- Cold Planer:
- PR-1000C (S/N: 5XC154-UP)
- PR-750B (S/N: 8AC1-UP)
- PR-750C (S/N: 7CK1-UP)
- PR-750B (S/N: 8AC1-UP)
- Integrated Toolcarrier:
- IT14G (S/N: FWL1-UP; 8ZM1-568; KZN1-UP; 1WN1-UP)
- Paving Compactor:
- CS-563 (S/N: 8XF1-UP; 7GG1-UP)
- CS-573 (S/N: 8PK1-UP)
- CS-583 (S/N: 8YJ1-UP; 1EL1-UP)
- PS-130 (S/N: 7ND1-UP)
- CS-573 (S/N: 8PK1-UP)
- Vibratory Soil Compactor:
- CP-563 (S/N: 1YJ1-UP; 5AJ1-UP)
- Track-Type Loader:
- 963C (S/N: BBD1-UP; 2DS1-UP)
- 973C (S/N: BCP1-UP; 3RZ1-UP)
- Compact Wheel Loader:
- 914G (S/N: PDF1-UP; 7ZM1-UP; 9WM1-UP)
- Wheel Tractor-Scraper:
- 631E Series II (S/N: 1BB1-UP)
- 631G (S/N: CMT1-UP; AXZ1-UP)
- 637E Series II (S/N: 1HB1-UP; 7CB1-UP)
- 637G (S/N: AWE1-UP; CEJ1-UP; CEM1-UP; AYN1-UP)
- 631G (S/N: CMT1-UP; AXZ1-UP)
Introduction
Revision     | Summary of Changes in REHS1837     |
03     | Added ""Canceled Part Numbers and Replaced Part Numbers" " section to document.     |
Added REHS1761 "Required Tooling for Bench Testing Hydraulic Components" to ""References" " section of document. |
© 2012 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.
This Special Instruction includes test procedures for piston pumps. This Special Instruction also provides specifications. The technician should have a good understanding of hydraulic piston pumps. The technician should be educated in the operation of the hydraulic test bench. The test benches in this document are available through the Caterpillar Service Tool Division. Gather all necessary tooling before you need to hook up the pump. Some of the required tooling appears in a table at the end of this document. There are many possible variations of tooling that could be used. Not every possible variation can be listed.
For questions or additional information concerning this guideline, submit a feedback form in the Service Information System website. In order to address an urgent need, use the following to relay your request to Caterpillar Repair Process Engineering:
- Cat Dealer Technical Communicator
- Dealer Solution Network
- Cat Technical Representative
- Knowledge Network (online)
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.
Safety
Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing 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. |
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. |
Pump test pressures in this guideline may exceed the normal operating range of the hydraulic test hoses utilized when connecting the tested pump to the test bench. However, the order of magnitude of these pressures is significantly below the burst strength of the Caterpillar "XT6" product. High pressure oil can escape through improperly assembled hoses and fittings. High pressure oil can also escape through poorly maintained hoses and fittings. High pressure oil may also leak through hose that has become damaged over the life of the hose due to the pressure levels that occur during test bench operation. Personal injury or death can result from improper hose & fitting inspection or improper hose replacement procedures. Escaping fluid under pressure can penetrate body tissue causing serious injury, and possible death. Thoroughly inspect all testing hoses, fittings, and quick disconnects prior to any testing operation. Check the assembly date tag or hose assembly log date for a hose life indicator. Replace all Test Bench hoses at a minimum of every 2 years or earlier if the hose or fittings appear to be damaged. |
Summary
This procedure is specific to the type of pump and the type of control. Refer to the test specifications and the tooling at the end of this document.
Note: A paper copy of this document may not be the latest version. Go to the Service Information System (SIS) in order to view the latest version.
References
References     | |
---|---|
Media Number     | Title     |
REHS1761     | Required Tooling for Bench Testing Hydraulic Components     |
SEBF8810     | Hydraulic Pump, Motor, and Cylinder Bench Test Procedure Reference Manual     |
SEHS8892     | Operating Instructions for Caterpillar 1U-9400 Series Hydraulic Test Center     |
NEHS0563     | Tool Operating Manual for 9U-5000 Series Hydraulic Test Bench     |
Connections for the Caterpillar Hydraulic Test Center
Illustration 1 | g01036452 |
Connections for the Test Center (1) "F3" flow meter inlet (2) "F3"outlet for the flow meter with pressure control (3) Signal pressure (4) Oil supply from the auxiliary pump (5) Return to tank |
Illustration 2 | g01037347 |
Control and Gauges for the Test Center (6) Control for signal pressure (7) "F3" discharge flow (8) "F3" Load control for discharge pressure |
Connections for the Caterpillar Hydraulic Test Bench
Illustration 3 | g01037348 |
(9) "Flow meter 1" loop and "Flow meter 2" loop |
Illustration 4 | g01037349 |
(10) "Flow meter 2" outlet (11) Signal pressure line (12) "Flow meter 2" inlet (13) "Flow meter 1" inlet |
Illustration 5 | g01089470 |
(14) Control for signal pressure (15) "Flow meter 2" discharge flow (16) "Flow meter 2" load control |
Port Locations
Illustration 6 | g01045999 |
Typical port locations and adjustments (17) Case drain ports (18) Adjustment screw for minimum angle (19) Pressure port for displacement control (20) Work ports (21) Adjustment screw for maximum angle |
Illustration 7 | g01440696 |
Hydraulic Schematic (17) Case drain ports (18) Adjustment screw for minimum angle (19) Pressure port for displacement control (20) Work ports (21) Adjustment screw for maximum angle |
Motor Pre-Test Set Up
- Connect a hose from an auxiliary oil supply to a work port (20) .
- Connect a hose from the other work port (20) to a flow meter inlet.
- Connect the outlet of the flow meter to the tank on the test bench.
- Connect a hose from the signal pressure line on the test bench to the pressure port for displacement control (19) on the motor.
- Connect an in-line flow meter to case drain port (17). Direct the oil to the sump on the test bench .
- The use of 1U-6602 Photo-Tachometer is necessary. The use of the Photo-Tachometer will be necessary to verify the RPM of the output shaft. Attach a piece of reflective tape to the output shaft of the motor.
Test Procedure
Note: The oil in the test bench should be one of the following.
- SAE 10W at 50 °C (122 °F) or
- Mobil DTE-11 at 46 °C (115 °F)
- Use an auxiliary pump on your test bench to start rotating the motor according to Step 1 of the test specifications. Listen for abnormal noise. Verify that all the connections are not leaking. Check for leaks around shaft seals and control valves.
Run the motor for at least 5 minutes in order to raise the temperature of the oil and purge the system of air.
- Increase the flow rate into the motor. Use the load control for the flow meter (16) in order to set the back pressure on the output flow of the motor according to Step 2 of the test specifications. Adjust the back pressure and the auxiliary pump pressure in order to make sure that the input flow to the pump is correct. The motor should be at slow speed. Check the motor RPM. If the RPM of the output shaft for the motor are not within specifications, adjustment is necessary. To decrease speed, loosen the locknut and turn the adjustment screw for maximum angle (21) counterclockwise. To increase speed, turn the adjustment screw for maximum angle (21) clockwise.
- Apply control pressure into the pressure port for displacement control (19) according to Step 3 of the test specifications. The motor should be at maximum speed. Check the motor RPM. If the RPM of the output shaft of the motor is not within specifications, adjustment is necessary. To decrease speed, loosen the locknut. Turn the adjustment screw for minimum angle (18) clockwise. To increase speed, turn the adjustment screw for minimum angle (18) counterclockwise.
Note: Some pumps shift at a certain pressure while other pumps shift over a pressure range. For motors that shift over a pressure range, verify the control pressure when the RPM for the output shaft of the motor increases. Also verify the control pressure when the RPM for the output shaft of the motor reaches maximum speed. These ranges are provided in the test specifications.
Note: For part number 111-0364 Step 3 must be modified. This motor has a minimum angle of 0°. Verify the control pressure when the motor begins to accelerate. Then stop the motor. Increase the control pressure that would put the motor at maximum speed. Attempt to put flow into the motor. The motor should be completely destroked. The motor should not turn.
Test Specifications
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input Flow Lpm (gpm)     | Control Pressure kPa (psi)     |
111-0364     | 1     | 707     | 0     | 114 (30)     | 0     |
2 | 1061     | 1724 (250)     | 151 (40)     | 0     | |
3 | 0     | 1724 (250)     | 151 (40)     | 500 (73) - (1)     |
( 1 ) | Adjust the set screw for the minimum angle 20.7 mm (0.8150 inch). |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
127-8335     | 1     | 568     | 0     | 114 (30)     | 0     |
2 | 757     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1165     | 1724 (250)     | 151 (40)     | 2400 (348)     |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
151-1244     | 1     | 454     | 0     | 114 (30)     | 0     |
2 | 605     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1826     | 1724 (250)     | 151 (40)     | 800 (116) - 1600 (232)     |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
168-1837 (1)     | 1     | 707     | 0     | 76 (20)     | 0     |
2 | 707     | 1724 (250)     | 76 (20)     | 0     | |
3 | 1327     | 1724 (250)     | 38 (10)     | 500 (73) - 2000 (290)     |
( 1 ) | for use on model 9ZM (914G) when equipped with 168-1836 conversion arrangement |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
168-1837 (2)     | 1     | 707     | 0 (0)     | 76 (20)     | 0     |
2 | 707     | 1724 (250)     | 76 (20)     | 0     | |
3 | 1763     | 1724 (250)     | 38 (10)     | 500 (73) - 2000 (290)     |
( 2 ) | For use on model 1WN (IT14G) when equipped with 168-1838 conversion arrangement |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
175-6469     | 1     | 339     | 0     | 114 (30)     | 0     |
2 | 452     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1377     | 1724 (250)     | 151 (40)     | 800 (116) - 1600 (232)     |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
187-3453     | 1     | 454     | 0     | 114 (30)     | 0     |
2 | 605     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1826     | 1724 (250)     | 151 (40)     | 800 (116) - 1600 (232)     |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
187-3454     | 1     | 339     | 0     | 114 (30)     | 0     |
2 | 452     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1377     | 1724 (250)     | 151 (40)     | 800 (116) - 1600 (232)     |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
196-3638     | 1     | 454     | 0     | 114 (30)     | 0     |
2 | 605     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1826     | 1724 (250)     | 151 (40)     | 800 (116) - 1600 (232)     |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
196-4702     | 1     | 454     | 0     | 114 (30)     | 0     |
2 | 605     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1826     | 1724 (250)     | 151 (40)     | 800 (116) - 1600 (232)     |
Part Number     | Step     | RPM     | Back pressure kPa (psi)     | Input FlowLpm (gpm)     | Control Pressure kPa (psi)     |
196-4703     | 1     | 339     | 0     | 114 (30)     | 0     |
2 | 452     | 1724 (250)     | 151 (40)     | 0     | |
3 | 1377     | 1724 (250)     | 151 (40)     | 800 (116) - 1600 (232)     |
Test Bench Tooling
Part Number     | Mounting Flange     | Split Flange     | Flange Adapter     | Pressure Port for Destroke     | Case Drain     |
111-0364     | 1U-9129     | 1P- 5766     | 9U- 7439     | 9/16-18 UNF     | 1 1/16-12 UNF     |
127-8335     | 1U-9129     | 1P- 5767     | 9U- 7440     | 9/16-18 UNF     | 1 1/16-12 UNF     |
151-1244     | 1U-9129     | 1P- 5767     | 9U- 7440     | 9/16-18 UNF     | 7/8-14 UNF     |
168-1837     | 1U-9129     | 1P- 5766     | 9U- 7439     | 9/16-18 UNF     | 1 1/16-12 UNF     |
175-6469     | 130-1986     | 5P- 8077     | 9U- 7439     | 9/16-18 UNF     | 1 5/16-12 UNF     |
187-3453     | 1U-9129     | 1P-5766     | 9U-7440     | 9/16-18 UNF     | 7/8-14 UNF     |
187-3454     | 1U-9129     | 5P- 8077     | 9U-7441     | 9/16-18 UNF     | 1 5/16-12UNF     |
196-3638     | 1U-9129     | 1P- 5767     | 9U- 7440     | 9/16-18 UNF     | 7/8-14 UNF     |
196-4702     | 1U-9129     | 1P- 5767     | 9U- 7440     | 9/16-18 UNF     | 7/8-14 UNF     |
196-4703     | 1U-9129     | 5P- 8077     | 9U- 7441     | 9/16-18 UNF     | 1 5/16-12 UNF     |