 from 0 to 475 L/min (0 to 125.5 US gpm).

See Figure 17.

(9) Pump Control Lever: Controls the direction of rotation and speed of the hydrostat motor (main drive) from 0 to 1250 rpm. In the center or neutral position, the flow rate is zero. Pushing the lever forward turns the main drive in a CCW rotation to a maximum of 1250 rpm. Pulling the lever back produces a CW rotation to a maximum of 1250 rpm.

(10) Motor Speed Control Knob: Produces hydrostat motor (main drive) rpm from 1250 to 2500 in either CW or CCW direction, depending on pump control lever position. Turning/pulling the knob produces higher rpm, but sacrifices torque.

(11) Load Valve - #10*: A reverse-flow loading valve which gives positive shut off and flow control in both directions of flow. The valve controls the flow of oil through flow meter #2 from 0 to 475 L/min (0 to 125.5 US gpm).

(12) Flow Meter - #2: Identical to flow meter #1, except this loop is only flow metering and reverse flow loading (no main oil supply).

(13) Flow Port #3 Pressure Gauge - #13*: Indicates pressure in the flow meter #2 loop. The gauge reads 0 to 21000 kPa (0 to 3045.8 psi). The gauge is protected by an in-line gauge minder which shuts off pressure to the gauge above 0 to 21000 kPa (0 to 3045.8 psi). Pressure greater than 0 to 21000 kPa (0 to 3045.8 psi) can then be read on the same gauge in flow meter #2.

(14) Switches and Indicator Lights: Refer to Section ""Control Console Switches and Indicator Lights" ".

Control Console Switches and Indicator Lights

Illustration 18	g02790119

(1) Reservoir Overfill: Indicates main 750 L (198.2 US gal) reservoir is over-filled and shuts down the sump pumps. (The indicator light is red).

(2) Main Supply Filter - Push to Test: Indicates main oil supply filter is dirty. (The indicator light is red.)

(3) Case Drain Filter - Push to Test: Indicates hydrostat system case drain filter is dirty. (The indicator light is red.)

(4) Sump Pump Filter - Push to Test: Indicates sump pump filters are dirty. (The indicator light is red.)

(5) By-Pass Filter - Push to Test: Indicates return filter from main reservoir heat exchanger is dirty. (The indicator light is red.)

(6) Low Oil - Indicates low oil level in 225 L (59.5 US gal) reservoir and shuts off main electric motor. (The indicator light is red.)

(7) RPM Indicator- A digital meter that displays the rpm of the main drive.

(8) Power On: Indicates control power switch (14) is ON. (The indicator light is green.)

(9) Stop - Push OFF: Stops the main electric motor.

(10) Sump 1 On: Indicates sump pump 1 is ON. (The indicator light is green.)

(11) Sump 2 On: Indicates sump pump 2 is ON. (The indicator light is green.)

(12) Heater On: Indicates main reservoir oil heater is ON. (The indicator light is green.)

(13) Charge Filter - Push to Test: Indicates charge filter for hydrostat system is dirty. When indicator light comes ON, filter must be changed immediately. To turn OFF indicator light, press reset button (19). (The indicator light is red.)

Note: The main electric motor will not start when the charge filter indicator light (13) is ON. The filter must be changed and the reset button pushed before test bench operation can resume. Failure to change the charge pump filter when indicated will void warranty!

(14) Control Power - Power ON/Turn to Release: Activates or deactivates the main power and electric controls required to start the test bench.

(15) Start: Starts the main electric motor which then powers the hydraulic pumps and motors. To activate the system, control power knob (14) must be ON, emergency stop (16) must be OUT, charge filter light (13) must be OFF, and pump control lever must be in neutral position.

(16) Emergency Stop - Push to Stop/Turn to Reset: Stops all functions on the test bench and cuts power to all circuits, except control power (14) .

(17) Off (Manual/Auto) - CCW-Manual/CW-Auto: Starts sump pumps in manual or automatic. For normal operation, switch should be in auto setting. Sump pumps, controlled by a float switch in the auto setting, operate in three stages: low, intermediate, and high. At a low level, auto setting will shut pumps OFF. In the manual setting, sump pump 1 runs continuously, and will not shut OFF at low level.

(18) Heater On/Off - CCW-ON/CW-OFF: Turns the main reservoir oil heater ON. Heater is activated only when main electric motor is running.

(19) Reset - Push to Reset: Turns the charge filter indicator light OFF after charge filter has been changed.

Hydraulic Connections on Control Console

Illustration 19	g02790120

(1) Port #4 Flow Meter #2 OUT: The outlet port in the flow meter #2 loop. Oil flow going out can be metered and pressure controlled by the flow meter load valve #10.

(2) Port #3 Flow Meter #2 IN: The inlet port in the flow meter #2 loop. Oil going in goes to flow meter #2.

(3) Port #5 Control and Lube Supply : An outlet supplying regulated oil pressure for bearing lubrication or test component controls. The output is variable between 0 to 3000 kPa (0 to 435.1 psi).

(4) Port #2 and Main Oil Supply Flow OUT: (Flow Meter #1) The outlet port in the flow meter #1 loop. Oil flow going out can be metered and pressure controlled by the flow meter load valve #9.

(5) Oil Drain: A drain for the pilot control and pressure reducing valves. This drain is directed back to the sump.

(6) Control Pressure Pilot Line: A pilot line which controls the setting of the pressure relief valve on the main oil supply gear pump.

(7) Main Oil Supply Line: An inlet from the gear pump supplying 200 L/min (52.8 US gpm) at 0 to 21000 kPa (0 to 3045.8 psi). Oil supply from the gear pump is directed through flow meter #1, and is also used for the control and bearing lube supply (port #5.)

(8) Port #1 Flow Meter #1 IN: The inlet port in the flow meter #1 loop. This loop can be used as a flow metering loop. Oil going in goes through flow meter #1.

Note: The hose connected to ports #1, 2, 3, 4 and 5 are dealer fabricated. Refer to FT2543 for a drawing and list of parts needed to fabricate these hoses.

Initial Main System Start-Up

Illustration 20	g02790122
(1) Main Reservoir (2) Main Reservoir Sight Glass (3) Hydrostat Reservoir (4) Hydrostat Reservoir Sight Glass

Illustration 21	g02790124
(5) Gear Pump Inlet Supply Valve

1. Fill main reservoir (1) with Mobil DTE 11 oil until it reads within 25 mm (1.0 inch) of the top of sight/temperature gauge (2). Open supply valve (5) to gear pump inlet.

2. Fill hydrostat reservoir (3) with Mobil DTE 26 oil or 10 to 30 weight oil until it reads within 25 mm (1.0 inch) of the top of sight/temperature gauge (4). Open supply valve to charge pump inlet. The valve is on the bottom of the hydrostat reservoir.

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Illustration 22	g02790133
(6) Hydrostat Motor Case Connection and Line

3. Before starting, hydrostat pump case and hydrostat motor case must be filled with oil. To fill hydrostat pump, remove case drain line (6) and pour approximately 8 L (2.1 US gal) of DTE 26 oil into line.

   While case drain line is disconnected, fill hydrostat motor case with Mobil DTE 26 oil and reconnect line.

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NOTICE
Do not allow the electrical motor to run continuously, until the hydrostat system has been purged of air. Trapped air can cause cavitation in the pump and motor, resulting in serious damage to both components.

4. Turn control power ON and jog electric motor to check for motor rotation. If motor will not start, make sure that pump control lever is in neutral (continuity between terminals #4 and #7 in electrical panel) and the charge filter light on control console is not lit. If the charge filter light is ON, push the reset button (19). The hydrostatic reservoir must also have the proper oil level.

   To observe motor shaft rotation, remove inspection port cover on gear pump end of electric motor. Shaft rotation of motor should be CW as viewed from gear pump end. If rotation is not CW, recheck electrical connections.

5. Continue to jog electrical motor until hydrostat system has been purged of air and is running quietly. Check oil level in both oil reservoirs, and fill as needed.

6. Once system is running, check operation of pump control lever. When lever is moved to CCW position, hydrostat motor should rotate CCW, as viewed from control console. If rotation is CW, hydrostat motor supply lines must be reversed. Move pump control lever to the maximum rpm position in both directions. The display should read approximately 1250 rpm in both CW and CCW directions. If rpms are not equal (±10 rpm) make linkage adjustments on the pump control cable at the main pump control lever.

7. Check operation of motor speed control lever. With pump control lever in a full flow position, rpm display should read approximately 1250 rpm. Pull out motor speed control lever, or rotate knob, and CCW and rpm should increase. When lever is pulled out completely, rpm display should read approximately 2500 rpm, If rpm does not increase, check motor control lever cable.

8. Check oil flow out system by hooking up a hose to port #2, and run other end into sump. Move supply flow handle (#8 Figure 17) to the ON position. Oil flow out of port #2 should be approximately 200 L/min (52.8 US gpm). Make sure that sump pump switch is in auto setting before starting this test.

9. Check operation of emergency stop button. Run hydrostat motor at 1000 rpm, and push emergency stop button. All systems should shut down, and only control power indicator light will be ON. To reset emergency stop button, turn button to release

Operation

To start the test bench for daily operation:

1. Turn control power knob "ON". Green "Power On" indicator light should be lit. If indicator light is not lit, check emergency stop button.

2. Turn sump pump switch to auto setting, and turn heater switch to "ON".

3. Start main electric motor by pressing start. If main electric motor will not start, check the following:

   1. Emergency stop button must be OUT

   2. Charge filter indicator light must be OFF

   3. Pump control lever must be in neutral position

   4. Low oil light must be OFF.

      Note: If charge filter indicator light is ON at anytime, the charge filter must be replaced before pushing the reset button. This is an internal safety circuit to ensure that the hydrostat charge filter is serviced before starting again.

4. Component testing can now be accomplished.

To stop test bench in an emergency, push emergency stop button. Normal shutdown of the test bench can be achieved by pressing stop and turning "OFF" the control power

Testing

This section will outline general testing and component hook-up procedures for the 9U-5000 Series Hydraulic Test Bench .

Specific instructions, and test specifications for any particular test component, such as transmissions, pumps, motors, and cylinders, can be found in the NEHT5000 Bench Testing Hydraulic Components, or from the components manufacturer.

Transmissions

The purpose of the transmission test is to make sure that the transmission will function properly when installed in the vehicle. The test bench is designed to rotate the transmission as if it were driven by an engine. This type of testing provides the best results.

By rotating the transmission, pressure settings can be adjusted. Shift points can be quickly set, and flows can be checked. Additionally, unacceptable operating conditions such as leakage, excessive noise, and vibration can also be identified.

The test bench is capable of simulating vehicle operation on most transmissions. The following information covers the setup and basic information needed to test a transmission.

1. The main drive (hydrostat motor) will rotate the transmission in the required direction, and at the desired speed. This task is accomplished through the pump control lever and the motor speed knob.

2. The main oil supply will provide regulated oil flow at a specific pressure to the valve and clutch package in the transmission. This main oil supply system takes the place of the vehicle charge pump where one is not integral to the transmission itself.

3. The control oil system will provide oil at low flow and pressure for lubrication.

4. The control oil system will provide oil at low flow and pressure for lubrication.

5. Six pressure gauges, located in the control console, can be tapped into the transmission for checks of internal pressures.

Mounting a Transmission

Illustration 23	g02790140
(1) Hydrostat Motor Lift Winch (2) Drive Shaft Guard (3) Transmission (4) Support Bar (5) Clamp Down Rails

1. Positioning and Leveling: A secure, level base should always be provided when testing transmissions. Mount the transmission on a universal-type mounting adapter, along with any special adapters for a particular transmission. If support bars (4) are used to mount the transmission, position the support bars as close to the ends of the transmission as possible. When mounting transmissions, use flat surfaces or special adapters to allow the transmission to securely rest on support bars.

   Position the transmission input shaft as closely as possible to the vertical centerline of the hydrostat main drive. Using the hydrostat motor lift winch (1), adjust the main drive output shaft horizontally to align with the transmission input shaft, and connect the drive shafts.

2. Securing: Bolt the mounting adapter and the transmission to the work support pump using the two clamp down rails (5). Use chains and load binders to secure the transmission to the mounting adapter or the work support sump. The load binders could be placed on opposite sides. This should keep the mounting snug and secure and should keep the transmission case from rotating during violent transmission shifts. After securing the transmission, recheck alignment of drive shaft, and install the drive shaft guard (2) .

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NOTICE
Failure to properly secure the transmission and its mounting adapters can result in damage to the transmission and the test bench. Some tests requiring shifting from forward to reverse, or down shifting, can generate a large amount of torque, which could rotate the transmission.

Hydraulic Connections

To obtain the proper oil supply flow to the transmission, follow the steps below:

1. Connect a supply hose from port # 2 (flow meter 1) to transmission oil inlet specified in test procedure.

2. Make sure main oil supply valve #6 is at its minimum setting (fully CCW).

3. Slowly open the supply flow valve #8 to the required oil flow.

4. Adjust the supply pressure valve #6 to the proper pressure value required for that particular transmission.

   Note: If a transmission has an integral relief valve, the main oil supply pressure must be set at 700 kPa (101.5 psi) ABOVE the relief valve setting of the transmission. If not, it would be impossible to determine which relief valve is controlling the pressure. If the transmission does not have a relief valve, then the main oil supply pressure must be set at the specified testing pressure to protect the transmission.

5. Adjust load valve #9 to supply the correct oil flow to the transmission. Flow rate can be read on the digital readout of flow meter #1.

Note: The main oil supply must be adjusted to the exact flow the transmission would receive in the vehicle. This does not mean the transmission should receive 200 L/min (52.8 US gpm) if the vehicle has a pump rated at that flow. Because pumps supply other components with oil flow, the supply to the transmission is generally less than the system supplies. Use the NEHT5000 manual to determine flow rates for Caterpillar transmissions and manufacturers specs for other transmission brands. If excessive oil flow is supplied to a transmission during testing, it will be impossible to determine clutch pack leakage, and therefore incorrect test results will be obtained.

Driving a Transmission

There are two drive arrangements on a transmission: remote type or direct mount.

1. Remote Type: The remote-mounted transmission is normally connected to the engine through a drive shaft. Therefore, it is necessary only to connect the transmission to the test bench main drive with a drive shaft and suitable flanges.

2. Direct Mount: On transmissions with torque converters that bolt directly to an engine, it is necessary to bolt on the proper drive adapter to the drive support mast and support the torque converter. After this has been done, the transmission will be connected to the test bench main drive in the same manner as the remote type.

All necessary mounting, drive, and accessory hardware to accomplish complete testing of many types of transmissions can be supplied by Caterpillar Inc.

Illustration 24	g02790145
(6) Control Lever (7) Main Drive and Direction of Rotation

To drive a transmission, move the pump control lever toward the specified direction of rotation (CW or CCW). Remember, as the lever is moved toward the CCW symbol on the control console, the main drive rotates in a CCW direction, as viewed looking at the main drive shaft.

Move the pump control lever in either direction rotates the test component up to 1250 rpm. The pump control ever is used for all; lower testing speeds (0 through 1250 rpm).

Note: If the test component requires speeds greater than 1250- rpm, the pump control lever (8) is used in combination with the motor speed control knob (9). Once the component speed is at the maximum rpm using the pump control lever, slowly turn the motor speed control knob to obtain a speed between 1250 and 2500 rpm. For slower, more precise rpm adjustment, turn the knob. For faster rpm adjustment, push the button (10) on the end of the knob, and slide the knob in or out.

Illustration 25	g02790146
(8) Pump Control Lever (9) Motor Speed Control Knob (10) Motor Speed Control Knob Push Button

As testing proceeds and the load on the transmission changes, the rpm must be adjusted to the proper settings.

Pump Testing

Rebuilt pumps should be tested to make sure that the pumping capacity is at an acceptable level. Also, testing under loaded conditions is necessary to assure proper reassembly and to check for shaft, seal, or cover leaks.

Checking Pump Efficiency

Pump efficiency can be determined by observing the amount of oil leakage occurring within the unit. A certain amount of leakage takes place between the high and low pressure sides of all pumps. Using the test bench and test specifications, it can be determined how much leakage is coming from a given pump, and whether that pump needs rebuilding.

Determining Worn Parts

Excessive leakage in certain types of pumps can also indicate the parts that are worn.

In vane pumps, the leakage depends on the amount of clearance between the rotor slots and vanes, the end plates and rotor vanes, or the contact between the vane tips and the ring surface.

In gear pumps, the leakage depends upon the gear match or the clearance between the gears, the fit of the gears to the side plates, or the fit of the gears to the housing.

In piston pumps, leakage can occur between the piston and piston barrel, the piston barrel and port plates, or the port plates and housing. In piston pumps, leakage is called case drain leakage.

Calculating Pump Efficiency

A standard pump testing practice is to compare pump flow at 700 kPa (101.5 psi) to pump flow at 7000 kPa (1015.3 psi) while maintaining a constant rpm. Pump flow loss from leakage is directly affected by pressure. This leakage-to-pressure comparison is quite useful in determining pump condition.

In testing a pump, it is generally rotated at a given rpm (usually 1200 or 1800) at 700 kPa (101.5 psi) back pressure on the pressure port. The resulting flow is the performance base of the pump. After recording the base flow, the pressure is increased to 7000 kPa (1015.3 psi) while the speed is maintained. The decreased flow at the higher pressure is expressed as a percentage loss, indicating the pump efficiency, and is calculated by:

% loss = flow rate @ 700 kPa (101.5 psi) minus flow rate @ 7000 kPa (1015.3 psi) divided by flow rate @ 700 kPa (101.5 psi)

For example, a pump that delivers 50 gpm at 100 psi and 48 gpm at 1000 psi shows a 4% loss.

4% (.04) = 50 minus 48 divided by 50

Determining Acceptable Leakage

Acceptable losses vary widely among various types, sizes, and manufacturers. For example, piston pumps are generally more efficient than either vane or gear pumps.

Most pump manufacturers have a maximum acceptable leakage rate. If this information is not available, a rule of thumb is as follows. A piston pump that loses no more than 10 percent base flow at 7000 kPa (1015.3 psi) or a gear or vane pump that loses no more than 20 percent is acceptable to return to service.

In determining acceptable leakage, consideration should be given to the type of machine or application in which the pump will work. A high production or high cycling machine probably requires minimum loss. A machine that works intermittently can possibly tolerate higher losses.

Oil temperature can also affect pump leakage. Pump leakage increases with the rise in operating temperature, due to the change in oil viscosity. The hotter or thinner the oil becomes, the easier it is to leak past the gears, vanes, or pistons.

Another rule of thumb in determining maximum acceptable leakage is as follows: pump capacity will decrease approximately 2 L (0.5 US gal) for every 10°F of temperature rise from 120°F to 180°F. Double this value if flow from two sections of a pump is combined.

Connecting a Pump

Follow these steps for connecting a typical pump to the test bench.

1. Connect a hose from pump suction port to pump supply port #11.

2. Connect a hose from pump outlets to port #1 or #3 (IN), through flow meters to port #2 or #4 (OUT), and directed back to the work support sump.

3. If testing a piston pump, connect a case drain and control pressure line.

   1. Control pressure can be obtained from port #5 and regulated with control pressure valve #7. Control pressure can be read on the 0 to 4000 kPa (0 to 580.2 psi) control pressure gauge #7.

   2. Connect a case drain line to the pump and measure the leakage using any suitable method. Optional flow meters can be connected to the external flow meter socket on either flow meter #1 or #2.

Testing a Pump

1. To test a typical gear pump or vane pump, open pump supply port #11 on test stand.

2. initially, hose connected from pump outlet port should be directed to work support sump for priming and rotation check. (Some oil will flow through pump at this point, providing lubrication.)

3. Jog pump at low speed (less than 600 rpm) until pump is primed. Also check for correct rotation.

4. When the pump is primed and oil flows from the loose pump outlet, connect line to port # 1 or #3 (IN). The hose from port #2 or #4 (OUT) should be directed into work support sump.

5. Proceed with testing, according to the pump or vehicle manufacturers specifications.

Note: When testing a typical piston pump, fill the case with oil from port #5.

Hydraulic Motors

Hydraulic motors can also be tested on the test bench. Testing specifications should proceed according to the hydraulic motor or vehicle manufacturers specifications.

1. Install fluid motor on test bench. Use NEHT5000 manual or Service Manual Test and Adjust Procedure for directions.

2. Fill case with oil, if testing a piston-style fluid motor.

3. Connect a hose from main oil supply port #2 (OUT) to motor inlet. On most fluid motors, either port can be used.

4. Connect a hose from motor outlet to port #3 (IN) flow meter #2.

5. Connect a hose from port #4 (OUT), flow meter #2, and direct oil to work support sump.

6. After properly making all connections, begin the motor test.

Testing a Motor

1. Make sure main oil supply valve #6 is at its minimum setting (fully CCW).

2. Slowly open the supply flow valve #8 to the full open position.

3. Adjust the supply pressure valve #6 to the proper pressure value required for that particular transmission.

4. Adjust load valve #10 to increase motor back-pressure to the recommended value. Flow rate and pressure can be read on flow meter #2.

Cylinders

Note: A 4C-4690 cylinder test manifold is required for testing cylinders on the test bench.

Cylinder testing on this bench can determine if the cylinders are operating correctly in respect to leakage, binding, and rod drifting.

1. Place cylinder on work support sump. Make sure that when cylinder rod is fully extended, it will not be damaged or cause any damage to any part of test bench.

2. Install appropriate fittings into cylinder input and output ports.

3. Connect hydraulic hoses from cylinder to cylinder test manifold.

4. Connect a hose from main oil supply port #2 to cylinder test manifold.

5. Cylinder testing consists of alternately directing a flow of oil, under pressure, to one cylinder port, while venting the other, in order to check rod extension and retraction.

   During cylinder rod travel, main oil supply pressure gauge #6 should be observed to determine whether any tight spots occur. With steady oil flow into the cylinder, there should be no appreciable change in pressure.

6. A second test consists of blocking one cylinder port and pressurizing the other, thus trapping pressure in the cylinder. Due to the effective piston area, pressure in the rod end will be higher than in the head end.

   With this method, poor piston sealing can be determined because oil from the high pressure side of the cylinder will try to leak past seals to reach the low pressure side. Any leakage of oil from the rod end will allow the rod to extend.

Maintenance

The 9U-5000 Series Hydraulic Test Bench is designed to give years of trouble free service with a minimum of regular maintenance. In order to assure reliable service, the maintenance procedures and time intervals below should be followed. It is also recommended to keep the entire test bench free of grease, dirt, and oil build-up.

An adequate amount of clean hydraulic fluid must be maintained in the test stand at all times. Oil is a very critical part of the test bench. Not only does it perform work, but it also lubricates the tested component. Keeping the reservoirs full of clean oil will extend the life of the test bench and the components being tested.

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NOTICE
To avoid damage to the test bench pumps and motors, never operate the test bench when oil is not visible in the oil level sight gauges.

Oil

Check the oil level daily using the oil oil-level sight gauges located on the front of the reservoirs. Oil can be added to the main reservoir by pouring it into the sump or filling through the fill cap. Oil is added to the hydrostat reservoir only through the fill cap.

Oil in the test stand should be checked periodically for quality. Physically, the oil can be tested by:

• Feeling the oil for grit or sludge

• Visually inspecting the color of the oil. Dark black oil is a sign of burnt oil. Milky color oil is a sign of water or air in the system.

Illustration 26	g02790150
(1) Main Reservoir Oil Level Sight Gauge and Fill Cap (2) Hydrostat Reservoir Oil Level Sight Gauge and Fill Cap (3) Oil Temperature Gauge

An oil temperature gauge is also mounted to the oil level sight gauges. Using DTE 26, the temperature in the hydrostat reservoir should not exceed 54° ± 78°C (130.0° ± 140.0°F). Using DTE 11, the main reservoir temperature can range from 43° ± 78°C (110.0° ± 140.0°F) depending on the requirements of the component being tested. Normal temperature for this reservoir is 46° ± 69°C (115.0° ± 125.0°F)

Oil Filters

Illustration 27	g02790153
(1) Sump Pump Filters (2) Case Drain Filter (3) Charge Filter

The sump pump filters (1) are located at the rear of the test stand. Sump pump oil filters should be changed whenever the sump pump indicator light comes ON.

The case drain filter (2) is located directly below and to the left of the sump pump filters. The filter should be changed whenever the case drain filter indicator light comes ON.

The charge filter (3) for the hydrostat system is located at the rear of the test stand behind the sump pump filters. The filter should be changed immediately when the charge filter indicator light comes ON. To reset the system, the filter must be changed, and then the reset button can be pushed.

Illustration 28	g02790157

The by-pass filters (4) are located next to the main oil supply filters. These oil filters should be changed whenever the by-pass filter indicator light comes ON.

The main oil supply filter (5) is located to the left of the hydrostat reservoir. The filter should be changed whenever the main supply filter indicator light comes ON.

Oil Strainers

Oil strainers in both reservoirs should be removed and cleaned every 1500 hours (12 months). These strainers are located inside the reservoir fill caps, on the main oil supply line, on the 101 mm (4.0 inch) pump supply line, and on the charge pump supply line.

The sump oil screen should be cleaned every 120 ours (1 month).

Heat Exchangers

There are two heat exchangers on the test bench: one for the main reservoir, and one for the hydrostat reservoir. Water for the exchangers can be supplied from a closed water cooling system, or directly from a municipal water supply

Illustration 29	g02790162

Illustration 30	g02790163
(1) Water Supply Control Valve (2) Thermostat for Hydrostat Reservoir Heat Exchanger (3) Heat Exchanger for Hydrostat Reservoir (4) Thermostat for Main Reservoir Heat Exchanger (5) Heat Exchanger for Main Reservoir

Through normal operation, the heat exchangers become dirty from oil, grease, rust, and scale. The heat exchangers should be drained and checked every 1500 hours (12 months) of operation.

To clean the heat exchangers, first drain the water and oil tubes by blowing compressed air through them. During disassembly of the unit, care should be taken to prevent damaged or bent tubes.

If the oil chamber of the heat exchanger becomes coated or filled with sludge, it will require cleaning to maintain maximum efficiency. If the chamber is not heavily coated with sludge, back flowing with solvent or clean oil may remove most of the sludge. For heavier build up, flood the unit with a commercial solvent, such as Trichloroethylene, and allow it to soak for one-half hour. Repeat soaking and back flowing procedure until unit is clean.

If the inside of the cooling tubes become restricted with scale or rust deposits, they must be cleaned. To clean the cooling tubes, use a fifty/fifty solution of muriatic acid and water. For heavy build up of scale, use a soft bristle brush to aid in cleaning the inside of the tubes. Use care to prevent scoring the inside of the tubes.

After the unit has been cleaned, wash away all chemicals and solvents before the unit is placed back into service. Also, replace the gaskets after end castings have been removed.

If salt water is used as a cooling medium, special heat exchangers having 90/10 copper tubes, bronze bonnets, and zinc anodes should be used.

Note: If a closed water cooling system is used, a corrosion preventative should be added. This treatment is effective under normal operating conditions for a period of six months, after which the system should be drained, flushed, and filled with new solution.

If the heat exchanger is installed where there is a chance of freezing, the water circuit should be filled with an antifreeze solution.

Main Reservoir Oil Heater

When the main reservoir is cleaned, the heater coil should be checked and cleaned of any scale build-up.

Electric Motors (Main and Sump Pump)

Illustration 31	g02790167
(1) Main Electric Motor

Illustration 32	g02790168
(2) Sump Pump Electric Motor

Periodically inspect the electric motors (1) and (2) for dirt, vibration, or unusual noise. Dust may be blown away from the motors using air. Grease and oil should be wiped away using a petroleum-based solvent.

Hydrostat Motor Lift Winch

The winch used to raise the hydrostat motor requires periodic preventative maintenance. Grease the winch gears and reel shaft, as needed. Also periodically place a drop of oil on the drive shaft bearings.

If the cable becomes worn or frayed, replace it immediately.

Electric Control Console Fan Filter

This cooling fan is only on test benches having the soft-start option. Replace the filter element of the cooling fan every 1500 hours (12 months) and clean the fan of built-up dirt.

Other Operations

Gear Pump

Illustration 33	g02790172
(1) Gear Pump Inlet (2) Gear Pump Filter Differential Pressure Switch (3) Gear Pump (4) Gear Pump Pilot Operated Relief Valve (5) Gear Pump Filter

Oil to the gear pump (3) is supplied from the main reservoir. From the gear pump, the oil passes through a filter (5) fitted with a differential pressure switch (2). Oil then flows to the control console where the flow can be metered and the pressure controlled.

Oil Reservoirs

There are two oil reservoirs: one is the main reservoir, the other is the hydrostat reservoir. Each reservoir is thermostatically cooled with a water-to-oil heat exchanger. Oil temperature can be read from the gauge under the oil-level sight gauge. The main reservoir can be filled by adding oil to the sump or through the fill cap located on the side of the reservoir. The hydrostat reservoir can only be filled through the fill cap on the side of the reservoir.

The oil level sight gauges should be checked daily, and the level should be clearly visible in the gauge.

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NOTICE
To avoid damage to the pumps or motors, do not operate the test bench when oil is not visible in the oil level sight gauge. The temperature of the main reservoir is controlled by the heat exchanger or the in-line heater. To heat oil in the main reservoir, turn the heater switch to ON. The oil temperature should remain between 46° ± 78°C (115.0° ± 140.0°F) with 46° ± 69°C (115.0° ± 125.0°F) being ideal. If the temperature goes over 78°C (140.0°F), discontinue testing, lower the supply pressure to zero, and allow the main electric motor to run. This allows the gear pump to circulate oil through the heat exchanger. Under certain testing conditions, the heat exchanger water valve or heater controls may have to be adjusted. The oil temperature in the hydrostat reservoir is controlled only by a heat exchanger. If the oil temperature in this reservoir exceeds 78°C (140.0°F), allow the test bench to operate without a load until the temperature is within the specified operating range. Depending on the component being tested, the temperature control on the heat exchangers may have to be readjusted.

Sump System

The sump system is made up of a sump, strainer, two sump pumps, and four filters. The normal operating setting for the sump pumps is the auto setting. The manual setting is used to remove more of the oil from the sump in a case where cleaning is required.

Oil from component testing is collected in the sump. The oil then goes through an oil screen and is pumped by the sump pumps to a bank of filters located at the rear of the test bench. Once filtered, the oil is returned directly to the main reservoir.

When the sump pump manual/auto switch is in the auto setting, the sump pumps are controlled by an oil-level float switch. At low level, both pumps are OFF. At an intermediate level, sump pump 1 is ON, and finally at the high level, setting, sump pump 2 also turns ON.

Flow Meters

The test bench is equipped with two flow meters for convenient checking of flow, pressure, and temperature. The flow meters are designed to withstand full pressure up to 47000 kPa (6816.9 psi). The flow meters are also equipped with a loading valve, allowing control of pressure on either side of the loop. Even though the flow meters can be used in both flow directions, it is recommended to use the IN and OUT ports on the control console.

Oil flow through the flow meter is digitally displayed in Lpm or gpm. The units are changed by pressing the units button.

The pressure gauge on the flow meter has an in-line shuttle valve which automatically reads the highest pressure in both directions of flow.

Oil temperature can be read on the digital display, and the units can be changed by pressing the "°F/°C" button.

Illustration 34	g02790174
(1) Flow Meter Selector Knob (2) External Socket for Recorder (3) Socket for External Tachometer (4) Socket for External Flow Meter (5) Pressure Gauge (6) Digital Display (7) On/Off Button (8) GPM/LPM Units Selector Button (9) Temperature Units Selector Button (10) Fast Button

The flow meter selector knob can be used to display rpm from a remote tach or flow, and temperature from an external remote flow meter. When not using an external tach or flow meter, the normal setting is Int. (internal) Flow. By using the two external flow meter sockets (located on flow meters #1 and #2) along with the two built-in test bench flow meters, four different flow meter readings can be obtained.

A Rec. (recorder) Out socket is available for sending information to a chart recorder or printer.

If service or repair of the digital flow meters is required, NEHS0565 Tool Operating Manual is available through the Caterpillar Service Technology Group.

Pressure-Test Gauges

Illustration 35	g02790177
(1) Pressure Gauge

Illustration 36	g02790179
(2) Pressure Gauge Inlet

A bank of six gauges is provided to register the pressure from the tested component. The gauges read 0 to 4000 kPa (0 to 580.2 psi).

Each pressure gauge has a corresponding pressure inlet fitting. These fittings are quick disconnect nipples, and a hose from the tested component can be connected to either fitting.

Serviceable Parts

Illustration 37	g02790189
Nomenclature for Serviceable Parts (1 of 4) Refer to Table 1 for Item Identification

Illustration 38	g02790190
Nomenclature for Serviceable Parts (2 of 4) Refer to Table 1 for Item Identification

Illustration 39	g02790191
Nomenclature for Serviceable Parts (3 of 4) Refer to Table 1 for Item Identification

Illustration 40	g02790192
Nomenclature for Serviceable Parts (4 of 4) Refer to Table 1 for Item Identification

Table 1 and Figures 37, 38, 39 and 40, provide a list of serviceable parts and their locations. The item numbers in Table 1 also correspond to the items in the schematics at the end of this manual

Table 1

Serviceable Parts
Item	Part No	Description
(1)	9U-7035	Gauge, Oil Level
(2)	9U-5877	Switch, Repair
(3)	- 141-4925 141-4926 141-4927 141-4928 141-4929	Heater, Immersion 480V/3ph/60Hz/ 380V/3ph/50Hz/ 240V/3ph/60Hz/ 575V/3ph/60Hz/ 415V/3ph/50Hz/
(4)	9U-5871	Element
(5)	135-5301	Switch
(6)	9U-5822	Hose Assembly
(7)	9U-5825	Hose Assembly
(8)	4C-9479	Element
(9)	9U-5824	Hose Assembly
(10)	9X-2353	Hose (Bulk)
(11)	9U-5870	Element
(12)	9U-5876	Switch
(13)	9X-2353	Hose (Bulk)
(14)	9X-2353	Hose (Bulk)
(15)	9U-5821	Hose Assembly
(16)	9X-2361	Hose (Bulk)
17	9X-2361	Hose (Bulk)
(18)	135-5302	Transformer
(19)	-	Not Used
(20)	-	Not Used
(21)	4C-6997	Coupling, Quick Disconnect
(22)	9U-5819	Strainer
(23)	9U-5820	Strainer
(24)	135-1795	Fuse, Note B, E
(25)	135-5303	Switch, Disconnect
(26)	135-5067	Contactor
(27)	135-5068	Relay
(28)	1U-9048	Contactor
(29)	4C-3867	Relay
(30)	4C-4006	Socket
(31)	4C-3859	Relay
(32)	135-5304	Valve
(33)	135-5305	Power Supply
(34)	135-1805	Fuse, Note E
(35)	4C-9910	Flow Meter
(36)	4C-4617	Gauge
(37)	9U-5823	Hose Assembly
(38)	9U-5848	Valve
(39)	9U-5813	Hose Assembly
(40)	9U-5815	Hose Assembly
(41)	-	Not Used
(42)	9U-5852	Gauge
(43)	9U-5849	Valve
(44)	-	Not Used
(45)	135-2564	Pilot Light
(46)	135-2557	Switch, Push Button
(47)	135-2565	Pilot Light
(48)	165-2563	Pilot Light
(49)	9U-5853	Indicator, RPM
(50)	8T-0850	Gauge
(51)	9U-5851	Gauge
(52)	4C-4023	Switch, Push Button
(53)	135-2559	Switch, Selector
(54)	4C-3857	Contact Block
(55)	135-2558	Switch, Selector
(56)	9U-5855	Cable
(57)	9U-5854	Cable
(58)	135-2562	Switch, Push Button
(59)	4C-3851	Contact Block
(60)	4C-4022	Switch, Push Button
(61)	135-2560	Switch, Push Button
(62)	135-2561	Lens
(63)	6E-2046	Pump (60 Hz)
(64)	8J-3632	Pump (50 Hz)
(65)	9X-2359	Hose (Bulk)
(66)	-	Motor, Electric
(67)	9U-5878	Valve
(68)	9U-5875	Valve
(69)	9U-5873	Valve, Water
(70)	9X-2358	Hose
(71)	135-5309	Pump
(72)	135-5310	Pump
(73)	4C-5094	Coupler
(74)	3J-1907	Seal
(75)	4C-5093	Nipple Assembly
(76)	2S-4078	Seal
(77)	9U-5819	Hose Assembly
(78)	9U-5203	Hose Assembly
(79)	9U-5867	Strainer
(80)	6V-3966	Nipple Assembly
(81)	9X-2360	Hose (Bulk)
(82)	9X-2360	Hose (Bulk)
(83)	125-6596	Valve
(84)	9X-2361	Hose
(85)	128-6766	Valve
(86)	9X-2359	Hose (Bulk)
(87)	135-5312	Valve
(88)	9U-5819	Hose
(89)	9U-5820	Hose
(90)	135-5313	Valve
(91)	135-5314	Valve, Check
(92)	135-5315	Motor
(93)	9U-5880	Winch
(94)	9U-5845	Pump, Sump (60 Hz)
(95)	9U-5847	Pump, Sump (50 Hz)
(96)	9U-5846	Switch, Sump Pump
(97)	135-5316	Valve, Check
(98)	9U-5812	Hose Assembly
(99)	9U-5814	Hose Assembly
(100)	9U-5859	Cooler
(101)	135-6971	Contactor, Note A, B, C, D, E, F
(102)	135-6972	Overload Relay, Note A, B, E, F
(103)	135-6973	Link Kit, Note A, B, C, D, E, F
(104)	135-6974	Terminal Kit, Note A, B, C, D, E, F
(105)	135-5308	Overload Relay, Note D, F
(106)	137-7305	Overload Relay, Note C, F
(107)	9U-7036	Gauge Oil Level
(108)	9U-7032	Filler
(109)	9U-7033	Filler
(110)	135-1793	Fuse, Note A, B, C, D, E
(111)	135-1794	Fuse, Note A
(112)	135-1796	Fuse, Note A
(113)	-	Not Used
(114)	135-1797	Fuse, Note B
(115)	135-1798	Fuse, Note B
(116)	135-1799	Fuse, Note B, E
(117)	135-1800	Fuse, Note C
(118)	135-1801	Fuse, Note C
(119)	135-1802	Fuse, Note D
(120)	135-1803	Fuse, Note D
(121)	135-1804	Fuse, Note C
(122)	138-2337	Controller
(123)	139-1544	Lampholder
(124)	139-1545	Contact Block
(125)	139-1546	Lampholder with Transformer
(126)	9U-5857	Bulb, Light
(127)	9U-5850	Valve
Note: These parts are required on the machines listed below: A = 9U-5000 460V/3ph/60Hz B = 9U-5001 380V/3ph/60Hz C = 9U-5882 230V/3ph/50Hz D = 9U-5883 575V/3ph/60Hz E = 9U-5884 415V/3ph/50Hz F = Not used when soft start option is required

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Series 5000 Installation Drawing

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Series 500 Hydraulic Schematic

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