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Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped. Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine. |
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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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, and the 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 machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number |
Description | Qty |
| A | 8T-0862 | Pressure Gauge 0 to 500 kPa (0 to 70 psi) |
2 |
| 6V-4144 | Quick Connect Coupler | 2 | |
| B | 8T-0855 | Pressure Gauge 0 to 4000 kPa (0 to 580 psi) |
2 |
| 6V-4144 | Quick Connect Coupler | 2 | |
| C | 177-7860 | Hose As | 2 |
| 6V-4142 | Fitting | 2 | |
| 6V-4143 | Quick Connect Coupler | 2 | |
| D | 110-6349 | Fitting As | 2 |
| 3J-7354 | O-Ring Seal | 2 | |
| E | 6V-9828 | Cap As | 1 |
| F | 6V-9507 | Plug | 1 |
| 4J-5477 | O-Ring Seal | 1 | |
| G | 6V-9829 | Cap As | 2 |
| H | 6V-9507 | Plug | 2 |
| 6V-8397 | O-Ring Seal | 2 | |
| J | 4C-6500 | Digital Thermometer | 1 |
- Drive the machine to a smooth, horizontal surface.
- Move propulsion lever (1) to the NEUTRAL position.
 | |
| Illustration 1 | g01407630 |
- Move parking brake switch (2) to the ON position.
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| Illustration 2 | g01407609 |
- Move throttle switch (3) to the LOW IDLE position.
 | |
| Illustration 3 | g01407610 |
- Move engine start switch (4) to the OFF position.
 | |
| Illustration 4 | g01407660 |
- Remove bolts (5) and remove right cover plate (6) .
 | |
| Illustration 5 | g01408900 |
- Remove bolts (7) and remove left cover plate (8) .
 | |
| Illustration 6 | g01408904 |
- Block the wheels. Block the drum.
- Raise the cab. Refer to Disassembly and Assembly, KENR6413, "Cab - Tilt".
- Loosen set screw (9). Fully rotate the needle valve in the clockwise direction in order to prevent the parking brake from releasing.
 | |
| Illustration 7 | g01408980 |
- Disconnect balance line (10) and balance line (11) from drum pump. Use Tool (G) to cap ports. Use Tool (H) to plug the hoses.
 | |
| Illustration 8 | g01408983 |
The Drum Pump is Shown From Left Side. | |
- Connect Tool (B) to Tool (C). Make two sets of tools.
- Remove the plug from port "X1" (13) of drum pump. Install Tool (D) in port "X1".
 | |
| Illustration 9 | g01410295 |
The Drum Pump is Shown From Left Side. | |
- Remove the plug from port "X2" (12) of the drum pump. Install second Tool (D) in port "X2".
- Disconnect tie rod (14) .
- Connect one Tool (C) to the tap in port "X1" (13). Connect second Tool (C) to the tap in port "X2" (12) .
- Lower the cab but do not install cover plate (6) or cover plate (8). Refer to Disassembly and Assembly, KENR6413, "Cab - Tilt".
Note: The cab mounting bolts must be installed and properly torqued before the engine is started.
- Move engine start switch (4) to the START position. Release the switch when the engine starts.
- Move shift switch (15) to the HIGH SPEED position.
 | |
| Illustration 10 | g01410299 |
- Operate the engine at low idle for few minutes. Move throttle switch (3) to the HIGH IDLE position.
- Monitor hydraulic oil temperature with Tool (J). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
- Move parking brake switch (2) to the OFF position.
- Read the pressure on the gauges. The pressure on both gauges should be equal. If the pressure is not equal, go to Step 24. If the pressure is equal, go to Step 26.
- Loosen locknut (16). Watch the pressure on the gauges. If necessary, rotate adjustment screw (17) until the pressure is equal on both gauges.
 | |
| Illustration 11 | g01410301 |
The Drum Pump is Shown From Left Side. Typical example (Tie rod is shown in place in the Illustration.) | |
- Hold adjustment screw (17) and tighten locknut (16) .
- Move throttle switch (3) to the LOW IDLE position.
- Move engine start switch (4) to the OFF position.
- Remove Tool (B) from Tool (C). Install Tool (A) on Tool (C). Make two sets of tools.
- Move engine start switch (4) to the START position. Release the switch when the engine starts.
- Operate the engine at low idle for few minutes. Move throttle switch (3) to the HIGH IDLE position.
- Monitor hydraulic oil temperature with Tool (J). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
Note: Do not adjust the pressure past the rating of the gauges in the following steps.
- Loosen locknut (16). Watch the pressure on the gauges. If necessary, rotate adjustment screw (17) until the pressure is equal on both gauges.
- Rotate adjustment screw (17) clockwise until the pressure at the pressure tap that is in port "X2" (12) just begins to increase. Note the angular position of the wrench.
- Rotate adjustment screw (17) counterclockwise until the pressure at the pressure tap that is in port "X1" (13) just begins to increase. Note the angular position of the wrench.
- Rotate the adjustment screw (17) to the center of the two positions that are noted above. Hold the adjustment screw in place, and tighten locknut (16) .
Note: Make sure that the pressure does not change when locknut (16) is tightened.
- Move throttle switch (3) to the LOW IDLE position.
- Move parking brake switch (2) to the ON position.
- Move engine start switch (4) to the OFF position.
- Raise the cab. Refer to Disassembly and Assembly, KENR6413, "Cab - Tilt".
- Remove Tool (A), Tool (C), and Tool (D) from port "X1" (13). Install the original plug in port "X1". Remove Tool (A), Tool (C), and Tool (D) from port "X2" (12). Install the original plug in port "X2".
- Remove Tool (G) and Tool (H) from balance line (10) and balance line (11). Reconnect both balance lines.
- Reconnect tie rod (14) .
- Fully rotate the needle valve in the counterclockwise direction. Tighten set screw (9) .
- Lower the cab. Refer to Disassembly and Assembly, KENR6413, "Cab - Tilt".
- Replace cover plates (6) and (8). Install bolts (5) and (7) .