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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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Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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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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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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Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin. |
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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 | 2 |
| C (1) | 198-4239 | Pressure Sensor Gp 0-41400 kPa (0-6000 psi) |
2 |
| D | 177-7860 | Hose As | 1 |
| 6V-4143 | Quick Connect Coupler | 2 | |
| E | 348-5430 | Multi-Tool Gp | 1 |
| F | 110-6349 | Fitting As | 2 |
| G | NA | Laptop Computer with Plus+1TM Software | 1 |
| H (2) | 317-7485 | Communication Adapter | 1 |
| J (2) | 370-4617 | Cable As | 1 |
| K (2) | 327-8981 | Cable As | 1 |
| ( 1 ) | Tool (A), tool (B), and Tool (C) are part of the 198-4240 Digital Pressure Indicator Gp . |
| ( 2 ) | Tool (H), Tool (J), and Tool (K) are part of the 317-7484 Communication Adapter Gp . |
- Drive the machine to a smooth, horizontal surface.
- Move propel lever (1) to the NEUTRAL position.
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| Illustration 1 | g03254576 |
- 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.
- Remove six bolts (5) and washers. Remove rear access panel (6).
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| Illustration 2 | g03256338 |
Left Side Of The Machine | |
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| Illustration 3 | g03256339 |
Right Side Of The Machine | |
- Move engine start switch (4) to the START position. Release the switch when the engine starts.
- Move parking brake switch (2) to the OFF position.
- Depress right offset switch (7). Hold the right offset switch until the rear drum reaches the steering stop.
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| Illustration 4 | g03256340 |
- Move parking brake switch (2) to the ON position.
- Move engine start switch (4) to the OFF position.
- Unlock latch (8), and open rear engine compartment door (9) on the left side of the machine.
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| Illustration 5 | g03256341 |
- Assemble both sets of Tool (B) and Tool (C).
- Connect both sets of Tool (B) to Tool (A) .
- Assemble Tool (D) .
- Connect one Tool (C) to port "Ma" (11) .
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| Illustration 6 | g03256342 |
- Connect other Tool (C) to port "Mb" (10) .
- Disconnect the machine harness from reverse solenoid (12).
- Install one Tool (F) in port "X1" (14). Install other Tool (F) in port "X2" (13) .
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| Illustration 7 | g03256343 |
- Connect one end of Tool (D) to port "X1" (14). Connect other end of Tool (D) to port "X2" (13) .
- Disconnect the machine harness from forward solenoid (15) .
- Assemble the tooling. Connect Tool (J) and Tool (K) to Tool (H). Connect Tool (K) to diagnostic connector (16). Connect Tool (J) to USB port on Tool (G)
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| Illustration 8 | g03256344 |
- 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. Depress throttle control switch (3) and hold the switch for approximately 2 seconds in order to operate the engine at 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) into the OFF position.
- Launch the Plus+1TM program on the computer.
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.
- Click on "Status" button (17) .
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| Illustration 9 | g03256346 |
- Check "Active Codes" (18). Clear any open "Active Codes".
- Click on "Hydraulics" icon (19) .
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| Illustration 10 | g03256347 |
- Click on "Piston Pump Neutral Test" (20) .
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| Illustration 11 | g03256348 |
- Click on "Enable" icon (21) .
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| Illustration 12 | g03256349 |
- When "Piston Pump Neutral Test" (20) is in "Enabled" mode (22), the Plus+1TM program is launched.
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| Illustration 13 | g03256350 |
- Record differential pressure on Tool (A). Differential pressure should be less than 200 kPa (29 psi).
- Move parking brake switch (2) into the ON position.
- Move engine start switch (4) to the OFF position.
- Remove the tooling from port "Ma" (11) and port "Mb" (10) .
- Remove the tooling from port "X1" (14) and port "X2" (13). Install plugs in port "X1" (14) and port "X2" (13).
- Connect the machine harness to reverse solenoid (12) .
- Connect the machine harness to propel forward solenoid (15) .
- Disconnect tooling from diagnostic connector (16) .
- If the differential pressure measured in Step 35 is greater than 200 kPa (29 psi), remove the pump and adjust the mechanical displacement control on a hydraulic test bench. Refer to Disassembly and Assembly,, "Piston Pump (Drum Propel) Remove and Install". Refer to Bench Test Procedure,, REHS3457, "Bench Test Procedure for Hydraulic Piston Pumps". If the differential pressure is less than 200 kPa (29 psi), go to Step 44.
- Position access panel (6), and install six bolts (5) and washers.
- Close rear engine compartment door (9) on the left side of the machine.