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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 |
- 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 (12) to the HIGH position.
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| Illustration 8 | g03151001 |
- Move parking brake switch (2) to the OFF position.
- Move propel lever (1) FORWARD. Allow the pressure to stabilize. Record the pressure reading at forward pressure tap "Ma" (11).
- Move propel lever (1) to REVERSE. Allow the pressure to stabilize. Record the pressure reading at reverse pressure tap "Mb" (10).
- 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.
- The pressure at both ports should be 45020 ± 1380 kPa (6525 ± 200 psi). If the pressure is out of specification, adjust the POR valve, go to Step 26. If the pressure is within specification, go to Step 29.
- Remove the cap from the POR valve. Loosen locknut (13). In order to increase pressure, rotate adjustment screw (14) clockwise. In order to decrease POR pressure, rotate adjustment screw (14) counterclockwise.
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| Illustration 9 | g03151003 |
- Hold adjustment screw (14) in place, and tighten locknut (13) .
- Go to Step 14 and recheck POR pressure.
- Loosen set screw (9) on needle valve (8) for the parking brake. Rotate needle valve (8) counterclockwise in order to open the valve. Tighten set screw (9) .
- Remove the tooling from forward pressure tap "Ma" (11) and reverse pressure tap "Mb" (10) .
- Remove and secure support bar (7). Close engine hood (6) .