To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause 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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
Note: All of the tests use 10W hydraulic oil at a temperature range of 55°C (130°F) to 65°C (150°F).
All test specifications are based on the use of DF-2 diesel fuel for the engine. Other types of fuels may produce different results.
The tests for the hydraulic system should be done in the following order. In order for the hydrostatic system to function properly, each component in the system must be set to the correct specifications. Some components must be set prior to the testing of other components. A component that is not set properly will have an impact on other components in the system.
It is not advisable to bypass preceding tests. Do not perform a test before the tests that precede that test have been done. A table lists the equipment that is needed to perform testing on the hydrostatic system. Equivalent tooling may be substituted. You will need additional wrenches, shop equipment and tools. You may need additional fittings. You may substitute additional fittings.
Clearly mark all of the hoses and the corresponding pressure gauges, when the hoses are installed. The hoses and the pressure gauges will be used multiple times in the testing and adjusting procedures.
Preparing the Machine for Testing
Close the Inching Valve
Many of the following tests require the application of the service brakes in order to prevent movement of the machine. The application of the service brakes causes the signal oil that flows to the pump to flow to the hydraulic tank. This causes hydrostatic braking. Hydrostatic braking causes the motor to upstroke and hydrostatic braking causes the pump to destroke. In order to obtain the correct pressures, the shutoff valve for hydrostatic braking is closed. This will prevent hydrostatic braking when the service brakes are depressed.
(S/N: 9WM1-87; 1WN1-94)
- The master cylinder is located under the floor panels and on the left side of the frame. Remove the nut (2) from the stud (3) .
Illustration 1 | g00492429 |
(1) Linkage. (2) Nut. (3) Stud. (4) Lever. |
- Disconnect linkage (1), which connects the inching valve to the master cylinder for the service brakes.
Note: Rotate the lever (4) fully forward toward the front of the machine. This will prevent the inching valve from actuating during the remainder of the test procedure.
(S/N: 9WM88-1298; 1WN95-898)
- The master cylinder is located under the floor panels on the left side of the frame. Linkage (5) connects the inching valve to the master cylinder for the service brakes.
Illustration 2 | g00492430 |
(5) Linkage. (6) Lever. |
- Disconnect the linkage (5) from the lever (6). The lever is attached by a ball joint with a quick release.
Note: Rotate the lever (6) fully forward toward the front of the machine. This will prevent the inching valve from actuating during the remainder of the test procedure.
Closing the Shutoff Valve (S/N: 9WM1299-UP; 1WN899-UP)
- The shutoff valve is located on the right side of the machine. Raise the engine hood. Prop the hood support.
Illustration 3 | g00474235 |
Shutoff valve (7) Stem. (8) Shutoff Valve. |
- Rotate stem (7) on shutoff valve (8) counterclockwise until the pin on the right side of the shutoff valve prevents further rotation. This blocks the hydraulic oil to the inching valve .
Deactivate the Neutralizer to the Hydrostatic System
When the parking brake is applied, the limit switch on the parking brake control lever will signal the hydrostatic system to neutralize. This procedure will allow the hydrostatic system to ignore the limit switch on the parking brake control lever.
- Remove the access panel on the lower right side of the machine by the door.
- Disable the neutralizer to the hydrostatic system by removing the parking brake alarm relay (9) and the parking brake relay (10) .
Illustration 4 | g00460744 |
Location of the Parking Brake Relay and Parking Brake Alarm Relay (9) Parking brake alarm relay. (10) Parking brake relay. |
- Insert 2G-5298 Wire Assembly or a suitable substitute into the relay panel at locations F3 (11) and D5 (12) .
Note: The 2G-5298 Wire Assembly can be substituted with the following parts:18 guage wire and two 3D-5365 Male Terminal .
Illustration 5 | g00460787 |
Jumper Wire Location (11) Location F3. (12) Location D5. |
Explanation of Tests
Do not perform any test until you understand the test.
Testing using gauges can be difficult. You can accurately perform all tests with the 131-5050 DataView Tool Group .
- Test of the Cold Start Advance
- Initial Pressure Tests
- Hydrostatic Stall Test
- Stall Test for the Work Tools
- Double Stall Test
- Starting to Move the Machine Test
- Tests for Pump Neutral
- Test of the Maximum Runout of the Pump and of the Motors
- Test of the Motor Displacement for the Large Motor
- Test of the Motor Displacement for the Small Motor
- Test of Machine Speed
- Test of Motor Signal Control Valve with the Signal Generator
- Test of Motor Signal Control Valve
- Test for the Speed Sensing Valve
- Test for the Inching Valve
- Final Tests
Note: Before testing the hydraulic system, check the performance of the engine.
Required Test Equipment and Accessories
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
9U-7330     | Digital Multimeter     | 1     |
JEBD3003     | Electronic Technician     | 1     |
7X-1700     | Communication Adapter Tool     | 1     |
8T-0846     | Gauge 0 to 1000 kPa (0 to 150 psi)     |
1     |
8T-0861     | Gauge 0 to 60000 kPa (0 to 8700 psi)     |
1     |
8T-0848     | Gauge 0 to 400 kPa (0 to 58 psi)     |
2     |
8T-0849     | Gauge 0 to 2000 kPa (0 to 290 psi)     |
1     |
8T-0850     | Gauge 0 to 4000 kPa (0 to 580 psi)     |
3     |
177-7860     | Hose Assembly     | 8     |
6V-4143     | Coupler     | 16     |
6V-3989     | Unvalved Nipple     | 8     |
1U-5481     | Gauges     | 1     |
1U-5482     | Adapter Kit     | 1     |
4C-4933     | Booster Cables     | 1     |
5P-2937     | O-Ring Adapter     | 2     |
8T-2352     | Face Seal Tee     | 1     |
6V-8397     | O-Ring Seal     | 3     |
6V-3966     | Fitting     | 4     |
6V-9829     | Cap As     | 1     |
6V-9508     | Face Seal Plug     | 1     |
6V-3989     | Fitting     | 1     |
8T-5200     | Generator and Counter Signal Group     | 1     |
131-5050     | DataView Installation Group     | 1     |
131-5051     | DataView Tool Group     | 1     |
143-4065     | Pressure Sensor (0 to 6900 kPa (0 to 1000 psi))     | 1     |
143-4066     | Pressure Sensor (0 to 51,700 kPa (0 to 7500 psi))     | 1     |
1U-7498     | Support Stand As     | 4     |
6V-4144     | Coupler     | 1     |
102-8802     | Receptacle Kit     | 2     |
9W-0852     | Connector Pin     | 2     |
6I-0755     | Connector Plug     | 1     |
Note: The following procedures can be performed without the DataView Tool Group. Caterpillar recommends the use of DataView Tool Group in order to improve accuracy.
Test of the Cold Start Advance for the Fuel Pump
The fuel injection pump contains a cold start advance unit. The cold start advance unit advances the engine timing in order to improve combustion during cold idling. The cold start advance unit contains a wax motor. The unit actuates with relatively slow response.
The engine must run normally in order to obtain the actual specifications from the machine.
- Access the fuel injection pump.
Illustration 6 | g00779314 |
- Attach the red lead of the test light or multimeter to the terminal on the bottom of the fuel injection pump. Attach the ground lead to a known ground.
Illustration 7 | g00779318 |
- Check for voltage. This may take several minutes. The machine is ready to test if the voltage or the light appears. If the voltage is not present or if the test light does not activate, then troubleshoot the electrical circuit for the cold start advance.
Note: Do not perform any of the following tests until the fuel system is operating properly.
Initial Pressure Tests
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
This test checks the following items:
- the engine rpm
- the charge pump pressure
- the pressure for the cooling loop
- the pressure for the pump case
- the signal oil pressure
- the pressure at the bank valve
- the steering pressure
The pressures are recorded, when the engine is at low idle and at high idle. During the test, the machine is in NEUTRAL. This test establishes that the machine can be tested and this test establishes a baseline for the remaining tests.
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
JEBD3003     | Electronic Technician     | 1     |
7X-1700     | Communication Adapter Tool     | 1     |
131-5050     | DataView Tool Gp     | 1     |
8T-0846     | Gauge 0 to 1000 kPa (0 to 150 psi)     |
1     |
8T-0861     | Gauge 0 to 60000 kPa (0 to 8700 psi)     |
1     |
8T-0848     | Gauge 0 to 400 kPa (0 to 58 psi)     |
2     |
8T-0849     | Gauge 0 to 2000 kPa (0 to 290 psi)     |
1     |
8T-0850     | Gauge 0 to 4000 kPa (0 to 580 psi)     |
3     |
177-7860     | Hose Assembly     | 8     |
6V-4143     | Coupler     | 16     |
6V-3989     | Unvalved Nipple     | 8     |
1U-5481     | Gauges     | 1     |
1U-5482     | Adapter Kit     | 1     |
4C-4933     | Booster Cables     | 1     |
Assembly of Gauge and Hose Assemblies
- Install 6V-3989 Unvalved Nipple to the following gauges: 8T-0846 Pressure Gauge, 8T-0848 Pressure Gauge, 8T-0849 Pressure Gauge, 8T-0850 Pressure Gauge and 8T-0861 Pressure Gauge .
- Install a hose assembly from step 1 to each of the gauges from step 2.
Performing the Initial Pressure Tests
- Raise the engine hood. Prop the hood support. Place disconnect switch (1) in the OFF position.
Illustration 8 | g00476048 |
Removing Batteries and Battery tray (1) Disconnect Switch. (2) Battery. (3) Two bolts. (4) Bolt. (5) battery tray. |
- Disconnect battery cables. Remove two bolts (3) that are on the front of battery tray (5). Loosen bolt (4).
Note: Check the thread engagement of bolt (4). Ensure that the battery tray (5) will be secured.
Note: The batteries can be attached to the machine without installation. Attach booster cables between batteries and the wire connection.
- Rotate the front side of battery tray (5) in order to access the pump.
Illustration 9 | g00491817 |
(5) Battery tray. |
- Install one 8T-0848 Pressure Gauge assembly with a range of 0 to 400 kPa (0 to 60 psi) to the pressure tap (PC) for the pump case (6) .
Illustration 10 | g00474837 |
Pressure Tap Locations on the Hydrostatic Pump (6) Pressure tap for the pump case (PC) (7) Pressure tap for the charge pump (PG) (8) Pressure tap for the signal oil (PS) |
- Install one 8T-0850 Pressure Gauge assembly with a range of 0 to 4000 kPa (0 to 580 psi) to the pressure tap (PG) for the charge pump (7) .
- Install one 8T-0850 Pressure Gauge assembly with a range of 0 to 4000 kPa (0 to 580 psi) to the pressure tap (PS) for the signal oil (8) .
- Remove access plate (9) .
Illustration 11 | g00530879 |
(9) Access plate. |
- Install one 8T-0861 Pressure Gauge assembly with a range of 0 to 60000 kPa (0 to 8700 psi) to the pressure tap for the high pressure oil of the drive loop (10) .
Note: This pressure gauge will not be used for this test. This pressure gauge was added for the stall test.
Illustration 12 | g00490808 |
(10) Pressure tap for the high pressure oil of the drive loop. |
- Clearly label the hydraulic test lines. Secure the hydraulic lines so that the pressure gauge can be viewed by the operator during the test. Do NOT hold the pressure gauge or the hydraulic line.
- Rotate battery tray (5) into the proper position. Tighten bolts (3) and (4). Ensure that the test hoses are not pinched.
Note: Do not perform this step, if booster cables connect the batteries to the cables.
Illustration 13 | g00476048 |
Installing Batteries and Battery tray (1) Disconnect Switch (2) Battery (3) Two bolts. (4) Bolt (5) Battery tray |
- Connect the battery cables.
- Place disconnect switch (1) in the ON position.
- Install one 8T-0846 Pressure Gauge assembly with a range of 0 to 1000 kPa (0 to 145 psi) to the pressure tap (CL) for the cooling loop (11) .
Illustration 14 | g00492661 |
Pressure Tap Location (S/N: 9WM1-10121WN1-659) (11) Pressure tap for the cooling loop (CL) . |
Illustration 15 | g00474831 |
Pressure Tap Location (S/N: 9WM1013-UP1WN660-UP) (11) Pressure tap for the cooling loop (CL) . |
- Install one 8T-0849 Pressure Gauge assembly with a range of 0 to 2000 kPa (0 to 300 psi) to the pressure tap (IP) for the work tools (12) .
Note: Do not move the lever for the work tools, because the pressure will exceed the maximum pressure of the pressure gauge.
Illustration 16 | g00474834 |
Pressure Tap Location (12) Pressure tap for the work tools (IP) . |
- Install the face seal tee and the nipple assembly (13) .
Illustration 17 | g00474835 |
(S/N: 9WM1-12981WN1-898) (13) Pressure tap for steering (SP) . |
Illustration 18 | g00541782 |
(S/N: 9WM1299-UP1WN899-UP) (13) Pressure tap for steering (SP) . |
- Install one 8T-0850 Pressure Gauge assembly with a range of 0 to 4000 kPa (0 to 580 psi) to the pressure tap (SP) for steering (13) .
Note: Do not move the steering wheel, because the pressure will exceed the maximum pressure of the pressure gauge.
- Install one 8T-0848 Pressure Gauge assembly with a range of 0 to 400 kPa (0 to 60 psi) to the pressure tap (SB) for the service brake (14) .
Note: Do not apply either service brake pedal, because the pressure will exceed the maximum pressure of the pressure gauge.
Illustration 19 | g00475023 |
Location of the Pressure Tap for the Service Brake (front) (14) Pressure tap for the service brake (front). |
- Clearly label the hydraulic test lines. Secure the hydraulic lines so that the pressure gauge can be viewed by the operator during the test. Do NOT hold the pressure gauge or the hydraulic line.
- Locate the service connector.
Illustration 20 | g00475147 |
The service connector for the electronic control module can be located under the right side of the cab next to the ladder. |
Illustration 21 | g00777310 |
The service connector for the electronic control module can be located at the base of the right console. |
- The engine speed can be checked with the Caterpillar Electronic Technician (ET). The 7X-1700 Communication Adapter is required in order to use ET. Use 139-4166 Data Link Cable to plug into the service connector. Use 7X-1425 Cable to connect from the data link cable to the personal computer.
- If the electronic technician is not available, then install 9U-7400 Multitach in order to record the engine speed.
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Press the speed select switch in the SLOW position. Do not move the direction control lever from the NEUTRAL position.
- Check the position of the creeper control lever. If the lever has the detent, the lever should be positioned before the detent. If the lever does not have the detent, position the lever fully forward. If necessary, see the Operation and Maintenance Manual.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature. Check the cold start solenoid.
Note: Do not move the steering wheel. The steering pressure may destroy the pressure gauge.
- Record the engine speed, the charge pump pressure, the signal oil pressure, the pressure for the pump case, the pressure for the cooling loop, the pressure at the bank valve for the work tools, and the steering pressure in Table 3.
- Increase the engine speed to high idle.
- Record the engine speed, the charge pump pressure, the signal oil pressure, the pressure for the pump case, the pressure for the cooling loop, the pressure at the bank valve for the work tools, the steering pressure, and the service brake pressure.
Show/hide table
Table 3 Initial Pressure Tests       Test     Low Idle     High Idle   Spec Actual     Spec     Actual     Engine Speed     ES     1005 ± 25 rpm         2320 ± 50 rpm         Charge Pressure     PG    
2900 ± 200 kPa (420 ± 30 psi)       
3150 ± 200 kPa (460 ± 30 psi)        Signal Oil Pressure     PS    
600 ± 200 kPa (90 ± 30 psi)       
3100 ± 300 kPa (450 ± 45 psi)        Pressure for the Pump Case     PC    
50 ± 30 kPa (7 ± 4 psi)       
135 ± 50 kPa (20 ± 7 psi)        Pressure for the Cooling Loop     CL    
225 ± 150 kPa (33 ± 22 psi)       
450 ± 125 kPa (65 ± 20 psi)        Pressure at the Bank Valve for the Work Tools     IP    
500 ± 200 kPa (73 ± 30 psi)       
1200 ± 400 kPa (175 ± 60 psi)        Steering Pressure(S/N: 9WM1-1298, 1WN1-898)     SP    
500 ± 200 kPa (75 ± 30 psi)       
1100 ± 400 kPa (160 ± 60 psi)        Steering Pressure (S/N: 9WM1299-UP, 1WN899-UP)     SP    
1000 ± 300 kPa (145 ± 45 psi)       
1300 ± 400 kPa (190 ± 60 psi)        Service Brake Pressure     SB            
0 to 20 kPa (0 to 3 psi)       
- If the engine speed is not within the specification, then refer to the Systems Operation and Testing and Adjusting, SENR5816 in order to adjust the idle speeds to the correct specifications.
- Decrease the engine to low idle. Stop the engine.
- If the pressures are within the correct specifications, then go to the next step.
- If the cooling pressure (CL) is too low, a bypass valve could be improperly assembled. The valve in the return manifold could be stuck open. If the cooling loop pressure is too high, a bypass valve could be stuck in the closed position. Also, there may be a line or a component that is restricted.
- If the signal pressure (PS) is too low or too high, verify the charge pressure on the gauge that is attached to pressure tap (6). Check the adjustment for the linkage to the inching valve for (S/N: 9WM1-1298, 1WN1-898). Refer to Systems Operation and Testing and Adjusting, SENR6772-01, "Service Brake Control - Adjust". Check that the inching valve actuates properly for (S/N: 9WM1299-UP, 1WN899-UP). Refer to Systems Operation and Testing and Adjusting, RENR2810-01, "Inching Valve - Test" for more information. Check the settings for the speed sensing valve. If the valve is not set to the correct specifications, refer to Systems Operation and Testing and Adjusting, SENR6766-03, "Speed Sensing Valve Adjustment" for the correct adjustment procedure. Check the settings for the speed sensing valve at the rated engine speed.
Note: Check the position or the adjustment of the creeper control lever. The valve for the creeper control lever reduces the signal pressure.
- If the pressure to the pump case (PC) is too low, check for a leaking lip seal. Check for leaks on the motor case. Check for a flushing valve that is stuck open. If the pump case is too high, check for a restricted line and check for a restricted component.
- If the pressure to the charge pump (PG) is not correct, a flushing valve may be stuck open or the charge relief valve is out of specification. Refer to Specifications, SENR6765, "Piston Pump (Hydrostatic)" for the specifications for the charge relief valve.
- If only the steering pressure is out of specification, then refer to Systems Operation, Testing and Adjusting for the Steering System, SENR6770-01 for (S/N: 9WM1-1298, 1WN1-898). Refer to Systems Operation, Testing and Adjusting for the Steering System, RENR2814 for (S/N: 9WM1299-UP, 1WN899-UP).
- After making, the proper adjustments repeat the initial pressure tests.
Note: If the pressures are low in low idle and the pressures are within the specifications in high idle, then this may indicate a leak.
- Remove the test lines for the service brakes (14). Remove the test line for the Work Tools (12). Remove the test line for the steering (13). Leave all the other gauges installed on the machine.
Stall Tests
These tests check the condition of the engine and the hydrostatic systems under a load. The gauges were already connected from the previous test. Use CAT Electronic Technician in order to record engine speed.
Hydrostatic Stall Test
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
This test checks that the hydrostatic drive is fit for use in a single stall condition. This test also establishes the proper settings for the valve for pressure override.
- Install chocks around the wheels.
- Remove bolt (1) .
Illustration 22 | g00533087 |
(1) Bolt. |
- Remove three bolts (2). Remove the cover for the parking brake (3) .
Illustration 23 | g00533088 |
(2) Bolts. (3) Cover for the parking brake. |
- Disengage the parking brake. Loosen nut (4). Adjust the parking brake cable (5) in order to remove 10 mm (0.40 inch) of slack. Fully engage the parking brake.
Note: The parking brake will remain adjusted during the following tests: stall test for the work tools and double stall test.
Illustration 24 | g00533089 |
(4) Nut. (5) Parking brake cable. |
- Remove the chocks from the wheels.
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position.
- Press the speed select switch in the SLOW position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Apply the service brake and hold the service brake.
- Raise the bucket or the work tool off the ground.
- Increase the engine speed to high idle.
Note: No movement of the machine is allowed. If the machine moves, refer to the Brake Systems Operation, Testing and Adjusting, SENR6772-01 for (S/N: 9WM1-12981WN1-898). Refer to the Brake Systems Operation, Testing and Adjusting, RENR2810 for (S/N: 9WM1299-UP1WN899-UP).
Note: The condition of the parking brake and the service brake may allow the machine to drive through the brakes. New brake pads and a new brake drum require a break-in period before the maximum braking capacity can be obtained. This break-in period varies and the period is dependent upon the braking applications.
- Move the direction control lever to the FORWARD position.
- Record the engine speed and the high pressure oil of the drive loop (AB). Release the accelerator pedal.
Show/hide table
Table 4 Hydrostatic Stall Test in FORWARD     Test     Spec     Actual     High Idle from Initial Pressure Test     2320 ± 50 rpm         Engine Speed at Stall             Engine Lug (Difference in Engine Speed From Initial Pressure Test and Step 14)     40 rpm or less         High Pressure Oil of the Drive Loop (AB)    
43000 ± 1000 kPa (6240 ± 150 psi)       
Note: Do not hold the drive pressure for more than 15 seconds.
- Calculate the engine lug.
- The parking brake is still engaged and the service brakes are still applied.
- Increase the engine speed to high idle.
Note: No movement of the machine is allowed. If the machine moves, refer to the Brake Systems Operation, Testing and Adjusting, SENR6772-01 for (S/N: 9WM1-12981WN1-898). Refer to the Brake Systems Operation, Testing and Adjusting, RENR2810 for (S/N: 9WM1299-UP1WN899-UP).
Note: The condition of the parking brake and the service brake may allow the machine to drive through the brakes. New brake pads and a new brake drum require a break-in period before the maximum braking capacity can be obtained. This break-in period varies and the period is dependent upon the braking applications.
- Move the direction control lever to the REVERSE position.
- Record the engine speed and the high pressure oil of the drive loop (AB). Release the accelerator pedal.
Show/hide table
Table 5 Hydrostatic Stall Test in REVERSE     Test     Spec     Actual     Engine Speed at High Idle     2320 ± 50 rpm         Engine Speed at Stall             Engine Lug (Difference in Engine Speed From Initial Pressure Test and Step 19)     60 rpm or less         High Pressure Oil of the Drive Loop (AB)    
43000 ± 2000 kPa (6250 ± 300 psi)       
Note: Do not hold the drive pressure for more than 15 seconds.
- Calculate the engine lug.
- The parking brake is still engaged. The service brakes are still applied. Move the directional control lever to the NEUTRAL position.
- Lower the bucket or the work tool to the ground. Stop the engine.
- If the engine lug is not within the specification in the FORWARD position and the engine lug is not within the specification in the REVERSE position, then check the following steps.
- If the engine lug is high, then the setting for the pressure override valve (POR) may be high. Go to Step 26.
- If the engine lug is high, then the crossover relief valve pressure setting may be low. Go to Step 25.
- If the engine lug is high and the pressures are within the specification, then there could be a problem with the engine fuel system. Refer to the 3054 Engine Systems Operation, Testing and Adjusting, SENR5816 for more information.
- If the high pressure oil of the drive loop (AB) is not within the specification in the FORWARD direction and in the REVERSE direction, then the POR valve must be adjusted. Go to the Step 26.
- If the engine lug is not in the specification in one direction with the correct high pressure oil of the drive loop (AB), then check the crossover relief valves. Go to the next step in order to check the crossover relief valves.
- To check the crossover relief valves, place the disconnect switch in the OFF position. Disconnect battery cables. Rotate the battery tray in order to access the pump. Loosen the four bolts (8) on the left side drive line. Rotate the drive line in order to access crossover relief valve (6). Switch the two crossover relief valves (6) and (7) .
- Repeat the hydrostatic stall test. If the problem moves to the other drive loop, then replace the faulty crossover relief valve.
Illustration 25 | g00475244 |
(6) Crossover relief valve for the forward direction. (7) Crossover relief valve for the reverse direction. (8) Bolts. |
- To make an adjustment to the POR valve, stop the engine. Place the disconnect switch in the OFF position. Disconnect the battery cables. Rotate the battery tray in order to access the pump. Loosen the locknut (9). Turn the adjustment screw (9) clockwise in order to increase the POR valve. Turn the adjustment screw (9) counterclockwise in order to decrease the POR valve. Tighten the locknut.
- Repeat the hydrostatic stall test.
Illustration 26 | g00475231 |
(9) Adjustment screw for the POR valve. |
Stall Test for the Work Tool System
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
8T-0852     | Gauge 0 to 40000 kPa     | 1     |
177-7860     | Hose Assembly     | 1     |
6V-4143     | Coupler     | 2     |
6V-3989     | Unvalved Nipple     | 1     |
8T-2352     | Swivel Tee     | 1     |
6V-3966     | Valved Nipple     | 1     |
6V-8397     | O-Ring Seal     | 1     |
The stall test for the work tools is performed in order to determine if the work tool system is causing a problem.
Note: If the machine is on stands, install the steering lock.
- Install one 8T-0852 Pressure Gauge assembly with a range of 0 to 40000 kPa (0 to 5800 psi) to the pressure tap for the work tools (10) .
Illustration 27 | g00491063 |
(10) Pressure tap for the main relief valve for the work tools. (11) Main relief valve for the work tools. |
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position. Fully engage the parking brake. Do not apply the service brake.
- Press the speed select switch in the SLOW position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Increase the engine speed to high idle.
- Raise the work tool off the ground. Move the bucket lever to the full TILT BACK position and hold in position.
Note: Do not hold the control lever for the work tool in the TILT BACK position for more than 15 seconds.
- Record the engine speed and the pressure at the bank valve for the work tool. Release the accelerator pedal.
Show/hide table
Table 7 Stall Test for the Work Tools     Test     Spec     Actual     Engine Speed at High Idle     2320 ± 50 rpm         Engine Speed from Step 8             Engine Lug (Difference in Engine Speed From Initial Pressure Tests and Step 8)     100 rpm or less         Pressure at the Bank Valve for the Work Tool    
24550 ± 700 kPa (3550 ± 100 psi)       
- Decrease the engine speed to low idle. Stop the engine.
- Calculate the engine lug.
- If the pressure for the work tool system is not within the specification, then adjust or replace the main relief valve for the work tools (11) .
- If the engine lug is high and the pressures are within the specification, then there could be a problem with the engine fuel system. Refer to the 3054 Engine Systems Operation, Testing and Adjusting, SENR5816 for more information.
Double Stall Test
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
This test determines that the engine output is set to the correct specification by stalling the hydrostatic system and the work tool system. This test also checks the engine condition and the setting for the POR valve.
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
8T-0852     | Gauge 0 to 40000 kPa     | 1     |
177-7860     | Hose Assembly     | 1     |
6V-4143     | Coupler     | 2     |
6V-3989     | Unvalved Nipple     | 1     |
8T-2352     | Swivel Tee     | 1     |
6V-3966     | Valved Nipple     | 1     |
6V-8397     | O-Ring Seal     | 1     |
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position. Fully engage the parking brake.
- Apply the service brake and hold the service brake.
- Place the speed selector switch in the SLOW position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Raise the work tool off the ground.
- Increase the engine speed to high idle.
Note: No movement of the machine is allowed. If the machine moves, refer to the Brake Systems Operation, Testing and Adjusting, SENR6772-01 for (S/N: 9WM1-12981WN1-898). Refer to the Brake Systems Operation, Testing and Adjusting, RENR2810 for (S/N: 9WM1299-UP1WN899-UP).
Note: The condition of the parking brake and the service brake may allow the machine to drive through the brakes. New brake pads and a new brake drum require a break-in period before the maximum braking capacity can be obtained. This break-in period varies and the period is dependent upon the braking applications.
- Move the direction control lever to the FORWARD position. Move the bucket lever to the full TILT BACK position and hold in position.
- Record the engine speed and high pressure oil of the drive loop. Release the accelerator pedal.
Show/hide table
Table 9 Hydrostatic Stall Test and the Stall Test for the Work Tool System     Test     Spec     Actual     Engine Speed at High Idle     2320 ± 50 rpm         Engine Speed from Step 9             Engine Lug (Difference in Engine Speed from Initial Pressure Test to Step 9)     less than 75 ± 55 rpm         High Pressure Oil of the Drive Loop (AB)    
43000 ± 2000 kPa (6240 ± 290 psi)       
Note: Do not hold the drive pressure for more than 15 seconds.
- Decrease the engine speed to low idle. Lower the bucket or attachment to the ground. Move the direction control lever to the NEUTRAL position. Stop the engine.
- Calculate the engine lug.
- If the engine lug is high, then check the crossover relief valve. Refer to the hydrostatic stall test.
- If the engine lug is high, then there may be low engine power. Refer to the 3054 Engine Systems Operation, Testing and Adjusting, SENR5816 for more information.
- If the engine lug is high, then perform the stall test of the work tools and the steering. Steer the machine to the right stop and stall the work tools. Check the engine speed. The speed of the engine should not be below 1980 rpm.
Note: Do not stall for more than 15 seconds.
- Install chocks around the wheels.
- Disengage the parking brake. Loosen nut (4). Adjust the parking brake cable to the original position. Fully engage the parking brake.
Illustration 28 | g00533089 |
(4) Nut. (5) Parking brake cable. |
- Install the cover for the parking brake (3). Engage the parking brake. Tighten three bolts (2) .
Illustration 29 | g00533088 |
(2) Bolts. (3) Cover for the parking brake. |
- Tighten bolt (1) .
Illustration 30 | g00533087 |
(1) Bolt. |
- Remove the chocks from the wheels.
Pump Tests
Start To Move
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
This test determines if the engine speeds and machine speeds are correct at the start of machine movement.
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
8T-0852     | Gauge 0 to 40000 kPa     | 1     |
177-7860     | Hose Assembly     | 1     |
6V-4143     | Coupler     | 2     |
6V-3989     | Unvalved Nipple     | 1     |
8T-2352     | Swivel Tee     | 1     |
6V-3966     | Valved Nipple     | 1     |
6V-8397     | O-Ring Seal     | 1     |
Note: In order to properly perform the following test, the steps that are outlined in "Preparing the Machine for Testing" must be completed.
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Press the speed select switch in the SLOW position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Place the creeper control lever just before the detent for 914G 9WM1-1989 and for IT14G, 1WN1-1491. Move the creeper control lever fully forward for other machines.
- Raise the work tool off the ground.
- Make sure that the parking brake is still engaged. Move the direction control lever to the FORWARD position.
- Increase the engine speed until the pressure gauge for high pressure oil of the drive loop indicates 8000 ± 4000 kPa (1160 ± 580 psi). Record the engine speed and signal oil pressure.
Show/hide table
Table 11 Test for the Speed Sensing Valve in the FORWARD position       Test     Spec     Actual     High Pressure Oil of the Drive Loop     AB    
8000 ± 4000 kPa (1160 ± 580 psi)        Engine Speed     EN     1065 ± 75 rpm         Signal Oil Pressure     PS    
650 ± 100 kPa (95 ± 15 psi)       
- Decrease the engine speed to low idle. Move the direction control lever to the NEUTRAL position.
- Make sure that the parking brake is still engaged. Move the direction control lever to the REVERSE position.
- Increase the engine speed until the pressure gauge for high pressure oil of the drive loop indicates 8000 ± 4000 kPa (1160 ± 580 psi). Record the engine speed and the signal oil pressure.
Show/hide table
Table 12 Test for the Speed Sensing Valve in the REVERSE position     Test     Spec     Actual     High Pressure Oil of the Drive Loop (AB)    
8000 ± 4000 kPa (1160 ± 580 psi)        Engine Speed     1065 ± 75 rpm         Signal Oil Pressure in FORWARD             Signal Oil Pressure in REVERSE             Change in Signal Oil Pressure From FORWARD to REVERSE    
± 100 kPa (± 15 psi)       
- Calculate the change in signal oil pressure from FORWARD to REVERSE.
- Lower the bucket or attachment to the ground. Decrease the engine speed to low idle. Move the direction control lever to the NEUTRAL position. Make sure that the parking brake is still engaged and stop the engine.
- If the signal pressure is within the specification and the change in signal pressure from FORWARD to REVERSE is within the specification, then go to the tests for the pump and for the motor. Skip the test for the pump neutral.
Illustration 31 | g00476343 |
(1) Adjustment Screw to the Speed Sensing Valve |
- If the signal pressure is not within the specification, then place the disconnect switch in the OFF position. Disconnect the battery cables. Rotate the battery tray in order to access the pump.
- If the signal pressure is low in both directions, then adjust the speed sensing valve. Loosen the locknut. Turn the adjustment screw (1) to the speed sensing valve counterclockwise in order to increase the pump signal pressure. Repeat this test procedure.
- If the signal pressure is high in both directions, then adjust the speed sensing valve. Loosen the locknut. Turn the adjustment screw (1) to the speed sensing valve clockwise in order to decrease the pump signal pressure. Repeat this test procedure.
- If the change in signal pressure from FORWARD to REVERSE is not within the specification or if the signal pressure is low in one direction and high in the other direction, then go to the test for the pump neutral.
Test for the Pump Neutral
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
8T-0850     | Gauge 0 to 4000 kPa     | 2     |
177-7860     | Hose Assembly     | 2     |
6V-4143     | Coupler     | 4     |
6V-3989     | Unvalved Nipple     | 2     |
5P-2937     | O-Ring Adapter     | 2     |
This test checks that the pump is fully destroked, while the machine is in the NEUTRAL position. The machine may move, if the pump is not fully destroked in the NEUTRAL position.
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Press the speed select switch in the SLOW position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature. Disengage the parking brake.
- If the machine does not move in NEUTRAL, then go to the tests for the pump and for the motor.
- If the machine moves in NEUTRAL, stop the engine.
- Place disconnect switch (2) in the OFF position. Disconnect battery cables. Remove two bolts (4). Loosen bolt (7) .
Note: Check the thread engagement on bolt (4) in order to hold the battery tray.
Illustration 32 | g00475861 |
Removing Batteries and battery tray (1) Support assembly. (2) Disconnect switch. (3) Bolts. (4) Bolts. (5) Bolts. (6) Plate. (7) Bolt. |
- Rotate the battery tray in order to access the pump.
- Remove plugs at port (8) and (9) .
Illustration 33 | g00475725 |
Pump Neutral (8) Port for the pump neutral. (9) Port for the pump neutral. (10) Adjustment for the pump actuator. |
- Install a 5P-2937 O-Ring Adapter with a 1/4 NPT test fitting in ports (8) and (9).
- Install one 8T-0850 Pressure Gauge assembly with a range of 0 to 4000 kPa (0 to 580 psi) to the fittings on port (8) .
- Install one 8T-0850 Pressure Gauge assembly with a range of 0 to 4000 kPa (0 to 580 psi) to the fittings on port (9) .
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Increase the engine speed to high idle.
- The difference between the pressures of the two gauges should be within 0 to 50 kPa (0 to 7 psi) of each other.
- If the difference between the pressures is within the specification, then remove the test equipment and reinstall plugs (8) and (9). Go to Step 19 in order to reinstall the batteries.
- If the pressures are not within the specification, then do the following steps:
- Turn adjustment screw (10) clockwise until the pressure increases in one of the two gauges. Mark the location on the screw.
- Turn adjustment screw (10) counterclockwise until the pressure increases in one of the two gauges. Mark the location on the screw.
- Turn the adjustment screw (10) clockwise to the halfway point between the two marks. Both gauges should indicate identical pressures.
- Tighten the locknut to 7 N·m (5 lb ft).
- Decrease the engine to low idle and stop the engine.
- Remove the gauges that were installed. Install plugs at port (8) and (9) .
- Rotate the battery tray into the proper position. Tighten three bolts (4) and (7) on the battery tray. Ensure that the test hoses are not pinched.
Illustration 34 | g00475861 |
Removing Batteries and Battery Tray (1) Support assembly (2) Disconnect switch (3) Bolts (4) Bolts (5) Bolts (6) Plates (7) Bolts |
- Connect the battery cables. Place the disconnect switch (2) in the ON position.
Tests for the Pump and for the Motor
Note: The following test will determine if the motor destrokes properly.
Destroking of the Motor
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Operate the machine at maximum speed in the SLOW mode.
- Select the FAST speed mode. If the machine speeds up then the motor has destroked.
- If the machine does not speed up, then perform the "Test for Pump Neutral" again.
Note: This test cannot determine if the motors are set properly. The following tests will determine if the motors are set properly.
Maximum Runout
This test checks the pump and motor displacement control. The test is used to determine if the engine speed and machine speed for the maximum speed in both speed modes are correct.
Note: This test requires the tires to be removed and this test requires the machine to be placed on stands.
Note: Table 15 should be used for a 914G high speed machine. Table 16 should be used for a IT14G high speed machine. Table 17 should be used for a 914G 20 kilometer per hour option. Table 18 should be used for a IT14G 20 kilometer per hour option.
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
1U-7498     | Stands     | 4     |
- Place the steering frame lock in the LOCKED position.
- Use ET in order to record the engine speed and the motor speed.
- Raise the machine with a suitable lifting device.
Illustration 35 | g00476696 |
Machine on Stands |
- Remove the tires. As each tire is removed, place 1U-7498 Stand under the outer end of each axle.
Note: Place the stands at the lowest height that is possible in order to increase stability.
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position.
- Press the speed select switch in the SLOW position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Move the direction control lever to the FORWARD position.
- Increase the engine speed to high idle. Read the pressure gauges. Compare these values to the columns for SLOW mode in Table 15. Move the directional control lever to the NEUTRAL position.
- Move the direction control lever to the REVERSE position.
- Increase the engine speed to high idle. Read the pressure gauges and ET. Compare these values to the columns for SLOW mode in Table 15 or Table 16. Move the directional control lever to the NEUTRAL position.
- Decrease engine speed to low idle. Move the direction control lever to the FORWARD position. Place the speed selector switch in the FAST position. Increase the engine speed to high idle.
- Compare these values to the columns for FAST mode in Table 15 or Table 16. Decrease the engine speed to low idle. Apply the service brake. Move the directional control lever to the NEUTRAL position. Stop the engine.
- Decrease the engine to low idle and stop the engine.
Maximum Runout for the 914G High Speed     |   | |||||
Item     | SLOW Mode     | FAST Mode |   | |||
Spec | Actual     | Spec     | Actual     | |||
Engine Speed     | EN     | 2310 ± 50 rpm     |     | 2250 ± 120 rpm     |     | |
Drive Shaft Speed     | DS     | 670 ± 27 rpm     |     | 2426 ± 90 rpm     |     | |
Motor Speed     | MN     | 1480 ± 60 rpm     |     | 5350 ± 200 rpm     |     | |
High Pressure Oil of the Drive Loop     | AB     | 6500 ± 1250 kPa (940 ± 180 psi)     |
    | 16600 ± 2500 kPa (2400 ± 360 psi)     |
    | |
Pump Signal     | PS     | 3050 ± 250 kPa (440 ± 35 psi)     |
    | 2900 ± 250 kPa (420 ± 36 psi)     |
    |
Maximum Runout for the IT14G High Speed     |   | |||||
Item     | SLOW Mode     | FAST Mode |   | |||
Spec | Actual     | Spec     | Actual     | |||
Engine Speed     | EN     | 2310 ± 50 rpm     |     | 2260 ± 120 rpm     |     | |
Drive Shaft Speed     | DS     | 595 ± 24 rpm     |     | 2167 ± 80 rpm     |     | |
Motor Speed     | MN     | 1480 ± 60 rpm     |     | 5390 ± 200 rpm     |     | |
High Pressure Oil of the Drive Loop     | AB     | 6500 ± 1250 kPa (940 ± 180 psi)     |
    | 16250 ± 2000 kPa (2350 ± 290 psi)     |
    | |
Pump Signal     | PS     | 3050 ± 250 kPa (440 ± 35 psi)     |
    | 2900 ± 250 kPa (420 ± 36 psi)     |
    |
Maximum Runout for the 914G 20 kilometer per hour machine     | |||||
Item     | SLOW Mode     | FAST Mode     | |||
Spec | Actual     | Spec     | Actual     | ||
Engine Speed     | EN     | 2310 ± 50 rpm     |     | 2310 ± 50 rpm     |     |
Drive Shaft Speed     | DS     | 670 ± 27 rpm     |     | 1451 ± 68 rpm     |     |
Motor Speed     | MN     | 1480 ± 60 rpm     |     | 3200 ± 150 rpm     |     |
High Pressure Oil of the Drive Loop     | AB     | 6500 ± 1250 kPa (940 ± 180 psi)     |
    | 9900 ± 1500 kPa (1435 ± 215 psi)     |
    |
Pump Signal     | PS     | 3050 ± 250 kPa (440 ± 35 psi)     |
    | 3000 ± 250 kPa (435 ± 35 psi)     |
    |
Maximum Runout for the IT14G 20 kilometer per hour machine     | |||||
Item     | SLOW Mode     | FAST Mode     | |||
Spec | Actual     | Spec     | Actual     | ||
Engine Speed     | EN     | 2310 ± 50 rpm     |     | 2310 ± 50 rpm     |     |
Drive Shaft Speed     | DS     | 595 ± 24 rpm     |     | 1447 ± 70 rpm     |     |
Motor Speed     | MN     | 1480 ± 60 rpm     |     | 3600 ± 175 rpm     |     |
High Pressure Oil of the Drive Loop     | AB     | 6500 ± 1250 kPa (940 ± 180 psi)     |
    | 10400 ± 1500 kPa (1500 ± 215 psi)     |
    |
Pump Signal     | PS     | 3050 ± 250 kPa (440 ± 35 psi)     |
    | 3000 ± 250 kPa (435 ± 35 psi)     |
    |
Setting the Maximum Runout Speed
Table 19 shows the dimension for factory settings for motor displacement control.
Illustration 36 | g00822446 |
(A) Set dimension for the Motor Displacement Control (B) Length of bolt for 20 kilometer per hour option is 70 mm (2.75 inch). Length of bolt for high speed machine is 50 mm (1.9 inch). |
Dimension for Motor Displacement Control     | |
914G High Speed     | 15 mm (0.6 inch)     |
IT14G High Speed     | 15 mm (0.6 inch)     |
914G 20 kilometer per hour machine     | 17.7 mm (0.7 inch)     |
IT14G 20 kilometer per hour machine     | 20.9 mm (0.8 inch)     |
Note: The set dimension is from the face of the jam nut to the end of the screw.
Test for the Motor Displacement Control with DataView Tool Gp
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
This test determines when the small variable displacement motor is destroking.
Note: Before the test, check the temperature of the hydraulic oil. Increase the oil temperature to 65 °C (150 °F) by starting the engine and moving the attachment.
Small Variable Displacement Motor
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
JEBD3003     | Electronic Technician     | 1     |
8T-5200     | Signal Generator     | 1     |
131-5050     | DataView Tool Gp     | 1     |
143-4065     | Pressure Sensor (0 to 6900 kPa (0 to 1000 psi))     | 1     |
143-4066     | Pressure Sensor (0 to 51,700 kPa (0 to 7500 psi))     | 1     |
6V-4144     | Coupler     | 1     |
6V-2198     | Cable     | 2     |
8T-2352     | Tee     | 2     |
6V-8397     | O-Ring Seal     | 3     |
6V-3966     | Valved Nipple Assembly     | 4     |
6V-9829     | Cap     | 1     |
6V-9508     | Face Seal Plug     | 1     |
6V-3989     | Unvalved Nipple     | 1     |
9W-0852     | Connector Pin     | 1     |
102-8802     | Receptacle Kit     | 1     |
6I-0755     | Connector Plug     | 1     |
- Assemble two 8T-2352 Face Seal Tee (2) with two 6V-8397 O-Ring Seal, two 6V-3966 Valved Nipple Assembly (3), and 6V-9829 Cap (4) .
Illustration 37 | g00476140 |
(1) Plug. (2) Tee. (3) Valved Nipple Assembly. (4) Cap. |
- Disconnect the pump signal line at port (5). Install 6V-9508 Face Seal Plug (1) and 6V-8397 O-Ring Seal onto the pump signal line. Install the assembled tee piece into port (5).
Illustration 38 | g00476141 |
(5) Forward signal line. (6) Valved nipple assembly. (7) Valved nipple assembly. |
- Install one 6V-4144 Coupler to the end of the 143-4065 Pressure Sensor (0 to 6900 kPa (0 to 1000 psi)). Install the pressure sensor to the valved nipple (7) for the MS pressure.
- Install one 6V-4144 Coupler to the end of the 143-4066 Pressure Sensor (0 to 51,700 kPa (0 to 7500 psi)). Install the pressure sensor to the port MS (8) .
Note: The MS pressure from the large variable displacement motor will be used instead of signal pressure, because the MS pressure is more stable. A signal generator will be used to control the motor signal control valve. The motor signal control valve will control the MS pressure.
Illustration 39 | g00531218 |
(8) Signal pressure for the motor (MS). |
- Install one 6V-4144 Coupler to the end of the 143-4066 Pressure Sensor (0 to 51,700 kPa (0 to 7500 psi)). Install the pressure sensor to the pressure tap for the high pressure oil of the motor M1 (9) .
Illustration 40 | g00476144 |
Location of the pressure tap for the high pressure oil (9) Pressure tap for the high pressure oil of the motor M1. |
- Clearly label the hydraulic test lines. Secure the hydraulic lines so that the pressure gauge can be viewed during the test. Do NOT hold the pressure gauge or the hydraulic line.
- Connect the 8T-5200 Signal Generator to the machine and rotate the dial to the minimum.
- Make a harness with 9U-7246 Connector Repair Kit. Follow the instructions that are provided with the kit.
Show/hide tableIllustration 41 g00808679
Harness
- Cut two wires to a length of 150 mm (6 inch).
- Use 102-8802 Receptacle Kit (11) and 9W-0852 Connector Pin (B) in order to make the harness. The receptacle kit has 3E-3364 Receptacle and 3E-3365 Wedge .
- Attach the wires to the 6I-0755 Connector Plug on pin (B) and (C) .
Note: Be sure that the wire lead from the 1 side of the 102-8802 Receptacle Kit (11) is matched with the number 1 side of the 102-8807 Plug kit (12). Match the wire lead from the 2 side of the receptacle (11) to the number 2 side of the plug (12). This is shown in Figure 41.
- Disconnect electrical harness (13). Install receptacle (11) and plug (12) of the harness from the signal generator to the electrical harness (13) .
Note: Disconnecting the drive shaft speed sensor will log a fault in the ECM as fault code 62 CID422, FMI 02). Clear the logged faults after each test with ET.
Illustration 42 | g00476432 |
(13) Electrical Harness. |
- Sit in the seat and fasten the seat belt.
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Press the speed select switch in the FAST position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Use ET in order to record the motor speed and the engine speed.
- Apply the service brakes and hold the service brakes. Move the direction control lever to the FORWARD position.
- Select the high speed mode on the signal generator. Very slowly increase the signal until the signal for the motor MS increases to 1400 kPa (230 psi). Record the M1 pressure.
- Increase the signal from the signal generator to an MS pressure of 1600 kPa (230 psi). Record the M1 pressure.
- Increase the signal from the signal generator to an MS pressure of 1800 kPa (260 psi). Record the M1 pressure.
- Increase the signal from the signal generator to an MS pressure of 2000 kPa (290 psi). Record the M1 pressure.
- Release the accelerator pedal. Move the direction control lever to the NEUTRAL position. Engage the parking brake and stop the engine.
- Plot the four points on Chart 43.
Illustration 43 | g00808635 |
OS Pressure versus M1 Pressure (A) MS Pressure (B) M1 Pressure (C) Maximum Value (D) Nominal Value (E) Minimum Value |
- If the pressures are not within the limits of the chart, then the displacement control valve must be adjusted.
- Remove the cap from the adjustment screw (14). Loosen the locknut. Mark the position of the adjustment screw (14) .
Show/hide tableIllustration 44 g00476146
Location of the Adjustment Screw for the Displacement Control Valve for the Motor
(14) Adjustment screw for the displacement control valve for the motor.
- If the point is above the line for the maximum value, then the motor will stroke too late causing the engine to lug. The pressure to the displacement control valve needs to be decreased. Turn the adjustment screw (14) clockwise in order to decrease the M1 pressure. Tighten the locknut.
- If the point is below the line for the minimum value, then the motor will stroke too soon causing the travel speed to be slow. The pressure to the displacement control valve needs to be increased. Turn the adjustment screw (14) counterclockwise in order to increase the M1 pressure. Tighten the locknut.
- Repeat the test for the motor displacement control.
- If the pressures are within the limits on the chart, then do the following steps.
- Remove the hose that connects the MS pressure (8) to the pump signal (5).
- Remove the tee fitting on port (5) .
- Connect the pump signal line to port (5) .
- Install a new tamperproof cap onto adjustment screw (14) .
Large Variable Displacement Motor
This test determines when the large variable displacement motor is destroking. A signal generator is used to signal the displacement control valve to destroke the large motor.
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
JEBD3003     | Electronic Technician     | 1     |
8T-5200     | Signal Generator     | 1     |
131-5050     | DataView Tool Gp     | 1     |
143-4065     | Pressure Sensor (0 to 6900 kPa (0 to 1000 psi))     | 1     |
143-4066     | Pressure Sensor (0 to 51,700 kPa (0 to 7500 psi))     | 1     |
6V-4144     | Coupler     | 1     |
6V-2198     | Cable     | 2     |
8T-2352     | Tee     | 2     |
6V-8397     | O-Ring Seal     | 3     |
6V-3966     | Valved Nipple Assembly     | 4     |
6V-9829     | Cap     | 1     |
6V-9508     | Face Seal Plug     | 1     |
6V-3989     | Unvalved Nipple     | 1     |
9W-0852     | Connector Pin     | 1     |
102-8802     | Receptacle Kit     | 1     |
6I-0755     | Connector Plug     | 1     |
- The 131-5050 Data View Tool Gp that was used in the "Test for the Small Variable Displacement Motor" will also be used for this test.
- Connect the 8T-5200 Signal Generator to the machine and rotate the dial to zero.
- Use the harness that was made in the previous test with 9U-7246 Connector Repair Kit .
- Disconnect plug (1) that was made for the "Test for the Small Variable Displacement Motor".
Illustration 45 | g00531269 |
(1) Plug. |
- Install one 6V-4144 Coupler to the end of the 143-4065 Pressure Sensor with a range of 0 to 6900 kPa (0 to 1000 psi). Install the pressure sensor to the pressure tap for the signal pressure for the motor (2) .
Illustration 46 | g00476441 |
(2) Signal pressure for the motor (MS). |
- Install one 6V-4144 Coupler to the end of the 143-4066 Pressure Sensor with a range of 0 to 51,700 kPa (0 to 7500 psi). Install the pressure sensor to the pressure tap for the high pressure of the large variable displacement motor MS (3) .
Illustration 47 | g00476443 |
(3) Pressure tap for the high pressure oil of the large variable displacement motor (MS). |
- Use ET in order to record the motor speed and the engine speed.
- If the 126-1355 Transmission Electronic Control Module has a 01 after the part number, then the machine has the software 1. If the 126-1355 Transmission Electronic Control Module has a 02 after the part number, then the machine has the software 2.
Show/hide tableIllustration 48 g00531298
Location of the part number and the version for the ECM
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature. Select the FAST mode on the machine.
- Select the high speed mode on the signal generator. Very slowly increase the signal until the signal for the motor MS begins to increase. There is a slight delay in the reaction of the MS pressure. After each incremental increase, wait for an increase in the MS pressure.
Note: This is the speed of the motor, when the overspeed valve is energized by the electronic control module (ECM). The overspeed valve allows charge oil to flow to the motor.
- Record the motor speed.
Show/hide table
Table 22 Test for the Energizing of the Motor Signal Control Valve     Test     Spec     Actual     Motor Speed     550 ± 50 rpm        
- Continue to very slowly increase the signal from the signal generator until the high pressure oil of the large variable displacement motor M2 begins to increase. There is a slight delay in the reaction of the signal pressure for the motor MS. After each incremental increase, wait for an increase in the MS pressure.
- Record the motor speed and the signal pressure for the motor MS. This is the point, when the motor begins to destroke.
Show/hide table
Table 23 Test for the Destroking of the Motor     Test     Spec     Actual     Signal Pressure for the Motor MS    
500 ± 200 kPa (73 ± 30 psi)        Speed of the Motor (ECM Software 1)     950 ± 200 rpm         Motor Speed (ECM Software 2)     880 ± 200 rpm        
- Increase the signal from the signal generator to a motor speed of 3000 rpm. The high pressure oil of the large variable displacement motor M2 should be equal to the charge pressure.
- Very slowly decrease the signal from the signal generator. There is a slight delay in the reaction of the hydraulic pressure. After each incremental decrease in the signal, wait for a decrease in the hydraulic pressure.
- Record the signal pressure for the motor MS and the motor speed, when the high pressure oil of the large variable displacement motor M2 decreases.
Show/hide table
Table 24 Test for the Minimum Displacement     Test     Spec     Actual     Signal Pressure for the Motor MS    
2000 ± 100 kPa (290 ± 14.5 psi)        Speed of Motor (ECM Software 1)     1975 ± 170 rpm         Motor Speed (ECM Software 2)     1760 ± 170 rpm        
- If the MS pressure is within the specification, then decrease the engine to low idle. Stop the engine and go to the next test.
- If the MS pressure is too high, then the point of control to the displacement control valve needs to be decreased. Turn the adjustment screw (3) counterclockwise in order to decrease the MS pressure. Tighten the locknut.
- If the MS pressure is too low, then the point of control to the displacement control valve needs to be increased. Turn the adjustment screw (3) clockwise in order to increase the MS pressure. Tighten the locknut.
- Repeat the test after making any adjustments.
Illustration 49 | g00531453 |
(5) Adjustment screw for the displacement control valve for the large motor |
Test of the Motor Signal Control Valve with the Signal Generator
Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the power train. |
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, 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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
This test determines if the motor signal control valve operates correctly for an overspeed condition. An overspeed condition will occur, when the motor speed is greater than 5400 rpm. The electronic control module senses the condition and the electronic control module energizes the motor signal control valve. This will cause the large motor to upstroke and the machine will decrease speed.
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
JEBD3003     | Electronic Technician     | 1     |
9U-7246     | Connector Repair Kit     | 1     |
8T-5200     | Signal Generator     | 1     |
8T-0850     | Gauge 0 to 4000 kPa     | 1     |
8T-0861     | Gauge 0 to 60000 kPa     | 1     |
177-7860     | Hose     | 2     |
6V-4143     | Coupler Assembly     | 4     |
6V-3989     | Unvalved Nipple     | 2     |
- Use the harness that was made with 9U-7246 Connector Repair Kit from the previous test. Use 8T-5200 Signal Generator that is plugged into the electrical harness (1) .
Illustration 50 | g00817606 |
(1) Electrical Harness |
- Engage the parking brake. Move the direction control lever to the NEUTRAL position.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Install one 6V-4144 Coupler to the end of the 143-4065 Pressure Sensor (0 to 6900 kPa (0 to 1000 psi)). Install the pressure sensor to the pressure tap for the signal pressure for the motor (2) .
Illustration 51 | g00476441 |
(2) Signal pressure for the motor (MS). |
- Install one 6V-4144 Coupler to the end of the 143-4066 Pressure Sensor with a range of 0 to 51,700 kPa (0 to 7500 psi). Install the pressure sensor to the pressure tap for the high pressure of the large variable displacement motor MS (3) .
Illustration 52 | g00476443 |
(3) Pressure tap for the high pressure oil of the large variable displacement motor (MS). (4) Adjustment screw for the motor displacement control for the large variable displacement motor. |
- Select the high speed mode on the signal generator. Slowly increase the signal until the high pressure oil of the large variable displacement motor M2 pressure is equal to the charge pressure.
- Record the motor speed and the MS pressure at the point just before the MS pressure decreases.
Show/hide table
Table 26 Overspeed Test RPM     Test     Spec     Actual     Motor Speed     5400 ± 200 rpm         MS Pressure    
1970 ± 150 kPa (285 ± 20 psi)       
- Decrease the engine to low idle and stop the engine.
- If the MS pressure is within the specification, go to the "Test for the Motor Signal Control Valve".
- If the MS pressure is not within the specification, then adjust the motor displacement control. Remove the cap from the adjustment screw (4). Loosen the locknut.
- If the motor speed is below the specification, then turn the adjustment screw (4) counterclockwise. Tighten the locknut.
- If the motor speed is above the specification, then turn the adjustment screw (4) clockwise. Tighten the locknut.
- Repeat the test.
Illustration 53 | g00817609 |
(4) Adjustment screw for the motor displacement control for the large variable displacement motor. |
- If the motor speed is not within the specification, the electronic control module may be malfunctioning or the motor signal control valve may need to be replaced.
Test of the Motor Signal Control Valve without the Signal Generator
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
Note: If the motor signal control valve was tested with a signal generator, continue to the next test.
This test determines if the motor signal control valve operates correctly during the condition of overspeed. An overspeed condition will occur, when the motor speed is greater than 5400 rpm. The electronic control module senses the condition and the electronic control module energizes the motor signal control valve. This will cause the large motor to upstroke and the machine will decrease speed.
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
JEBD3003     | Electronic Technician     | 1     |
2G-5298     | Wire Assembly     | 1     |
1U-7498     | Support Stand     | 4     |
131-5050     | DataView Tool Gp     | 1     |
143-4065     | Pressure Sensor (0 to 6900 kPa (0 to 1000 psi))     | 1     |
143-4066     | Pressure Sensor (0 to 51,700 kPa (0 to 7500 psi))     | 1     |
- Use ET in order to record the drive shaft speed and the engine speed.
- If an Electronic Technician is unavailable, use two 9U-7400 Multitach Tool Groups in order to measure drive shaft speed and the engine speed.
- Ensure that the machine is on four 1U-7498 Support Stand .
- Remove service code plug (1) from the harness connector. Place the 2G-5298 Wire in the harness connector between sockets 2 and 7 for the 914G machine. Place the 2G-5298 Wire in the harness connector between sockets 2 and 6 for the IT14G machine.
Illustration 54 | g00492371 |
(1) Service code plug. (2) Diagnostic indicator lamp. (3) Service Connector. (4) Electronic Control Module. |
- Enter the test mode. Turn the key switch to the ON position for five seconds. Then turn the key switch to the OFF position. Turn the key switch to the ON position and observe the diagnostic indicator lamp (2). For the 914G, a code of 21 should be indicated. For the IT14G, a code of 22 should be indicated.
Note: This procedure must be done with the Electronic Control Module (ECM) in the test mode. In the test mode, the ECM will sense an overspeed condition during normal machine operation. In the test mode, the motor will upstroke at approximately 4400 rpm. When the ECM is not in the test mode the motor will upstroke at approximately 5400 rpm.
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Start and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Press the speed select switch in the FAST position.
- Disengage the parking brake.
- Move the direction control lever to the FORWARD position.
- Slowly increase the engine speed until the MS pressure is approximately 2350 kPa (340 psi). Continue to increase the engine speed until the MS pressure decreases to a minimum pressure or until the MS pressure surges. Record the engine speed, the drive shaft speed, and the MS pressure.
Show/hide table
Table 28 Overspeed Test RPM     Test     Spec     Actual     Engine Speed     1885 ± 100 rpm         Motor Speed     4480 ± 200 rpm         MS Pressure    
1970 ± 150 kPa (285 ± 20 psi)       
- Reduce engine speed to low idle.
- Move the direction control lever to the NEUTRAL position. Apply the parking brake.
- Stop the engine.
- If the MS pressure is not within the specification, then adjust the motor displacement control. Remove the cap from the adjustment screw (5). Loosen the locknut.
- If the motor speed is below the specification, then turn the adjustment screw (5) counterclockwise. Tighten the locknut.
- If the motor speed is above the specification, then turn the adjustment screw (6) clockwise. Tighten the locknut.
- Repeat the test of the motor signal control valve.
Illustration 55 | g00531531 |
(5) Signal pressure for the large motor MS. |
- If the motor speed is not within the specification, the electronic control module may be malfunctioning or the motor signal control valve may need to be replaced.
- Remove the jumper wire that was installed in the harness connector. Install service code plug (1) .
Test for the Motor Signal Control Valve
This test determines if the output pressure of the motor signal control valve is correct for a known current input.
Determine the software on the machine before performing this test.
If the 126-1355 Transmission Electronic Control Module has a 01 after the part number, then the machine has the software 1. If the 126-1355 Transmission Electronic Control Module has a 02 after the part number, then the machine has the software 2.
Required Tools     | ||
---|---|---|
Part Number     | Description     | Quantity     |
146-4080     | Digital Multimeter     | 1     |
    | Fabricated Harness     | 1     |
102-8802     | Receptacle Kit     | 2     |
102-8807     | Connecting Plug Kit     | 1     |
8T-5200     | Signal Generator     | 1     |
8T-0850     | Pressure Gauge     | 1     |
- Disconnect the electrical harness at the motor signal control valve.
Note: If the motor signal control valve is disconnected and the key switch is turned on, the ECM will log a fault code 39.
Illustration 56 | g00822923 |
The Motor Signal Control Valve is located on top of the fuel tank for 9WM1-1298 and 1WN1-898. |
Illustration 57 | g00822924 |
The Motor Signal Control Valve is located on top of the fuel tank for 9WM1299-UP and 1WN899-UP. |
- Assemble a test harness with the 102-8802 Receptacle Kit (2) on one end and the 102-8807 Connecting Plug Kit (1) on the other end.
- Install the 102-8802 Receptacle Kit (3) of the test harness to the electrical harness of the machine.
- Install the 102-8807 Connecting Plug Kit (1) of the test harness to the motor signal control valve.
- Connect the Multimeter (5) between pin 2 of the plug kit (1) and pin 2 of the receptacle (3) .
Illustration 58 | g00822439 |
(1) Plug kit (2) Orange wire755 (3) Receptacle (4) White wire 975 (5) Multimeter |
- Connect the signal generator.
- Connect the 8T-0850 Pressure Gauge to the signal pressure port for the motor (6) .
Illustration 59 | g00823074 |
- Increase the output of the signal generator until the DC current that is measured by the DC ammeter equals the values that are listed in Tables 30 and 31. For each current value, the signal pressure for the motor MS should fall within the upper and lower pressure ranges.
- Decrease the engine to low idle. Move the direction control lever to the NEUTRAL position. Engage the parking brake and stop the engine.
- Replace the motor signal control valve if the current is not within the specifications.
114-2679 Solenoid Valve Gp     | |||
Current     | Signal Pressure (kPa)     | ||
Lower | Mean     | Upper     | |
0.0     | 0     | 0     | 0     |
0.05     | 0     | 0     | 33     |
0.1     | 0     | 60     | 190     |
0.15     | 59     | 163     | 348     |
0.2     | 224     | 327     | 505     |
0.25     | 389     | 490     | 663     |
0.3     | 553     | 653     | 820     |
0.35     | 718     | 817     | 978     |
0.4     | 883     | 980     | 1135     |
0.45     | 1048     | 1144     | 1293     |
0.5     | 1213     | 1307     | 1450     |
0.55     | 1378     | 1470     | 1608     |
0.6     | 1543     | 1634     | 1765     |
0.65     | 1708     | 1797     | 1923     |
0.7     | 1873     | 1961     | 2080     |
0.75     | 2038     | 2124     | 2238     |
0.8     | 2202     | 2287     | 2395     |
0.85     | 2367     | 2451     | 2553     |
0.9     | 2532     | 2614     | 2710     |
122-4973 Solenoid Valve Gp     | |||
Current     | Signal Pressure     | ||
Lower | Mean     | Upper     | |
0     | 0     | 0     | 0     |
0.1     | 0     | 0     | 0     |
0.2     | 0     | 0     | 87.5     |
0.3     | 0     | 75     | 288     |
0.4     | 62.5     | 286.5     | 510     |
0.5     | 312     | 556     | 800     |
0.6     | 575     | 850     | 1150     |
0.7     | 925     | 1212     | 1525     |
0.8     | 1300     | 1600     | 1900     |
0.9     | 1725     | 2025     | 2350     |
1.0     | 2125     | 2412     | 2700     |
Test for the Inching Valve
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
8T-0861     | Gauge 0 to 60000 kPa (0 to 8700 psi)     |
1     |
8T-0850     | Gauge 0 to 4000 kPa (0 to 580 psi)     |
3     |
177-7860     | Hose Assembly     | 8     |
6V-4143     | Coupler     | 16     |
6V-3989     | Unvalved Nipple     | 8     |
- Install one 8T-0850 Pressure Gauge assembly with a range of 0 to 4000 kPa (0 to 580 psi) to the pressure tap (PS) for the signal oil (1) .
Illustration 60 | g00818143 |
(1) Pressure tap for the signal oil (PS) |
- Install one 8T-0861 Pressure Gauge assembly with a range of 0 to 60000 kPa (0 to 8700 psi) to the pressure tap for the high pressure oil of the drive loop (2) .
Illustration 61 | g00818147 |
(2) Pressure tap for the high pressure oil of the drive loop. |
- Sit in the seat and fasten the seat belt. Engage the parking brake.
- Start the engine and allow the machine to reach normal operating temperature.
- With the machine at low idle, raise the empty bucket or attachment slightly.
- For (S/N: 9WM1-1299, 1WN1-900), ensure that the Hystat linkage is properly connected for this test.
- Move the directional control lever to the FORWARD direction. The parking brake is still engaged. If the machine is equipped with a speed select switch, press the speed select switch to SLOW. If the machine is equipped with a creeper speed control, move the lever for the creeper speed control all the way back into the SLOW detent.
- Increase the engine speed until the high pressure oil of the drive loop is 15000 ± 5000 kPa (2175 ± 725 psi).
- Slowly apply the service brake until the high pressure oil of the drive loop decreases to 6000 ± 2000 kPa (870 ± 290 psi).
- Record the first signal oil pressure. This pressure represents the inching pressure.
- Continue to apply the service brake until the service brake pressure is 500 ± 200 kPa (75 ± 30 psi).
- Record the second signal oil pressure. This pressure represents the braking pressure.
Show/hide table
Table 33 Test for the Inching Valve     Test     Spec     Actual     First Signal Oil Pressure     Larger         Second Signal Oil Pressure     Smaller        
- Decrease the engine to low idle and stop the engine.
- The first signal oil pressure should be larger than the second signal oil pressure. This verifies that the signal oil pressure during the inching mode is greater than the signal oil pressure during braking.
- If the first signal oil pressure is lower than the second signal oil pressure, then do one of the following steps:
- For (S/N: 9WM1-1299, 1WN1-900), check the adjustment for the inching valve. Refer to Systems Operation, Testing and Adjusting, SENR6772-01, " 914G Wheel Loader and IT14G Integrated Toolcarrier", "Service Brake Control - Adjust".
- For (S/N: 9WM1299-UP, 1WN900-UP), replace the brake valve.
Final Tests
To prevent personal injury when checks are made while the machine is in operation, make sure only approved personnel are on the machine. Keep other personnel off the machine and in view of the operator. Make sure checks are done in an open area. |
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, 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. |
REQUIRED TOOLS     | ||
Part Number     | Description     | Quantity     |
JEBD3003     | Electronic Technician     | 1     |
8T-0846     | Gauge 0 to 1000 kPa (0 to 150 psi)     |
1     |
8T-0861     | Gauge 0 to 60000 kPa (0 to 8700 psi)     |
1     |
8T-0848     | Gauge 0 to 400 kPa (0 to 58 psi)     |
2     |
8T-0849     | Gauge 0 to 2000 kPa (0 to 290 psi)     |
1     |
8T-0850     | Gauge 0 to 4000 kPa (0 to 580 psi)     |
3     |
177-7860     | Hose Assembly     | 8     |
6V-4143     | Coupler     | 16     |
6V-3989     | Unvalved Nipple     | 8     |
Do the final tests only if a pump or a motor has been replaced. If the final tests are not required, then remove all test equipment and go to the next procedure.
- Install the steering frame lock into the LOCKED position.
- Raise the machine with a suitable lifting device.
Illustration 62 | g00476696 |
Machine on Stands |
- Remove the tires. As each tire is removed, place a 1U-9760 Stand under the outer end of each axle.
Note: For maximum stability, place the stands at the lowest possible height.
- Lower the bucket or the attachment to the ground.
- Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Ensure that the proper gauge assemblies are still connected to the following test ports:pump case, the charge pump pressure, the signal oil pressure, the pressure for the cooling loop and the OS pressure.
- Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.
- Press the speed select switch in the FAST position. Move the direction control lever to the FORWARD position.
- Increase the engine speed to high idle. Record the engine speed, the pressure for the pump case, the charge pump pressure, the signal oil pressure, the pressure for the cooling loop, and the OS pressure.
Show/hide table
Table 35 Final Test for the 914G High Speed       Test     High Idle     Spec Actual     Engine Speed     EN     2270 ± 120 rpm         Motor Speed     MN     5400 ± 300 rpm         Drive Shaft Speed     DS     2448 ± 136 rpm         Charge Pressure     PG    
3100 ± 250 kPa (450 ± 36 psi)        Signal Oil Pressure     PS    
2950 ± 250 kPa (430 ± 36 psi)        Pressure for the Pump Case     PC    
125 ± 50 kPa (18 ± 7 psi)        Pressure for the Cooling Loop     CL    
400 ± 150 kPa (60 ± 20 psi)        OS Pressure     OS    
2400 ± 300 kPa (350 ± 45 psi)        Show/hide tableTable 36 Final Test for the IT14G High Speed       Test     High Idle     Spec Actual     Engine Speed     EN     2270 ± 120 rpm         Motor Speed     MS     5400 ± 300 rpm         Drive Shaft Speed     DS     2171 ± 121 rpm         Charge Pressure     PG    
3100 ± 250 kPa (450 ± 36 psi)        Signal Oil Pressure     PS    
2950 ± 250 kPa (430 ± 36 psi)        Pressure for the Pump Case     PC    
125 ± 50 kPa (18 ± 7 psi)        Pressure for the Cooling Loop     CL    
400 ± 150 kPa (60 ± 20 psi)        OS Pressure     OS    
2400 ± 300 kPa (350 ± 45 psi)       
- Decrease the engine to low idle. Move the direction control lever to the NEUTRAL position. Stop the engine.
- Place disconnect switch (1) in the OFF position.
Illustration 63 | g00476048 |
Install the batteries and the battery tray. (1) Disconnect Switch. (2) Battery. (3) Bolts. (4) Bolt. (5) Battery Tray. |
- Disconnect battery cables. Rotate the battery tray (5) in order to access the pump.
- Remove all of the test equipment.
- Rotate the battery tray (5) into the proper position. Tighten bolts (3) and (4) to a torque of 55 ± 10 N·m (40 ± 7 lb ft). Connect the battery cables. Place disconnect switch (1) in the ON position.
Returning the Machine to Operating Condition
Removing the Stands and Replacing the Tires
- Raise the machine with a suitable lifting device.
Illustration 64 | g00476696 |
Machine on Stands |
- Replace the tires. As each tire is replaced, remove a 1U-9760 Stand under the outer end of each axle.
- Lower the machine and remove the lifting device.
Open the Inching Valve
(S/N: 9WM1-87; 1WN1-94)
- Connect linkage (1), which connects the inching valve to the master cylinder for the service brakes. Remove the nut (2) from the stud (3) .
Illustration 65 | g00492429 |
(1) Linkage. (2) Nut. (3) Stud. (4) Lever. |
(S/N: 9WM88-1298; 1WN95-898)
- Connect the linkage (5) to the lever (6). The lever is attached by a ball joint with a quick release.
Illustration 66 | g00492430 |
(5) Linkage. (6) Lever. |
(S/N: 9WM1299-UP; 1WN899-UP)
- The shutoff valve is located on the right side of the machine. Raise the engine hood. Prop the hood support.
Illustration 67 | g00474235 |
Shutoff valve (7) Stem (8) Shutoff Valve |
- Rotate stem (7) on shutoff valve (8) clockwise until the pin on the shutoff valve prevents further rotation. This opens the hydraulic oil to the inching valve.
Activate the Neutralizer to the Hydrostatic System
When the parking brake is applied, the limit switch on the parking brake control lever will signal the hydrostatic system to neutralize. This procedure will allow the hydrostatic system to ignore the limit switch on the parking brake control lever.
- Remove 2G-5298 Wire Assembly from the relay panel at locations F3 (9) and D5 (10) .
Illustration 68 | g00492763 |
Jumper Wire Location (9) Location F3. (10) Location D5. |
- Enable the neutralizer to the hydrostatic system by installing the parking brake alarm relay (11) and the parking brake relay (12) .
Illustration 69 | g00492764 |
(11) Parking brake alarm relay (12) Parking brake relay |
- Install the access panel on the lower right side of the machine by the door.