554 and 574 Forwarders Power Train Filling and Flushing the Hydrostatic System - Test Caterpillar

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Personal injury or death can result if two persons are not used in the following procedure.

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To prevent injury or death, never work under a machine while a test is being performed.

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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.

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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 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.

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Use a stable work platform placed in a secure location when lubricating the pillar, working on the fuel tank, or working on the hydraulic tank. If a secure location is not available, use the appropriate safety equipment to prevent falling off of the machine. Failure to work from a secure location may result in injury or death from a slip or a fall.

Note: Ensure that the machine is on a level surface prior to filling and flushing the power train oil tank.

The initial filling of the power train system must be carried out in such a way that all of the air can escape from the high pressure circuit. Air must be able to escape from the pump case and the motor case prior to operation of the power train components. Ensure that all case drain, control and high pressure hydraulic lines and hydraulic ports are covered prior to removing or replacing a component. Ensure that the power train pump housing and the power train motor housing are filled with clean oil prior to installation.

Connect and tighten each hydraulic line one at a time. Remove any caps or any covers just prior to making each connection. Pipes must be deburred, washed and blown through. Scaled pipes or rusted pipes must be scoured and then neutralized prior to use. Hoses must be brushed through and flushed through prior to installation if they are contaminated.

554 Forwarder 1AM1-UP 574 Forwarder ; 1FM1-433

Note: Prior to starting the following procedure you must tilt the cab up.

Reference: For more information about tilting the cab, refer to Operation and Maintenance Manual, "Cab Tilting".

Illustration 1	g00931551
Power Train Oil Tank with Breaker Relief Valve

The breaker relief valve will help ensure that the oil tank can be purged of any air that is inside the oil tank.

Fill the Hydrostatic System

Note: In order to obtain information about the following items: oil change intervals, oil and oil filters refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change".

Illustration 2	g00874274

The power train oil tank is located on the right side of the machine.

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Illustration 3	g00931551
Power Train Oil Tank with Breaker Relief Valve

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Illustration 4	g00931596
(3) Toggle switch.

1. Fill the power train oil tank with new oil.

   If the machine is equipped with an electric hydraulic oil makeup pump, attach the hose to coupling (2) and place the end of the other hose in the new oil. Push toggle switch (3) in the down direction in order to pump the oil into the power train oil tank. Push toggle switch (3) to the up position in order to stop pumping the oil into the power train oil tank.

   If the tank is not equipped with an electric hydraulic oil makeup pump, a manual pump should be used.

   Reference: Refer to Operation and Maintenance Manual, "Lubricant Viscosities and Refill Capacities" for the correct type of lubricant and for the capacity of the power train oil tank.

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Illustration 5	g00874282
Typical Example

2. The sight gauge for the power train oil tank is mounted on the power train oil tank on the right side of the machine. Maintain the oil level to the midpoint of the upper region of the sight gauge. Add oil, if necessary.

   Note: Do not maintain the oil level above the midpoint of the upper region. Otherwise, power train oil can spill from the top of the tank.

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Illustration 6	g00931551
Power Train Oil Tank with Breaker Relief Valve

3. Remove breaker relief valve (1). Clean breaker relief valve (1) in a clean, nonflammable solvent. Install breaker relief valve (1) .

4. Disconnect hose from coupling (2) .

Flush the Hydrostatic System

1. Throughout the entire procedure, ensure that the power train oil tank is filled to the recommended capacity. Ensure that the power train pump and the power train motor are filled to capacity prior to flushing the hydrostatic system.

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Illustration 7	g00914328

2. Slowly loosen fitting (4) that is located on the right side of the power train pump. Do not remove fitting (4) completely.

3. Allow the air that is in the system to purge from the power train pump.

4. Tighten fitting (4) .

5. Check the level of the power train oil tank. Add additional oil if necessary.

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Illustration 8	g00914330

6. Slowly loosen fitting (5) that is located on top of the power train motor. Do not remove fitting (5) completely.

7. Allow the air that is in the system to purge from the power train motor.

8. Tighten fitting (5) .

9. Check the level of the power train oil tank. Add additional oil if necessary.

10. Lower the cab onto the frame.

    Reference: For more information about tilting the cab, refer to Operation and Maintenance Manual, "Cab Tilting".

574 Forwarder 1FM434-UP

Note: Prior to starting the following procedure you must tilt the cab up.

Reference: For more information about tilting the cab, refer to Operation and Maintenance Manual, "Cab Tilting".

Illustration 9	g00914492
Breaker relief valve location.

Your machine is equipped with a breaker relief valve. This valve will help to relieve system pressure when filling the hydraulic tank and when flushing the hydraulic tank.

Note: The 574 Forwarder 1FM434-UP uses an integrated hydraulic and power train oil tank.

Fill the Hydrostatic System

Note: In order to obtain information about the following items: oil change intervals, oil and oil filters refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change".

Illustration 10	g00874274

The hydraulic oil tank is located behind the cab.

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Illustration 11	g00931657
Oil Tank (1) Breaker relief valve. (2) Coupling. (3) Toggle switch.

1. Fill the power train oil tank with new oil.

   If the machine is equipped with an electric hydraulic oil makeup pump, attach the hose to coupling (2) and place the end of the other hose in the new oil. Push toggle switch (3) in the down direction in order to pump the oil into the power train oil tank. Push toggle switch (3) to the up position in order to stop pumping the oil into the power train oil tank.

   If the tank is not equipped with an electric hydraulic oil makeup pump, a manual pump should be used.

   Reference: Refer to Operation and Maintenance Manual, "Lubricant Viscosities and Refill Capacities" for the correct type of lubricant and for the capacity of the power train oil tank.

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Illustration 12	g00938548

2. The sight gauge for the oil tank is mounted on the oil tank on the right side of the machine. Maintain the oil level to the midpoint of the upper region of the sight gauge. Add oil, if necessary.

   Note: Do not maintain the oil level above the midpoint of the upper region. Otherwise, oil can spill from the top of the tank.

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Illustration 13	g00931657
Oil Tank (1) Breaker relief valve. (2) Coupling. (3) Toggle switch.

3. Remove breaker relief valve (1). Clean breaker relief valve (1) in a clean, nonflammable solvent. Install breaker relief valve (1) .

4. Disconnect hose from coupling (2) .

Flush the Hydrostatic System

1. Throughout the entire procedure, ensure that the power train oil tank is filled to the recommended capacity. Ensure that the power train pump and the power train motor are filled to capacity prior to flushing the hydrostatic system. Ensure that the oil cooler is filled to capacity prior to flushing the hydrostatic system.

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Illustration 14	g00914549

2. Loosen fitting (4) and fitting (5) that are located on the oil coolers. Do not completely remove the fittings.

3. Allow air in the oil coolers to purge out of fitting (4) and fitting (5) .

4. Tighten fitting (4) and fitting (5) .

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Illustration 15	g00914551
Implement pump and power train pump.

5. Loosen fitting (6) and fitting (7) that are located on the power train pump and the implement pump. Do not completely remove the fittings.

6. Allow air in the pumps to purge out of fitting (6) and fitting (7) .

7. Tighten fitting (6) and fitting (7) .

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Illustration 16	g00914552

8. Disconnect the electrical connector at temperature sensor (8) .

9. Loosen temperature sensor (8) that is located on the power train motor.

10. Allow air in the power train motor to purge out of temperature sensor (8) .

11. Tighten temperature sensor (8) .

12. Check the level of the hydraulic tank. If the oil level is not within specification, fill as necessary.

13. The following steps will ensure that the hydrostatic system is properly primed. The following steps will prevent the implement pump from upstroking immediately after the machine is started. This will allow the hydrostatic system to be safely primed.

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Illustration 17	g00931695

14. Disconnect the oil line at fitting (9). Ensure that you cap all open connections at fitting (9) and manifold (10) .

    Note: This will prevent oil from the cold start solenoid valve upstroking the implement pump. The pump will upstroke when the machine is started in order to ensure that the brake accumulators are fully charged.

15. Lower the cab onto the frame.

    Reference: For more information about tilting the cab, refer to Operation and Maintenance Manual, "Cab Tilting".

16. Start the engine and let the engine run at low idle for approximately ten minutes in order to allow the system to be purged by the charge pump.

17. Stop the engine.

18. Raise the cab in order to access the oil line that was disconnected in Step 14.

    Reference: For more information about tilting the cab, refer to Operation and Maintenance Manual, "Cab Tilting".

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Illustration 18	g00931695

19. Reconnect the oil line at fitting (9) to manifold (10) .

20. Lower the cab onto the frame.

    Reference: For more information about tilting the cab, refer to Operation and Maintenance Manual, "Cab Tilting".

21. Start the engine. Set the engine idle speed to 1300 RPM.

22. Set the machine to WORKING MODE.

23. Set maximum travel speed to 20 percent.

24. Drive the machine over a level surface for approximately five minutes in order to ensure that the power train system has been completely purged of any air.