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. |
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. |
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. |
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 (1)     | 198-4234     | Pressure Gauge Tool Gp     | 2     |
198-4236 | Adapter Cable As     | 3     | |
B (1)     | 198-4239     | Pressure Sensors 0 to 69000 kPa (0 to 10000 psi)     |
2     |
C     | 198-4238     | Pressure Sensors 0 to 35000 kPa (0 to 5000 psi)     |
1     |
D     | 6V-9828     | Cap As     | 1     |
E     | 6V-9507     | Plug     | 1     |
4J-5477 | O-Ring Seals     | 1     | |
F     | 6V-9829     | Cap As     | 2     |
G     | 6V-9508     | Plug     | 2     |
6V-8397 | O-Ring Seal     | 2     | |
H     | 6V-9511     | Plug     | 1     |
6V-9746 | O-Ring Seal     | 1     | |
J     | 124-2121     | Couplings     | 2     |
122-6872 | Hydraulic Hose     | 1     | |
6V-8733 | Union     | 1     | |
6V-9746 | O-Ring Seals     | 3     | |
K     | 4C-8688     | Flow meter .4 ± 7.5 L/min (-.1 ± 2 US gpm)     |
1     |
8C-6874 | Connectors     | 2     | |
L     | 122-6872     | Hydraulic Hose     | 1     |
124-2121 | Coupling     | 1     | |
124-2153 | Coupling     | 1     | |
6V-9746 | O-Ring Seal     | 1     | |
M     | 124-2117     | Coupling     | 1     |
122-6870 | Hydraulic Hose     | 1     | |
124-2147 | Coupling     | 1     | |
6V-8398 | O-Ring Seals     | 2     | |
N     | 4C-8689     | Flow Meter     | 1     |
8B-2664 | Reducer Bushing     | 2     | |
8C-6872 | Connectors     | 2     | |
P     | 124-2117     | Couplings     | 2     |
122-6870 | Hydraulic Hose     | 1     | |
6V-8731 | Union     | 1     | |
6V-8398 | O-Ring Seals     | 3     | |
R     | 6V-7788     | Flow Meter     | 1     |
8C-6874 | Connectors     | 2     | |
S     | 124-2153     | Couplings     | 2     |
122-6872 | Hydraulic Hoses     | 2     | |
124-2121 | Couplings     | 2     | |
6V-9746 | O-Ring Seals     | 4     | |
T     | 4C-6500     | Digital Thermometer     | 1     |
( 1 ) | Tool (A) is part of 198-4240 Digital Pressure Indicator . |
- Drive the machine to a smooth, horizontal surface.
- Move propulsion lever (1) to the NEUTRAL position.
Illustration 1 | g01415204 |
- Move parking brake switch (2) to the ON position.
Illustration 2 | g01415246 |
- Move throttle control switch (3) to the LOW IDLE position.
Illustration 3 | g01415249 |
- Move engine start switch (4) to the OFF position.
Illustration 4 | g01415252 |
- Assemble Tool (J) to the outlet port of Tool (K) . Assemble Tool (L) to the inlet port of Tool (K) , as shown.
Illustration 5 | g01415466 |
- Assemble Tool (M) to the inlet port of Tool (N) , as shown. Assemble Tool (P) to the outlet port of Tool (N) , as shown.
Illustration 6 | g01415644 |
- Assemble Tool (S) to the inlet port of Tool (R) , as shown. Assemble second Tool (S) to the outlet port of Tool (R) , as shown.
Illustration 7 | g01415649 |
- Disconnect the brake supply line (5) from the drum. Use Tool (C) to cap the port. Use Tool (D) to plug the hose.
Illustration 8 | g01415658 |
- Raise the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- Disconnect upper balance line (6) and lower balance line (7) from the pump for the drum. Use Tool (E) to cap ports. Use Tool (F) to plug the hoses.
Illustration 9 | g01415663 |
The Pump for the Drum is Shown From the Left Side. |
- Disconnect hose (8) from port "T2" on the vibratory pump.
Illustration 10 | g01415668 |
The Vibratory Pump is Shown From the Left Side. |
- Connect Tool (M) (inlet side of the flow meter) to port "T2".
- Connect Tool (P) (outlet side of flow meter) to hose (8) .
- Disconnect hose (9) from port "T1" on the pump for the axle.
Illustration 11 | g01415673 |
- Connect Tool (L) (inlet side of the flow meter) to port "T1".
- Connect Tool (J) (outlet side of flow meter) to hose (9) .
- Remove four bolts (10) and washers. Remove plate (11) .
Illustration 12 | g01415687 |
- Clean the area around cap (12) . Remove the cap from the hydraulic tank.
- Disconnect hose (13) from port "T1" on the pump for the drum. Use Tool (H) to plug the hose.
Illustration 13 | g01415690 |
- Attach Tool (S) on the inlet side of flow meter to port "T1" on the pump for the drum.
- Make sure that Tool (S) is clean. Place Tool (S) on the outlet side of the flow meter into the hydraulic tank. Cover the opening of the hydraulic tank.
Illustration 14 | g01415694 |
- Connect one Tool (B) to each of the following pressure taps:
- Reverse pressure tap (14) on the pump for the drum
- Forward pressure tap (15) on the pump for the drum
- Reverse pressure tap (14) on the pump for the drum
Illustration 15 | g01415701 |
- Connect Tool (C) to charge pressure tap (16) on the propulsion pump for the drum.
- Connect one Tool (A) to each Tool (B) . Connect remaining Tool (A) to Tool (C) .
- Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- 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 (T) . Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
- Read charge pressure on Tool (A) . The pressure should be 2600 ± 250 kPa (377 ± 36 psi).
- Read the flow of the pump for the drum on Tool (R) . The flow should be 37.9 ± 5 L (10 ± 1.3 US gal).
- Read the flow of the pump for the axle on Tool (K) . The flow should be 4.9 ± 1.1 L (1.3 ± 0.3 US gal).
- Read vibratory pump flow on Tool (N) . The flow should be 7.6 ± 1.9 L (2 ± .5 US gal).
- Move throttle switch (3) to the LOW IDLE position.
- Move engine start switch (4) to the OFF position.
- If the pressure and the flow rates are inside the specified range, go to Step 60. If the pressure is outside the specified range, go to Step 37.
- Raise the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- Analyze the test results according to Table 2.
Show/hide table
Table 2 Test Parameters     Actions     Charge Pressure     Drum Flow     Axle Flow     Vibratory Flow     Low     -     -     -     Shim the charge relief valve for the drum.
Go to Step 39    High     Low     High     High     Remove shims from the relief valve for the drum.
Go to Step 39    OK     Low     OK     OK     Check the flow of the steering pump flow.
Check the case drain for the motor.
Refer to Testing and Adjusting, "Gear Pump Flow (Steering) - Test"    OK     High     Low     OK     Check the orifice in the charge relief valve for the axle. Step 61     OK     High     OK     Low     Check the orifice in the vibratory charge relief valve.
Go to Step 53    
- Remove charge relief valve (17) from the pump for the drum.
Illustration 16 | g01415754 |
The Pump for the Drum |
- Remove the following components from the housing for the pump for the drum:
- Spool (18)
- Poppet (19)
- Shims (20)
- Spring (21)
- Spool (18)
Illustration 17 | g01415766 |
- Add shims (20) in order to increase pressure. Remove shims in order to decrease pressure.
Note: A change of 1 mm (0.0394 inch) shim thickness results in a pressure change of 390 kPa (57 psi).
- Install the following components in the pump housing:
- Spring (21)
- Shims (20)
- Poppet (19)
- Spool (18)
- Spring (21)
- Install charge relief valve (17) .
- Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- Go to Step 27.
- Remove charge relief valve (22) on the pump for the axle.
Illustration 18 | g01415789 |
Vibratory Pump |
- Remove the following components from the housing for the pump for the axle:
- Spool (23)
- Poppet (24)
- Shims (25)
- Spring (26)
- Spool (23)
Illustration 19 | g01415800 |
- Check each orifice in charge relief valve (22) for debris. If necessary, clean the valve body.
- Install the following components in the pump housing:
- Spring (26)
- Shims (25)
- Poppet (24)
- Spool (23)
- Spring (26)
- Install charge relief valve (22) .
- Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- Go to Step 27.
- Remove charge relief valve (27) on the vibratory pump.
Illustration 20 | g01415808 |
Vibratory Pump |
- Remove the following components from the vibratory pump housing:
- Spool (28)
- Poppet (29)
- Shims (30)
- Spring (31)
- Spool (28)
Illustration 21 | g01415826 |
- Check each orifice in charge relief valve (27) for debris. If necessary, clean the valve body.
Note: A change of 1 mm (.04 inch) in shim thickness results in a pressure change of 390 kPa (57 psi).
- Install the following components in the vibratory pump housing:
- Spring (31)
- Shims (30)
- Poppet (29)
- Spool (28)
- Spring (31)
- Install vibratory charge relief valve (27) .
- Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- Go to Step 27.
- Raise the cab, if necessary. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- Remove Tool (C) from charge pressure tap (16) on the propulsion pump for the drum.
- Remove each Tool (B) from forward and reverse pressure taps (15) and (14) on the propulsion pump for the drum.
- Remove each Tool (S) and Tool (R) from the propulsion pump for the drum and the hydraulic tank.
- Reconnect hose (13) to port "T1" on the pump for the drum.
- Clean the area around cap (12) . Replace the cap on the hydraulic tank.
- Replace plate (11) , washers, and four bolts (10) .
- Remove Tool (J) , Tool (K) , and Tool (L) from the propulsion pump for the axle.
- Reconnect hose (9) to port "T1" on the pump for the axle.
- Remove Tool (M) , Tool (N) , and Tool (P) from the vibratory pump.
- Reconnect hose (8) to port "T2" on the vibratory pump.
- Remove Tool (E) and Tool (F) from balance line (6) and balance line (7) . Reconnect both of the balance lines.
- Lower the cab. Refer to Disassembly and Assembly, KENR6047, "Cab - Tilt".
- Remove Tool (C) and Tool (D) . Reconnect brake supply line (5) to the drum motor.