D3G, D4G and D5G Track-Type Tractors Electrohydraulic Power Train Systems Caterpillar

Worksheets - Troubleshoot

Usage:

D3G CFC

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Table 1
TROUBLESHOOTING WORKSHEET FOR INITIAL PRESSURE TESTS
Date	Product Identification Number
Initial Tests at LOW IDLE
Item	Specification	Actual
Engine Speed	850 ± 50 RPM
Charge Oil Pressure for the Front Pump	2300 ± 225 kPa (330 ± 30 psi)
Charge Oil Pressure for the Rear Pump	2300 ± 225 kPa (330 ± 30 psi)
Cooling Loop Pressure	200 ± 100 kPa (29 ± 15 psi)
Case Drain Pressure	30 ± 20 kPa (4 ± 3 psi)
Implement Pressure	300 ± 200 kPa (44 ± 29 psi)
Parking Brake Oil Pressure	2300 ± 200 kPa (330 ± 30psi)
Initial Tests at Rated RPM
Item	Specification	Actual
Engine Speed	2550 ± 50 RPM
Charge Oil Pressure for the Front Pump	2500 ± 150 kPa (363 ± 22 psi)
Charge Oil Pressure for the Rear Pump	2500 ± 150 kPa (363 ± 22 psi)
Cooling Loop Pressure	550 ± 150 kPa (80 ± 22 psi)
Case Drain Pressure	100 ± 50 kPa (15 ± 7 psi)
Implement Pressure	1400 ± 400 kPa (205 ± 58 psi)
Parking Brake Oil Pressure	2500 ± 150 kPa (363 ± 22 psi)
Initial Test at HIGH IDLE
Item	Specification	Actual
Engine Speed	2550 ± 50 RPM

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Table 2
TROUBLESHOOTING WORKSHEET FOR THE SERVICE BRAKE TEST
Date	Product Identification Number
Item	Specification	Actual
Parking Brake Oil Pressure
The Service Brake Is Released.	2500 ± 150 kPa (363 ± 22 psi)
The Service Brake Is Applied.	100 ± 100 kPa (15 ± 15 psi)

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Table 3
TROUBLESHOOTING WORKSHEET FOR THE DECELERATION PEDAL TEST
Date	Product Identification Number
The Deceleration Pedal Is Depressed.
Item	Specification	Actual
Engine Speed	850 ± 50 RPM
Left Motor Speed	0 to 20 RPM
Right Motor Speed	0 to 20 RPM

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Table 4
TROUBLESHOOTING WORKSHEET FOR THE IMPLEMENT STALL TEST
Date	Product Identification Number
Item	Specification	Actual
Engine Speed before Stall	2550 ± 50 RPM
Engine Speed during Stall	Actual Engine Speed
Engine Lug (Engine Speed before Stall − Engine Speed during Stall)	65 RPM
Implement Pressure	20600 ± 350 kPa (2990 ± 50 psi)

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Table 5
TROUBLESHOOTING WORKSHEET FOR THE HYDROSTATIC STALL TEST
Date	Product Identification Number
Hydrostatic Stall Test in the FORWARD Position
Item	Specification	Actual
Engine Speed before Stall	High Idle
Engine Speed during Stall
Engine Lug (Engine Speed before Stall − Engine Speed during Stall)	40 ± 20 RPM
Drive Loop Pressure for the Front Pump	44000 ± 1000 kPa (6400 ± 150 psi)
Drive Loop Pressure for the Rear Pump	44000 ± 1000 kPa (6400 ± 150 psi)
Hydrostatic Stall Test in the REVERSE Position
Item	Specification	Actual
Engine Speed before Stall	High Idle
Engine Speed during Stall
Engine Lug (Engine Speed before Stall − Engine Speed during Stall)	40 ± 20 RPM
Drive Loop Pressure for the Front Pump	44000 ± 1000 kPa (6400 ± 150 psi)
Drive Loop Pressure for the Rear Pump	44000 ± 1000 kPa (6400 ± 150 psi)

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Table 6
TROUBLESHOOTING WORKSHEET FOR THE HYDROSTATIC AND IMPLEMENT STALL TEST
Date	Product Identification Number
Hydrostatic Stall in the FORWARD Position and Implement Stall in the TILT RIGHT position
Item	Specification	Actual
Engine Speed before Stall	High Idle
Engine Speed during Stall
Engine Lug (Engine Speed before Stall − Engine Speed during Stall)	100 ± 40 RPM
Drive Loop Pressure for the Front Pump	44000 ± 1000 kPa (6400 ± 150 psi)
Drive Loop Pressure for the Rear Pump	44000 ± 1000 kPa (6400 ± 150 psi)
Implement Pressure	20600 ± 350 kPa (2990 ± 50 psi)

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Table 7
SPEED PARAMETERS OF THE ELECTRONIC CONTROL MODULE (ECM)
Date	Software Version
Parameter	Default	Actual
Forward Maximum Ground Speed	9.0 km/h (5.6 mph)
Reverse Maximum Ground Speed	9.7 km/h (6.0 mph)
Reverse Speed as a percent of Forward Speed	125%

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Table 8
TROUBLESHOOTING WORKSHEET FOR THE FINAL HYDROSTATIC SPEED TEST
Date	Product Identification Number
Hydrostatic Speed Test in the FORWARD Position
Item	D3G, D4G Specification	D5G Specification	Actual
Engine Speed	2480 ± 60 RPM	2500 ± 60 RPM
Drive Loop Pressure for the Front Pump	7000 ± 2000 kPa (1015 ± 290 psi)
Drive Loop Pressure for the Rear Pump	7000 ± 2000 kPa (1015 ± 290 psi)
Speed of the Left Drive Motor	3158± 160 RPM	3122 ± 160 RPM
Speed of the Right Drive Motor	3158± 160 RPM	3122 ± 160 RPM
Hydrostatic Speed Test in the REVERSE Position
Item	D3G, D4G Specification	D5G Specification	Actual
Engine Speed	2480 ± 60 RPM	2500 ± 60 RPM
Drive Loop Pressure for the Front Pump	7000 ± 2000 kPa (1015 ± 290 psi)
Drive Loop Pressure for the Rear Pump	7000 ± 2000 kPa (1015 ± 290 psi)
Speed of the Left Drive Motor	-3384± 160 RPM	-3345± 160 RPM
Speed of the Right Drive Motor	-3384± 160 RPM	-3345± 160 RPM

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Table 9
SPEED PARAMETERS OF THE ELECTRONIC CONTROL MODULE (ECM)
Date	Software Version
Parameter	Default	Actual
Forward Maximum Ground Speed	9.0 km/h (5.6 mph)
Reverse Maximum Ground Speed	9.7 km/h (6.0 mph)
Reverse Speed as a percent of Forward Speed	125%

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Table 10
TROUBLESHOOTING WORKSHEET FOR THE STEERING TEST IN THE FORWARD POSITION.
Date	Product Identification Number
Steering and Transmission Control in the full LEFT Position
Item	D3G, D4G Specification	D5G Specification	Actual
Engine Speed	2490 ± 100 RPM	2510 ± 100 RPM
Drive Loop Pressure for the Front Pump	5000 ± 1250 kPa (725 ± 180 psi)
Drive Loop Pressure for the Rear Pump	5000 ± 1250 kPa (725 ± 180 psi)
Speed of the Left Drive Motor	-2105 ± 100 RPM	-2081 ± 100 RPM
Speed of the Right Drive Motor	2150 ± 100 RPM	2081 ± 100 RPM
Steering and Transmission Control in the full RIGHT Position
Item	D3G, D4G Specification	D5G Specification	Actual
Engine Speed	2490 ± 100 RPM	2510 ± 100 RPM
Drive Loop Pressure for the Front Pump	5000 ± 1250 kPa (725 ± 180 psi)
Drive Loop Pressure for the Rear Pump	5000 ± 1250 kPa (725 ± 180 psi)
Speed of the Left Drive Motor	2150 ± 100 RPM	2081 ± 100 RPM
Speed of the Right Drive Motor	-2105 ± 100 RPM	-2081 ± 100 RPM

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Table 11
TROUBLESHOOTING WORKSHEET FOR THE STEERING TEST IN THE REVERSE POSITION.
Date	Product Identification Number
Steering and Transmission Control in the full LEFT Position
Item	D3G, D4G Specification	D5G Specification	Actual
Engine Speed	2490 ± 100 RPM	2510 ± 100 RPM
Drive Loop Pressure for the Front Pump	5000 ± 1250 kPa (725 ± 180 psi)
Drive Loop Pressure for the Rear Pump	5000 ± 1250 kPa (725 ± 180 psi)
Speed of the Left Drive Motor	2256 ± 100 RPM	2230 ± 100 RPM
Speed of the Right Drive Motor	-2256 ± 100 RPM	-2230 ± 100 RPM
Steering and Transmission Control in the full RIGHT Position
Item	D3G, D4G Specification	D5G Specification	Actual
Engine Speed	2490 ± 100 RPM	2510 ± 100 RPM
Drive Loop Pressure for the Front Pump	5000 ± 1250 kPa (725 ± 180 psi)
Drive Loop Pressure for the Rear Pump	5000 ± 1250 kPa (725 ± 180 psi)
Speed of the Left Drive Motor	-2256 ± 100 RPM	-2230 ± 100 RPM
Speed of the Right Drive Motor	2256 ± 100 RPM	2230 ± 100 RPM

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Table 12
TROUBLESHOOTING WORKSHEET FOR THE PUMP AND MOTOR MAXIMUM DISPLACEMENT TEST
Date	Product Identification Number
Pump and Motor Maximum Displacement Test in FORWARD Position
Item	D3G, D4G Specification	D5G Specification	Actual
Engine Speed	High Idle
Left Motor Speed	0.700 times Engine Speed	.0.523 times Engine Speed
Right Motor Speed