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Personal injury or death can result if two persons are not used in the following procedure. |
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To prevent injury or death, never work under a machine while a test is being performed. |
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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the power train. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Use a stable work platform placed in a secure location when lubricating the pillar, working on the fuel tank, or working on the hydraulic tank. If a secure location is not available, use the appropriate safety equipment to prevent falling off of the machine. Failure to work from a secure location may result in injury or death from a slip or a fall. |
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Note: The hydraulic lines and components must be cleaned by hand. Use the same oil or use an equivalent oil that is in the machine. Install new filters. After the system has been flushed dispose of the fluid properly. Do not use mineral spirits, if biodegradable oil is used in the machine. If biodegradable oil is used in the machine, flush the machine with biodegradable oil only.
Filling the Hydrostatic System
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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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
The hydraulic oil that is being added to the hydrostatic system should be filtered and free of moisture. As a recommendation, the hydraulic oil that is added to the system should pass ISO 18/15. The ISO 18/15 is shown in Table 1 for a 50 mL sample.
| Hydraulic Oil Contamination | |
| Particle Size (Microns) | Maximum Number of Particles in a 50 mL Sample |
| >5 | 125000 |
| >15 | 16000 |
Air must be able to escape from the pump case and the motor case prior to operation of the power train components.
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| Illustration 1 | g00902147 |
The hydraulic oil tank is located behind the cab.
- Fill the power train oil tank with new oil through coupling (2) .
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| Illustration 2 | g00925211 |
- Attach hose (3) to coupling (2) and place the end of the other hose in the new oil.
- Push toggle switch (1) in the down direction in order to pump the oil into the power train oil tank. Push toggle switch (1) to the up position in order to stop pumping the oil into the power train oil tank.
Reference: Refer to Operation and Maintenance Manual, SEBU7596, "Lubricant Viscosities and Refill Capacities" for the correct type of lubricant and for the capacity of the power train oil tank.
- The sight gauge for the power train oil tank is mounted on the power train oil tank on the right side of the machine. Maintain the oil level to the midpoint of the upper region of the sight gauge. Add oil, if necessary.
Note: Do not maintain the oil level above the midpoint of the upper region. Otherwise, power train oil can spill from the top of the tank.
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| Illustration 3 | g00903451 |
- Loosen fitting (4) and fitting (5). Do not remove the fittings completely.
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| Illustration 4 | g00925724 |
- Purge the air in the oil coolers from fitting (4) and fitting (5) .
- Tighten fitting (4) and fitting (5) .
- Loosen fitting (6) and fitting (7). Do not remove the fittings completely.
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| Illustration 5 | g00925725 |
- Purge the air in the pumps from fitting (6) and fitting (7) .
- Tighten fitting (6) and fitting (7) .
- Disconnect the electrical connector at temperature sensor (8) .
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| Illustration 6 | g00925727 |
- Loosen temperature sensor (8) that is located on the power train motor.
- Purge the air in the power train motor from temperature sensor (8) .
- Tighten temperature sensor (8) .
- Check the level of the hydraulic tank. Add hydraulic oil until the hydraulic tank is full.
- Lower the cab onto the frame.
Reference: For more information about tilting the cab, refer to Operation and Maintenance Manual, "Cab Tilting".
- Turn the fuel shutoff valve to the OFF position.
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| Illustration 7 | g00925543 |
- Turn the engine start switch key to the ON position in order to activate the IQAN system on your machine.
- At the main menu of the IQAN display, press the right arrow key. The following window will appear.
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| Illustration 8 | g00916713 |
- Crank the engine without starting for at least 10 seconds and read the charge pressure on the IQAN display. Do not crank the engine for more than 15 seconds. Repeat this step at least five times or until the charge pressure reads 23 Bar.
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| Illustration 9 | g00916714 |
- If the charge pressure is low, check the hydraulic oil level in the tank. Use hydraulic oil that is clean and free of moisture. Determine the cause for low charge oil pressure before you restart the engine. When the pressure is correct, turn the fuel shutoff valve to the ON position.
- Start the engine and run the engine at low idle. Read the charge pressure on the IQAN display. The pressure reading should not exceed 23 bar within 15 seconds of start-up.
- If the pressure is low, stop the engine. Check the hydraulic oil level in the tank. Determine the cause for low charge oil pressure before you restart the engine.
Note: If charge pressure is not reached within 15 seconds, damage to the hydrostatic system will occur. Do not allow the hydrostatic system to operate with incorrect charge system pressures.
- Disconnect hose from coupling (2) .
Flushing the Hydrostatic System
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. |
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| NOTICE |
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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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
Note: Flushing of the entire hydrostatic system should be performed after a failure of a component or replacement of a component.
If the oil becomes contaminated, premature component failure could result. Contaminated oil can also contribute to overheating. Use the following procedure to sample the oil in the system.
- Disconnect wire connector (9) from parking brake valve (10). This prevents the parking brake from disengaging.
Note: The spring applied parking brake is released by oil pressure. Disconnecting wire connector (5) blocks the oil that releases the parking brakes. This allows the machine to be tested and adjusted while the brakes are applied.
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| Illustration 10 | g00925573 |
- Start the engine and run the engine at low idle. Fully apply the service brakes and hold the service brakes.
- At the main menu of the IQAN display, press the menu key and then press the right arrow key. The following window will appear.
- Press the function key beside the "Measure" option. The following window will appear.
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| Illustration 11 | g00918446 |
- Press the function key beside the "Voltage in" option. The following window will appear.
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| Illustration 12 | g00918447 |
- Move the direction selector switch to the FORWARD position.
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| Illustration 13 | g00918444 |
- Depress the accelerator pedal halfway.
- Slowly increase the machine speed potentiometer until the high pressure of "HP FWD" reaches 350 Bar. Maintain the engine speed for 30 seconds. Return the engine speed to low idle.
- Move the direction selector switch to the REVERSE position.
- Slowly increase the machine speed potentiometer until the high pressure of "HP REV" reaches 350 Bar. Maintain the engine speed for 30 seconds. Return the engine speed to low idle.
- Repeat Step 6 through Step 10 six times (three times in FORWARD and three times in REVERSE).
- Decrease the engine speed to low idle. Apply the service brake pedal. Move the direction selector switch to the NEUTRAL position.
Note: The sampling of the hydraulic oil must be performed within 5 minutes of the fill and flush procedures.
- Wipe off the sampling port (11) in order to remove any dirt. Use a purge bottle in order to purge the sampling valve of 50 mL of hydraulic oil. Use a new 1U-5814 Bottle Assembly in order to draw a 50 mL oil sample through the sampling valve. As a recommendation, the contamination level should pass ISO 18/15. The ISO 18/15 is shown in Table 2 for a 50 mL sample.
Show/hide table
Table 2 Hydraulic Oil Contamination Particle Size (Microns) Maximum Number of Particles in a 50 mL Sample >5 125000 >15 16000
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| Illustration 14 | g00925829 |
(11) Sampling port | |
- If the particle count exceeds the limits in the Table, then repeat Steps 2 through 12.
- Obtain another oil sample. Measure the contamination level. Compare the sample to Table 2. If the particle count exceeds the limit on the second attempt, replace the oil filters. Repeat Steps 2 through 12.
- Obtain another oil sample after repeating the procedure for a third time. Measure the contamination level. Compare the sample to Table 2. If the particle count exceeds the limit on the third attempt, find the component that is causing the contamination and replace the component.
- After you obtain an acceptable oil sample, stop the engine.