Filling and Flushing the Hydrostatic System Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the power train. 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 work tools have been lowered to the ground, 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. Table 1
REQUIRED TOOLS Part Number Description Quantity Laptop Computer with Electronic Technician (ET) 1 FT1845 Brake Release Pump 1 7X-1700 or 171-4400 Communication Adapter Group 1 7X-1425 (1) Adapter Cable 1 139-4166 (1) Data Link Cable Assembly 1 196-0055 (2) Serial Cable 1 160-0133 (2) Data Link Cable Assembly 1 6V-4144 Coupler 1 061-9463 Fitting 1 6V-7830 Tetragauge 2 ( 1 ) This cable is used with the 7X-1700 Communication Adapter Group. ( 2 ) This cable is used with the 171-4400 Communication Adapter Group. Filling Procedure for the Hydrostatic System
Illustration 1 g00839160 1. Fill reservoir (1) of brake release pump with approximately 3.8 L (1 US gal) of the same hydraulic oil that is in the machine. Refer to Operation and Maintenance Manual, SEBU7479, "Lubricant Viscosities". Illustration 2 g00796009 2. Open the access door on the right side of the machine. Illustration 3 g00838528 Connect the hose of the brake release pump to port (2) on filter inlet hose 3. (3) of the outer filter.
Illustration 4 g00839163 6. Turn bypass handle (5) of the brake release pump to the CLOSED position. 4. Operate handle (4) of the brake release pump in order to fill the pump case. 5. Once the pump is full, turn bypass handle (5) of the brake release pump to the OPEN position. Disconnect the hose.
Illustration 5 g00840283 7. 8. Connect the hose to port (6) on filter inlet hose (7) of the inner filter. Repeat Step 3 through Step 6 for the other pump. Illustration 6 g00838526
9. Connect a tetragauge to pressure tap "1". Illustration 7 g00838527 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Connect a tetragauge to pressure tap "2". Enter the machine. Fasten the seat belt. Start the engine and run the engine at LOW IDLE. Both loop pressures must be 2300 ± 600 kpa (335 ± 85 psi) within 20 seconds after you start the engine. If the pressure is low, stop the engine. Check the hydraulic oil level. Add hydraulic oil, if necessary. Determine the cause of the low pressure and repair the cause. Repeat Step 11 through Step 17 until the loop pressure is correct. If the engine is still running, stop the engine. Exit the machine.
Illustration 8 g00840286 21. Turn screws (9) counterclockwise and remove panel (8). Illustration 9 g00840287 Connect the data link cable for the communication adapter to service tool 22. connector (10). 23. 24. 25. 26. 27. 28. Use the Electronic Technician to place the machine in STALL TEST MODE. Refer to Testing and Adjusting, "Transmission Stall Test - Setup". Enter the machine. Fasten the seat belt. Start the engine. Increase the engine speed to 1500 ± 50 rpm. Move the speed and direction control to the FORWARD position. 29. Slowly, increase the max speed setting until both loop pressures reach 15000 ± 5000 kpa (2175 ± 725 psi). Maintain this pressure for 90 ± 30 seconds in order to fill the motor case.
30. 31. 32. 33. 34. 35. 36. Repeat Step 29 for the REVERSE position. Return the speed and direction control to the NEUTRAL position. Decrease engine speed to LOW IDLE. Engage the parking brake. Stop the engine. Exit the machine. Check the hydraulic tank level. Add hydraulic oil, if necessary. Calibration Procedure After Pump/Motor Replacement The tracks will move during the procedure. Keep all personnel away from the machine during the procedure. Severe injury or death could result if someone was caught in the moving tracks. If the tracks of the machine are not off the ground, start at the beginning of the following procedure. Otherwise, start at Step 10. Table 2 REQUIRED TOOLS Part Number Description Quantity 1P-0074 Slide Hammer Puller Gp 1 4C-5660 Thread Adapter 1 1. Place chocks in front of the tracks and behind the tracks.
Illustration 10 g00781471 2. Remove the drain plug and allow the oil to drain into a suitable container. Refer to the Operation and Maintenance Manual, "Refill Capacities" for the amount of fluid that will be in the housing of the final drive. Clean the drain plug and replace the drain plug after all of the fluid is drained. 3. Illustration 11 g00781472 4. Remove bolts (1), washers (2), and cover (3).
Illustration 12 g00840288 5. 6. 7. Install slide hammer (6) and adapter (5) onto sun gear (4). Remove the sun gear from the final drive housing. Fill the final drive housing with oil until the oil is at the bottom of the opening behind cover (3). Refer to Operation and Maintenance Manual, SEBU7479, "Lubricant Viscosities" for oil recommendations. Replace the cover in order to prevent dirt from entering the final drive housing. 8. 9. 10. 11. Repeat Step 4 through Step 8 for the other final drive. Use ET to calibrate the pumps and the motors. Refer to Testing and Adjusting, "Forward Solenoids of Drive Pumps and Solenoids of Drive Motors - Calibrate" and refer to Testing and Adjusting, "Reverse Solenoids of Drive Pumps - Calibrate". Continue with the flushing procedure. Flushing Procedure for the Hydrostatic System The tracks will move during the procedure. Keep all personnel away from the machine during the procedure. Severe injury or death could result if someone was caught in the moving tracks.
Table 3 REQUIRED TOOLS Part Number Description Quantity 8T-9208 Probe Assembly 1 8T-9190 Fluid Sampling Bottle 1 1. 2. 3. 4. 5. 6. Enter the machine. Fasten the seat belt. Start the engine. Disengage the parking brake. Select the lowest max speed setting. Increase engine speed to HIGH IDLE. Move the speed and direction control to the FORWARD position for 607. ± 30 seconds. Move the speed and direction control to the NEUTRAL position and allow 8. the tracks to stop. Move the speed and direction control to the REVERSE position for 60 ± 9. 30 seconds. Move the speed and direction control to the NEUTRAL position and allow 10. the tracks to stop. 11. 12. 13. Lower the engine speed to LOW IDLE. Engage the parking brake. Obtain an oil sample. Measure the contaminant level in the oil sample. The particle counts must be less than the values that are shown in the following table. Table 4 ACCEPTABLE PARTICLE COUNT FOR THE HYDROSTATIC SYSTEM Range of Size Maximum Particle Count per 50 ± 10 ml (1.7 ± 0.3 ounces) 5 to 15 microns 64000 16 to 25 microns 11400 26 to 50 microns 2050 51 to 100 microns 150 Larger than 100 microns 20
14. 15. 16. 17. If the particle counts exceed the limits, repeat the flushing procedure and obtain another sample. If the second oil sample exceeds the limits, replace the filter elements. Refer to Operation and Maintenance Manual, SEBU7479, "Hydraulic Oil Filter - Replace" and refer to Operation and Maintenance Manual, SEBU7479, "Winch Hydraulic Oil Filter - Replace". Repeat the flushing procedure and obtain another oil sample. If the particle counts are still too high and if the particle counts do not show improvement, find the component that is causing the contamination and replace the component. If the particle counts are still too high but the particle counts show improvement, replace the hydraulic oil filters with 102-2828 Oil Filters and repeat the flushing procedure. Note: If the machine is equipped with a winch, install a 126-1815 Oil Filter in place of the oil filter for the winch. 18. After an acceptable sample is obtained, stop the engine. If 102-2828 Oil Filters were installed, replace these oil filters with the correct 19. filters. 20. 21. If no additional tests are necessary, remove the hose assemblies and disconnect the communication adapter. If the sun gears were removed from the final drives, install the sun gears. Fill the final drives with oil. Proceed with the initial tests. Refer to Testing and Adjusting, "Initial Test". 22.