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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 | Extension Cable | 2 |
| C(1) | 198-4239 | Pressure Sensor Gp
Zero to |
2 |
| D | 6V-9830 | Cap As | 2 |
| E | 6V-9509 | Plug | 2 |
| 6V-8398 | O-Ring Seal | 2 | |
| (1) | Tool (A), Tool (B), and Tool (C) are part of the 198-4240 Digital Pressure Indicator Gp. |
Note: Perform , "Relief Valve (Charge) Test and Adjust (Solid Drum)" before , "Relief Valve (Main) Test and Adjust (Solid 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 g06155478 - Disconnect brake supply hose assembly (11) at the drums. Use Tool (E) to plug the hose assembly. Use Tool (D) to cap the port.
- 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 8 g06155492 - Connect Tool (C) to port "Ma" (13) on the propel pump. Connect other Tool (C) to port "Mb" (12) of the propel pump.
- Move engine start switch (8) to the START position. Release the switch when the engine starts.
- 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.
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Illustration 9 g06144770 - Use speed control buttons (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." The pressure should be
38000 ± 2000 kPa (5500 ± 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." The pressure should be
38000 ± 2000 kPa (5500 ± 290 psi) . - 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.
- 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 23. If both forward pressure and reverse pressure were inside the specified range, go to Step 26.
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Illustration 10 g06155555 Show/hide table
Illustration 11 g06155559 Show/hide table
Illustration 12 g06155562 - Remove relief valve cap (13) or (14) from the relief valve which is to be adjusted.
- If the pressure at port "Ma" (13) was out of specification, remove reverse cartridge (16). Remove spring (17) and relief valve cartridge (18) from the pump housing. Reinstall the reverse relief valve cap to prevent oil from leaking out the port.
- If the pressure at port "Mb" (12) was out of specification, remove forward cartridge (15). Remove spring (17) and relief valve cartridge (18) from the pump housing. Reinstall the forward relief valve cap to prevent oil from leaking out the port.
- Use the following procedure to adjust the main relief valves:
- Clamp the relief valve cartridge in a soft vise jaw, refer to Illustration 13. Loosen locking setscrew (19) with a 3 mm Allen wrench.
Note: The spring must be compressed in the next step. Turning spindle (20) without the spring being compressed will damage the spindle.
- Use a 5 mm wrench to turn spindle (20). Turn the spindle clockwise to increase pressure. Turn the spindle counterclockwise to decrease pressure.
Note: One quarter turn of spindle (20) changes the pressure setting by approximately
2500 kPa (363 psi) . - Tighten locking setscrew (19) to a torque of
12 N·m (9 lb ft) . - Remove the relief valve cartridge from the vise.
- Remove relief valve cap, and install the relief valve cartridge in the manifold. Reinstall the relief valve cap to a torque of
70 N·m (52 lb ft) .
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Illustration 13 g06155577 Arrows indicate Clamping Position. - Clamp the relief valve cartridge in a soft vise jaw, refer to Illustration 13. Loosen locking setscrew (19) with a 3 mm Allen wrench.
- Go to Step 11.
- Remove Tool (C) to port "Ma" (13) and port "Mb" (12) of the propel pump.
- Remove Tool (D) from brake supply hose assembly (11) at the drum propel motors. Remove Tool (C) from the brake inlet port at the drum propel motors. Connect brake supply hose (9) to the brake inlet ports on the propel motors.
- Close engine compartment door (10) on the right side of machine and secure latch (9).
