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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 can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped. Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine. |
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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 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 Number | Description | Qty |
| A(1) | 198-4234 | Digital Indicator | 1 |
| B(1) | 198-4236 | Adapter Cable As | 4 |
| C(1) | 198-4237 | Pressure Sensor Gp |
2 |
| D(1) | 198-4239 | Pressure Sensor Gp |
2 |
| E | 348-5430 | Multi-Tool Gp | 1 |
| F | 110-6349 | Fitting As | 2 |
| G | 177-7860 | Hose As | 1 |
| 6V-4143 | Quick Connect Coupler | 2 | |
| H | N/A | Laptop Computer With Plus+1TM Software | 1 |
| J(2) | 317-7485 | Communication Adapter | 1 |
| K(2) | 327-8981 | Cable As | 1 |
| L(2) | 370-4617 | Cable As | 1 |
| (1) | Tool (A), Tool (B), Tool (C), and Tool (D) are part of the 198-4240 Digital Pressure Indicator Gp. |
| (2) | Tool (J), Tool (K), and Tool (L) are part of the 317-7484 Communication Adapter Gp. |
- Drive the machine to a smooth, horizontal surface.
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Illustration 1 g03159030 - 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 ECO mode or in low idle.
Note: Two things indicate when the engine is in ECO mode. First, "ECO" will appear on the display. Second, the second LED next to throttle control switch (3) will be illuminated. Two things indicate when the engine is at low idle. First,"Low Idle" will appear on the display. Second, the first LED next to the throttle control switch will be illuminated.
- Move engine start switch (4) to the OFF position.
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Illustration 2 g03159031 - Unlock latch (5) and open engine compartment door (6) on the right side of the machine.
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Illustration 3 g03159033 - Remove ten bolts (7) and remove side panel (8) on the right side of the machine.
- Assemble the tooling. Connect Tool (D) to Tool (B). Make two sets of Tool (D) and Tool (B).
- Connect both sets of Tool (B) to Tool (A).
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Illustration 4 g03159034 - Connect one Tool (D) to port "Ma" (9) on the machine valve.
- Connect other Tool (D) to port "Mb" (10) of the machine valve.
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Illustration 5 g03159035 - Mark the solenoid electrical connections. Disconnect solenoid electrical connections (11).
- Assemble Tool (G).
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Illustration 6 g03159037 - Remove the plug from port "M4" (12). Install one Tool (F) in port "M4" (12). Tighten Tool (F) to a torque of
12 N·m (9 lb·ft) . Connect one end of Tool (G) to Tool (F) in port "M4" (12).Show/hide table
Illustration 7 g03159056 - Remove the plug from port "M5" (13). Install one Tool (F) in port "M5" (13). Tighten Tool (F) to a torque of
12 N·m (9 lb·ft) . Connect other end of Tool (G) to Tool (F) in port "M5" (13).Show/hide table
Illustration 8 g03159058 - Connect Tool (K) and Tool (L) to Tool (J). Connect Tool (K) to diagnostic connector (14). Connect Tool (L) to USB port on Tool (H).
- 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 in high idle.
Note: Two things indicate when the engine is at high idle. First, "High Idle" will appear on the display. Second, all three LED's next to throttle control switch (3) will be illuminated.
- Monitor the hydraulic oil temperature with Tool (E). Operate the machine until the oil temperature reaches
43 ± 5.6 °C (110 ± 10 °F) . - Use throttle control switch (3) in order to operate the engine in ECO mode or in low idle.
Note: Two things indicate when the engine is in ECO mode. First, "ECO" will appear on the display. Second, the second LED next to throttle control switch (3) will be illuminated. Two things indicate when the engine is at low idle. First,"Low Idle" will appear on the display. Second, the first LED next to the throttle control switch will be illuminated.
- Move parking brake switch (2) to the OFF position.
Note: First time users need to perform the tasks in the Communication and Connections Wizard. This wizard allows the Windows® operating system to recognize the USB device. Follow the on screen instructions.
- Launch the Plus+1TM program on the computer.
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Illustration 9 g03159076 - Click on "Status" button (15).
- Check "Active Codes" (16). Clear any open "Active Codes".
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Illustration 10 g03159116 - Click on "Hydraulics" icon (17).
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Illustration 11 g03159121 - Click on "Piston Pump Neutral Test" (18).
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Illustration 12 g03159156 - Click on "Enable" icon (19).
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Illustration 13 g03159177 - When "Piston Pump Neutral Test" (18) is in "Enabled" mode (20), the Plus+1TM program is launched.
- Record pressure differential on Tool (A). The pressure differential should be less than
150 kPa (22 psi) . If the pressure differential is within150 kPa (22 psi) , go to Step 55. If the pressure differential is not equal, go to Step 30. - Move parking brake switch (2) to the ON position.
- Move engine start switch (4) to the OFF position.
- Disconnect Tool (G) from Tool (F) in port "M4" (12) and port "M5" (13).
- Assemble the tooling. Connect Tool (C) to Tool (B). Make two sets of Tool (C) and Tool (B).
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Illustration 14 g03159181 - Connect Tool (C) to Tool (F) in port "M4" (21). Connect Tool (B) to Tool (A).
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Illustration 15 g03159183 - Connect other Tool (C) to Tool (F) in port "M5" (22). Connect Tool (B) to Tool (A).
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Illustration 16 g03159186 - Remove lock-screws (25) and lock-plate (24) from "M4" servo cylinder cap (23).
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Illustration 17 g03159187 - Remove lock-screws (28) and lock-plate (26) from "M5" servo cylinder cap (27).
- Using a 3/4" deep socket, unthread servo cylinder cap (23) and servo cylinder cap (27) two to three turns. This action will ensure that the servo cylinder caps are not in contact with the servo piston.
- Move engine start switch (4) to the START position. Release the switch when the engine starts.
- Use throttle control switch (3) in order to operate the engine in ECO mode or in low idle.
Note: Two things indicate when the engine is in ECO mode. First, "ECO" will appear on the display. Second, the second LED next to throttle control switch (3) will be illuminated. Two things indicate when the engine is at low idle. First,"Low Idle" will appear on the display. Second, the first LED next to the throttle control switch will be illuminated.
- Move parking brake switch (2) to the OFF position.
- Repeat Step 22 through Step 28 in order to launch the Plus+1TM program on the computer.
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Illustration 18 g03159191 - Loosen locknut (29) and rotate adjustment screw (30). Note the pressure at port "M4" and port "M5". Rotate adjustment screw (30) until the servo pressure at port "M4" is
95 - 200 kPa (14 - 29 psi) greater than port "M5". - The system pressure at port "Ma" and port "Mb" should indicate displacement. Clockwise rotation of adjustment screw (30) will increase pressure at port "Ma". Counter clockwise rotation of adjustment screw (30) will increase pressure at port "Mb". This action indicates the servo piston is in contact with the servo cylinder cap on the "M5" side of the pump.
- Slowly turn servo cylinder cap (27), on the "M5" side of the pump, in until the system pressure differential starts to decrease. Maintain "M4" servo pressure
95 - 200 kPa (14 - 29 psi) higher than "M5" servo pressure during this step. - Continue turning cylinder cap (27), on the "M5" side of the pump, in until the system pressure differential between port "Ma" and port "Mb" is less than
150 kPa (22 psi) . This action will set the servo and swashplate to mechanical neutral on the M5 side. - Replace lock-screws (28) and lock-plate (26) on the "M5" servo cylinder cap (19). Tighten lock-screws to a torque of
14.5 N·m (11 lb·ft) . - Rotate adjustment screw (30). Note the pressure at port "M4" and port "M5". Rotate adjustment screw (30) until the servo pressure at port "M5" is
95 - 200 kPa (14 - 29 psi) greater than port "M4". - The system pressure at port "Ma" and port "Mb" should indicate displacement. Clockwise rotation of adjustment screw (30) will increase pressure at port "Ma". Counter clockwise rotation of adjustment screw (30) will increase pressure at port "Mb". This action indicates the servo piston is in contact with the servo cylinder cap on the "M4" side of the pump.
- Slowly turn servo cylinder cap (23), on the M4 side of the pump, in until the system pressure differential starts to decrease. Maintain "M5" servo pressure
95 - 200 kPa (14 - 29 psi) higher than "M4" servo pressure during this step. - Continue turning servo cylinder cap (23), on the M4 side of the pump, in until the system pressure differential between port "Ma" and port "Mb" is less than
150 kPa (22 psi) . This action will set the servo and swashplate to mechanical neutral on the "M4" side. - Replace lock-screws (25) and lock-plate (16) on the "M4" servo cylinder cap (23). Tighten lock-screws to a torque of
14.5 N·m (11 lb·ft) . - Turn adjustment screw (30) until pressures at"M4" and "M5" are equal.
- Hold adjustment screw (30) in place and tighten locknut (21). Tighten locknut to a torque of
10 N·m (7 lb·ft) . - Move parking brake switch (2) to the ON position.
- Move engine start switch (4) to the OFF position.
- Remove tooling from diagnostic connector (14).
- Remove tooling from port "Ma" (9) and port "Mb" (10) on the machine valve.
- Remove the tooling from port "M4" (12) and from port "M5" (13). Install plugs. Tighten plugs to a torque of
12 N·m (9 lb·ft) . - Connect solenoid electrical connectors (11).
- Position side panel (8) on the right side of the machine and install ten bolts (7).
- Close engine compartment door (6) on the right side of machine and secure latch (5).
