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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. Stay clear of all rotating and moving parts. Never attempt adjustments while the engine is running unless otherwise specified. |
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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 | Extension Cable | 2 |
| C(1) | 198-4239 | Pressure Sensor Gp
0 to |
2 |
| D | 6V-9828 | Cap As | 4 |
| E | 6V-9507 | Plug | 4 |
| 4J-5477 | O-Ring Seal | 2 | |
| (1) | Tool (A), Tool (B), and Tool (C) are part of the 198-4240 Digital Pressure Indicator Gp. |
Note: Perform Test and Adjust, "Relief Valve (Charge) Test and Adjust (Split Drum)" before Test and Adjust, "Relief Valve (Main) - Test and Adjust (Split Drum)".
- Drive the machine to a smooth, horizontal surface.
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Illustration 1 g06144094 - Move propel lever (1) to the NEUTRAL position.
- Move parking brake switch (2) to the ON position.
- Place the engine in ECO mode or low idle.
- Select "Main Menu" (3) on the machine display.
- Select "Machine Setup" (4).
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Illustration 3 g06148261 - Select "Engine Spd Sw" (5).
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Illustration 4 g06148286 - Select "ECO" (6) or "Low" (7).
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Illustration 2 g06148038 Show/hide table
Illustration 5 g06144108 - Move engine start switch (8) to the OFF position.
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Illustration 6 g06143919 - Unlock latch (9) and open engine compartment door (10) on the right side of the machine.
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Illustration 7 g06153059 Show/hide table
Illustration 8 g06153062 - Disconnect brake supply hose assembly (11) from all four motors. Use Tool (D) to cap the port. Use Tool (E) to plug the hose.
- Assemble the tooling. Connect Tool (B) to Tool (C). Assemble two sets of tooling.
- Connect both sets of Tool (B) to Tool (A).
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Illustration 9 g06155397 - Connect one Tool (C) to port "Ma" (12) of the propel pump.
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Illustration 10 g06155406 - Connect other Tool (C) to port "Mb" (13) on the propel pump.
- Move engine start switch (8) to the START position. Release the switch when the engine starts.
- Place the engine in high idle.
- Operate the hydraulic system until the oil temperature reaches the test temperature of
45 °C (113 °F) .Show/hide table
Illustration 11 g06144770 - Use speed control switches (14) to set the propel speed to 50 percent.
Note: Two things indicate when the propel speed is set to 50 percent. First, "Speed Control % 50" will appear on the display. Second, four LEDs next to speed control buttons (14) will be illuminated.
- Move parking brake switch (2) to the OFF position.
- Modulate propel lever (1) reverse until the peak pressure is registered (approximately one half of the total travel). Record the pressure at port "Ma" (12) The pressure should be
42500 ± 2000 kPa (6164 ± 290 psi) . - Modulate propel lever (1) to forward until the peak pressure is registered (approximately one half of the total travel). Record the pressure at port "Mb" (13) The pressure should be
42500 ± 2000 kPa (6164 ± 290 psi) . - Move propel lever (1) to the NEUTRAL position.
- Place the engine in ECO mode or in low idle.
- Move parking brake switch (2) to the ON position.
- Move engine start switch (8) to the OFF position.
- If either the forward pressure or the reverse pressure was outside the specified range, go to Step 24. If both the forward pressure and the reverse pressure are inside the specified range, go to Step 27.
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Illustration 12 g06155428 - If the reverse pressure is outside the specified range, "Ma" relief valve (16) must be cleaned or replaced.
- If forward pressure is outside the specified range, "Mb" relief valve (15) must be cleaned or replaced.
- Go to Step 12.
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Illustration 13 g06155450 - Disconnect Tool (C) from port "Mb" (13). Connect Tool (C) to port "Mc" (17).
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Illustration 14 g06155452 - Disconnect Tool (C) from port "Ma" (12). Connect Tool (C) to port "Md" (18).
- Move engine start switch (8) to the START position. Release the switch when the engine starts.
- Place the engine in high idle.
- Operate the hydraulic system until the oil temperature reaches the test temperature of
45 °C (113 °F) . - Move parking brake switch (2) to the OFF position.
- Modulate propel lever (1) reverse until the peak pressure is registered (approximately one half of the total travel). Record the pressure at port "Mc" (17) The pressure should be
42500 ± 2000 kPa (6164 ± 290 psi) . - Modulate propel lever (1) to forward until the peak pressure is registered (approximately one half of the total travel). Record the pressure at port "Md" (18). The pressure should be
42500 ± 2000 kPa (6164 ± 290 psi) . - Move propel lever (1) to the NEUTRAL position.
- Place the engine in ECO mode or in low idle.
- Move parking brake switch (2) to the ON position.
- Move engine start switch (8) to the OFF position.
- If either the forward pressure or the reverse pressure was outside the specified range, go to Step 40. If both the forward pressure and the reverse pressure are inside the specified range, go to Step 43.
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Illustration 15 g06155463 - If the reverse pressure is outside the specified range, "Mc" relief valve (19) must be replaced.
- If the forward pressure is outside the specified range, "Md" relief valve (20) must be replaced.
- Go to Step 29.
- Remove Tool (C) from port "Mc" (17). Remove Tool (C) from port "Md" (18).
- 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 (11) to the brake inlet ports on the propel motors.
- Close engine compartment door (10) on the right side of machine and secure latch (9).
