Caterpillar 9U-5000 Series Hydraulic Test Bench Tool Operating Manual - PDF DOWNLOAD

R

TOOL OPERATING MANUAL 9U-5000 Series Hydraulic Test Bench SMCS: 0784

NEHS0563-04 June 2001

Series 5000 Installation Drawing . . . . . . . . 40 Series 5000 Hydraulic Schematic. . . . . . . . 42 Series 5000 Electrical Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 44

Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Information . . . . . . . . . . . . . . . . . . . . 3 Warning Signs and Labels . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Repair and Maintenance . . . . . . . . . . . . . . 4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Before Starting the Test Center. . . . . . . . . . 6 Basic Capabilities . . . . . . . . . . . . . . . . . . . . 8 Main Systems of the Test Bench . . . . . . . . . 8 Features and Specifications . . . . . . . . . . . . . 9 Oil Specifications . . . . . . . . . . . . . . . . . . . . 10 Dimensions and Capacities . . . . . . . . . . . . 10 General Installation Instructions . . . . . . . . . 11 Control Console Gauges and Controls . . . . 14 Control Console Switches and Indicator Lights . . . . . . . . . . . . . . . . . . . . . 17 Hydraulic Connections on Control Console . . . . . . . . . . . . . . . . . . . . . 19 Initial Main System Start-up . . . . . . . . . . . . 20 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 21 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Transmissions . . . . . . . . . . . . . . . . . . . . . 22 Pump Testing . . . . . . . . . . . . . . . . . . . . . . 24 Hydraulic Motors . . . . . . . . . . . . . . . . . . . 26 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 27 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 27 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . 28 Oil Strainers . . . . . . . . . . . . . . . . . . . . . . . 29 Heat Exchangers . . . . . . . . . . . . . . . . . . . 29 Main Reservoir Oil Heater . . . . . . . . . . . . 30 Electric Motors (Main and Sump Pump) . . . . . . . . . . . . . . . . . . . . . 30 Hydrostat Motor Light Winch . . . . . . . . . . . 31 Electric Control Console Fan Filter . . . . . . . 31 Other Operations . . . . . . . . . . . . . . . . . . . . 31 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . 31 Oil Reservoirs . . . . . . . . . . . . . . . . . . . . . 31 Sump System. . . . . . . . . . . . . . . . . . . . . . 32 Flow Meters . . . . . . . . . . . . . . . . . . . . . . . . 32 Pressure - Test Gauges . . . . . . . . . . . . . . 33 Serviceable Parts. . . . . . . . . . . . . . . . . . . . 34

Introduction The Caterpillar 9U-5000 Series Hydraulic Test Bench is a low-cost alternative used to test many Caterpillar hydraulic components: hydrostatic and powershift transmissions, hydraulic pumps and motors, cylinders, and valves.

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.

Caterpillar 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.

The Caterpillar 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.

2

Safety Information

Safety

Warning Signs and Labels There may be several specific safety signs on the test bench. Please take the time to familiarize yourself with the safety signs.

Make sure that you can read all safety signs.

Clean or replace them if you cannot read the words, or see the pictures. When cleaning the labels use a cloth, water and soap. Do not use solvents, gasoline, etc., to clean safety signs. The use of solvents, gasoline, etc., could loosen the sign's adhesive and cause the sign to fall off.

You must replace a label if it is damaged, missing or cannot be read. If a label is on a part that is replaced, make sure a new label is installed on the replaced part.

Most accidents involving product operation, maintenance, and repair occur through failure to observe basic safety rules or operations. An accident can often be avoided by being alert and recognizing potentially hazardous situations before an accident occurs. Any individuals performing product operation, maintenance, or repair should have the necessary training, skills, and tools required to perform the functions properly and safely. The safety information in this manual serves as a basic guide in an attempt to prevent injury or death.

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 specifically mentioned by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. Make sure the product or machine will not be damaged or be made unsafe by any operation, lubrication, maintenance, or repair procedures that you choose.

If any doubt arises about the correct, safe method of performing any steps of these procedures, DO NOT proceed. Seek out expert assistance from a qualified person.

3

Use all cleaning solutions with care.

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment. DO NOT operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals.

Contact CSTG for replacement manuals.

Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

Never put maintenance fluids into glass containers, since glass containers can break.

Report all needed repairs.

Do not weld or flame cut on pipes or tubes that contained flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.

Shields, which protect hot components from oil spray in the event of a line, tube or seal failure, must be installed correctly.

Repair and Maintenance

WARNING

do not operate signed by

Clean and tighten all electrical connections.

Check regularly for loose or frayed electrical wires. Refer to maintenance schedules for interval. Before operating the machine, have all loose or frayed electrical wires tightened, repaired or replaced.

WARNING

Unless Instructed Differently, Perform all Maintenance as Follows:

do not remove this tag see other side

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

date SEHS7332-01

• Do not attempt repairs you do not understand.

PRINTED IN U.S.A.

0563-01

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

• Start the test center from the operators station.

Attach a "DO NOT OPERATE" or similar warning tag to start switch or controls before performing maintenance or repairing the engine.

These tags, Form SEHS7332, are available from Caterpillar.

Do not allow unauthorized personnel on, around, or in the machine while it is being serviced.

4

Operation

Always wear protective clothing while operating any machines or equipment.

DO NOT wear any loose clothing, jewelry, watches, gloves, or anything else that might catch on controls, tooling, side bars, or any part of the equipment.

WARNING

do not operate

To prevent personal injury, make sure all protective guards and covers are in place and secured before operating any equipment.

signed by

WARNING

do not remove this tag see other side

date SEHS7332-01

PRINTED IN U.S.A.

0563-01

Lubricants and some coolant mixtures are flammable.

Store all oily rags or other flammable material in a protective container, in a safe place.

Do not start the test center or move any of the controls if there is a warning tag attached to the controls. Check with the person who attached the tag before starting.

Remove all flammable materials such as oil and other debris before they accumulate on the machine.

Make sure no one is working on, or close to, the test center or test center driven components before starting it. Always make an inspection of the test center before, and after, starting.

Have a fire extinguisher available and know how to use it. Inspect and have it serviced as recommended on its instruction plate.

Never attempt adjustments while the test center is running, unless otherwise specified in this manual.

Stay clear of all rotating and moving parts. Guard should be in place whenever maintenance is not being performed.

5

Inspection

Oils

Check hydraulic oil lines, tubes, and hoses carefully.

DO NOT use your bare hand to check for potential leaks.

Always use a board or cardboard when checking for a leak. Escaping hydraulic fluid under pressure, even a pinhole 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.

Contact with hot oil and components can result in severe burns.

D O NOT allow any hot oil or components to contact the skin.

Before Starting the Test Center

Be sure all protective guards and covers are installed. To help prevent accidents, work carefully around rotating parts.

Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes, or hoses.

Repair any loose or damaged fuel and oil lines, tubes, and hoses. Leaks can cause fires.

Do not disable or bypass automatic shutoff circuits. They are provided to prevent personal injury and equipment damage.

Inspect all lines, tubes, and hoses carefully. Do not use your bare hands to check for leaks.

Tighten all connections to the recommended

If there is an overspeed on start-u up after maintenance is performed, make provisions for shutting off the power.

torque.

Check for the following:

Inspect test center for potential hazards.

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

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

• Outer covering ballooning at spots.

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

6

Main Electrical Panel

Cooling Water Service Connections Sump Pump Filter Bank

Charge Pump and Case Drain Filters (not shown) Sump Pump 2 Sump Pump 1

Hydrostat Motor (Main Drive) Hydrostat Motor Lift Winch Test Stand Drive Support Mast

Main Oil Supply and By-Pass Filters (not shown)

Port #11 Pump Supply Main Reservoir In-Line Heater

Flow Meter #1

Port #1

Pump Control

#2

Sump Pump Screen

Work Support Sump

#3 #5

Motor Speed Control

#4 Flow Meter #2

Control Console

0563-02

9U-5000 Series Hydraulic Test Bench.

7

Basic Capabilities

Main Systems of the Test Bench

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.

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

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

• 2500 maximum rpm.

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

• 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.

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

1. The Hydrostat System: It consists of a 125 hp electric motor which drives two hydraulic pumps. The hydrostat 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 liter (60 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 may be supplied from any one of three sources to a component being tested. Pressurized oil can be supplied from a 200 Lpm (55 gpm) gear pump (main oil supply), a 102 mm (4.0 in) suction line (pump supply), and a 13 Lpm (3.5 gpm) lube circuit. Depending on the oil source, the test bench provides all the test requirements for proper testing of hydraulic components.

8

3. The Sump Pump Return to Tank System: Oil used in the testing of components is directed to a sump under the work support table. Oil is then returned, through a series of filters, to the main 750 liter (200 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 sump.

• Motor Speed Control Provided by a variable control valve. The valve controls rpm of hydrostat motor from 1250 rpm 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 3000 psi) main oil supply up to 200 Lpm (55 gpm) for general purpose testing.

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.

A lube flow circuit provides 0 to 3000 kPa (0 to 400 psi) oil flow up to 13 Lpm (3.5 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 in) line to the inlet of pump being tested.

• Oil Flow and Pressure Metering Loops

• Primary Drive System

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

A main electric motor drives the hydrostat system and a 200 Lpm (55 gpm) gear pump.

One flow metering loop has an added pressurized oil supply of 200 Lpm (55 gpm).

50 Hertz — 125 hp at 1450 rpm

Both loops are capable of metering 475 Lpm (125 gpm) with a maximum pressure of 47000 kPa (6800 psi). Reverse flow loading can be performed with both loops.

Features and Specifications

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.

• Sump Pump System Two 225 Lpm (60 gpm) sump pumps work in combination to return oil from work support sump back to main reservoir.

• Hydrostat System (Main Drive) Consists of a variable displacement piston pump, charge pump, and hydrostat motor capable of 2500 rpm, 38000 kPa (5500 psi) with a maximum of 781 N·m (6911 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.

9

For the 225 liter (60 gal) hydrostat system reservoir, Mobil DTE 26 oil, 10 to 30 weight, is acceptable. Using DTE 26 should extend the service life of the hydrostat system components.

• 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.

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

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.

Dimensions and Capacities

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

Test Stand • Main reservoir: 750 liters (200 gallons)

• Oil Temperature

• Length: 1829 mm (72.0 in)

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.

• Width: 1359 mm (54.0 in) • Height: 1700 mm (67.0 in)

Work Support Sump • Sump reservoir: 225 liters (60 gallons)

Oil temperature in main 750 liter (200 gal) reservoir is controlled by an oil-to-water heat exchanger and an in-line heater. With the use of Mobil DTE 11 oil, temperature in main reservoir is controlled at 115 to 125°F to simulate oil viscosity under field conditions.

• Length: 3750 mm (148.0 in) • Width: 1753 mm (69.0 in) • Height: 280 mm (11.0 in) • Height with drive mast support: 2375 mm (93.0 in)

Oil temperature in 225 liter (60 gal) reservoir is controlled by an oil-to-water heat exchanger with automatic temperature control for maximum efficiency of hydrostat system. With the use of Mobil DTE 26 oil, temperature in this reservoir should range from 130 to 140°F.

Control Console • Length: 914 mm (36.0 in) • Width: 711 mm (28.0 in) • Height: 1346 mm (53.0 in)

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 liter (200 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 115 to 125°F.

10

General Installation Instructions 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.

The installation drawing 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 the three major test bench components can be adjusted to customer requirements.

4. Control Pressure Line. 5. Main Oil Supply Line.

2. Bolt work support sump to floor.

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 and route oil drain line (1) to work support sump fitting (6).

1. Oil Drain Line - Console Fitting. 2. Control Pressure Line Connection Fitting. 3. Main Oil Supply Line Connection Fitting.

6. Oil Drain Line, Sump Fitting.

11

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.

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 installation drawing.

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.

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.

12

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.

22. Electrical Connecting Lugs.

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 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.

17. Main Pump Control Cable. 18. Motor Speed Control Cable.

13

Control Console Gauges and Controls

1. Control Pressure Gauge — #7*: Indicates the pressure setting of control pressure valve #7. The gauge reads 0 to 4000 kPa (0 to 600 psi).

5. Flow Port #1 Pressure Gauge — #12*: Indicates pressure in the flow meter #1 loop. The gauge reads 0 to 7000 kPa (0 to 1000 psi). The gauge is protected by an in-line gauge minder which shuts off pressure to the gauge above 0 to 7000 kPa (0 to 1000 psi). Pressure greater than 0 to 7000 kPa (0 to 1000 psi) can then be read on the gauge in flow meter #1.

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 400 psi).

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.)

3. Main Oil Supply Gauge — #6*: Indicates the pressure relief setting of the gear pump relief valve. The gauge reads from 0 to 21000 (0 to 3000 psi).

* See illustration on next page.

4. Main Oil Supply Valve — #6*: Relieves 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 0 to 200 Lpm (0 to 55 gpm).

14

7. Flow Meter — #1*: A digital display read-out indicates oil flow through the flow loop in Lpm, U.S. 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 8000 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.

TG2 TG1

TG4 TG3

TG6

TG5

Port #4 FM#2 Out

Out

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 through the flow meter #1 from 0 to 475 Lpm (0 to 125 gpm). * See illustration below.

Back of Control Console as viewed from Work Support Sump.

Port #3 FM#2 In

Port #2 FM#1 Out

Drain

Port #5 Control & Lube

Main Oil Control Supply Pressure Pressure #6

#7

Flow Port #1 Gauge #12

Main Oil Supply Pressure In

Control Pressure Pilot

Port #1 FM#1 In

TG1

TG2

TG3

TG4

TG5

TG6

Flow Port #3 Gauge #13

Supply Flow #8

Flow Meter #1 Load Valve #9

Pump Control

Flow Meter #2

Motor Speed Control

Load Valve #10 0563-15

Control Console Gauges And Ports.

15

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 Lpm (0 to 125 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 3000 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 3000 psi). Pressure greater than 0 to 21000 kPa (0 to 3000 psi) can then be read on the gauge in flow meter #2.

14. Switches and Indicator Lights: Refer to Control Console Switches and Indicator Lights.

16

Control Console Switches and Indicator Lights

1. Reservoir Overfill: Indicates main 750 liter (200 gal) reservoir is over-filled and shuts down the sump pumps. (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.)

2. Main Supply Filter — Push to Test: Indicates main oil supply filter is dirty.

(The indicator light is red.)

9. Stop — Push OFF: Stops the main electric motor.

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

3. Case Drain Filter — Push to Test: Indicates hydrostat system case drain filter is dirty.

(The indicator light is red.)

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

4. Sump Pump Filter — Push to Test: Indicates sump pump filters are dirty.

(The indicator light is red.)

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

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

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.)

6. Low Oil: Indicates low oil level in 225 liter (60 gal) reservoir and shuts off main electric motor. (The indicator light is red.)

17

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 the warranty!

14. Control Power — Push ON/Turn to Release: Activates or deactivates the main power and electronic 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.

18

Hydraulic Connections on Control Console

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.

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.

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 400 psi).

7. Main Oil Supply Line: An inlet from the gear pump supplying 200 Lpm (55 gpm) at 0 to 21000 kPa (0 to 3000 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).

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.

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.

19

Initial Main System Start-Up Eye protection is required when operating this product.

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pin-h hole size leak, can penetrate body tissue, causing serious injury, and possibly death. If fluid is injected into your skin, it must be removed surgically within a few hours, by a doctor familiar with this type of injury.

5. Gear Pump Inlet Supply Valve.

1. Main Reservoir. 2. Main Reservoir Sight Glass.

3. Hydrostat Reservoir. 4. Hydrostat Reservoir Sight Glass.

6. Hydrostat Motor Case Drain Connection and Line.

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

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 liters (2 gal) of DTE 26 oil into line.

2. Fill hydrostat reservoir (3) with Mobil DTE 26 oil or 10 to 30 weight oil until it reads within 25 mm (1.0 in) 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.

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

20

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 page 13) to the ON position. Oil flow out of port #2 should be approximately 200 Lpm (55 gpm). Make sure sump pump switch is in auto setting before starting this test.

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.

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.

4. Turn control power ON and jog electric motor to check for motor rotation.

If motor will not start, make sure pump control lever is in neutral (continuity between terminals #4 and #7 in electrical panel) and the charge filter light (13 page 14) 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.

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.

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.

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:

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.

a. Emergency stop button must be OUT b. Charge filter indicator light must be OFF c. Pump control lever must be in neutral position.

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 rpm's are not equal (± 10 rpm) make linkage adjustments on the pump control cable at the main pump control lever.

d. 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 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 shut down of the test bench can be achieved by pressing stop and turning OFF the control power.

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 motor speed control lever out, 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.

21

Testing

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

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

Mounting a Transmission

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 component manufacturer, if not available in the NEHT5000 manual.

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. Hydrostat Motor Lift Winch. 2. Drive Shaft Guard.

3. Transmission. 4. Support Bar. 5. Clamp Down Rails.

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.

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.

2. The main oil supply system 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 flow meters provide a means to check the amount of flow and leakage in a system.

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.

22

2. Securing: Bolt the mounting adapter and the transmission to the work support sump 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 should 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).

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 Lpm (55 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.

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.

Driving a Transmission Hydraulic Connections

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

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

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.

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).

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.

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 (100 psi) ABOVE the relief valve setting of the transmission. If not, it would be impossible to determine which relief valve is controlling the pressure.

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

by Caterpillar Inc.

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.

23

CCW HYDROSTAT DRIVE CONTROL

P U M P

Before Starting: 1. Pump Control must be in neutral position.

2. Motor Control must be in slowest speed position.

To Run: 1. Pump Control regulates speed to 1200 rpm.

2. Motor Control regulates fine adjustment and speeds up to 2500 rpm.

6

C O N T R O L

7

TO INCREASE SPEED FROM 0 TO 1200 RPM IN CCW ROTATION

M O T DECREASE O R

CCW

8

CW

P U M P

S P E E D

C O N T R O L

0563-22

6. Control Lever. 7. Main Drive and Direction of Rotation.

C O N T R INCREASE O L

CW

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.

TO INCREASE SPEED FROM 1250 TO 2500 RPM

9 10

0563-23

8. Pump Control Lever. 9. Motor Speed Control Knob.

10. Motor Speed Control Knob Push-Button.

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

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

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.

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.

24

Checking Pump Efficiency

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

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.

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.

Determining Worn Parts

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 (1000 psi) or a gear or vane pump that loses no more than 20 percent is acceptable to return to service.

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 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.

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.

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.

Calculating Pump Efficiency A standard pump testing practice is to compare pump flow at 700 kPa (100 psi) to pump flow at 7000 kPa (1000 psi) while maintaining a constant rpm. Pump flow loss from leakage is directly affected by pressure; therefore, this leakage-to-pressure comparison is quite useful in determining pump condition.

Another rule of thumb in determining maximum acceptable leakage is as follows: pump capacity will decrease approximately 2 liters (0.5 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

In testing a pump, it is generally rotated at a given rpm (usually 1200 or 1800) at 700 kPa (100 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 (1000 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:

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 outlet(s) to port #1 or #3 (IN), through flow meters to port #2 or #4 (OUT), and directed back to the work support sump.

% loss = flow rate @ 700 kPa (100 psi) minus flow rate @ 7000 kPa (1000 psi) divided by flow rate @ 700 kPa (100 psi).

25

Hydraulic Motors

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

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

a. 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 600 psi) control pressure gauge #7.

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

b. 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.

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.

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

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

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.)

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

Testing a Motor

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

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

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.

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

5. Proceed with testing, according to the pump or vehicle manufacturer's specifications.

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.

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

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

26

Cylinders

Maintenance

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

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.

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.

Pressure air can cause personal injury. The maximum air pressure must be below 200 kPa (30 psi) for cleaning purposes.

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

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

When using pressure air for cleaning, wear a protective face shield, and protective clothing.

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.

Use all cleaning solvents with care.

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.

solutions

and

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

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.

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

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.

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pin-h hole size leak, can penetrate body tissue, causing serious injury, and possibly death. If fluid is injected into your skin, it must be removed surgically within a few hours, by a doctor familiar with this type of injury.

27

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.

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 130 to 140°F. Using DTE 11, the main reservoir temperature can range from 110 to 140°F depending on the requirements of the component being tested. Normal temperature for this reservoir is 115 to 125°F.

Oil Filters NOTICE

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.

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-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.

1. Sump Pump Filters. 2. Case Drain Filter. 3. Charge Filter.

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.

1. Main Reservoir Oil-Level Sight Gauge and Fill Cap. 2. Hydrostat Reservoir Oil-Level Sight Gauge and Fill Cap. 3. Oil Temperature Gauge.

28

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.

4. By-Pass Filter. 5. Main Oil Supply Filters.

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.

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.

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.

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.

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 in) pump supply line, and on the charge pump supply line.

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.

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

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.

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.

29

Electric Motors (Main and Sump Pump)

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.

1. Main 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.

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.

2. Sump Pump Electric Motor.

30

Hydrostat Motor Lift Winch

Oil Reservoirs

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.

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.

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.

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

Replace the filter element of the cooling fan every 1500 hours (12 months) and clean the fan of built-up dirt.

NOTICE

Other Operations

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.

Gear Pump The gear pump provides 0 to 21000 kPa (0 to 3000 psi) supply of oil at 200 Lpm (55 gpm). This oil supply is used for testing transmissions, hydraulic motors, and other components requiring pressurized oil. Oil flow and pressure are controlled through flow meter #1.

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 115 to 140°F with 115 to 125°F being ideal. If the temperature goes over 140°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 140°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.

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.

31

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.

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.

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.

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.

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 (6800 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.

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.

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.

32

Pressure-Test Gauges

1. Pressure Gauge.

A bank of six gauges is provided to register the pressure from the tested component. The gauges read 0 to 4000 kPa (0 to 600 psi).

2. Pressure Gauge Inlet.

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.

33

Serviceable Parts

Chart A. (continued)

Chart A and the following nomenclature drawings, 1 through 4, provide a list of serviceable parts and their locations. The item numbers in Chart A also correspond to the items in the schematics at the end of this manual.

Chart A. Serviceable Parts

Item

Part No.

34

135-1805

Fuse, Note E

Description

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

Gauge, Oil Level

43

9U-5849

9U-5877

Switch, Reservoir

44

—

Not Used

— 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

45

135-2564

Pilot Light

46

135-2557

Switch, Push Button

47

135-2565

Pilot Light

48

135-2563

Pilot Light

49

9U-5853

Indicator, RPM

4

9U-5871

Element

50

8T-0850

Gauge

5

135-5301

Switch

51

9U-5851

Gauge

6

9U-5822

Hose Assembly

52

4C-4023

Switch, Push Button

7

9U-5825

Hose Assembly

53

135-2559

Switch, Selector

8

4C-9479

Element

54

4C-3857

Contact Block

9

9U-5824

Hose Assembly

55

135-2558

Switch, Selector

10

9X-2353

Hose (Bulk)

56

9U-5855

Cable

11

9U-5870

Element

57

9U-5854

Cable

12

9U-5876

Switch

58

135-2562

Switch, Push Button

13

9X-2353

Hose (Bulk)

59

4C-3851

Contact Block

14

9X-2353

Hose (Bulk)

60

4C-4022

Switch, Push Button

15

9U-5821

Hose Assembly

61

135-2560

Switch, Push Button

16

9X-2361

Hose (Bulk)

62

135-2561

Lens

17

9X-2361

Hose (Bulk)

63

6E-2046

Pump (60 Hz)

18

135-5302

Transformer

64

8J-3632

Pump (50 Hz)

19

—

Not Used

65

9X-2359

Hose (Bulk)

20

—

Not Used

66

—

Motor, Electric

21

4C-6997

Coupling, Quick Disconnect

67

9U-5878

Valve

22

9U-5819

Strainer

68

9U-5875

Valve

23

9U-5820

Strainer

69

9U-5873

Valve, Water

24

135-1795

Fuse, Note B, E

70

9X-2358

Hose

25

135-5303

Switch, Disconnect

71

135-5309

Pump

26

135-5067

Contactor

72

135-5310

Pump

27

135-5068

Relay

73

4C-5094

Coupler

28

1U-9048

Contactor

74

3J-1907

Seal

29

4C-3867

Relay

75

4C-5093

Nipple Assembly

30

4C-4006

Socket

76

2S-4078

Seal

31

4C-3859

Relay

77

9U-5819

Hose Assembly

32

135-5304

Valve

78

9U-5203

Hose Assembly

33

135-5305

Power Supply

Item

Part No.

1

9U-7035

2 3

Description

34

Valve

Chart A. (continued) Item

Part No.

79

9U-5867

Chart A. (continued) Item

Part No.

Strainer

Description

124

139-1545

Contact Block

Description

80

6V-3966

Nipple Assembly

125

139-1546

Lampholder with Transformer

81

9X-2360

Hose (Bulk)

126

9U-5857

Bulb, light

127

9U-5850

Valve

82

9X-2360

Hose (Bulk)

83

135-6596

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

113

—

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

Note: These parts are required on the machines listed below: A = 9U-5000 460V/3ph/60Hz B = 9U-5001 380V/3ph/50Hz C = 9U-5882 230V/3ph/60Hz D = 9U-5883 575V/3ph/60Hz E = 9U-5884 415V/3ph/50Hz F = Not used when soft start option is required.

Fuse, Note A Not Used

35

Nomenclature for Serviceable Parts (1 of 4). Refer to Chart A for Item Identification.

36

Nomenclature for Serviceable Parts (2 of 4). Refer to Chart A for Item Identification.

37

Nomenclature for Serviceable Parts (3 of 4). Refer to Chart A for Item Identification.

38

Nomenclature for Serviceable Parts (4 of 4). Refer to Chart A for Item Identification.

39

Suggested Minimum Working Clearance

5588 (220)

965 (38) 762 (30) Main Electrical Pane l IN OUT 1" Water Pipe Connections 1359 (53.5)

Test Stand

279 (11)

* 5435 (214) 3760 (148) Control Console

914 (36)

Work Support Sump 3378 (133)

711 (28)

*

determined * Location by customer

978 (38.5) 1753 (69)

0563-40a

Series 5000 Installation Drawing 40

1090 (43)

1829 (72) 2375 (93)

Test Stand 2110 (83)

Control Console 1700 (67)

1346 (53)

241 MIN. (9.5) 1524 MAX. (60.0) 280 (11)

864 (34) Water Pipe Elevation (Out) 927 (36.5) Water Pipe Elevation (In)

0563-40b

41

Port #3 In

Port #4 Out

Port #1 In

0-3000 PSI

Port #2 Out

0-1000 PSI

36

51

Port #5

Supply Pressure Relief Valve (38, 41) #6

Transmission Control & Bearing Lube Supply

0-600 PSI Control Pressure Relief Valve (43, 44)

#7 0-3000 PSI 42 #8 Supply Flow Valve Flow Meter 2 (35)

200 Gallon Reservoir Heat Exchanger (64)

Flow Meter 1 (35) Main Oil Supply Filter (4, Element)

Main Oil Supply Temperature Regulator Valve (67)

Sump Pump Filter (11-Element)

Main Oil Supply Relief Valve

200 Gallon Main Reservoir

12 By-Pass Filter (11-Element)

23

125 H.P. Electric Motor (66)

22

Heater (3) 4

12

3 32

#11 4" Pump Supply (3) Sump Pump 1 (94, 95)

2 83 Main Oil Supply Gear Pump (63)

Sump Pump 2 (94, 95) 1

Work Support Sump Cooling Water Service Main Shut-Off Valve (69)

0563-41a

Series 5000 Hydraulic Schematic 42

Hydrostat Motor (92)

Charge Pump Filter (8, Element)

60 Gallon Reservoir Heat Exchanger

Hydrostat System Temperature Regulator Valve (68)

4 3 2

Hydrostat Pump (71, 72)

Case Drain Filter

85

79

60 Gallon Hydrostat Reservoir

1

0563-41b

43

L1

L2

L3

4L2

4L3 X

2L4

2L5

2L7

2L6

2L8

2L9

2L1

2L2

2L3

5M 3M

1M

4M T10

T1

T2

T3

T14

T13

T15

T17

T16

T11

T12

115VAC

T18 1

M

M

125HP MOTOR 480VAC 60HZ DELTA WOUND

3

M SUMP PUMP 2

SUMP PUMP 1

TANK HEATER

CONTROL POWER PUSH PULL OFF ON 2

EMERGENCY STOP 4

1

3

G POWER ON CONTROL POWER

G

4

CR1

STOP

PUMP NEU CR4

10

9

START 7

1M

CR3

8

CHARGE FILTER

11

13

SET

14

RESET

OL'S

1M

3

MAIN PUMP MOTOR

CHARGE FILTER LATCHING RELAY

CR1

RESET

1

CR1

2

Series 5000 Electrical Control Schematic 44

0563-39a

1

2

PTT CR1

35

R

CHARGE FILTER PLUGGED

R

SUMP PUMP FILTER PLUGGED

R

MAIN SUPPLY FILTER PLUGGED

R

CASE DRAIN FILTER PLUGGED

PTT

17

PTT

19

PTT

21

9VDC

+

9VDC POWER SUPPLY FOR FLOWMETERS

-

9VDC TO FLOWMETERS

RPM

TACH METER

MAG PICKUP

4

HEATER ON OFF

WATER VALVE

1M

23

5M

LOW OIL LEVEL

COOLING WATER MAIN CONTROL VALVE

3

HEATER CONTACTOR

G

HEATER ON

CR3

LOW OIL 60 GALLON RESERVOIR

16

LOW OIL

CR3

12

LOW OIL LEVEL

R RESERVOIR OVERFILL

4

27

CR2

3

CR2

26

200 GALLON OVERFILL

R CR2

AUTO

28

OFF MAN

29

*

28

*

LOW (RED)

36 *

INTER 30 (YELLOW)

31

3M

200 GALLON RESERVOIR

OL'S

HIGH (BLUE)

3M

SUMP PUMP 1

G

SUMP 1 ON

32

OL'S

4M

SUMP PUMP 2

G

SUMP 2 ON

4M

0563-39b

45

Notes

46

Notes

47

For information on service tools or shop supplies, contact Caterpillar Service Technology Group on: Caterpillar Service Technology 501 S.W. Jefferson Ave. Peoria, Illinois 61630-2184 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6650 (Fax) Hotline Email “CSTG” or Caterpillar Service Technology Caterpillar Overseas S.A. P. O. Box 6000 1211 Geneva 6 Switzerland +41 (22) 849 40 56 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)

©2001 Caterpillar Inc. All Rights Reserved

NEHS0563-04 Printed in U.S.A.