| REQUIRED TOOLS | ||
| Part Number | Description | Quantity |
| 4C-9710 | Hand Pump | 1 |
| 8T-0850 | Gauge 0 to 4000 kPa | 1 |
| 8T-0861 | Gauge 0 to 60000 kPa | 1 |
| 6V-3014 | Hose Assembly | 4 |
| 6V-4143 | Coupler | 6 |
| 6V-3989 | Unvalved Nipple | 2 |
| 1U-5482 | Gauges | 1 |
| 1U-5481 | Adapter Kit | 1 |
| 5P-2937 | Adapter | 1 |
| 6V-3966 | Valved Nipple | 1 |
Fill the Hydrostatic System
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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. |
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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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| NOTICE |
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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 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. |
Fill the Pump Case
- Raise the engine hood. Prop the hood support. Place disconnect switch (1) in the OFF position.
Note: The hood support should be used at all times. The gas springs assist only.
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| Illustration 1 | g00472547 |
Removing Batteries and Battery Tray (1) Disconnect Switch. (2) Battery. (3) Two bolts. (4) Bolt. (5) Battery tray. | |
- Disconnect battery cables.
- Remove two bolts (3) that are on the front of battery tray (5). Loosen bolt (4) on the rear of battery tray (5) .
Note: Ensure that there is enough thread engagement on bolt (4) to hold battery tray (5) .
- Rotate the front side of battery tray (5) in order to access the pump.
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| Illustration 2 | g00492823 |
- Remove the hydraulic tank filler cap. Loosen the pressure tap for pump case (6). Do one of the following procedures. Filling the pump case through the filters is the preferred method. The hydraulic oil that is being added should be filtered and free of moisture. As a recommendation, the hydraulic oil that is added to the system should pass ISO 16/13. The ISO 16/13 is shown in Table 2.
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Table 2 Hydraulic Oil Contamination Particle Size (Microns) Maximum Number of Particles in a 100 mL Sample >5 64000 >15 8000 - If the machine contains port (7), then install a 6V-4143 Coupler Assembly to the end of the hose from 4C-9710 Hand Pump. Install the hose to port (7). Add oil to the system until oil begins to flow around the loose pressure tap (6). Tighten pressure tap (6) .
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Illustration 4 g00530653
(PIN: 7ZM192-UP8ZM161-UP)
(7) Port for filling.
Note: Do not exceed 3500 kPa (500 psi) in order to fill the charge circuit. Seal failure could result.
- If the machine does not contain port (7), then remove the fluid sampling valve from port (8). Install 5P-2937 O-Ring Adapter to port (8). Install 6V-3966 Valved Nipple Assembly to the O-Ring Adapter. Install a 6V-4143 Coupler Assembly to the end of the hose from 4C-9710 Hand Pump. Install the hose to port (8). Add oil to the system until oil begins to flow around the loose pressure tap (6). Tighten pressure tap (6) .
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Illustration 5 g00472388
(PIN: 7ZM1-1918ZM1-160)
(8) Sampling port.
Note: Do not exceed 3500 kPa (500 psi) in order to fill the charge circuit. Seal failure could result.
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| Illustration 3 | g00472393 |
Pressure Tap for the Pump Case (6) Pressure tap. | |
- If a filter cart is used in order to add oil directly to the hydraulic tank, use hydraulic oil that is free of moisture. As a recommendation, the hydraulic oil that is added to the system should pass ISO 16/13. Look at the hydraulic oil level indicator on the right side of the machine. Add hydraulic oil until the hydraulic tank is full.
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| Illustration 6 | g00473728 |
Oil Level Indicator | |
- For the machines that required removing the sampling port (8), reinstall the sampling port (8) .
Fill the Motor Case
- Install one 6V-4143 Coupler Assembly to each end of the 6V-3014 Hose. Install 6V-3989 Unvalved Nipple to 8T-0850 Pressure Gauge. The pressure gauge has a range of 4000 kPa (580 psi). Install the pressure gauge to one end of the 6V-3014 Hose. Install the other end of the hose assembly to charge pressure tap (9) on the pump.
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| Illustration 7 | g00472527 |
(9) Pressure tap for the Charge oil. (10) Access plate. | |
- Remove access plate (10) .
- Install one 6V-4143 Coupler Assembly to each end of the 6V-3014 Hose. Install 6V-3989 Unvalved Nipple to 8T-0820 Pressure Gauge. The pressure gauge has a range of 60000 kPa (8700 psi). Install the pressure gauge to one end of the 6V-3014 Hose. Install the other end of the hose to the test port (11) for the high pressure oil of the drive loop.
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| Illustration 8 | g00472528 |
(11) Pressure tap for the high pressure oil of the drive loop. | |
- Clearly label the hydraulic test lines. Secure the hydraulic lines so that the pressure gauge can be viewed by the operator during the test. Do NOT hold the pressure gauge or the hydraulic line.
- Rotate battery tray (5) into the proper position. Tighten bolts (3) and (4). Ensure that the test hoses are not pinched.
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| Illustration 9 | g00472547 |
Removing Batteries and Battery Tray (1) Disconnect Switch. (2) Battery. (3) Two bolts. (4) Bolt. (5) Battery tray. | |
- Connect the battery cables.
- Place disconnect switch (1) in the ON position.
- Disconnect wires (12) from the fuel shutoff solenoid. Crank the engine without starting and look at the charge oil pressure. Do not crank the engine for more than 20 seconds. The charge pressure must be a minimum of 1500 kPa (220 psi).
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| Illustration 10 | g00472595 |
Fuel Shutoff Solenoid (12) Wires to the fuel shutoff solenoid. | |
- If the charge pressure is low, check the hydraulic oil level in the tank. Refill to the full mark. Use hydraulic oil that is clean and free of moisture. Determine the cause for low charge oil pressure before restarting the engine. When the charge pressure is correct, connect wires (12) to the fuel shutoff solenoid.
- Start the engine and run the engine at low idle.
- Look at the pressure gauges. The charge oil pressure and the high pressure oil of the drive loop should be 2500 ± 500 kPa (350 ± 75 psi). The pressures should be reached within 15 seconds of start-up.
- If the pressures are low, stop the engine. Check the hydraulic oil level in the tank. Refill to the full mark. Determine the cause for low oil pressure before you restart the engine.
Note: If charge pressure is not reached within 15 seconds damage to the hydrostatic system will occur. Do not allow the hydrostatic system to operate with incorrect charge system pressures.
- Start the engine and run the engine at low idle. Select the SLOW speed mode. Fully apply the service brakes and hold the service brakes. Disengage the parking brake.
- Move the direction control lever to the FORWARD position.
- Slowly increase the engine speed until the high pressure oil of the drive loop is 15000 ± 500 kPa (2175 ± 73 psi). Maintain the engine speed for one to two minutes. Return the engine speed to low idle.
- Movement of the wheels are not permitted.
- Move the direction control lever to the REVERSE position.
- Slowly increase the engine speed until the high pressure oil of the drive loop is 15000 ± 500 kPa (2175 ± 73 psi). Maintain the engine speed for one to two minutes. Return the engine speed to low idle.
- Movement of the wheels are not permitted.
- Repeat Step 13 through Step 20 six times (three times in FORWARD and three times in REVERSE).
Flush the Hydrostatic System
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
| REQUIRED TOOLS | ||
| Part Number | Description | Quantity |
| 6V-3014 | Hose Assembly | 2 |
| 6V-4143 | Coupler | 2 |
After the failure of a component or replacement of a component, then change all filters and clean all strainers. Refer to the Disassembly and Assembly for the procedure to disassemble the return block that is attached to the hydraulic tank.
Flush the Drive Lines
- Sit in the seat and fasten the seat belt.
- Move the directional control lever to the NEUTRAL position. Engage the parking brake.
- Press the speed select switch in the SLOW mode.
- Start the engine and run the engine at low idle.
- Disengage the parking brake. Move the direction control lever to the FORWARD position.
- Increase the engine to high idle. Run the machine for 60 ± 30 seconds. Repeat in REVERSE for 60 ± 30 seconds.
- Move each attachment control lever one at a time to the FULL positions. Hold each attachment control lever for 7 to 13 seconds in the FULL position.
- Decrease the engine speed to low idle. Apply the service brake pedal. Move the direction control lever to the NEUTRAL position. Engage the parking brake.
- Go to the procedure for sampling the hydraulic oil.
Sampling the Hydraulic Oil
- Wipe off the sampling valve in order to remove any dirt. Use a purge bottle in order to purge the sampling valve of 50 mL of hydraulic oil. Use a new 1U-5814 Bottle Assembly in order to draw a 100 mL oil sample through the sampling valve. As a recommendation, the contamination level should pass ISO 18/15. The ISO 18/15 is shown in Table 4.
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Table 4 Hydraulic Oil Contamination Particle Size (Microns) Maximum Number of Particles in a 100 mL Sample >5 250000 >15 32000
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| Illustration 11 | g00499230 |
Sampling Valve | |
- If the particle count exceeds the limits in the table, then repeat the procedures for the filling of the motor case. Then repeat the procedures for the flushing of the implement lines and repeat the procedures for the flushing of the drive lines.
- Obtain another oil sample after repeating the procedure. Measure the contamination level. Compare the sample to Table 4. If the particle count exceeds the limit on the second attempt, replace the charge oil filters. 102-2828 Clean up filters can also be used. Repeat the procedures for the filling of the motor case. Then repeat the procedures for the flushing of the implement lines. Repeat the procedures for the flushing of the drive lines.
- Obtain another oil sample after repeating the procedure for a third time. Measure the contamination level. Compare the sample to Table 4. If the particle count exceeds the limit on the third attempt, find the component that is causing the contamination and replace the component.
- After you obtain an acceptable oil sample, stop the engine.