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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the bucket and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
Note: If the machine will not move, check the fuse for the power train electronic control module (ECM). The fuse panel is located under the access panel at the right rear side of the cab. Open the cab door on the right side of the machine in order to access the fuse panel.
Perform visual checks first when you are troubleshooting a problem. Before you make these checks, stop the engine and engage the parking brake. Shift the transmission direction and speed control to the NEUTRAL position. During these checks, use a magnet to separate ferrous particles (iron) from nonferrous particles (O-ring seals, aluminum, bronze, etc), if necessary.
- Check the oil level in the differentials.
- Check the transmission oil level. Look for air bubbles in the oil or water in the oil. Many problems in the transmission are caused by low oil level or by air in the oil. Add oil to the transmission, if necessary. Refer to Operation and Maintenance Manual, SEBU7928, "Lubricant Viscosities and Refill Capacities" for the recommended oil grade and the recommended oil viscosity.
- Air bubbles may be caused by a fitting that is loose or damaged. A loose fitting or damaged fitting allows air to enter the suction side of the system and oil is also allowed to leak. Also, if the transmission oil level is too high and the gears are agitating the oil in the sump, air bubbles may result.
- A leaking transmission oil cooler may cause coolant to enter the system. Water may enter the system if the filler cap or the dipstick is not properly installed.
- Check all oil lines, all hoses, and all connections for damage and for leaks. Look for oil on the ground under the machine.
Note: If oil can leak out of a fitting or out of a connection, air can leak into the system. Air in the system is as harmful as having too little oil.
- Remove the drain plug in the bottom of the output transfer gear case in order to drain the oil from the transmission. Remove the suction screen and clean the suction screen. Inspect the oil and the suction screen for foreign material. Remove the power train oil filter and inspect the filter for foreign material. (Cut the filter open, if necessary.)
Note: There is an oil filter bypass valve on the inlet side of the power train oil filter. Whenever the pressure difference between the inlet oil and the outlet oil is more than 248 ± 21 kPa (36 ± 3 psi), the bypass valve will open and oil will be allowed to bypass the oil filter element. Any oil that does not flow through the oil filter element flows directly into the hydraulic control circuit. This dirty oil can cause valves to become stuck and valve orifices could become restricted.
- Rubber particles indicate a seal failure or a hose failure.
- Shiny steel particles indicate a mechanical failure or gear wear of the transmission or of a pump.
- A thick accumulation of fibrous material indicates worn clutch discs in the transmission.
- Aluminum particles indicate torque converter wear, a torque converter failure, or a worn clutch piston.
- Iron particles or steel particles indicate broken components in the transmission.
Note: If any of these particles are found during any visual check, all components of the transmission hydraulic system must be cleaned. Do not use any damaged parts. Any damaged parts must be removed and new parts must be installed.
- The drive shafts and universal joints must rotate freely unless cold oil is causing a resistance. If the drive shafts do not turn freely, disconnect the drive shafts and check that the transmission will turn.