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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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| 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 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 | 8C-6874 | Connector | 2 |
| 6V-9746 | O-Ring Seal | 2 | |
| B | 4C-8689 | Flow Meter Gp | 1 |
| C | 6V-8942 | O-Ring Reducer | 1 |
| 6V-8398 | O-Ring Seal | 1 | |
| D | 6V-8556 | Nut | 1 |
| E | 124-2147 | Coupling | 3 |
| 6V-8398 | O-Ring Seal | 3 | |
| F | 122-6890 | Hydraulic Hose 100 cm (39.5 inch) |
2 |
| G | 124-2117 | Coupling | 1 |
| 6V-8397 | O-Ring Seal | 2 | |
| H | 5P-3413 | Pipe Sealant (50-ML TUBE) | 1 |
| J | 6V-7788 | Flow Meter Gp (5 TO 60-L/MIN (2 TO 15-US GPM)) | 1 |
| K | 8C-6874 | Connector | 2 |
| 6V-9746 | O-Ring Seal | 2 | |
| L | 124-2153 | Coupling | 2 |
| 6V-9746 | O-Ring Seal | 2 | |
| M | 122-6872 | Hydraulic Hose 100 cm (39.5 inch) |
2 |
| N | 124-2121 | Permanent Coupling | 2 |
| 6V-9746 | O-Ring Seal | 2 | |
| P | 122-6872 | Hydraulic Hose 120 cm (47 inch) |
1 |
| R | 124-2153 | Coupling | 1 |
| S | 6V-9832 | Cap As | 1 |
| T | 348-5430 | Multi-Tool Gp | 1 |
| U | 6V-9851 | Elbow | 1 |
| V | 6V-8731 | Union | 1 |
Note: Perform the parking brake test prior to performing this procedure. Refer to Systems Operation, Testing and Adjusting,, " "Parking Brake Test"".
- 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 |
- 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) .
- Apply Tool (H) to the NPT side of each Tool (A). Install one Tool (A) in each side of Tool (B) .
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| Illustration 7 | g03151400 |
- Assemble Tool (C) and Tool (D). Connect one Tool (D) to each Tool (A) on Tool (B) .
- Assemble Tool (E) to each end of one Tool (F). Assemble Tool (E) and Tool (G) to other Tool (F). Connect Tool (E) from tool assemblies to Tool (C) on each side of the flowmeter.
- Connect Tool (U) to Tool (E) on the hose assembly installed in inlet side of Tool (B). Connect Tool (V) to Tool (G) on the hose assembly installed in outlet side of Tool (B) .
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| Illustration 8 | g03151401 |
- Disconnect case drain hose assembly (10) from the right motor.
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| Illustration 9 | g03151402 |
- Connect Tool (U) to the case drain port in the right motor.
- Connect Tool (V) to hose assembly (10) .
- 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 (T). Operate the machine until the oil temperature reaches 43 ± 5.6° C (110 ± 10° F).
- Move shift switch (11) to the HIGH position.
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| Illustration 10 | g03151416 |
- Move parking brake switch (2) to the OFF position.
- Read the flow on the flow meter. The flow should be 3.8 L/min (1 US gpm).
- Move propel lever (1) out of the NEUTRAL position one quarter to one half of the full travel.
- Record the flow on the flow meter as "right motor case flow". The flow should be less than 15 L/min (4 US gpm). If the flow is less than 15 L/min (4 US gpm), go to Step 25. If the flow is greater than 15 L/min (4 US gpm), repair or replace the right propel motor.
Note: The flushing valve directs 9.5 ± 1.9 L/min (2.5 ± 0.5 US gpm) into the motor case. In order to determine actual motor leakage, subtract the flushing valve flow from the total flow.
- 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.
- Remove the tooling, and reconnect case drain hose assembly (10) on the right motor.
- Apply Tool (H) to the NPI side of each Tool (K). Install one Tool (K) in each side of Tool (J) .
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| Illustration 11 | g03151417 |
- Assemble Tool (L), Tool (N), and Tool (M). Make two sets of this tool assembly. Connect Tool (L) from one of tool assemblies to Tool (K) on each side of Tool (J) .
- Connect Tool (P) to Tool (R) .
- Disconnect hose assembly (12) from the thermal bypass valve.
Note: The thermal bypass valve is located on the left side of the machine.
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| Illustration 12 | g03151419 |
- Connect Tool (N) on inlet end of Tool (J) to the thermal bypass valve. Connect Tool (N) on outlet end of Tool (J) to hose assembly (12) .
- Disconnect hose assembly (13) from the left propel motor. Hand tighten Tool (S) to tee (14) on the motor. Connect Tool (R) to hose assembly (13). Place hose end of Tool (P) into the filler port of the hydraulic tank.
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| Illustration 13 | g03151420 |
- 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).
- Move propel lever (1) out of NEUTRAL (one quarter to one half full travel).
- Record the flow on the flow meter as "total motor case drain plus flushing flow". The flow should be less than 19 L/min (5 US gpm).
- 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.
- Subtract the measurement recorded in Step 24 from the measurement recorded in Step 34. The total should be 3.8 L/min (1 US gpm). If the flow is greater than 3.8 L/min (1 US gpm), repair or replace the left propel motor.
- Remove the tooling and reconnect hose assembly (13) .
- Remove the tooling and reconnect hose assembly (12) to the thermal bypass valve.
- 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 and secure support bar (7). Close engine hood (6) .