RENR4113-01

September 2002

Systems Operation
Troubleshooting
Testing and Adjusting
140H, 143H, 160H and
163H Motor Graders
Hydraulic and Steering System
ASD1-Up (Machine)
ARL1-Up (Machine)
APM1-Up (Machine)
APN1-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Hydraulic and Steering System
Table of Contents

Table of Contents
Systems Operation Section
Introduction ............................................................ 4
Location Of Components ........................................ 6
Hydraulic and Steering System ........................... 10
Hydraulic Tank and Filter ..................................... 12
Piston Pump (Hydraulic and Steering) .................. 13
Combination Valve ............................................... 22
Implement System ............................................... 28
Control Valve (Implement) .................................... 31
Control Valve (Blade Lift) ...................................... 32
Centershift Lock ................................................... 38
Blade Cushion ..................................................... 39
Steering System .................................................. 40
Metering Pump (Steering) .................................... 44
Fan Drive System ................................................. 48
Piston Pump (Hydraulic Fan) ................................ 50
Hydraulic Schematic ............................................. 51
Color Chart ........................................................... 53

Troubleshooting Section
Introduction
General Information .............................................. 56
Machine Preparation for Troubleshooting ............. 56
Visual Inspection ................................................... 57
Operational Checks .............................................. 57

Symptom Procedures
Hydraulic and Steering System ............................ 59

Testing and Adjusting Section

Testing and Adjusting
Bearing End Play (Piston Pump) - Adjust ............. 64
Pressure and Flow Compensator Valve (Hydraulic
and Steering) - Test and Adjust ........................... 65
Relief Valve (Implement) - Test and Adjust ........... 73
Accumulator (Blade Cushion) - Test and Charge .. 74
Hydraulic Cylinder Drift - Check ............................ 77
Disc Pack Preload for Circle Drive - Adjust ........... 77
Cylinder Cycle Time - Check ................................ 78
Steering Wheel Slip - Check ................................. 80
Relief Valve (Steering) - Test and Adjust .............. 80
Steering System - Purge ....................................... 81
Axle Toe-In (Front) - Adjust ................................... 84
Position Sender (Articulation) - Adjust .................. 85
Piston Pump Cutoff Pressure (Hydraulic Fan) - Test
and Adjust ........................................................... 86
Piston Pump Margin Pressure (Hydraulic Fan) - Test
and Adjust ........................................................... 88

Index Section
Index ..................................................................... 90
4
Hydraulic and Steering System
Systems Operation Section

Systems Operation Section

i01785822

Introduction
SMCS Code: 4300; 5050

g00923168
Illustration 1

This module discusses the features and operation Hydraulic Tank and Filter
of the hydraulic and steering system. The following
motor graders are covered in this module: Piston Pump (Hydraulic and Steering)
140H Combination Valve
160H Control Valve (Implement)
143H Control Valve (Blade Lift)
163H Centershift Lock
The hydraulic system is a proportional priority Blade Cushion
pressure compensated (PPPC) system. The PPPC
system is a load sensing system. The PPPC system Metering Pump (Steering)
uses a load sensing hydraulic and steering pump
in order to perform the pressure compensation Piston Pump (Hydraulic Fan)
function. The implement control valves have an
internal flow compensator. This flow compensator
performs the proportional priority function.

The hydraulic and steering system has the following

main components:

Hydraulic Tank and Filter
The hydraulic tank supplies hydraulic oil to the
hydraulic and steering system. The hydraulic tank
is not vented. Pressure is relieved when the cap
is loosened. The hydraulic tank contains a bypass
valve. If the filter becomes full of debris, the bypass
valve will open. Correct maintenance must be used
in order to ensure that the hydraulic fluid flows
through the filter.
Piston Pump (Hydraulic and
Steering)
The hydraulic and steering pump is a variable
displacement axial piston pump. When the engine
is operating, the pump will produce flow in order to
satisfy the following conditions:
The demand of the steering system
The pressure setting of the pressure compensator
The demand of the hydraulic implements
The internal lubrication of the pump components
The margin pressure of the pump
Combination Valve
The combination valve directs the oil from the
hydraulic and steering pump to the steering circuit
and to the implement circuit.
Control Valve (Implement)
The implement control valve regulates the operation
of each implement. Each implement control valve
contains a compensator valve. The compensator
valve distributes the oil flow that is available. The
implement control valve may contain a relief valve.
The relief valve will protect the rod end of the
cylinders from high pressures.
Control Valve (Blade Lift)
The blade lift control valve regulates the operation
of the blade lift cylinders. The blade lift control
valve may contain a hydraulic detent. The blade lift
control valve may contain a mechanical detent.
5
Hydraulic and Steering System
Systems Operation Section
Centershift Lock
The centershift lock control sends a signal to the
solenoid valve in order to engage the centershift
lock pin. Transmission fluid is used in this circuit on
all of the machines that are covered in this manual
except the machines with all wheel drive. On the
machines with all wheel drive, the fluid that is used
in this circuit comes from the all wheel drive pump.
Blade Cushion
The blade cushion dampens the shocks that
are made in the blade lift hydraulic circuit when
the blade contacts an object that will not move.
The blade cushion accumulators have a nitrogen
precharge pressure that provides the cushion.
Metering Pump (Steering)
The steering metering pump is made up of two
parts, the control section and the metering section.
When the steering wheel is turned, the control
section sends oil to the metering section. The
metered oil is then directed by the control section to
either the left steering cylinder or the right steering
cylinder.
Piston Pump (Hydraulic Fan)
The piston pump for the hydraulic fan is a variable
displacement axial piston pump. The piston pump
for the hydraulic fan is used to supply oil to the
fan motor. The piston pump for the hydraulic fan
contains a pressure and flow compensator valve.
The pressure and flow compensator valve regulates
the fan circuit.
i01786995
Location Of Components
SMCS Code: 4300; 5050
6
Hydraulic and Steering System
Systems Operation Section

Hydraulic and Steering System

g00917159
Illustration 2
Typical Location of Components
(1) Fan motor (9) Left valve bank (19) Fan drive pump
(2) Articulation cylinder (10) Blade tip cylinder (20) Right valve bank
(3) Fan speed solenoid (11) Blade lift cylinder (21) Centershift cylinder
(4) Pressure and flow compensator valve (12) Circle drive (22) Sideshift cylinder
(hydraulic and steering pump) (13) Steering cylinder (23) Blade lift cylinder
(5) Combination valve (14) Oil pressure sensor (24) Swivel
(6) Steering accumulator (15) Makeup valve (25) Steering cylinder
(7) Pressure and flow compensator (fan (16) Articulation cylinder (26) Wheel lean cylinder
pump) (17) Hydraulic Tank
(8) Steering metering pump (18) Hydraulic and steering pump

Note: Some of the motor graders may have different

implements. The number of control valves in each
valve group may vary.
 7
Hydraulic and Steering System
Systems Operation Section

Hydraulic Tank Pressure and Flow Compensator Valve

(Hydraulic and Steering)

g00920264
Illustration 3
The hydraulic tank is not vented. The hydraulic tank
contains a reverse flow element. The hydraulic tank
is located directly behind the operators cab.
Hydraulic and Steering Pump
g00920277
Illustration 5
The pressure and flow compensator valve for the
hydraulic and steering keeps the pump pressure
and the pump flow at the level that is needed to
fulfill the requirements of the hydraulic and steering
system. The pressure and flow compensator valve
is attached to the hydraulic and steering pump.

Combination Valve

g00920265
Illustration 4

The hydraulic and steering pump is a variable

displacement axial piston pump. The hydraulic and
steering pump is located below the cab in front of g00920267
Illustration 6
the engine.
The combination valve directs hydraulic fluid to the
steering system and the implement system. The
combination valve is located underneath the cab
next to the hydraulic and steering pump.

Steering Priority Valve

The steering priority valve establishes a priority to

the steering circuit before the implement circuit.

Steering Relief Valve

The steering relief valve limits the maximum

pressure that is allowed to the steering circuit. The
steering relief valve is set at 19300 689 kPa
(2800 100 psi).
8
Hydraulic and Steering System
Systems Operation Section

Implement Relief Valve Steering Accumulator

The implement relief valve protects the hydraulic
and steering pump from excessively high pressures.
The implement relief valve is set at 26900 kPa
(3900 psi).

Load Check Valve

The load check valve maintains the steering

accumulator pressure at the inlet of the steering
metering pump. This pressure will allow a more
responsive steering operation.

Signal Resolver Valve

The signal resolver valve selects the higher of the
two signal pressures from the steering circuit and
the implement circuit. The highest signal is then
routed to the pressure and flow compensator valve.
Signal Relief Valve
g00920270
Illustration 8
The steering accumulator prevents the momentary
interruption in the steering operation that is caused
by sudden changes in pump demand. The steering
accumulator is mounted to the combination valve.

The signal relief valve limits the maximum implement Steering Metering Pump
signal pressure. The signal relief valve is set at
22050 kPa (3200 psi).

Signal Purge Valve

The signal purge valve allows the signal pressure

to go to the hydraulic tank when the implement
controls are returned to the HOLD position.

Centershift Lock Cylinder

g00920271
Illustration 9

The steering metering pump directs hydraulic oil to

the right steering cylinder and to the left steering
cylinder. The steering metering pump is located
inside the steering column.

g00920877
Illustration 7

Centershift lock cylinder is located on the rear of

the link bar. When the lock pin is not engaged with
the arm assembly, the arm assembly and the circle
can be moved in order to place the blade in the
correct position.
 9
Hydraulic and Steering System
Systems Operation Section

Implement Control Valves

g00920274
Illustration 10

There are typically eight implement control valves

on each machine. There is a maximum of fourteen
implement control valves that can be installed on
each machine. The implement control valves direct
oil to the corresponding implement. The implement
control valves are located underneath the cab.

Fan Drive Pump

g00923120
Illustration 11

The fan drive pump is a variable displacement axial

piston pump. The fan drive pump is mounted on
the hydraulic and steering pump.
10
Hydraulic and Steering System
Systems Operation Section

i01678231

Hydraulic and Steering System

SMCS Code: 4300; 5050

Illustration 12
Diagram for oil flow
(1) Right valve group
(2) Steering accumulator
(3) Implement supply line
(4) Steering metering pump
(5) Steering metering pump drain line
(6) Lines to steering cylinders
(7) Combination valve
(8) Pressure and flow compensator
(9) Hydraulic and steering pump
(10) Signal line for the implements
g00866042
(11) Steering metering pump supply line
(12) Drain line for the implements
(13) Left valve group
 11
Hydraulic and Steering System
Systems Operation Section

g00921387
Illustration 13
(3) Implement supply lines (10) Signal lines for the implements (14) Hydraulic pump suction line from
(7) Combination valve (12) Drain lines for the implements hydraulic tank

In a low pressure standby situation, the implement i01765274

circuit and the steering circuit do not demand any
oil from hydraulic and steering pump (9). Hydraulic Hydraulic Tank and Filter
and steering pump (9) sends low pressure oil to
combination valve (7). The low pressure oil flows SMCS Code: 4332; 5056; 5068
through implement supply line (3) to right valve
group (1) and to left valve group (13). Since the
valve groups do not require any flow, the hydraulic
oil flows back to the hydraulic tank through drain
line (12).

Hydraulic oil also flows to steering metering pump

(4) through supply line (11). Since pump (4) does
not demand any oil flow, the oil flows through an
internal orifice in pump (4). The oil then flows back
to the hydraulic tank through line (5). The steering
signal acts upon pressure and flow compensator
valve (8) in order to keep pump (9) at a low
pressure standby situation.
12
Hydraulic and Steering System
Systems Operation Section

The oil reservoir is not vented. The oil reservoir

contains a reverse flow element. Pressure is relieved
when the cap is loosened. Hydraulic oil tank (1)
is designed with internal baffle (2). Internal baffle
(2) improves the oil circulation in hydraulic oil tank
(1). Internal baffle (2) provides a continuous flow
of hydraulic oil to the charge pump. Supply port
(11) is provided in hydraulic oil tank (1) for the
charge pump. Supply port (6) provides oil flow
to the fan drive. Supply port (7) provides oil flow
to the Hydraulic and steering pump. Supply port
(5) provides oil flow for the supplemental steering
pump.

Implement return port (9) and case drain return port

(8) combine the oil into the manifold. The manifold
routes the oil through the bottom of filter element (3)
and inside of filter element (3). The filter element
is positioned below the oil level in order to reduce
turbulence.

If filter element (3) becomes full of debris, oil cannot

pass through the filter element. The restriction to
oil flow causes a pressure increase which opens
bypass valve (4). A pressure of 35 kPa (5 psi)
will cause the bypass valve to open. Now, the oil
is allowed directly into hydraulic tank (1). When
oil bypasses filter element (3), debris in the oil
will cause damage to other system components.
Correct maintenance must be used in order to make
sure that the filter element does not stop the flow of
clean oil to the hydraulic system.

g00903100
Illustration 14
(1) Hydraulic oil tank
(2) Internal baffle
(3) Filter element
(4) Bypass valve
(5) Supply port for supplemental steering
(6) Supply port for the fan drive
(7) Supply port for the hydraulic and steering
(8) Case drain return port
(9) Implement return port
(10) Port for the temperature switch
(11) Supply port for the charge pump
 13
Hydraulic and Steering System
Systems Operation Section

i01785894

Piston Pump (Hydraulic and

Steering)
SMCS Code: 4306; 5070

g00921866
Illustration 15
Typical Hydraulic Pump
(1) Pump drive shaft (5) Inlet opening from the hydraulic tank (9) Control Piston
(2) Pistons (6) Swashplate (10) Outlet opening to the combination valve
(3) Bias spring (7) Slipper (11) Pressure and flow compensator valve
(4) Barrel (8) Retraction Plate

The hydraulic and steering pump is a variable When the engine is operating, the pump will
displacement axial piston pump. produce flow in order to satisfy the following
conditions:
The hydraulic and steering pump has nine pistons
(2). When drive shaft (1) turns, barrel (4), slippers The demand of the steering system
(7) and retraction plate (8) turn. The piston ends
connect to the slippers. Swashplate (6) does not The pressure setting of the pressure compensator
turn. There is a bearing journal on each side of the
swashplate. The two bearing journals are inside The demand of the hydraulic implements
bearings which allow movement of the swashplate.
Oil flow through the passages in the pistons The internal lubrication of the pump components
lubricates the internal components of the pump.
The margin pressure of the pump
When swashplate (6) is at the maximum angle and
drive shaft (1) is turning, pistons (2) are moved in
and out of barrel (4). As the pistons move out of the
barrel, the pistons create a vacuum at inlet opening
(5). The pressure in the hydraulic tank pushes the
oil into the inlet opening. The oil passes through the
inlet opening and into the piston bore in the barrel.
As the barrel continues to turn, the pistons are
pushed into the barrel as the slippers rotate up the
angle of swashplate (6). The pistons push the oil
from the piston bore through pump outlet opening
(10) and into the combination valve.
14
Hydraulic and Steering System
Systems Operation Section

Pressure and Flow Compensator

Valve

Illustration 16
(12) Line for signal oil pressure
(13) Adjustment screw for the flow
compensator
(14) Adjustment screw for the pressure
compensator
(15) Spring (pressure compensator)
g00921974
(16) Spring (flow compensator)
(17) Oil flow to the pump case
(18) Oil flow to the control piston
(19) Oil flow from the output port of the pump
(20) Spool (flow compensator)
(21) Spool (pressure compensator)

Pressure and flow compensator valve (11) keeps the The pressure and flow compensator valve limits
pump pressure and the pump flow at the level that the pressure in order to prevent overloads of the
is needed to fulfill the requirements of the hydraulic hydraulic system.
and steering system. When the hydraulic circuits
are not active, the pump is at low pressure standby. When the system pressure exceeds the setting of
However, if one or more circuits are active, the the pressure and compensator valve, the pressure
resolver valve in the combination valve compares compensator will override the flow compensator.
the signal pressure of the hydraulic system. The This will lower the output flow of the pump. This
highest resolved signal pressure is then routed protects the hydraulic system from damaging high
to the pressure and flow compensator valve. The pressures.
pressure and flow compensator valve adjusts the
swashplate angle of the pump in order to maintain
flow and pressure requirements. The margin
pressure is defined as the difference between the
pump pressure and the signal pressure (12) with
the force of spring (16).
 15
Hydraulic and Steering System
Systems Operation Section

Low Pressure Standby

g00923159
Illustration 17
Typical Example of a Piston Pump at Low Pressure Standby
(1) Pump drive shaft (9) Control piston (19) Oil flow from the output port of the pump
(2) Pistons (12) Signal oil from the combination valve (20) Spool (flow compensator)
(3) Bias spring (15) Spring (Pressure compensator) (21) Spool (pressure compensator)
(4) Barrel (16) Spring (flow compensator) (22) Bias piston
(6) Swashplate (18) Oil passage to the control piston

When the engine is off, spring (3) holds swashplate
(6) at the maximum angle. When the engine is
started, shaft (1) begins to rotate. Oil is drawn into
the bore of pistons (2). Barrel (4) starts to rotate
and pistons (2) stroke. This forces hydraulic oil into
the hydraulic system.
There is no demand on the steering.
When the steering metering pump is in the HOLD
position, pump flow is blocked at the steering
metering pump and no signal pressure is generated
in line (12).

The pump is in low pressure standby when the As the pump produces flow, the system pressure
following conditions are met: begins to increase. The system pressure overcomes
the spring force of spring (16) and the signal
The machine is operating. pressure in line (12).

The implements are in the HOLD position.

16
Hydraulic and Steering System
Systems Operation Section

Spool (20) moves up and oil flows into passage

(18) to piston (9). The oil pressure inside piston
(9) overcomes the spring force of spring (3) and
the system pressure inside piston (22). Piston (9)
moves the swashplate to the minimum angle. When
the swashplate is moved to the minimum angle, the
oil flows through the cross-drilled passage to the
pump case. The system pressure at this point is
called low pressure standby. The system pressure
at this point is approximately 3300 kPa (480 psi).

When the pump is at low pressure standby, the

pump produces enough flow in order to compensate
for internal leakage. Also, the pump produces
enough flow in order to maintain sufficient system
pressure. Low pressure standby is maintained in
order to ensure instantaneous response under one
of the following conditions:

The steering is activated.

An implement is activated.
Low pressure standby is higher than margin
pressure. This characteristic is due to a higher back
pressure that is created by the closed center valves
that are in the HOLD position. The pump supply oil
moves spool (20) upward. This compresses spring
(16). Since spool (20) is moved upward, more of the
pump supply oil is allowed to flow through passage
(18). The oil will flow through passage (18) and flow
out of the cross-drilled passage to the pump case.
 17
Hydraulic and Steering System
Systems Operation Section

Upstroke

g00922729
Illustration 18
Typical Example of a Piston Pump During Upstroke
(1) Pump drive shaft (15) Spring (Pressure compensator)
(2) Pistons (16) Spring (flow compensator)
(3) Bias spring (18) Oil passage to the control piston
(4) Barrel (19) Oil flow from the output port of the pump
(6) Swashplate (20) Spool (flow compensator)
(9) Control piston (21) Spool (pressure compensator)
(12) Signal oil from the combination valve (22) Bias piston

When more oil flow is needed, the hydraulic pump

upstrokes. When the steering requires increased
oil flow or when any implement control valves
require increased oil flow, signal oil is sent from
the combination valve to the pressure and flow
compensator valve. The combination of the signal
pressure in line (12) and the force of spring (16)
cause spool (20) to block the oil flow into passage
(18). With no oil flow to piston (9), spring (3) is
now allowed to increase the swashplate angle. The
hydraulic pump will produce more oil flow.
18
Hydraulic and Steering System
Systems Operation Section

Constant Flow

g00918289
Illustration 19
Typical Example of a Piston Pump During Constant Flow
(1) Pump drive shaft (15) Spring (Pressure compensator)
(2) Pistons (16) Spring (flow compensator)
(3) Bias spring (18) Oil passage to the control piston
(4) Barrel (19) Oil flow from the output port of the pump
(6) Swashplate (20) Spool (flow compensator)
(9) Control piston (21) Spool (pressure compensator)
(12) Signal oil from the combination valve (22) Bias piston

As the pump flow increases, the pump supply

pressure increases. When the pump supply
pressure increases to the point of equalling the
sum of the signal pressure (12) and the spring
(16), spool (20) moves to a metering position. The
difference between the signal pressure (12) and the
pump supply pressure is the value of spring (16).
The value of spring (16) is 2100 kPa (305 psi).
 19
Hydraulic and Steering System
Systems Operation Section

Destroke

g00922730
Illustration 20
Typical Example of a Piston Pump During Destroke
(1) Pump drive shaft (9) Control piston (19) Oil flow from the output port of the pump
(2) Pistons (12) Signal oil from the combination valve (20) Spool (flow compensator)
(3) Bias spring (15) Spring (Pressure compensator) (21) Spool (pressure compensator)
(4) Barrel (16) Spring (flow compensator) (22) Bias piston
(6) Swashplate (18) Oil passage to the control piston

When less oil flow is required, the hydraulic pump
destrokes. The pump destrokes when the force on
the bottom of spool (20) is greater than the force
of spring (16) and signal pressure (12) combined.
Spool (20) moves upward. This allows more oil to
flow to piston (9). With increased oil pressure on
piston (9), the swashplate angle decreases. The
hydraulic pump will produce less oil.
The following conditions will cause the pump to
destroke:
All implement control valves are moved to the
HOLD position. The pump returns to low pressure
standby.
The control valves directional stem is moved in
order to reduce flow.
Any of the additional circuits are deactivated.
If the engine rpm increases, the pump speed
increases. The pump will destroke in order to
maintain the systems flow requirements.
20
Hydraulic and Steering System
Systems Operation Section

Note: In order for the pump to destroke, the signal

pressure may not always decrease. For example, if
two implements are activated with one implement
at 13800 kPa (2000 psi) and the other implement at
6900 kPa (1000 psi), the system pressure will be at
15900 kPa (2305 psi). The system pressure is equal
to the signal pressure plus the spring pressure. The
signal pressure is 13800 kPa (2000 psi). The spring
pressure is 2100 kPa (305 psi). When the operator
returns the implement with 6900 kPa (1000 psi) to
the HOLD position, the system pressure will still be
15900 kPa (2305 psi), but the pump supply pressure
will increase due to reduced flow requirements. The
pump supply pressure will push spool (20) upward.
This will allow more oil to flow through passage (18)
in order to increase the pressure on piston (9). The
angle of swashplate (6) will decrease.
 21
Hydraulic and Steering System
Systems Operation Section

High Pressure Stall

g00922732
Illustration 21
Typical Example of a Piston Pump at High Pressure Stall
(1) Pump drive shaft (15) Spring (Pressure compensator)
(2) Pistons (16) Spring (flow compensator)
(3) Bias spring (18) Oil passage to the control piston
(4) Barrel (19) Oil flow from the output port of the pump
(6) Swashplate (20) Spool (flow compensator)
(9) Control piston (21) Spool (pressure compensator)
(12) Signal oil from the combination valve (22) Bias piston

Note: The following description is for a single circuit

that is in operation.
22
Hydraulic and Steering System
Systems Operation Section

When signal pressure (12) and the spring force i01765565

from spring (16) are equal to the output pressure
in line (19), spool (20) moves downward. This Combination Valve
blocks the pressure oil from piston (9). The angle
of swashplate (6) increases. When the implement SMCS Code: 5051; 5064
is stalled, the pressure in line (19) increases to
the setting of spring (15). This causes spool (21)
to move upward. The oil in the inlet passage now
flows through passage (18) into piston (9). The flow
of oil from passage (18) moves piston (9). Piston
(9) moves swashplate (6) toward the minimum
angle. The pump output is decreased. The pump
produces enough flow in order to compensate for
internal leakage. Also, the pump produces enough
flow in order to maintain system pressure.

When the system pressure decreases to a pressure

that is less than the setting of spring (15), spool
(21) moves downward. Spool (20) now controls the
flow from the pump.

When several circuits are actuated in a stall

condition, the pump will not destroke. The angle of
swashplate (6) will decrease enough to supply oil to
the remaining circuits that are not stalled.

g00903280
Illustration 22
(1) Combination Valve
(2) Steering Relief Valve
(3) Implement Relief Valve
(4) Signal Relief Valve
(5) Signal Resolver Valve
(6) Signal Purge Valve

Combination valve (1) contains the steering priority

valve. The steering priority valve directs the oil from
the hydraulic and steering pump to the metering
pump. When the steering metering pump is in the
HOLD position, oil from the hydraulic and steering
pump is directed to the implement circuit. As the
steering metering pump is rotated, oil from the
hydraulic and steering pump is directed to the
steering circuit. Steering relief valve (2) protects the
steering circuit. Implement relief valve (3) protects
the hydraulic and steering pump from excessively
high pressure. Signal relief valve (4) limits the signal
pressure in the implement circuit. Signal purge
valve (6) is used to relieve the implement signal
pressure when the implement control valves are
moved to the HOLD position. Signal resolver valve
(5) directs the highest signal pressure from either
the steering circuit or the implement circuits to
the pressure and flow compensator valve of the
hydraulic and steering pump.

Low Pressure Standby
Illustration 23
(2) Steering relief valve
(3) Implement relief valve
(4) Signal relief valve
(5) Signal resolver
(6) Signal purge valve
(7) Port from the secondary steering pump
(8) Check valve for the steering circuit
(9) Signal pressure line from the implement
control valves
23
Hydraulic and Steering System
Systems Operation Section
g00919800
(10) Signal pressure line to the steering
metering pump
(11) Signal pressure line to hydraulic and
steering pump
(12) Ports to implement control valves
(13) Port for hydraulic pump output
(14) Line to the hydraulic tank
(15) Supply port for steering
(16) Steering priority valve
24
Hydraulic and Steering System
Systems Operation Section

When the combination valve is in the low pressure

standby condition, pump supply oil enters the
combination valve through port (13). The oil that
flows through port (12) is blocked at the implement
control valves. Pump supply oil flows through the
orifice to the left of the priority valve spring. The
signal oil flows through line (10) to the steering
metering pump. The signal oil then flows through
an orifice within the steering metering pump. The
signal oil then flows back to the hydraulic tank. Also,
signal oil flows through line (11) to the pressure
and flow compensator valve. Signal oil that flows
through line (11) causes the hydraulic and steering
pump to move toward the minimum angle. Low
pressure standby is 3300 kPa (480 psi).

The pump supply oil is approximately 1900 kPa

(275 psi) due to the spring pressure 1030 kPa
(150 psi) and the pressure of the signal oil 850 kPa
(125 psi).
 25
Hydraulic and Steering System
Systems Operation Section

Steering Actuated

Illustration 24
(2) Steering relief valve
(3) Implement relief valve
(4) Signal relief valve
(5) Signal resolver
(6) Signal purge valve
(7) Port for the secondary steering pump
(8) Check valve for the steering circuit
(9) Signal pressure line from the implement
control valves
g00919801
(10) Signal pressure line to the steering
metering pump
(11) Signal pressure line to hydraulic and
steering pump
(12) Ports to implement control valves
(13) Port for hydraulic pump output
(14) Line to the hydraulic tank
(15) Supply port for steering
(16) Steering priority valve

When the steering metering pump is activated, the
pressure in line (15) decreases. Valve (16) shifts
to the left in order to allow more oil flow through
line (15). As more oil flows through line (15),
pressure increases on the left end of valve (16). The
increased pressure causes valve (16) to shift to the
right in order to modulate the flow.
When the steering system pressure increases to
6895 kPa (1000 psi), the accumulator will start to
become charged. The steering accumulator will
eliminate any fluctuations in the steering system.
The accumulator will become fully charged when
the steering system is activated in the fully right
position or in the fully left position.
26
Hydraulic and Steering System
Systems Operation Section

Steering and Implements Actuated

Illustration 25
(2) Steering relief valve
(3) Implement relief valve
(4) Signal relief valve
(5) Signal resolver
(6) Signal purge valve
(7) Port for the secondary steering pump
(8) Check valve for the steering circuit
(9) Signal pressure from the implement
control valves
(10) Signal pressure line to the steering
metering pump
(11) Signal pressure to hydraulic and
steering pump
(12) Ports to implement control valves
g00919802
(13) Port for hydraulic pump output
(14) Line to the hydraulic tank
(15) Supply port for steering
(16) Steering priority valve

When both the steering circuit and the implement
circuits are used, steering priority valve (16) will
constantly shift. Valve (16) constantly shifts in
order to satisfy the oil demands of the system.
The steering circuit always has priority over the
implements. When any of implement control valves
are operated, the signal oil is directed through line
(9) to signal resolver (5), signal purge valve (6) and
signal relief valve (4).
If signal pressure (9) is higher than steering signal
pressure (10), the ball in signal resolver valve (5)
will move upward. This will direct implement signal
pressure (9) to the pressure compensator valve.
As the implement signal pressure increases above
1035 kPa (150 psi), valve (6) will move upward
in order to block the drain passage. When an
implement is deactivated, valve (6) will move in
order to open the drain passage.
 27
Hydraulic and Steering System
Systems Operation Section

If the implement signal pressure increases above

the pressure setting of signal relief valve (4), signal
relief valve (4) will limit the signal pressure that goes
to the pressure compensator valve. This will prevent
the pump from destroking.

Implement relief valve (3) provides protection for the

system if the pressure compensator fails to destroke
the hydraulic and steering pump. Also, the valve
limits a spike in the pump circuit.

Signal Network

g00919804
Illustration 26
Flow of Signal Oil from the Right Blade Lift Control Valve (25)
(1) Combination valve (19) Circle drive control valve (25) Right blade lift control valve
(5) Signal resolver (20) Blade tip control valve (26) Signal check valve for the right blade lift
(11) Line to pressure and flow compensator (21) Drain (27) Signal oil to signal purge valve and
valve (22) Articulation control valve signal relief valve
(17) Left blade lift control valve (23) Centershift control valve (28) Line from the combination valve
(18) Sideshift control valve (24) Wheel lean control valve
28
Hydraulic and Steering System
Systems Operation Section

The signal oil for the blade lift forces all the signal
check valves to be in the CLOSED position. The
signal oil for the blade lift also forces all the
compensator valves that are in the implements to
be in the CLOSED position. Even though there is
steering signal oil pressure, the signal oil pressure
is lower than the signal pressure for the blade lift.
The ball in signal resolver (5) moves in order to
direct the signal oil pressure for the blade lift to the
pressure compensator valve.

The hydraulic and steering pump transfers oil from

the hydraulic tank to the implement cylinders and to
the circle drive motor through the implement control
valves. The combination valve provides the priority
for the steering circuit. The combination valve also
transfers load signals from the implement control
valves to the hydraulic pump.

i01780817

Implement System
SMCS Code: 5050

The implement circuits are composed of four main

components:

Hydraulic and steering pump

Combination valve
Implement control valves
Cylinders and the circle drive
The hydraulic and steering pump transfers oil
from the hydraulic tank to the implement cylinders
and the circle drive through the implement control
valves. The combination valve provides the priority
for the steering circuit. The combination valve also
transfers load signals from the implement control
valves to the hydraulic and steering pump.
 29
Hydraulic and Steering System
Systems Operation Section

g00919857
Illustration 27
Typical Left Valve Group
(1) Left Blade Lift (3) Blade Tip
(2) Sideshift (4) Circle Drive

g00919862
Illustration 28
Typical Right Valve Group
(5) Articulation (7) Wheel Lean
(6) Centershift (8) Right Blade Lift
30
Hydraulic and Steering System
Systems Operation Section

Illustration 29
Front View of Typical Linkage and Valve Group
(9) Right blade lift control (lever)
(10) Wheel lean control (lever)
(11) Articulation control (lever)
(12) Centershift control (lever)
(13) Circle drive control (lever)
(14) Blade tip control (lever)
(15) Sideshift control (lever)
(16) Left blade lift control (lever)
(17) Left blade lift control valve
(18) Sideshift control valve
(19) Circle drive control valve
(20) Blade tip control valve
g00910582
(21) Articulation control valve
(22) Centershift control valve
(23) Wheel lean control valve
(24) Right blade lift control valve

There are typically eight implement circuits on
the machine. Seven are cylinder circuits and one
is a hydraulic motor circuit for rotating the blade
circle about the drawbar. An implement system
can accommodate as many as fourteen implement
control valves. The individual control valves regulate
the operation of each implement. Operator control
levers for operating the implement control valves
are located on the operator console on both the
right side of the steering wheel and the left side of
the steering wheel.
Note: Some of the motor graders may have different
implements. The number of the control valves in
each valve group may vary.
Note: When you replace an implement control valve
use the same part number. This will keep the control
valve and the cylinder matched.
Note: For additional information on the hydraulic
system, refer to the hydraulic schematic for your
machine.
 31
Hydraulic and Steering System
Systems Operation Section

i01780813

Control Valve (Implement)

SMCS Code: 5051

Implement Control Valve without a

Relief Valve

g00913785
Illustration 30
Typical implement control valve in the HOLD position
(1) Lock valve poppets (7) Flow to the hydraulic tank (13) Flow from the output port of the
(2) Port to head end of cylinder (8) Centering spring hydraulic and steering pump
(3) Lock valve seats (9) Rotary actuator (14) Control stem
(4) Lock valve piston (10) Signal to combination valve (15) Counterbalance spring
(5) Port to rod end of cylinder (11) Manifold (16) Signal chamber
(6) Compensator valve (12) Signal check valve

The following implement circuits do not have line Centershift

relief valves:
Circle Drive
Articulation
Wheel Lean
32
Hydraulic and Steering System
Systems Operation Section

Control stem (14) has metering holes and slots that Ripper
are designed to match the flow requirements of
each circuit. If the components become damaged Scarifier
or worn, the components in the control valves are
replaceable. Snow plow/dozer lift
Lock valve poppets (1) are incorporated into the Snow plow/dozer angle
control valve body. A guided poppet is used in
order to reduce leakage. The reduced valve leakage The following implement circuits include two line
reduces cylinder drift. relief valves:

When the total flow demand exceeds the maximum
pump flow, compensator valve (6) distributes
the hydraulic pump flow that is available. The
compensator valve creates an additional restriction
in each circuit. This is done so a single circuit
cannot use all of the available pump flow. Valve
(6) maintains an equal pressure drop across each
opening. The oil flow from each implement control
valve is proportional to the opening of control stem
(14).
Wing lift
Wing tilt
The blade lift control valves have a FLOAT position.
The control valve for the snow plow/dozer lift also
has a FLOAT position. These valves will be covered
separately in the service manual.
i01780807

Signal check valve (12) allows pressure oil for

the load cylinder to travel out of the implement
Control Valve (Blade Lift)
control valve through a passage and into the signal SMCS Code: 5051; 5136
network. The signal check valve also prevents back
pressure from the other control valves from acting
on the valve. The highest load pressure is the only
pressure that passes through signal check valve
(12). All other signal check valves are seated. This
signal pressure also becomes the input signal to
compensator valve (6). Signal chamber (16) is on
top of compensator valve (6) in each implement
control valve. Compensator valve (6) regulates the
flow of oil to the cylinders when multiple implement
circuits are being used.

Centering spring (8) centers control stem (14) in the

control valve body. When the operator moves the
control lever forward or backward, counterbalance
spring (15) compensates for the weight of the
linkage rod. Spring (15) also compensates for the
difference of force of the control lever. This added
force makes the operation of the lever approximately
equal in both direction. This also improves the feel
of the lever controls.

Implement Control Valve with a

Relief Valve
Line relief valves protect the rod end of the circuit
from high pressures. The following implement
circuits include a line relief valve:

Blade lift
Blade tip
Blade sideshift
 33
Hydraulic and Steering System
Systems Operation Section

g00913804
Illustration 31
Control valve with blade float detent (if equipped) in the HOLD position
(1) Lock valve poppets (7) Line to the hydraulic tank (14) Control stem
(2) Line to the head end of the cylinder (8) Rotary actuator (15) Detent spring for blade float function (if
(3) Lock valve seats (9) Line to the combination valve equipped)
(4) Lock valve piston (10) Manifold (16) Detent
(5) Line to the rod end of the cylinder (11) Centering spring (17) Counterbalance spring
(6) Line relief valve for the rod end of the (12) Signal check valve (18) Compensator valve
cylinder (13) Line from the hydraulic pump

The following implement circuits have control valves If equipped, float detent (16) is attached to the
with a blade float detent: end of control stem (14).

Blade lift The line relief valve for the rod end of the cylinder
(6) is present.
Snow Plow/Dozer Lift
Several of the other implement circuits require a
The blade lift control valve is different from the line relief valve on the rod end of the cylinder. This
typical control valve. The differences are listed protects the over-pressurization of the cylinders.
below: Also, this protects the cylinders from failure. These
failures can result from thermal expansion and
Lock valve piston (4) is made of two pieces. from linkage interferences. The following implement
circuits require a line relief valve:
34
Hydraulic and Steering System
Systems Operation Section

Blade tip
Blade sideshift
Front mounted scarifier (if equipped)
Rear mounted ripper/scarifier (if equipped)
Note: Some machines provide the capability to
lower implements to the ground with an inoperable
engine. Refer to the appropriate Operation and
Maintenance Manual for the correct procedure.

Control Valve with Blade Float

Detent (If Equipped) in the RAISED
Position

g00913948
Illustration 32
Control valve with blade float detent (if equipped)
 35
Hydraulic and Steering System
Systems Operation Section

(1) Lock valve poppets (7) Line to the hydraulic tank (15) Detent spring for blade float function (if
(2) Line to the head end of the cylinder (8) Rotary actuator equipped)
(3) Lock valve seats (9) Line to the combination valve (16) Detent
(4) Lock valve piston (11) Centering spring (17) Counterbalance spring
(5) Line to the rod end of the cylinder (12) Signal check valve (18) Compensator valve
(6) Line relief valve for the rod end of the (13) Line from the hydraulic pump
cylinder (14) Control stem

Control stem (14) is moved fully to the right in order

to raise the blade. The hydraulic oil flows around
stem (14). The hydraulic oil moves compensator
valve (18) upward. After compensator valve (18)
is moved upward, the hydraulic oil flows in three
directions. First, the hydraulic oil flows to pistons
(4). Pistons (4) are forced outward in order to unseat
poppets (1) from seats (3). Next, the hydraulic oil
flows through check valve (12). Finally, the pump oil
flows through port (5) to the implement cylinder.
36
Hydraulic and Steering System
Systems Operation Section

Control Valve in the FLOAT Position

g00913949
Illustration 33
Typical control valve with blade float detent (if equipped)
(1) Lock valve poppets (7) Line to the hydraulic tank (14) Control stem
(2) Line to the head end of the cylinder (8) Rotary actuator (15) Detent spring for blade float function (if
(3) Lock valve seats (9) Line to the combination valve equipped)
(4) Lock valve piston (10) Manifold (16) Detent
(5) Line to the rod end of the cylinder (11) Centering spring (17) Counterbalance spring
(6) Line relief valve for the rod end of the (12) Signal check valve (18) Compensator valve
cylinder (13) Line from the hydraulic pump

The control valve is in the FLOAT position. When

stem (14) is moved to the DETENT position, oil
from the hydraulic pump is directed to the center of
lock valve pistons (4). The oil pressure moves the
pistons outward in order to unseat poppets (1) from
seats (3). The rod end of the blade lift cylinders and
the head end of the blade lift cylinders are then
opened to the hydraulic tank.
 37
Hydraulic and Steering System
Systems Operation Section

Typical Control Valve with

Hydraulic Detent

g00920334
Illustration 34
Typical control valve with hydraulic blade float detent (if equipped)
(14) Control stem (22) Retainer (24) Balls
(21) Passage for pressurized pump oil (23) Piston

A control valve with a hydraulic detent operates
in the same manner as a control valve with a
mechanical detent. The differences from the control
valve with a mechanical detent are listed below:
Hydraulic activated detent
Passage for pressurized pump oil (21)
When the control valve lever is moved to the HOLD
position, control stem (14) moves to the right.
Control stem (14) unseats balls (24). If there is a
loss of hydraulic pressure and/or a loss of engine
power, pressurized oil in passage (21) decreases.
This allows piston (23) to move to the left. Control
stem (14) and the control lever move into the HOLD
position.

The hydraulic activated detent allows the control

valves to return to the HOLD position when there is
a loss of hydraulic pressure and/or a loss of engine
power.

When the control valve lever is in the FLOAT

position, pressurized oil in passage (21) forces
piston (23) to the right. This seats balls (24) into
retainer (22). The hydraulically activated detent
locks control stem (14) in the FLOAT position.
38
Hydraulic and Steering System
Systems Operation Section

i01765115

Centershift Lock
SMCS Code: 5221

g00903422
Illustration 35
(1) Cab floor (2) Line to the solenoid valve (3) Line for the centershift lock cylinder

The location of the centershift lock cylinder is on

the rear of the link bar. When the lock pin is not
engaged with arm assembly (5), arm assembly (5)
and the circle can be moved in order to place the
blade in the correct position for the job.

g00792649
Illustration 36
Location of Centershift Indicator
(4) Centershift indicator
(5) Arm Assembly
 39
Hydraulic and Steering System
Systems Operation Section

Note: If the centershift lock indicator does not turn

off, slightly move arm assembly (5) in order to align
the hole with the centershift lock pin.

When the engine start switch is in the OFF position,

the solenoid valve is not energized. Therefore, the
centershift lock pin can only retract if the engine
start switch is in the ON position.

Note: In machines that have an all wheel drive

system, the hydraulic oil flows from the flushing
and cooling control valve instead of the differential
lock control.

g00920152
Illustration 37 i01797024
(6) Centershift lock control (switch)
Blade Cushion
Centershift lock control (6) is located on the console
SMCS Code: 5077; 6151
to the right of the operators seat. The position of
centershift lock control (6) controls the solenoid
valve. The solenoid valve is used to engage the
centershift lock pin. The solenoid valve is used to
disengage the centershift lock pin.

When centershift lock control (6) is moved to the

DISENGAGED position, the solenoid valve redirects
the hydraulic oil from the differential lock control in
order to disengage the centershift lock pin. When
the centershift lock pin is disengaged, the light on
the instrument panel for the centershift indicator
will come on.

When centershift lock control (6) is moved to the

ENGAGED position, the solenoid valve allows the Illustration 38 g00869705
hydraulic oil from the differential lock control to
(1) Blade cushion accumulators
engage the centershift lock pin. The machine is
normally operated with the centershift lock pin in the
The blade cushion dampens the shocks that are
LOCK position. Since the centershift lock pin cannot
made in the blade lift hydraulic circuit when the
be seen by the operator, centershift indicator (4)
blade contacts an object that will not move. Blade
shows the operator when the centershift lock pin is
cushion accumulators (1) have a nitrogen precharge
in alignment with the correct hole in arm assembly
pressure that provides the cushion.
(5).

The hydraulic oil flows from the differential lock

control to the centershift lock cylinder. In the
LOCK position, the hydraulic oil flows through the
centershift lock cylinder. This holds the centershift
lock pin in the LOCK position.

In order to move arm assembly (5) and the circle

to another location, push the latch tab forward and
move centershift lock control (6) to the DISENGAGE
position. The centershift lock pin will pull out of arm
assembly (5). The centershift cylinder and the lift
cylinders are then operated in order to move arm
assembly (5) and the circle to the desired location.
g00869564
Illustration 39
When the centershift lock pin is at the correct hole
(2) Switch
in arm assembly (5), centershift lock control (6) is
moved to the ENGAGED position.
40
Hydraulic and Steering System
Systems Operation Section

The blade cushion is activated by switch (2) on

the right side of the operator on the shift console.
Switch (2) energizes the solenoids which control
the check valves for the blade cushion. A manifold
is located at the base of each blade cushion
accumulator. Each manifold contains an oil passage
to the corresponding blade cushion accumulator.
The solenoid operated valves are mounted to the
manifolds. The solenoid operated valves regulate
the flow of oil to the blade cushion accumulators.

Blade Cushion that is Deactivated

With switch (2) in the OFF position, the solenoids
are de-energized. Oil pressure from the lines
cannot pass through the manifolds in order to enter
the blade cushion accumulators. The cartridge
assemblies in the manifolds contain one-way check
valves. This allows oil into the head of the blade
lift cylinders. The one-way check valves prevent oil
from flowing back into the accumulators.

Blade Cushion that is Activated

With switch (2) in the ON position, the solenoids
are energized. The cartridge assemblies are pulled
back out of the manifolds. There is now an open
passage from the hydraulic circuit to the blade
cushion accumulators.

When a shock occurs, oil pressure flows through

the lines and the manifolds into blade cushion
accumulators (1). Accumulators (1) cushion the
force of the pressure oil in the hydraulic circuit.
Once the shock has passed, pressure oil from
the accumulators re-enters the hydraulic circuit.
Oil flows back into the head end of the blade lift
cylinders. This allows the blade to return to the
original position.

i01670934

Steering System
SMCS Code: 4300

Illustration 40
Steering components locations
(AA) Outlet port to the combination valve
(BB) Inlet port from the combination valve
(CC) Outlet port to the steering cylinders for
a right turn
The steering circuit is composed of the following
components:
The hydraulic tank
The hydraulic and steering pump with the
pressure and flow compensator valve
The accumulator
41
Hydraulic and Steering System
Systems Operation Section
g00903402
(DD) Load sensing signal port (GG) Line to steering cylinder for a left turn
(EE) Outlet port to the steering cylinders for
a left turn
(FF) Line to steering cylinder for a right turn
The steering metering pump
The left and right steering cylinders
Hydraulic oil for the steering circuit is supplied
by the hydraulic and steering pump. The steering
priority valve gives the steering function priority over
the available hydraulic pump flow. The priority valve
senses pressure in the steering circuit.
42
Hydraulic and Steering System
Systems Operation Section

Typically, the requirements of the oil flow for the

steering circuit are significantly less than the
available hydraulic pump flow. This means that
oil flow to other implement circuits will not be
interrupted when the steering is operated. The
steering metering pump provides oil flow to the
steering cylinders. This depends on the direction
and the rotation of the steering wheel.

Oil Flow of the Steering Hydraulic

System

g00863442
Illustration 41
Steering system in the HOLD position
(1) Steering metering pump (7) Anticavitation check valve (13) Steering priority valve
(2) Gerotor (8) Hydraulic and steering pump (14) Pressure compensator valve
(3) Steering cylinders (9) Hydraulic tank (15) Flow compensator valve
(4) Rotary sleeve (10) Signal purge valve (16) Implement relief valve
(5) Line relief valves with anticavitation (11) Signal relief valve (17) Steering relief valve
valves (12) Signal resolver valve (18) Combination valve
(6) Check valve for supply oil
 43
Hydraulic and Steering System
Systems Operation Section

In the hold position, the top envelope of valve (13) is

activated. This allows oil to flow to both the steering
and to the implements. Oil flows through the center
envelope in sleeve (4). The oil then flows back to
hydraulic tank (9). Flow compensator valve (15) is
in the metering position due to signal oil from signal
resolver (12). Signal pressure is approximately
345 kPa (50 psi).

g00863450
Illustration 42
Steering system during a right turn
(1) Steering metering pump (5) Line relief valves with anticavitation (13) Steering priority valve
(2) Gerotor valves (14) Pressure compensator valve
(3) Steering cylinders (8) Hydraulic and steering pump (15) Flow compensator valve
(4) Rotary sleeve (9) Hydraulic tank (18) Combination valve

When the steering wheel is turned to the right,
sleeve (4) is rotated in order to make the bottom
envelope active. At the same time, gerotor (2)
pumps oil to cylinders (3). The oil is supplied to
steering metering pump (1) through the center
envelope in priority valve (13). The signal pressure
to pump (1) and to valve (15) is supplied from valve
(13).
Two line relief valves (19) are located inside pump
(4). Valves (19) prevent damage from pressure
spikes. If the oil pressure increases to the setting of
relief valve (19), the relief valve will open. This will
allow oil to flow from one side of the steering circuit
to the other side of the steering circuit.
44
Hydraulic and Steering System
Systems Operation Section
i01765851
Metering Pump (Steering)
SMCS Code: 4312
g00903469
Illustration 43
(1) Outlet port to the left steering cylinders
(2) Load sensing signal port
(3) Outlet port to the right steering cylinders
(4) Outlet port to the combination valve
(5) Inlet port from the combination valve
(FF) Control section
(GG) Metering section
The steering metering pump is made up of two
sections:
Control section (FF) (9) Inner spool
Metering section (GG) (12) Drive
When the steering wheel is turned, control section
(FF) sends oil to metering section (GG). The
metered oil from metering section (GG) is then
directed by control section (FF). The metered oil
flows to the outlet port to left steering cylinders (1)
or to the outlet port to right steering cylinders (3).
As the steering wheel is rotated faster, there is an
increase in the flow of oil. Inside inlet port (5) is a
check valve. The check valve prevents steering
wheel kickback that is caused by high pressure
spikes in the steering circuit.
Neutral Position
g00920470
Illustration 44
Typical Steering Metering Pump in the NEUTRAL Position
(1) Outlet port to the left steering cylinders
(3) Outlet port to the right steering cylinders
(4) Outlet port to the combination valve
(5) Inlet port from the combination valve
(6) Outer sleeve
(7) Passage
(8) Stator
(10) Centering spring
(11) Pin
(13) Passage
(14) Rotor
(FF) Control section
(GG) Metering section
Note: The steering metering pump is shown without
the steering wheel column control or the shaft.
Section (FF) of the steering metering pump is a
closed center type. When the steering wheel is
in the NEUTRAL position, there is no alignment
between the holes in outer sleeve (6) and the
passages in inner spool (9). Oil flows through an
internal orifice to the hydraulic tank.
 45
Hydraulic and Steering System
Systems Operation Section

Right Turn

g00920651
Illustration 46
(6) Outer sleeve
(9) Inner spool
(15) Slots for springs
(16) Grooves for oil flow
(17) Oil holes
(18) Holes for pin

When the steering wheel is turned clockwise to

make a right turn, inner spool (9), pin (11) and drive
(12) start to rotate. Outer sleeve (6) does not rotate
at the same time because the diameter of the holes
(18) for pin (11) in sleeve (6) is slightly larger than
the diameter of pin (11). This allows spool (9) to
rotate in sleeve (6). This aligns the holes (17) in
Illustration 45 g00920469 sleeve (6) with the grooves (16) in spool (9). The
Typical Steering Metering Pump
rotation from the NEUTRAL position of spool (9) and
sleeve (6) provide an oil path between outlet port
(1) Outlet port to the left steering cylinders
(3) Outlet port to the right steering cylinders
(3) and load sensing signal port (2).
(4) Outlet port to the combination valve
(5) Inlet port from the combination valve The pump oil from inlet port (5) flows through holes
(6) Outer sleeve (17) in sleeve (6) into grooves (16) in spool (9). The
(7) Passage oil in grooves (16) flows outward through holes (17)
(8) Stator
(9) Inner spool in sleeve (6) and flows into passage (13). Oil flows
(10) Centering spring through passage (13) into metering section (GG).
(11) Pin Then, the oil is directed into a space between stator
(12) Drive (8) and rotor (14).
(13) Passage
(14) Rotor
(FF) Control section Rotor (14) is splined to drive (12). As drive (12)
(GG) Metering section rotates, rotor (14) rotates and pumps oil out
passage (7). The metered oil flows through holes
(17) in sleeve (6) into other grooves (16) in spool
(9). The metered oil continues out through sleeve
(6) into the outlet port (3).

When the steering wheel is not used, the rotation of

spool (9), pin (11), drive (12) and rotor (14) stops.
Holes (17) in outer sleeve (6) do not line up with
grooves (16) in inner spool (9). The oil flow from
inlet port (5) stops. The flow of metered oil to outlet
port (3) stops. When the flow of oil is stopped, the
wheels will stay in the fixed position.
46
Hydraulic and Steering System
Systems Operation Section

Left Turn Oil flows through inner spool (9) and through outer
sleeve (6) into passage (7) and into metering
section (GG). The metered oil flows outward through
passage (13). Then, the oil flows back through inner
spool (9) and outer sleeve (6). Then, the oil flows
out of outlet port (1).

Load Sensing

g00920468
Illustration 47
Typical Steering Metering Pump in the LEFT TURN Position
(1) Outlet port to the left steering cylinders
(3) Outlet port to the right steering cylinders
(4) Outlet port to the combination valve
(5) Inlet port from the combination valve
(6) Outer sleeve
(7) Passage
(8) Stator g00920467
Illustration 48
(9) Inner spool
(10) Centering spring Typical Steering Metering Pump in the NEUTRAL Position
(11) Pin (1) Outlet port to the left steering cylinder
(12) Drive (3) Outlet port to the right steering cylinder
(13) Passage (4) Outlet port to the combination valve
(14) Rotor (5) Inlet port from the combination valve
(FF) Control section (6) Outer sleeve
(GG) Metering section (7) Passage
(8) Stator
When the steering wheel is turned counterclockwise (9) Inner spool
the machine makes a left turn. The same (10) Centering spring
(11) Pin
components are used for both the right turn and (12) Drive
the left turn. For these sequences, the same (13) Passage
components move in opposite direction. Oil comes (14) Rotor
back into the inlet port from combination valve (FF) Control section
(5). Spool (9) and sleeve (6) rotate in the opposite (GG) Metering section
direction. This allows a different set of holes to line
up with a different set of grooves. The outlet port to
the left steering cylinders (1) is now open to the
load sensing signal port (2).
 47
Hydraulic and Steering System
Systems Operation Section

In addition to the four ports that have already been

described, the steering metering pump has a load
sensing signal port (2). The load sensing signal port
connects internally by the rotation of inner spool (9)
and outer sleeve (6) to the orifice in outlet port (4).
When this occurs, the steering metering pump is in
the NEUTRAL position. Also, the load sensing signal
port connects internally to outlet port (3) during a
right turn and to outlet port (1) during a left turn.

When signal port (2) is connected to a turn port,

signal port (2) senses the resistance pressure to
rotation. This resistance creates a specific signal
pressure. This signal pressure originates from the
signal relief valve that is in the combination valve.
The signal pressure plus the margin pressure will
provide oil flow to the steering metering pump in
order to meet the steering demand. The signal
pressure is also communicated to the signal
resolver in the combination valve. The signal
resolver is compared to the implement signal
pressure. The highest signal pressure is sent to the
flow compensator valve on the hydraulic pump in
order to upstroke the pump. Upstroking the pump
will meet the greater oil demand.

Also, the steering metering pump has steering line

relief valves with anticavitation valves.
48
Hydraulic and Steering System
Systems Operation Section

i01677645

Fan Drive System

SMCS Code: 1386; 1387

Hydraulic Fan Drive

Illustration 49
Lines for the hydraulic fan system
(1) Line to the fan motor from the fan speed
control valve
(2) Return line to the hydraulic tank
(3) Signal line
g00903515
(4) Line from the pump to the fan speed
control valve
(5) Test port for the hydraulic fan
(6) Fan speed control valve

Illustration 50
(6) Fan Speed Control Valve (8) Fan Drive Pump
(7) Pressure and Flow Compensator Valve (9) Fan Speed Solenoid
The fan drive system consists of a fan drive pump
(8), fan speed control valve (6), and a fan drive
motor (11). Motor (11) is a fixed displacement motor
and pump (8) is a variable displacement pump.
Oil flows from pump (8) to motor (11). The output
oil from motor (11) flows back to the hydraulic tank.
In machines that are equipped with all wheel drive,
the oil returns to the tank through the return circuit
for the all wheel drive.
Makeup valve (10) for motor (11) allows the fan to
stop gradually when the engine is stopped. Makeup
valve (10) prevents motor (11) from cavitating
when the engine is stopped. When pump (8) stops
producing flow, makeup valve (10) will allow oil to
enter the inlet of motor (11).
49
Hydraulic and Steering System
Systems Operation Section
g00921299
(10) Makeup Valve
(11) Fan Drive Motor
The fan speed depends on the volume of oil that is
supplied by pump (8). The displacement of pump
(8) is changed by fan speed control valve (6).
Fan speed solenoid (9) receives a variable current
from the engine electronic control module (ECM)
that changes the output of pump (8). The engine
ECM receives information from engine coolant
temperature sensors and from inlet air temperature
sensors. In machines that are equipped with
all wheel drive, the engine ECM also receives
information from the hydraulic oil temperature
sensor.
When the current to the solenoid (9) is at the
maximum, pump (8) is at minimum output. If
solenoid (9) fails or there is another problem in the
electrical circuit for the fan drive system, pump (8)
will produce maximum output.
The maximum pressure in the fan drive system is
controlled by the setting of pressure compensator
valve (7).
50
Hydraulic and Steering System
Systems Operation Section

i01765946

Piston Pump (Hydraulic Fan)

SMCS Code: 1387-QP; 5070-HFN

g00921834
Illustration 51
Fan Drive Pump (Typical Example)
(1) Piston (6) Inlet opening (11) Control piston
(2) Piston (7) Drive shaft (12) Outlet opening
(3) Barrel (8) Swashplate (13) Pressure and flow compensator
(4) Spring (9) Slipper
(5) Port plate (10) Retraction plate

The fan drive pump is a variable displacement axial
piston pump.
The fan drive pump has nine pistons (2). When
drive shaft (7) turns, barrel (3), retraction plate (10),
and slippers (9) turn. The piston ends connect to
the slippers. Swashplate (8) does not turn. There is
a bearing journal on each side of swashplate (8).
The two bearing journals are inside bearings which
allow movement of swashplate (8). Oil flow through
the passages in the pistons lubricates the internal
components of the pump.
When swashplate (8) is at the maximum angle and
drive shaft (7) is turning, pistons (2) are moved
in and out of the barrel. As pistons (2) move out
of barrel (3), pistons (2) create a vacuum at inlet
opening (6). The pressure in the hydraulic tank
pushes the oil into inlet opening (6). The oil passes
through inlet opening (6) and into the piston bore in
barrel (4). As barrel (4) continues to turn, pistons (2)
are pushed into barrel (4) as slippers (9) rotate up
the angle of swashplate (9). Pistons (2) push the oil
from the piston bore through pump outlet opening
(12) and into the hydraulic fan system.
 51
Hydraulic and Steering System
Systems Operation Section

Pressure and Flow Compensator Signal pressure enters through cavity (16). The
signal pressure and the force of spring (17) moves
Valve (Fan Drive Pump) flow compensator spool (14) to the left. Since spool
(14) is blocking the flow of the oil to port (19), spring
(4) will upstroke the pump.

Destroking

Destroking occurs when one of the temperature

sensors sense a lower temperature. When a lower
temperature is sensed, a signal is sent to the engine
electronic control module (ECM). The engine ECM
controls the amount of current that is sent to the fan
speed control valve. The fan speed control valve
decreases the signal pressure that is sent to the
pressure and flow compensator valve (13).

Signal pressure enters through cavity (16). Now, the

signal pressure and the force of spring (17) are less
than the pump pressure in port (18).

Flow compensator spool (14) is moved to the right.

Oil will flow through port (19) toward piston (11).
The force of the oil will act against spring (4). This
g00923793 will cause the pump to destroke.
Illustration 52
Components of Pressure and Flow Compensator Valve
(14) Spool (flow compensator) i01806248
(15) Seat
(16) Cavity (flow compensator)
(17) Spring (flow compensator)
Hydraulic Schematic
(18) Port passage to the pump outlet
(19) Port passage to the control piston SMCS Code: 4300; 5050
(20) Port passage for case drain
(21) Spool (pressure compensator)
(22) Seat
(23) Cavity (pressure compensator)
(24) Spring (pressure compensator)

Pressure and flow compensator valve (13) keeps

the pump pressure and the pump flow at the level
that is needed to fulfill the requirements of the fan
drive system.

When the engine is operating, the oil from the fan

pump flows through port (18). The force of the oil
moves flow compensator spool (14) to the right in
order to allow the oil to flow through port (19). The
oil flow will then act upon piston (11) in order to
adjust the angle of swashplate (8).

Upstroking

Upstroking occurs when one of the temperature

sensors sense a higher temperature. When a higher
temperature is sensed, a signal is sent to the
engine electronic control module (ECM). The engine
ECM controls the amount of current that is sent to
the fan speed control valve. The fan speed control
valve increases the signal pressure that is sent to
pressure and flow compensator valve (13).
52
Hydraulic and Steering System
Systems Operation Section

g00924358
Illustration 53
 53
Hydraulic and Steering System
Systems Operation Section

The first six control valves are optional for your Steering accumulator (31)
machine.
Hydraulic and steering pump (32)
Control valve for the snow wing (1)
Oil pressure sensor (33)
Tilt control valve for the snow wing (2)
Makeup valve (34)
Ripper control valve (3)
Fan motor (35)
Scarifier control valve (4)
i01803851
Control valve for the snow plow/bulldozer (5)
Color Chart
Control valve for the dozer angle (6)
SMCS Code: 4300; 5050
Blade cushion accumulator (7)
Solenoid for the blade cushion (8)
Blade lift cylinders (9)
Side shift cylinder (10)
Swivel (11)
Blade tip cylinder (12)
Circle drive (13)
Steering cylinders (14)
Articulation cylinders (15)
Center shift cylinder (16)
Wheel lean cylinder (17)
Left blade lift control valve (18)
Sideshift control valve (19)
Circle drive control valve (20)
Blade tip control valve (21)
Steering metering pump (22)
Articulation control valve (23)
Centershift control valve (24)
Wheel lean control valve (25)
Right blade lift control valve (26)
Hydraulic tank (27)
Fan speed solenoid (28)
Fan drive pump (29)
Combination valve (30)
54
Hydraulic and Steering System
Systems Operation Section
 55
Hydraulic and Steering System
Systems Operation Section

g00923019
Illustration 54
56
Hydraulic and Steering System
Troubleshooting Section
Troubleshooting Section
Introduction
i01792901
General Information
SMCS Code: 4300-035; 5050-035
Visual checks are the first steps in order to
troubleshoot a problem. When the visual inspections
are complete and the problem is not fully
understood, perform operational checks. After visual
inspections and operation checks are complete
and the problem is not fully understood, perform
test procedures. These procedures will help identify
system problems. These procedures are located in
the Testing and Adjusting module for your machine.
For the locations of your individual system
components, refer to the Systems Operation module
for your machine.
For more information on the electrical system, refer
to the Electrical Schematic for your machine.
For more information on the hydraulic system, refer
to the Hydraulic Schematic for your machine.
i01792733
Machine Preparation for
Troubleshooting
SMCS Code: 4300-035; 5050-035
Personal injury or death can result from sudden
machine movement.
Sudden movement of the machine or release of oil
under pressure can cause injury to persons on or
near the machine.
To help prevent possible injury, perform the proce-
dure that follows before testing and adjusting the
hydraulic and steering system:
Check valves in the hydraulic system may allow
pressure to exist in the hydraulic lines after the en-
gine has been stopped. Pressure must be relieved
prior to servicing the components of the hydraulic
system. Failure to relieve pressure prior to servic-
ing may result in personal injury.
1. Move the machine to a smooth horizontal
location. Move away from operating machines
and move away from all personnel. Lower all
implements to the ground. If equipped, place
the control lever for the blade lift control valve
in the FLOAT position.
2. Install the wheel lean locking bolt in the front
axle. Install the frame lock pin. Engage the
parking brake and stop the engine.
3. Permit only one operator on the machine. Keep
all other personnel away from the machine. Also,
all personnel should be visible to the operator.
4. Place chocks in front of the wheels and behind
the wheels.
5. Carefully loosen the filler cap on the hydraulic
tank in order to release the pressure in the tank.
6. Make sure that all hydraulic pressure is released
before you perform any of the following
procedures:
Loosen any fitting, any hose, or any
component.
Tighten any fitting, any hose, or any
component.
Remove any fitting, any hose, or any
component.
Adjust any fitting, any hose, or any component.
7. Tighten the filler cap on the hydraulic tank.
8. After the pressure in the system has been
released, carefully loosen fittings and remove
lines or components.

i01807320
Visual Inspection
SMCS Code: 4300-035; 5050-035
Always use a board or cardboard when checking
for a leak. Escaping fluid under pressure, even a
pin hole leak, can penetrate body tissue, causing
serious injury and possible death. If fluid is inject-
ed into your skin, it must be treated immediately
by a doctor familiar with this type of injury.
When you identify a problem, visually inspect the
hydraulic system, the steering system and the
different components. Stop the engine and lower
the implements to the ground. To remove the
hydraulic tank filler cap, slowly turn the filler cap
until the cap is loose. If the hydraulic oil starts to
splash up onto the hydraulic tank, allow the tank
pressure to decrease before you remove the filler
cap. Move the sideshift cylinder to the right in order
to reduce pressure in the hydraulic tank. Also, move
the sideshift cylinder to the right in order to reduce
the oil level in the hydraulic tank. Make the following
inspections:
1. Trace all of the hydraulic implement lines from the
implement connections to the valve connections.
Check the following components for damage
and check the following components for leaks:
All of the hydraulic implement lines
All of the connections on the components
2. Trace all of the hydraulic fan drive lines from the
hydraulic fan pump to the hydraulic fan motor.
Check the following components for damage
and check the following components for leaks:
All of the hydraulic fan drive lines
The hydraulic fan pump
The hydraulic fan motor
All of the connections on the components
3. Check the control valves for leaks.
4. Check the following components for damage
and check the following components for leaks:
The hydraulic and steering pump
The connections on the components
57
Hydraulic and Steering System
Troubleshooting Section
5. Trace the lines from the hydraulic and steering
pump to the hydraulic tank. Also, trace the
lines from the hydraulic and steering pump to
the valves. Check the following components for
damage and check the following components
for leaks:
The lines from the hydraulic and steering
pump to the hydraulic tank
The lines from the hydraulic and steering
pump to the valves
The hydraulic tank
The connections on the components
6. Check the hydraulic tank oil level.
7. Immediately after the machine has stopped,
use a clean, clear bottle or use a clean, clear
container in order to obtain an oil sample from
the hydraulic tank. Check for air bubbles in the
oil sample.
8. Remove the filter element and the strainer. Check
for particles that have been removed from the
oil by the filter element. A magnet will separate
ferrous particles from nonferrous particles.
Ferrous materials such as piston rings contain
iron. If necessary, replace the filter and clean
the strainer.
i01807333
Operational Checks
SMCS Code: 4300-035; 5050-035
The operation checks can be used to find leakage
in the system. Also, the operation checks can be
used to find a failed valve or a failed hydraulic and
steering pump.
The oil in the hydraulic system must be at an
operating temperature of 46 to 52C (115 to 125F).
Extend the implement cylinders and retract the
implement cylinders several times. Allow the
implement cylinders to travel full stroke in each
direction.
1. Watch the cylinder as the cylinder is extended
and retracted. The movement of the cylinder
must be smooth and regular.
2. Listen to the hydraulic and steering pump for
noise.
58
Hydraulic and Steering System
Troubleshooting Section

3. Move each control valve into the HOLD position

while the implement is off the ground. Watch
for cylinder rod drift. If the cylinder moves more
than 19.0 mm (.75 inch) in 60 minutes, then the
cylinder drift is excessive.

Implement cylinder drift is caused by oil leakage

past cylinder piston seals, line relief valves or a
leaking lock valve in the implement control valve.

Symptom Procedures
i01807383
Hydraulic and Steering System
SMCS Code: 4300-035; 5050-035
Hydraulic and Steering System
Problem
The temperature of the oil is too hot.
Probable Cause
The viscosity of the oil is incorrect.
The signal relief valve on the combination valve
is set too high. Refer to Testing and Adjusting,
Pressure and Flow Compensator Valve (Steering)
- Test and Adjust.
The implement relief valve is set too low.
The hydraulic and steering pump has too much
wear (high leakage).
The hydraulic fan pump has too much wear (high
leakage).
There is a restriction in an oil passage.
The load of the system is too high.
The signal purge valve has malfunctioned. The
signal purge valve is in the combination valve and
the signal purge valve is in the CLOSED position.
There is air in the oil.
Outside air temperature is too hot.
Problem
The hydraulic and steering pump makes unusual
noise. The cylinder rods do not move evenly. Air
bubbles are in the oil.
Problem
There is a large amount of air in the oil.
Probable Cause
There is a leak in the oil line between the hydraulic
tank and the hydraulic and steering pump.
There is a leak in the oil line between the hydraulic
tank and the hydraulic fan pump.
59
Hydraulic and Steering System
Troubleshooting Section
The hydraulic system was not purged correctly
after assembly of the hydraulic system, after
inspection of the hydraulic system, or after testing
of the hydraulic system. Refer to Testing and
Adjusting, Steering System - Purge.
The relief valve constantly cycles.
There is leakage around the cylinder seals.
The operator is using the blade float function (if
equipped) in order to drop the blade.
Problem
The maximum pressure of the hydraulic and
steering pump is too low.
Probable Cause
The signal relief valve is set too low.
There is a leak in the signal network or there is an
restriction in the signal network.
The pressure compensator valve is set incorrectly.
Refer to Testing and Adjusting, Pressure and
Flow Compensator Valve (Steering) - Test and
Adjust.
The low standby pressure is set too low.
The hydraulic and steering pump is not
upstroking. The swashplate is blocked.
Problem
The pressure of the hydraulic and steering pump
is too high.
Probable Cause
The signal relief valve is set too high. Refer
to Testing and Adjusting, Pressure and Flow
Compensator Valve (Steering) - Test and Adjust.
The hydraulic and steering pump is not
destroking. The actuator piston is stuck or the
swashplate is blocked.
Problem
The hydraulic and steering pump has no pressure.
Probable Cause
The hydraulic system is low on oil.
The hydraulic and steering pump has
malfunctioned or the pump drive shaft has
malfunctioned.
60
Hydraulic and Steering System
Troubleshooting Section
The pressure compensator valve is set incorrectly.
Problem
The hydraulic and steering pump remains at
standby pressure. When the implements are used
or the steering is used, the pump will not upstroke.
Probable Cause
The hydraulic and steering pump is not receiving
a signal.
The pressure and flow compensator valve is not
working.
The hydraulic and steering pump is not
upstroking. The swashplate is blocked.
Problem
Low standby pressure is too high.
Probable Cause
All controls are not in the HOLD position. In a
no load condition, the implement signal and the
steering signal should be less than 690 kPa
(100 psi).
All controls are not in the HOLD position. In a
no steer condition, the implement signal and
the steering signal should be less than 690 kPa
(100 psi).
The flow compensator (margin pressure) is set
too high.
Steering System
Problem
The front wheels vibrate, when you steer the
machine.
Probable Cause
Air is in the steering cylinders and air is in the
steering system. Refer to Testing and Adjusting,
Steering System - Purge.
The steering metering pump has failed.
Check the steering priority valve that is in the
combination valve.
Problem
When an implement is used, you can feel hard
spots in the steering.
Probable Cause
The signal resolver in the combination valve has
been installed incorrectly after assembly.
Problem
The steering wheel kicks back, when the steering
wheel is steered against the stop.
Probable Cause
Air is in the steering cylinders and air is in the
steering system. Refer to Testing and Adjusting,
Steering System - Purge.
The check valve is missing or the check valve
is not working. This check valve is in the steering
metering pump at the hydraulic pump pressure
port.
Problem
The steering wheel has a tendency to stick when
the steering wheel is against the stop.
Probable Cause
The steering metering pump has failed and the
steering metering pump has trapped pressure
in the steering system.
An incorrect steering metering pump has been
installed on the machine.
Problem
When the steering wheel is released, the steering
wheel oscillates more than three times.
Probable Cause
The steering metering pump has failed.
An incorrect steering metering pump has been
installed on the machine.
Problem
When the steering wheel is steered against the
stop, the steering wheel does not stop.

Probable Cause
The steering relief valve is set too high. This
allows the relief valve to remain open.
The relief valve in the steering metering pump
is set too low.
The steering metering pump has failed. This
allows the wheel to continuously turn.
The steering cylinder has failed or the steering
cylinder is leaking.
The port is blocked on the steering metering
pump or the steering metering pump has a loose
connection. This allows air to enter the steering
system.
Problem
The steering does not work but the implements do
work.
Probable Cause
The hydraulic and steering pump is not receiving
a signal pressure from the steering system.
The steering priority valve is malfunctioning. The
pressure from the hydraulic and steering pump is
blocked to the steering circuit.
There is blockage or damage to the steering
circuit or components.
Problem
The steering wheel does not turn the correct
number of turns.
Probable Cause
The steering metering pump is leaking internally.
The steering cylinders are leaking or the cylinders
have incorrect parts.
An incorrect steering metering pump is installed
on the machine.
Implement System
Problem
The response of one implement is too slow.
Probable Cause
The lever linkage is restricted or the travel is
restricted.
61
Hydraulic and Steering System
Troubleshooting Section
The valve spool that is installed in the control
valve is incorrect for the implement.
The signal check valve in the signal network is
functioning incorrectly.
The implement control valve has failed.
The implement relief valve is set too low.
The signal relief valve is set too low.
Problem
The response of all the implements are too slow.
Probable Cause
Air is in the signal system.
The check valve is leaking or the ball resolver in
the signal network system is leaking.
There is contamination in any of the control valves.
Air is in the system.
The signal purge valve is stuck open.
The signal relief valve malfunctions.
The flow compensator (margin pressure) is set
too low.
The implement relief valve is set too low or the
implement relief valve leaks.
The steering priority valve in the combination
valve has malfunctioned.
Problem
Implement circuits will not operate when one
cylinder is stalled.
Probable Cause
The pressure compensator (pressure cutoff) is set
too low or the signal relief valve is set too high.
Refer to Testing and Adjusting, Pressure and
Flow Compensator Valve (Steering) - Test and
Adjust.
Problem
The performance of a single implement circuit is
erratic.
Probable Cause
The implement control valve is contaminated.
62
Hydraulic and Steering System
Troubleshooting Section
The control valve stem is incorrect for this circuit.
The flow compensator (margin pressure) is set
incorrectly.
Problem
The performance of all the implement circuits are
erratic.
Probable Cause
The hydraulic oil in the hydraulic system has not
reached normal operating temperature.
The hydraulic and steering pump has failed or the
pressure and flow compensator valve has failed.
Air is in the hydraulic system.
Problem
Any implement moves with the control lever in the
HOLD position.
Probable Cause
The cylinder piston seals have failed or the
cylinder piston seals are worn. The steering line
relief valve has failed or the steering line relief
valve is worn.
The lock check valve has failed or the port relief
has failed.
The implement relief valve is malfunctioning.
Problem
When the implement is first activated, the implement
surges.
Probable Cause
The slots in the control stem are incorrectly
machined.
Air is in the circuit.
The flow compensator (margin pressure) is set
too high.
The discharge pressure of the hydraulic and
steering pump remains too high after the signal
pressure drops.
Problem
Too much effort is needed to move the control lever.
Probable Cause
The lever linkage is restricted or the lever linkage
has interference.
The bias spring in the implement control valve
is missing or the bias spring in the implement
control valve is incorrect.
The implement control valve has a sticking control
stem or the implement control valve has a failed
control stem.
Problem
The implements do not work but the steering does
work.
Probable Cause
The combination valve has a failed ball resolver
or the combination valve has a failed signal
check valve.
The steering priority valve is stuck. This stops the
oil flow to the implements.
The signal relief valve has failed in the OPEN
position or the pressure setting is set incorrectly.
Problem
The response of the implements is too fast.
Probable Cause
An incorrect control stem is installed in the
implement control valve.
The implement control valve has failed.
The flow compensator (margin pressure) is set
too high.
Problem
The hydraulic and steering pump does not return
to the low standby pressure after the implement is
used.
Probable Cause
The control lever has interference. The control
lever does not return to the HOLD position. The
signal pressure is still sent to the pressure and
flow compensator valve.
The signal purge valve has malfunctioned in the
CLOSED position.
 63
Hydraulic and Steering System
Troubleshooting Section

In a no steer condition, a steering signal that is
greater than 690 kPa (100 psi) is coming from the
steering metering pump. There is contamination
in the signal port of the steering metering pump.
Replace the steering priority valve. Replace the
steering metering pump.
The hydraulic and steering pump has failed or the
pressure and flow compensator valve has failed.
Problem
When you steer the machine, the implements slow
down or the implements stop.
The operator is using the blade float function (if
equipped) in order to drop the blade.
Problem
The hydraulic fan pump makes unusual noise. Air
bubbles are in the oil.
Probable Cause
The viscosity of the oil is incorrect.
There is a loose oil line on the inlet side of the
hydraulic fan pump.

Probable Cause The hydraulic fan pump has too much wear.
The low standby pressure of the hydraulic and Problem
steering pump is set low.
The maximum pressure of the hydraulic fan pump is
The steering priority valve has failed. too low.

The hydraulic and steering pump has insufficient Probable Cause

flow.
The pressure compensator valve is set incorrectly.
Problem Refer to Testing and Adjusting , Piston Pump
Cutoff Pressure (Fan Drive) - Test and Adjust.
If equipped, the blade float will not work. Also refer to Testing and Adjusting , Piston Pump
Margin Pressure (Fan Drive) - Test and Adjust.
Probable Cause
The hydraulic fan pump is not upstroking. The
The implement control valve has an incorrect swashplate is blocked.
control stem.
Problem
There is leakage in the signal network.
The pressure of the hydraulic fan pump is too high.
The implement control valve has an incorrect lock
valve piston.
Probable Cause
The signal purge valve malfunctions.
The pressure compensator valve is set incorrectly.
Refer to Testing and Adjusting , Piston Pump
There is contamination in the control stem of the Cutoff Pressure (Fan Drive) - Test and Adjust.
blade lift control valve.
Also refer to Testing and Adjusting , Piston Pump
Margin Pressure (Fan Drive) - Test and Adjust.
Hydraulic Fan Drive
Probable Cause
The viscosity of the oil is incorrect.
The implement relief valve opens at low oil
pressure.

There is a loose oil line connection on the inlet

side of the hydraulic and steering pump. Oil
aeration.

The hydraulic and steering pump has too much

wear.
64
Hydraulic and Steering System
Testing and Adjusting Section

Testing and Adjusting Cone (3) or (7)

Section Cup (5) or (8)
Head (6)
Testing and Adjusting Note: Do not install pump rotating group (9) when
you perform this procedure.
i01802231 1. Refer to Disassembly and Assembly, Piston
Bearing End Play (Piston Pump (Hydraulic and Steering) - Disassemble
for the correct procedure to disassemble this
Pump) - Adjust pump.

SMCS Code: 4306-025; 5070-025 2. Position the pump so that the taper on shaft (2)
is pointing upward.
Table 1
Required Tools 3. Rotate the shaft backward and rotate the shaft
forward several times in order to seat the cones
Part Number Description Quantity properly.
8T-5096 Dial Indicator Gp 1
4. Install an appropriate nut on the threaded end
of the shaft.

5. Position an 8T-5096 Dial Indicator Group so that

the contact point of the dial indicator is on the
face of the threaded end of the shaft.

6. Position the dial indicator to zero.

7. Apply a suitable force to the nut in order to move

the shaft upward. Read the dial indicator while
the shaft is under an upward force.

8. Subtract desired shaft bearing end play of

0.010 to 0.100 mm (0.0004 to 0.0039 inch) from
the dial indicator reading that is noted in Step 7.
This is the thickness of shims (4) to use in order
to achieve proper shaft bearing end play.
Table 2
EXAMPLE

Illustration 55 g00795034 Shaft bearing end play

reading from Step 8
Piston Pump (Hydraulic and Steering) 1.016 mm (0.0400 inch)
(1) Shaft Subtract desired shaft 0.010 to 0.100 mm
(2) Housing bearing end play. (0.0004 to 0.0039 inch)
(3) Cone
(4) Shims Required thickness of 1.006 to 0.916 mm
(5) Cup shims (0.0396 to 0.0361 inch)
(6) Head
(7) Cone
(8) Cup 9. Refer to Disassembly and Assembly, Piston
(9) Pump Rotating Group
Pump (Hydraulic and Steering) - Assemble for
the correct procedure to assemble this pump.
Perform the following procedure for shaft bearing
end play adjustment when any of these components
are replaced:

Shaft (1)
Housing (2)
 65
Hydraulic and Steering System
Testing and Adjusting Section

i01807201

Pressure and Flow

Compensator Valve (Hydraulic
and Steering) - Test and Adjust
SMCS Code: 5086-025-HR; 5086-025-ZH;
5086-081-HR; 5086-081-ZH

Low Standby Pressure Adjustment

Note: Before you perform this adjustment, refer to
Testing and Adjusting, Machine Preparation for
Troubleshooting.
Table 3
Required Tools
Part Description Quantity
Number
1U-5796 Pressure Differential Gauge 1
Group
1U-5481 Pressure Gauge Group 1
1U-5482 Pressure Adapter Group 1
1U-7563 Hex Key Wrench 1
66
Hydraulic and Steering System
Testing and Adjusting Section

Illustration 56
Side view of combination valve
(1) Combination valve
(2) Supply port for the valve group
(3) Supply port for the valve group
(4) Steering signal
(5) Steering relief valve
(6) Signal relief valve
g00848353
(7) Pump signal (12) Implement relief valve
(8) Signal purge valve (13) Valve group return port
(9) Control valve signal (14) Hydraulic tank return port
(10) Pressure test port for the hydraulic and (15) Steering supply port
steering pump (16) Pressure switch port
(11) Auxiliary return port (17) Secondary steering pump port
 67
Hydraulic and Steering System
Testing and Adjusting Section

4. Remove the dust cover from the combination

valve. Install a pressure gauge from the 1U-5481
Pressure Gauge Group into pressure test port
(10).

5. Start the engine. Operate the engine at high idle.

Record the pressure reading from the pressure
gauge at pressure test port (10). The pressure
should read 3300 689 kPa (480 100 psi). If
the low pressure standby is too high, refer to the
Problem: Low standby pressure is too high within
Testing and Adjusting, Hydraulic and Steering
System Troubleshooting.

6. Use the 1U-7563 Hex Key Wrench to open

purge valve (18) counterclockwise by one turn. A
small amount of oil may leak by the purge valve
during this procedure.

7. Read the pressure gauge. The correct setting

for true low pressure standby is 2100 150 kPa
Illustration 57 g00111740 (305 22 psi). This reading is without any
Pressure and flow compensator valve
load from the implements or any load from the
steering on the hydraulic system.
(18) Purge valve for the flow compensator
(19) Port
(20) Adjustment screw for the flow compensator (margin pressure) 8. If the pressure reading is incorrect, close purge
(21) Locknuts valve (18). Proceed to Section Adjustment for
(22) Adjustment screw for the pressure compensator (pressure Flow Compensator (Margin Pressure) .
cutoff)

Adjustment for Flow Compensator

(Margin Pressure)
Note: Before you perform this adjustment, refer to
Testing and Adjusting, Machine Preparation for
Troubleshooting.
Table 4
Required Tools
Part Description Quantity
Number
1U-5796 Pressure Differential 1
g00111741 Gauge Group
Illustration 58
Section A-A of pressure and flow compensator valve
(18) Purge valve for the flow compensator
(19) Port

The combination valve and the pressure and flow

compensator valve are accessible from the ground.
The valves are located under the cab platform and
on the left side of the machine. These components
are near the rear cab support.

1. Start the engine.

2. Operate the engine at low idle. Operate the

implement controls for three to ten minutes in
order to raise the hydraulic oil temperature to
normal operating temperature range.

3. Stop the engine.

68
Hydraulic and Steering System
Testing and Adjusting Section

4. Operate the engine at low idle. Operate the

implement controls for three to ten minutes in
order to raise the hydraulic oil temperature to
normal operating temperature range.

5. When you obtain the normal operating

temperature for the hydraulic oil, operate the
engine at high idle.

6. Operate the circle drive and rotate the blade at

full speed. Record the gauge pressure. While the
circle is in motion, gently tap the glass of the
pressure gauge in order to obtain an accurate
reading from the pressure gauge.

7. Stop the engine. The pressure reading should be

2100 150 kPa (305 22 psi).

8. If the pressure reading is incorrect, loosen

locknuts (21) on adjustment screw (20). Turn
the adjustment screw clockwise in order to
Illustration 59 g00111740 increase the setting. Turn the adjustment screw
Pressure and flow compensator valve
counterclockwise in order to decrease the
setting.
(18) Purge valve for the flow compensator
(19) Port
(20) Adjustment screw for the flow compensator (margin pressure) 9. When you tighten locknuts (21) hold adjustment
(21) Locknuts screw (20) secure. Repeat Steps 5 through Step
(22) Adjustment screw for the pressure compensator (pressure 8 until you obtain the correct pressure setting
cutoff) in Step 7.

10. Remove the pressure gauge. Replace the dust

caps on pressure test port (10) and port (19).

g00111748
Illustration 60
(10) Pressure test port for the hydraulic and steering pump
(19) Port

1. Connect the low side of the 1U-5796 Pressure

Differential Gauge Group into port (19). Port
(19) receives the resolved signal from the
combination valve.

2. Connect the high side of the 1U-5796 Pressure

Differential Gauge Group into pressure test port
(10).

3. Start the engine.

 69
Hydraulic and Steering System
Testing and Adjusting Section

Adjustment for Hydraulic System

Pressure

Illustration 61
Side view of combination valve
(1) Combination valve
(2) Supply port for the valve group
(3) Supply port for the valve group
(4) Steering signal
(5) Steering relief valve
(6) Signal relief valve
g00848353
(7) Pump signal (12) Implement relief valve
(8) Signal purge valve (13) Valve group return port
(9) Control valve signal (14) Hydraulic tank return port
(10) Pressure test port for the hydraulic and (15) Steering supply port
steering pump (16) Pressure switch port
(11) Auxiliary return port (17) Secondary steering pump port

Note: Before you perform this adjustment, refer to Note: When you perform this adjustment and
Testing and Adjusting, Machine Preparation for there is a loss of oil from spillage, use approved
Troubleshooting. containers to contain the oil. Also, use these
approved containers in order to dispose of the oil.
Table 5
Tools Needed 1. Start the engine.
Part Description Quantity 2. Operate the engine at low idle. Operate the
Number implement controls from three minutes to ten
1U-5481 Pressure Gauge Group 1 minutes in order to raise the hydraulic oil
temperature to the normal operating temperature
1U-5482 Pressure Adapter Group 1 range.
1U-7563 Hex Key Wrench 2
3. Stop the engine. Remove the dust cover from
1U-7577 Hex Key Wrench 1 pressure test port (10). Install the 1U-5481
1U-7581 Hex Key Wrench 1 Pressure Gauge Group into pressure test port
(10).
70
Hydraulic and Steering System
Testing and Adjusting Section
Illustration 62 g00111740
Pressure and flow compensator valve
(18) Purge valve for the flow compensator
(19) Port
(20) Adjustment screw for the flow compensator (margin pressure)
(21) Locknuts
(22) Adjustment screw for the pressure compensator (pressure
cutoff)
4. Start the engine and operate the engine at high
idle. When you are checking for the implement
cylinder stall pressure, move the wheel lean
cylinder to the end of the stroke. Then stall the
wheel lean cylinder. The correct pressure reading
should be 24132 1034 kPa (3500 150 psi).
5. Stop the engine if the pressure reading is
incorrect. Loosen the locknut for signal relief
valve (6). The locknut is a 9/16 inch hex head.
Turn the signal relief setscrew clockwise in order
to increase maximum pump pressure. Turn the
signal relief setscrew counterclockwise in order to
decrease maximum pump pressure. Use a 3/16
inch hex key wrench in order to adjust the signal
relief valve. One clockwise turn of the setscrew
will increase the setting by approximately
4700 kPa (682 psi). One counterclockwise turn
of the setscrew will decrease the setting by the
same amount. While you tighten the locknut, hold
the setscrew firmly. Start the engine and recheck
the pressure reading.
6. Stop the engine in order to adjust implement
relief valve (12). Remove signal relief valve (6)
from the combination valve. Remove the left
blade lift relief valve from the left blade lift control
valve. Install signal relief valve (6) in the left
blade lift control valve. Install the left blade lift
relief valve in the combination valve.
7. Loosen locknuts (21) and turn adjustment screw
(22) clockwise by two complete turns. Use the
4 mm hex key wrench.
8. Start the engine and operate the engine at
high idle. Move the wheel lean cylinder to the
end of the stroke and stall the cylinder. The
pressure gauge should read 27600 400 kPa
(3900 60 psi). This is the pressure setting of
implement relief valve (12).
9. If the pressure is incorrect, stop the engine.
Loosen the locknut on implement relief valve (12).
10. Use a 3/8 inch hex key wrench in order to
turn the setscrew on implement relief valve
(12). Turning the setscrew clockwise will
increase the pressure and turning the setscrew
counterclockwise will decrease the pressure.
While you tighten the locknut, hold the setscrew
firmly. Start the engine and operate the engine
at high idle. Move the wheel lean cylinder to the
maximum stroke and stall. Check the pressure
reading.
Note: If you cannot achieve 27600 400 kPa
(3900 60 psi), replace the implement relief valve
(12).
11. Stop the engine. Turn adjustment screw (22)
counterclockwise by two complete turns. Use the
4 mm hex key wrench.
12. When you adjust adjustment screw (22), start
the engine. Operate the engine at high idle.
Move the wheel lean cylinder to the end of the
stroke and stall the cylinder. The pressure gauge
should read 25500 350 (3700 70 psi).
13. If the pressure is incorrect, stop the engine.
Loosen locknuts (21) on adjustment screw (22).
14. Turn adjustment screw (22) clockwise in order
to increase the pressure. Turn adjustment screw
(22) counterclockwise in order to decrease the
pressure. While you tighten locknuts (21), hold
adjustment screw (22) firmly. Start the engine
and operate the engine at high idle. Move the
wheel lean cylinder to the maximum stroke and
stall. Check the pressure reading.
15. After you achieve the correct pressure reading,
remove the left blade lift relief valve from the
combination valve. Remove signal relief valve
(6) from the blade lift control valve. Install signal
relief valve (6) into the combination valve. Install
the left blade lift relief valve into the blade
lift control valve. Tighten relief valves to the
specified torque.
16. Repeat Step 4.
 71
Hydraulic and Steering System
Testing and Adjusting Section

17. If the pressure reading is incorrect, repeat Step

5.

18. When the pressure reading is correct, stop the

engine. Remove the pressure gauge. Install the
dust cover on pressure test port (10).

Adjustment for Signal Network

Note: Before you perform this adjustment, refer to
Testing and Adjusting, Machine Preparation for
Troubleshooting.
Table 6
Tools Needed
Part Description Quantity
Number
8T-0856 Pressure Gauge 1
8T-0860 Pressure Gauge 1
1U-5754 Hose Assembly 1
6V-4143 Coupler Assembly 2
6V-3989 Unvalved Nipple 1

g00111748
Illustration 63
(10) Pressure test port for the hydraulic and steering pump
(19) Port
72
Hydraulic and Steering System
Testing and Adjusting Section

g00924231
Illustration 64
(1) Combination valve (28) Articulation (34) Line to the pressure and flow
(23) Left blade lift (29) Centershift compensator valve on the hydraulic and
(24) Sideshift (30) Wheel lean steering pump
(25) Circle drive (31) Right blade lift (35) Line to the steering metering pump
(26) Blade tip (32) Signal check valve (36) Line from the steering priority valve and
(27) Line to the implement compensator (33) Line to the signal purge valve and the the steering relief valve
valves signal relief valve (37) Signal resolver

Note: The number of control valves in the valve
bank may vary with the different equipment that is
on the machine.
1. Operate the engine at low idle.
2. Operate the implement controls for three minutes
to ten minutes in order to raise the hydraulic oil
temperature to the normal operating temperature
range.
3. Stop the engine. Remove the dust cover from
pressure test port (10). Install the 8T-0856
Pressure Gauge in pressure test port (10).
4. Start the engine and operate the engine at high
idle. The correct pressure reading should be
3300 689 kPa (480 100 psi).
5. If the pressure that is measured at pressure test
port (10) is within the tolerance that is indicated
in Step 4, proceed to Step 6. If the pressure
reading is not within the tolerance, adjust the low
standby pressure. Refer to the procedure that is
found in the Low Standby Pressure Adjustment
section. Then continue with Section Adjustment
for Signal Network .
6. Stop the engine. Remove the 8T-0856 Pressure
Gauge from pressure test port (10). Replace
the 8T-0856 Pressure Gauge with a 8T-0860
Pressure Gauge.
7. In order to obtain pump signal pressure, install
the 8T-0860 Pressure Gauge into port (19) of
the pressure and the flow compensator valve.
 73
Hydraulic and Steering System
Testing and Adjusting Section

8. Move the control lever for blade tip (26) in order
to move the blade tip cylinder to the maximum
stroke and stall. Read the pressure gauges. The
pressure gauge that is reading the pump signal
should increase. The pressure gauge that is
reading the pump output should increase.
9. If the pump signal pressure increases and the
pump output pressure does not increase, the
pressure and flow compensator valve on the
hydraulic and steering pump has failed. Stop
the engine.
10. Replace the pressure and flow compensator
valve.
11. Test signal resolver (37) in the combination valve
by following Step 12 and Step 13.
19. If a blade lift cylinder drifts during the operation
of another implement that is in the same valve
bank, the signal check ball in the blade lift
cylinder is faulty. A missing signal check ball in
any implement valves or a faulty signal check
ball in any implement valves may cause any one
of the implements to be inoperative in that valve
bank. The implement that is working will be the
implement valve that is missing a signal check
ball or the implement valve that has a faulty
signal check ball in that implement valve.
20. Operate the circle drive. If a low flow circuit fails
to operate during operation of the engine at low
idle, refer to Testing and Adjusting, Hydraulic
and Steering System Troubleshooting.
21. Stop the engine.

12. Start the engine and operate the engine at low

i01533374
idle.

13. If the steering is operable with at least one

Relief Valve (Implement) - Test
implement in operation, signal resolver (37) in and Adjust
the combination valve has failed. When the
implement ceases to operate and the steering is SMCS Code: 5117-025-TB; 5117-081-TB
not being operated, signal resolver (37) in the
combination valve has failed. Note: Before you perform this adjustment, refer to
Testing and Adjusting, Machine Preparation for
14. Stop the engine. Remove the pressure gauge Troubleshooting.
from pressure test port (10). Replace the dust
cover. Table 7
Tools Needed
15. In order to check for a faulty signal check ball
in the implement control valves, follow Steps 16 4C-4441 Relief Valve Test Tool Gp 1
through Step 21. In order to check for a missing 1U-9358 Test Block Manifold 1
signal check ball in the implement control valves,
follow Steps 16 through Step 21.

16. Start the engine and operate the engine at low

idle. Check the implement cycle times.

17. If the cycle time for each of the implements

is longer than the specifications that are
allowed except for one implement, the following
information is true. The signal check ball in that
implement control valve is faulty or the signal
check ball in that implement control valve is
missing.

18. The signal from the right valve bank can be

isolated from the signal from the left valve bank
at the combination valve. This will pinpoint the
problem with the signal to the right valve bank or
to the left valve bank.

g00563513
Illustration 65
Combination Valve
(1) Implement relief valve
74
Hydraulic and Steering System
Testing and Adjusting Section

8. Measure the leakage oil. If the leakage oil is

greater than 0.004 L/min (0.0011 US gpm),
replace the relief valve.

9. Install the relief valve on the combination

valve. Refer to Disassembly and Assembly,
Combination Valve - Assemble for the correct
procedure to install the relief valve.

i01767235

Accumulator (Blade Cushion) -

Test and Charge
g00563514
Illustration 66 SMCS Code: 5077-081-BG
Implement relief valve
(2) Retainer assembly
(3) Nut

Personal injury or death can result from improper

Use the 1U-9358 Test Block Manifold in order to
accumulator charging.
test implement relief valve (1) on the 4C-4441
Relief Valve Test Tool Gp. The pressure setting for
Dry nitrogen is the only gas approved for use in
the relief valve is 27600 400 kPa (3900 60 psi).
the accumulator. Charging the accumulator with
oxygen gas will cause an explosion. This danger
1. Remove implement relief valve (1) from the
will not happen if nitrogen cylinders with standard
combination valve and install implement relief
CGA Compressed Gas Association, Inc.Number
valve (1) on the 4C-4441 Relief Valve Test Tool
580 connections are used.
Gp.
When ordering nitrogen gas, be sure that the cylin-
Note: Refer to Disassembly and Assembly,
ders are equipped with CGA Number 580 Connec-
Combination Valve - Disassemble for the correct
tions. Do not use color codes or other methods of
procedure to remove the relief valve.
identification to tell the difference between nitro-
gen and oxygen cylinders.
2. Purge the air from the system. The temperature
of the oil must be 49 3C (120 5F).
Never use an adapter to connect your nitrogen
charging group to a valve outlet used on both ni-
3. Apply flow of 38 4 L/min (10 1 US gpm) to
trogen, oxygen or other gas cylinders. Be sure you
the valve and note the pressure that opens the
use dry nitrogen (99.8 % purity).
relief valve.

4. Turn retainer assembly (2) clockwise in order to

increase the pressure and turn retainer assembly
(2) counterclockwise in order to decrease the
pressure. One turn of the retainer assembly will
change the setting approximately 6300 kPa
(915 psi).
5. Repeat Step 2 and repeat Step 4 until
you achieve a setting of 27600 400 kPa
(3900 60 psi).
Sudden movement of the machine or release of oil
under pressure can cause serious injury to per-
sons on or near the machine.
To prevent possible injury, perform the procedure
that follows before testing and adjusting the hy-
draulic system.

6. After you set the retainer assembly to the correct Refer to Testing and Adjusting, Machine Preparation
pressure setting, tighten nut (3) to 50 7 Nm for Troubleshooting before you begin the test.
(37 5 lb ft). Hold retainer assembly (2) when
you tighten nut (3).

7. Set the test pressure at 5600 70 kPa

(812 10 psi). Maintain the temperature of the
oil at 26 C to 28 C (79 F to 82 F).
 75
Hydraulic and Steering System
Testing and Adjusting Section

In order to correctly charge the accumulator,

the piston in the blade cushion accumulator
must be on the bottom of the cylinder. The air
temperature outside the accumulator is the ambient
temperature. Before the dry nitrogen pressure in
the accumulator can be accurately checked, the
temperature of the accumulator must be equal to
the ambient temperature. Before the accumulator
may be correctly charged, the temperature of
the accumulator must be equal to the ambient
temperature.

Use table 9 in order to determine the correct

charging pressure for the 162-7450 Accumulator.
g00794031
Illustration 67 Table 9
Nitrogen Charging Group
Charging Pressure and Temperature Relationship
(1) Pressure regulating screw for the 2068 kPa (300 psi) Accumulator
(2) Pressure gauge
(3) Regulator Temperature Pressure(1)
(4) Valve handle  
(5) Connection to the nitrogen cylinder -1 C (30 F) 1882 kPa (273 psi)
(6) Nitrogen charging chuck
(7) Valve handle 4C (40F) 1924 kPa (279 psi)
(8) Pressure gauge
10C (50F) 1965 kPa (285 psi)
Table 8  
16 C (60 F) 2006 kPa (291 psi)
Tools Needed  
21 C (70 F) 2048 kPa (297 psi)
175-5507 Nitrogen Charging Group 1  
27 C (80 F) 2089 kPa (303 psi)
32C (90F) 2130 kPa (309 psi)
Lower the Piston in Blade Cushion 38C (100F) 2172 kPa (315 psi)
Accumulators 
43 C (110 F) 
2213 kPa (321 psi)
 
Equipped with the Blade Float Function 49 C (120 F) 2234 kPa (324 psi)
(1) The allowable tolerance on nominal pressure is 207 kPa
1. Start the engine. Turn the blade cushion ON. (30 psi).

2. Move the blade lift levers all the way forward

into the detent position. The blade float will be
activated.

3. Turn the blade cushion OFF. Deactivate the

blade float. Stop the engine.

Equipped Without the Blade Float

Function
1. Start the engine. Turn the blade cushion ON.

2. Raise the blade to the full up position. Raise

the blade slowly. Hold the lift levers back for 10
seconds. The accumulator pistons will bottom.
Do not use down pressure.

3. Do not move the levers again. Turn the blade

cushion OFF. Stop the engine.
76
Hydraulic and Steering System
Testing and Adjusting Section
Checking the Blade Cushion
Accumulator
g00794305
Illustration 68
(9) Cap
(10) Cover
1. Remove both cover (10) and the cap from valve
assembly (9) on the accumulator.
2. Install pressure gauge (8) into the quick
disconnect on valve (7). Pressure gauge (8) is
a 25000 kPa (3625 psi) pressure gauge. This
pressure gauge should be used in order to
check the nitrogen pressure in the accumulator.
Close valve (7).
3. Install chuck (6) onto valve (9) of the accumulator.
4. Turn valve (4) fully in the clockwise direction.
Measure the air temperature around the
accumulator. This outside temperature is the
ambient temperature. When you measure the
precharge pressure of the 162-7450 Hydraulic
Accumulator Gp, refer to Table 9. Locate the
ambient temperature in the left column of the
table. Read the pressure that is located in the
right column of this row in order to find the
correct charging pressure. The reading on
pressure gauge (8) corresponds to the pressure
of the dry nitrogen gas in the accumulator.
The pressure on the gauge must be within the
tolerances that are shown in table 9.
5. Decrease the nitrogen pressure if the nitrogen
pressure in the 162-7450 Hydraulic Accumulator
Gp is greater than the specified value in Table
9. Slowly open valve (4) in order to decrease
the pressure.
6. Increase the nitrogen pressure if the nitrogen
pressure in the 162-7450 Hydraulic Accumulator
Gp is less than the specified value in Table 9.
Increase the nitrogen pressure to the specified
level. Increase the nitrogen pressure according
to , Charging the Blade Cushion Accumulator.
7. Repeat Step 1 through Step 6 for the other
accumulator.
Charging the Blade Cushion
Accumulator
Increase the nitrogen pressure in the accumulators
according to the following procedure:
1. Connect the hose to regulator (3) on the nitrogen
cylinder. Connect the other end of the hose to
valve (7).
2. Close valve (7). Open the valve on the nitrogen
cylinder. Adjust pressure regulating screw (1)
on regulator assembly (3). Adjust pressure
regulating screw (1) until pressure gauge (2) is
at the correct charging pressure. Use Table 9 in
order to determine the correct charge pressure
for the accumulator.
3. Open valve (7). Charge the accumulator. Close
valve (7). Compare the reading on pressure
gauge (2) with the reading on pressure gauge
(8). If the two readings remain constant and if the
readings are equal, the accumulator has been
correctly charged.
If there is a decrease in the reading on pressure
gauge (8), open valve (7). Allow more of the dry
nitrogen gas to flow into the accumulator. Repeat
Step 3 until pressure gauge (2) and pressure
gauge (8) have the same reading. These two
readings do not change when valve (7) is closed.
4. Close valve (7). Close the valve on the nitrogen
cylinder.
5. Turn valve (4) fully in the counterclockwise
direction.
6. Remove the charging equipment.
7. Repeat Step 1 through Step 6 for the other
accumulator.

Accumulator Charge Procedure for
a Rebuilt Accumulator
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
It is necessary to remove all of the air from the
accumulator. After the accumulator is rebuilt, put
approximately 0.9 L (1 qt) of SAE 10W hydraulic oil
in the nitrogen chamber of the accumulator. This
oil will be used to help remove the air from the
nitrogen chamber of the accumulator. This hydraulic
oil also lubricates the top seal of the piston in the
accumulator.
Install the rebuilt accumulator on the machine.
Follow the following procedure to charge the rebuilt
accumulator.
1. Install the 175-5507 Nitrogen Charging Group.
2. Turn valve (4) fully to the right. Open valve (7).
3. Start the engine and allow the engine to run until
the engine is warm. Activate the blade cushion
control.
Hydraulic oil will flow into the bottom of the
accumulator. The air will first be forced out of
the upper chamber of the accumulator through
the test equipment. Then, the hydraulic oil will
be forced out of the upper chamber of the
accumulator through the test equipment. When
the hydraulic oil stops flowing out of the top
of the accumulator, the upper chamber of the
accumulator will contain no air.
4. Close valve (7) completely. The piston in the
accumulator will be at the top of the accumulator.
5. Charge the accumulator according to the
procedure in Charging the Blade Cushion
Accumulator. Rebuilt accumulators require
longer charging times. New accumulators require
less charging time. When the accumulator has
been rebuilt, the piston is located in the top of the
cylinder. The piston will be forced to the bottom
of the cylinder during the charging procedure.
77
Hydraulic and Steering System
Testing and Adjusting Section
6. If necessary, repeat Step 1 through Step 5 for
the other accumulator.
i01552775
Hydraulic Cylinder Drift -
Check
SMCS Code: 7562-535-D9
Hydraulic cylinder drift is any movement of the
cylinder rod, when the control lever is in the HOLD
position. During normal operation, movement of the
cylinder can have an effect on the performance of
the machine.
Any of the following examples may cause cylinder
drift:
The cylinder piston seal is damaged.
A scratch in the cylinder bore or a groove in the
cylinder bore
A scratch on the cylinder rod or a groove on the
cylinder rod
The cylinder head seal is damaged.
Dirt in the lock valve or the lock valve is damaged
in the implement control valve.
Loose fittings or damaged hydraulic lines that
have oil leaks.
Dirt in the line relief valves or the line relief valves
are damaged.
The maximum allowable amount of cylinder rod
travel in any blocked circuit:
The cylinder can travel 1.5 mm (0.06 inch)

in 5
minutes at a temperature of 38 C (100 F).
The cylinder can travel 1.5 mm (0.06 inch)

in 3.2
minutes at a temperature of 49 C (120 F).
The cylinder can travel 1.5 mm (0.06 inch)

in 1.7
minutes at a temperature of 66 C (150 F).
i01133676
Disc Pack Preload for Circle
Drive - Adjust
SMCS Code: 5207-025-ZP
Note: Before you perform this procedure, refer to
Testing and Adjusting, Machine Preparation for
Troubleshooting.
78
Hydraulic and Steering System
Testing and Adjusting Section

7. Measure the distance between bracket (2) and

the circle drive housing with a feeler gauge.

8. Remove the dial indicator and bracket (2). Use

the correct amount of shims (4) to give a preload
dimension of 0.00 to 0.13 mm (.000 to .005 inch).

i01678610

Cylinder Cycle Time - Check

SMCS Code: 7562-535-VF
Table 10
Required Tools
A Stopwatch or Timer 1

Note: Before you perform this check, refer to

Testing and Adjusting, Machine Preparation for
Illustration 69 g00600098 Troubleshooting.
Circle Drive
Use Table 11 in order to determine the correct
(1) Motor
(2) Bracket
cylinder cycle times. Choose the column that has
(3) Nuts the cycle times for your Motor Grader. Record the
(4) Shims actual cycle times in the column that is on the right
(5) Bolts side of the table. The cycle times that are shown in
(6) Plate Table 11 are in seconds. The number of steering
(7) Spacer
(8) Friction disc wheel rotations from the left stop to the right stop
(9) Disc determines the steering check.

1. Assemble 6Y-7953 Friction Disc (8) and
2G-0478 Disc (9).
2. Remove three bolts (5) and plate (6).
3. Measure the dimension from the top of spacer
(7) to the top of shims (4). The top of spacer (7)
must be above the top of shims (4). The distance
between the spacer and the shims must be
2.3 0.2 mm (.09 .01 inch).
4. For the correct dimension, remove the correct
number of shims (4) or install the correct number
of shims (4).
For most cylinders, a test cycle is the full range of
movement. For the following cylinders, a test cycle
is movement through a 305 mm (12 inch) distance:
blade lift cylinders, ripper cylinder, and scarifier
cylinder. For the circle, a test cycle is 1/4 of 1 full
rotation.
All of the checks of the implement cycle times must
be performed at high idle. The hydraulic oil must be
at normal operating temperature. Ensure that the
cylinder bears no additional loads. The following
causes will create additional loads: interference
from other machine components, contact with
foreign objects, and contact with the ground.

5. Install plate (6) and tighten three bolts (5) to a
torque of 130 7 Nm (95 5 lb ft).
6. Remove motor (1). Put bracket (2) in position on
the new circle drive housing.
If any test results are unacceptable refer to Testing
and Adjusting, Hydraulic and Steering System
Troubleshooting.

Note: Do not install oring seal or shims (4) at this

time. Install nuts (3), but leave nuts (3) loose.

Attach a magnetic base dial indicator onto

bracket (2) with the dial indicator against the
worm assembly. Tighten nuts (3) while you rotate
the worm. Rotate the worm until the end play
for the worm is at zero.
 79
Hydraulic and Steering System
Testing and Adjusting Section

Table 11

Implement Cycle Times for Motor Graders

Implement Cycle Times

Actual Implement
Implement Action 12H, 140H, Cycle Times
120H and 135H 143H, 160H 14H and 16H
and 163H

Blade Lift Rod In (1) 2.9 0.4 3.3 0.7 2.6 0.4
Rod Out (1) 2.9 0.4 3.2 0.6 2.5 0.4
Centershift Rod In (2) 6.6 1.1 6.6 1.1 6.4 1.1
Rod Out (2) 6.3 0.9 6.3 0.9 6.2 0.9
Wheel Lean Rod In (2) 2.0 0.3 2.0 0.3 2.0 0.3
Rod Out (2) 2.0 0.3 2.0 0.3 2.0 0.3
Blade Tip Rod In (2) 2.7 0.4 2.7 0.4 2.6 0.3
Rod Out (2) 2.7 0.4 2.7 0.4 2.6 0.4
Sideshift Rod In (2) 9.2 1.4 9.2 1.4 9.0 1.3
Rod Out (2) 9.3 1.3 9.3 1.3 9.1 1.3
Scarifier (If Rod In (1) 4.2 0.6 2.8 0.4
Equipped) Rod Out (1) 2.8 0.4 4.2 0.6
Ripper (If Rod In (1) 6.3 0.9 6.3 0.9 5.4 1.5
Equipped) Rod Out (1) 4.8 0.7 4.8 0.7 4.1 0.6
Articulation Rod In (2) (3) 4.0 0.5 4.0 0.5 3.9 0.9
Rod Out (2) (3) 4.0 0.5 4.0 0.5 3.9 0.9
Blade Circle 1/4 Rotation 12.2 1.5 12.2 1.5 12.0 1.4
Steering Wheel Number of Turns 6-7 6-7 6
(1) Cycle times are for a running distance of 305 mm (12 inch).
(2) Cycle time is through full travel.
(3) When you check the cycle times for these cylinders, operate the machine at high idle and place the transmission control (lever) in the FIRST
SPEED position. The differential must be unlocked.

Procedure To Check Blade Lift

Cycle Times, Ripper (If Equipped)
Cycle Times and Scarifier (If
Equipped) Cycle Times
Table 12
Required Tools
A Stopwatch or Timer 1
1U-9366 Tape Measure 1

g00820940
Illustration 70
(1) Cylinder rod
(2) Marks
(3) Tape measure
(A) Running distance

1. Raise the implement that needs to be checked

to the maximum height.
80
Hydraulic and Steering System
Testing and Adjusting Section

2. Place a mark on the rod. Place the mark just Table 13

below the cylinder head. Use ink in order Tools Needed
to create all marks. Do not create marks by
scratching or by scoring. Part Description Quantity
Number
3. Use the stopwatch in order to determine the time 1U-5796 Pressure Differential Gauge 1
that is required to lower the cylinder by 305 mm Group
(12 inch). Use the tape measure in order to
determine 305 mm (12 inch) of movement. Use 1U-7577 Hex Key Wrench 1
the mark as a reference.

4. Position the implement just above the ground.

5. . Place two marks on the rod. Place the marks

305 mm (12 inch) away from each other.

6. Use the stopwatch in order to determine the time

that is required to raise the cylinder by 305 mm
(12 inch). Use the marks for reference.

i01810463

Steering Wheel Slip - Check

SMCS Code: 4312-535; 4343-535

Note: Before you perform this check, refer to

Testing and Adjusting, Machine Preparation for
Troubleshooting.

To check the steering wheel slip, do the following

checks.

1. Steer the wheel left or steer the wheel right

against the stops. The pressure should be
19300 689 kPa (2800 100 psi).

2. Check the steering wheel revolutions. When you

turn the wheel from stop to stop, you should
achieve a total of six and a half turns.

3. Turn the steering wheel while you operate the

circle. Check for rough steering.

i01810516

Relief Valve (Steering) - Test

and Adjust
SMCS Code: 4322-025; 4322-081

Note: Before you perform this check, refer to

Testing and Adjusting, Machine Preparation for
Troubleshooting.
 81
Hydraulic and Steering System
Testing and Adjusting Section

Illustration 71
Side View of Combination Valve
(1) Combination valve
(2) Supply port for the valve group
(3) Supply port for the valve group
(4) Steering signal
(5) Steering relief valve
(6) Signal relief valve
g00848353
(7) Pump signal (12) Implement relief valve
(8) Signal purge valve (13) Valve group return port
(9) Control valve signal (14) Hydraulic tank return port
(10) Pressure test port for the hydraulic and (15) Steering supply port
steering pump (16) Pressure switch port
(11) Auxiliary return port (17) Secondary steering pump port

1. Remove the dust cover from the pressure test
port for the hydraulic and steering pump (10).
Install the pressure gauge in the test port.
2. Start the engine and operate the engine at high
idle. Cycle the implements until the hydraulic oil
reaches normal operating temperature.
3. Steer the wheel left against the stop or turn the
wheel right against the stop. The pressure gauge
should read 19300 689 kPa (2800 100 psi).
This is the maximum steering pressure.
4. If the maximum steering pressure is incorrect,
stop the engine and adjust steering relief valve
(5). Turn the adjustment screw clockwise in
order to increase the pressure setting and turn
the adjustment screw counterclockwise in order
to decrease the pressure setting. One turn of
the adjustment screw provides an approximate
change of 5300 kPa (770 psi).
i01640423
Steering System - Purge
SMCS Code: 4300-542; 4303-542; 4307-542

Note: Before you perform this procedure, refer to

Testing and Adjusting, Machine Preparation for
Troubleshooting.
82
Hydraulic and Steering System
Testing and Adjusting Section

Table 14
Required Tools
Part
Tool Number Part Description Qty
8T-2362 Straight Thread Adapter(1) 4
7J-0204 O-Ring Seal 4
6V-8628 Elbow 4
A
3J-7354 O-Ring Seal 4
4J-5477 O-Ring Seal 4
9C-2394 Hose As 2
(1) The adapter must be change 02. Exterior thread is 3/8 by 24.
Interior threads are 7/16 by 20.

g00111755
Illustration 72
Typical Top View of Front Axle
(1) Cylinders for steering (2) Location of plugs

1. Remove the plugs (2) from each steering cylinder 4. Steer the wheels against the left stop. Turn the
(1). steering wheel to the left 50 complete revolutions.

2. Use the parts that are listed in Table 14 in order
to connect the port of the rod end to the port of
the head end. Perform this procedure for both of
the cylinders.
3. Start the engine and operate the engine at low
idle.
5. Steer the wheels against the right stop. Turn
the steering wheel to the right 50 complete
revolutions.
6. Shut off the engine.
7. Remove the parts that are listed in Table 14 from
each cylinder and install the plugs (2).
 83
Hydraulic and Steering System
Testing and Adjusting Section

8. Check the oil level in the hydraulic tank.
Purge Procedure (Signal Network)
Note: Before you perform this procedure, refer to
Testing and Adjusting, Machine Preparation for
Troubleshooting.
Note: Perform the Steering SystemPurge
procedures before you perform the purge
procedure.
2. Start the engine and operate the engine at low
idle. During this procedure, a small amount of oil
may leak by the purge valve.
3. Move each implement control lever forward and
hold the lever for five seconds. Then, move
the levers backward and hold the lever for five
seconds.
Note: When your are moving each implement control
lever, start sequentially from right to left.

4. After all implement control valves have been

operated, turn the steering wheel to the left and
to the right ten times.

5. Turn purge valve (3) clockwise in order to close

the valve.

6. Stop the engine.

g00111758
Illustration 73
Pressure and Flow Compensator Valve
(3) Purge valve for flow compensator
(4) Resolved signal from the combination valve
(5) Adjustment screw for margin pressure
(6) Locknuts
(7) Adjustment screw for Pressure cutoff

g00111759
Illustration 74
Section A-A of Pressure and Flow Compensator Valve
(3) Purge valve for flow compensator
(4) Resolved signal from the combination valve

1. Use a hex wrench. Turn purge valve (3)

counterclockwise by one turn in order to open
the valve.
84
Hydraulic and Steering System
Testing and Adjusting Section

i01124525

Axle Toe-In (Front) - Adjust

SMCS Code: 4313-025

g00594728
Illustration 75

1. Raise the front wheels off the ground. Install the
wheel lean locking bolt into the lean bar.
2. Use a block of wood to hold your hand steady
when you mark the front tire. Rotate the wheel so
that you can put a mark around the center of the
tread of each front tire.
3. Measure the distance at spindle height. Measure
the distance from the mark on one front tire
to the mark that is on the other front tire. This
should be done at both the front of the tires and
at the rear of the tires. The toe-in is correct if the
measurement (K) at the front of the front tires is
less than the measurement (L) at the rear of the
front tires. The measurement at the front of the
front tire should be smaller by 6.0 mm (.25 inch).

4. Adjust the toe-in, as needed. Loosen the nuts

(1) in the clamps on the tie rod (2). Rotate tie
rod (2) in the direction that is needed to achieve
the correct toe-in for the front wheels. When
the toe-in adjustment is correct, orient the bolts
that are in the clamps on the tie rod, as shown.
Tighten the nuts (1) that are on the clamps on tie
rod (2) to the specified torque.

g00008331
Illustration 76
 85
Hydraulic and Steering System
Testing and Adjusting Section

i01124142

Position Sender (Articulation) -

Adjust
SMCS Code: 4806-025

g00123478
Illustration 77
Articulation Position Sender Assembly
(1) Plate assembly (6) Setscrew
(2) Articulation alignment gauge assembly (7) Articulation Position Sender
(3) Stem (8) Screws
(4) Arm (9) Nut
(5) Clamp (10) Pin

Table 15 2. Center the articulation of the machine in order

Tools Needed to allow the frame lock pin to move freely in the
frame.
Qty Part Number Description
1 127-8073 Articulation Alignment Gauge
3. Position arm (4) so that pin (10) is engaged with
Assembly (2) the arm, as shown.

4. Make sure that arm (4) is positioned against the

Adjustment Procedure for the Arm
on the Articulation Position Sender
Before you perform the Procedure for Adjusting
the Articulation Position Sender, do this procedure
first. When you have installed the arm (4) correctly,
the arm will have a normal range of motion without
interference. The correct position of the arm
allows stem (3) to achieve a center position in the
articulation position sender.
1. Install the frame lock pin.
flat spot of stem (3). Install the arm to the stem by
tightening setscrew (6) to the specified torque.
Procedure for Adjusting the
Articulation Position Sender
If you performed Adjustment Procedure for the
Arm on the Articulation Position Sender first, go
to Step 3.
1. Install the frame lock pin.
86
Hydraulic and Steering System
Testing and Adjusting Section
2. Center the articulation of the machine in order
to allow the frame lock pin to move freely in the
frame.
3. Loosen nut (9) in order to allow the 3E-5383
Articulation Position Sender (7) to be moved.
4. Loosen two screws (8) for final adjustment.
5. Install the 127-8073 Articulation Alignment
Gauge Assembly (2) on top of the articulation
position sender (7). Make sure that the
articulation alignment gauge assembly is
engaged in the 123-3688 Plate Assembly (1).
Note: Make sure that the pin in the articulation
alignment gauge assembly (2) is inserted into plate
assembly (1). When you install the articulation
alignment gauge, the articulation alignment gauge
must be level.
6. If the articulation alignment gauge is not level,
adjust clamp (5) on the stem (3). Be sure that
arm (4) remains against the flat spot of the stem.
Tighten setscrew (6) to the specified torque.
7. Adjust the articulation position sender (7) with
the articulation alignment gauge assembly (2) in
place. Adjust the sender until the needle in the
articulation alignment gauge in the cab is in the
CENTER position.
8. Tighten nut (9). Remove the articulation alignment
gauge assembly (2). Check the articulation
alignment gauge in the cab for CENTER position.
If the needle in the articulation alignment gauge
is centered, tighten screws (8).
9. Final adjustment of the articulation position
sender (7) may be made by rotating the sender.
Rotate the sender in order to achieve CENTER
position. If the needle in the articulation alignment
gauge is centered, tighten screws (8).
10. Remove the frame lock pin in order to check the
gauge in the cab for the entire articulation range.
11. If the needle in the articulation alignment gauge
in the cab is not in the CENTER position, repeat
Steps 1 through 10.
i01536696
Piston Pump Cutoff Pressure
(Hydraulic Fan) - Test and
Adjust
SMCS Code: 1387-025-PX; 1387-081-PX;
5070-025-PX; 5070-081-PX; 5086-025-PX;
5086-081-PX
The drive shaft rotates between the torque con-
verter and the transmission whenever the engine
is running. Contact with the rotating shaft can
result in personal injury or death. The rotating
shaft is located under the implement and steering
pumps.
Do not allow personnel into the pump bay area
behind the cab when the engine is running.
Sudden movement or accidental starting of the
machine can cause personal injury or death to per-
sons on or near the machine.
To prevent personal injury or death, perform the
following:
Park the machine on a smooth, level surface.
Lower the work tool to the ground and engage the
parking brake.
Stop the engine and remove the key.
Block the wheels and install the steering frame
lock.
The fan drive pump is a variable displacement
piston pump. There is no pressure relief valve
in the fan drive system. The pressure and flow
compensator valve on the pump controls the pump
cutoff pressure. The pressure and flow compensator
valve also controls the flow of hydraulic oil to the
fan drive motor.
The Caterpillar Electronic Technician (ET) software
must be used in order to override the fan control
solenoid valve. Caterpillar ET will then provide
the correct control pressure to the pump control.
The fan control solenoid valve is controlled by the
engine ECM.
Note: Caterpillar ET is a software program that can
be used on an IBM compatible personal computer.
 87
Hydraulic and Steering System
Testing and Adjusting Section

Table 16 3. Shift the transmission to neutral.

Required Tools
4. Start the engine. Run the engine at high idle.
Part
Description Quantity
Number 5. Move the wheel lean cylinder to the end of the
8T-0860 Pressure Gauge 1 stroke. Stall the cylinder. At the same time, circle
the moldboard. This will warm the hydraulic oil to
6V-3989 Unvalved Nipple 1 normal operating temperature of approximately
1U-6602 Photo-Tachometer 1 60 5C (140 9F).

6. Connect Caterpillar ET to the data link connector.

Before proceeding to the test procedure that The data link connector is located on the front
follows, complete the procedure: Testing and face of the shift console. Start Caterpillar ET.
Adjusting, Machine Preparation for Troubleshooting
7. Select the engine Electronic Control Module
(ECM) for your machine. Select Diagnostics.
Select Diagnostic Tests. Select Override
Parameters. Select Engine Fan Bypass.

8. Enter 0% for the Engine Fan Bypass Override

Parameter. Press Enter until all warning
messages disappear. This will cause the fan to
run at maximum speed when the engine is at
high idle.

9. With the engine at high idle, use the 1U-6602

Photo-Tachometer in order to measure the fan
speed. The pressure reading of the pressure
g00798545
gauge should be used as reference only. The
Illustration 78 fan speed must match the value that is listed
(1) Pressure tap for output pressure of the fan drive in Table 17.
Table 17
Fan Speeds
Model Fan Speed Reference
Pressure
12H, 140H, 1210 25 RPM 8000 500 kPa
and 160H (1160 73 psi)
12H(1), 140H(1), 1350 25 RPM 10000 500 kPa
143H, 160H(1), (1450 73 psi)
and 163H
(1) High Ambient

10. If the pump cutoff pressure of the fan drive pump

g00798628
Illustration 79 is not correct, the cutoff valve must be adjusted.
(2) Pressure and flow compensator valve
(3) Fan drive pump 11. Stop the engine.
(4) Fan control solenoid valve
(5) Adjustment screw for cutoff pressure 12. Loosen locknut (6).
(6) Locknut

13. Turn adjustment screw (5) clockwise in order to

The components of the fan drive are located in the
increase the pressure setting. Turn adjustment
back of the pump compartment.
screw (5) counterclockwise in order to decrease
the pressure setting.
1. Attach an unvalved nipple to a 0 to 16000 kPa
(0 to 2321 psi) pressure gauge. Attach a section
14. Tighten locknut (6).
of hydraulic line to the unvalved nipple. Attach
the hydraulic line to pressure tap (1) on fan
15. Repeat Step 9 through Step 14 until the proper
control solenoid valve (4).
fan speed is obtained.
2. Engage the parking brake.
88
Hydraulic and Steering System
Testing and Adjusting Section

16. Use Caterpillar ET in order to reset the Engine
Fan Bypass Override Parameter.
17. Exit the Caterpillar ET program and disconnect
ET from the machine.
i01537760
Piston Pump Margin Pressure
Measure the margin pressure with the pump
swashplate midway between the MAXIMUM
OUTPUT position and the MINIMUM OUTPUT
position. The Caterpillar Electronic Technician (ET)
software must be used in order to override the
fan control solenoid valve. Caterpillar ET will then
provide the correct control pressure to the pump
control. The fan control solenoid valve is controlled
by the engine ECM.

(Hydraulic Fan) - Test and Note: Caterpillar ET is a software program that can
be used on an IBM compatible personal computer.
Adjust
Table 18
SMCS Code: 1387-025-PX; 1387-081-PX;
5070-025-PX; 5070-081-PX; 5086-025-PX; Required Tools
5086-081-PX Part Number Description Quantity
8T-0855 Pressure Gauge 1
6V-3989 Unvalved Nipple 1
The drive shaft rotates between the torque con- 1U-6602 Photo-Tachometer 1
verter and the transmission whenever the engine
is running. Contact with the rotating shaft can
result in personal injury or death. The rotating Before proceeding to the test procedure that
shaft is located under the implement and steering follows, complete the following procedure:
pumps. Testing and Adjusting, Machine Preparation for
Troubleshooting
Do not allow personnel into the pump bay area
behind the cab when the engine is running.

Sudden movement or accidental starting of the

machine can cause personal injury or death to per-
sons on or near the machine.

To prevent personal injury or death, perform the

following:

Park the machine on a smooth, level surface.

g00798545
Lower the work tool to the ground and engage the Illustration 80
parking brake. (1) Pressure tap for output pressure of the fan drive

Stop the engine and remove the key.

Block the wheels and install the steering frame

lock.

The fan drive pump is a variable displacement

piston pump that is pressure compensated and flow
compensated. The pressure compensator valve
controls the maximum pump pressure. The margin
pressure is the difference between the output
pressure of the pump and the signal pressure of
the pump. The fan control solenoid valve varies
the control signal to the pump. The control signal
changes the pump output.
 89
Hydraulic and Steering System
Testing and Adjusting Section

10. Use the 1U-6602 Photo-Tachometer in order

to measure the fan speed. The pressure gauge
should read approximately 1300 kPa (189 psi).
The pressure reading of the pressure gauge
should be used as reference only. The fan speed
must be 500 25 RPM.

11. If the cutoff pressure of the fan drive pump is

not correct, the pressure compensator must be
adjusted.

12. Stop the engine.

13. Loosen locknut (6).

g00798563
Illustration 81
(2) Pressure and flow compensator valve
(3) Fan drive pump
(4) Fan control solenoid valve
(5) Adjustment screw for margin pressure
(6) Locknut
The components of the fan drive are located in the
back of the pump compartment.
14. Turn adjustment screw (5) clockwise in order to
increase the pressure setting. Turn adjustment
screw (5) counterclockwise in order to decrease
the pressure setting.
15. Tighten locknut (6).
16. Start the engine. Run the engine at high idle.

1. Attach an unvalved nipple to a 0 to 4000 kPa
(0 to 580 psi) pressure gauge. Attach a section
of hydraulic line to the unvalved nipple. Attach
the hydraulic line to pressure tap (1) on fan
control solenoid valve (4).
17. Repeat Step 10 through Step 15. The pressure
gauge should read approximately 1300 kPa
(189 psi). The pressure reading of the pressure
gauge should be used as reference only. At high
idle, the fan speed must be 500 50 RPM.

2. Engage the parking brake.
3. Shift the transmission to neutral.
4. Start the engine. Run the engine at high idle.
18. Use Caterpillar ET in order to reset the Engine
Fan Bypass Override Parameter.
19. Exit the Caterpillar ET program and disconnect
ET from the machine.

5. Move the wheel lean cylinder to the end of the

stroke. Stall the cylinder. At the same time, circle
the moldboard. This will warm the hydraulic oil to
normal operating temperature of approximately
60 5C (140 9F).

6. Connect Caterpillar ET to the data link connector.

The data link connector is located on the front
face of the shift console. Start Caterpillar ET.

7. Select the engine Electronic Control Module

(ECM) for your machine. Select Diagnostics.
Select Diagnostic Tests. Select Override
Parameters. Select Engine Fan Bypass.

8. Enter 100% for the Engine Fan Bypass

Override Parameter. Press Enter until all
warning messages disappear. The fan is now
set to minimum speed.

9. Run the engine at low idle.

90
Hydraulic and Steering System
Index Section
Index
A H
Accumulator (Blade Cushion) - Test and Charge .. 74
Accumulator Charge Procedure for a Rebuilt
Accumulator ..................................................... 77
Charging the Blade Cushion Accumulator ......... 76
Checking the Blade Cushion Accumulator......... 76
Lower the Piston in Blade Cushion
Accumulators ................................................... 75
Axle Toe-In (Front) - Adjust.................................... 84
B I
Bearing End Play (Piston Pump) - Adjust.............. 64
Blade Cushion ....................................................... 39
Blade Cushion that is Activated ......................... 40
Blade Cushion that is Deactivated ..................... 40
C Control Valve (Blade Lift) ..................................... 5
Centershift Lock..................................................... 38
Color Chart ............................................................ 53
Combination Valve................................................. 22
Low Pressure Standby....................................... 23
Signal Network................................................... 27
Steering Actuated .............................................. 25
Steering and Implements Actuated.................... 26
Control Valve (Blade Lift) ....................................... 32
Control Valve in the FLOAT Position .................. 36
Control Valve with Blade Float Detent (If Equipped)
in the RAISED Position .................................... 34
Typical Control Valve with Hydraulic Detent....... 37
Control Valve (Implement) ..................................... 31
Implement Control Valve with a Relief Valve...... 32
Implement Control Valve without a Relief Valve.. 31
Cylinder Cycle Time - Check ................................. 78
Procedure To Check Blade Lift Cycle Times,
Ripper (If Equipped) Cycle Times and Scarifier (If
Equipped) Cycle Times .................................... 79
D
Disc Pack Preload for Circle Drive - Adjust ........... 77
F
Fan Drive System .................................................. 48
Hydraulic Fan Drive............................................ 48
G High Pressure Stall ............................................
General Information............................................... 56
Hydraulic and Steering System ....................... 10, 59
Hydraulic and Steering System.......................... 59
Hydraulic Fan Drive............................................ 63
Implement System ............................................. 61
Steering System ................................................ 60
Hydraulic Cylinder Drift - Check ............................ 77
Hydraulic Schematic.............................................. 51
Hydraulic Tank and Filter ....................................... 12
Implement System................................................. 28
Important Safety Information ................................... 2
Introduction........................................................ 4, 56
Blade Cushion...................................................... 5
Centershift Lock ................................................... 5
Combination Valve ............................................... 5
Control Valve (Implement) ................................... 5
Hydraulic Tank and Filter ..................................... 5
Metering Pump (Steering).................................... 5
Piston Pump (Hydraulic and Steering)................. 5
Piston Pump (Hydraulic Fan) ............................... 5
L
Location Of Components......................................... 6
Hydraulic and Steering System............................ 6
M
Machine Preparation for Troubleshooting .............. 56
Metering Pump (Steering) ..................................... 44
Left Turn............................................................. 46
Load Sensing ..................................................... 46
Neutral Position.................................................. 44
Right Turn .......................................................... 45
O
Operational Checks ............................................... 57
P
Piston Pump (Hydraulic and Steering) .................. 13
Constant Flow .................................................... 18
Destroke............................................................. 19
21
Low Pressure Standby....................................... 15
Pressure and Flow Compensator Valve............. 14
Upstroke............................................................. 17
 91
Hydraulic and Steering System
Index Section

Piston Pump (Hydraulic Fan)................................. 50

Pressure and Flow Compensator Valve (Fan Drive
Pump)............................................................... 51
Piston Pump Cutoff Pressure (Hydraulic Fan) - Test
and Adjust............................................................ 86
Piston Pump Margin Pressure (Hydraulic Fan) - Test
and Adjust............................................................ 88
Position Sender (Articulation) - Adjust................... 85
Adjustment Procedure for the Arm on the
Articulation Position Sender ............................. 85
Procedure for Adjusting the Articulation Position
Sender.............................................................. 85
Pressure and Flow Compensator Valve (Hydraulic
and Steering) - Test and Adjust ........................... 65
Adjustment for Flow Compensator (Margin
Pressure).......................................................... 67
Adjustment for Hydraulic System Pressure ....... 69
Adjustment for Signal Network........................... 71
Low Standby Pressure Adjustment .................... 65

Relief Valve (Implement) - Test and Adjust............ 73

Relief Valve (Steering) - Test and Adjust ............... 80

Steering System .................................................... 40

Oil Flow of the Steering Hydraulic System......... 42
Steering System - Purge ....................................... 81
Purge Procedure (Signal Network) .................... 83
Steering Wheel Slip - Check.................................. 80
Symptom Procedures ............................................ 59
Systems Operation Section ..................................... 4

Table of Contents..................................................... 3
Testing and Adjusting ............................................ 64
Testing and Adjusting Section ............................... 64
Troubleshooting Section ........................................ 56

Visual Inspection ................................................... 57

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