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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 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 | 2 |
| D | 177-7860 | Hose As | 1 |
| 6V-4143 | Quick Connect Coupler | 2 | |
| E | 251-0030 | Infrared Thermometer | 1 |
| F | 110-6349 | Fitting As | 2 |
| G | 6V-9830 | Cap As | 2 |
| H | 6V-9507 | Plug | 2 |
| 4J-5477 | O-Ring Seal | 2 | |
| J | N/A | Laptop Computer with Plus+1TM Software | 1 |
| K(2) | 317-7485 | Communication Adapter (3)(CA3) | 1 |
| L(2) | 327-8981 | Cable As (DATA LINK) | 1 |
| M(2) | 370-4617 | Cable As | 1 |
| (1) | Tool (A), Tool (B), and Tool (C) are part of the 198-4240 Digital Pressure Indicator Gp. |
| (2) | Tool (K), Tool (L), and Tool (M) are part of 317-7484 Communication Adapter Gp |
- Drive the machine to a smooth, horizontal surface.
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Illustration 1 g03117156 - 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 g03372926 - Unlock latch (5) and open engine compartment door (6) on the right side of the machine.
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Illustration 3 g03373027 - Remove ten bolts (7) and remove side panel (8) on the right side of the machine.
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Illustration 4 g03131696 - Disconnect brake supply hose assembly (9) from both propel motors. Use Tool (G) to cap the port. Use Tool (H) to plug the hose.
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Illustration 5 g03131716 - Mark the electrical connections. Disconnect solenoid electrical connections (10).
- Assemble the tooling. Connect Tool (C) to Tool (B). Assemble two sets of Tool (C) and Tool (B).
- Install both sets of Tool (B) to Tool (A).
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Illustration 6 g03132978 - Install one Tool (F) in port "X1" (12). Install other Tool (F) in port "X2" (11).
- Connect one Tool (C) to Tool (F) in port "X1" (12). Connect second Tool (C) to Tool (F) in port "X2" (11).
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Illustration 7 g03132980 - Connect Tool (L) and Tool (K) to Tool (J). Connect Tool (K) to diagnostic connector (13). Connect Tool (L) to USB port on Tool (J).
- 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) . - 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 8 g03364948 - Click on "Status" button (14).
- Check "Active Codes" (15). Clear any open "Active Codes".
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Illustration 9 g03364958 - Click on "Hydraulics" icon (16).
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Illustration 10 g03364978 - Click on "Piston Pump Neutral Test" (17).
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Illustration 11 g03364991 - Click on "Enable" icon (18).
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Illustration 12 g03364997 - When "Piston Pump Neutral Test" (19) is in "Enabled" mode (20), the Plus+1TM program is launched.
- 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.
- Read differential pressure on Tool (A). Differential pressure should be less than
260 kPa (38 psi) . - If differential pressure is less than
260 kPa (38 psi) , go to Step 31. If the pressure is greater than260 kPa (38 psi) , go to Step 29.Show/hide table
Illustration 13 g03132987 Note: Small movement of the adjustment screw can result in a large pressure change. Hold the adjustment securely in place when loosening the lock screw.
- Loosen lock screw (21). Watch pressure on Tool (A). If necessary, rotate adjustment screw (22) until the differential pressure is less than
260 kPa (38 psi) . - Hold adjustment screw (22), and tighten lock screw (21).
- Move parking brake switch (2) to the ON position.
- Move engine start switch (4) to the OFF position.
- Remove the tooling from port "X1" and from port "X2". Reinstall plugs in port "X1" and port "X2".
- Connect solenoid electrical connectors (10).
- Remove the tooling from the diagnostic port.
- Remove Tool (E) from brake supply hose assembly (9) at the drum propel motors. Remove Tool (D) from the brake inlet port at the drum propel motors. Connect brake supply hose (9) to the brake inlet ports on the propel motors.
- Position side panel (8) on the right side of the machine and install ten bolts (7).
- Close the right engine compartment door
