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. |
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. |
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. |
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. |
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. |
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. |
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. |
NOTICE |
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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 | |||
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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 | 110-6349 | Fitting As | 2 |
E | 6V-9828 | Cap As | 4 |
F | 6V-9507 | Plug | 4 |
4J-5477 | O-Ring Seal | 4 | |
G | 177-7860 | Hose As | 1 |
6V-4143 | Quick Connect Coupler | 2 | |
H | N/A | Laptop Computer with Plus+1 Software | 1 |
J(2) | 317-7485 | Communication Adapter (3)(CA3) | 1 |
K(2) | 457-6114 | Cable As (DATA LINK) | 1 |
L(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 (J), Tool (K), and Tool (L) are part of 466-6258 Communication Adapter Gp |
Note: To perform this test and adjust, the brakes must be disconnected, or the machine must be placed on jack stands.
- 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).
Show/hide tableIllustration 2 g06148038 Show/hide tableIllustration 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.
Note: To adjust the neutral on the propel pump, disconnect the brakes or place the machine on jack stands. The weight of the machine is approximately
12160 kg (26808 lb) .Show/hide tableIllustration 7 g06153059 Show/hide tableIllustration 8 g06153062 - Disconnect brake supply hose assembly (11) from all four motors. Use Tool (E) to cap the port. Use Tool (F) to plug the hose.
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Illustration 9 g06155631 - Mark the electrical connections. Disconnect electrical solenoid connections (12).
- Assemble Tool (G).
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Illustration 10 g06155635 - Remove the plug from port "M5" (13) on the left side of the pump. Install one Tool (D) in port "M5". Tighten Tool (D) to a torque of
12 N·m (9 lb ft) . Connect one end of Tool (G) to Tool (D) in port "M5".Show/hide tableIllustration 11 g06155637 - Remove the plug from port "M4" (14) on the right side of the pump. Install one Tool (D) in port "M4". Tighten Tool (D) to a torque of
12 N·m (9 lb ft) . Connect other end of Tool (G) to Tool (D) in port "M4". - Assemble the tooling. Connect Tool (C) to Tool (B). Make two sets of Tool (C) and Tool (B).
- Connect both sets of Tool (B) to Tool (A).
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Illustration 12 g06155660 Show/hide tableIllustration 13 g06155664 - Connect one Tool (C) to port "Mb" (15) on the top of the front section of the propel pump.
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Illustration 14 g06155669 - Connect one Tool (C) to port "Ma" (16) on the bottom of the front section of the propel pump.
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Illustration 15 g06155673 - Connect Tool (L) and Tool (K) to Tool (J). Connect Tool (K) to diagnostic connector (17). Connect Tool (L) to USB port on Tool (H).
- Move engine start switch (8) to the START position. Release the switch when the engine starts.
- Move parking brake switch (2) to the OFF position.
- Place the engine in high idle.
- Operate the hydraulic system until the oil temperature reaches the test temperature of
45 °C (113 °F) . - Place the engine in ECO mode or in low idle.
- 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 16 g06155678 - Click "Status" button (18).
- Check "Active Codes". Clear any open "Active Codes".
- Click "Machine Controls" (19).
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Illustration 17 g06155682 - Click "Hydraulics" icon (20).
- Click "Piston Pump Neutral Test" (21).
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Illustration 18 g06156175 - Click "Piston Pump Neutral Test" icon (22).
- Click "Enable" icon (23).
- When "Piston Pump Neutral Test" (22) is in "Enabled" mode, thePlus+1TM program is launched.
- Record the differential pressure between port "Ma" and port "Mb" on Tool (A). Differential pressure should be less than
150 kPa (22 psi) . - Move parking brake switch (2) to the ON position.
- Move engine start switch (8) to the OFF position.
- If the differential pressure measured in Step 32 is greater than
150 kPa (22 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, REHS3447, "Bench Test Procedure for Hydraulic Piston Pumps". If the differential pressure is less than150 kPa (22 psi) , go to Step 36. - Remove Tool (G) from port "M4" (14) and port "M5" (13). Remove Tool (E) from port "M4" and port "M5". Install plugs in port "M4" and port "M5". Tighten plugs to a torque of
12 N·m (9 lb ft) .Show/hide tableIllustration 19 g06156184 - Remove the plug from port "M4" (24) on the right side of the pump. Install one Tool (D) in port "M4". Tighten Tool (D) to a torque of
12 N·m (9 lb ft) . Connect one end of Tool (G) to Tool (D) in port "M4".Show/hide tableIllustration 20 g06156188 - Remove the plug from port "M5" (25) on the left side of the pump. Install one Tool (D) in port "M5". Tighten Tool (D) to a torque of
12 N·m (9 lb ft) . Connect other end of Tool (G) to Tool (D) in port "M5". - Disconnect Tool (C) from port "Mb" (15) and port "Ma" (16) on the front section of the propel pump.
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Illustration 21 g06156202 Show/hide tableIllustration 22 g06156204 - Connect one Tool (C) to port "Mc" (26) on the top of the rear section of the propel pump.
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Illustration 23 g06156207 - Connect one Tool (C) to port "Md" (27) on the bottom of the rear section of the propel pump.
- Move engine start switch (8) to the START position. Release the switch when the engine starts.
- Move parking brake switch (2) to the OFF position.
- Place the engine in ECO mode or in low idle.
- Move parking brake switch (2) to the OFF position.
- Launch the Plus+1TM program on the computer to energize the parking brake.
- Record the differential pressure between port "Mc" and port "Md" on Tool (A). Differential pressure should be less than
150 kPa (22 psi) . - Move parking brake switch (2) to the ON position.
- Move engine start switch (8) to the OFF position.
- If the differential pressure measured in Step 47 is greater than
150 kPa (22 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,, REHS3447, "Bench Test Procedure for Hydraulic Piston Pumps". If the differential pressure is less than150 kPa (22 psi) , go to Step 51. - Remove the tooling from port "M4" (24) and port "M5" (25). Install plugs in port "M4" and port "M5". Tighten plugs to a torque of
12 N·m (9 lb ft) . - Disconnect Tool (C) from port "Mc" (26) and port "Md" (27) on the rear section of the propel pump.
- Connect electrical solenoid connections (12).
- Exit the Plus+1TM program. Remove tooling from diagnostic connector (17).
- Remove Tool (F) from brake supply hose assembly (11) at the drum propel motors. Remove Tool (E) from the brake inlet port at the drum propel motors. Connect the brake supply hose to the brake inlet ports on the propel motors.
- Close the right engine compartment door.