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Diesel engine exhaust contains products of combustion which may cause personal injury. Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside. |
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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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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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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 attachments have been lowered, 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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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 No | Description | Qty |
| A (1) | 198-4234 | Digital Indicator (PRESSURE) | 1 |
| B (1) | 198-4236 | Adapter Cable As | 2 |
| C (1) | 251-9600 | Pressure Sensor Gp (0 TO 68,900-KPA (0 TO 10,000-PSI)) | 2 |
| D | 348-5430 | Multi-Tool Gp | 1 |
| ( 1 ) | Tool (A), (B), and (C) are part of 198-4240 Digital Pressure Indicator Gp |
Note: Verify that the charge relief valve is within specification prior to performing this procedure. Refer to Systems Operation, Testing and Adjusting,, " "Relief Valve (Charge) Test and Adjust"".
- Drive the machine to a smooth, horizontal surface.
- Move propel lever (1) to the NEUTRAL position.
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| Illustration 1 | g03148936 |
- Move parking brake switch (2) to the ON position.
- Use throttle control switch (3) in order to operate the engine in low idle.
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| Illustration 2 | g03148937 |
- Move engine start switch (4) to the OFF position.
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| Illustration 3 | g03148938 |
- Block the wheels with appropriate devices.
- Unlock latches (5) and open engine hood (6) .
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| Illustration 4 | g03148939 |
- Raise support bar (7) and secure the engine hood.
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| Illustration 5 | g03148940 |
- Loosen set screw (9) on needle valve (8) for the parking brakes.
Note: Needle valve (8) is located in the engine compartment, on the right side of the machine.
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| Illustration 6 | g03149696 |
- Rotate needle valve (8) clockwise in order to close the valve. Tighten set screw (9) .
- Assemble the tooling. Connect Tool (B) to Tool (C). Make two sets of tooling.
- Connect both sets of Tool (B) to Tool (A) .
- Connect Tool (C) to forward pressure tap "Ma" (11) on the propel pump. Connect other Tool (C) to reverse pressure tap "Mb" (10) on the propel pump.
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| Illustration 7 | g03149697 |
- Remove the cap from the POR valve. Then, loosen locknut (12). Rotate adjustment screw (13) clockwise two turns. Hold adjustment screw (13) and tighten locknut (12) .
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| Illustration 8 | g03149698 |
- Move engine start switch (4) to the START position. Release the switch when the engine starts.
- Operate the engine at low idle for a few minutes. Use throttle control switch (3) in order to operate the engine at 2250 rpm (high idle).
- Monitor the hydraulic oil temperature with Tool (D). Operate the machine until the oil temperature reaches 43 ± 5.6° C (110 ± 10° F).
- Move speed selector switch (14) to the HIGH position.
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| Illustration 9 | g03149699 |
- Move parking brake switch (2) to the OFF position.
- Move propel lever (1) fully forward. Read pressure on Tool (A) in forward pressure tap "Ma" (11). The pressure should be 48020 ± 1730 kPa (6960 ± 250 psi).
- Move propel lever (1) to the NEUTRAL position.
- Move parking brake switch (2) to the ON position.
- Use throttle control switch (3) in order to operate the engine in low idle.
- Move engine start switch (4) to the OFF position.
- If the pressure is outside the specified range, go to Step 26. If the pressure is inside the specified range, go to Step 28.
- Remove the cap from forward relief valve (15). Loosen locknut (16) on the relief valve. In order to increase pressure, rotate adjustment screw (17) clockwise. In order to decrease pressure, rotate adjustment screw (17) counterclockwise. Hold adjustment screw (17) and tighten locknut (16) .
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| Illustration 10 | g03149700 |
- Go to Step 15.
- Move propel lever (1) to the rear. Read pressure on Tool (A) in reverse pressure tap "Mb" (10). The pressure should be 48020 ± 1730 kPa (6960 ± 250 psi).
- Move propel lever (5) to the NEUTRAL position.
- Move parking brake switch (2) to the ON position.
- Use throttle control switch (3) in order to operate the engine in low idle.
- Move engine start switch (4) to the OFF position.
- If the pressure is outside the specified range, go to Step 36. If the pressure is inside the specified range, go to Step 34.
- Remove the cap from forward relief valve (20). Loosen locknut (18) on the relief valve. In order to increase pressure, rotate adjustment screw (19) clockwise. In order to decrease pressure, rotate adjustment screw (19) counterclockwise. Hold adjustment screw (19) and tighten locknut (18) .
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| Illustration 11 | g03149701 |
- Go to Step 15.
- Loosen locknut (12) on the POR valve. Rotate adjustment screw counterclockwise two turns. Hold adjustment screw (13) and tighten locknut (12) .
- Adjust the POR pressure. Refer to Systems Operation, Testing and Adjusting,, " "Relief Valve (Pressure Override) Test and Adjust"".
Note: Removal of the tooling is not necessary. The tooling installed on the machine in this procedure is required in another procedure, refer to Systems Operation, Testing and Adjusting,, " "Relief Valve (Override) Test and Adjust"". The tooling will be removed during the Testing and Adjusting procedure for the pressure override relief valve.
Note: Some of the steps in Systems Operation, Testing and Adjusting,, " "Relief Valve (Override) Test and Adjust"" will have already been performed. However, read each step of the procedure in order to make sure that the machine setup steps were properly performed.