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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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Injury to personnel can result if they are not in the operator's view. Allow only essential personnel near the machine, and make sure the personnel are in the operator's view when testing, to prevent injury. Make sure checks are done in an open area. |
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Personal injury can result from rotating and moving parts. Moving fan blades and moving parts will throw or cut any object or tool that falls or is pushed into them. Make sure no one is working on, underneath or close to an engine that is running. Make sure the area is free of personnel. |
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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 machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Description | Qty |
| A(1) | 198-4234 | Pressure Gauge Tool Gp | 1 |
| B(1) | 198-4236 | Adapter Cable As | 2 |
| C(1) | 198-4237 | Pressure Sensor Gp
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1 |
| D(1) | 198-4238 | Pressure Sensor Gp
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1 |
| (1) | Tool (A), Tool (B), Tool (C), and Tool (D) are part of the 198-4240 Digital Pressure Indicator. |
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Description | Qty |
| E | 8T-0855 | Pressure Gauge
|
2 |
| 6V-4144 | Quick Connect Coupler | 2 | |
| F | 177-7860 | Hose As | 2 |
| 6V-4142 | Fitting | 2 | |
| 6V-4143 | Quick Connect Coupler | 2 | |
- Drive the machine to a smooth, horizontal surface.
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Illustration 1 g01390805 - Move propulsion lever (4) to the NEUTRAL position.
- Rotate speed dial (2) to the MINIMUM position.
- Move travel mode switch (3) to the PAVE position.
- Move parking brake switch (1) to the ON position.
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Illustration 2 g01390807 - Move screed lift switch (5) to the RAISE position. Completely lift the screed.
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Illustration 3 g01390809 - Engage screed lock mechanism (6) on both sides of the machine.
- Move screed lift switch (5) to the FLOAT position. Allow the tow arms to rest on screed locks (6a).
Note: The screed lift switch on the inactive operator station must also be in the FLOAT position in order to lower the screed.
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Illustration 4 g01390811 - Move throttle control switch (7) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (8) to the OFF position.
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Illustration 5 g01390812 - Open pump compartment cover (9), which is on the right side of the machine.
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Illustration 6 g01390820 - Remove the cap from case drain tap (10) on the right propulsion pump. Connect Tool (C) to the drain tap.
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Illustration 7 g01390854 - Remove the cap from charge pressure tap (11) on the left material feed pump. Connect Tool (D) to the pressure tap.
- Connect one Tool (B) to Tool (C). Connect the second Tool (B) to Tool (D). Connect each Tool (B) to Tool (A).
Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.
- Move engine start switch (8) to the START position. Release the engine start switch when the engine starts.
- Operate the engine at low idle for a few minutes.
- Move throttle control switch (7) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.
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Illustration 8 g01390858 - Monitor the hydraulic oil temperature on the operator display. Operate the machine until the oil temperature reaches
43 ± 5.6 °C (110 ± 10 °F) . - Move throttle control switch (7) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (8) to the OFF position.
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Illustration 9 g01390860 - Loosen locknut (12) on the charge relief valve on the right propulsion pump. Rotate charge relief valve adjustment screw (13) clockwise by three turns. Hold the adjustment screw and tighten the locknut to
52 N·m (39 lb ft) .Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.
- Move engine start switch (8) to the START position. Release the engine start switch when the engine starts.
- Operate the engine at low idle for a few minutes.
- Move throttle control switch (7) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.
- Record pressure at charge pressure tap (11).
- Record pressure at case drain tap (10).
- Subtract the pressure that was recorded in Step 26 from the pressure that was recorded in Step 25. The differential pressure should be
3100 ± 170 kPa (450 ± 25 psi) . - Move throttle control switch (7) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (8) to the OFF position.
- If the pressure is within the specified range, go to Step 33. If the pressure is not within the specified range, go to Step 31.
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Illustration 10 g01390868 - Loosen the locknut on charge relief valve (14) on the left material feed pump. In order to increase pressure, rotate the adjustment screw clockwise. In order to decrease pressure, rotate the adjustment screw counterclockwise.
- Hold the adjustment screw in place, and tighten the locknut to
17 N·m (13 lb ft) . Go to Step 22. - Loosen locknut (12) on the charge relief valve on the right propulsion pump. Rotate charge relief valve adjustment screw (13) counterclockwise by three turns. Tighten the locknut to
52 N·m (39 lb ft) .Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.
- Move engine start switch (8) to the START position. Release the engine start switch when the engine starts.
- Operate the engine at low idle for a few minutes.
- Move throttle control switch (7) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.
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Illustration 11 g01390878 - Monitor the hydraulic oil temperature on the operator display. Operate the machine until the oil temperature reaches
43° ± 5.6°C (110° ± 10°F) . - Record pressure at charge pressure tap (11).
- Record pressure at case drain tap (10).
- Subtract the pressure that was recorded in Step 39 from the pressure that was recorded in Step 38. The differential pressure should be
2690 ± 170 kPa (390 ± 25 psi) . - If the pressure is within the specified range, go to Step 46. If the pressure is not within the specified range, go to Step 42.
- Move throttle control switch (7) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (8) to the OFF position.
- Loosen locknut (12) on the charge relief valve on the right propulsion pump. In order to increase pressure, rotate adjustment screw (13) clockwise. In order to decrease pressure, rotate adjustment screw (13) counterclockwise.
Note: One turn of the adjustment screw changes the pressure by approximately
400 kPa (58 psi) . - Hold adjustment screw (13) in place, and tighten locknut (12) to
52 N·m (39 lb ft) . Go to Step 34. - Test the flushing system by performing the following Steps.
Note: The machine will move during the flushing system test.
Show/hide tablePersonal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or near the machine.
To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.
- Rotate speed dial (2) to one quarter of maximum.
- Move parking brake switch (1) to the OFF position.
Note: The parking brake switch on the inactive operator station must also be in the OFF position.
- Slowly move propulsion lever (4) to the FULL FORWARD position. Observe pressure at charge pressure tap (11). The pressure should momentarily decrease.
- Move propulsion lever (4) to the NEUTRAL position. Then, move the lever to the FULL REVERSE position. Observe pressure at charge pressure tap (11). The pressure should momentarily decrease.
- Move propulsion lever (4) to NEUTRAL position. Move speed dial (2) to the MINIMUM position. Move parking brake switch (1) to the ON position.
- Move throttle control switch (7) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (8) to the OFF position.
- If the flushing system operates in both directions as described, go to Step 58.
If the flushing pressure does not drop in either direction, replace the flushing relief valve.
If flushing pressure drops drastically in both directions, replace the flushing valve. Go to Step 58.
If the flushing system does not operate properly after the flushing relief valve is replaced, the propulsion motor may be leaking internally.
If the flushing system does not operate properly after the flushing relief valve is replaced, the propulsion motor may be leaking internally.
If the flushing system performs as described in one direction but not the other, check the flushing spool.
Note: The switch for the screed lift must be reset to the HOLD position before the machine will start.
- Move engine start switch (8) to the START position. Release the engine start switch when the engine starts.
- Operate the engine at low idle for a few minutes.
- Move throttle control switch (7) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm. Go to Step 47.
- Remove the tooling.
