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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 | 2 |
| D | 177-7860 | Hose As | 1 |
| 6V-4143 | Quick Connect Coupler | 2 | |
| E | 110-6349 | Fitting As | 2 |
| F | 6V-9830 | Cap As | 2 |
| G | 6V-9507 | Plug | 2 |
| 4J-5477 | O-Ring Seal | 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 |
- 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) from both propel motors. Use Tool (F) to cap the port. Use Tool (G) to plug the hose.
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Illustration 8 g06156227 - Mark the electrical connections. Disconnect solenoid electrical connections (12).
- Connect Tool (B) to Tool (C). Assemble two sets of Tool (B) to Tool (C).
- Connect both sets of Tool (B) to Tool (A).
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Illustration 9 g06156232 - Connect one Tool (C) to port "Ma" (14).
- Connect other Tool (C) to port "Mb" (13).
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Illustration 10 g06156235 - Install one Tool (E) in port "X1" (16). Install other Tool (E) in port "X2" (15).
- Assemble Tool (D).
- Connect one end of Tool (D) to Tool (E) in port "X1" (16). Connect other end of Tool (D) to Tool (E) in port "X2" (15).
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Illustration 11 g06155673 - Connect Tool (K) and Tool (L) 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.
- Operate the hydraulic system until the oil temperature reaches the test temperature of
45 °C (113 °F) . - Place the engine in ECO mode or 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 12 g06155678 - Click "Status" button (18).
- Check "Active Codes". Clear any open "Active Codes".
- Click "Machine Controls" (19).
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Illustration 13 g06155682 - Click "Hydraulics" icon (20).
- Click "Piston Pump Neutral Test" (21).
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Illustration 14 g06156175 - Click "Piston Pump Neutral Test" icon (22).
- Click "Enable" icon (23).
- When "Piston Pump Neutral Test" (22) is in "Enabled" mode, the Plus+1TM program is launched.
- Record the pressure differential between port "Ma" and port "Mb" on Tool (A). The pressure differential between port "Ma" and port "Mb" should be less than
200 kPa (29 psi) . If the pressure differential between port "Ma" and port "Mb" is less than200 kPa (29 psi) , go to Step 32. If the pressure differential between port "Ma" and port "Mb" is greater than200 kPa (29 psi) , go to Step 31.Show/hide table
Illustration 15 g06156242 - Use a pass through socket wrench to loosen locknut (24) and rotate adjustment screw (25) until the pressure differential between port "Ma" and port "Mb" is equal. Hold the adjustment screw and tighten the locknut to a torque of
20 N·m (15 lb·ft) . If the pressure differential is less than200 kPa (29 psi) , go to Step 32. - Move parking brake switch (2) to the ON position.
- Move engine start switch (8) to the OFF position.
- Remove Tool (A), Tool (B), and Tool (C) from port "Mb" (13) and port "Ma" (14).
- Remove Tool (D) from port "X1" (16) and from port "X2" (15).
- Remove Tool (E) from port "X1" (16) and from port "X2" (15). Install the plugs.
- Remove Tool (G) from brake supply hose assembly (11) at the drum propel motors. Remove Tool (F) from the brake inlet port at the drum propel motors. Connect the brake supply hose to the brake inlet ports on the propel motors.
- Connect solenoid electrical connectors (11).
- Remove the tooling from the diagnostic port.
- Close the right engine compartment door
