IT14G Integrated Toolcarrier and 914G Wheel Loader Power Train Caterpillar


Hydrostatic System - Test and Adjust

Usage:

IT14G 1WN

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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)




    Illustration 1g00492429

    (1) Linkage. (2) Nut. (3) Stud. (4) Lever.

  1. 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) .

  1. 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)




    Illustration 2g00492430

    (5) Linkage. (6) Lever.

  1. 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.

  1. 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)




    Illustration 3g00474235

    Shutoff valve

    (7) Stem. (8) Shutoff Valve.

  1. The shutoff valve is located on the right side of the machine. Raise the engine hood. Prop the hood support.

  1. 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.

  1. Remove the access panel on the lower right side of the machine by the door.



    Illustration 4g00460744

    Location of the Parking Brake Relay and Parking Brake Alarm Relay

    (9) Parking brake alarm relay. (10) Parking brake relay.

  1. Disable the neutralizer to the hydrostatic system by removing the parking brake alarm relay (9) and the parking brake relay (10) .



    Illustration 5g00460787

    Jumper Wire Location

    (11) Location F3. (12) Location D5.

  1. 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 .

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

Table 1
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.




    Illustration 6g00779314

  1. Access the fuel injection pump.



    Illustration 7g00779318

  1. 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.

  1. 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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

Table 2
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

  1. Install one 6V-4143 Coupler Assembly to each end of each 177-7860 Hose .

  1. 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 .

  1. Install a hose assembly from step 1 to each of the gauges from step 2.

Performing the Initial Pressure Tests




    Illustration 8g00476048

    Removing Batteries and Battery tray

    (1) Disconnect Switch. (2) Battery. (3) Two bolts. (4) Bolt. (5) battery tray.

  1. Raise the engine hood. Prop the hood support. Place disconnect switch (1) in the OFF position.

  1. 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.




    Illustration 9g00491817

    (5) Battery tray.

  1. Rotate the front side of battery tray (5) in order to access the pump.



    Illustration 10g00474837

    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)

  1. 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) .

  1. 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) .

  1. 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) .



    Illustration 11g00530879

    (9) Access plate.

  1. Remove access plate (9) .



    Illustration 12g00490808

    (10) Pressure tap for the high pressure oil of the drive loop.

  1. 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.

  1. 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.



    Illustration 13g00476048

    Installing Batteries and Battery tray

    (1) Disconnect Switch

    (2) Battery

    (3) Two bolts.

    (4) Bolt

    (5) Battery tray

  1. 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.

  1. Connect the battery cables.

  1. Place disconnect switch (1) in the ON position.



    Illustration 14g00492661

    Pressure Tap Location

    (S/N: 9WM1-10121WN1-659)

    (11) Pressure tap for the cooling loop (CL) .




    Illustration 15g00474831

    Pressure Tap Location

    (S/N: 9WM1013-UP1WN660-UP)

    (11) Pressure tap for the cooling loop (CL) .

  1. 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 16g00474834

    Pressure Tap Location

    (12) Pressure tap for the work tools (IP) .

  1. 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 17g00474835

    (S/N: 9WM1-12981WN1-898)

    (13) Pressure tap for steering (SP) .




    Illustration 18g00541782

    (S/N: 9WM1299-UP1WN899-UP)

    (13) Pressure tap for steering (SP) .

  1. Install the face seal tee and the nipple assembly (13) .

  1. 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.




    Illustration 19g00475023

    Location of the Pressure Tap for the Service Brake (front)

    (14) Pressure tap for the service brake (front).

  1. 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.

  1. 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.



    Illustration 20g00475147

    The service connector for the electronic control module can be located under the right side of the cab next to the ladder.




    Illustration 21g00777310

    The service connector for the electronic control module can be located at the base of the right console.

  1. Locate the service connector.

  1. 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.

    1. If the electronic technician is not available, then install 9U-7400 Multitach in order to record the engine speed.

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. Press the speed select switch in the SLOW position. Do not move the direction control lever from the NEUTRAL position.

  1. 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.

  1. 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.

  1. 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.

  1. Increase the engine speed to high idle.

  1. 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.

    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)    
       

  1. 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.

  1. Decrease the engine to low idle. Stop the engine.

    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.

  1. If the pressures are within the correct specifications, then go to the next step.

    1. 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.

    1. 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.

    1. 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.

    1. 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.

    1. 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).

    1. After making, the proper adjustments repeat the initial pressure tests.

  1. 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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

  1. Install chocks around the wheels.



    Illustration 22g00533087

    (1) Bolt.

  1. Remove bolt (1) .



    Illustration 23g00533088

    (2) Bolts. (3) Cover for the parking brake.

  1. Remove three bolts (2). Remove the cover for the parking brake (3) .



    Illustration 24g00533089

    (4) Nut. (5) Parking brake cable.

  1. 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.

  1. Remove the chocks from the wheels.

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position.

  1. Press the speed select switch in the SLOW position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Apply the service brake and hold the service brake.

  1. Raise the bucket or the work tool off the ground.

    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.

  1. 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).

  1. Move the direction control lever to the FORWARD position.

    Note: Do not hold the drive pressure for more than 15 seconds.

  1. Record the engine speed and the high pressure oil of the drive loop (AB). Release the accelerator pedal.

    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)    
       

  1. Calculate the engine lug.

  1. The parking brake is still engaged and the service brakes are still applied.

    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.

  1. 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).

  1. Move the direction control lever to the REVERSE position.

    Note: Do not hold the drive pressure for more than 15 seconds.

  1. Record the engine speed and the high pressure oil of the drive loop (AB). Release the accelerator pedal.

    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)    
       

  1. Calculate the engine lug.

  1. The parking brake is still engaged. The service brakes are still applied. Move the directional control lever to the NEUTRAL position.

  1. Lower the bucket or the work tool to the ground. Stop the engine.

  1. 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.

    1. If the engine lug is high, then the setting for the pressure override valve (POR) may be high. Go to Step 26.

    1. If the engine lug is high, then the crossover relief valve pressure setting may be low. Go to Step 25.

    1. 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.

    1. 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.

  1. 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.



    Illustration 25g00475244

    (6) Crossover relief valve for the forward direction. (7) Crossover relief valve for the reverse direction. (8) Bolts.

  1. 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) .

    1. Repeat the hydrostatic stall test. If the problem moves to the other drive loop, then replace the faulty crossover relief valve.



    Illustration 26g00475231

    (9) Adjustment screw for the POR valve.

  1. 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.

    1. Repeat the hydrostatic stall test.

Stall Test for the Work Tool System

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.


Table 6
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.




    Illustration 27g00491063

    (10) Pressure tap for the main relief valve for the work tools. (11) Main relief valve for the work tools.

  1. 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) .

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position. Fully engage the parking brake. Do not apply the service brake.

  1. Press the speed select switch in the SLOW position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Increase the engine speed to high idle.

  1. 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.

  1. Record the engine speed and the pressure at the bank valve for the work tool. Release the accelerator pedal.

    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)    
       

  1. Decrease the engine speed to low idle. Stop the engine.

  1. Calculate the engine lug.

  1. 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) .

  1. 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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

Table 8
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    

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position. Fully engage the parking brake.

  1. Apply the service brake and hold the service brake.

  1. Place the speed selector switch in the SLOW position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Raise the work tool off the ground.

    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.

  1. 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).

  1. Move the direction control lever to the FORWARD position. Move the bucket lever to the full TILT BACK position and hold in position.

    Note: Do not hold the drive pressure for more than 15 seconds.

  1. Record the engine speed and high pressure oil of the drive loop. Release the accelerator pedal.

    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)    
       

  1. 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.

  1. Calculate the engine lug.

  1. If the engine lug is high, then check the crossover relief valve. Refer to the hydrostatic stall test.

  1. 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.

  1. 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.

  1. Install chocks around the wheels.



    Illustration 28g00533089

    (4) Nut. (5) Parking brake cable.

  1. Disengage the parking brake. Loosen nut (4). Adjust the parking brake cable to the original position. Fully engage the parking brake.



    Illustration 29g00533088

    (2) Bolts. (3) Cover for the parking brake.

  1. Install the cover for the parking brake (3). Engage the parking brake. Tighten three bolts (2) .



    Illustration 30g00533087

    (1) Bolt.

  1. Tighten bolt (1) .

  1. Remove the chocks from the wheels.

Pump Tests

Start To Move

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

Table 10
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.

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. Press the speed select switch in the SLOW position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. 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.

  1. Raise the work tool off the ground.

  1. Make sure that the parking brake is still engaged. Move the direction control lever to the FORWARD position.

  1. 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.

    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)    
       

  1. Decrease the engine speed to low idle. Move the direction control lever to the NEUTRAL position.

  1. Make sure that the parking brake is still engaged. Move the direction control lever to the REVERSE position.

  1. 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.

    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)    
       

  1. Calculate the change in signal oil pressure from FORWARD to REVERSE.

  1. 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.



    Illustration 31g00476343

    (1) Adjustment Screw to the Speed Sensing Valve

  1. 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.

  1. 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.

    1. 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.

    1. 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.

  1. 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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

Table 13
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.

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. Press the speed select switch in the SLOW position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature. Disengage the parking brake.

  1. If the machine does not move in NEUTRAL, then go to the tests for the pump and for the motor.

  1. If the machine moves in NEUTRAL, stop the engine.



    Illustration 32g00475861

    Removing Batteries and battery tray

    (1) Support assembly. (2) Disconnect switch. (3) Bolts. (4) Bolts. (5) Bolts. (6) Plate. (7) Bolt.

  1. 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.

  1. Rotate the battery tray in order to access the pump.



    Illustration 33g00475725

    Pump Neutral

    (8) Port for the pump neutral. (9) Port for the pump neutral. (10) Adjustment for the pump actuator.

  1. Remove plugs at port (8) and (9) .

  1. Install a 5P-2937 O-Ring Adapter with a 1/4 NPT test fitting in ports (8) and (9).

  1. 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) .

  1. 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) .

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Increase the engine speed to high idle.

  1. The difference between the pressures of the two gauges should be within 0 to 50 kPa (0 to 7 psi) of each other.

  1. 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.

  1. If the pressures are not within the specification, then do the following steps:

    1. Turn adjustment screw (10) clockwise until the pressure increases in one of the two gauges. Mark the location on the screw.

    1. Turn adjustment screw (10) counterclockwise until the pressure increases in one of the two gauges. Mark the location on the screw.

    1. Turn the adjustment screw (10) clockwise to the halfway point between the two marks. Both gauges should indicate identical pressures.

    1. Tighten the locknut to 7 N·m (5 lb ft).

  1. Decrease the engine to low idle and stop the engine.

  1. Remove the gauges that were installed. Install plugs at port (8) and (9) .



    Illustration 34g00475861

    Removing Batteries and Battery Tray

    (1) Support assembly

    (2) Disconnect switch

    (3) Bolts

    (4) Bolts

    (5) Bolts

    (6) Plates

    (7) Bolts

  1. 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.

  1. 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

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Operate the machine at maximum speed in the SLOW mode.

  1. Select the FAST speed mode. If the machine speeds up then the motor has destroked.

  1. 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.

Table 14
REQUIRED TOOLS    
Part Number     Description     Quantity    
1U-7498     Stands     4    

  1. Place the steering frame lock in the LOCKED position.

  1. Use ET in order to record the engine speed and the motor speed.



    Illustration 35g00476696

    Machine on Stands

  1. Raise the machine with a suitable lifting device.

  1. 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.

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position.

  1. Press the speed select switch in the SLOW position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Move the direction control lever to the FORWARD position.

  1. 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.

  1. Move the direction control lever to the REVERSE position.

  1. 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.

  1. 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.

  1. 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.

  1. Decrease the engine to low idle and stop the engine.

Table 15
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)    
   

Table 16
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)    
   

Table 17
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)    
   

Table 18
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 36g00822446

(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).

Table 19
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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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

Table 20
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    



    Illustration 37g00476140

    (1) Plug. (2) Tee. (3) Valved Nipple Assembly. (4) Cap.

  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 38g00476141

    (5) Forward signal line. (6) Valved nipple assembly. (7) Valved nipple assembly.

  1. 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).

  1. 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.



    Illustration 39g00531218

    (8) Signal pressure for the motor (MS).

  1. 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.

    1. Install one 6V-4143 Coupler Assembly to each end of the 177-7860 Hose. Install one end of the hose assembly to the pressure tap for MS pressure (8). Install the other end of the hose assembly to the valved nipple assembly (6) .



    Illustration 40g00476144

    Location of the pressure tap for the high pressure oil

    (9) Pressure tap for the high pressure oil of the motor M1.

  1. 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) .

  1. 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.

  1. Connect the 8T-5200 Signal Generator to the machine and rotate the dial to the minimum.



      Illustration 41g00808679

      Harness

    1. Make a harness with 9U-7246 Connector Repair Kit. Follow the instructions that are provided with the kit.

    1. Cut two wires to a length of 150 mm (6 inch).

    1. 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 .

    1. 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.




    Illustration 42g00476432

    (13) Electrical Harness.

  1. 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.

  1. Sit in the seat and fasten the seat belt.

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. Press the speed select switch in the FAST position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Use ET in order to record the motor speed and the engine speed.

  1. Apply the service brakes and hold the service brakes. Move the direction control lever to the FORWARD position.

  1. 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.

  1. Increase the signal from the signal generator to an MS pressure of 1600 kPa (230 psi). Record the M1 pressure.

  1. Increase the signal from the signal generator to an MS pressure of 1800 kPa (260 psi). Record the M1 pressure.

  1. Increase the signal from the signal generator to an MS pressure of 2000 kPa (290 psi). Record the M1 pressure.

  1. Release the accelerator pedal. Move the direction control lever to the NEUTRAL position. Engage the parking brake and stop the engine.



    Illustration 43g00808635

    OS Pressure versus M1 Pressure

    (A) MS Pressure

    (B) M1 Pressure

    (C) Maximum Value

    (D) Nominal Value

    (E) Minimum Value

  1. Plot the four points on Chart 43.

  1. If the pressures are not within the limits of the chart, then the displacement control valve must be adjusted.



      Illustration 44g00476146

      Location of the Adjustment Screw for the Displacement Control Valve for the Motor

      (14) Adjustment screw for the displacement control valve for the motor.

    1. Remove the cap from the adjustment screw (14). Loosen the locknut. Mark the position of the adjustment screw (14) .

    1. 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.

    1. 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.

    1. Repeat the test for the motor displacement control.

  1. If the pressures are within the limits on the chart, then do the following steps.

    1. Remove the hose that connects the MS pressure (8) to the pump signal (5).

    1. Remove the tee fitting on port (5) .

    1. Connect the pump signal line to port (5) .

  1. 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.

Table 21
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    

  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.

  1. Connect the 8T-5200 Signal Generator to the machine and rotate the dial to zero.

    1. Use the harness that was made in the previous test with 9U-7246 Connector Repair Kit .



    Illustration 45g00531269

    (1) Plug.

  1. Disconnect plug (1) that was made for the "Test for the Small Variable Displacement Motor".



    Illustration 46g00476441

    (2) Signal pressure for the motor (MS).

  1. 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 47g00476443

    (3) Pressure tap for the high pressure oil of the large variable displacement motor (MS).

  1. 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) .

  1. Use ET in order to record the motor speed and the engine speed.



      Illustration 48g00531298

      Location of the part number and the version for the ECM

    1. 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.

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. 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.

  1. 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.

  1. Record the motor speed.

    Table 22
    Test for the Energizing of the Motor Signal Control Valve    
    Test     Spec     Actual    
    Motor Speed     550 ± 50 rpm        

  1. 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.

  1. Record the motor speed and the signal pressure for the motor MS. This is the point, when the motor begins to destroke.

    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        

  1. 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.

  1. 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.

  1. 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.

    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        



    Illustration 49g00531453

    (5) Adjustment screw for the displacement control valve for the large motor

  1. If the MS pressure is within the specification, then decrease the engine to low idle. Stop the engine and go to the next test.

    1. 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.

    1. 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.

    1. Repeat the test after making any adjustments.

Test of the Motor Signal Control Valve with the Signal Generator

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

Table 25
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    



    Illustration 50g00817606

    (1) Electrical Harness

  1. 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) .

  1. Engage the parking brake. Move the direction control lever to the NEUTRAL position.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.



    Illustration 51g00476441

    (2) Signal pressure for the motor (MS).

  1. 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 52g00476443

    (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.

  1. 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) .

  1. 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.

  1. Record the motor speed and the MS pressure at the point just before the MS pressure decreases.

    Table 26
    Overspeed Test RPM    
    Test     Spec     Actual    
    Motor Speed     5400 ± 200 rpm        
    MS Pressure    
    1970 ± 150 kPa (285 ± 20 psi)    
       

  1. Decrease the engine to low idle and stop the engine.

  1. If the MS pressure is within the specification, go to the "Test for the Motor Signal Control Valve".



    Illustration 53g00817609

    (4) Adjustment screw for the motor displacement control for the large variable displacement motor.

  1. 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.

    1. If the motor speed is below the specification, then turn the adjustment screw (4) counterclockwise. Tighten the locknut.

    1. If the motor speed is above the specification, then turn the adjustment screw (4) clockwise. Tighten the locknut.

    1. Repeat the test.

  1. 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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

Table 27
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    

  1. Use ET in order to record the drive shaft speed and the engine speed.

    1. If an Electronic Technician is unavailable, use two 9U-7400 Multitach Tool Groups in order to measure drive shaft speed and the engine speed.

  1. Ensure that the machine is on four 1U-7498 Support Stand .



    Illustration 54g00492371

    (1) Service code plug. (2) Diagnostic indicator lamp. (3) Service Connector. (4) Electronic Control Module.

  1. 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.

  1. 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.

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. Start and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Press the speed select switch in the FAST position.

  1. Disengage the parking brake.

  1. Move the direction control lever to the FORWARD position.

  1. 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.

    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)    
       

  1. Reduce engine speed to low idle.

  1. Move the direction control lever to the NEUTRAL position. Apply the parking brake.

  1. Stop the engine.



    Illustration 55g00531531

    (5) Signal pressure for the large motor MS.

  1. 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.

    1. If the motor speed is below the specification, then turn the adjustment screw (5) counterclockwise. Tighten the locknut.

    1. If the motor speed is above the specification, then turn the adjustment screw (6) clockwise. Tighten the locknut.

    1. Repeat the test of the motor signal control valve.

  1. 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.

  1. 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.

Table 29
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    



    Illustration 56g00822923

    The Motor Signal Control Valve is located on top of the fuel tank for 9WM1-1298 and 1WN1-898.




    Illustration 57g00822924

    The Motor Signal Control Valve is located on top of the fuel tank for 9WM1299-UP and 1WN899-UP.

  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.

  1. 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.

  1. Install the 102-8802 Receptacle Kit (3) of the test harness to the electrical harness of the machine.

  1. Install the 102-8807 Connecting Plug Kit (1) of the test harness to the motor signal control valve.



    Illustration 58g00822439

    (1) Plug kit

    (2) Orange wire755

    (3) Receptacle

    (4) White wire 975

    (5) Multimeter

  1. Connect the Multimeter (5) between pin 2 of the plug kit (1) and pin 2 of the receptacle (3) .

  1. Connect the signal generator.



    Illustration 59g00823074

  1. Connect the 8T-0850 Pressure Gauge to the signal pressure port for the motor (6) .

  1. 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.

  1. Decrease the engine to low idle. Move the direction control lever to the NEUTRAL position. Engage the parking brake and stop the engine.

  1. Replace the motor signal control valve if the current is not within the specifications.

Table 30
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    

Table 31
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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

Table 32
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    



    Illustration 60g00818143

    (1) Pressure tap for the signal oil (PS)

  1. 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 61g00818147

    (2) Pressure tap for the high pressure oil of the drive loop.

  1. 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) .

  1. Sit in the seat and fasten the seat belt. Engage the parking brake.

  1. Start the engine and allow the machine to reach normal operating temperature.

  1. With the machine at low idle, raise the empty bucket or attachment slightly.

  1. For (S/N: 9WM1-1299, 1WN1-900), ensure that the Hystat linkage is properly connected for this test.

  1. 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.

  1. Increase the engine speed until the high pressure oil of the drive loop is 15000 ± 5000 kPa (2175 ± 725 psi).

  1. Slowly apply the service brake until the high pressure oil of the drive loop decreases to 6000 ± 2000 kPa (870 ± 290 psi).

  1. Record the first signal oil pressure. This pressure represents the inching pressure.

  1. Continue to apply the service brake until the service brake pressure is 500 ± 200 kPa (75 ± 30 psi).

  1. Record the second signal oil pressure. This pressure represents the braking pressure.

    Table 33
    Test for the Inching Valve    
    Test     Spec     Actual    
    First Signal Oil Pressure     Larger        
    Second Signal Oil Pressure     Smaller        

  1. Decrease the engine to low idle and stop the engine.

  1. 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.

  1. If the first signal oil pressure is lower than the second signal oil pressure, then do one of the following steps:

    1. 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".

    1. For (S/N: 9WM1299-UP, 1WN900-UP), replace the brake valve.

Final Tests

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

Table 34
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.

  1. Install the steering frame lock into the LOCKED position.



    Illustration 62g00476696

    Machine on Stands

  1. Raise the machine with a suitable lifting device.

  1. 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.

  1. Lower the bucket or the attachment to the ground.

  1. Move the direction control lever to the NEUTRAL position. Engage the parking brake.

  1. 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.

  1. Start the engine and run the engine at low idle. Allow the engine to reach normal operating temperature.

  1. Press the speed select switch in the FAST position. Move the direction control lever to the FORWARD position.

  1. 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.

    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)    
       

    Table 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)    
       

  1. Decrease the engine to low idle. Move the direction control lever to the NEUTRAL position. Stop the engine.



    Illustration 63g00476048

    Install the batteries and the battery tray.

    (1) Disconnect Switch. (2) Battery. (3) Bolts. (4) Bolt. (5) Battery Tray.

  1. Place disconnect switch (1) in the OFF position.

  1. Disconnect battery cables. Rotate the battery tray (5) in order to access the pump.

  1. Remove all of the test equipment.

  1. 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




    Illustration 64g00476696

    Machine on Stands

  1. Raise the machine with a suitable lifting device.

  1. Replace the tires. As each tire is replaced, remove a 1U-9760 Stand under the outer end of each axle.

  1. Lower the machine and remove the lifting device.

Open the Inching Valve

(S/N: 9WM1-87; 1WN1-94)




    Illustration 65g00492429

    (1) Linkage. (2) Nut. (3) Stud. (4) Lever.

  1. Connect linkage (1), which connects the inching valve to the master cylinder for the service brakes. Remove the nut (2) from the stud (3) .

(S/N: 9WM88-1298; 1WN95-898)




    Illustration 66g00492430

    (5) Linkage. (6) Lever.

  1. Connect the linkage (5) to the lever (6). The lever is attached by a ball joint with a quick release.

(S/N: 9WM1299-UP; 1WN899-UP)




    Illustration 67g00474235

    Shutoff valve

    (7) Stem

    (8) Shutoff Valve

  1. The shutoff valve is located on the right side of the machine. Raise the engine hood. Prop the hood support.

  1. 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.




    Illustration 68g00492763

    Jumper Wire Location

    (9) Location F3. (10) Location D5.

  1. Remove 2G-5298 Wire Assembly from the relay panel at locations F3 (9) and D5 (10) .



    Illustration 69g00492764

    (11) Parking brake alarm relay

    (12) Parking brake relay

  1. Enable the neutralizer to the hydrostatic system by installing the parking brake alarm relay (11) and the parking brake relay (12) .

  1. Install the access panel on the lower right side of the machine by the door.

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