kenr8566-01-00-all_MANUALS-SERVICE-MODULES

KENR8566-01
February 2014
Specifications
Systems Operation
Testing and Adjusting
D6R Track-Type Tractor
Hydraulic System
EMM 1-Up (Machine)
JEN 1-Up (Machine)
S6T 1-Up (Machine)
S6X 1-Up (Machine)
S6Y 1-Up (Machine)
SAFETY.CAT.COM
i05296198
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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and 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.
A non-exhaustive list of 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. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. 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 you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
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. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR8566 3
Table of Contents
Table of Contents Pilot Hydraulic System.................. .................. 93

Implement Control Valve................. ................ 97
Specifications Section Steering Control Valve .................. .................. 98
Bulldozer Lift Control Valve.............. ............. 104
Hydraulic Tank and Filter ................. ................. 4 Quick-Drop Valve..................... ..................... 123
Implement Hydraulic Pump ............... ............... 7 Bulldozer Tilt Control Valve.............. ............. 133
Lines (Pump) ......................... ......................... 10 Ripper Lift Control Valve ................ ............... 138
Steering Motor ........................ .........................11 Pressure Reducing Valve ............... .............. 144
Pump Control Valve .................... .................... 13 Accumulator......................... ......................... 145
Implement and Steering Control Valve Group 14 Oil Cooler and Bypass Valve ............ ............ 146
Implement and Steering Control Valve Group 15 Counterbalance Valve ................. ................. 148
Steering Control Valve .................. .................. 16 Steering Motor ....................... ....................... 150
Pressure Reducing Valve (Pilot)........... .......... 19 Graphic Color Codes .................. .................. 151
Pressure Reducing Valve (Pilot)........... .......... 20
Accumulator.......................... .......................... 21 Testing and Adjusting Section
Main Relief Valve ...................... ...................... 22
Counterbalance Valve (Steering).......... ......... 23 Testing and Adjusting
Control Valve (Bulldozer)................ ................ 24 Pressure Taps........................ ....................... 155
Bulldozer Lift Control Valve............... .............. 25 Troubleshooting Procedures ............ ............ 155
Bulldozer Tilt Control Valve............... .............. 29 Machine Preparation .................. .................. 156
Ripper Control Valve.................... ................... 32 Visual Inspection ..................... ..................... 158
Pilot Control Valve (Bulldozer Lift and Tilt)... ... 35 Hydraulic System Troubleshooting........ ....... 159
Pilot Control Valve (Bulldozer Lift and Tilt)... ... 41 Operation Checks..................... .................... 165
Pilot Control Valve (Ripper Lift)............ ........... 46 Steering Hydraulic Circuit - Test .......... ......... 171
Lines (Pilot)........................... .......................... 49 Pump Discharge Pressure - Test......... ......... 174
Quick-Drop Valve...................... ...................... 50 Pump Control Valve (Steering) - Adjust .... .... 179
Bulldozer Lift Cylinder................... .................. 51 Pressure Limiter Valve - Test ............ ............ 182
Cylinder Mounting...................... ..................... 53 Pressure Reducing Valve - Test and Adjust. . 185
Cylinder Mounting...................... ..................... 55 Accumulator (Pilot) - Test and Charge..... ..... 188
Bulldozer Tilt Cylinder................... .................. 57 Pilot Control Valve - Test and Adjust....... ...... 191
Bulldozer Tilt Cylinder................... .................. 59 Main Relief Valve and Crossover Relief Valve -
Lines (Tilt Cylinder)..................... .................... 61 Test ............................... .............................. 193
Lines (Tilt Cylinder)..................... .................... 62
Ripper Lift Cylinder ..................... .................... 64 Index Section
Ripper Lift Cylinder ..................... .................... 65
Index............................... .............................. 197
Push Arm............................ ............................ 67
Bulldozer Blade (Cutting Edges and End Bits) 69
Bulldozer Blade (Cutting Edges and End Bits) 70
Bulldozer Brace ....................... ....................... 71
Bulldozer Brace ....................... ....................... 72
Bulldozer Trunnion..................... ..................... 73
Bulldozer Trunnion..................... ..................... 74
Systems Operation Section
General Information.................... .................... 75

Signal Resolver Network ................ ................ 78
Hydraulic Tank and Filter ................ ................ 81
Hydraulic Pump - Piston ................. ................ 84
Main Relief Valve ...................... ...................... 91
4 KENR8566
Specifications Section
i05706969
Hydraulic Tank and Filter

SMCS Code: 5056; 5068
Part No.: 224-4946

KENR8566 5
Illustration 1 g03625136
6 KENR8566
Table 1
Specification for 224-4946 Hydraulic Tank Gp
Item Qty Part Specification Description
1 2 4T-0521 Bolt Torque to 60 ± 7 N·m (44 ± 5 lb ft).
Length under test force is 85.73 mm (3.375 inch).

2 2 8J-8443 Spring Test force is 721 ± 71 N (162 ± 16 lb).
Free length after test is 127.0 mm (5.00 inch).
3 4 6V-7744 Locknut Torque to 30 ± 5 N·m (266 ± 44 lb in).

4 1 9T-3005 Spring Test force is 187 ± 15 N (42 ± 3 lb).
5 2 4K-0367 Full Nut Before you install the filter assembly, tighten the nut by hand.

6 1 7B-3039 Spring Test force is 14.32 to 16.81 N (3.22 to 3.78 lb).
7 1 9J-7031 Drain Plug Torque to 68 ± 7 N·m (50 ± 5 lb ft)

KENR8566 7
i05707070
Implement Hydraulic Pump

SMCS Code: 5070
Part No.: 227-0830

8 KENR8566
KENR8566 9
Table 2
Specification for 227-0830 Piston Pump Gp
1 1 197-0075 Race Before assembly, apply retaining compound to out side diameter of the race.
2 1 197-0083 Spring Free length after test is 51.5 mm (2.03 inch).
3 1 7X-1553 Lip Type Seal Before assembly, apply retaining compound to out side diameter of the seal.
4 4 8U-3297 Bolt Before assembly, apply retaining compound to the threads.
5 1 199-4193 Shim Kit Select the required shim from the shim kit for the proper adjustment.
6 1 197-0094 Spring Free length after test is 125.5 mm (4.94 inch).
Use as required to obtain the bearing end play of 0.010 ± 0.500 mm (0.0004 ± 0.0197 inch).
1 5W-7461 Shim Thickness is 1.05 mm (0.041 inch).
7 1 5W-7463 Shim Thickness is 1.15 mm (0.045 inch).
8 1 333-8366 Shaft Seal Before assembly, apply retaining compound to out side diameter of the seal shaft.
10 KENR8566
i05713951
Lines (Pump)
SMCS Code: 5057-NP
Part No.: 317-3942
Table 3
Specification for 317-3942 Pump Lines Gp
Item Qty Part Specification description
1 2 148-8449 Swivel Tee Torque to 95 ± 5 N·m (70 ± 4 lb ft).
2 2 148-8388 Elbow As Torque to 95 ± 5 N·m (70 ± 4 lb ft).
3 1 5G-7191 Spring Free length after test is 550 mm (21.7 inch).

KENR8566 11
i04724989
Steering Motor
SMCS Code: 4136
Part No.: 159-7156
Table 4
Specification for 159-7156 Piston Motor Gp
The procedure on adjustment of the drive units is in the following module in the service manual for your machine. Testing and Adjusting for Hy-
draulic Systems, “Adjustment of the Steering Motor”.

12 KENR8566
Table 5
2 1 171-3061 Spring Free length is 47.90 mm (1.886 inch).
A - - Dimension is 111.20 to 111.30 mm (4.378 to 4.382 inch).
As required, use the following shims in order to achieve dimension (A):
3 1 9T-1576 Shim Thickness is 0.10 mm (0.004 inch).
1 9T-1579 Shim Thickness is 0.30 mm (0.012 inch).
Before assembly, apply blue Loctite 242 to threads.

4 7 113-4420 Screw
Torque to 15.5 ± 1.5 N·m (137.2 ± 13.3 lb in).
B - - Dimension is 0.325 ± 0.075 mm (0.0128 ± 0.0030 inch).
As required, use any one of the following shims in order to achieve dimension (B):
1 171-3060 Shim Thickness is 3.60 mm (0.142 inch).

5

KENR8566 13
i04728489
Pump Control Valve

SMCS Code: 5455
Part No.: 227-3021
Table 6
Specification for 227-3021 Pump Control Valve Gp
1 1 9T-4186 Spring Free length is 45.1 mm (1.78 inch).
2 1 195-6947 Spring Free length is 19 mm (0.7 inch).
Cutoff pressure is 39000 ± 700 kPa (5655 ± 100 psi).

Flow rate for above test is 5.0 L/min (1.3 US gpm).
Margin pressure is 2100 ± 100 kPa (300 ± 15 psi).
Flow rate for above test is 80 L/min (21 US gpm).
Maximum standby pressure is 4000 kPa (580 psi).
Flow rate for bench test is 196 ± 2 L/min (51.8 ± 0.5 US gpm).
Pressure for above bench test is 6900 ± 500 kPa (1000 ± 75 psi).
14 KENR8566
i05713590
Implement and Steering Control Valve Group

SMCS Code: 4307; 5137
Part No.: 224-4937
Table 7
Specification for 224-4937 Bank Valve Gp
1 3 6V-8188 Nut Torque to 105 ± 10 N·m (77 ± 7 lb ft).
2 1 9T-3541 Relief Valve Gp Torque to 65 ± 7 N·m (48 ± 5 lb ft).

KENR8566 15
i05351632
Implement and Steering Control Valve Group

SMCS Code: 4307; 5137
Part No.: 224-4936
Table 8
Specification for 224-4936 Bank Valve
1 3 6V-8188 Nut Torque to 105 ± 10 N·m (77 ± 7 lb ft).

16 KENR8566
i04907646
Steering Control Valve

SMCS Code: 4307; 5051
Part No.: 235-0402

KENR8566 17
18 KENR8566
Table 9
Specification for 235-0402 Control Valve Gp
1 1 6L-9716 Pipe Plug Torque to 9 to 14 N·m (80 to 124 lb in).
2 1 4T-1860 Shuttle Valve Gp Torque to 32 ± 5 N·m (283 ± 44 lb in).
3 2 099-3649 Bolt Torque to 20 ± 3 N·m (177 ± 27 lb in).
Apply blue Loctite 242 to threads.

5 1 8C-3325 Bolt
Torque to 34 ± 3 N·m (301 ± 27 lb in).
Length under test force is 59 mm (2.3 inch).

As required, use the following shims:
7 2 256-9637 Shim Thickness is 0.61 mm (0.024 inch).
2 4J-6806 Shim Thickness is 1.22 mm (0.048 inch).
8 1 100-8011 Plug Torque to 300 ± 40 N·m (221± 30 lb ft).

9 3 2S-2596 Spring Test force is 4.226 ± 0.338 N (0.950 ± 0.076 lb).
10 2 8T-4177 Bolt Torque to 20 ± 3 N·m (177 ± 27 lb in).

11 1 9T-6316 Spring Test force is 133.5 ± 10.6 N (30.0 ± 2.4 lb).
12 2 100-8012 Body Torque to 145 ± 15 N·m (107 ± 11 lb ft).

KENR8566 19
i04732350
Pressure Reducing Valve (Pilot)

SMCS Code: 5117; 5467
Part No.: 226-4751
Table 10
Specification for 226-4751 Control Manifold Gp
Before assembly, lubricate all seals.
Before assembly, apply blue Loctite 242 to threads.

1 1 6E-5066 Screen
Torque to 7 ± 2 N·m (62 ± 18 lb in).
170-3357 Pressure Reducing

2 1 Torque to 40 ± 4 N·m (30 ± 3 lb ft).
Valve
3 - - Torque locknut to 12 ± 1 N·m (106 ± 9 lb in).
4 1 225-8026 Relief Valve Gp Torque to 50 ± 5 N·m (37 ± 4 lb ft).
Torque to 50 ± 5 N·m (37 ± 4 lb ft).

Final installation torque for nut is 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
5 1 201-0950 Solenoid Valve Gp
Operating voltage is 24 VDC.
Coil resistance at 25 ± 5 °C (77 ± 9 °F) is 41.9 ± 2.1 Ohms.
6 1 158-9956 Check Valve Gp Torque to 40 ± 4 N·m (30 ± 3 lb ft).

20 KENR8566
i05713609
Pressure Reducing Valve (Pilot)

SMCS Code: 5117; 5467
Part No.: 170-3357
Table 11
Specification for 170-3357 Pressure Reducing Valve
1 1 Nut Torque to 12 N·m (106 lb in).
2 - - Tighten to 40 N·m (30 lb ft).

KENR8566 21
i05707253
Accumulator
SMCS Code: 5077
Part No.: 317-6394

S/N: S6T1–Up
Part No.: 317-6394
S/N: S6X1–Up
Part No.: 317-6394
S/N: S6Y1–Up
Table 12
Specification for 317-6394 Pilot Oil Accumulator Gp
1 1 317-6749 Cover Torque to 19.0 ± 1.5 N·m (14.0 ± 1.0 lb ft).
2 1 317-6748 Gas Valve Assembly Torque to 12.0 ± 1.0 N·m (9.0 ± 0.5 lb ft).
22 KENR8566
i04728550
Main Relief Valve

SMCS Code: 5069; 5117
Part No.: 9T-3541
Table 13
Specification for 9T-3541 Relief Valve Gp
1 1 9X-6395 Nut Torque to 50 ± 7 N·m (37 ± 5 lb ft).
2 1 9T-1621 Valve Body Torque to 65 ± 5 N·m (48 ± 4 lb ft).

4 1 7J-9933 O-Ring Seal Lubricate bore with the lubricant that is being sealed.
KENR8566 23
i04735211
Counterbalance Valve
(Steering)
SMCS Code: 5051
Part No.: 227-0832
Table 14
Specification for 227-0832 Counterbalance Valve Gp
1 2 5P-6719 Plug Torque to 40 ± 5 N·m (30 ± 4 lb ft).
2 2 9T-6522 Cap Torque nut to 30 ± 5 N·m (266 ± 44 lb in).
3 2 9T-6521 Nut Torque to 30 ± 5 N·m (266 ± 44 lb in).
6 1 9T-5949 Spring Free length is 82.5 mm (3.25 inch).

24 KENR8566
i05717130
Control Valve (Bulldozer)

SMCS Code: 5051; 5115
Part No.: 234-5126
Table 15
Specifications for 234-5126 Bulldozer Valve and Mounting
1 1 - Final installation torque to 50 ± 5 N·m (37 ± 4 lb ft).
2 1 156-5970 Nut Final installation torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
3 4 316-1438 Cartridge As Torque to 35 ± 3 N·m (26 ± 2 lb ft).
4 4 198-2914 Nut Torque to 20 ± 3 N·m (177 ± 27 lb in).

KENR8566 25
i05710130
Bulldozer Lift Control Valve

SMCS Code: 5051; 5115; 5136
Part No.: 235-0403
Table 16
2 2 9X-6154 Bolt Torque to 20 ± 3 N·m (177 ± 27 lb in).
4 2 085-8091 Bolt Torque to 60 ± 7 N·m (44 ± 5 lb ft).

26 KENR8566
Section B-B
KENR8566 27
Table 17
5 1 4T-1108 Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 1 100-8012 Body Torque to 145 ± 15 N·m (107 ± 11 lb ft).

8 1 153-7553 Spring Test force is 50 N (11 lb).
9 1 161-2685 Screw Torque to 20 ± 3 N·m (177 ± 27 lb in).
As required, use the following shim in order to obtain the clearance (D) of 0.10 mm (0.004 inch) gap between spring and shim.
Assemble thick shim next to spring.
10
3 2J-2866 Shim Thickness is 0.12 mm (0.005 inch).

11 1 170-4001 Spring Test force is 130 N (29 lb).
Free length after test is 60 mm (2.4 inch).

12 1 164-0938 Spring Test force is 67.6 ± 5.4 N (15.2 ± 1.2 lb).
13 1 100-8011 Plug Torque to 300 ± 40 N·m (221 ± 30lb ft).

As required, use the following shim. Assemble thick shim next to spring.
15 2 8J-8462 Shim Thickness is 0.25 mm (0.010 inch).
3 6E-1637 Shim Thickness is 1.0 mm (0.04 inch).
16 1 9J-8126 Orifice Plug Torque to 10 ± 1 N·m (89 ± 9 lb in).
346-3800 Relief Valve Gp
28 KENR8566
Table 18
Use as required.
17 1 096-6166 Hard Washer
Thickness of one hard washer is 1.0 mm (0.04 inch)

19 1 366-4972 Backup Ring Before assembly, lubricate bore lightly with the fluid that is being sealed.
20 1 6V-5556 O-Ring Seal Before assembly, lubricate bore lightly with the fluid that is being sealed.
22 1 4T-4509 Seat Torque to 22 ± 2 N·m (195 ± 18 lb in).

KENR8566 29
i05710259
Bulldozer Tilt Control Valve

SMCS Code: 5051; 5115; 5123
Part No.: 235-0404
Table 19
2 2 6V-5192 Socket Head Bolt Torque to 20 ± 3 N·m (177 ± 27 lb in).

30 KENR8566
Section B-B
Table 20
As required, use the shims in order to obtain the clearance (D) of 0.75 mm (0.030 inch).

10 1 153-6976 Spring
11 1 100-8011 Plug Torque to 300 ± 40 N·m (221 ± 30 lb ft).

KENR8566 31
Table 21
Use as required.


32 KENR8566
i05710398
Ripper Control Valve

SMCS Code: 5351
Part No.: 235-0405
Table 22
2 2 6V-5192 Socket Head Bolt Torque to 20 ± 3 N·m (177 ± 27 lb in).

KENR8566 33
Section B-B
Table 23
As required, use the shims in order to obtain the clearance (D) of 1.2 mm (0.05 inch).

10 1 153-6976 Spring
11 1 100-8011 Plug Torque to 300 ± 40 N·m (221 ± 30 lb ft).

34 KENR8566
Table 24
Use as required.


KENR8566 35
i04743888
Pilot Control Valve (Bulldozer Lift and Tilt)

SMCS Code: 5059
Part No.: 322-8631

36 KENR8566
KENR8566 37
Table 25
Specification for 322-8631 Pilot Valve Gp
Apply blue Loctite 242 to threads.

1 2 4B-9808 Setscrew
Torque to 9 ± 1 N·m (80 ± 9 lb in).
3 1 145-2334 Adapter Torque to 45 ± 5 N·m (33 ± 4lb ft).
Voltage is 24 VDC.
5 1 137-9755 Detent Coil As
Resistance at 25 °C (77 °F) is 76.3 ± 3.8 ohms.
8 5 183-7263 Plug As Torque to 28 ± 4 N·m (248 ± 35 lb in).
Detail view of A
38 KENR8566
Table 26
Apply sealant to threads.

10 1 175-4168 Screw
Torque to 0.92 ± 0.10 N·m (8.14 ± 0.89 lb in).
11 2 175-4170 Screw Torque to 1.69 ± 0.23 N·m (14.96 ± 2.04 lb in).
12 - - As required, apply Plexus MA330 acrylic adhesive to lock thumb locker motion.
13 3 175-4165 Screw Torque to 1.53 ± 0.15 N·m (13.54 ± 1.33 lb in).
227-8348Lever As (2)
(16) 199-7834 Detent As (19) 146-6317 Retainer
Table 27
Apply blue Loctite 242 to threads and remove excess after applying torque.
15 3 5C-2890 Nut
Torque to 12 ± 3 N·m (106 ± 27 lb in).
Assemble after or mask from painting process.

17 1 159-3781 Spring
Test force is 24.0 ± 2.0 N (5.4 ± 0.4 lb).
Assemble after or mask from painting process.

18 3 146-6315 Adjustment Pin
KENR8566 39
194-5033Pilot Cartridge Valve Gp (6)
Table 28
20 2 259-0509 O-Ring Seal Lubricate with the lubricant that is being sealed.


23 2 191-3028 Cage Torque to 15 ± 2 N·m (133 ± 18 lb in).
24 2 4K-2039 O-Ring Seal Lubricate with the lubricant that is being sealed.
25 2 6M-5062 O-Ring Seal Lubricate with the lubricant that is being sealed.
26 2 116-4527 Orifice Torque to 2.5 ± 0.5 N·m (22.1 ± 4.4 lb in).

28 2 153-8925 Stop Torque to 6 ± 1 N·m (53 ± 9 lb in).

40 KENR8566
Table 29




KENR8566 41
i04744251
Pilot Control Valve (Bulldozer Lift and Tilt)

SMCS Code: 5059
Part No.: 200-0189
Table 30
Use as required.
2 8 200-5003 Shim
Thickness is 0.25 mm (0.010 inch).

42 KENR8566
Table 31
Voltage is 24 VDC.
6 1 137-9755 Detent Coil As
Resistance at 25 °C (77 °F) is 76.3 ± 3.8 ohms.
196-5515Lever As (1)
(12) 199-7834 Detent As (16) 146-6317 Retainer

KENR8566 43
Table 32
11 3 5C-2890 Nut
Torque to 12 ± 3 N·m (106 ± 27 lb in).
13 3 146-6315 Adjustment Pin Apply blue Loctite 242 to threads and remove excess after applying torque.
14 - - Apply lubricant sparingly to moving parts before painting.

44 KENR8566
Table 33




KENR8566 45
Table 34




46 KENR8566
i05713229
Pilot Control Valve (Ripper Lift)

SMCS Code: 5059
Part No.: 167-1177
Table 35

KENR8566 47
Section C-C
Table 36
4 1 199-6609 Spacer Torque to 30 ± 20 N·m (266 ± 177 lb in).
Before assembly, apply blue Loctite 242 to the threads.

5 2 5C-2890 Nut
Torque to 12 ± 3 N·m (106 ± 27 lb in).
Before assembly, apply blue Loctite 242 to the threads.

6 1 105-3481 Bolt
Torque to 28 ± 4 N·m (248 ± 35 lb in).
48 KENR8566
194-5033 Pilot Cartridge Valve Gp
Table 37




KENR8566 49
i05713470
Lines (Pilot)
SMCS Code: 5057
Part No.: 222-1167

S/N: S6T1–Up
Part No.: 222-1167
S/N: S6X1–Up
Part No.: 222-1167
S/N: S6Y1–Up
Table 38
Specification for 222-1167 Pilot Lines Gp
1 1 148-8326 Connector As Torque to 40 ± 8 N·m (30 ± 6 lb ft).
2 1 148-8325 Connector As Torque to 80 ± 15 N·m (59 ± 11 lb ft).

50 KENR8566
i05707272
Quick-Drop Valve
SMCS Code: 5110
Part No.: 227-0831
Table 39
Specifications for 227-0831 Quick-Drop Valve
1 1 3J-3679 Plug As Apply red Loctite 271 to the threads.
- As required, use the following shims in order to balance spring (2) force:
3 3 4M-6980 Shim Thickness is 0.25 mm (0.010 inch).
4 3 4T-4659 Shim Thickness is 0.80 mm (0.032 inch).
5 2 083-7784 Shim Thickness is 2.00 mm (0.079 inch).

KENR8566 51
i05709991
Bulldozer Lift Cylinder

SMCS Code: 5102
Part No.: 227-0844

S/N: EMM1–Up
Part No.: 227-0844
S/N: JEN1–Up
Part No.: 227-0844
S/N: S6T1–Up
Part No.: 227-0844
S/N: S6X1–Up
Part No.: 227-0843
S/N: S6Y1–Up
Typical example
52 KENR8566
Table 40
Specifications for 227-0843 Bulldozer Lift Cylinder Gp and 227-0844 Bulldozer Lift Cylinder Gp
1 1 1F-6762 Bolt Torque to 3600 ± 400 N·m (2655 ± 295 lb ft).
2 2 1U-4074 Piston Insert The piston inserts must not extend beyond the face of the piston.
A 1 9T-3885 Piston Diameter is 101.10 ± 0.03 mm (3.980 ± 0.001 inch).
3 2 4J-6374 Bushing Inside diameter before assembly is 50.622 ± 0.013 mm (1.9930 ± 0.0005 inch).
B 1 - Bore is 101.60 ± 0.08 mm (4.000 ± 0.003 inch).
C 1 364-4115 Rod As Diameter is 63.450 ± 0.038 mm (2.4980 ± 0.0015 inch).
D Bore of the head is 63.83 ± 0.03 mm (2.513 ± 0.001 inch).
1 172-9981 Head Before assembly, apply clean grease to the threads.

4
Torque to 600 ± 130 N·m (443 ± 96 lb ft).
As required, use the shim:

5 26 8E-9212 Shim
6 1 167-2201 Buffer Seal As Lubricate the sealing lip lightly with lubricant that is being sealed.
7 1 167-2312 U-Cup Seal Lubricate the sealing lip lightly with lubricant that is being sealed.
8 1 225-3281 Wiper Seal Lubricate the sealing lip lightly with lubricant that is being sealed.
9 - - Before assembly, apply green Loctite 609 to wiper seal groove.

KENR8566 53
i05713390
Cylinder Mounting
SMCS Code: 5102
Part No.: 362-4548

54 KENR8566
Table 41
Specifications for 362-4548 Cylinder Mounting Gp
1 4 362-4549 Cap As Pack the cap assembly with 1P-0808 Multipurpose Grease.
2 8 7X-2557 Bolt Torque to 270 ± 40 N·m (199 ± 30 lb ft).
Outside diameter before assembly is 73.496 ± 0.038 mm (2.8935 ± 0.0015 inch).

3 1 3G-9402 Bushing
Thickness is 6.438 ± 0.025 mm (0.2535 ± 0.0010 inch).
4 2 5P-2671 Lip Type Seal Lubricate the lip type seal with 1P-0808 Multipurpose Grease.
Orient the lift cylinder at the ground level angle. Relax the hoses and then tighten the hose
B - - flanges.
Ground level angle from vertical for lift cylinder on LGP machine is 33 degrees.
C - - flanges.
Ground level angle from vertical for lift cylinder on XL machine is 27 degrees.
5 2 3B-8489 Grease Fitting Fill Grease Fitting with 1P-0808 Multipurpose Grease.
KENR8566 55
i05707329
Cylinder Mounting
SMCS Code: 5102
Part No.: 238-9559

S/N: S6T1–Up
Part No.: 238-9559
S/N: S6X1–Up
Part No.: 238-9559
S/N: S6Y1–Up
56 KENR8566
Table 42
Specifications for 238-9559 Cylinder Mounting Gp
Outside diameter before assembly is 73.496 ± 0.038 mm (2.8935 ± 0.0015 inch).

2 1 3G-9402 Bushing
3 2 5P-2671 Lip Type Seal Lubricate the lip type seal with 1P-0808 Multipurpose Grease.
A - - flanges.
Ground level angle from vertical for lift cylinder on LGP machine is 33 degrees.
B - - flanges.
Ground level angle from vertical for lift cylinder on XL and XW machine is 27 degrees.
KENR8566 57
i05707349
Bulldozer Tilt Cylinder

SMCS Code: 5104
Part No.: 233-9134

S/N: S6T1–Up
Part No.: 233-9134
S/N: S6X1–Up
Part No.: 233-9134
S/N: S6Y1–Up
58 KENR8566
Table 43
Specifications for 233-9134 Tilt Cylinder Gp
Inside diameter before assembly is 44.602 ± 0.025 mm (1.7560 ± 0.0010 inch).

1 1 2J-8489 Bearing
Install bearing flush with cylinder assembly.
Before assembly, lubricate the threads.

2 1 1J-2921 Bolt
Torque to 2700 ± 275 N·m (1991 ± 203 lb ft).
A 1 233-9135 Cylinder As Bore is 165.15 ± 0.10 mm (6.502 ± 0.004 inch).
B 1 233-9138 Cylinder Head Bore of head over the two land is 76.48 ± 0.03 mm (3.011 ± 0.001 inch).
C 1 1U-4069 Rod As Diameter is 76.150 ± 0.038 mm (2.9980 ± 0.0015 inch).
3 4 6V-8133 Bolt Torque to 900 ± 100 N·m (664 ± 74 lb ft).
4 4 6V-9167 Bolt Torque to 520 ± 70 N·m (384 ± 52 lb ft).
Inside diameter before assembly is 76.2 mm (2.99999 inch)

5 1 9T-0094 Wear Ring
Thickness is 1.50 ± 0.03 mm (0.059 ± 0.001 inch)
Before assembly, apply green Loctite Retaining Compound 620 to the wiper seal
9 - -
groove.
KENR8566 59
i05707370
Bulldozer Tilt Cylinder

SMCS Code: 5104
Part No.: 227-0841

S/N: EMM1–Up
Part No.: 227-0841
S/N: JEN1–Up
Part No.: 227-0841
S/N: S6T1–Up
Part No.: 227-0841
S/N: S6X1–Up
60 KENR8566
Table 44
Specifications for 227-0841 Tilt Cylinder Gp
Inside diameter before assembly is 44.602 ± 0.025 mm (1.7560 ± 0.0010 inch).

1 1 2J-8489 Bearing
Install bearing flush with cylinder assembly.

2 1 5J-5731 Locknut
Torque to 2200 ± 220 N·m (1623 ± 162 lb ft).
B 1 230-7887 Head As Bore for head over the four land is 63.78 ± 0.03 mm (2.511 ± 0.001 inch).
C 1 9T-6093 Piston Rod Diameter is 63.450 ± 0.038 mm (2.4980 ± 0.0015 inch).
Inside diameter before assembly is 63.5 mm (2.50 inch).

4 1 8T-5668 Wear Ring
Before assembly, apply green Loctite Retaining Compound 620 to the wiper seal
8 - -
groove.
KENR8566 61
i05713689
Lines (Tilt Cylinder)

SMCS Code: 5057; 5104
Part No.: 391-2580

S/N: EMM1–Up
Part No.: 389-6159, 391-2581
S/N: JEN1–Up
Part No.: 252-5849
S/N: S6X1–Up
Typical example
Table 45
Specification for 389-6159 Tilt Cylinder Lines Gp, 391-2581 Tilt Cylinder Lines Gp, 252-5849 Tilt Cylinder Lines Gp, 223-3994 Tilt
Cylinder Lines Gp and 391-2580 Tilt Cylinder Lines Gp

62 KENR8566
i05713752
Lines (Tilt Cylinder)

SMCS Code: 5057; 5104
Part No.: 391-2583

S/N: EMM1–Up
Part No.: 391-2583
S/N: JEN1–Up
Part No.: 255-8954
S/N: S6T1–Up
Part No.: 255-8954
S/N: S6X1–Up
Typical example
Table 46
Specification for 391-2583 Tilt Cylinder Lines Gp and 255-8954 Tilt Cylinder Lines Gp

KENR8566 63
View area of A
Table 47

64 KENR8566
i05709929
Ripper Lift Cylinder

SMCS Code: 5352
Part No.: 384-5351
Table 48
Specification for 384-5351 Ripper Cylinder Gp
Lubricate the threads.

1 1 5J-5731 Locknut
Torque to 3000 ± 300 N·m (2213 ± 221 lb ft).
2 2 4K-3128 Bushing Inside diameter before assembly is 63.508 ± 0.020 mm (2.5003 ± 0.0008 inch).
3 1 2K-4507 Bushing Inside diameter before assembly is 63.660 ± 0.020 mm (2.5063 ± 0.0008 inch).
B 1 384-8725 Rod As Diameter is 69.930 ± 0.038 mm (2.7531 ± 0.0015 inch).
Bore over two lands is 70.33 ± 0.03 mm (2.769 ± 0.001 inch).

C 1 355-4712 Head Lubricate the threads with clean grease.
Torque to 600 ± 130 N·m (443 ± 96 lb ft).
4 1 167-2235 Buffer Seal As Lubricate the sealing lip of the buffer seal lightly with the fluid that is being sealed.
5 1 167-2299 U-Cup Seal Lubricate the sealing lip of the u-cup seal lightly with the fluid that is being sealed.
6 1 278-2324 Wiper Seal Lubricate the sealing lip of the wiper seal lightly with the fluid that is being sealed.
7 1 - Before assembly, apply green Loctite 609 to the wiper seal groove.
KENR8566 65
i05709789

SMCS Code: 5352
Part No.: 227-0842

S/N: S6T1–Up
Part No.: 227-0842
S/N: S6X1–Up
Part No.: 227-0842
S/N: S6Y1–Up
66 KENR8566
Table 49
Specification for 227-0842 Ripper Cylinder Gp
2 2 4K-3128 Bushing Before assembly, bore is 63.508 ± 0.020 mm (2.5003 ± 0.0008 inch).

3 1 2J-0564 Locknut
Torque to 2700 ± 270 N·m (1991 ± 199 lb ft).
C 1 230-4873 Cylinder As Bore is 127.05 ± 0.10 mm (5.002 ± 0.004 inch).
D 1 9T-2714 Rod As Diameter is 63.450 ± 0.038 mm (2.4980 ± 0.0015 inch).
E 1 230-4872 Head Bore of the head over four lands is 63.78 ± 0.03 mm (2.5110 ± 0.0012 inch).
4 1 2K-4507 Bushing Before assembly, bore is 63.660 ± 0.020 mm (2.5063 ± 0.0008 inch).
6 1 167-2201 Buffer Seal As Lubricate lightly with the lubricant that is being sealed.
7 1 167-2312 U-Cup Seal Lubricate lightly with the lubricant that is being sealed.
8 1 225-3281 Wiper Seal Lubricate lightly with the lubricant that is being sealed.
Before assembly, apply green Loctite Retaining Compound 620 to the wiper
9 - -
seal groove.
KENR8566 67
i05707449
Push Arm
SMCS Code: 6061
Part No.: 252-5853

S/N: EMM1–Up
Part No.: 230-5554
S/N: JEN1–Up
Part No.: 230-5554
S/N: S6T1–Up
Part No.: 252-5853
S/N: S6X1–Up
Part No.: 223-4004
S/N: S6Y1–Up
Typical example
68 KENR8566
Table 50
Specifications for 223-4004 Push Arm Gp, 252-5853 Push Arm Gp and 230-5554 Push Arm Gp
As required, use the shims to obtain a clearance of 0.3 to 0.8 mm (0.01 to 0.03 inch) with the blade
1 78 8E-5703 Shim trunnion balls:
2 12 8C-8478 Bolt Torque to 520 ± 70 N·m (384 ± 52 lb ft).
As required, use the shims:

5 52 4T-4866 Shim
6 4 7Y-5235 Bolt Torque to 900 ± 100 N·m (664 ± 74 lb ft).

KENR8566 69
i05707611
Bulldozer Blade
(Cutting Edges and End Bits)
SMCS Code: 6060
Part No.: 450-6401, 6Y-1744, 9W-3762

S/N: EMM1–Up
Part No.: 450-6401, 9W-3762
S/N: JEN1–Up
Part No.: 9W-3762
S/N: S6T1–Up
Part No.: 6Y-1744, 9W-3762
S/N: S6X1–Up
Typical example
Table 51
Specifications for 6Y-1744 Bit and Cutting Edge Gp, 450-6401 Bit and Cutting Edge Gp and 9W-3762 Bit and Cutting Edge Gp
1 - 5J-4773 Bolt Torque to 475 ± 60 N·m (350 ± 44 lb ft).

70 KENR8566
i05707750
Bulldozer Blade
(Cutting Edges and End Bits)
SMCS Code: 6060
Part No.: 6Y-2039

S/N: EMM1–Up
Part No.: 6Y-2039
S/N: JEN1–Up
Part No.: 6Y-2039
S/N: S6T1–Up
Part No.: 6Y-2039
S/N: S6X1–Up
Part No.: 229-6957
S/N: S6Y1–Up
Typical example
Table 52
Specification for 6Y-2039 Bit and Cutting Edge Gp and 229-6957 Bit and Cutting Edge Gp
1 32 5J-4773 Bolt Torque to 475 ± 60 N·m (350 ± 44 lb ft).

KENR8566 71
i04557258
Bulldozer Brace
SMCS Code: 6060; 6074
Part No.: 251-9814

S/N: EMM1–Up
Part No.: 251-9814
S/N: JEN1–Up
Part No.: 251-9814
S/N: S6T1–Up
Part No.: 251-9814
S/N: S6X1–Up
Right side view
Table 53
Specifications for 251-9814 Bulldozer Brace, 358-0111 Bulldozer Brace, and 348-6701 Bulldozer Brace
As required, use the shims to obtain a clearance of 0.3 to 0.8 mm (0.01 to 0.03 inch) with
2 104 251-9834 Shim the trunnion balls:
3 2 1U-1176 Pin The head of the pin faces towards to the outside of the machine.
5 52 8E-5701 Shim the trunnion balls:
6 2 3J-6573 Adjustment Screw Apply 1P-0808 Multipurpose Grease to the threads of two adjustment screws.

72 KENR8566
i05717050
Bulldozer Brace
SMCS Code: 6060; 6074
Part No.: 431-9791

S/N: S6T1–Up
Part No.: 431-9791
S/N: S6X1–Up
Table 54
Specifications for 431-9791 Bulldozer Brace
2 52 8E-5701 Shim the trunnion balls:
3 2 1U-1176 Pin The head of the pin faces towards to the outside of the machine.
Before assembly, apply 1P-0808 Multipurpose Grease to the threads of two adjustment
4 2 1U-0929 Adjustment Screw
screws.
5 2 1U-1267 Brace Before assembly, apply 1P-0808 Multipurpose Grease.
6 2 1U-0928 Adjustment Screw
screws.
7 104 251-9834 Shim the trunnion balls:
9 2 3J-6573 Adjustment Screw
screws.
KENR8566 73
i04557281
Bulldozer Trunnion
SMCS Code: 6069
Part No.: 109-1352

S/N: EMM1–Up
Part No.: 109-1352
S/N: JEN1–Up
Part No.: 109-1352
S/N: S6T1–Up
Part No.: 109-1352
S/N: S6X1–Up
Table 55
Specifications for 109-1352 Bulldozer Trunnion Gp

74 KENR8566
i04557330
Bulldozer Trunnion
SMCS Code: 6069
Part No.: 109-1353

S/N: S6Y1–Up
Table 56
Specifications for 109-1353 Bulldozer Trunnion Gp

KENR8566 75
i04004043
General Information
SMCS Code: 5050
Implement and Steering Hydraulic System
The components of the hydraulic system are shown.
(1) Bulldozer lift cylinders (8) Steering control valve (15) Accumulator
(2) Quick-drop valve (9) Inlet manifold (16) Counterbalance valve
(3) Bulldozer tilt cylinder (10) Ripper cylinder (17) Steering motor
(4) End plate (11) Pilot control valve for the ripper (18) Tank and filters for the hydraulic oil
(5) Ripper lift control valve (12) Pilot control valve for the bulldozer (19) Hydraulic pump for implements and for
(6) Bulldozer tilt control valve (13) Pilot shutoff valve steering
(7) Bulldozer lift control valve (14) Pressure reducing valve
76 KENR8566
The hydraulic system controls the steering, the pressure reaches an approximate pressure of
bulldozer, or the ripper (if equipped). The hydraulic 39000 kPa (5655 psi), the pump destrokes enough to
system is a load sensing, pressure compensated maintain the pressure until the system pressure
system. In a load sensing, pressure compensated decreases.
system, oil flow does not change according to the
load conditions. Cylinder speeds remain constant The main relief valve in the system limits the pressure
under all load conditions. increases (spikes) to approximately 42000 kPa
(6100 psi). The main relief valve is located on inlet
manifold (9) at the bottom of the valve stack.
Hydraulic pump (19) is a variable displacement piston Illustration 59 g02178509

pump that is load sensing and pressure Steering control lever
compensated. The pump provides oil for all
implement circuits and for the steering circuit. This An open loop hydraulic system is used for steering.
circuit has one pump. The pump is oversized so that The operator uses the steering control lever to initiate
the steering circuit and the implement circuit can be a turn. The steering control lever is mechanically
operated simultaneously. The maximum pump flow is connected to steering control valve (8). Steering
set at 214 L/min (57 US gpm) and the steering control valve (8) is part of the valve stack.
function has priority to use up to 155 L/min
(41 US gpm). The remaining oil is available to the
implement circuits, as needed.
In order to keep the pressure in the system at a
minimum, the pump destrokes. Higher oil pressure is
not needed in the system until a control lever is
moved to an operating position. The destroked pump
compensates for system leakage with a small output.
The destroked pump maintains an approximate
system pressure of 3000 kPa (435 psi).
If an implement circuit is activated, the compensator
valve on hydraulic pump (19) senses the load
increase from the signal resolver network. The signal
from the signal resolver network causes the pump to
upstroke. The pump continues to upstroke until the
system pressure is approximately 2100 kPa (305 psi)
higher than the load signal from the control valve.
Pressure limiters in the implement control valves Steering control valve (8) directs oil to steering motor
control the maximum pressure in the implement (17). The steering motor is a fixed displacement
circuits. motor. The steering motor drives the steering
differential gears. Power is transferred from one track
The system pressure will be less than 2100 kPa to the other track during the steering operation. This
(305 psi) higher than the load signal from the control allows an efficient application of power to the ground.
valve under two circumstances. This lower system
pressure occurs when the pump reaches the Counterbalance valve (16) is attached to the steering
maximum displacement and the pump does not motor. The counterbalance valve controls the speed
achieve the necessary flow. This also occurs when of steering motor (17) so that additional torque from
the pressure cutoff setting is reached. the transmission and from the tracks does not drive
the motor beyond the control of the operator.
If the steering circuit is activated, the pump upstrokes
in the same manner. However, pressure in the The steering motor and the hydraulic pump are
steering circuit is controlled by the cutoff spool in the equipped with a flushing system. The flushing system
pump compensator valve. When the steering circuit uses oil that has passed through the oil cooler and
implements. This system assists in cooling the
KENR8566 77
steering motor and the hydraulic pump during high pressure reducing valve is blocked and the oil is
ambient temperature conditions. diverted to the tank line. This allows the oil from the
pilot control valves to drain to the hydraulic tank.
When, switch (21) is toggled to the LOCK position the
solenoid valve is de-energized and spring force
moves the shutoff valve to the LOCK position. Also, a
lamp on the instrument panel is activated.
Pilot control lever (12) is used for operator control of

the bulldozer. Pilot control lever (11) is used for
operator control of the ripper (if equipped).
When the pilot control lever is moved to an operating
position, the pilot supply oil instructs the implement
control valve to send oil to the cylinder.
Valve stack for a machine
(4) End plate
(5) Ripper lift control valve
(6) Bulldozer tilt control valve
(7) Bulldozer lift control valve
(8) Steering control valve
(9) Inlet manifold
The valve stack has an inlet manifold (9) and an end

cover (4). The valve stack can have as many as four
control sections. The implement control valves are in
parallel with each other. Refer to Illustration 63 .
The steering control valve is controlled by a
(13) Solenoid for the Shutoff Valve
(14) Manifold and reducing valve
mechanical linkage from the steering control lever.
(15) Accumulator The steering control valve has priority over the
implement control valves. This means that no less
Manifold and reducing valve (14) supplies pilot oil to than half of the steering speed is available at all
the control valves for the bulldozer and the times. The steering control has three positions:
attachments. The manifold and reducing valve STEER RIGHT, HOLD and STEER LEFT.
includes a pressure reducing valve, a screen, a relief
valve, a check valve, and an attached accumulator The control valves for the bulldozer and the ripper (if
(15). The accumulator and the check valve are used equipped) are controlled by the pilot control system.
to maintain supply pressure during momentary drops The bulldozer lift control valve has four positions:
in system pressure and for a short time after the RAISE, HOLD, LOWER and FLOAT. FLOAT is a
engine is shut off. detent position.
A shutoff valve (13) is located in the manifold of the The bulldozer tilt control valve has three positions:
pressure reducing valve. A solenoid valve operates TILT RIGHT, HOLD and TILT LEFT.
the shutoff valve that is in the manifold. The solenoid The ripper lift control valve has three positions:
valve is energized when the machine is running. RAISE, HOLD and LOWER.
When, the solenoid valve is energized the shutoff
valve is moved to the UNLOCK position. Pilot supply
oil from the pressure reducing valve enters the shutoff
valve of the manifold. In the UNLOCK position, the
shutoff valve directs pilot supply oil to the pilot control
valve. In the LOCK position, the line from the
78 KENR8566
i04003961
Signal Resolver Network

SMCS Code: 5079
The illustration includes the resolver for the ripper.
(1) Float Boost Signal (3) Passage from Bulldozer Tilt Control Valve (5) Passage from Steering Control Valve
(2) Passage from Ripper Lift Control Valve (4) Passage from Bulldozer Lift Control Valve (6) Signal to Pump Compensator
KENR8566 79
The resolver network consists of a resolver (ball

check valve) in each implement control valve. Each
resolver compares the pressure signal from the
previous control valve and the pressure signal from
the current control valve. The resolver ball shifts in
order to allow the higher signal to flow to the next
resolver.
For example, Illustration 64 shows the resolver
network when the ripper lift control valve is activated.
The resolver in the ripper lift control valve compares
float boost signal (1) to signal (2) from the ripper lift
control valve. Since the ripper lift control valve is
activated, signal (2) is higher. The resolver ball shifts
and signal (2) is sent to the next resolver. The next
resolver compares the signal from the ripper lift
control valve to signal (3) from the bulldozer tilt
control valve. Since the bulldozer tilt control valve is
not activated, the signal from the resolver in the ripper
lift control valve is higher. The ball shifts in order to
send the higher signal to the next resolver in the
blade lift control valve (4). The signal from each of the
implement control valves is compared in this way.
The highest resolved signal from the implement
control valves goes through line (6) to the
compensator valve on the implement pump. The
signal instructs the pump to vary output in order to
meet the highest load requirement. Also, the pump
compensator valve adds margin pressure to the load
requirement.
Note: The resolver network does not add various

loads together. Instead, the single highest resolved
load governs the pump output.
When the blade lift control valve is in the FLOAT
position or in the LOWER position, pilot oil enters the
end of the resolver network as float boost signal (1).
When the blade lift control valve is in FLOAT and
none of the other implements are activated, float
boost signal (1) is sent through the resolver network
to the pump compensator valve. This signal adjusts
the pump output in order to maintain the necessary
supply pressure that is required for pilot oil to keep
the valve spool in the FLOAT position.
When all of the implements are in HOLD, the
pressure in the resolver network is equal to tank
pressure. The pump compensator valve keeps the
implement pump at LOW PRESSURE STANDBY
until an implement is activated.
AccuGrade Ready Machines
80 KENR8566
The illustration includes the resolver for the ripper and the resolver for AccuGrade Boost Signal.
(1) Float Boost Signal (4) Passage from Bulldozer Tilt Control Valve
(2) Passage from the AccuGrade Boost (5) Passage from Bulldozer Lift Control Valve
Solenoid (6) Passage from Steering Control Valve
(3) Passage from Ripper Lift Control Valve (7) Signal to Pump Compensator
Machines that are equipped with AccuGrade use an

electrohydraulic control group to operate the pilot
hydraulic system. The electrohydraulic control group
has five solenoids. Four of the solenoids are used to
operate the features of the blade. The other solenoid
is referred to as the AccuGrade boost solenoid. This
solenoid is energized whenever the AccuGrade is
activated. Refer to Systems Operation, “Pilot
Hydraulic System” that is located in this module for
more information about the electrohydraulic control
group.
An additional shuttle valve is added to the resolver
network with the addition of the electrohydraulic
control group. The additional shuttle valve is installed
in line with the float boost signal prior to the resolver
for the ripper. When the AccuGrade boost solenoid
is energized and none of the other implements are
activated, pilot oil is sent through the resolver network
to the pump compensator valve. This adjusts the
pump output in order to maintain full pump pressure
while AccuGrade is activated.
The function of the remaining resolver network is
described earlier in this module.
KENR8566 81
i02429592
Hydraulic Tank and Filter

SMCS Code: 5056; 5068
Hydraulic Tank
Hydraulic Oil Tank
(1) Hydraulic Oil Tank (6) Suction Port (10) Return Port from Pilot Control Valves
(2) Filler Tube (7) Return Port from Pressure Reducing (11) Return Port from the End Housing of the
(3) Case Drain Filter Valve Implement Valve
(4) Vacuum Breaker (8) Implement Return Oil (12) Port for a Temperature Sensor
(5) Implement Return Oil Filter (9) Case Drain Return
82 KENR8566
Hydraulic oil tank (1) is located on the front of the right (3) Cavity
fender of the machine. (4) Spring
(5) Bypass Valve
Hydraulic oil tank (1) is sealed in order to prevent (6) Filter Base
contamination to the hydraulic oil. Suction port (6) (7) Case Drain Return Port
supplies hydraulic oil to the hydraulic pumps. Oil
flows from the hydraulic components into hydraulic oil The case drain oil filter is located within the hydraulic
tank (1) through five passages. oil tank. The case drain oil filter removes debris from
the hydraulic oil that returns through case drain return
Passage (7) collects oil from the pressure reducing port (7).
valve. Passage (7) also collects oil from the pilot
control valve (bulldozer angle), if equipped. Oil from Hydraulic oil flows through filter base (6) into cavity
passage (7) flows directly into hydraulic oil tank (1). (3). The oil fills the space between the inside of filter
element (2). Then, oil flows through filter element (2)
Passage (8) collects implement return oil that drains and back to hydraulic oil tank (1). Filter element (2)
through the inlet manifold. Oil from passage (8) flows stops any debris that is in the hydraulic oil.
into hydraulic oil tank (1) through implement return oil
filter (8). Implement return oil filter (8) stops any If filter element (2) becomes full of debris, the
debris that is in the hydraulic oil. restriction to the flow of oil causes a pressure
increase inside filter element (2). The pressure of the
Passage (9) collects return oil from the following oil causes filter bypass valve (5) to move against
sources: spring (4). Unfiltered oil is allowed to pass through
bypass valve (5) and flow directly into hydraulic oil
• Case drain from the implement pump tank (1). Unfiltered oil can cause damage to
components in the hydraulic system.
• Case drain from the steering motor
Correct maintenance procedures must be followed in
Oil from passage (9) flows into hydraulic oil tank (1) order to ensure that the filter element does not
through case drain filter (3). Case drain filter (3) stops become full of debris which will stop the flow of clean
any debris that is in the hydraulic oil. oil to the hydraulic tank.
Passage (10) collects pilot return oil from the pilot Oil Filter (Implement Return Oil)
control valves. Oil from passage (10) flows directly
into hydraulic oil tank (1).
Passage (11) collects pilot return oil from the
implement control valves and from the pilot manifold.
Oil from passage (11) flows directly into hydraulic oil
tank (1).
Oil Filter (Case Drain)
Hydraulic Oil Tank
(1) Hydraulic Oil Tank
(2) Filter Element
(3) Cavity
(4) Spring
(5) Bypass Valve
(6) Filter Base
(7) Port for Implement Return Oil
The implement return oil filter is located within the
Hydraulic Oil Tank hydraulic oil tank. The implement return oil filter
(1) Hydraulic Oil Tank
(2) Filter Element
KENR8566 83
removes debris from the hydraulic oil that returns

through implement return port (7).
Hydraulic oil flows through filter base (6) into cavity
(3). The oil fills the space between the inside of filter
element (2). Then, oil flows through filter element (2)
and back to hydraulic oil tank (1). Filter element (2)
stops any debris that is in the hydraulic oil.
If filter element (2) becomes full of debris, the
restriction to the flow of oil causes a pressure
increase inside filter element (2). The pressure of the
oil causes filter bypass valve (5) to move against
spring (4). Unfiltered oil is allowed to pass through
bypass valve (5) and flow directly into hydraulic oil
tank (1). Unfiltered oil can cause damage to
components in the hydraulic system.
Correct maintenance procedures must be followed in
order to ensure that the filter element does not
become full of debris which will stop the flow of clean
oil to the hydraulic tank.
84 KENR8566
i03973532
Hydraulic Pump - Piston

SMCS Code: 5070
Engine Off
(1) Margin spool (8) Swashplate (15) Cutoff spool
(2) Signal oil (9) Drive shaft (16) Spring
(3) Springs (10) Piston and barrel assembly (17) Passage
(4) Chamber (11) Case drain (18) Passage
(5) Pump output (12) Large actuator piston (19) Chamber
(6) Passage (13) Passage
(7) Small actuator piston (14) Piston
KENR8566 85
The hydraulic pump for the implements and for the

steering is an automatically controlled slipper type
piston pump. The pump senses the pressure in order
to determine the flow that is needed by the system.
When drive shaft (9) rotates, the cylinder barrel also
turns. Nine pistons (10) are held against the
nonrotating swashplate (8) by the retaining plate. As
shown above, at the maximum swashplate angle,
part of pistons (10) are pulled out of the cylinder
barrel (not shown). The remaining pistons (10) are
pushed into the cylinder barrel. Rotation of the
cylinder barrel causes the pistons to move in and out
of the cylinder barrel. Oil is pulled into the pump and
oil is pushed out of the pump by the push-pull
movement of the pistons.
The angle of the swashplate determines the amount
of oil that is pulled into each piston bore. Therefore,
the angle determines the amount of oil that is pushed
out of each piston bore by the drive shaft rotation.
There are infinite swashplate angle positions between
the neutral angle (zero degrees) and the maximum
angle. A greater amount of oil is pulled into the pump
and a greater amount of oil is pushed out of the pump
by an increased swashplate angle.
When the swashplate angle is zero degrees, pistons
do not move in and out of the rotating cylinder barrel.
Therefore, no oil is pulled into the pump, and no oil is
pushed out of the pump. There is zero displacement
from the pump. The pump is not generating oil flow.
Therefore, there is not a restriction to flow that can
generate pressure. The pump is not often at the zero
swashplate angle. The pump is only at the zero
swashplate angle when signal oil pressure suddenly
drops to zero or when system pressure suddenly
surges to the maximum pressure cutoff setting. These
conditions can cause the swashplate to move
momentarily to the zero angle position.
The compensator valve keeps pump oil flow at a level
that is needed to fulfill the system load and flow
needs. These needs are met by the compensator
valve in two ways: Either pump oil is sent to large
actuator piston (12) or pump oil is drained from large
actuator piston (12). The large actuator piston works
with small actuator piston (7) and the spring in order
to continually adjust the swashplate angle. Pressure
at the pump outlet is kept at about 2100 kPa
(305 psi) above the signal oil pressure by the margin
spool in the compensator valve. The compensator
valve also has a pressure cutoff spool that prevents
overloads of the pump and of the system. When,
work port pressure goes over 39000 kPa (5655 psi)
the cutoff spool will override the margin spool and
lower pump output while system pressure is
maintained at 39000 kPa (5655 psi).
The following schematics show the actions of the
pump and the compensator valve under different
conditions in the hydraulic system.
Upstroking
86 KENR8566
KENR8566 87
Upstroking means that the pump is increasing the

displacement (output). Upstroking occurs when the
signal oil pressure increases due to an increased
load. The highest signal oil pressure from the control
valves flows through line (2) and the oil fills chamber
(4). The force of signal oil pressure plus the force of
springs (3) now move margin spool (1) to the left. The
spool movement blocks the flow of pump oil to large
actuator piston (12). The spool movement also opens
the passages to the large actuator piston to case
drain (11). The combined force of the actuator spring
and of the system oil pressure that is behind small
actuator piston (7) now moves swashplate (8) toward
the maximum angle (upstroke).
Pump output is increased by upstroking until the
pressure in passage (18) moves margin spool (1) to
the right to the metering position. When the margin
spool is first at the metering position, system oil
pressure in passage (18) is higher than the signal oil
pressure and the force of springs (3) in chamber (4).
The greater pressure moves the margin spool farther
to the right. This sends system oil pressure through
passages (17) and (13) to large actuator piston (12).
Because the force of large actuator piston (12) is
greater than the force of small actuator piston (7) plus
the force of the actuator spring, the force that is on
swashplate (8) toward the minimum angle is greater
than the force that is on swashplate (8) toward the
maximum angle. The difference in force causes a
decrease in the angle of the swashplate and the
pump output. The decrease in pump output causes a
decrease in pressure. When the pump flow
decreases enough, the combined signal pressure
and the force of springs (3) in chamber (4) cause the
margin spool to move to the left. The pump oil that is
behind large actuator piston (12) flows to the case
drain again. The small actuator piston and the
actuator spring increase the swashplate angle.
The continuous oscillation (metering) of margin spool
(1) maintains the system pressure in chamber (19) at
2100 kPa (305 psi) higher than the signal pressure
that is in chamber (4), because the force of springs
(3) is equal to 2100 kPa (305 psi). The difference is
called margin pressure.
88 KENR8566
Destroking
Destroking means that the pump is decreasing the

displacement (output). Destroking occurs when signal
oil pressure decreases from lower loads. Destroking
also occurs when all of the control valves are in the
HOLD position and signal oil pressure decreases to
0 kPa (0 psi). The lower signal oil pressure in
chamber (4) causes the higher system oil pressure in
chamber (19) to move margin spool (1) to the right.
The spool movement allows system oil pressure to
flow through passages (17) and (13) to large actuator
piston (12). The force that is created by the system oil
pressure that is behind large actuator piston (12) is
now higher than the force of the actuator spring and
the system oil pressure that is behind small actuator
piston (7). The angle of the swashplate decreases.
Pump output decreases until the pump flow is not
adequate to maintain system pressure.
System pressure decreases. When system pressure
approaches 2100 kPa (305 psi) (margin pressure)
above the signal oil pressure, margin spool (1) moves
to the left and the spool begins to meter oil at the
large actuator piston to case drain (11). When system
pressure approaches 4000 kPa (580 psi) (low-
pressure standby), margin spool (1) moves to the left
and the spool begins to meter oil at the large actuator
piston to case drain (11). Signal oil pressure is zero
when the control valves are in the HOLD position.
Swashplate (8) increases the angle slightly, so that
the pump output makes up system leakage. Also, the
higher swashplate angle maintains the margin
pressure in the system.
KENR8566 89
Low Pressure Standby
When the engine is running with the control valves in

the HOLD position, there is no signal oil pressure in
line (2) to chamber (4). Without signal oil pressure in
chamber (4), system oil pressure in chamber (19)
moves the margin spool to the right against the force
of springs (3). Pump oil then flows through passages
(17) and (13) to large actuator piston (12). Then, large
actuator piston (12) moves swashplate (8) toward the
minimum angle that is required for enough output to
maintain system pressure at 4000 kPa (580 psi).
Note: Do not confuse low-pressure standby with

margin pressure. Margin pressure is 2100 kPa
(305 psi). The pressure that is required to compress
springs (3) is 2100 kPa (305 psi). This pressure is
not sufficient to move swashplate (8) against the
force of the actuator spring and of small actuator
piston (7). Pump output increases until the
swashplate can move against the small actuator
piston and the actuator spring. System pressure then
stays at 4000 kPa (580 psi), which is Low Pressure
Standby. Margin pressure can only be measured in a
nonstall load sensing condition. Some variation in
low-pressure standby can occur from low idle to high
idle. For the margin pressure test procedure, refer to
Testing and Adjusting, “Pump Discharge Pressure
Tests” in this manual.
90 KENR8566
High Pressure Stall
When the hydraulic system stalls under a load in the

steering circuit, the oil pressure increases. A stall
occurs when system oil pressure gets to 39000 kPa
(5655 psi). Signal oil pressure in line (2) and chamber
(4) now equals system oil pressure in chamber (19).
Springs (3) keep margin spool (1) moved to the left
which puts the pump in an upstroking position. As
system oil pressure approaches 39000 kPa
(5655 psi), pressure cutoff spool (15) moves to the
left against spring (16). Pump oil flows through
passage (13) to large actuator piston (12). The
pressure that is behind large actuator piston (12)
moves swashplate (8) until the system pressure is
maintained at 39000 kPa (5655 psi).
When the pump output flow is insufficient for
maintaining the system pressure and the pressure
decreases below 39000 kPa (5655 psi), the force of
spring (16) moves pressure cutoff spool (15) further to
the right. This spool movement stops the flow of oil
past the spool to the large actuator piston. As system
pressure decreases further, pressure cutoff spool (15)
moves further to the right and large piston actuator
(12) opens to margin spool (1).
When system pressure approaches margin pressure
over signal oil pressure, margin spool (1) moves to
the metering position. The metering position allows
the swashplate angle to increase until pump flow is
sufficient to make up system leakage and the lower
required pressure is maintained. If there is no signal
oil pressure, system pressure goes to low-pressure
standby.
KENR8566 91
Constant Flow
Constant flow is achieved when the force of the i04004019

pressure of the pump supply in passage (18) is equal
to the sum of the force of springs (3) and the signal
pressure in signal line (2). The forces on both sides of
Main Relief Valve
margin spool (1) will be equal. The equal forces move SMCS Code: 5069; 5117
the spool to a metering position. The metering of the
margin spool provides a stabilized system with
constant flow.
As the signal pressure in line (2) decreases, the force
on the left of margin spool (1) is greater than the sum
of the force of the signal pressure and the force of
springs (3). The decrease in signal pressure causes
the margin spool to move to the right. The spool
movement allows pump oil pressure to flow through
passages (17) and (13) to large actuator piston (12).
Large actuator piston (12) will decrease the angle of
swashplate (8). The decreased angle will decrease
pump output. As pump output decreases, the
pressure on the left of margin spool (1) decreases.
The decrease in pressure allows the margin spool to
move into a metering position again.
Main relief valve in the inlet manifold
92 KENR8566
The main relief valve is located in the inlet manifold.

The inlet manifold is attached to the bottom of the
control valve stack.
Main relief valve
(1) Nut
(2) Spring
(3) Valve
(4) Inlet passage
(5) Drain passages
(6) Setscrew
The main relief valve is a directly operated valve.

Since the setting of the main relief valve is above all
of the operating pressures, the valve serves as a
backup valve. The main relief valve limits the
increases (spikes) in pump pressure.
Note: The main relief valve is not capable of handling

full pump flow.
Pump oil flows through passage (4) to valve (3).
Spring (2) keeps valve (3) closed when the oil
pressure is less than the setting of the relief valve.
When the oil pressure increases to the setting of the
relief valve, valve (3) opens. The oil in passage (4)
flows around valve (3). The oil flows through drain
passages (5) to the tank. The pump pressure cannot
exceed the setting of the main relief valve.
The compressed length of spring (2) determines the
force that is applied by spring (2) to valve (3). An
increase or a decrease in the force that is applied by
spring (2) changes the pressure setting of the relief
valve.
Loosen nut (1) and turn setscrew (6) clockwise in
order to increase the pressure setting. Loosen nut (1)
and turn setscrew (6) counterclockwise in order to
decrease the pressure setting.
KENR8566 93
i04003920
Pilot Hydraulic System

SMCS Code: 5050; 5050-PS
Schematic for the pilot hydraulic system
(1) Steering motor (4) Hydraulic tank (7) Implement lockout valve
(2) Control valve stack (5) Pilot valve for the bulldozer (8) Accumulator
(3) Hydraulic pump (6) Pilot valve for the ripper (9) Pressure reducing valve
94 KENR8566
The pilot hydraulic system is used to operate the (6) Pilot valve lever for the ripper
control valve stack. Refer to Systems Operation,
“Implement Control Valve”Systems Operation, Refer to Systems Operation, “Pressure Reducing
Implement Control Valve for information on the Valve” that is in this module for more details about the
operation of the control valve stack. The pilot implement lockout valve.
hydraulic system consists of the following
components: control valve stack (2), pilot valve for the Pilot Valve (Bulldozer)
bulldozer (5), pilot valve for the ripper (6), implement
lockout valve (7), accumulator (8) and pressure
reducing valve (9).
The pilot hydraulic system receives oil from the
hydraulic pump (3). The hydraulic pump is a piston
pump. Refer to Systems Operation, “Hydraulic Pump
- Piston”Systems Operation, Hydraulic Pump - Piston
for information on the operation of the hydraulic
pump.
The system oil flows from the hydraulic pump into the
pressure reducing valve (9), which is located under
the right console with accumulator (8). Refer to
Systems Operation, “Pressure Reducing
Valve”Systems Operation, Pressure Reducing Valve
for information on the operation of the pressure
reducing valve. Illustration 79 g01215632
Location of the pilot valve lever (bulldozer)
Accumulator (5) Pilot valve lever
(A) HOLD position
The pilot supply oil flows from the pressure reducing (B) RAISE position
valve (9) to accumulator (8). The accumulator (C) LOWER position
provides limited pilot oil after the engine is shut down. (D) FLOAT position
0.75 L (0.8 qt) of oil is provided. This reservoir of pilot (E) TILT LEFT position
oil permits attachments to be lowered up to 1.5 (F) TILT RIGHT position
minutes after the engine is off.
The pilot valve lever (5) for the bulldozer is located on
Accumulator (8) is charged with dry nitrogen to the right console. The pilot valve lever (5) controls the
1050 kPa (150 psi). Accumulator (8) has a service lift cylinders and the tilt cylinder through two control
pressure of 3100 kPa (450 psi). Refer to Systems valves in the valve stack.
Operation, “Accumulator”Systems Operation,
Accumulator that is this module for information on the HOLD Position
operation of the accumulator.
When the control lever of pilot valve (5) is in HOLD
Implement Lockout Valve position (A), the pilot supply line is blocked. The
control lever will return to HOLD position (A) when the
Then, the oil flows to implement lockout valve (7). The lever is released from the following positions: RAISE
implement lockout valve deactivates the implement (B), LOWER(C), TILT LEFT(E) and TILT RIGHT(F).
pilot valves (bulldozer and ripper). The bulldozer blade will remain in the selected
position.
RAISE Position
When the operator moves the control lever of pilot
valve (5) to RAISE position (B), the pilot oil moves the
control valve spool in the bulldozer lift control valve
and the lift cylinders raise the bulldozer blade. Refer
to Systems Operation, “Bulldozer Lift Control Valve”
for information on the operation of the control valve.
The control lever will return to the HOLD position
when the control lever is released and the bulldozer
blade remains in the raised position.
LOWER Position
Location of the switch for the implement control When the operator moves the control lever of pilot
shutoff valve (5) to LOWER position (C), the pilot oil moves
the control valve spool in the bulldozer lift control
(5) Pilot valve lever for the bulldozer valve and the lift cylinders lower the bulldozer blade.
(10) Switch for the implement lockout valve
KENR8566 95
Refer to Systems Operation, “Bulldozer Lift Control (C) LOWER position

Valve” for information on the operation of the control
valve. The control lever will return to the HOLD The pilot valve lever (6) for the ripper is located on the
position when the control lever is released and the right console. The pilot valve lever for the ripper
bulldozer blade remains in the lowered position. controls the lift cylinder for the ripper through the
control valve in the valve stack.
FLOAT Position
HOLD Position
When the operator moves the control lever of pilot
valve (5) to FLOAT position (D), the pilot valve is held When the control lever of the pilot valve (6) is in
in the FLOAT position by a magnet. The control HOLD position (A), the pilot supply line is blocked.
remains in the FLOAT position until the control is The control lever will return to HOLD position (A)
pulled out of the position. When the oil pressure in when the lever is released from the following
both ends of the lift cylinders is equal, the weight of positions: RAISE(B) and LOWER(C). The ripper will
the bulldozer causes the bulldozer to lower to the remain in the selected position.
ground. When the control lever is pulled out of the
FLOAT position, and when the control lever is
released, the control lever will return to the HOLD RAISE Position
position.
When the operator moves the control lever of the pilot
valve (6) to the RAISE position (B), the pilot oil moves
TILT LEFT Position the control valve spool in the ripper lift control valve
and the lift cylinder raises the ripper. Refer to
When the operator moves the control lever of pilot Systems Operation, “Ripper Lift Control
valve (5) to TILT LEFT position (E), the pilot oil moves Valve”Systems Operation, Ripper Lift Control Valve
the control valve spool in the bulldozer tilt control for information on the operation of the control valve.
valve and the tilt cylinder tilts the bulldozer blade. The control lever will return to the HOLD position
Refer to Systems Operation, “Bulldozer Tilt Control when the control lever is released and the ripper
Valve” for information on the operation of the control remains in the raised position.
valve. The control lever will return to the HOLD
position when the control lever is released and the
bulldozer blade remains in the tilted left position. LOWER Position
When the operator moves the control lever of the pilot
TILT RIGHT Position valve (6) to the LOWER position (C), the pilot oil
moves the control valve spool in the ripper lift control
When the operator moves the control lever of pilot valve and the lift cylinder lowers the ripper. Refer to
valve (5) to TILT RIGHT position (F), the pilot oil Systems Operation, “Ripper Lift Control
moves the control valve spool in the bulldozer tilt
Valve”Systems Operation, Ripper Lift Control Valve
control valve and the tilt cylinder tilts the bulldozer
for information on the operation of the control valve.
blade. Refer to Systems Operation, “Bulldozer Tilt
The control lever will return to the HOLD position
Control Valve” for information on the operation of the
when the control lever is released and the ripper
control valve. The control lever will return to the remains in the lowered position.
HOLD position when the control lever is released and
the bulldozer blade remains in the tilted right position.
AccuGrade Ready Machines
Pilot Valve (Ripper)
Location of the pilot valve lever (ripper)
(6) Pilot valve for the ripper
(A) HOLD position
(B) RAISE position
96 KENR8566
Proportional solenoid (5, 6, 7, 8)

electrohydraulic control group that is used to operate
the bulldozer. The electrohydraulic control group
consists of the following components: Machine ECM
and Five solenoid valves for standard blades.
The electrohydraulic control group allows the
machine ECM to move the blade when AccuGrade
is active.
When the implement is in the HOLD position, the
solenoid is de-energized. When the solenoid is de-
energized, the spring forces the valve spool to the
left. In this position, pilot supply oil in passage (12) is
blocked.
Oil from the end of the spool for the implement control
valve then drains through passage (5). The oil flows
through the valve spool and the oil returns to the
hydraulic tank through passage (2).
When an implement is activated, the solenoid is
energized. Solenoid (3) forces the valve spool to the
right. In this position, passage (2) to passage (5) is
blocked.
Passage (12) is open and pilot supply oil flows
through the valve spool to passage (5). Pilot oil
Illustration 81 g01216895 pressure is reduced after flowing through the valve
(1) Manifold
spool. Pilot oil from passage (5) exerts pressure on
(2) Port to tank the end of the spool for the implement control valve
(3) Proportional solenoid for tilt left and the spool shifts.
(4) Proportional solenoid for blade lower
(5) Line to blade tilt control valve (tilt left) Solenoid (3) is a proportional solenoid. The solenoid
(6) Line to blade lift control valve (blade lower and blade float) moves the valve spool to the right by an amount that
(7) Line to blade lift control valve (blade raise) is proportional to the amount of movement in the
(8) Line to blade tilt control valve (tilt right) implement control lever. When the valve spool is
(9) Proportional solenoid for blade raise pushed to the right further, passage (5) is opened
(10) Proportional solenoid for tilt right
(11) Port to float boost signal
further. More pilot oil is allowed into passage (5). The
(12) Port for pilot oil supply implement control spool shifts proportionally to pilot
(13) Solenoid for AccuGrade boost oil pressure.
The pressure of pilot supply (12) stays relatively
constant, but pressure (5) to the implement control
valve depends on the amount of flow past the valve
spool.
The pilot oil is sent to the electrohydraulic control
group from the pressure reducing valve. The pilot oil
enters manifold (1) at port (12). When, the bulldozer
control lever is moved an electronic signal is sent to
the solenoid by the machine ECM. When, the
solenoid is energized pilot oil from port (12) is allowed
into the line to the implement control valve. The oil will
move the valve spool which will cause the implement
to move. The bulldozer control lever will return to the
HOLD position when the control lever is released.
Solenoid (13) is used to send pilot oil to the resolver
network whenever AccuGrade is activated. Refer to
Systems Operation, “Signal Resolver Network” that is
in this manual for more information about the resolver
network.
KENR8566 97
i03968769 The implement control valves are assembled in a

valve stack. The valve stack for the hydraulic system
Implement Control Valve is located below the platform in the right side of the
cab. If the machine is equipped with a ripper, an
SMCS Code: 5051-II; 5051; 5115; 5123; 5136; 5140 additional control valve is added to the valve stack.
If, the machine is equipped with a ripper then the
valve stack includes the following valves.
• Ripper lift control valve

• Bulldozer tilt control valve
• Bulldozer lift control valve

• Steering control valve
• Inlet manifold and main relief valve
Implement control valves
(1) Identification plate
(2) Signal port (pilot valve)
(3) Housing (drain)
(4) Inlet manifold
(5) Steering control valve
(6) Bulldozer lift control valve
(7) Bulldozer tilt control valve
(8) Ripper lift control valve (if equipped)
(9) Cover
(10) Signal to pump
(11) Return oil to tank
(12) Housing (drain)
(13) Pump supply
98 KENR8566
i04000947
Steering Control Valve

SMCS Code: 4135; 4307; 4343
General Information
HOLD
(1) Control valve spool (9) Makeup valve (17) Outlet passage
(2) Spring (10) Outlet passage (18) Inlet passage
(3) Signal oil passage (11) Resolver (19) Flow control valve
(4) Outlet passage (12) Passage (20) Chamber
(5) Makeup valve (13) Passage (21) Passage
(6) Steer left (14) Chamber (22) Load check valve
(7) Outlet passage (15) Passage
(8) Steer right (16) Spring
KENR8566 99
The steering control valve is the first control valve in all implement control valves are in the HOLD position,
the valve stack. The steering control valve has priority pump oil fills the parallel oil passages at
over the remaining control valves. This is important approximately 3000 kPa (435 psi). Passage (3),
so that the tractor has the ability to turn regardless of resolver (11), passage (12), passage (13), and
the load requirements and flow requirements of the chamber (14) are drained. The oil that is in steer
implement circuits that are down stream. The steering passages (6) and (8) and passage (21) is blocked.
control valve controls the speed of the steering motor
and the direction of rotation for the steering motor.
The pump oil flows to the steering control valve from
the inlet manifold. The oil flow to the steering control
valve is limited to 155 L/min (41 US gpm) by the flow
control valve (19). The control valve has control valve
spool (1), makeup valves (5) and (9), resolver (11),
priority flow control valve (19), and load check valve
(22).
The steering valve is spring centered. Control valve
spool (1) is a closed center spool and a manually
operated spool with three positions: STEER RIGHT,
HOLD and STEER LEFT.
Spring (2) keeps the spool in the HOLD position when
the steering circuit is not active. Movement of the
spool is controlled manually by the operator. The
steering control lever is connected to valve spool (1)
by a linkage.
Resolver (11) is a two-way check valve. Resolver (11)
sends the signal oil with the highest pressure to the
inlet manifold. The inlet manifold sends the signal oil
to the compensator valve on the pump. Priority flow
control valve (19) gives flow priority to the steering
control valve over all of the implement control valves.
Descriptions of the resolver and of the priority flow
control valve are in this section. These descriptions
are given with the steering valve spool in different
positions. Descriptions for makeup valves (5) and (9)
and for load check valve (22) are in separate
sections.
Load Check Valve

Load check valve (22) will not open until pump oil
pressure in chamber (20) becomes greater than the
force of the spring for the load check valve and the
steering oil pressure in passage (21).
Makeup Valves
Makeup valve (5) or (9) opens when steering oil
pressure in passage (6) or (8) drops 14 kPa (2 psi)
below the return oil pressure in outlet passage (7).
Makeup valves (5) and (9) add return oil in outlet
passage (7) to steering oil passages (6) and (8). The
additional oil keeps the lines for the steering motor full
and the additional oil prevents cavitation (vacuum)
and aeration in the steering motor.
Basic Valve Operation

When the control valve spool and all implement valve
spools are in the HOLD position, pump oil from the
inlet manifold flows to inlet passage (18). Then, oil
flows through metering holes in priority flow control
valve (19). The oil moves priority flow control valve
(19) against spring (16). Then, pump oil flows out of
outlet passage (17) to the next control valve. Because
100 KENR8566
KENR8566 101
STEER LEFT
(28) Lift cylinders (29) Quick drop valve
102 KENR8566
(30) Dual tilt cylinders (Optional) (39) Blade tilt control valve (48) Counter balance valve
(31) Single tilt cylinder (40) Ripper lift control valve (49) Blade lift control valve
(32) Vacuum breaker (41) Float pilot boost (50) Steering control valve
(33) Hydraulic tank (42) Ripper raise (51) Inlet manifold
(34) Tilt right (43) Ripper lower (52) Main relief valve
(35) Tilt left (44) Pressure reducing manifold (53) Hydraulic pump
(36) Blade lower (45) Accumulator (54) Hydraulic oil cooler
(37) Blade raise (46) Ripper lift cylinder
(38) Cooler bypass (47) Steering motor
STEER LEFT
(1) Control valve spool (9) Makeup valve (17) Outlet passage
(2) Spring (10) Outlet passage (18) Inlet passage
(3) Signal oil passage (11) Resolver (19) Flow control valve
(4) Outlet passage (12) Passage (20) Chamber
(5) Makeup valve (13) Passage (21) Passage
(6) Steer left (14) Chamber (22) Load check valve
(7) Outlet passage (15) Passage
(8) Steer right (16) Spring
KENR8566 103
When control valve spool (1) is moved to the STEER The return oil flows around control valve spool (1) and
LEFT position, chamber (14) is closed off from outlet through outlet passage (4) to tank.
passage (10). Passage (3) is opened to steer left
passage (6). Even when priority flow control valve
(19) is moved to the right, some pump oil flows
through the metering holes in the priority flow control
valve. The flow opens load check valve (22) and the
pump oil flows around control valve spool (1) to steer
left passage (6). The pressure in steer left passage
(6) increases and oil is sent through passage (3) to
chamber (14). The oil now becomes signal oil. Some
of the signal oil flows through passage (15) to the
spring chamber that is behind priority flow control
valve (19). The signal oil moves priority flow control
valve (19) to the left. The remaining signal oil pushes
resolver (11) to the side and the signal oil flows
through passage (13) to the inlet manifold. The inlet
manifold sends the signal oil to the compensator
valve on the pump. The signal oil causes the pump to
upstroke until system pressure is reached. System
pressure is approximately 2100 kPa (305 psi) above
the pressure of the signal oil.
As pump oil flow and system pressure increases, the
steering oil flow and the pressure through steer left
passage (6) increases. The increased oil flow through
steer left passage (6) flows through the
counterbalance valve to the steering motor and the
machine turns left.
Return oil comes to steer right passage (8) from the
steering motor and from the counterbalance valve.
The return oil flows around control valve spool (1) and
through outlet passage (10) to tank.
When, steering control valve spool (1) is moved to
STEER RIGHT position is like the operation of
steering control valve spool (1) is moved to the
STEER LEFT position.
When steering valve spool (1) is moved to STEER
RIGHT position, chamber (14) is closed off from outlet
passage (10). Passage (3) is opened to steer right
passage (8). Pump oil flow through priority flow
control valve (19) opens load check valve (22) and
flows around control valve spool (1) to steer right
passage (8). The pressure in steer right passage (8)
increases and oil is sent through passage (3) to
chamber (14). The oil now becomes signal oil. Some
of the signal oil flows through passage (15) to the
spring chamber that is behind priority flow control
valve (19). Priority flow control valve (19) moves to
the left. The remaining signal oil pushes resolver (11)
to the side and the signal oil flows through passage
(13) to the inlet manifold. The inlet manifold sends the
signal oil to the compensator valve in order to
upstroke the pump.
As pump oil flow and system pressure increases, the
steering oil flow and the pressure through steer right
passage (8) increases. The increased oil flow through
steer right passage (8) flows through the
counterbalance valve to the steering motor and the
machine turns right.
Return oil comes to steer left passage (6) from the
steering motor and from the counterbalance valve.
104 KENR8566
i03996389
Bulldozer Lift Control Valve

SMCS Code: 5051; 5115; 5136
General Information
(1) Spring (10) Passage (19) Flow control valve

(2) Signal oil passage (11) Resolver (20) Metering slots
(3) Rod end (12) Passage (21) Chamber
(4) Outlet passage (13) Passage (22) Passage
(5) Head end (14) Passage (23) Load check valve
(6) Makeup valve (15) Pressure limiter valve (24) Spring
(7) Outlet passage (16) Spring (25) Outlet passage
(8) Signal oil chamber (17) Chamber (26) Control valve spool
(9) Pilot port (18) Inlet passage (27) Pilot port
KENR8566 105
The bulldozer lift control valve is located between the Note: Different designs of the control valve stem that
steering control valve and the bulldozer tilt control are used in the various valves change the limits of the
valve in the valve stack. maximum flow into the various cylinders.
Pilot supply oil from the pilot control valve is used to
control the position of control valve spool (26). When, Pressure Limiter Valve Operation
pilot supply oil with sufficient pressure enters the
bulldozer lift control valve at port (9) control valve Pressure limiter valve (15) is used in the bulldozer lift
spool (26) is shifted to the left. This action causes control valve in order to limit the pressure to the lift
pilot supply oil at the opposing end of control valve circuit. The pressure setting of the pressure limiter
spool to flow out of port (27). This oil flows to the pilot valve is 19300 ± 300 kPa (2800 ± 45 psi).
control valve. Then, the oil flows to the tank. When
the spool is shifted to the left, the valve is in the When the bulldozer lift control valve is in an operating
RAISE position. position, cylinder oil flows through passage (2) and
the oil becomes signal oil. Signal oil flows to chamber
Similarly, when pilot supply oil with sufficient pressure (8). Then, the oil flows to resolver (11) and through
enters the bulldozer lift control valve at port (27) passage (14) to spring chamber (17).
control valve spool (26) is shifted to the right. This
action causes pilot supply oil at the opposing end of When the signal oil pressure in spring chamber (17)
control valve spool to flow out of port (9). This oil reaches approximately 19300 kPa (2800 psi), the
flows to the pilot control valve. Then, the oil flows to spool in pressure limiter valve (15) moves from the
the tank. When the spool is shifted to the right, the valve seat. Oil is sent through outlet passage (7) to
valve is in the LOWER position. the tank.
The lift valve has four positions. The signal oil causes flow control valve (19) to move
to the right. The flow of pump oil to the lift circuit
• RAISE decreases until the pressure of the cylinder oil
decreases.
• HOLD
• LOWER Load Check Valve
• FLOAT Load check valve (23) prevents reverse oil flow from
the lift cylinders which can cause cylinder drift or load
The bulldozer lift control valve is spring centered. The loss. The load check valve will not open until pump oil
springs that are located at the left end of control valve pressure in chamber (21) creates a force against load
spool (26) keep the spool in the HOLD position when check valve (23) that is higher than the opposing
the lift circuit is not active. force against the other side of the check valve. The
opposing force is the sum of the force of spring (24)
Resolver (11) is a two-way check valve. Signal oil and the force that is created by the oil pressure in
from the previous resolver enters signal oil passage passage (22).
(12). Resolver (11) compares the pressure signal that
is between the bulldozer lift control valve and the Makeup Valve
following control valve. The pressure signal from the
bulldozer lift control valve enters the resolver through
passage (10). The higher pressure of signal oil exits Makeup valve (6) is in the head end of the lift circuit.
signal oil passage (13). Refer to Systems Operation, The makeup valve opens when cylinder oil pressure
“Signal Resolver Network” for detailed information in passage (5) drops approximately 14 kPa (2 psi)
about the resolver network. below the return oil pressure in outlet passage (4).
Makeup valve (6) adds return oil in outlet passage (4)
to cylinder oil in passage (5). The additional oil
Flow Control Valve prevents cavitation (vacuum) in the lift cylinders.
Flow control valve (19) limits the maximum flow of the
oil to the lift circuit. As the oil flows from passage (22)
to either rod end passage (3) or head end passage
(5), the design of control valve spool (26) causes a
pressure drop. The left end of flow control valve (19)
is at the same pressure as passage (22). The right
end of the flow control valve is at the same pressure
as either rod end passage (3) or head end passage
(5). As the flow increases from passage (22) through
control valve spool (26) to the cylinders, the pressure
differential between the left and the right ends of flow
control valve (19) increases. Flow control valve (19)
moves to the right against spring (16), closing off
metering slots (20) and reducing pump oil flow into
passage (22) through load check valve (23). The flow
control valve limits the flow of oil to the lift cylinders at
180 L/min (47.5 US gpm).
106 KENR8566

KENR8566 107
HOLD
108 KENR8566

When the control valve spool, all of the implement

valve spools, and the steering valve spools are in the
HOLD position, pump oil through the steering control
valve flows to inlet passage (18). Then, oil flows
around the flow control valve and into metering slots
(20). Oil through metering slots (20) moves the flow
control valve against spring (16). This valve
movement allows all the oil flow through inlet passage
(18) to flow to the next control valve. Because all the
valve spools are in the HOLD position, pump oil fills
the parallel oil passage of the control valves. The
pump maintains the pressure at approximately
3000 kPa (435 psi). Passage (2), chamber (8),
passage (10), resolver (11), and passage (13) are
drained. The oil that is in passages (3), (5), and (22)
is blocked.
KENR8566 109
110 KENR8566
RAISE
KENR8566 111
RAISE
112 KENR8566
When pilot control pressure causes control valve

spool (26) to move to the RAISE position, cylinder oil
from passage (3) flows through the passage (2) to
chamber (8). The oil now becomes signal oil. Some of
the signal oil flows through an orifice to spring
chamber (17) that is behind flow control valve (19).
Then, flow control valve (19) moves to the left. The
remaining signal oil moves to resolver (11) and the
signal oil flows through passage (13) to the previous
control valve. Then, the signal oil flows to the inlet
manifold. The inlet manifold sends signal oil to the
compensator valve in order to upstroke the pump.
The increased pump oil flows to inlet passage (18)
and through metering slots (20) to chamber (21) and
load check valve (23) opens. The oil through load
check valve (23) flows to passage (22), around
control valve spool (26), and out of passage (3) to the
rod end of the lift cylinders. The bulldozer blade
raises.
Return oil from the head end of the lift cylinders
comes through passage (5), around control valve
spool (26), and through outlet passage (7) to the tank.
KENR8566 113
114 KENR8566
LOWER
KENR8566 115
116 KENR8566
KENR8566 117
AUTO LOWER with Accugrade
118 KENR8566
(37) Blade raise (46) Ripper lift cylinder (55) Accugrade control manifold
LOWER
KENR8566 119
Note: Refer to the hydraulic schematic that is for

ACCUGRADE READY machines if the machine that
is being worked on is equipped with AccuGrade .
spool (26) to move to the LOWER position, the same
pilot oil flows into the resolver network at passage
(12). This flow causes the pump to upstroke to pilot
control pressure plus margin pressure. The oil now
becomes signal oil. Some of the signal oil flows
through the orifice to spring chamber (17) that is
behind flow control valve (19). The remaining signal
oil moves resolver (11) to the right, if the signal oil is
the highest resolved pressure. The signal oil flows
through passage (13) to the previous control valve
and to the inlet manifold. The inlet manifold sends the
signal oil to the compensator valve in order to
upstroke the pump. System pressure is
approximately 2100 kPa (305 psi) above the
pressure of the signal oil.
The increased pump oil flows to inlet passage (18)
and through metering slots (20) to chamber (21). The
pump oil opens load check valve (23). The oil flows to
passage (22), around control valve spool (26), and
through passage (5) to the head end of the lift
cylinders. The bulldozer blade lowers.
Return oil comes from the rod end of the lift cylinders,
through passage (3), around control valve spool (26),
and through outlet passage (25) to the tank.
hydraulic system. Refer to Systems Operation,
“Signal Resolver Network” and Systems Operation,
“Pilot Hydraulic System” that are in this manual for
more information on machines that are equipped with
AccuGrade .
120 KENR8566
KENR8566 121
FLOAT
122 KENR8566
FLOAT
KENR8566 123
When pilot control pressure causes the control valve

spool to move to the FLOAT position, there is no
signal oil pressure. Chamber (8) is open to outlet
passage (7). Pilot control pressure enters the signal
resolver network at passage (12). The pressure at
passage (12) is the same pressure that is supplied by
the pilot signal pressure at pilot port (27) that is
causing the control valve spool to move to the FLOAT
position. This flow causes the pump to maintain
margin pressure over pilot control pressure. Margin
pressure over pilot control pressure is required in
order to shift control valve spool (26) to the FLOAT
position.
Because of the position of control valve spool (26),
passages (3) and (5) are open to outlet passages
(25) and (7). Because both ends of the lift cylinders
are opened to the tank, the cylinder rods move freely
in either direction. The amount and direction of the
force on the blade controls the movement of the
blade.
hydraulic system. Refer to Systems Operation,
“Signal Resolver Network” and Systems Operation,
“Pilot Hydraulic System” that are in this manual for
more information on machines that are equipped with
AccuGrade .
i03997515
Quick-Drop Valve
SMCS Code: 5110
The quick-drop valve allows the bulldozer blade to
drop quickly to the ground. Also, the quick-drop valve
minimizes the pause time after the blade hits the
ground and before full down pressure is exerted.
The quick-drop valve has the following five
modes of operation:
• HOLD
• RAISE
• LOWER
• QUICK-DROP
• DOWN PRESSURE
The variable orifice sleeve is the essential component
in the quick-drop valve. This component creates the
pressure that is necessary to move the valve spool.
The valve spool directs oil from the rod end to the
head end when the quick-drop valve is in QUICK-
DROP mode.
124 KENR8566
HOLD
Quick-Drop Valve (HOLD)
(1) Passage from Control Valve (Head End) (7) Passage to Left Blade Lift Cylinder (Head (12) Cover
(2) Passage from Control Valve (Rod End) End) (13) Passage to Spool End
(3) Orifice Sleeve (8) Passage to Right Blade Lift Cylinder (14) Left Blade Lift Cylinder
(4) Cover (Head End) (15) Right Blade Lift Cylinder
(5) Plunger (9) Passage to Right Blade Lift Cylinder (Rod (16) Bypass Valve
(6) Passage to Left Blade Lift Cylinder (Rod End) (17) Passage to Rod End
End) (10) Passage to Plunger End (18) Passage to Head End
(11) Valve Spool
The components of the quick-drop valve in Illustration When the blade control lever is in the HOLD position,
97 are shown with the blade on the ground. Both the pressure of the hydraulic oil is equalized and the
orifice sleeve (3) and plunger (5) can float in the oil is trapped between the quick-drop valve, blade lift
valve. When the blade lift control valve is in the HOLD cylinders, and the blade lift control valve.
position, the position of orifice sleeve (3) and plunger
(5) depends on the previous action of the blade lift
control valve. The previous action will be either
RAISE, LOWER, or FLOAT.
KENR8566 125
RAISE
Quick-Drop Valve (RAISE)
(1) Passage from Control Valve (Head End) (7) Passage from Left Blade Lift Cylinder (12) Cover
(2) Passage from Control Valve (Rod End) (Head End) (13) Passage to Spool End
(3) Orifice Sleeve (8) Passage from Right Blade Lift Cylinder (14) Left Blade Lift Cylinder
(5) Plunger (9) Passage to Right Blade Lift Cylinder (Rod (16) Bypass Valve
(6) Passage to Left Blade Lift Cylinder (Rod End) (17) Passage to Rod End
End) (10) Passage to Plunger End (18) Passage to Head End
(11) Valve Spool
When the blade control lever is in the RAISE position,

the blade lift control valve shifts into the RAISE
position. Reduced pump oil enters the quick-drop
valve through passage (2). This moves orifice sleeve
(3) to the right. This oil flows around valve spool (11)
and through passage (6) and passage (9) to the rod
end of the blade lift cylinders. The blade raises.
126 KENR8566
Return oil from the head end of the cylinders enters

the quick-drop valve through passage (7) and
passage (8). This oil pressure is felt at the right side
of plunger (5). However, the pressure of the reduced
pump pressure on the left side of plunger (5) is higher
than the return oil pressure. This pressure keeps
plunger (5) shifted to the right. Blade RAISE pressure
also enters the passage to the right end of valve
spool (11). Since the same pressure is felt on the left
end of valve spool (11), the spring keeps the spool
shifted to the right.
Return oil from the head end flows around valve
spool (11) and out of the quick-drop valve from
passage (1). The blade lift control valve sends this oil
through the charging valve to the hydraulic oil tank.
Bypass Valve
Bypass valves (16) are built into the cylinder pistons.
Bypass valves are used to allow completion of the
blade raise function when the blade is tilted and one
of the lift cylinders reaches the end of the stroke prior
to the other lift cylinder.
When the piston reaches the end of the stroke, the
left end of the bypass valve touches the end of the
cylinder barrel. As the piston moves further, the
bypass valve is pushed open to the right. Allowing oil
to pass from the rod end to the head end through the
piston.
KENR8566 127
LOWER
Quick-Drop Valve (LOWER)
(5) Plunger (9) Passage from Right Blade Lift Cylinder (16) Bypass Valve
(6) Passage from Left Blade Lift Cylinder (Rod End) (17) Passage to Rod End
(Rod End) (10) Passage to Plunger End (18) Passage to Head End
(11) Valve Spool
When the blade control lever is moved less than 75 At the same time, the reduced pump pressure enters
percent of the maximum travel in the LOWER passage (10). This causes plunger (5) to shift to the
position, reduced pump pressure enters the quick- left. This pressure with the force from the spring acts
drop valve through passage (1). This oil flows around against valve spool (11) in order to keep the valve
valve spool (11) and through passage (7) and spool shifted to the right.
passage (8) to the head end of the cylinders.
128 KENR8566
Return oil from the rod end of the cylinders enters the
quick-drop valve through passage (6) and passage
(9). The return oil flows past orifice sleeve (3) to the
blade lift control valve. The blade lowers. The return
oil moves orifice sleeve (3) to the left against the
retaining ring. This oil flow creates a pressure
differential across the orifice sleeve.
Reduced pump pressure from the blade lift control
valve enters the quick-drop valve through passage
(1). This oil flows past valve spool (11) and flows to
the head end of the cylinders through passage (7)
and passage (8).
Return oil from the rod end of the cylinders enters
passage (13) on the right end of valve spool (11). This
pressure is also felt on the major diameter at the left
end of valve spool (11). The major diameter at the left
end of valve spool (11) is just to the right of orifice
sleeve (3). In addition, return oil pressure with the
pressure drop is felt on the minor diameter at the left
end of valve spool (11). As a result, the spool and the
plunger are kept to the right because of the spring
and the pressure of the return oil. The effective areas
of the major diameters of the spool are canceled. The
pressure on the right end of the spool is not high
enough to overcome the spring and return oil
pressure on the minor diameter at the left end of the
spool.
The return oil flows around valve spool (11) through
passage (2) to the blade lift control valve. The blade
lift control valve sends this oil through the charging
valve to the hydraulic oil tank.
KENR8566 129
QUICK-DROP

Quick-Drop Valve (QUICK-DROP)
(5) Plunger (9) Passage from Right Blade Lift Cylinder (16) Bypass Valve
(6) Passage from Left Blade Lift Cylinder (Rod End) (17) Passage to Rod End
(Rod End) (10) Passage to Plunger End (18) Passage to Head End
(11) Valve Spool
When the blade control lever is moved more than 75

percent of the maximum travel in the LOWER
position, the quick-drop valve operates in the QUICK-
DROP mode.
130 KENR8566
The increased travel of the blade control lever results

in higher oil flow from the rod end of the cylinders.
There will be a higher pressure drop across orifice
sleeve (3). There is only one difference between the
blade LOWER mode and the QUICK-DROP mode. In
the QUICK-DROP mode, the pressure drop across
orifice sleeve (3) that is felt on the minor diameter of
the right end of valve spool (11) overcomes the sum
of the force of the spring and the oil pressure. This
force is felt against the inside of the plug at the right
end of valve spool (11). As a result, the spool starts to
move.
The minimum flow that causes the necessary
pressure drop across the orifice sleeve to begin
movement of the spool is referred to as the “Trigger
Point”. The “Trigger Point” occurs at 75 percent of the
maximum movement of the blade control lever. When
the spool starts to move, the effective area of the
orifice sleeve decreases and the pressure drop
increases. This drop in pressure will cause the spool
to shift farther.
As a result, the spool shifts completely to the left. This
movement connects the rod end of the cylinders to
the head end of the cylinders across the slots in the
spool. This connection supplements the pump flow
into the head end of the cylinders. As a result, the
blade lowers faster as the flow from the rod ends
increases.
The position of the spool also provides a “filling”
function that minimizes the pause time. Some of the
oil from the rod ends still flows across orifice sleeve
(3). This flow continues to cause a pressure drop that
will keep valve spool (11) shifted to the left.
KENR8566 131
DOWN PRESSURE

Quick-Drop Valve (Down Pressure)
(1) Passage from Control Valve (Head End) (8) Passage to Right Blade Lift Cylinder (16) Bypass Valve
(2) Passage from Control Valve (Rod End) (Head End) (17) Passage to Rod End
(3) Orifice Sleeve (9) Passage from Right Blade Lift Cylinder (18) Passage to Head End
(4) Cover (Rod End) (BB) Cutaway Section
(5) Plunger (10) Passage to Plunger End (CC) Component Surface
(6) Passage from Left Blade Lift Cylinder (11) Valve Spool (FF) Activated Component
(Rod End) (12) Cover (GG) Tank Pressure
(7) Passage to Left Blade Lift Cylinder (Head (13) Passage to Spool End (KK) First Pressure Reduction
End) (14) Left Blade Lift Cylinder (LL) Second Pressure Reduction
(15) Right Blade Lift Cylinder
When the blade contacts the ground and stops, flow

from the rod end of the cylinders stops momentarily.
With no pressure drop across orifice sleeve (3), the
spring shifts valve spool (11) to the right. Reduced
pump pressure oil fills the head end of the cylinders.
The pressure at the head end begins to increase. The
blade will begin to lower. The blade will exert down
pressure.
132 KENR8566
Reduced pump pressure enters passage (10) to the

right end of plunger (5). Return oil pressure from the
rod end of the cylinders is felt on the left end of
plunger (5). This pressure is lower than the oil
pressure on the right end of plunger (5). As a result,
plunger (5) shifts to the left. The pressure drop across
orifice sleeve (3) that is felt on the minor diameter of
the right end of valve spool (11) tends to cause the
spool to move to the left. However, this movement is
resisted by the spring and the reduced pump
pressure that is acting on the left side of plunger (5).
As a result, valve spool (11) stays shifted to the right.
Oil returns from the rod end of the lift cylinders
through passage (6) and passage (9). This oil flows
around orifice sleeve (3) to the hydraulic oil tank.
Bypass Valve
Bypass valves (15) are built into the cylinder pistons.
Bypass valves are used to allow completion of the
blade raise function when the blade is tilted and one
of the lift cylinders reaches the end of the stroke prior
to the other lift cylinder.
When the piston reaches the end of the stroke, the
left end of the bypass valve touches the end of the
cylinder barrel. As the piston moves further, the
bypass valve is pushed open to the right. Allowing oil
to pass from the rod end to the head end through the
piston.
KENR8566 133
i03999632
Bulldozer Tilt Control Valve

SMCS Code: 5051; 5115; 5123
General Information

HOLD
(1) Spring (10) Resolver (19) Metering slots
(2) Signal oil passage (11) Passage (20) Chamber
(3) Head end (12) Passage (21) Passage
(4) Outlet passage (13) Passage (22) Load check valve
(5) Rod end (14) Pressure limiter valve (23) Spring
(9) Passage (18) Flow control valve
134 KENR8566
Flow Control Valve Pump oil also flows through inlet passage (17) to the
next control valve.
Flow control valve (18) limits the maximum flow of the
oil to the tilt circuit. As the oil flows from passage (21) Since all the valve spools are in the HOLD position,
to either rod end passage (5) or head end passage pump oil fills the parallel oil passages of the control
(3), the design of control valve spool (25) causes a valves. The pump maintains oil pressure at 3000 kPa
pressure drop. The left end of flow control valve (18) (435 psi). Passage (2), chamber (7), and resolver (10)
is at the same pressure as passage (21). The right are drained. Passages (3), (5) and (21) are blocked.
end of the flow control valve is at the same pressure
as either rod end passage (5) or head end passage
(3). As the flow increases from passage (21) through
control valve spool (25) to the cylinders, the pressure
differential between the left and the right ends of flow
control valve (18) increases. Flow control valve (18)
moves to the right against spring (15), closing off
metering slots (19) and reducing pump oil flow into
passage (21) through load check valve (22). The flow
control valve limits the flow of oil to the tilt cylinders at
80 L/min (21 US gpm).
Note: Different designs of the control valve stem that
are used in the various valves change the limits of the
maximum flow into the various cylinders.
Pressure Limiter Valve Operation

Pressure limiter valve (14) is used in the bulldozer tilt
control valve in order to limit the pressure to the tilt
circuit. The pressure setting of the pressure limiter
valve is 19300 ± 300 kPa (2800 ± 45 psi).
When the bulldozer tilt control valve is in an operating
position, cylinder oil flows through passage (2) and
(7). Then, the oil flows to resolver (10).
When the signal oil pressure in spring chamber (16)
reaches approximately 19300 kPa (2800 psi), the
spool in pressure limiter valve (14) moves from the
valve seat. Oil is sent through outlet passage (6) to
the tank.
The system oil causes flow control valve (18) to move
to the right. The flow of pump oil to the tilt circuit
decreases until the pressure of the cylinder oil
decreases.
Load Check Valve

Load check valve (22) prevents reverse oil flow in the
tilt cylinder which can cause cylinder drift or load loss.
The load check valve will not open until system
pressure in chamber (20) creates a force against load
check valve (23) that is higher than the opposing
force against the other side of the check valve. The
opposing force is the sum of the force of spring (24)
and the force that is created by the oil pressure in
passage (21).
Tilt Left
When the control valve spools are in the HOLD
position, pump oil flows to inlet passage (17). Oil
flows around the flow control valve (18) and oil flows
in metering slots (19). Oil through metering slots (19)
moves the flow control valve against spring (15).
KENR8566 135

136 KENR8566

TILT LEFT
(1) Spring (10) Resolver (19) Metering slots
(2) Signal oil passage (11) Passage (20) Chamber
(3) Head end (12) Passage (21) Passage
(4) Outlet passage (13) Passage (22) Load check valve
(5) Rod end (14) Pressure limiter valve (23) Spring
(9) Passage (18) Flow control valve
KENR8566 137

spool (25) to move to the TILT LEFT position,
passage (2) is opened to passage (3). Cylinder oil
from passage (3) flows through passage (2) to
chamber (7). The oil functions as signal oil. Part of the
signal oil flows to the spring chamber (16) behind flow
control valve (18). The rest of the signal oil flows
through resolver (10) to the inlet manifold and to the
The increase of pump oil flow to inlet passage (17)
flows through metering slots (19) into chamber (20).
The pump oil opens load check valve (22). The oil
flows through load check valve (22). The oil then
flows through passage (21) around control valve
spool (25) and out passage (3) to the head end of the
tilt cylinder. The tilt cylinder then tilts the bulldozer
blade to the left.
Return oil from the rod end of the tilt cylinder flows
through passage (5), around control valve spool (25)
and through outlet passage (6) to the oil tank.
hydraulic system. The use of the electrohydraulic
control group does not change the operation of the
bulldozer tilt control valve. Refer to Systems
Operation, “Pilot Hydraulic System” located in this
module for more information about the
electrohydraulic control group.
Tilt Right
The operation of the tilt control valve in the TILT
RIGHT position is like the operation of the tilt control
valve in the TILT LEFT position.
spool (25) to move to the TILT RIGHT position,
passage (2) is opened to passage (5). Cylinder oil
chamber (7). The oil functions as signal oil. Part of the
signal oil flows to spring chamber (16) behind flow
control valve (18). The rest of the signal oil flows
through resolver (10) to the inlet manifold and to the
flows through metering slots (19) into chamber (20).
The pump oil opens load check valve (22). The oil
flows through load check valve (22). The oil then
flows through passage (21) around control valve
spool (25) and out passage (5) to the rod end of the
tilt cylinder. The tilt cylinder then tilts the bulldozer
blade to the right.
Return oil from the head end of the tilt cylinder flows
through passage (3), around control valve spool (25)
and through outlet passage (24) to the oil tank.
138 KENR8566
i04001186
Ripper Lift Control Valve

SMCS Code: 5351
General Information

HOLD
(1) Shims (8) Chamber (15) Flow control valve
(2) Spring (9) Passage (16) Metering slots
(3) Signal oil passage (10) Resolver (17) Chamber
(4) Head end (11) Pressure limiter valve (18) Passage
(5) Outlet passage (12) Spring (19) Load check valve
(6) Rod end (13) Chamber (20) Outlet passage
(7) Outlet passage (14) Inlet passage (21) Control valve spool
KENR8566 139
When the machine is equipped with a bulldozer and

with a ripper, the ripper lift control valve is the fourth
valve in the valve stack. The ripper lift control valve
controls the raising and the lowering of the ripper. The
control valve is equipped with these components:
resolver (10), pressure limiter valve (11), load check
valve (19) and valve spool (21).
The ripper lift control valve is spring centered. Control
valve spool (21) is a closed center spool and a pilot
operated spool with three positions: RAISE, HOLD
and LOWER. Spring (2) keeps the valve spool in the
HOLD position when the ripper lift control valve is not
active. Movement of the spool is controlled by the
pilot control system. The pilot control system
connects the ripper control lever to valve spool (21).
Resolver (10) is a double check valve. The functions
of the resolver and of the control valve spool are
described in the sections on positions of the control
valve. The descriptions of the functions of pressure
limiter valve (11) and load check valve (19) are in the
following separate sections.
Load Check Valve

Load check valve (19) prevents reverse oil flow in the
ripper lift cylinders, which can cause cylinder drift or
load loss. The load check valve does not open until
pump oil pressure in passage (17) overcomes the
force of the spring for the load check valve and of the
cylinder oil pressure in passage (18).
Pressure Limiter Valve Operation

Pressure limiter valve (11) is used in the ripper lift
control valve in order to limit the pressure to the lift
circuit. The pressure setting of the pressure limiter
valve is 19300 ± 300 kPa (2800 ± 45 psi).
When the ripper lift control valve is in an operating
position, cylinder oil flows through passage (3) and
(8). Then, the oil flows to resolver (10).
When the signal oil pressure in spring chamber (13)
reaches approximately 19300 kPa (2800 psi), the
spool in pressure limiter valve (11) moves from the
valve seat. Oil is sent through outlet passage (7) to
the tank.
The signal oil causes flow control valve (15) to move
to the right. The flow of pump oil to the tilt circuit
decreases until the pressure of the cylinder oil
decreases.

When the control valve spools are in the HOLD
position, pump oil flows to inlet passage (14). This
passage is common to all sections of the valve stack
and this passage has no outlet. Since all the valve
spools are in the HOLD position, pump oil fills the
parallel oil passages of the control valves. The pump
maintains oil pressure at 3000 kPa (435 psi).
Passage (3), chamber (8), and resolver (10) are
drained. Passages (4), (6), and (18) are blocked.
140 KENR8566
KENR8566 141

RAISE
142 KENR8566

RAISE
(1) Shims (8) Chamber (15) Flow control valve
(2) Spring (9) Passage (16) Metering slots
(3) Signal oil passage (10) Resolver (17) Chamber
(4) Head end (11) Pressure limiter valve (18) Passage
(5) Outlet passage (12) Spring (19) Load check valve
(6) Rod end (13) Chamber (20) Outlet passage
(7) Outlet passage (14) Inlet passage (21) Control valve spool
KENR8566 143
When the pilot control pressure causes the valve

spool (21) to move to the RAISE position, cylinder oil
chamber (8). The oil functions as signal oil. The
signal oil opens resolver (10) and flows to the
previous control valve and to the inlet manifold.
opens load check valve (19). The oil flows through
load check valve (19), through passage (18), and
around valve spool (21). Then, the oil flows through
passage (4) to the head ends of the ripper lift
cylinders. The ripper lift cylinders then raise the
ripper.
Return oil from the rod ends of the ripper lift cylinders
flows through passage (6), around valve spool (21)
and through outlet passage (7) to the tank.
The operation of the ripper control valve in the
RIPPER LOWER position is like the operation of the
ripper control valve in the RIPPER RAISE position.
When the pilot control pressure causes valve spool
(21) to move to the LOWER position, cylinder oil from
passage (6) flows through passage (3) to chamber
(8). The oil functions as signal oil. The signal oil
opens resolver (10). The signal oil flows to the
previous control valve and to the inlet manifold.
opens load check valve (19). The oil flows through
load check valve (19). The oil then flows around valve
spool (21) and out passage (6) to the rod ends of the
ripper lift cylinders. The ripper lift cylinders then lower
the ripper.
Return oil from the head ends of the ripper lift
cylinders flows through passage (4), around valve
spool (21), and through outlet passage (20) to the
tank.
144 KENR8566
i02428404
Pressure Reducing Valve

SMCS Code: 4807; 5467-PS; 5467
(1) Valve Body (5) Port (T) (tank) (9) Check Valve
(2) Port (P) (Discharge from pump) (6) Port (CP) (pilot supply oil) (10) Screen
(3) Pressure Reducing Valve (7) Solenoid Valve for Implement Lockout
(4) Relief Valve (8) Port for Accumulator (ACC)
KENR8566 145
Refer to Testing and Adjusting, “Pressure Taps” for

the location of the pressure tap.
• Use the 164-0758 Bolt (9/16 inch by 18 by 2

inch) that is mounted behind the access plate on
the front of the right console to activate the valve
spool.
Lockout of the control levers is accomplished in the
following manner. Solenoid valve (7) operates the
shutoff valve that is in the manifold. The solenoid
valve (7) is energized when the machine is running.
When the solenoid valve is energized the shutoff
valve is moved to the UNLOCK position. Pilot supply
oil from the pressure reducing valve enters the shutoff
valve of the manifold. In the UNLOCK position, the
Illustration 109 g01213585 shutoff valve directs pilot supply oil to the pilot control
Location of manifold and reducing valve valve. In the LOCK position, the line from the
pressure reducing valve is blocked and the oil is
The manifold for the pressure reducing valve is diverted to the tank line. This allows the oil from the
located behind an access door on the right fender of pilot control valves to drain to the hydraulic tank.
the machine. The manifold for the pressure reducing When the switch is toggled to the LOCK position the
valve contains a pressure reducing valve (3), a relief solenoid valve is de-energized and spring force
valve (4), an accumulator port (8), a check valve (9), moves the shutoff valve to the LOCK position. Also, a
and screen (10). lamp on the instrument panel is activated.
The pressure reducing valve reduces the implement i02428087

hydraulic pressure to a maximum of 3275 ± 175 kPa
(475 ± 25 psi). Accumulator
A pump discharge line attaches at port (P). The SMCS Code: 5077
pressure reducing valve reduces the system pressure
to pilot supply pressure. The reduced pressure is
termed pilot supply oil. Pilot supply oil exits the
pressure reducing valve at port (CP). Next, the pilot
supply oil proceeds to the shutoff valve.
The pressure reducing valve is coupled with the
accumulator. The accumulator attaches to the
manifold at port (8). For more information about the
accumulator, refer to Systems Operation,
“Accumulator”.
The relief valve provides a secondary relief in case of
pressure spikes and over pressurization of the pilot
system. The check valve stops backflow of oil during
conditions of low pump discharge pressure.
The accumulator and the check valve maintain supply
pressure during momentary drops in pump pressure. Illustration 110 g01213553
This system will permit the attachment to be lowered Location of accumulator
up to 1.5 minutes after the engine is off.
The pilot accumulator is located behind an access
There are three methods of lowering attachments door on the right fender of the machine. The
after the engine has been off for 1.5 minutes. accumulator is attached to the top of the manifold and
reducing valve.
• Use the pilot control lever to lower the
attachments. You need to crank the engine in
order to operate the control lever.
• Use the 7H-1680 Compressor Assembly to

provide pilot pressure to the valve. Turn the shutoff
valve to the UNLOCK position. If the shutoff valve
is not in the UNLOCK position the oil will be
pumped to the hydraulic tank. Oil is applied
through the pressure tap for pilot supply after the
pressure reducing valve. The pressure tap is
located under an access plate on the right fender.
146 KENR8566
i02431169
Oil Cooler and Bypass Valve

SMCS Code: 5071

Accumulator
The accumulator stores potential energy by
accumulating a quantity of pressurized hydraulic fluid.
The pressurized fluid is stored in a bladder type
accumulator. A bladder that contains gas is located Illustration 112 g01214842
within the accumulator. The accumulator is charged (1) Oil cooler
to 1030 kPa (150 psi) with dry nitrogen. (2) Oil cooler (outlet)
(3) Inlet from oil cooler bypass valve
The pressurized hydraulic fluid enters the
accumulator and the fluid creates pressure within the
accumulator. Energy is stored as the bag that is
within the accumulator is compressed by the
hydraulic fluid. The pressurized hydraulic fluid that is
stored in the accumulator permits the operator to
lower the implements for a maximum of 1.5 minutes
after the engine is turned off.

Oil cooler bypass valve
(4) Outlet to the oil cooler
(5) Valve
(6) Spring
(7) Outlet to the tank
KENR8566 147
The oil cooler bypass valve is installed at the port for

the implement return oil that is located on the
hydraulic oil tank. When the implement or steering
circuits are active, the return oil flows through the
bypass valve. Valve (5) and spring (6) cause a back
pressure of approximately 270 kPa (39 psi). The
back pressure causes the flow of part of the return oil
through outlet (4) to the oil cooler. The larger part of
the return oil flows through outlet (7) to the tank. The
bypass valve opens quickly in order to relieve the
increases (surges) of flow of the return oil. The
bypass valve keeps pressure increases (spikes) from
the oil cooler. The oil that flows out of the oil cooler is
sent to the case of the implement pump and the
steering motor case in order to lubricate the pump
and the motor.
148 KENR8566
i02431005
SMCS Code: 5051; 5420

(1) Chamber (7) Valve port (right turn) (13) Passage
(2) Orifice (8) Passage (14) Crossover relief valve
(3) Check Valve (9) Check valve (15) Motor port (steering motor for right turn)
(4) Passage (10) Orifice (16) Motor port (steering motor for left turn)
(5) Valve port (left turn) (11) Chamber (17) Crossover relief valve
(6) Stem (12) Passages (18) Passage
KENR8566 149
counterbalance valve (motor port (15), passage (13),

and valve port (7) ) is restricted. The restricted oil flow
counteracts the feedback torque that drives the
steering motor. Now, the steering motor speed is
sustained close to the speed that is demanded by the
steering control valve.
Crossover relief valves (14) and (17) prevent damage
to the steering system from pressure increases
(spikes). These valves are pilot controlled relief
valves that open at approximately 41500 kPa
(6000 psi). When the crossover relief valves open,
the valves send oil to the opposite motor port.

Location of the counterbalance valve
The counterbalance valve is attached to the steering
motor. The steering motor is located below the
operator's station.
The counterbalance valve is used in order to keep the
steering motor under the operator's control during
overspeed steering load conditions. An overspeed
condition exists when the machine is working in
conditions that involve an underfoot side slope and
the fast track drawbar pull is lower than the slow
track. This decreased pull causes feedback torque
through the steering gears that are attempting to turn
the steering motor faster than the demand of the
steering control valve.
During a normal left turn, oil from the steering control
valve flows in valve port (5) and through stem (6) to
check valve (3). Oil also flows through passage (4),
around stem (6), and through orifice (2) into chamber
(1). Oil opens check valve (3) and the oil flows
through stem (6), through passage (18), and to motor
port (16). Oil then flows through the steering motor
and the oil turns the steering motor clockwise. Oil
through the motor flows to motor port (15). Motor port
(15) sends oil through passage (13) to check valve
(9). Oil at check valve (9) is temporarily blocked and
the pressure of the oil increases. When the oil
pressure reaches a threshold of approximately
7000 kPa (1015 psi), stem (6) moves to the right.
Now, oil in passage (13) flows through passages (12)
and through stem (6) to valve port (7) and to the tank.
As stem (6) moves to the right, oil in chamber (11) is
sent through orifice (10) to passage (8). Then, the oil
flows through valve port (7) to the tank. Once stem (6)
has moved approximately 2 mm (.08 inch), oil in
chamber (11) flows directly through passage (8) and
valve port (7) to the tank and the stem is allowed to
move faster to the right.
During overspeed conditions, feedback torque that
comes through the steering gears attempts to turn the
steering motor at a faster speed than the speed that
is necessary. This feedback causes reduced
pressure on the inlet side of the counterbalance valve
(valve port (5), passage (18), and motor port (16) ).
When the inlet pressure decreases lower than
threshold pressure, stem (6) moves to the left. The
flow of oil through the outlet side of the
150 KENR8566
i02430962
Steering Motor
SMCS Code: 4136; 5058

Steering motor
(1) Pivot pin (7) Head (13) Bearing
(2) Pistons (seven) (8) Passage (lubricating oil for the pivot pin) (14) Shims
(3) Case drain port (9) Retaining plate (15) Snap ring and shims
(4) Barrel (10) Shaft (16) Cover
(5) Port plate (11) Bearing
(6) Case (12) Ring
KENR8566 151
As shaft (10), pistons (2), and barrel (4) continue

rotation, the pistons reach the top center (full
retracted position). At the same time, the cylinder
begins to overlap the outlet control slot in port plate
(5). The piston begins to move downward. Because
the piston moves downward, the piston pushes oil out
of the cylinder, into the outlet control slot in port plate
(5), and through the outlet control slot in head (7). The
same oil is then pushed to the counterbalance valve,
to the steering control valve, and to the tank.
The ball end of pivot pin (1) is the pivot point for barrel
(4). Oil passage (8) provides lubricating oil to a drilled
passage in pivot pin (1). The oil then flows to pivot pin
(1). Then, the oil flows to the pivot pin socket, and on
through passages to bearings (11) and (13). The oil
Illustration 117 g01214588 drains from case (6) through port (3).
The steering motor is located between the i03960106

counterbalance valve and an adapter. The adapter is
attached to the frame below the operator's station.
Graphic Color Codes
The steering motor is a fixed displacement bent axis
motor of the piston type. The steering motor is SMCS Code: 5050
operated by oil from the variable displacement piston
pump. The steering motor can produce the same
amount of output torque in either direction.
Oil flow through the steering motor can be in either
direction. A change in the direction of oil flow causes
a change in the direction of rotation for barrel (4), for
pistons (2), and for shaft (10).
The following components are the parts of the motor
that turn: shaft (10), snap ring and shims (15),
retaining plate (9), pistons (2) and barrel (4). The
parts that do not turn are the following components:
head (7), case (6), port plate (5), shims (14), ring (12)
and cover (16).
Oil from the pump flows to the steering motor through
the steering control valve and through the
counterbalance valve. Then, oil flows through the
inlet control slot in head (7) to the inlet control slot in
port plate (5).
Note: The direction of rotation determines the inlet
and the outlet of the two slots in head (7). Likewise,
the direction of rotation determines the inlet and the
outlet of the two slots in port plate (5).
Oil through port plate (5) flows into the cylinders of
barrel (4) that are over the inlet control slot of port
plate (5).
The cylindrical ends of pistons (2) are held in sockets Illustration 118 g01861138
in shaft (10) by retaining plate (9). The sealed end of
pistons (2) are positioned in barrel (4). Barrel (4) (AA) Black ...................Mechanical connection or seal
rotates around pivot pin (1), which is at a fixed angle
of 40 degrees to the axis of shaft (10). (BB) Dark Gray .................................Cutaway section
Because the steering motor is a bent axis type motor,
seven pistons (2) move in and out of the cylinders as (CC) Light Gray ..............................Surface of the part
oil leaves the cylinders and as oil enters the cylinders.
The motion forces the pistons to rotate around pivot (DD) White ...............Atmosphere or air (no pressure)
pin (1). Rotation of the pistons forces shaft (10) and
barrel (4) to rotate. (EE) Purple .................................Pneumatic pressure
(FF) Yellow ..... Moving parts or activated components

152 KENR8566
(GG) Green ...........Tank oil, suction oil, return oil, and

case drain oil
(HH) Brown ...........................................Lubricating oil
(JJ) Green Stripes and White Stripes ..... Scavenge or

suction oil
(KK) Red ..........................................High pressure oil
(LL) Red Stripes and White Stripes ......... Signal (First

pressure reduction)
(MM) Red Crosshatch ..........Signal (Second pressure

reduction)
(NN) Pink ................Signal (Third pressure reduction)
(PP) Red and Pink Stripes .....Secondary source of oil

pressure
(RR) Orange ...... Pilot, charge, or torque converter oil
(SS) Orange Stripes and White Stripes ........Reduced

pilot, charge, or torque converter oil
(TT) Orange Crosshatch .....Second reduction in pilot,

charge, or torque converter oil
(UU) Blue .................................................. Trapped oil

Note: Write the color code term on the blank lines
next to the colored boxes for your use.
1
KENR8566
1 FOLDOUT(S)
KENR8566 155
Testing And Adjusting i02396681
Section Troubleshooting Procedures

SMCS Code: 5050; 7000
Testing and Adjusting General Procedure

1. Know the Machine.
Understand the operation of the machine. Know if
i03937353 the symptom is a characteristic of normal operation
or if the symptom is a failure.
Pressure Taps Read the information in the Systems Operation in
SMCS Code: 7000 your Service Manual in order to understand the
systems of the machine. You must understand the
interaction of the machine systems.
NOTICE
Do not connect or disconnect hose fittings to or from 2. Prepare the machine for troubleshooting.
the quick disconnect nipples when there is pressure
in the system. This will prevent damage to the seals Complete Testing and Adjusting, “Machine
that are in the fitting. Preparation (Implement and Steering Hydraulic
System)” in this module.
Locations 3. Identify the Symptoms.
a. You need to speak with the operator about the

symptom.
• Ask about the performance of the machine

prior to the failure.
• Determine the time of the first occurrence of

the symptoms.
• Determine the operating conditions at the

time of the failure.
• Ask the operator about the sequence of

events prior to the failure. Determine the
order of the occurrences.
• Ask the operator about the steps that have

been taken to troubleshoot the machine.
• Check the history of repairs of the machine.
• Ask about the preventive maintenance of

the machine.
The pressure taps are located behind an access
door on the right fender of the cab. b. Inspect the machine. Look for problems.
(1) Pilot supply pressure (CP) Notice any unusual odors in the air. Listen for
(2) Discharge pressure of the Implement pump (HA)
(3) Implement hydraulics (Scheduled oil sampling) (SOS)
unusual noises.
(4) Accumulator pressure (CPG)
(5) Signal pressure for the Implement pump at the compensator
Complete Testing and Adjusting, “Visual
valve (HB) Inspection” in this module.
If you complete the visual inspection and the
problem is not identified, follow Testing and
Adjusting, “Operation Checks” in this module.
156 KENR8566
If necessary, complete the appropriate Note: The monitoring system (if equipped) for your
component tests and adjustments in order to machine accesses many values that are useful in
help identify the problem. Refer to the table of troubleshooting the hydraulic system. When the
contents for a list of the tests and adjustments situation is appropriate, use the monitoring system in
for each component. order to find a pressure or determine a system
problem.
4. Troubleshoot using the description of the
symptom. Warnings
Refer to Testing and Adjusting, “Hydraulic System Refer to the following warnings and notices for all
Troubleshooting” in this module. inspections and test of the hydraulic system.
After the complaint is resolved, prepare the
machine for operation. Refer to the instructions in
the Operation and Maintenance Manual for your
machine. Sudden movement of the machine or release of
oil under pressure can cause serious injury to
i03416220 persons on or near the machine.
Machine Preparation To prevent possible injury, perform the procedure

that follows before testing and adjusting the hy-
SMCS Code: 7000 draulic system.
Note: During a diagnosis of the hydraulic system,

remember that correct oil flow, correct temperature,
and correct pressure are necessary for correct
operation. Hot hydraulic oil under high pressure can remain
in the components of the hydraulic system or the
General Information power train system after the engine has been
When you are defining a problem with the hydraulic stopped. The uncontrolled release of the hydraul-
system, the following procedure should be followed: ic oil can cause sudden machine movement and
can also result in the following conditions:
1. Prepare the machine for service.
• Burns
2. Perform the visual inspection.
• The penetration of body tissue
3. If the problem has not been identified, perform the
• Other personal injury
operational checks that apply to your machine.
• Death
4. Perform any applicable calibration procedures that
apply to your machine. If hydraulic oil penetrates body tissue, the injury
must be treated immediately by a doctor who is
5. If the problem is not fully understood, perform the familiar with this type of injury. Use a board or a
instrument tests. piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have
6. When the problem is defined, go to the been lowered to the ground and that all trapped
Troubleshooting Section. Troubleshooting pressure has been released from the hydraulic
system and the power train system. Also, make
information can be found either in this manual or in sure that the hydraulic oil is cool before the re-
a separate Troubleshooting manual for this moval of any components or lines. Remove the
machine. The Troubleshooting Section lists the hydraulic oil filler cap only when the engine is
probable causes of a known problem. As there stopped and the filler cap is cool enough to touch
may be more than one cause for a problem, the with your bare hand.
Troubleshooting information may suggest specific
inspections or instrument tests be done. These
inspections and tests help identify the most
probable causes of a problem. The list cannot give
all possible problems and corrections.
Locations of the pressure taps and of the components
are given in the Systems Operation portion of this
manual. Pressure taps are also identified in the
individual Test and Adjust procedures.
KENR8566 157
4. Engage the parking brake.
5. On Track-Type Tractors and Track-Type Loaders

Boom must be raised and lowered through its full
lower the attachments to the ground. On
arc to test the hydraulics.
Pipelayers make sure that there is not a load on
To avoid personal injury, perform this test in an the hook then fully retract the counterweight.
area with sufficient boom clearance especially
from electrical power line contact and that is free 6. Stop the engine.
of personnel. Prevent machine movement by ap-
plying the parking brake. 7. Turn the key to the ON position, but do not start the
engine.
8. Verify that the implement shutoff control is in the

UNLOCKED position.
Personal injury or death can result from not en-
gaging the parking brake. 9. Move the control levers through the full range of
travel several times. This will relieve any pressure
Transmission engagement alone will not prevent that may be present in the implement hydraulic
machine from rolling when the engine is stopped. system.
10. Loosen the filler cap on the hydraulic tank so that

the pressure in the tank is released. The machine
may be equipped with a breaker valve. The
Personal injury can result if the machine moves breaker valve will be located on top of the tank. To
while testing. release the pressure of the tank, press the button
If the machine begins to move during test, reduce on top of the breaker valve (if equipped).
the engine speed immediately and engage the
parking brake. 11. Tighten the filler cap on the hydraulic tank.
12. Make sure that the pressure in the entire hydraulic

NOTICE system has been released.
Care must be taken to ensure that fluids are con-
Reference: Refer to Troubleshooting for additional
tained during performance of inspection, mainte-
guidance for preparing the machine for testing.
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers Note: The monitoring system (if equipped) for your
before opening any compartment or disassembling machine accesses many values that are useful in
any component containing fluids. troubleshooting the hydraulic system. When the
situation is appropriate, use the monitoring system in
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies order to find a pressure or determine a system
suitable to collect and contain fluids on Caterpillar problem.
products.
Visual Inspection
Dispose of all fluids according to local regulations and
mandates. 1. Check all hydraulic oil line connections for damage
and for leaks.
Procedure 2. Follow all hydraulic oil lines from the attachment to

the valve. Check the lines and connections for
Before you troubleshoot, complete the following damage and for leaks.
procedure.
3. Check the control valves for leaks.
1. Move the machine to a smooth, horizontal location
that is away from operating machines and away 4. Check the connections on the pumps and motors
from personnel. (if equipped) for damage and for leaks.
2. Permit only one operator on the machine. Keep all 5. Follow the pump lines and the motor lines (if
other personnel away from the machine or in the equipped) to the tank and to the valves. Check for
operator's sight. damage and for leaks on the hydraulic lines and on
the hydraulic tank .
3. Place the steering control lever in the NEUTRAL
position. 6. Check the oil level in the tank.
158 KENR8566
7. Remove the filter element. Check for particles in • The oil level is at the FULL level in the sight
the filter elements. A magnet separates ferrous glass.
particles from nonferrous particles.
Results
If you find metal or rubber particles, all components of
the hydraulic oil system must be cleaned out. Always • OKAY: Proceed to “Check for Oil Leaks”.
replace damaged parts with new parts.
Check for Oil Leaks
i03939391
1. Inspect these components for leaks and for
Visual Inspection damage: oil lines, hoses and fittings.
SMCS Code: 7000 2. Look under the machine for oil that has leaked from
the machine onto the ground.
Expected Results
Personal injury can result from hydraulic oil pres-
sure and hot oil. • No leaks exist.
Hydraulic oil pressure can remain in the hydraulic Results

system after the engine has been stopped. Seri-
ous injury can be caused if this pressure is not re- • OKAY: Proceed to “Check the Electrical
leased before any service is done on the System”.
hydraulic system.
• NOT OKAY: Repair all leaks. Check the
Make sure all of the attachments have been low- machine for the original problem. If the
ered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the conditions are not resolved, proceed to “Check
engine is stopped, and the filler cap is cool the Electrical System”.
enough to touch with your bare hand.
Check the Electrical System
1. Inspect the wires and check the electrical

connectors to the component that is suspect.
Do not check for leaks with your hands. Pin hole
(very small) leaks can result in a high velocity oil Expected Results
stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal • The wires and the electrical connectors are not
injury. Use cardboard or paper to locate pin hole damaged. The electrical connectors are clean.
leaks.
Results
Implement System • OKAY: Proceed to “Check for Oil

Contamination”.
When you are troubleshooting a problem, a visual
inspection of the system is the first step. Turn the • NOT OKAY: Replace any damaged wires.
engine OFF before you inspect the machine. Lower Replace any damaged electrical connectors.
the implements to the ground. Place all controls in the Ensure that all of the seals are properly in
PARK or HOLD position. After performing the visual place. Check the machine for the original
inspection, check the operation of the machine and
note any unusual noises. problem. If the conditions are not resolved,
proceed to “Check for Oil Contamination”.
Check the Hydraulic Oil Tank Level
Check for Oil Contamination
1. Fill the hydraulic oil tank to the correct level in the
1. Use the 175-7546 Oil Filter Cutter Gp to cut open
sight glass.
spin-on filters in order to inspect the filter media for
Reference: Refer to the Operation and Maintenance contaminants.
Manual, “Hydraulic System Oil Level - Check” for your
machine. 2. Check the oil for air and for excessive particles. Air
in the oil causes the oil to foam. If particles are in
Expected Results the oil, the oil appears sandy.
KENR8566 159
3. Check the hydraulic oil by taking an oil sample from Problem List for the Hydraulic Oil
the S·O·S Sampling Valve next to the pressure
reducing valve. • “The Temperature of the Oil is Too High”
Reference: Refer to Operation and Maintenance • “The Machine Has Harsh Steering and the
Manual, “Hydraulic System Oil Sample - Obtain” for Hydraulic Cylinders Move Roughly”
your machine.
• “The Hydraulic Oil Contains a Large Amount of Air”
Check for Particles in the Oil • “The Hydraulic System is Losing Oil”
1. Shiny steel particles indicate a pump failure. • “One or More of the Control Levers Moves when
another Control Lever Is Operated.”
2. Rubber particles indicate a seal failure or hose
• “A Pause Occurs in the Increase to Full Pressure
failure. in the Circuits.”
3. If metal particles or rubber particles are found, then
all components of the implement, steering, and fan The Temperature of the Oil is Too
systems must be washed. High
4. Replace all damaged parts with new parts. Probable Causes
Reference: Refer to Disassembly and Assembly in 1. The oil cooler core is plugged or air flow over the
the Service Manual for your machine. core is low.
Expected Results 2. The viscosity of the oil is wrong.
• The original problem is resolved. 3. The oil level is low.
Results 4. The oil contains air.
• OKAY: Stop. 5. The pressure setting on the oil cooler bypass valve
is suspect and the valve is providing low flow to the
• NOT OKAY: The cause of the problem is oil cooler.
uncertain. Please call technical support with the
6. Outside air temperature is too high.
information that has been gathered.
7. A control valve spool is partially shifted.
i02397296
8. The settings on the crossover relief/makeup valves
Hydraulic System on the steering pump are too low.
Troubleshooting 9. The setting on the main relief valve in the inlet
SMCS Code: 5050 manifold is too low.
10. The pressure cutoff setting for the pump is too
Problem Checklist high.
This story contains the following troubleshooting
information: 11. An oil passage in an active hydraulic circuit is
restricted.
• Problems with the Hydraulic Oil
12. The setting for the margin pressure of the
• Problems with the Steering System Components implement pump is too high.
• Problems with the Implement System Components 13. The pump or the steering motor has wear.
The Machine Has Harsh Steering

and the Hydraulic Cylinders Move
Roughly
Probable Causes
1. The viscosity of the oil is wrong.
160 KENR8566
2. The pump has too much wear. The steering motor

has too much wear. 3. There is a restriction in the orifice in the flow control
valve.
3. The oil level is low.
4. The oil has been aerated, because a loose Problem List for the Steering
connection or restriction exists on the inlet side of System Components
either the steering charge pump or the implement
pump. • “The Machine Pauses Before the Machine Starts
to Steer”
5. The hydraulic cylinders and the hydraulic lines are
• “The Steering Speed is Slow in Both Directions
not properly purged of air. and Oil Output of the Pump is Low”
The Hydraulic Oil Contains a Large • “The Machine Has Low Turning Force in Both
Amount of Air Directions and the Output Pressure of the Pump is
Low in Both Directions”
Probable Causes
• “The Machine Has Low Turning Force in One
1. The oil line from the hydraulic tank to the Direction and the Pressure Output of the Pump is
implement pump is leaking. Low in One Direction”
2. The procedure to bleed the air from the hydraulic • “The Machine Will Not Turn in Either Direction”
system was not completed correctly.
• “The Pump Remains at NEUTRAL in One
3. The main relief valve in the inlet manifold is Direction and the Machine Does Not Turn in One
unstable. Direction”
4. The oil level is too low. • “Pump Pressures in NEUTRAL Are Too High or
Too Low”
5. The hydraulic tank has a broken baffle.
• “Steering Speed Changes with a Step or Steering
The Hydraulic System is Losing Oil Modulation is Poor”
Probable Causes • “The Steering is Jerky or Unstable”

1. A hydraulic hose or fitting is leaking. • “The Machine Continues to Turn When the
Steering Control Lever is Returned to NEUTRAL”
2. The cylinder rod seals have excessive leakage.
• “The Pressure or the Flow From the Pump is Low”
3. The seal on the pump shaft is leaking excessively.
• “The Machine Will Not Turn or the Steering Radius
4. The steering motor shaft seal is leaking is Very Large”
excessively.
• “The Turning Radius is Too Large in Both
One or More of the Control Levers Directions”
Moves when another Control Lever • “The Turning Radius is Too Large in One Direction”
Is Operated. The Machine Pauses Before the
1. The plug is missing in the end of a control valve Machine Starts to Steer
spool.
Probable Causes
2. The drain holes in the end cover of the valve stack 1. The hydraulic oil is too thick or the type of oil is
are misaligned. The drain holes do not intersect. incorrect.
A Pause Occurs in the Increase to 2. Steering charge pressure or flow is low.
Full Pressure in the Circuits. 3. The pump controls are suspect.
1. The hydraulic circuit for the signal oil contains air.
4. The orifice in the pump control is partially blocked.
2. The setting for the margin spool in the pressure
and flow compensator valve is too low. Refer to 5. The NEUTRAL setting for the pump is improperly
Testing and Adjusting, “Pump Control Valve adjusted.
(Steering) - Adjust”.
KENR8566 161
The Steering Speed is Slow in Both 2. Both pressure settings of the crossover relief/
Directions and Oil Output of the makeup valves are low or the valves are suspect.
Pump is Low 3. The pump or the steering motor has too much
wear.
Probable Causes
1. The steering control linkage is not correctly The Machine Has Low Turning
adjusted. Refer to Testing and Adjusting, “Steering Force in One Direction and the
Checks”. Pressure Output of the Pump is
2. The setting for the margin spool in the pressure Low in One Direction
and flow compensator valve is too low, or the spool
Probable Causes
is stuck. Refer to Testing and Adjusting, “Pump
Control Valve (Steering) - Adjust”. 1. One pressure setting of a crossover relief/makeup
valve is low or the valve is suspect.
3. The crossover relief valves are damaged or stuck
open. The crossover relief valves have seals which 2. The pump or the steering motor has excessive
are failing. The crossover relief valves have relief wear or excessive leakage.
settings which are too low. Refer to Testing and
Adjusting, “Main Relief Valve and Crossover Relief The Machine Will Not Turn in Either
Valve - Test”. Direction
4. The main relief valve is stuck open. The seals of Probable Causes
the main relief valve are failing. The relief setting is
too low. Refer to Testing and Adjusting, “Main 1. The steering control linkage is not correctly
Relief Valve and Crossover Relief Valve - Test”. adjusted. Refer to Testing and Adjusting, “Steering
Checks”.
5. A makeup valve in the steering control valve is
stuck open. A makeup valve has seals which are 2. The pump pressure or flow is low.
failing.
3. The pump cutoff valve is suspect.
6. The signal line orifice to the pump has a restriction.
4. The pump or the steering motor has failed.
7. The signal circuit is leaking internally. Check the
5. The steering differential has mechanical damage.
following causes for leakage.
6. The pump or the steering motor is loose. The pump
a. The shuttle valve is stuck or the seals of the
or the steering motor has backed out of the drive
shuttle valve are failing.
splines.
b. The seals of the flow control valve are failing.
7. The pump is not developing pressure for steering
c. The plug in the end of the control valve spool requirements. Check these causes for the lack of
for the steering control valve is leaking. pump output.
8. The setting is too low in the pressure cutoff spool of a. A line in the circuit for signal oil is damaged.
the counterbalance valve. Refer to Testing and
b. The shuttle valve is stuck or the seals of the
Adjusting, “Pump Control Valve (Steering) -
Adjust”.
c. The seals of the flow control valve are failing.
9. The pump or the steering motor have excessive
internal leakage. d. The plug in the end of the control valve spool
for the steering control valve is leaking.
The Machine Has Low Turning
Force in Both Directions and the e. The orifice for signal oil for steering is plugged.
Output Pressure of the Pump is f. The main relief valve is stuck open. The seals
Low in Both Directions of the main relief valve are failing. The relief
setting is too low. Refer to Testing and
Probable Causes
Adjusting, “Main Relief Valve and Crossover
1. The cutoff pressure setting for the pump is too low. Relief Valve - Test”.
162 KENR8566
2. The hydraulic oil is too thick or the oil is the wrong

g. The margin spool, the pressure cutoff spool, or type. Warm the oil to operating temperature.
the piston in the pressure cutoff spool is stuck.
The Machine Continues to Turn
h. The relief valve setting for the crossover valve
is too low, or the seals are failing in the
When the Steering Control Lever is
crossover valve. Refer to Testing and Returned to NEUTRAL
Adjusting, “Main Relief Valve and Crossover Probable Causes
Relief Valve - Test”.
1. The steering control linkage is loose. The steering
8. The parking brake is not releasing. Check the control linkage is not correctly adjusted. Refer to
following causes: Testing and Adjusting, “Steering Checks”.
a. The wiring has a fault. 2. The steering control valve spool is sticking.
b. The brake valve spool is stuck. 3. The pump control is suspect. Check these causes:
c. The brake valve has excessive internal a. A spring in the pump control is broken.
leakage.
b. The valve spool for the pump is sticking.
The Pump Remains at NEUTRAL in
One Direction and the Machine 4. The pump has failed.
Does Not Turn in One Direction The Pressure or the Flow From the
Probable Causes Pump is Low
1. The pump controls in the pump are suspect. Probable Causes
2. The steering pump controls have excessive 1. The oil level in the hydraulic tank is too low.
leakage.
2. The pump inlet or the suction line is blocked or
Pump Pressures in NEUTRAL Are crushed.
Too High or Too Low 3. The pump has failed or the pump is worn.
Probable Causes 4. The pressure control valve is suspect or the valve
setting is too low.
1. The pressure setting of the charging valve for
steering is too high or too low. The Machine Will Not Turn or the
2. The setting for the pressure control valve for Steering Radius is Very Large
steering is low.
Reference: Refer to Testing and Adjusting,
Steering Speed Changes with a “Operational Checks” in this module for information
about the cycle time test and the drift tests.
Step or Steering Modulation is Poor
The operational tests can be used to find leakage in
Probable Causes the system. The operational tests can find a valve
that is failing. The operational tests can also find a
1. The hydraulic oil is too thick or the oil is the wrong pump or a motor that is failing. The speed of rod
type. Warm the oil to operating temperature. movement of the cylinders (cycle time) is a measure
of the condition of the cylinders and the pump.
2. The steering supply flow is partially blocked.
Probable Causes
3. The pump control is suspect or the control needs
1. The oil level in the hydraulic tank is low.
adjustment.
2. The pump or the steering motor has failed.
The Steering is Jerky or Unstable
3. The parking brake is ON. Check the following
Probable Causes
causes:
1. The pump cutoff valve and the crossover relief/
a. The oil pressure in the power train is low.
makeup valves have an undesirable interaction.
KENR8566 163
b. The brake valve has excessive internal b. The pump controls are misadjusted or
leakage. damaged.
4. A mechanical problem in the drive train is c. The pump is worn or failed.

interfering with the steering.
3. The steering motor is malfunctioning. Check the
The Turning Radius is Too Large in following causes:
Both Directions a. The steering motor is worn or failed.
Probable Causes
b. The pressure control valve is suspect.
1. The system pressure in the steering circuit is low.
Check the following causes: Problem List for the Implement
System Components
a. The pump is faulty or worn. See Step 2.
• “The Response of One Implement Is Too Slow”
b. The bypass valve is suspect.
• “All Implement Cycle Times Are Too Slow”
c. The pressure control valve is set too low.
• “The Implement Droops When the Control Lever Is
d. The pressure control valve has excessive Moved From HOLD to LIFT”
leakage.
• “The Implement Drift Is Excessive”
e. The steering motor is failing. See Step 3.
• “All Implement Circuits Are Unstable”
2. The pump is malfunctioning. Check the following
• “Implement Cycle Times Are Too Fast”
causes:
a. The crossover relief/makeup valve is leaking • “The Bulldozer Blade Has an Excessive Pause at
Ground Level When You Lower the Blade”
excessively.
• “The Pump Does Not Return to Standby Pressure
b. The pump controls are misadjusted or After the Implement Is Used”
damaged.
• “The Bulldozer Blade Has Too Little Travel Before
c. The stops are incorrect or worn. the Quick-Drop Valve Is Activated for the D6R
Series IIITrack-Type Tractor ”
3. The steering motor is malfunctioning. Check the
following causes: • “The Bulldozer Blade Has Too Much Travel Before
the Quick-Drop Valve Is Activated for the D6R
a. The steering motor is worn or failed. Series IIITrack-Type Tractor ”
b. The pressure control valve is suspect. • “The Ripper Does Not Function Properly”
The Turning Radius is Too Large in • “The Hydraulic Circuits Have Weak Response”
One Direction The Response of One Implement Is
Probable Causes Too Slow
1. The system pressure in the steering circuit is low. Probable Causes
Check the following causes:
1. The valve spool in the control valve is not correctly
a. The pressure control valve has excessive centered. A spring is broken. The control valve
leakage. spool is sticking.
b. The pump or the steering motor is failing. See 2. The implement valve spool does not fully shift.
Steps 2 and 3.
3. Cylinder piston seals are failing in the affected
2. The steering pump is malfunctioning. Check the circuit.
following causes:
4. Makeup valve seals are failing in the affected
a. The crossover relief/makeup valve is leaking. circuit or the makeup valve has internal leakage.
164 KENR8566
5. The quick-drop valve for the lift cylinder is leaking. 1. The valve spool in the control valve is not correctly
The bypass valves in the piston heads are leaking. centered. The problem is caused by the following
causes:
6. The wrong control valve for the implement is
installed in the valve stack. a. The spring on the valve spool is broken.
7. The control valve is suspect. b. The valve spool is sticking.
8. The shuttle valve is stuck or a seal is failed. 2. The cylinder piston seals are leaking excessively.
All Implement Cycle Times Are Too 3. The makeup valve has excessive leakage or the
Slow makeup valve seals have failed.
Probable Causes 4. The quick-drop valve or the end stroke bypass

valves are leaking excessively.
1. The setting for the margin spool in the pressure
and flow compensator valve is too low. Refer to 5. The control valve has too much wear.
Testing and Adjusting, “Pump Control Valve
(Steering) - Adjust”. All Implement Circuits Are Unstable
2. The circuit for signal oil has internal leakage or Probable Causes
internal blockage. Check the following causes for 1. The hydraulic oil is too thick or the oil is the wrong
leakage or for blockage. type. Warm the oil to operating temperature.
a. The shuttle valve is stuck or the seals of the 2. The hydraulic pump is suspect.
3. The oil contains air or air is trapped in a signal line.
b. The seals of the flow control valve are failing.
Implement Cycle Times Are Too
c. The plug in the end of a control valve spool for
an implement control valve is leaking. Fast
Probable Causes
d. The pressure limiter valve is leaking or the
seals of the pressure limiter valve are failing. 1. The setting for the margin spool in the pressure
and flow compensator valve is too high. Refer to
3. The pump control is suspect. Testing and Adjusting, “Pump Control Valve
(Steering) - Adjust”.
4. The pump is not operating at full stroke.
2. Flow control valves are failing.
5. The diameter of the hoses or the fittings are
incorrect. 3. The wrong control valve spools are installed.
The Implement Droops When the The Bulldozer Blade Has an
Control Lever Is Moved From HOLD Excessive Pause at Ground Level
to LIFT When You Lower the Blade
Probable Causes Probable Causes
1. The load check valve is not closing. The problem is 1. The quick-drop valve is not operating correctly.
caused by the following causes:
2. The makeup valve is stuck open.
a. The spring in the load check valve is weak or
broken. 3. A hydraulic line is blocked.
b. The load check valve has dirt or debris. The Pump Does Not Return to
c. The valve seat in the load check valve is Standby Pressure After the
suspect. Implement Is Used
The Implement Drift Is Excessive Probable Causes
Probable Causes 1. The hydraulic pump or the pump compensator
valve is suspect.
KENR8566 165
The Bulldozer Blade Has Too Little 6. The pump or the implement circuits have excessive
Travel Before the Quick-Drop Valve internal leakage.
Is Activated for the D6R Series 7. The makeup valve is stuck open.
IIITrack-Type Tractor 8. The pressure setting of the main relief valve is
Probable Causes wrong or the relief valve is suspect.
1. The springs in the quick-drop valve have the wrong i03939429

number of shims.
2. The orifice sleeve in the quick-drop valve is the Operation Checks
wrong diameter. SMCS Code: 5050
3. The quick-drop valve has a weak spring.
The Bulldozer Blade Has Too Much

Do not check for leaks with your hands. Pin hole
Travel Before the Quick-Drop Valve (very small) leaks can result in a high velocity oil
Is Activated for the D6R Series stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal
IIITrack-Type Tractor injury. Use cardboard or paper to locate pin hole
leaks.
Probable Causes
1. The orifice sleeve in the quick-drop valve is
missing or suspect. Introduction
The operation checks can be used to find leakage in
2. The quick-drop valve has a wrong spring or the the system. The operation checks can find a valve
quick-drop valve has too many shims. that is failing. The operation checks can also find a
pump or a motor that is failing. The speed of rod
3. The orifices or the passages in the valve spool of movement of the cylinders is a measure of the
the quick-drop valve are plugged with debris. condition of the cylinders and the pump.
4. The valve spool of the quick-drop valve is stuck or Machine Preparation

the quick-drop valve is jammed with debris.
1. Move the machine to a smooth horizontal location.
The Ripper Does Not Function 2. Permit only one operator on the machine. Keep all
Properly other personnel away from the machine or in the
sight of the operator.
Probable Causes
1. A control valve spool is stuck or a control valve 3. Place the steering control lever in the NEUTRAL
spool is damaged. Check both the ripper lift control position.
valve and the ripper tip control valve.
2. A spring on a control valve spool is broken.
5. Lower the attachments to the ground.
The Hydraulic Circuits Have Weak 6. Stop the engine.
Response
7. Turn the key to the ON position, but do not start the
Probable Causes engine.
1. The signal line is blocked. 8. Verify that the implement shutoff control is in the
2. The pressure control valve is sticking. UNLOCKED position .
3. The pressure setting of the pump compensator 9. Move the control levers through the full range of
valve is low. travel several times. This procedure should relieve
any pressure that may be present in the implement
4. A spring in the pump control is broken. hydraulic system.
5. The pump is failing.

166 KENR8566
10. Loosen the filler cap on the hydraulic tank so that The oil in the hydraulic system must be SAE 10 at a
the pressure in the tank is released. The machine temperature of 75° ± 3°C (167° ± 5°F) in order to get
may be equipped with a breaker valve. The the correct results.
breaker valve will be located on top of the tank. To If, test results match the table the circuit is normal.
release the pressure of the tank, press the button Check the relief valve for the correct opening
on top of the breaker valve (if equipped). pressure. See Testing and Adjusting, “Main Relief
Valve and Crossover Relief Valve - Test” in this
11. Tighten the filler cap on the hydraulic tank. module for the correct setting.
If only one of the cycle times is slow, check that circuit
12. Make sure that the pressure in the entire hydraulic for cylinder drift.
system has been released.
Table 57
13. Turn the key to the OFF position. Cycle Times
Reference: Refer to Troubleshooting for additional Bulldozer Lift Cylinder Time in Seconds
guidance for preparing the machine for testing. Move the blade from the ground to the fully
2.5
raised position.
14. Raise and lower the blade and the ripper several
times. Operate the tilt control valve until the tilt
Table 58
cylinder is fully extended and retracted several
Cycle Times
times.
Bulldozer Tilt Cylinder Time in Seconds
15. Watch the cylinders as the cylinders are extended
and retracted. Movement must be smooth and Move the bulldozer blade from TILT RIGHT to
1.7
regular. TILT LEFT.
Move the bulldozer blade from TILT LEFT to
16. Listen for noise from the pump. 1.4
TILT RIGHT.
17. Listen for the sound of the operation of the Table 59

pressure limiter valves. The pressure settings of
Cycle Times
the pressure limiter valves are listed in Testing and
Adjusting, “Pressure Limiter Valve - Test”Testing Ripper Lift Cylinder Time in Seconds
and Adjusting, Pressure Limiter Valve - Test.
Move the ripper to the fully raised position from
1.8
the fully lowered position.
Tests for Cycle Times
Check these items if the cycle time is not correct.
1. Check the adjustment of the controls.

Hydraulic oil pressure can remain in the hydraulic
system on this machine after the engine and Reference: Refer to Specifications, “Hydraulic
pump have been stopped. Serious injury can re- System” in this manual.
sult if this pressure is not released before any
service is done on the hydraulic systems. In order 2. Check pump efficiency.
to prevent possible injury, release the hydraulic
system pressure before working on any fitting, 3. Check the setting of the relief valve.
hose, or hydraulic component.
4. Check the cylinders for leakage.
Lower all attachments to the ground before serv-
ice is started. If the hydraulic system must be 5. Check the makeup valves for leakage.
serviced, tested, or adjusted with the attachment
in the raised position, the attachments and lift cyl- 6. Check the pressure limiter valve.
inders must be supported properly.
7. The valve spools in the bulldozer control valves
Always move the machine to a location away from and in the ripper control valve could be worn.
the travel of other machines. Be sure that other
personnel are not near the machine when the en-
gine is running and tests or adjustments are
being made.
All tests for cycle times are performed with the engine
at high idle.
KENR8566 167
Drift Tests for Bulldozer Lift Drift Tests for Bulldozer Tilt
Cylinders Cylinder
Table 60 Table 62
Lift Cylinder Drift Tilt Cylinder Drift
28° to 48°C 49° to 68°C 69° to 88°C 49° to 66°C Above

38°C
Oil Temperature (82° to 119° (120 to 155° (156° to Oil Temperature (120° to 150° 66°C
(100°F)
F) F) 190°F) F) (150°F)
Minutes until maximum Minutes until maximum

permissible drift of 5.0 2.7 1.7 permissible drift of 5.0 2.7 1.7
38.0 mm (1.50 inch) 11.2 mm (0.44 inch)
Test
Tests
1. Raise the front of the machine off the ground by
lowering a level blade. Put the control lever in the 1. Position the blade flat on the ground. Raise the
HOLD position. Shut off the engine and watch the front of the machine off the ground by lowering the
lift cylinder rods for movement. right side of the blade to the TILT RIGHT position.
Put the tilt control lever in the HOLD position. Shut
2. Raise the front of the machine off the ground by off the engine. Watch the tilt cylinder rod for
lowering a level blade. Shut off the engine. Hold movement.
the lift control lever in the LOWER position. Watch
the lift cylinder rods for movement. 2. Position the blade flat on the ground. Raise the
front of the machine off the ground by lowering the
3. Raise the blade off the ground. Put the control right side of the blade to the TILT RIGHT position.
lever in the HOLD position. Shut off the engine and Hold the tilt control lever in the TILT RIGHT
watch the lift cylinder rods for movement. position. Shut off the engine. Watch the tilt cylinder
for movement.
4. Raise the blade off the ground. Shut off the engine.
Hold the lift control lever in the RAISE position. 3. Position the blade flat on the ground. Raise the
Watch the lift cylinder rod for movement. front of the machine off the ground by lowering the
left side of the blade to the TILT LEFT position. Put
Results the tilt control lever in the HOLD position. Shut off
Table 61
the engine. Watch the tilt cylinder rod for
Lift Cylinder movement.
Test Results Most Probable Causes(1) 4. Position the blade flat on the ground. Raise the
The makeup valve in the lift cir- front of the machine off the ground by lowering the
Drifting occurs in Tests 1 and 2.
cuit leaks in the head ends. left side of the blade to the TILT LEFT position.
Leakage between the spool and Hold the tilt control lever in the TILT LEFT position.
Drifting occurs in Tests 1 and 3. the body of the bulldozer lift con- Shut off the engine. Watch the tilt cylinder for
trol valve movement.
Leakage between the pistons Table 63
and the cylinders Tilt Cylinder
Drifting occurs in Tests 1, 2, 3
The valves in the cylinder pis-
and 4. Test Results Most Probable Causes(1)
tons are failing.
The quick-drop valve is leaking.
Excessive drift occurs in Tests 1 Leakage between the spool and
The load check valve or the flow and 3. the body of the control valve
Drifting occurs in Tests 2 and 4. control valve in the lift circuit is
Leakage between the piston
leaking.
Excessive drift occurs in Tests 2 and the tilt cylinder
(1) Note that an O-ring seal failure in the circuit will have the same and 4. Leakage in the load check valve
effect as a major component failure. of the tilt circuit
(1) Note that an O-ring seal failure in the circuit will have the same
effect as a major component failure.
168 KENR8566
Drift Tests for Ripper Lift Cylinder 1. Move the machine to an open area that is flat and
Table 64
dry. The ground conditions must limit the amount of
track slip when the machine is turning. Check that
Drift of the Ripper Lift Cylinder
the steering linkage is correctly adjusted.
49° to 66°C
Above 66°C
Oil Temperature 38°C (100°F) (120° to 150° 2. Start and run the machine at high idle. Raise all of
(150°F)
F) the implements to a full RAISE position.
Minutes until maxi-
3. Release the parking brake. Put the transmission in
mum permissible
drift of 9.6 mm
5.0 2.7 1.7 FIRST SPEED FORWARD.
(0.38 inch)
4. Move the tiller handle to the full STEER LEFT
POSITION.
Tests 5. Make a full turn of 360 degrees.
1. Raise the ripper off the ground. Put the control 6. Stop the machine after the full turn. Lower all of the
lever in the HOLD position. Shut off the engine and implements to the ground. Stop the engine.
watch the ripper cylinder rod drift.
2. Raise the ripper off the ground. Shut off the engine.
Move the ripper lift control lever to the RAISE
position. Watch the ripper cylinder rod drift.
Table 65
Test Results Most Probable Causes(1)
Leakage between the spool and

Excessive drift occurs in Test 1.
the body of the control valve
Leakage between the pistons

and the cylinders
Excessive drift occurs in Test 2.
Leakage in the load check valve
of the ripper circuit
(1) Note that an O-ring seal failure in the circuit will have the same
effect as a major component failure.
Steering Checks

Steering check
Personal injury or death can result from sudden
machine movement. (A) Diameter of the turn
Sudden movement of the machine can cause in- 7. Measure distance (A). See Illustration 121 .
jury to persons on or near the machine. Distance (A) should be 1.8 to 2.3 m (5.9 to 7.5 ft).
To prevent injury or death, make sure that the area
around the machine is clear of personnel and ob- 8. Do Steps 1 through 7 again with the tiller handle in
structions before operating the machine. the full STEER RIGHT POSITION.
9. Do Steps 1 through 6 again with the tiller handle in
Steering checks indicate when the operation of the the full STEER RIGHT POSITION and in the full
steering circuit is normal. The sprocket speed checks STEER LEFT POSITION. Hold the bulldozer
and the steering turn checks will give an indication of control lever in the full RAISE position.
steering circuit problems.
10. Measure distance (A). See Illustration 121 .
Steering Turn Diameter Check Distance (A) should be 4.8 to 6.0 m (16 to 20 ft).
Test Results
KENR8566 169
If distance (A) is too long after Steps 1 through 8, 7. Move the tiller handle to the full STEER LEFT
check the steering linkage, the implement hydraulic POSITION. Do Steps 5 and 6 again. The sum of
pump, the steering motor, the steering control valve, the speeds between the left sprocket and the right
and the counterbalance valve for correct operation.
sprocket should be 22.5 ± 1.1 rpm.
If distance (A) is too long after Steps 9 through 10,
check the priority flow control valve in the steering 8. When the checks, the tests and any needed
control valve. adjustments are completed, stop the engine.
Remove all test equipment. Connect the track.
If a problem is indicated by the checks, use the
Testing and Adjusting, “Steering Hydraulic Circuit - Results
Test”Testing and Adjusting, Steering Hydraulic Circuit
- Test in order to determine the specific problem. If the sprocket speeds are not within the tolerances,
check the component operation: hydraulic pump,
steering motor, control valve and counterbalance
Sprocket Speed Difference valve.
Test If Step 6 is low, check these causes: engine speed,
leaks in the signal circuit and the priority flow control
Note: This check should be done primarily after valve in the steering control valve.
machine repair or machine rebuilding.
If Step 6 is high, check the adjustments of the priority
1. Move the machine to a clear area that is level. flow control valve and the pressure and flow
Lower the implements to the ground. Stop the compensator valve on the pump.
engine. If a problem is indicated by the checks, use the
Testing and Adjusting, “Steering Hydraulic Circuit -
2. Separate the tracks. Remove the tracks from the Test”Testing and Adjusting, Steering Hydraulic Circuit
sprockets on the final drives. - Test in order to determine the specific problem.
Reference: Disassembly and Assembly,
RENR8173, “D6R Series III Track-Type Tractor
Power Train”
3. Before you do the checks, make sure that the
steering linkage is correctly adjusted. Mark the
sprockets of both final drives in order to count the
revolutions during the checks.
4. Start the engine. Run the engine at high idle.
5. Release the parking brake. Move the tiller handle

to the stop in the STEER RIGHT position. Keep
the transmission to the NEUTRAL position.
6. This step checks the oil flow through the steering

system. Use a stopwatch to accurately count the
number of revolutions per minute of each sprocket.
Add the rpm of the right sprocket to the rpm of the
left sprocket. The sum of the rpm of the left
sprocket and the right sprocket should be 22.5 ±
1.1 rpm.
Example
Table 66
A Check of the Sprocket Speeds for Steering Oil Flow
Rpm of left sprocket 12.5 rpm
Add rpm of right sprocket. + 10.5 rpm
Sum of the rpm of the sprockets = 23.0 rpm

170 KENR8566
Worksheet
Table 67
Worksheet
Date Product
Item Specification Actual
Cycle Time
Oil Temperature 75° ± 3°C (167° ± 5°F)
Move the blade from the

ground to the fully raised 2.5
position.
Move the bulldozer blade

from TILT RIGHT to TILT 1.7
LEFT.
Move the bulldozer blade
from TILT LEFT to TILT 1.4
RIGHT.
Move the ripper to the fully
raised position from the fully 1.8
lowered position.
Drift Test
69° to 88°C
Oil Temperature 28° to 48°C (82° to 119°F) 49° to 68°C (120 to 155°F)
(156° to 190°F)
Minutes until maximum per-

missible drift of 38.0 mm
5.0 2.7 1.7
(1.50 inch) in the lift
cylinders

missible drift of 11.2 mm 5.0 2.7 1.7
(0.44 inch) in the tilt cylinder

missible drift of 9.6 mm
5.0 2.7 1.7
(0.38 inch) in the ripper lift
cylinder
Steering Turn Diameter
Full STEER LEFT

1.8 to 2.3 m (5.9 to 7.5 ft)
POSITION
Full STEER RIGHT
1.8 to 2.3 m (5.9 to 7.5 ft)
POSITION
Full STEER LEFT POSI-
TION with bulldozer control
4.8 to 6.0 m (16 to 20 ft)
lever in the full RAISE
position
Full STEER RIGHT POSI-

TION with bulldozer control
4.8 to 6.0 m (16 to 20 ft)
lever in the full RAISE
position
Sprocket Speed
Rpm of left sprocket
Rpm of right sprocket +
Sum of the rpm of the

22.5 ± 1.1 rpm =
sprockets
KENR8566 171
i03909175 Table 68
Required Tools
Steering Hydraulic Circuit -
Tool Item Part No Description Qty
Test
Digital Pressure Indicator
SMCS Code: 4300-081 B 198-4240
Gp
B1 198-4234 Digital Indicator 1
Pressure Sensor Gp
Personal injury or death can result from sudden 0 to 41,368 kPa (0 to 6,000
B2 198-4239 2
machine movement. psi)
Sudden movement of the machine or release of

oil under pressure can cause injury to persons on B3 198-4236 Adapter Cable As 2
or near the machine.
Pressure Differential Tool
D 1U-5796
To help prevent possible injury, perform the pro- Gp
cedure that follows before testing and adjusting D1 177-7861 Hose As 2
the hydraulic and steering system:
D2 6V-4143 Quick Connect Coupler 4
D3 6V-3965 Fitting 3
Introduction
This test is used primarily in order to identify problems
in the steering hydraulic circuit. The test can identify Pressure Gauge
some problems in the circuit for an implement. 0 to 25,000 kPa (0 to 3,600
D5 8T-0859 1
psi)
Required Tools
Pressure Gauge
0 to 60,000 kPa (0 to 8,700
D5 8T-0861 1
psi)
D6 8C-8431 Tee 1
Oil Filter Pressure Differen-
D7 1U-5793 1
tial Gauge Gp
D8 6V-0484 O-Ring Adapter 1
Reference: Tool Operating Manual, NEHS0818,

“Using the 198-4240 Digital Pressure Indicator
Group” for more information on using Tooling (B).

Machine Preparation
Tooling (B) 198-4240 Digital Pressure Indicator Gp 1. Move the machine to a smooth horizontal location.
2. Permit only one operator on the machine. Keep all
other personnel away from the machine or in the

position.
6. Stop the engine.

engine.
Tooling (D) 1U-5796 Pressure Differential Tool Gp
172 KENR8566

UNLOCKED position .
9. Move the control levers through the full range of

travel several times. This procedure should relieve
hydraulic system.

breaker valve will be located on top of the tank. To
release the pressure of the tank, press the button
on top of the breaker valve (if equipped).
11. Tighten the filler cap on the hydraulic tank.
The pressure tap is located behind an access
12. Make sure that the pressure in the entire hydraulic door on the right fender of the cab.
system has been released. (HB) Signal oil pressure tap
13. Turn the key to the OFF position. 15. Attach the high-pressure end of Tooling (D) to
pressure tap (HA). Attach the low-pressure end of
Reference: Refer to Troubleshooting for additional Tooling (D) to pressure tap (HB).
Note: Perform Step 14 and Step 15 if you are using

Tooling (D). Perform Step 16 if you are using Tooling
(B).
14. Assemble Tooling (D). Refer to Illustration 123 for

the orientation of the parts. Refer to Table 68 for
the required parts information.

door on the right fender of the cab.
(HA) Implement pump (discharge pressure)

KENR8566 173
4. Release the parking brakes. Fully activate the

service brakes. Position the tiller handle with the
speed control in the NEUTRAL position and the
direction control in the NEUTRAL position.
5. Keep the engine running at high idle. Move the tiller

handle to the MID STEER RIGHT POSITION. The
hydraulic system is now in a steer stall condition.
Note: The machine must not move. If the machine

moves, the brake system must be checked.
6. With the machine in a steer stall condition, record

the following readings:
Illustration 127 g02149201 a. Pump discharge pressure from the gauge on

The pressure tap is located behind an access the tee side of the pressure differential gauge
(HB) Signal oil pressure tap b. Engine rpm
c. Pressure on the pressure differential gauge

16. Attach Tooling (B) to pressure taps (HA) and (HB).
7. The correct readings from Step 6 follow:
17. Make sure that the steering linkage is correctly
adjusted. Refer to the test for low-pressure a. 39000 ± 700 kPa (5655 ± 100 psi)
standby in Testing and Adjusting, “Pump
Discharge Pressure - Test” in this module. b. 50 rpm or less below the reading from Step 1
18. Place the main display in the operator station in c. A maximum of 345 kPa (50 psi) with a
SERVICE MODE of operation in order to monitor maximum oil temperature of 66°C (151°F)
the engine rpm.
When all of the results are within the
Test Procedure specifications, the hydraulic circuit for steering
should operate normally. However, an
1. Start the engine. Operate the engine at HIGH individual implement circuit may still have a
problem. If a steering problem still persists, the
IDLE. Refer to the Engine Information Plate or steering differential or the final drive may have
refer to the Fuel Settings and Related Information a mechanical problem. Implement circuit
Microfiche. Record the engine rpm. problems which could persist are incorrectly
adjusted pressure limiter valves and worn
2. When the engine is still at HIGH IDLE, move the cylinders. If reading 7.a. is too high or too low,
bulldozer control lever to a midway position then adjust the pressure cutoff valve . Refer to
between the HOLD and FULL RAISE positions. the Testing and Adjusting, “Pump Control
While the bulldozer blade is being raised, read the Valve (Steering) - Adjust”.
pressure differential. Record the reading. The Note: If the pressure cutoff setting cannot be
reading on the gauge is called the margin lowered, the pump or the pressure and flow
pressure. This pressure differential is the compensator valve has failed.
difference between the pump discharge pressure
and the signal pressure from the control valve. The These sets of readings indicate that the signal
circuit is leaking between the steering control
margin pressure should be 2100 ± 100 kPa valve and the pressure and flow compensator
(305 ± 15 psi). If the margin pressure is not correct, valve: a correct reading in Step 7.a. or a low
refer to Testing and Adjusting, “Pump Control reading in Step 7.a., a correct reading in Step
Valve (Steering) - Adjust” for adjustment of the 7.b. and a high reading in Step 7.c.. Possible
margin pressure and the pressure and flow sources of leaks in the signal circuit follow:
compensator valve. When the margin pressure is
• Failed seals on the shuttle valve in the
adjusted, the setting should be in the range of
steering control valve
2100 ± 100 kPa (305 ± 15 psi).
• Dirt or foreign material in the shuttle valve in
3. Lower the bulldozer blade to the ground. Move all
the steering control valve
implement control levers to the HOLD position.
• A failed seal on the plug at the end of the
control valve spool for steering
174 KENR8566
• Failed seals on the sleeve behind the spring (Table 69, contd)
in the priority flow control valve Steering Hydraulic Circuit Test
• Dirt or foreign material in the orifice in the Date Equipment ID Code
signal circuit between the inlet manifold and
the pressure and flow compensator valve
Maximum Differential 345 kPa (50 psi)
• The pressure and flow compensator valve Pressure at 66° C
is failing. Do a pump load test in order to (151° F) oil
make sure. temperature
Steering Stall (Mid Steer Left Position)

• A scratched valve spool or valve body in the
steering control valve Pump Discharge 39000 ± 700 kPa
(HA) (5655 ± 100 psi)
When reading 7.b. is not correct and reading 7.
a. is correct, the pump is using excessive Engine RPM HIGH IDLE - 50 RPM
power in the steer stall condition. When Maximum Differential 345 kPa (50 psi)
reading 7.b. is not correct and reading 7.a. is Pressure at 66° C
low, the pump is using excessive power in the (151° F) oil
steer stall condition. The possible causes for temperature
the excessive use of power follow:
• The setting of the main relief valve is too i05713809

low. Refer to the Testing and Adjusting,
“Main Relief Valve and Crossover Relief Pump Discharge Pressure -
Valve - Test”.
Test
• The settings of the crossover relief valves in SMCS Code: 5070-081
the counterbalance valve are too low.
• The makeup valves in the steering control

valve are leaking.
• The pump is failing. Do a pump load test in machine movement.
order to make sure. Sudden movement of the machine or release of
oil under pressure can cause injury to persons on
• The steering motor is failing. or near the machine.
8. Move the tiller handle to the MID STEER LEFT To help prevent possible injury, perform the pro-
POSITION. Do Steps 3 through 6 again. cedure that follows before testing and adjusting
the hydraulic and steering system:
9. After all tests, adjustments and any needed repairs
are completed, remove all test equipment.
Worksheet
Table 69
Steering Hydraulic Circuit Test
Date Equipment ID Code

Engine RPM HIGH IDLE
Margin Pressure 2100 ± 100 kPa

(305 ± 15 psi)
Steering Stall (Mid Steer Right Position)
Pump Discharge 39000 ± 700 kPa

(HA) (5655 ± 100 psi)
Engine RPM HIGH IDLE - 50 RPM
(continued)
KENR8566 175

system on this machine after the engine and
pump have been stopped. Serious injury can re-
service is done on the hydraulic systems. In order
system pressure before working on any fitting,
ice is started. If the hydraulic system must be
in the raised position, the attachments and lift cyl-
inders must be supported properly. Illustration 129 g01623868
Tooling (B) 198-4240 Digital Pressure Indicator Gp
Always move the machine to a location away from
being made.
Introduction
This procedure includes the following tests:
• Low Pressure Standby
• Margin Pressure
• High Pressure Cutoff
Required Tools
Table 70
Required Tools
Tool Item Part No Description Qty

Pressure Gauge
0 to 10,000 kPa (0 to 1,450
A1 8T-0857 1
psi)
A2 6V-3989 Fitting 1
A
A3 6V-4143 Quick Connect Coupler 2
Hose As
Illustration 128 g01089423 A4 177-7862 5.5 m (18 ft) 1
Tooling (A)
B 198-4240
Gp
Pressure Sensor Gp
0 to 41,368 kPa (0 to 6,000
B2 198-4239 2
psi)
(continued)
176 KENR8566
(Table 70, contd) 10. Loosen the filler cap on the hydraulic tank so that
Required Tools the pressure in the tank is released. The machine
Tool Item Part No Description Qty breaker valve will be located on top of the tank. To
B3 198-4236 Adapter Cable As 2 release the pressure of the tank, press the button
D 1U-5796
Gp 11. Tighten the filler cap on the hydraulic tank.
D1 177-7861 Hose As 2
D2 6V-4143 Quick Connect Coupler 4 system has been released.
13. Turn the key to the OFF position.
Pressure Gauge guidance for preparing the machine for testing.
0 to 25,000 kPa (0 to 3,600
D5 8T-0859 1
psi)
Pressure Gauge
0 to 60,000 kPa (0 to 8,700
D5 8T-0861 1
psi)
D6 8C-8431 Tee 1
Oil Filter Pressure Differen-
D7 1U-5793 1
tial Gauge Gp

Machine Preparation for Test The pressure tap is located behind an access
Procedure (Low Pressure Standby) (HA) Implement pump (discharge pressure)
1. Move the machine to a smooth horizontal location. 14. Attach Tooling (A) or Tooling (B) to pressure tap
2. Permit only one operator on the machine. Keep all (HA).
15. Place the main display in the operator station in
SERVICE MODE of operation in order to monitor
3. Place the steering control lever in the NEUTRAL the engine rpm.
position.
Test Procedure (Low Pressure
4. Engage the parking brake. Standby)
5. Lower the attachments to the ground. 1. Start the engine. Run the engine at high idle. Make
sure that the parking brake is engaged.
6. Stop the engine.
2. Move all the control levers into the HOLD position.
engine. 3. The correct reading on Tooling (A) or Tooling (B) is
3000 kPa (435 psi), which is the output pressure
of the pump in the low pressure standby condition.
UNLOCKED position .
If the pressure reading is below 2000 kPa
9. Move the control levers through the full range of (290 psi) or above 4000 kPa (580 psi), check the
travel several times. This procedure should relieve margin pressure setting. Refer to the test for
any pressure that may be present in the implement margin pressure in Testing and Adjusting, “Pump
hydraulic system. Discharge Pressure - Test”.
KENR8566 177
4. Apply the service brake. Disengage the parking

brake. Move the tiller handle back and forth to the
stops for steering. Release the tiller. If the pressure
on the tetragauge does not return to the reading
from Step 3, the steering linkage should be
adjusted.
5. Adjustments to the pump output should not be

made based on the results of the test. If the
reading is not correct, run the margin pressure test.
Machine Preparation for Test

Procedure (Margin Pressure) and
Test Procedure (High Pressure
Cutoff) The pressure tap is located behind an access
1. Perform Steps 1 through 13 in “Machine
(HB) Signal oil pressure tap
Preparation for Test Procedure (Low Pressure
Standby)”. 3. Attach the high-pressure end of Tooling (D) to
Note: Perform Step 2 and Step 3 if you are using pressure tap (HA). Attach the low-pressure end of
Tooling (D). Perform Step 4 if you are using Tooling Tooling (D) to pressure tap (HB).
(B).
2. Assemble Tooling (D). Refer to Illustration 130 for

the orientation of the parts. Refer to Table 70 for
the required parts information.


178 KENR8566
Test Procedure (High Pressure

Cutoff)
The High Pressure Cutoff test indicates if the
pressure compensator spool needs to be adjusted.
The pressure compensator spool controls the cutoff
pressure.
1. Start the engine. Run the engine at high idle.

Release the parking brake. Apply the service
brakes. Place the transmission in NEUTRAL.
2. Move the tiller handle to a position between HOLD
and the MID STEER LEFT POSITION.
3. The correct reading on Tooling (A5) is
39000 ± 700 kPa (5655 ± 100 psi). This pressure
door on the right fender of the cab. is the output pressure of the pump in the condition
of high-pressure stall. The reading for the pressure
(HB) Signal oil pressure tap
differential should be below 345 kPa (50 psi) with
4. Attach Tooling (B) to pressure taps (HA) and (HB). a maximum oil temperature of 66°C (151°F).
5. Make sure that the steering linkage is correctly 4. If the high-pressure reading is not correct, the
adjusted. Refer to the test for low-pressure pressure cutoff spool should be adjusted. Refer to
standby in Testing and Adjusting, “Pump Testing and Adjusting, “Pump Control Valve
Discharge Pressure - Test” in this module. (Steering) - Adjust”Testing and Adjusting, Pump
Control Valve (Steering) - Adjust. The following test
6. Place the main display in the operator station in results indicate leakage in the signal circuit: a high
SERVICE MODE of operation in order to monitor reading on the pressure differential gauge and a
the engine rpm. low reading or a normal reading on high pressure.
Refer to Testing and Adjusting, “Steering Hydraulic
Test Procedure (Margin Pressure) Circuit - Test”Testing and Adjusting, Steering
Hydraulic Circuit - Test for more information.
The margin pressure test indicates if the flow
compensator spool needs to be adjusted. The flow Worksheet
compensator spool controls the margin pressure.
Table 71
1. Start the engine. Run the engine at high idle. Make Pump Discharge Pressure Test
sure that the parking brake is engaged. Put the
tiller handle in the NEUTRAL position. Date Equipment ID Code
Low Pressure Standby
2. Move the bulldozer control lever to a position
between the HOLD position and the FULL RAISE Item Specification Actual
position. The reading on the pressure differential Pump Discharge 3000 kPa (435 psi)
gauge is the margin pressure. Margin pressure is (HA)
the difference between the pump output pressure
Margin Pressure
and the signal oil pressure from the control valve.
The correct margin pressure is 2100 ± 100 kPa Margin Pressure 2100 ± 100 kPa
(305 ± 15 psi). (305 ± 15 psi)
High Pressure Cutoff

3. When the reading of the margin pressure is not
correct, refer to the Testing and Adjusting, “Pump Pump Discharge 39000 ± 700 kPa
Control Valve (Steering) - Adjust”Testing and (HA) (5655 ± 100 psi)
Adjusting, Pump Control Valve (Steering) - Adjust. Maximum Differential 345 kPa (50 psi)
When the margin pressure is adjusted, set the Pressure at 66° C
pressure differential for the valve to (151° F) oil
temperature
2100 ± 100 kPa (305 ± 15 psi).
KENR8566 179
i03914589 Required Tools

Pump Control Valve (Steering)
- Adjust
SMCS Code: 5455-025-ZH

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 pro-
cedure that follows before testing and adjusting Illustration 136 g01623868
the hydraulic and steering system: Tooling (B) 198-4240 Digital Pressure Indicator Gp

in the raised position, the attachments and lift cyl- Illustration 137 g01879273
the travel of other machines. Be sure that other Table 72
personnel are not near the machine when the en- Required Tools
being made. Tool Item Part No Description Qty
B 198-4240
Introduction Gp
The pump control valve (steering) on the pump can B1 198-4234 Digital Indicator 1
be tested with one of the pump discharge tests. The Pressure Sensor Gp
high-pressure stall test indicates the needs for 0 to 41,368 kPa (0 to 6,000
adjustment of the pressure cutoff spool. The margin B2 198-4239 2
psi)
pressure test indicates the needs for adjustment of
the margin spool.
B3 198-4236 Adapter Cable As 2

D 1U-5796
Gp
D1 177-7861 Hose As 2
(continued)
180 KENR8566
(Table 72, contd) 13. Turn the key to the OFF position.
Required Tools
Tool Item Part No Description Qty guidance for preparing the machine for testing.
Pressure Gauge 14. Remove the floorplate.
0 to 25,000 kPa (0 to 3,600
D5 8T-0859 1
psi) Adjustment Procedure (Pressure
Pressure Gauge
Compensator Spool)
0 to 60,000 kPa (0 to 8,700 Reference: Refer to “High Pressure Stall Test” in
D5 8T-0861 1
psi)
Testing and Adjusting, “Pump Discharge Pressure -
Test” in this module.
D6 8C-8431 Tee 1
When a high-pressure stall test indicates a need for
Oil Filter Pressure Differen- adjustment of the pressure compensator spool, follow
D7 1U-5793 1
tial Gauge Gp this procedure:

Machine Preparation

position. Illustration 138 g01200333
The pressure compensator spool is located on the
4. Engage the parking brake. implement pump under the floorplate of the cab.
5. Lower the attachments to the ground. (5) Pressure compensator spool
(8) Flow compensator spool
6. Stop the engine.

engine.

UNLOCKED position .

hydraulic system.


KENR8566 181

The flow compensator spool is located on the
implement pump under the floorplate of the cab.
(5) Pressure compensator spool
(8) Flow compensator spool

Pressure compensator spool in the pump control
valve (steering)
(3) Adjustment screw
(4) Spring
(5) Pressure compensator spool
(6) Cover
(7) Locknut
1. Hold adjustment screw (3) and loosen locknut (7).

Turn adjustment screw (3) counterclockwise in
order to decrease the pressure setting. Turn
adjustment screw (3) clockwise in order to
increase the pressure setting.
2. When the pressure setting is adjusted, hold

adjustment screw (3) with the hex wrench and
tighten locknut (7) to a torque of 16 ± 4 N·m
(12 ± 3 lb ft).
3. Repeat the high-pressure stall test. Make sure that

the cutoff pressure is 39000 ± 700 kPa Illustration 141 g00866897
(5655 ± 100 psi). Flow compensator spool in the pump control valve
(steering)
Adjustment Procedure (Flow (8) Flow compensator spool
Compensator Spool) (9) Springs
(10) Cover
Reference: Refer to “Margin Pressure Test” in (12) Locknut
Testing and Adjusting, “Pump Discharge Pressure -
Test” in this module. 1. Hold adjustment screw (8) and loosen locknut (12).
When a margin pressure test indicates a need for Turn adjustment screw (8) counterclockwise in
adjustment of the flow compensator spool, follow this order to decrease the pressure setting. Turn
procedure. adjustment screw (8) clockwise in order to
increase the pressure setting.
2. When the pressure setting is adjusted, hold

adjustment screw (8) with the hex wrench and
tighten locknut (12) to a torque of 16 ± 4 N·m
(12 ± 3 lb ft).
182 KENR8566
3. Repeat the margin pressure test. Make sure that Required Tools
the margin pressure is 2100 ± 100 kPa
(305 ± 15 psi).
i03914678
Pressure Limiter Valve - Test

SMCS Code: 5051-081

service is done on the hydraulic systems. In order Illustration 142 g01089423
to prevent possible injury, release the hydraulic Tooling (A)
in the raised position, the attachments and lift cyl-
being made.
Introduction
Pressure limiter valves are installed on each of the Illustration 143 g01623868
implement control valves. These valves limit the Tooling (B) 198-4240 Digital Pressure Indicator Gp
maximum pressure in each implement circuit.
Table 73 Table 74
Settings of the Pressure Limiter Valves Required Tools
Circuit Setting Tool Item Part No Description Qty
Bulldozer Lift 19300 ± 300 kPa (2800 ± 45 psi) Pressure Gauge

0 to 40,000 kPa (0 to 5,800
Bulldozer Tilt 19300 ± 300 kPa (2800 ± 45 psi) A1 8T-0860 1
psi)
Ripper 19300 ± 300 kPa (2800 ± 45 psi)
A2 6V-3989 Fitting 1
A
Hose As
A4 177-7862 5.5 m (18 ft) 1

B 198-4240
Gp
Pressure Sensor Gp
0 to 41,368 kPa (0 to 6,000
B2 198-4239 1
psi)

KENR8566 183

Machine Preparation

position.
4. Engage the parking brake. Illustration 144 g02149200
5. Lower the attachments to the ground. The pressure tap is located behind an access
6. Stop the engine. (HA) Implement pump (discharge pressure)
7. Turn the key to the ON position, but do not start the 14. Attach Tooling (A) or Tooling (B) to pressure tap
engine. (HA).
8. Verify that the implement shutoff control is in the 15. Place the main display in the operator station in
UNLOCKED position . SERVICE MODE of operation in order to monitor
the engine rpm.
travel several times. This procedure should relieve Bulldozer Lift Control Valve
hydraulic system.



Reference: Refer to Troubleshooting for additional Bulldozer lift cylinder with a blocking plate in a
guidance for preparing the machine for testing. hydraulic line
(13) Blocking plate assembly
1. Disconnect the rod end hydraulic line from each lift

cylinder and install blocking plate assembly (13) in
each line.
2. Start the engine and run the engine at high idle.
Watch the test gauge while the bulldozer control
lever is slowly moved to the RAISE position. The
high reading on the pressure gauge is the pressure
setting of the pressure limiter valve. The correct
setting for the pressure limiter valve in the
bulldozer lift control valve is 19300 ± 300 kPa
(2800 ± 45 psi).
184 KENR8566
3. Stop the engine before you adjust the setting of the

pressure limiter valve.
4. Remove the floorplates.

Pressure limiter valve in the bulldozer tilt control valve
(5) Pressure limiter valve
(6) Locknut
Pressure limiter valve in the bulldozer lift control valve 5. Loosen locknut (6) on the bulldozer tilt control
(5) Pressure limiter valve valve. Turn adjusting screw (7) clockwise in order
(6) Locknut to increase the pressure setting. Turn adjusting
screw (7) counterclockwise in order to decrease
the pressure setting. One revolution will change
5. Loosen locknut (6) on the bulldozer lift control
the pressure setting 5520 kPa (800 psi). Repeat
valve. Turn screw (7) clockwise in order to
Step 2.
increase the pressure setting. Turn screw (7)
counterclockwise in order to decrease the 6. When the pressure setting is correct, tighten
pressure setting. One revolution will change the locknut (6) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
pressure setting 5520 kPa (800 psi). Repeat Step Remove the floorplates and the test equipment.
2. Install the floorplates.
6. When the pressure setting is correct, tighten
locknut (6) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
Ripper Lift Circuit
Remove the floorplates and the test equipment. 1. Start the engine and run the engine at high idle.
Install the floorplates. Watch the test gauge while the ripper lift control
lever is slowly moved to the RAISE position. The
Bulldozer Tilt Circuit high reading on the pressure gauge is the pressure
1. Start the engine and run the engine. Lift the setting of the pressure limiter valve. The correct
bulldozer blade 300 mm (12 inch) off the ground. setting for the pressure limiter valve of the ripper lift
Tilt the blade all the way to the right. circuit is 19300 ± 300 kPa (2800 ± 45 psi).
2. Run the engine at high idle. Watch the test gauge 2. Stop the engine before you adjust the setting of the
while the bulldozer control lever is slowly moved to pressure limiter valve.
the TILT RIGHT position. The high reading on the
pressure gauge is the setting of the pressure 3. Remove the floorplates.
limiter valve. The correct setting of the pressure
limiter valve for the bulldozer tilt circuit is
19300 ± 300 kPa (2800 ± 45 psi).
3. Stop the engine before you adjust the setting of the

pressure limiter valve.
4. Remove the floorplates.

KENR8566 185
i03914930
Pressure Reducing Valve - Test

and Adjust
SMCS Code: 5117-025; 5117-081; 5467-025; 5467-
081

Pressure limiter valve in the ripper lift control valve system pressure before working on any fitting,
(5) Pressure limiter valve hose, or hydraulic component.
(6) Locknut
(7) Adjustment screw Lower all attachments to the ground before serv-
4. Loosen locknut (6) on the pressure limiter valve. serviced, tested, or adjusted with the attachment
Turn adjusting screw (7) clockwise in order to in the raised position, the attachments and lift cyl-
increase the pressure setting. Turn adjusting screw inders must be supported properly.
(7) counterclockwise in order to decrease the Always move the machine to a location away from
pressure setting. One revolution will change the the travel of other machines. Be sure that other
pressure setting 5520 kPa (800 psi). Repeat Step personnel are not near the machine when the en-
1. gine is running and tests or adjustments are
being made.
Remove the floorplates and the test equipment. Introduction
Install the floorplates. The pressure reducing valve reduces the implement
hydraulic pressure. The relief valve prevents
Worksheet excessive pressure buildup in the pilot system. If a
Table 75 high-pressure situation occurs, the relief valve will
open. Excess pressure is relieved through the valve.
Pressure Limiter Valve Test
Date Equipment ID Code The pressure in the pilot system controls the
response of the implements. Low pilot pressure
Item Specification Actual produces poor response in the implement control
levers. High pilot pressure produces extreme
Bulldozer Lift 19300 ± 300 kPa sensitivity in the implement control levers.
(2800 ± 45 psi)
The following test procedure will verify whether the
Bulldozer Tilt 19300 ± 300 kPa pressure setting for the pilot pressure is within the
(2800 ± 45 psi) specified limit. The following adjustment procedure
Ripper 19300 ± 300 kPa will explain the procedure for adjusting the pilot
(2800 ± 45 psi) pressure.
Pilot pressure is controlled by the pressure reducing
valve, which is located in the pilot manifold.
186 KENR8566
Required Tools Reference: Tool Operating Manual, NEHS0818,

Machine Preparation

position.

Illustration 149 g01089423 5. Lower the attachments to the ground.
Tooling (A)
6. Stop the engine.

engine.

UNLOCKED position .

hydraulic system.

Tooling (B) 198-4240 Digital Pressure Indicator Gp release the pressure of the tank, press the button
Table 76
Required Tools 11. Tighten the filler cap on the hydraulic tank.
Tool Item Part No Description Qty 12. Make sure that the pressure in the entire hydraulic
Pressure Gauge system has been released.
A1 8T-0856 0 to 6,000 kPa (0 to 870 psi) 1
A2 6V-3989 Fitting 1 Reference: Refer to Troubleshooting for additional
A
Hose As
A4 177-7862 5.5 m (18 ft) 1

B 198-4240
Gp
Pressure Sensor Gp
0 to 41,368 kPa (0 to 6,000
B2 198-4239 1
psi)

KENR8566 187
Note: Low pilot pressure produces poor response at

the pilot control levers. High pilot pressure produces
extreme sensitivity at the pilot control levers.
1. Operate the engine at HIGH IDLE and exercise the

implement hydraulics. The pilot pressure should be
a maximum of 3275 ± 175 kPa (475 ± 25 psi).
2. If the pilot pressure is not correct, perform the steps

in “Adjustment of the Pressure Reducing Valve”.
Adjustment of the Pressure

Reducing Valve
1. Operate the engine and exercise the implement
hydraulics.
door on the right fender of the cab. 2. Loosen the locknut on the adjustment screw of
(HA) Implement pump (discharge pressure) pressure reducing valve (5). Turn the adjustment
screw until the pilot pressure is correct.
14. Attach Tooling (A) or Tooling (B) to pressure tap
(HA). Note: One turn adjusts the pilot pressure by
1380 kPa (200 psi).
SERVICE MODE of operation in order to monitor 3. Tighten the locknut on the adjustment screw to a
the engine rpm. torque of 12 N·m (9 lb ft).
Test of the Pressure Reducing Test of the Relief Valve

Valve The pressure reducing valve is located behind an
access door on the right fender of the operator
The pressure reducing valve is located behind an station.
access door on the right fender of the operator
station.

(1) Accumulator
(2) Manifold and reducing valve
(1) Accumulator (3) Pilot supply pressure (pressure after pressure reducing valve)
(2) Manifold and reducing valve (4) Relief valve
(3) Pilot supply pressure (pressure after pressure reducing valve) (5) Pressure reducing valve
(4) Relief valve
(5) Pressure reducing valve The relief valve can be removed for a bench test, if
necessary. The relief valve is a nonserviceable valve.
Test relief valve in order to ensure proper operation.
188 KENR8566
1. Remove relief valve (4). Install the relief valve in

NOTICE
the test bench to a torque of 50 ± 5 N·m
Care must be taken to ensure that fluids are con-
(37 ± 4 lb ft). tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
2. The relief valve should open at 6485 ± 345 kPa Be prepared to collect the fluid with suitable contain-
(940 ± 50 psi) with the oil flow rate at 1.0 L/min ers before opening any compartment or disassem-
(0.26 US gpm). If the relief valve pressure is bling any component containing fluids.
correct, then go to Step 3. If the relief valve
pressure is not correct, the valve must be Refer to Special Publication, NENG2500, “Dealer
replaced. Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
3. Install the relief valve in the machine. Tighten relief Dispose of all fluids according to local regulations and
valve (4) to a torque of 50 ± 5 N·m (37 ± 4 lb ft). mandates.
i04650877
Specifications
Accumulator (Pilot) - Test and
Charge
SMCS Code: 5077-036-PS; 5077-045-PS; 5077- Dry nitrogen is the only gas approved for use in
045; 5077-081-PS; 5077-081; 5077-PS; 5077 the accumulator. Charging the accumulator with
oxygen gas will cause an explosion. This danger
will not happen if nitrogen cylinders with standard
CGA (Compressed Gas Association, Inc.) Num-
Hot hydraulic oil under high pressure can remain ber 580 connections are used. When you order ni-
in the components of the hydraulic system or the trogen gas, be sure that the cylinders are
power train system after the engine has been equipped with CGA No. 580 Connections. Do not
stopped. The uncontrolled release of the hydraul- use color codes or other methods of identification
ic oil can cause sudden machine movement and to tell the difference between nitrogen and oxygen
can also result in the following conditions: cylinders.
• Burns
Nitrogen gas pressure varies with the temperature. To
• The penetration of body tissue obtain the most accurate nitrogen charge, the
temperature of the accumulator must be identical to
• Other personal injury the air temperature around the accumulator.
• Death Note: Adjust the pressure for ambient conditions, as

required. Refer to the following table for the
If hydraulic oil penetrates body tissue, the injury accumulator precharge pressure/temperature
must be treated immediately by a doctor who is relationship.
familiar with this type of injury. Use a board or a Table 77
piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have Charging Pressure for the Accumulator at Different
been lowered to the ground and that all trapped Temperatures
pressure has been released from the hydraulic
system and the power train system. Also, make Temperature Pressure
sure that the hydraulic oil is cool before the re- −40° C (−40° F) 811 kPa (118 psi)
moval of any components or lines. Remove the
hydraulic oil filler cap only when the engine is −34.4° C (−30° F) 833 kPa (121 psi)
stopped and the filler cap is cool enough to touch
with your bare hand. −28.9° C (−20° F) 854 kPa (124 psi)
−23.3° C (−10° F) 876 kPa (127 psi)
−17.8° C (0° F) 898 kPa (130 psi)
−12.2° C (10° F) 920 kPa (133 psi)
−6.7° C (20° F) 941 kPa (137 psi)
−1.1° C (30° F) 963 kPa (140 psi)
(continued)
KENR8566 189
(Table 77, contd) Table 79

4.4° C (40° F) 985 kPa (143 psi) Part
Tool Item Qty Description
Number
10° C (50° F) 1007 kPa (146 psi)
Pressure Gauge
15.6° C (60° F) 1028 kPa (149 psi) B1 1 8T-0856 0 to 6,000 kPa (0 to 870 psi)
21.1° C (70° F) 1050 kPa (152 psi)
B B2 1 6V-3989 Fitting
26.7° C (80° F) 1072 kPa (155 psi)
B3 2 6V-4143 Quick Connect Coupler
32.2° C (90° F) 1093 kPa (159 psi)
B4 1 177-7860 Hose As (10 ft)
37.8° C (100° F) 1115 kPa (162 psi)
43.3° C (110° F) 1137 kPa (165 psi)

Test Preparation - Accumulator
48.9° C (120° F) 1159 kPa (168 psi)
Leak Down
54.4° C (130° F) 1180 kPa (171 psi)
60° C (140° F) 1202 kPa (174 psi)
Table 78
3. Lower all of the implements.
Accumulator Specification
Date Equipment ID Code 4. Stop the engine.
Specification
Engine 5. Turn the key to the ON position. Make sure that the
Item Actual
Speed implement lockout switch is turned to the
Accumulator 3275 ± 170 kPa UNLOCKED position. Move the implement control
High Idle
Charge Pressure (475 ± 25 psi) levers to all positions several times in order to
release any pressure in the hydraulic system.
Introduction
The accumulator stores hydraulic oil pressure that
can be used to lower the implements when the
engine is off. The accumulator is located on the pilot
manifold.
The following procedure will determine if the
accumulator for the pilot system is charged to the
appropriate pressure.
Required Tools

(1) Accumulator
(2) Pilot Manifold
(3) Pressure Tap for Accumulator Pressure
Illustration 154 g02726620 6. Attach tooling (B) to pressure tap (3).

Tooling (B)
Test Procedure - Accumulator Pilot
Oil Pressure Leak Down
190 KENR8566
1. Start the engine. Warm the hydraulic oil to a

minimum temperature of 65° C (150° F).
2. Record the pressure reading on pressure tap (3).
3. Stop the engine. Turn the key to the ON position

but do not start the machine.
4. With the implement lockout switch in the
UNLOCKED position, record the pressure reading
at pressure tap (3).
5. The pressure reading should not drop more than

700 kPa (101 psi) in 2 minutes. If a pressure drop
greater than 700 kPa (101 psi) occurs, the pilot oil
system should be checked for excessive leakage.
Adjustment Procedure - Pressure

Leak Down
There are no adjustments that can be made to reduce
pressure leaks in the system. Investigate the
components of the charging system to determine the
cause of the system leakage. (1) Accumulator
(2) Pilot Manifold
(3) Pressure Tap for Accumulator Pressure
Test Preparation - Accumulator
Charge Pressure 6. Attach tooling (B) to pressure tap (3) on pilot
manifold (2).
Test Procedure (Accumulator
Charge Pressure)
3. Lower all of the implements.
1. Start the engine. Warm the hydraulic oil to a
4. Stop the engine. minimum temperature of 65° C (150° F).
5. Turn the key to the ON position. Make sure that the 2. Operate the engine at HIGH IDLE.
implement lockout switch is turned to the
UNLOCKED position. Move the implement control 3. Exercise the implement hydraulics. At the
levers to all positions several times in order to accumulator, the pilot pressure at tooling (3)
release any pressure in the hydraulic system. should be 3275 ± 170 kPa (475 ± 25 psi).
4. Shut off the engine. Turn the key to the ON

position. The accumulator charge pressure should
remain steady until an implement control is
exercised.
5. With the implement lockout switch in the
UNLOCKED position, move the implement control
out of the HOLD position in any direction in order
to actuate a function. Return the handle to the hold
position between activations of the handle. Quick
movement of the handle should increase the
accuracy of this test.
6. With the handle in the HOLD position between

activations, record the reading on tooling (B).
7. Repeat Step 5 and Step ,6 recording the reading

each time the handle is returned to the HOLD
position until the pressure reading at tooling (B) is
zero.
KENR8566 191
8. The last pressure reading recorded on tooling (B) is Required Parts

a close approximation of the nitrogen precharge in Table 80
the accumulator.
Required Parts
9. Refer to Table 77 for the appropriate accumulator
Item Part Number Description Qty
charge.
1 200-5003 Shim As Required
10. If the precharge of the original accumulator is out
of the specifications, the accumulator will need to
be replaced. The replacement accumulator has a Machine Preparation
charging valve and may be charged if needed.
Charging Procedure - Accumulator
Charge other personnel away from the machine or in the
1. Refer to Special Instruction, REHS5464,
“Accumulator Discharging and Charging 3. Place the steering control lever in the NEUTRAL
Procedures”. position.
6. Stop the engine.

engine.

UNLOCKED position .

Illustration 157 g01099044 hydraulic system.
(4) Accumulator
(5) Cap 10. Loosen the filler cap on the hydraulic tank so that
(6) Valve
2. The accumulator (4) is located on the pilot
manifold. Charging valve (6) is located on the top
of the accumulator under the cap (5).
Note: Do not attempt to charge the accumulator until
all pressure has been removed from the pilot 11. Tighten the filler cap on the hydraulic tank.
accumulator.
3. When all of the adjustments are complete, remove system has been released.
all tooling and reinstall all guards.
i03925892 Reference: Refer to Troubleshooting for additional
Pilot Control Valve - Test and
Adjust Test Procedure
SMCS Code: 5059-025; 5059-081 1. Start the machine.
Introduction UNLOCKED position .
The following testing and adjustment procedures will
help to ensure that the implement pilot control valve
properly engages the detent point.
192 KENR8566
3. Move the control lever to the FLOAT position.

Remove your hand from the control handle. The
bulldozer control handle should stay in the FLOAT
position.
4. Switch the implement shutoff control to the

LOCKED position .
5. The control lever must pop back into NEUTRAL

position when the pilot hydraulics are locked out
with the shut off valve. If, the control lever does not
pop back to the NEUTRAL position perform the
steps in “Adjustment Procedure”.
Adjustment Procedure

The pilot control lever for the bulldozer is shown without the bulldozer angle control. This option is not available on
all models.
Detail (B) shows the correct position of the detent on the plate, when the pilot control lever is in the FLOAT position.
Dimension (C) is 1.75 ± 0.2 mm (0.07 ± 0.008 inch).
1. Remove rubber boot (3) from bulldozer control 4. Position the rib of the detent plate (5) as close to
lever (4). the sharp edge of the detent assembly (6) as
possible without allowing the two parts to touch.
2. Move detent plate (2)0.25 mm (0.01 inch) away
from the detent assembly (7). 5. Adjust the detent plate (2) so the sharp edge (6) is
centered from one side to the other side.
3. Move control handle (4) so the sharp edge of the
detent assembly (6) is just below the rib of the 6. Adjust the detent plate (2) in order to be parallel
detent plate (5). with the sharp edge (6).
KENR8566 193
7. Tighten the bolts that secure the detent plate. Introduction

Tighten bolts to a torque of 20 ± 3 N·m
The pressure settings for the main relief valve and for
(15 ± 2 lb ft). the crossover relief valves are higher than the setting
for the pump cutoff pressure. Therefore, normal
8. Move the control lever (4) to FLOAT position, such system pressures will not open these relief valves. A
that washer (8) is magnetically attached to hold test for low-pressure settings consists of a check of
coil (9). engine rpm under test conditions.
9. The tip of sharp edge (6) must ride on the upper Machine Preparation
side of the rib of detent plate (2).
10. If, sharp edge (6) does not ride on the upper side
of the rib then add or subtract shims (1) from the 2. Permit only one operator on the machine. Keep all
detent plate (2). Retest the assembly. Repeat the other personnel away from the machine or in the
procedure until the assembly is correct. sight of the operator.
11. Make sure that sharp edge (6), ball pin (10), and 3. Place the steering control lever in the NEUTRAL
detent contact (11) are lubricated with 161-9203 position.
Grease Cartridge
12. Install the rubber boot on the bulldozer control
lever.
13. Perform the steps in “Test Procedure”. Repeat the 6. Stop the engine.
procedure until the assembly is correct. 7. Turn the key to the ON position, but do not start the
14. If still not correct inspect washer (8) at ball pin engine.
(10) for excessive wear. 8. Verify that the implement shutoff control is in the
UNLOCKED position .
i03928970
Main Relief Valve and travel several times. This procedure should relieve
Crossover Relief Valve - Test any pressure that may be present in the implement
hydraulic system.
SMCS Code: 5069-081; 5111-081
Hydraulic oil pressure can remain in the hydraulic breaker valve will be located on top of the tank. To
system on this machine after the engine and release the pressure of the tank, press the button
pump have been stopped. Serious injury can re- on top of the breaker valve (if equipped).
service is done on the hydraulic systems. In order 11. Tighten the filler cap on the hydraulic tank.
system pressure before working on any fitting, 12. Make sure that the pressure in the entire hydraulic
hose, or hydraulic component. system has been released.
Lower all attachments to the ground before serv- 13. Turn the key to the OFF position.
serviced, tested, or adjusted with the attachment Reference: Refer to Troubleshooting for additional
in the raised position, the attachments and lift cyl- guidance for preparing the machine for testing.
Test of the Main Relief Valve and
the travel of other machines. Be sure that other Crossover Relief Valve
gine is running and tests or adjustments are 1. Start the engine and run the engine at high idle.
being made.
SERVICE MODE of operation in order to monitor
the engine rpm.
3. Record the engine rpm at high idle.

194 KENR8566
4. Release the parking brake and engage the service

brakes. Move the tiller handle to the MID STEER
LEFT POSITION and to the MID STEER RIGHT
POSITION. Record the engine rpm at each
position.
5. If both of the readings from Step 4 are more than

50 rpm different from the reading in Step 3, then
the main relief valve or the crossover relief valves
may have low-pressure settings.
If one reading from Step 4 is more than 50 rpm
different from the reading in Step 3, then one of the
crossover relief valves has a low-pressure setting.
The makeup valve in the steering control valve Illustration 160 g01175114
may also be leaking. Counterbalance valve
(2) Crossover relief valve for left turn
(3) Crossover relief valve for right turn
7. If both of the readings from Step 4 are less than 50

rpm different from the reading in Step 3, then the
main relief valve must be replaced or adjusted on a
test bench.
If both of the readings from Step 4 are more than
50 rpm different from the reading in Step 3, then
the main relief valve must be replaced or
inspected. Repeat Step 4. If both of the readings
remain more than 50 rpm different from the rpm at
high idle, then the crossover relief valves must be
replaced or inspected.
When the rpm reading for only one of the
movements to either the MID STEER RIGHT
POSITION or the MID STEER LEFT POSITION is
more than 50 rpm from the rpm at high idle,
exchange the crossover relief valves. Repeat Step
4. If the rpm reading does not improve and the
reading is on the same side as the first reading that
was taken, the result is due to internal leakage in
Illustration 159 g01175113 either the crossover relief valve or the main control
(1) Main Relief Valve valve.
When the rpm reading for the MID STEER LEFT
6. Steps 6 and 7 determine whether the main relief POSITION is over 50 rpm from the rpm at high idle,
valve or both crossover relief valves have low- crossover relief valve (2) must be replaced. The
pressure settings. Turn the adjustment screw for crossover relief valve may be adjusted on a test
the main relief valve by 45 degrees clockwise. bench. Valve (2) is located toward the left side of
Repeat Step 4. the machine.
When the rpm reading for the MID STEER RIGHT
POSITION is over 50 rpm from the rpm at high idle,
crossover relief valve (3) must be replaced. The
crossover relief valve may be adjusted on a test
bench. Valve (3) is located toward the right side of
the machine.
8. Turn the adjustment screw for the main relief valve
by 45 degrees counterclockwise, if the main relief
valve has not been replaced.
KENR8566 195
Testing and Adjusting the Main

Relief Valve
Note: The main relief valve can only be tested and
adjusted on a test bench after the valve has been
removed from the machine.

Counterbalance valve
The crossover relief valves are located on the
counterbalance valve under the floorplates of the
operator station.
(2) Crossover relief valve for left turn
(3) Crossover relief valve for right turn
The main relief valve is located in the inlet 3. Remove the crossover relief valves from the
manifold at the bottom of the control valve stack. counterbalance valve.
(4) Locknut
(5) Adjustment screw 4. Warm the hydraulic oil to a temperature of
49° ± 3°C (120° ± 5°F).
1. Loosen locknut (4) on the main relief valve.
5. Test the crossover relief valves on a test bench.
2. Turn adjustment screw (5) clockwise in order to The pressure setting for the crossover relief valves
increase the pressure setting. Turn adjustment is 42000 ± 500 kPa (6100 ± 70 psi) at a flow rate
screw (5) counterclockwise in order to decrease of 10 L/min (2.64 US gpm).
the pressure setting.
6. Follow Steps 7 through 11 in order to adjust the
3. Warm the hydraulic oil to a temperature of crossover relief valves.
49° ± 3°C (120° ± 5°F).
4. The correct pressure setting of the main relief valve

is 42000 ± 400 kPa (6100 ± 60 psi) at a flow rate
of 5 L/min (1.32 US gpm). When the pressure
setting is correct, tighten locknut (4) to a torque of
50 ± 7 N·m (37 ± 5 lb ft).
5. Reinstall the main relief valve on the machine.

Tighten the valve to a torque of 65 ± 7 N·m
(48 ± 5 lb ft).
Adjustment of the Crossover Relief

Valve
1. First, test the crossover relief valves. Refer to “Test Illustration 163 g01175118
of the Main Relief Valve and Crossover Relief (6) Cap
Valve” above. (7) Relief valve
(8) Locknut
2. Remove the floorplates. (9) Adjustment screw
7. Remove cap (6) from crossover relief valve (7).
8. Loosen locknut (8) on the crossover relief valve.

196 KENR8566
9. Turn adjustment screw (9) clockwise in order to

increase the pressure setting. Turn adjustment
screw (9) counterclockwise in order to decrease
the pressure setting.
Note: One turn of adjustment screw (9) changes the
pressure by 15000 kPa (2175 psi).

11. Install the cap. Tighten cap (6) to a torque of

30 ± 5 N·m (22 ± 4 lb ft).
12. Install the crossover relief valves on the

counterbalance valve. Torque the two relief valves
to 100 ± 10 N·m (74 ± 7.4 lb ft).
13. Install the floorplates.

KENR8566 197
Index Section
Index
A Graphic Color Codes ..................................... 151
Accumulator............................................. 21, 145
Accumulator (Pilot) - Test and Charge........... 188 H
Adjustment Procedure - Pressure Leak Down
................................................................. 190 Hydraulic Pump - Piston .................................. 84
Charging Procedure - Accumulator Charge Constant Flow .............................................. 91
................................................................. 191 Destroking.................................................... 88
Introduction ................................................ 189 High Pressure Stall ...................................... 90
Required Tools ........................................... 189 Low Pressure Standby................................. 89
Specifications............................................. 188 Upstroking.................................................... 85
Test Preparation - Accumulator Charge Hydraulic System Troubleshooting................ 159
Pressure................................................... 190 A Pause Occurs in the Increase to Full
Test Preparation - Accumulator Leak Down Pressure in the Circuits. ........................... 160
................................................................. 189 All Implement Circuits Are Unstable .......... 164
Test Procedure - Accumulator Pilot Oil All Implement Cycle Times Are Too Slow .. 164
Pressure Leak Down................................ 189 Implement Cycle Times Are Too Fast ........ 164
Test Procedure (Accumulator Charge One or More of the Control Levers Moves
Pressure).................................................. 190 when another Control Lever Is Operated.
................................................................. 160
Problem Checklist...................................... 159
B Problem List for the Hydraulic Oil............... 159
Problem List for the Implement System
Bulldozer Blade (Cutting Edges and End
Components............................................. 163
Bits)................................................................ 69
Problem List for the Steering System
Bulldozer Blade (Cutting Edges and End
Components............................................. 160
Bits)................................................................ 70
Pump Pressures in NEUTRAL Are Too High or
Bulldozer Brace ......................................... 71–72
Too Low.................................................... 162
Bulldozer Lift Control Valve...................... 25, 104
Steering Speed Changes with a Step or
Basic Valve Operation................................ 106
Steering Modulation is Poor ..................... 162
General Information ................................... 104
The Bulldozer Blade Has an Excessive Pause
Bulldozer Lift Cylinder...................................... 51
at Ground Level When You Lower the Blade
Bulldozer Tilt Control Valve...................... 29, 133
................................................................. 164
The Bulldozer Blade Has Too Little Travel
Tilt Left ....................................................... 134
Before the Quick-Drop Valve Is Activated for
Tilt Right ..................................................... 137
the D6R Series IIITrack-Type Tractor ....... 165
Bulldozer Tilt Cylinder.................................57, 59
The Bulldozer Blade Has Too Much Travel
Bulldozer Trunnion..................................... 73–74
Before the Quick-Drop Valve Is Activated for
the D6R Series IIITrack-Type Tractor ....... 165
C The Hydraulic Circuits Have Weak Response
................................................................. 165
Control Valve (Bulldozer)................................. 24
The Hydraulic Oil Contains a Large Amount of
Counterbalance Valve ................................... 148
Air............................................................. 160
Counterbalance Valve (Steering)..................... 23
The Hydraulic System is Losing Oil ........... 160
Cylinder Mounting.......................................53, 55
The Implement Drift Is Excessive .............. 164
The Implement Droops When the Control
G Lever Is Moved From HOLD to LIFT ........ 164
The Machine Continues to Turn When the
General Information......................................... 75 Steering Control Lever is Returned to
Implement and Steering Hydraulic System.. 75 NEUTRAL ................................................ 162
198 KENR8566
Index Section
The Machine Has Harsh Steering and the M

Hydraulic Cylinders Move Roughly .......... 159
Machine Preparation ..................................... 156
The Machine Has Low Turning Force in Both
Directions and the Output Pressure of the
Procedure .................................................. 157
Pump is Low in Both Directions ............... 161
Visual Inspection........................................ 157
The Machine Has Low Turning Force in One
Warnings.................................................... 156
Direction and the Pressure Output of the
Main Relief Valve ........................................22, 91
Pump is Low in One Direction.................. 161
Main Relief Valve and Crossover Relief
The Machine Pauses Before the Machine
Valve - Test .................................................. 193
Starts to Steer .......................................... 160
Adjustment of the Crossover Relief Valve.. 195
The Machine Will Not Turn in Either Direction
Introduction ................................................ 193
................................................................. 161
Machine Preparation.................................. 193
The Machine Will Not Turn or the Steering
Test of the Main Relief Valve and Crossover
Radius is Very Large ................................ 162
Relief Valve .............................................. 193
The Pressure or the Flow From the Pump is
Testing and Adjusting the Main Relief Valve
Low........................................................... 162
................................................................. 195
The Pump Does Not Return to Standby
Pressure After the Implement Is Used ..... 164
The Pump Remains at NEUTRAL in One O
Direction and the Machine Does Not Turn in
Oil Cooler and Bypass Valve ......................... 146
One Direction ........................................... 162
Operation Checks.......................................... 165
The Response of One Implement Is Too Slow
Drift Tests for Bulldozer Lift Cylinders ........ 167
................................................................. 163
Drift Tests for Bulldozer Tilt Cylinder .......... 167
The Ripper Does Not Function Properly .... 165
Drift Tests for Ripper Lift Cylinder .............. 168
The Steering is Jerky or Unstable.............. 162
Introduction ................................................ 165
The Steering Speed is Slow in Both Directions
and Oil Output of the Pump is Low........... 161
Steering Checks......................................... 168
The Temperature of the Oil is Too High...... 159
Tests for Cycle Times................................. 166
The Turning Radius is Too Large in Both
Worksheet.................................................. 170
Directions ................................................. 163
The Turning Radius is Too Large in One
Direction................................................... 163 P
Hydraulic Tank and Filter ..............................4, 81
Hydraulic Tank ............................................. 81 Pilot Control Valve - Test and Adjust.............. 191
Oil Filter (Case Drain) .................................. 82 Adjustment Procedure ............................... 192
Oil Filter (Implement Return Oil) .................. 82 Introduction ................................................ 191
Required Parts ........................................... 191
I Test Procedure........................................... 191
Pilot Control Valve (Bulldozer Lift and Tilt)...... 35,
Implement and Steering Control Valve
41
Group....................................................... 14–15
194-5032 Pilot Cartridge Valve Gp (5) ....... 44
Implement Control Valve.................................. 97
Implement Hydraulic Pump ............................... 7
Important Safety Information ............................. 2
196-5515 Lever As (1) ............................... 42
L 227-8348 Lever As (2) ............................... 38
Pilot Control Valve (Ripper Lift)........................ 46
Lines (Pilot)...................................................... 49
Pilot Hydraulic System..................................... 93
Lines (Pump) ................................................... 10
AccuGrade Ready Machines ...................... 95
Lines (Tilt Cylinder).................................... 61–62
Accumulator................................................. 94
Implement Lockout Valve............................. 94
KENR8566 199
Index Section
Pilot Valve (Bulldozer).................................. 94 QUICK-DROP............................................ 129

Pilot Valve (Ripper) ...................................... 95 RAISE ........................................................ 125
Pressure Limiter Valve - Test ......................... 182
Bulldozer Lift Control Valve ........................ 183
Bulldozer Tilt Circuit ................................... 184 R
Introduction ................................................ 182 Ripper Control Valve........................................ 32
Machine Preparation.................................. 183 Ripper Lift Control Valve ................................ 138
Required Tools ........................................... 182 Basic Valve Operation................................ 139
Ripper Lift Circuit........................................ 184 General Information ................................... 138
Worksheet.................................................. 185 Ripper Lift Cylinder .................................... 64–65
Pressure Reducing Valve .............................. 144
Pressure Reducing Valve - Test and Adjust... 185
Adjustment of the Pressure Reducing Valve S
................................................................. 187 Signal Resolver Network ................................. 78
Introduction ................................................ 185 AccuGrade Ready Machines ...................... 79
Machine Preparation.................................. 186 Specifications Section ....................................... 4
Required Tools ........................................... 186 Steering Control Valve ................................16, 98
Test of the Pressure Reducing Valve ......... 187 Basic Valve Operation.................................. 99
Test of the Relief Valve............................... 187 General Information ..................................... 98
Pressure Reducing Valve (Pilot)................ 19–20 Steering Hydraulic Circuit - Test .................... 171
Pressure Taps................................................ 155 Introduction ................................................ 171
Locations.................................................... 155 Machine Preparation.................................. 171
Pump Control Valve ......................................... 13 Required Tools ........................................... 171
Pump Control Valve (Steering) - Adjust ......... 179 Test Procedure........................................... 173
Adjustment Procedure (Flow Compensator Worksheet.................................................. 174
Spool)....................................................... 181 Steering Motor ..........................................11, 150
Adjustment Procedure (Pressure Systems Operation Section............................. 75
Compensator Spool) ................................ 180
Introduction ................................................ 179
Machine Preparation.................................. 180 T
Required Tools ........................................... 179 Table of Contents............................................... 3
Pump Discharge Pressure - Test................... 174 Testing and Adjusting .................................... 155
Introduction ................................................ 175 Testing and Adjusting Section ....................... 155
Machine Preparation for Test Procedure (Low Troubleshooting Procedures ......................... 155
Pressure Standby) ................................... 176 General Procedure..................................... 155
Machine Preparation for Test Procedure
(Margin Pressure) and Test Procedure (High
Pressure Cutoff) ....................................... 177 V
Required Tools ........................................... 175 Visual Inspection ........................................... 158
Test Procedure (High Pressure Cutoff) ...... 178 Implement System ..................................... 158
Test Procedure (Low Pressure Standby) ... 176
Test Procedure (Margin Pressure)............. 178
Worksheet.................................................. 178
Push Arm......................................................... 67
Q
Quick-Drop Valve..................................... 50, 123
DOWN PRESSURE................................... 131
HOLD ......................................................... 124
LOWER...................................................... 127
©2014 Caterpillar CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

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When replacement parts are required for this

Table of Contents Pilot Hydraulic System.................. .................. 93

Systems Operation Section

General Information.................... .................... 75

Hydraulic Tank and Filter

Part No.: 224-4946

Item Qty Part Specification Description

1 2 4T-0521 Bolt Torque to 60 ± 7 N·m (44 ± 5 lb ft).

Length under test force is 85.73 mm (3.375 inch).

3 4 6V-7744 Locknut Torque to 30 ± 5 N·m (266 ± 44 lb in).

Length under test force is 38.4 mm (1.51 inch).

Length under test force is 26.19 mm (1.031 inch).

7 1 9J-7031 Drain Plug Torque to 68 ± 7 N·m (50 ± 5 lb ft)

Implement Hydraulic Pump

Part No.: 227-0830

Item Qty Part Specification Description

2 1 197-0083 Spring Free length after test is 51.5 mm (2.03 inch).

4 4 8U-3297 Bolt Before assembly, apply retaining compound to the threads.

6 1 197-0094 Spring Free length after test is 125.5 mm (4.94 inch).

1 5W-7461 Shim Thickness is 1.05 mm (0.041 inch).

1 5W-7462 Shim Thickness is 1.10 mm (0.043 inch).

7 1 5W-7463 Shim Thickness is 1.15 mm (0.045 inch).

1 5W-7464 Shim Thickness is 1.25 mm (0.049 inch).

1 5W-7465 Shim Thickness is 1.50 mm (0.059 inch).

1 5W-7466 Shim Thickness is 1.75 mm (0.069 inch).

Part No.: 317-3942

Item Qty Part Specification description

1 2 148-8449 Swivel Tee Torque to 95 ± 5 N·m (70 ± 4 lb ft).

2 2 148-8388 Elbow As Torque to 95 ± 5 N·m (70 ± 4 lb ft).

3 1 5G-7191 Spring Free length after test is 550 mm (21.7 inch).

Part No.: 159-7156

Item Qty Part Specification Description

1 4 8T-3957 Bolt Torque to 85 ± 15 N·m (63 ± 11 lb ft).

2 1 171-3061 Spring Free length is 47.90 mm (1.886 inch).

A - - Dimension is 111.20 to 111.30 mm (4.378 to 4.382 inch).

As required, use the following shims in order to achieve dimension (A):

3 1 9T-1576 Shim Thickness is 0.10 mm (0.004 inch).

1 9T-1579 Shim Thickness is 0.30 mm (0.012 inch).

Before assembly, apply blue Loctite 242 to threads.

B - - Dimension is 0.325 ± 0.075 mm (0.0128 ± 0.0030 inch).

1 171-3060 Shim Thickness is 3.60 mm (0.142 inch).

1 171-3059 Shim Thickness is 3.70 mm (0.146 inch).

1 171-3057 Shim Thickness is 3.90 mm (0.154 inch).

1 171-3055 Shim Thickness is 4.00 mm (0.157 inch).

Pump Control Valve

Part No.: 227-3021

Item Qty Part Specification Description

1 1 9T-4186 Spring Free length is 45.1 mm (1.78 inch).

2 1 195-6947 Spring Free length is 19 mm (0.7 inch).

Cutoff pressure is 39000 ± 700 kPa (5655 ± 100 psi).

Implement and Steering Control Valve Group

Part No.: 224-4937

Item Qty Part Specification Description

1 3 6V-8188 Nut Torque to 105 ± 10 N·m (77 ± 7 lb ft).

2 1 9T-3541 Relief Valve Gp Torque to 65 ± 7 N·m (48 ± 5 lb ft).

Implement and Steering Control Valve Group