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Product:  MOTOR GRADER 
Model:  120G MOTOR GRADER 87V03888 
Configuration: 120G MOTOR GRADER 87V01138-05274 (MACHINE) 
POWERED BY 3304 ENGINE 

Testing and Adjusting

120G MOTOR GRADER HYDRAULIC SYSTEM AND STEERING
Media Number -REG01681-04 Publication Date -01/03/1983 Date Updated -10/10/2001

Testing And Adjusting

Specifications
NOTE: For Specifications with illustrations, make reference to the HYDRAULIC SYSTEM AND STEERING
SPECIFICATIONS for 120G MOTOR GRADER, Form No. REG01682. If the Specifications in Form No.
REG01682 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date
on the back cover of each book. Use the Specifications given in the book with the latest date.

Hydraulic System And Steering

A visual inspection of the hydraulic system and its components is the first step when making a diagnosis of a
problem.

Before making any tests, visually inspect the complete hydraulic system by looking for leakage of oil and for
parts that have damage.

A stop watch or timer is used when making the first tests. The first tests are used to find the circuit or circuits in
the hydraulic system that need adjustment or a repair of components. The 9S2000 Flow Meter and the FLOW
METER TEST PROCEDURE IX can be used to find the component in the circuit that needs the adjustment or
repair.

Remove the filter elements and cut them apart. Look for particles in the cut elements; pieces of dirt, rubber, cork
and metal. A magnet will separate the iron or steel particles from the bronze and aluminum metal pieces.

Clean the strainer and install new filter elements. Fill the hydraulic tank to the mark on the guage before starting
the engine. Start the engine and operate the components in the hydraulic system until the temperature of the oil
is between 32° and 65°F (0° and 18°C) more than the temperature of the atmosphere.

When testing and adjusting the hydraulic system, move the machine to
a smooth horizontal location. Move away from working machines and
personnel. There must be only one operator. Keep all other personnel
away from the machine or where the operator can see the personnel.
Tests For Systems Operation (Time)
With the hydraulic oil heated, run the engine at high idle rpm. The lock pin must be in the center hole and the
blade should be near the ground when the time for the movements of the cylinder rods are made.

Wheel Lean

The wheel lean from left to right, takes a little less time than from right to left. When the front wheel lean moves
from full right to full left, the rod moves into the hydraulic cylinder in 2.5 ± .5 seconds. If it takes too much time
for the cylinder rod to move in either direction, make a record of the time and the direction*.

Articulation

There is no difference in time for the frame to move from full right to full left, or full left to full right
(articulation). The time for the frame to move in either direction from stop to stop is 3.5 ± .5 seconds.

If it takes too much time for a cylinder rod to move in either direction, make a record of the time and the
direction*.

Blade Center Shift

The movement of the rod, either into or out of the hydraulic cylinder, moves the drawbar either to the left or to
the right. The time for the rod to move from the extended rod position into the cylinder, or from the retracted rod
position to the rod extended position, is 5.5 ± .5 seconds.

If it takes too much time for the rod to move either into or out of the hydraulic cylinder, make a record of the
time and the direction*.

Blade Lift

Both rods go into the hydraulic cylinders to lift the blade. It may not be easy to move both control levers to
BLADE LIFT positions at the same time and both cylinders may not start and stop at the same time. The
movement of one rod in a hydraulic cylinder, must not be more than .5 second different than the movement of
the other rod. When the blade is on the ground, the time for the movement of the rods into the hydraulic cylinder
to lift the blade until it stops is 4.5 ± .5 seconds.

If it takes too much time for either or both rods to move into the cylinders, make a record of the time or times
for the rods to move*.

Blade Side Shift

The blade will move from stop to stop in either direction in approximately the same time. The time is 10 ± 1
seconds.

If it takes too much time for the blade to move in either direction, make a record of the time and the direction*.
Blade Tip

The rods of the hydraulic cylinders that tip the blade move out of the cylinders in a little less time than it takes
for the rods to move into the cylinders. The average time for the rods of the cylinders to tip the blade is 3 ± .5
seconds.

If it takes too much time for the rods to move either into or out of the cylinders, make a record of the time and
the direction of the rods*.

Circle Rotation

One fourth of a revolution (90°) of the circle is enough movement to time. Be sure the blade is in a position
where it will not go against a tire when one fourth revolution is being made in both directions (counterclockwise
and clockwise). The time for the circle to go one fourth of a revolution (in either direction) is 10 ± 1 seconds.

If it takes too much time for the circle to go one fourth revolution, make a record of the time and the direction
(either clockwise or counterclockwise or both)*.

Steering

Make this test while turning the steering wheel at a constant rate of one complete turn in one second. Count the
steering wheel turns (at one revolution in one second) needed to move the front wheels from a full left turn to a
full right turn then, from a full right turn to a full left turn. 5 to 6 turns (seconds) will move the wheels from a
full turn in one direction to a full turn in the other direction.

If it takes too many turns (seconds), make a record of the direction and the turns (seconds)*.

*Ifthe record of time for each operation is too much (slow), the implement pump, the combination valve or both
the pump and the combination valve need either an adjustment or a repair. If the time for only one operation
(other than the steering operation) is correct and the other operations will not move, or some of the operations
move very slow, the check valve is open in the implement valve section with the correct time.
Hydraulic Cylinder Drift
If the hydraulic cylinder drift (rods move either in or out of the cylinder when control lever is in HOLD
position) is more than .03 in. (0.76 mm) in a time of 5 minutes when there is a load on the hydraulic cylinder,
there is either a component with damage or a component that must be disassembled and cleaned.

For an example: There is a load on the lift cylinders when the blade has been lowered enough to move the front
wheels off the ground.

Causes for cylinder drift.

1. Damage or defect on cylinder surface.

2. Seal on piston has damage.
3. Scratch or groove in cylinder.
4. Scratch or groove on cylinder rod.
5. Damage on seal in cylinder head.
6. Dirt or damage in lock check valve.
7. Loose fittings or hydraulic lines with damage that have oil leaks.

Oil Pressure Tests

A 7S8880 Oil Pressure Gauge (0 to 5000 psi), a 5S4648 Hose Assembly with a 7M1293 Adapter Assembly and
a 4M5317 Reducing Bushing are used to make these oil pressure tests.
CONTROL VALVE ON RIGHT SIDE
1. Plug (into passage for pump oil). 2. Plug (for valve for control of oil flow, spacers, shims and springs). 3. Cover (for resolver valve
and valve for control of flow).

A 1/4 in. hex wrench is used to remove hollow hex plug (1) to the passage for the pump oil. Install the 7S8880
Oil Pressure Gauge, the hose and fittings in the plug opening.

Start and run the engine at high idle rpm. Move the control levers which operate the hydraulic cylinders to get
an increase in the temperature of the hydraulic oil. When the temperature of the hydraulic oil is approximately
30° F (17° C) more than the temperature of the atmosphere, run the engine at high idle rpm. With the control
levers in HOLD position, look at the pressure gauge.

The correct pressure is 2500 psi (175.7 kg/cm2). If the pressure of the pump oil is too low, the pump or the
combination valve or both the pump and the combination valve need an adjustment or a repair.

If the oil pressure for both positions of each control lever is too low, the pump or the combination valve, or both
the pump and the combination valve need an adjustment or a repair.

If the oil pressure for both positions of only one lever is correct and all of the other lever positions have too low
oil pressure, the check valve is open in the control valve with the correct oil pressures.

If the oil pressure for one position of a control lever for one valve section is low and the other lever position has
correct oil pressure, there is damage in the resolver valve.

Hot Oil In Hydraulic Tank

The temperature of the oil in the hydraulic tank is controlled by the pump (1) for the oil through the oil cooler
and the oil cooler.

PUMP FOR OIL THROUGH THE OIL COOLER

1. Pump. 2. Line for oil leak from variable displacement pump. 3. Line from variable displacement pump to the hydraulic system. 4.
Line from pump. 5. Line to tank. 6. Relief valve. 7. Plug. 8. Line to oil cooler.
The normal temperature of the oil in the tank, when the machine is operating, is 32° to 65° F (17° to 35° C)
more than the temperature of the atmosphere.

Causes for too much heat in oil tank:

1. Oil lines (8) to the oil cooler and the line from the oil cooler have damage.
2. Relief valve (6) for oil cooler not closed.
3. Too much dirt on oil cooler fins.
4. Oil passages in oil cooler not open (dirt in passages).
5. Pump (1) for oil cooler has damage (low output).
6. The leak oil, in line (2) from the variable displacement pump, is too hot. Too much leak oil, because of
damage in the variable displacement pump, makes an increase in the temperature of the oil in line (3).
When the temperature of the oil in line (3) is 60° F (33° C) more than the temperature of the oil in the
tank, the hot oil will not cool enough when the oil goes through the oil cooler and into the hydraulic tank.

If relief valve (6) is open, remove plug (7) and clean the valve and the seat in relief valve (6). Install a new
spring for the valve in relief valve (6) if necessary.

The pressure setting of the oil cooler relief valve is 15 psi (1.05 kg/cm2) with an oil flow of 10 U.S. gpm (37.8
lit/min). There is no adjustment for the pressure setting of the valve.

Combination Valve
The location of the combination valve is below the floor on the left side of the machine.

When the oil in line (1), from the variable displacement pump goes through the combination valve and back
through line (2) to the hydraulic tank, either the unloader valve or the relief valve or both valves are open. When
either one of the valves or both valves are open, the components in the hydraulic system can not operate and the
combination valve needs cleaning, or an adjustment must be made.

COMBINATION VALVE
1. Oil line from pump. 2. Oil line to tank. 3. Plug for valve stem and spring in unloader valve. 4. Plug for relief valve.
Unloader Valve

UNLOADER VALVE (Valve stem and spring removed)

The unloader valve stem and spring are removed for cleaning or repair after the plug for the spring and the lever
are removed from the valve body. If the lever does not move easily in the housing, the boot, the nut, the screw
and the bearings must be taken apart and cleaned. The lever must have .006 ± .003 in. (0.15 ± 0.08 mm) of end
clearance after the lever and housing are installed on the valve body.

Relief Valve

Remove plug (16), retainer (13) and pilot valve (12). Shims (15) are under spring (14) in retainer (13). Add
shims for an increase, or remove shims to get a decrease in the pressure setting of the relief valve. The pressure
setting of the relief valve is 3200 ± 50 psi (225 ± 3.5 kg/cm2), with an oil flow of 2.5 ± .2 U.S. gpm (9.5 ± 0.8
lit/min). If it is necessary to make an inspection and clean the other parts of the relief valve, remove plug (1),
spacer (5), spacer (8), valve (9) and spring (10). The seat (11) and body (7) for pilot valve (12) and valve (9)
must be pushed out the opening for plug (1).

RELIEF VALVE AND CHECK VALVE (Part of Combination Valve)

1. Plug. 2. Check valve. 3. Spring. 4. Retainer. 5. Spacer. 6. Fitting. 7. Body. 8. Spacer. 9. Valve. 10. Spring. 11. Seat. 12. Pilot valve.
13. Retainer. 14. Spring. 15. Shims. 16. Plug

To remove check valve (2), spring (3), and retainer (4), disconnect the oil line from the combination valve to the
steering system and remove fitting (6).
Motor For Circle Drive
The hydraulic motor for the circle drive is an orbital gear motor.

When the circle is easy to turn but the motor does not turn the circle with enough speed, the motor must be
removed and disassembled.

Inspect the motor parts for wear and if the parts have too much wear new parts and seals must be used when the
motor is assembled.

HYDRAULIC MOTOR AND CIRCLE DRIVE

Control Valve

CONTROL VALVE (RIGHT SIDE)

1. Line for oil to hydraulic tank.

A control valve is on each side of the steering wheel below the floor plates. Each of the two control valves can
have either three, four or five valve sections, between the inlet and outlet manifold and the end manifold. The
parts (valves, springs, spacers and shims) can be removed for cleaning or for an adjustment when the control
valve is on the machine.
CONTROL VALVE (RIGHT SIDE)
15. Plug (five). 20. Plug with 3/8 in. (9.5 mm) hex opening (four). 21. Cover (five).

CONTROL VALVE SECTION

2. Retainers (for spring). 3. Plug. 4. Cap lock. 5. Bolts (two). 6. Bearings. 7. Boot and nut. 8. Valve (control of oil flow). 9. Lever. 10.
Seat and screen. 11. Screw (for lever adjustment). 12. Ball. 13. Spring. 14. Spring. 15. Plug. 16. Valve spool. 17. Spring. 18. Spacers
and shims. 19. Resolver valve. 20. Plug. 21. Cover.

Oil, from the hydraulic tank in line (1), can run out of the control valve when a cover is removed. Disconnect
and put a plug in line (1) before removing any covers or plugs from the valve section.

Check Valve

The check valve that is open is in the valve section with the highest pressure. When the check valve is open in
one valve section, the pressure of the oil in all of the other valve sections will be too low.

The plug (15) and the surface of the valve section near the plug must be clean before the plug is removed.
Remove plug (15), spring (13) and ball (12). Use a 3/8 in. hex wrench in the hex opening in seat and screw (10)
to remove it.

If the screen has damage or there is a rough seat, install a new seat and screen (10). If there is a rough surface on
ball (12), install a new ball. Use new O-ring seals on seat and screen (10), and on plug (15). Torque for plug (15)
is 12 ± 2 lb.ft. (1.7 ± 0.3 mkg).
Valve for Flow Control

A broken spring (17) will not let the pump oil go through the valve section to the hydraulic cylinder. If it is
necessary to remove valve (8), spring (17) and spacers and shims (18), the plug (20) and cover (21) near the
plug must be clean. Use a 3/8inch hex wrench in the hex opening in the plug to remove the plug. Spacers and
shims (18) and the spring (17) will fall out of the opening when plug (20) is removed. The thickness of spacers
and shims (18) control the pressure of spring (17) on valve (8). The correct thickness spacers and shims were
installed at the factory. When a shim is added to the spacers and shims, there is a decrease in the time for the
cylinder to operate (the cylinder operates faster).

Oil can keep valve (8) in the valve section. Use a magnet on the valve if necessary, to remove it. When the
valve, spring, spacers and shims are installed, use a new O-ring seal on plug (20). The torque for plug (20) is 35
± 5 lb.ft. (4.8 ± 0.7 mkg).

Resolver Valve

A resolver valve with damage, is the cause for the speed of either the hydraulic cylinders or the hydraulic motor,
to be too slow in one direction.

Before cover (21) is removed from the control valve section, the cover and the control valve near the cover must
be clean.

Remove the eight bolts through cover (21) and remove the cover. It will take force to remove the cover from the
valve section after the bolts are removed.

NOTE: When cover (21) is removed, look for valve (8) and remove it before it falls out of the valve section.
Remove resolver valve (19) by using a No. 8-32 screw as a puller.

The edges and surfaces of both the cover and the valve section must be clean before the parts and cover are
installed. New O-ring seals are used when the parts are installed in the valve section.

NOTE: The part number for the valve section is on a tab between two bolts through the cover. The tab with the
part number must be installed on the same valve section it was on before the bolts and tab were removed.

Control Lever

A control lever (9) that does not move easy needs to be taken apart and cleaned. Lever (9) should have .006 ±
.003 in. (0.15 ± 0.08 mm) end clearance. To make an adjustment for end clearance, loosen boot and nut (7) and
turn screw (11) counterclockwise for more end clearance. Turn it clockwise for less end clearance. The torque
for boot and nut (7) is 25 lb.ft. (3.5 mkg).

CONTROL VALVE (RIGHT SIDE)

4. Cap lock (five). 9. Lever (five). 22. Linkage rod (five).
If it is necessary to remove lever (9) and the lever housing for cleaning, first remove the pin from linkage rod
(22) and lever (9).

Remove bolts (5), the lever housing, and lever (9) as a unit. The O-ring seal and half of bearing (6) will fall out
of the lever housing. Lever (9) can be pulled out of boot and nut (7), and out the opening in the lever housing
that was against the valve section. Remove the ring with the seal and the other half of bearing (6).

Use new O-ring seals when lever (9) and the lever housing are installed on the valve section. Lever (9) must
have .006 ± .003 in. (0.15 ± 0.8 mm) end clearance.

Valve Spool

When either an adjustment for the location of valve spool (16) is made, or when the valve spool is to be
removed, the housing and lever (9) must be removed from the valve section.

Cap lock (4) is removed when the adjustment for the location of the valve spool is made. The location for valve
spool (16) is correct when plug (3) is against the retainers and there is no end clearance for the valve spool.

When plug (3) is not against the retainers, the unit of valve spool (16), spring (13) and retainers (2) have end
clearance. When plug (3) is turned in too far, and it moves the retainers at one end of spring (13) too near the
retainers at the other end of the spring, valve spool (16) has end clearance between the retainers.

Install cap lock (4) when the adjustment for the location of the valve spool is correct.

It may be necessary to turn the retainers at the top to a position where the end of lever (9) can be installed in the
hole in the end of valve spool (16).

VALVE SPOOL
2. Retainers (two parts for each retainer). 13. Spring. 16. Valve spool.

Valve spool (16), spring (13) and retainers (2) are removed as a unit when either cover (21) is removed, or cap
lock (4) and plug (3) are removed from the valve section.

Use new O-ring seals when the parts are installed in the valve section.

Lock Check Valve

There are three types of lock check valves in the hydraulic system. The piston (5), the seats (7), the springs (4),
and the plugs (3) in each of the three types of check valves are the same. The leaning wheel cylinder, the
cylinder to side shift the blade and the cylinders for the blade tip, have check valves with minimum resistance
for the oil. There are outlet chokes (1) in the check valves for the articulation cylinders, the cylinder for center
shift, and the lift cylinder for the blade on the right side of the machine. The check valve for the lift cylinder on
the left side of the machine, has outlet chokes and also a relief valve in the passage to the rod end of the lift
cylinder.
A piston (5) that does not move easy in the check valve is a cause for a hydraulic cylinder to move too slow.
Outlet chokes (1) that will not move away from the fittings (2) is a cause for a hydraulic cylinder to move too
slow. Balls (6) and seats (7) with rough surfaces is a cause for cylinder rod drift.

LOCK CHECK VALVE

1. Outlet chokes. 2. Fittings (two). 3. Plug (two). 4. Spring (two). 5. Piston. 6. Ball (two). 7. Seat (two).

Do not disconnect an oil line from a check valve until the hydraulic cylinder is in a position where there is low
or no oil pressure in the cylinder. Put the blade and ripper on the ground and install the lock pin in the tie bar for
the wheel lean, then, stop the engine.

Remove plugs (3), springs (4) and balls (6). Put a metal rod [1/4 in. (6.4 mm) diameter and 4 in. (101.6 mm)
long] through seat (7) and against piston (5). Use a small hammer on the rod and the piston will move one of the
seats out of the valve body. Use the small hammer and a metal rod [11/16 in. (17.5 mm) diameter and 6 in.
(152.4 mm) long] to remove the other seat. If the lock check valve has outlet chokes, remove fittings (2) and
outlet chokes (1).

LOCK CHECK VALVE (For articulation cylinders)

2. Fittings. 3. Plugs.

Clean and inspect the parts for damage. Install new O-ring seals on plugs (3).
Install piston (5) and both seats (7). Use the small hammer and 11/16 in. (17.5 mm) rod on the seats to get them
into the valve body.

Install balls (6), springs (4) and plugs (3). Torque for plugs (3) is 25 ± 5 lb.ft. (3.5 ± 0.7 mkg). Install outlet
chokes (1). The torque for fittings (2) is 55 ± 5 lb.ft. (7.6 ± 0.7 mkg).

Relief Valve For Steering

RELIEF VALVE FOR STEERING

1. Plug for relief valve. 2. Plug for relief valve.

If the steering wheel moves the wheels too slow in either or both directions, or does not move the wheels when
the steering wheel is turned, the relief valve can be a cause.

When the setting of a relief valve is too low, the oil to one end of the steering cylinders can go through the relief
valve, into the oil from the other end of the steering cylinders.

Remove plugs (1 and 2) and remove the springs and the valves. A rough surface on the valves, or in the seats,
can let the oil go through the relief valve. See the topic, Testing the Steering Circuit.

Metering Valve For Steering

If the steering wheel moves the wheels too slow in either or both directions, or does not move the wheels when
the steering wheel is turned, there is either a part with damage, or there is dirt in the metering valve for steering.

There is no adjustment for the metering valve. It must be disassembled to find the cause. See the topic, Testing
the Steering Circuit.

Testing The Steering Circuit

If the steering wheel moves the front wheels too slowly or does not move them at all, check the pressure at the
steering pressure reducing valve (15) and the dual crossover relief valves (2) and (3).

To make a check of the dual crossover relief valves (2) and (3) and the steering metering pump (6), the pressure
at the steering pressure reducing valve (15) must be checked first.

NOTE: There can be no pressure difference between the dual crossover relief valves or between the steering
pressure reducing valve and the dual crossover relief valves. Use the same gauge to check each valve.

Steering Pressure Reducing Valve Check

To check and adjust the steering pressure reducing valve (15), do the following.
1. Remove plug (16) and install the 7S8712 gauge from the 5S5123 Hydraulic Test Group or the 7S8714 gauge
from the 5P5224 Hydraulic Test Group.

2. Start the engine and operate the implements to raise the temperature of the hydraulic oil to 150 ± 5° F (65 ±
3° C).

SCHEMATIC OF STEERING CIRCUIT (82V1-82V869, 87V1-87V4689)

1. Steering wheel.

2. Crossover relief valve.

3. Crossover relief valve.

4. Plug.

5. Oil return line to tank.

6. Steering metering pump.

7. Plug.

8. Shims.

9. Shims.

10. Oil supply line from pump.

11. Left steering cylinder.

12. Right steering cylinder.

13. Oil return line to tank.

14. Shims.
15. Steering pressure reducing valve.

16. Plug.

3. Increase the engine rpm to Hi Idle. The pressure reading on the gauge must be 3200 ± 50 psi (225.0 ± 3.5
kg/cm2). Add or remove shims (14) to get the correct pressure setting.

Dual Crossover Relief Valve Check

If the steering pressure reducing valve (15) is adjusted correctly and the front wheels still do not steer or steer
slowly, check the steering pressure at the dual crossover relief valves as follows.

1. Remove plug (7) from crossover relief valve (2) and install the same gauge that was used in the previous test
of the steering pressure reducing valve.

2. Start the engine and operate the implements until the oil temperature gets to 150 ± 5° F (65 ± 3° C).

3. Increase the engine rpm to Hi Idle.

4. Turn the steering wheel (1) to the left (counterclockwise) until the wheels are against the stops. Hold the
steering wheel and read the pressure on the gauge. It must be 1825 ± 25 psi (128.3 ± 1.8 kg/cm2).

5. Remove plug (4) from crossover relief valve (3) and install the same pressure gauge. Install plug (7). Turn the
steering wheel to the right (clockwise until the wheels are against the stops). Hold the steering wheel and read
the pressure on the gauge. It must be 1825 ± 25 psi (128.3 ± 1.8 kg/cm2).

NOTE: If the steering wheel continues to turn after hitting the stops, it is an indication of a low crossover relief
setting or badly damaged valve seat.
SCHEMATIC OF STEERING CIRCUIT (82V870-Up, 87V4690-Up)

1. Steering wheel.

2. Crossover relief valve.

3. Crossover relief valve.

4. Plug.

5. Oil return line to tank.

6. Steering metering pump.

7. Plug.

8. Shims.

9. Shims.

10. Oil supply line from pump.

11. Left steering cylinder.

12. Right steering cylinder.

13. Oil return line to tank.

14. Shims.

15. Steering pressure reducing valve.

16. Plug.
Remove the dual crossover relief valves and test them on the hydraulic bench. The opening pressure for the
9J6353 Relief Valve is 2900 ± 25 psi (203.9 ± 1.8 kg/cm2) at 2 ± .25 gpm (8 ± 1 liter/min). The opening
pressure for the 3G8436 Relief Valve is 2200 ± 25 psi (154.7 ± 1.8 kg/cm2) at 2 ± .25 gpm (8 ± 1 liter/min) and
for the 3G7448 Relief Valve it is 2372 ± 29 psi (166.8 ± 2.0 kg/cm2) at 5 ± 0.3 gpm (19 ± 1 liter/min).

Steering Metering Pump

If the pressure in the previous tests was less than 1825 ± 25 psi (128.3 ± 1.8 kg/cm2), the problem can be in the
steering metering pump or the setting of the dual crossover relief valve can be too low. In either case the unit
must be removed from the machine to be checked.

Remove the steering metering pump (6) and inspect it for worn or damaged parts and correct assembly. See
Vehicle Systems Disassembly and Assembly Form No. SENR7219 for the 120G Motor Grader.

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