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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, "AVSpare Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in AVSpare 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 | 1 |
| 198-4236 | Adapter Cable As | 2 | |
| B | 251-9600 | Pressure Sensor 0 to 69000 kPa (0 to 10000 psi) |
2 |
| C | 6V-9829 | Cap As | 2 |
| D | 6V-9508 | Plug | 2 |
| 6V-8397 | O-Ring Seal | 2 | |
| E | 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.
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| 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.
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| Illustration 3 | g01407610 |
- Move engine start switch (4) to the OFF position.
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| Illustration 4 | g01407660 |
- Remove bolts (5) and remove right cover plate (6) .
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| Illustration 5 | g01408900 |
- Remove bolts (7) and remove left cover plate (8) .
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| Illustration 6 | g01408904 |
- Raise the cab. Refer to Disassembly and Assembly, KENR6413, "Cab - Tilt".
- Loosen set screw (9) and fully rotate the needle valve in the clockwise direction in order to prevent the parking brake from releasing.
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| Illustration 7 | g01408980 |
- Disconnect balance line (10) and balance line (11) from drum pump. Use Tool (E) to cap ports. Use Tool (F) to plug the hoses.
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| Illustration 8 | g01408983 |
The Drum Pump is Shown From Left Side. | |
- Disconnect electrical connector (12) for the axle interlock from the axle pump.
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| Illustration 9 | g01408988 |
The Axle Pump is Shown From Left Side. | |
- Connect one Tool (B) to each of the following pressure taps:
- Reverse pressure tap (13) that is located on the drum pump.
- Forward pressure tap (14) that is located on the drum pump.
- Reverse pressure tap (13) that is located on the drum pump.
 | |
| Illustration 10 | g01408991 |
The Drum Pump is Shown From Left Side. | |
- Remove the cap from POR valve (15). Loosen the locknut. Rotate the adjustment screw for two turns in the clockwise direction. Hold the adjustment screw and tighten the locknut.
 | |
| Illustration 11 | g01408993 |
The Drum Pump is Shown From Left Side. | |
- Lower the cab but do not install cover plates (6) and (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.
- Operate the engine at low idle for few minutes. Move throttle switch (3) to the HIGH IDLE position.
- Monitor hydraulic oil temperature with Tool (G). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
- Move shift switch (16) to the HIGH SPEED position. Move parking brake switch (2) to the RELEASE position.
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| Illustration 12 | g01408994 |
- Modulate propulsion lever (1) forward until the peak pressure is registered at forward pressure tap (14) (approximately one-half of the total travel). Read pressure on Tool (A). The pressure should be 46500 ± 1000 kPa (6740 ± 145 psi).
- Modulate propulsion lever (1) to the rear until the peak pressure is registered at reverse pressure tap (13) (approximately one-half of the total travel). Read pressure on Tool (A). The pressure should be 46500 ± 1000 kPa (6740 ± 145 psi).
- Move the propulsion lever to the NEUTRAL position.
- Move throttle control 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.
- If either pressure reading is outside the specified range, go to Step 26. If both pressure readings are inside the specified range, go to Step 29.
- Raise the cab. Refer to Disassembly and Assembly, KENR6413, "Cab - Tilt".
- Use the following procedure in order to adjust the main relief valves:
- Remove cap (17) or cap (18) from the relief valve for the valve that is being adjusted.
- Remove spring (19) and relief valve cartridge assembly (20) from the drum pump. Reinstall cap (17) or cap (18) on the pump in order to prevent oil from leaking out of the port.
Show/hide table
Illustration 15 g01409001
The Arrows Indicate the Clamping Position.
- Clamp the relief valve cartridge in a soft vise jaw. See Illustration 15. Loosen locking setscrew (21) with a 3 mm Allen wrench.
- Use a 5 mm wrench to turn spindle (22). Turn the spindle clockwise in order to increase pressure. Turn the spindle counterclockwise in order to decrease pressure.
Note: One full revolution of spindle (22) changes the pressure setting by approximately 4400 kPa (638 psi).
- Tighten locking setscrew (21) .
- Remove the relief valve cartridge from the vise.
- Remove cap (17) or cap (18) from the drum pump.
- Install spring (19) and relief valve cartridge (20) in the cap. Reinstall the cap in the drum pump.
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| Illustration 13 | g01408997 |
Reverse Main Relief Valve on Left Side of Drum Pump | |
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| Illustration 14 | g01409000 |
Forward Main Relief Valve on Right Side of Drum Pump | |
- Go to Step 14.
- Raise the cab. Refer to Disassembly and Assembly, KENR6413, "Cab - Tilt".
- Loosen the locknut and reset the setting for POR valve (15) by rotating the adjustment screw for two turns in the counterclockwise direction. Hold the adjustment screw and tighten the locknut.
- Remove Tool (E) and Tool (F) from balance line (10) and balance line (11). Reconnect both of the balance lines.
- Reconnect electrical connector (12) for the axle interlock.
- Remove Tool (B) from pressure tap (13) and from pressure taps (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 plate (6) and cover plate (8). Install bolt (5) and bolt (7) .