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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 |
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. |
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Table 1
Required Tools     |
Tool     |
Part Number     |
Description     |
Qty     |
A (1)     |
198-4234     |
Pressure Gauge Tool Gp     |
1     |
B (1)     |
198-4236     |
Adapter Cable As     |
2     |
C     |
198-4238     |
Pressure Sensor Gp     |
1     |
D     |
6V-3965     |
Fitting As     |
2     |
3J-1907 |
O-Ring Seal     |
2     |
E     |
4C-6500     |
Digital Thermometer     |
1     |
F     |
124-8909     |
Elbow     |
1     |
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( 1 ) | The 198-4234 Pressure Gauge Tool Gp, 198-4236 Adapter Cable As, and the 198-4238 Pressure Sensor Gp are part of the 198-4240 Digital Pressure Indicator . |
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Table 2
Optional Tools (1)     |
Tool     |
Part Number     |
Description     |
Qty     |
G     |
8T-0862     |
Pressure Gauge
0 to 500 kPa (0 to 70 psi)     |
1     |
H     |
6V-3989     |
Fitting     |
1     |
J     |
6V-4143     |
Quick Connect Coupler     |
2     |
177-7860 |
Hose As     |
1     |
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( 1 ) | The optional tools can be used in place of the 198-4240 Digital Pressure Indicator tools which are specified in the required tool list. |
Preparation for Test
- Drive the machine to a smooth, horizontal surface.
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Illustration 1 | g01163553 |
- Move propulsion lever (2) to the NEUTRAL position.
- Rotate speed dial (3) to the MINIMUM position.
- Move parking brake switch (4) to the ON position.
- Move screed lower switch (6) to the DOWN position. Lower the screed to the ground.
- Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (1) to the OFF position.
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Illustration 2 | g01163556 |
- Move key start switch (7) to the OFF position.
- Open the pump compartment on the left side of the machine.
Right Auger Pump
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Illustration 3 | g02038215 |
- Remove the plug from port "M4" (8) on the auger section of the right conveyor and auger pump.
- Install Tool (D) to port "M4" (8) .
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Illustration 4 | g02038254 |
- Disconnect the forward EDC at connector (10). Mark this connector for identification.
Note: The C778-BR wire and the F760-PU wire are connected to the forward EDC connector for the right auger pump.
- Connect one end of Tool (C) to the tap which was installed in port "M4" (8) .
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Illustration 5 | g02038216 |
- Remove the plug from port "M5" (9) on the auger section of the right conveyor and auger pump.
- Install Tool (D) in port "M5" (9) .
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Illustration 6 | g02038256 |
- Disconnect the reverse EDC at connector (11). Mark this connector for identification.
Note: The K967-WH wire and the F761-BR wire are connected to the reverse EDC connector for the right auger pump.
- Connect another Tool (C) to the tap which was installed in port "M5" (9) .
- Connect both sensors Tool (C) to Tool (A) by using two extension cables Tool (B) .
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Illustration 7 | g01163556 |
- Move key start switch (7) to the ON position.
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Illustration 8 | g01163553 |
- Move engine start switch (1) to the START position. Release the engine start switch after the engine starts.
- Move throttle control switch (5) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2310 rpm.
- Monitor the hydraulic oil temperature with Tool (F). Operate the machine until the oil temperature reaches 43 ± 5.6° (110 ± 10°F).
- Use Tool (A) to read the pressure differential between port "M4" (8) and port "M5" (9). If the pressure differential is within 150 kPa (22 psi), go to Step 18. If the pressure differential is not within 150 kPa (22 psi), go to Step 15.
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Illustration 9 | g02039079 |
Note: Do not adjust the pressure beyond the rating of the sensors during the next two steps.
- Loosen locknut (12) on the pump adjustment. Turn adjustment screw (13) until the pressure at port "M4" (8) is equal to the pressure at port "M5" (9). Record the pressure reading at port "M4". Note the angular position of the wrench.
- Rotate adjustment screw (13) in the opposite direction until the pressure at port "M5" (9) is equal to the pressure that was recorded during Step 15.
- Rotate adjustment screw (13) to the center of the two positions that were noted in Step 12 and Step 13. Hold the adjustment screw in place and tighten locknut (12) to a torque of 20 N·m (15 lb ft). Go back to Step 14.
- Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (1) to the OFF position.
- Move key start switch (7) to the OFF position.
- Allow the oil to cool. Remove the tooling. Reconnect the reverse EDC connector (10). Reconnect the forward EDC connector (11) .
Right Conveyor Pump
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Illustration 10 | g02040213 |
- Remove the plug from port "M4" (14) on the conveyor section of the right conveyor and auger pump.
Note: Loosen and rotate hose assembly (X) in order to install Tool (D) .
- Install Tool (D) in port "M4" (14) .
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Illustration 11 | g02039133 |
- Connect one pressure sensor Tool (C) to the tap that was installed in port "M4" (14) .
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Illustration 12 | g02039145 |
- Remove the plug from port "M5" (15) on the conveyor section of the right conveyor and auger pump. Install Tooling (F) .
- Install Tooling (D) into Tooling (F) .
- Disconnect the forward EDC at connector (16). Mark this connector for identification.
Note: The K727-GY wire and the F761-BR wire are connected to the forward EDC connector for the right auger pump.
- Connect another pressure sensor Tool (C) to the tap that was installed in port "M5" (15) .
- Connect the sensors to Tool (A) by using two extension cables Tool (B) .
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Illustration 13 | g01163556 |
- Move key start switch (7) to the ON position.
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Illustration 14 | g01163553 |
- Move engine start switch (1) to the START position. Release the engine start switch after the engine starts.
- Move throttle control switch (5) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2310 rpm.
- Monitor the hydraulic oil temperature with Tool (E). Operate the machine until the oil temperature reaches 43 ± 5.6°C (110 ± 10°F).
- Use Tool (A) in order to read the pressure differential between port "M4" (14) and port "M5" (15). If the pressure differential is within 150 kPa (22 psi), go to Step 17. If the pressure differential is not within 150 kPa (22 psi), go to Step 14.
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Illustration 15 | g02039527 |
Note: Do not adjust the pressure beyond the rating of the sensors during the next two steps.
- Loosen locknut (17) on the pump adjustment mechanism. Turn adjustment screw (18) until the pressure at port "M4" (14) is equal to the pressure at port "M5" (15). Record the pressure reading at port "M4" (14). Note the angular position of the wrench.
- Rotate adjustment screw (18) in the opposite direction until the pressure at port "M5" (15) is equal to the pressure that was recorded during Step 14. Note the angular position of the wrench.
- Rotate adjustment screw (18) to the center of the two positions that were noted in Step 14 and Step 15. Hold adjustment screw (18), and tighten locknut (17) to a torque of 20 N·m (15 lb ft). Go back to Step 13.
- Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (1) to the OFF position.
- Move key start switch (7) to the OFF position.
- Allow the oil to cool. Remove the tooling. Reconnect forward EDC connector (16) .
Left Auger Pump
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Illustration 16 | g02040253 |
- Remove the plug from port "M4" (20) on the auger section of the left conveyor and auger pump.
- Install Tool (D) in port "M4" (20) .
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Illustration 17 | g02039455 |
- Connect one pressure sensor Tool (C) to the tap which was installed in port "M4" (20) .
- Disconnect the reverse EDC at connector (21). Mark this connector for identification.
Note: The 896-GN wire and the F760-PU wire are connected to the reverse EDC connector for the left auger pump.
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Illustration 18 | g02040256 |
- Remove the plug from port "M5" (22) on the auger section.
- Install Tool (D) in port "M5" (22) .
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Illustration 19 | g02039456 |
- Disconnect the forward EDC at connector (23). Mark this connector for identification.
Note: The A912-PU wire and the F760-PU wire are connected to the forward EDC connector for the left auger pump.
- Connect the second pressure sensor Tool (C) to the tap which was installed in port "M5" (22) .
- Connect the other end of Tool (H) to the tap which was installed in port "M5" (22) .
- Connect the sensors to Tool (A) in order to connect two extension cables, Tool (B) .
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Illustration 20 | g01163556 |
- Move key start switch (7) to the ON position.
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Illustration 21 | g01163553 |
- Move engine start switch (1) to the START position. Release the engine start switch after the engine starts.
- Move throttle control switch (5) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2310 rpm.
- Monitor the hydraulic oil temperature with Tool (E). Operate the machine until the oil temperature reaches 43 ± 5.6°C (110 ± 10°F).
- Use Tool (A) to read the pressure differential between port "M4" (20) and port "M5" (22). If the pressure differential is within 150 kPa (22 psi), go to Step 18. If the pressure is not within 150 kPa (22 psi), go to Step 16.
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Illustration 22 | g02039529 |
Note: Do not adjust the pressure beyond the rating of the sensors during the next two steps.
- Loosen locknut (24) on the pump adjustment mechanism. Turn adjustment screw (25) until the pressure at port "M4" (20) is equal to the pressure at port "M5" (22) .
- Hold adjustment screw (25), and tighten locknut (24) to a torque of 20 N·m (15 lb ft). Go back to Step 11.
- Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (1) to the OFF position.
- Move key start switch (7) to the OFF position.
- Allow the oil to cool. Remove the tooling. Reconnect reverse EDC connector (10). Reconnect forward EDC connector (23) .
Left Conveyor Pump
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Illustration 23 | g02040393 |
- Remove the plug from port "M4" (26) on the conveyor section of the left conveyor and auger pump.
Note: Loosen and rotate hose assembly (Z) in order to install Tool (D) .
- Install Tool (D) in port "M4" (26) .
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Illustration 24 | g02040413 |
- Connect one end of Tool (H) to the tap that was installed in port "M4" (26) .
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Illustration 25 | g02039532 |
- Remove the plug from port "M5" (27) on the conveyor section of the right conveyor and auger pump.
- Install Tool (D) in port "M5" (27) .
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Illustration 26 | g02039531 |
- Connect the other end of Tool (H) to the tap that was installed in port "M5" (27) .
- Disconnect the forward EDC at connector (28) .
Note: The C736-WH wire and the F760-PU wire are connected to the forward EDC connector for the right conveyor pump.
- Connect one pressure sensor (Tool (C) ) to port "M5" (27) on the conveyor section of the right conveyor and auger pump. Connect the second pressure sensor (Tool (C) ) to port "M4" (26) on the conveyor section of the right conveyor and auger pump. Connect the sensors to Tool (A) by using two extension cables (Tool (B) ).
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Illustration 27 | g01163556 |
- Move key start switch (7) to the ON position.
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Illustration 28 | g01163553 |
- Move engine start switch (1) to the START position. Release the engine start switch after the engine starts.
- Move throttle control switch (5) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2310 rpm.
- Monitor the hydraulic oil temperature with Tool (E). Operate the machine until the oil temperature reaches 43 ± 5.6°C (110 ± 10°F).
- Use Tool (A) to read the pressure differential between port "M4" (26) and port "M5" (27). If the pressure differential is within 150 kPa (22 psi), go to Step 16. If the pressure is not within 150 kPa (22 psi), go to Step 14.
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Illustration 29 | g02039534 |
Note: Do not adjust the pressure beyond the rating of the sensors during the next two steps.
- Loosen locknut (29) on the pump adjustment mechanism. Turn adjustment screw (30) until the pressure at port "M4" (26) is equal to the pressure at port "M5" (27) .
- Hold the adjustment screw (30) and tighten locknut (29) to a torque of 20 N·m (15 lb ft). Go back to Step 9.
- Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.
- After the engine reaches low idle, move engine start switch (1) to the OFF position.
- Move key start switch (7) to the OFF position.
- Allow the oil to cool. Remove the tooling. Reconnect forward EDC connector (28) .