101602-1401 ZEXEL F 01G 09U 038 BOSCH INJECTION-PUMP ASSEMBLY f01g09u038 1016021401

Illustration 4 g06005614
(A) Hydraulic tank drain
Drain the hydraulic tank. Refer to Illustration 4.Note: After draining, if a significant number of metal particles are visible in the tank, contact BCP STTT support through the DSN for guidance before proceeding further.
Drain the hydraulic cylinders.
Disconnect and drain the lines at all cylinders.
Retract and extend the cylinder rods to evacuate cylinders.
Illustration 5 g06005620
(B) Inlet lines
(C) Outlet lines
Drain the hydraulic oil cooler. Refer to Illustration 5.
Remove inlet and outlet lines at cooler.
Drain the cooler and the lines.Note: Ensure that the cooler has been drained.
Illustration 6 g06005623
(D) Case plug
Drain the hystat pumps. Refer to Illustration 6.
Remove case plug (D) on the rear right side of the pump.
Drain pumps and suction remaining oil from pump housing.Note: Ensure that the pump case has been drained.
Illustration 7 g06005628
(E) Parking brake lines
Drain the parking brake lines. Refer to Illustration 7.
Disconnect and drain the parking brake line (E) at the bottom of the pumps.
Disconnect and drain the right-hand brake line (E) connection.
Illustration 8 g06005631
(F) Case drain lines and hystat motors
Drain the drive motors. Refer to Illustration 8.
Disconnect the case drain lines at the hystat motors.Note: Ensure that the motor cases have been drained.
Illustration 9 g06005637
Standard Machine
(G) Hydraulic filter
Illustration 10 g06005640
Winch Machine
(G) Hydraulic filter
(H) Winch hydraulic filter
Drain the hydraulic filters. Refer to Illustrations 9 and 10.
Replace the standard and winch (if equipped) filters with each drain cycle.
Check filters for metal particles.
Refill the hydraulic system, repeat Steps 2 through 8, running and warming the hydraulic oil between drain, fill, and filter change cycles. Cycle all cylinders and travel circuits after every fill cycle to achieve full circulation throughout the hydraulic and power train systems with the new oil. Perform SOS check after each run cycle and follow standard SOS guidelines, specifically checking for DEF.Note: Typically takes 5 to 6 drain/refill cycles to clean the hydraulic system and get a clean SOS sample. Clean oil will be red and transparent or clear / light yellow and transparent. If there is any milky appearance to the color, repeat Steps 2 through 9.
Confirm that charge pressure can be set and maintained to specification, especially at pump stall.
Recalibrate the hystat pumps and drive motors, ensuring that calibration is successfully completed. Confirm that the hystat pump pressure can be adjusted to the correct specificationNote: Refer to Testing and Adjusting, UENR4089, "D3K2, D4K2, and D5K2 Track-Type Tractor Systems" for the correct procedure and specification.
Illustration 11 g06005642
(1) 484-5902 Diesel Exhaust Fluid (DEF) film(U.S.)(Shown)
(1A) 393-2614 Diesel Exhaust Fluid (DEF) film(International)
(2) 484-5903 Hydraulic oil film
(3) 430-3036 Diesel Exhaust Fluid (DEF) Gauge (Inst) film(Inside Door)
Illustration 12 g06237577
(1) 484-5902 Diesel Exhaust Fluid (DEF) film
(1A) 393-2614 Diesel Exhaust Fluid (DEF) film (International)
(2) 484-5903 Hydraulic oil film
Illustration 13 g06166475
(3) 430-3036 Diesel Exhaust Fluid (DEF) Gauge (Inst) film
New extra DEF (1), hydraulic oil (2), and DEF gauge instruction (3) films will be used in production. Refer to Table 2 for the affected machines that require the new films. For the film locations, refer to Illustrations 11, 12, and 13.Note: Adding these stickers to reduce chances of a recurrence of this issue is recommended.Note: Refer