Testing Adjusting GD 16 M Update

“TESTING AND ADJUSTING GRADER 16 M
TESTING AND ADJUSTING GRADER 16 M
Document No. xx-xx-xx-x-xxxx
Rev No.A
1 of 110
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Document No.: PTP-HC-TPL-G-xxxx Rev No. 0 1 of 110
Engine Oil Pressure - Test

The engine oil pressure may be checked electronically by using the electronic service
tool. The engine oil pressure can be measured with the electronic service tool. Refer to
Troubleshooting for information on the use of the electronic technician.
Measuring Engine Oil Pressure
Work carefully around an engine that is running. Engine

parts that are hot, or parts that are moving, can cause
personal injury.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, testing,
adjusting, and repair of the product. Be prepared to
collect the fluid with suitable containers before opening
any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer

Service Tool Catalog" for tools and supplies suitable to
collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and mandates.
Table 1
Required Tools
Tool Part Number Part Name Quantity
1U-5470 Engine Pressure Group
A or or 1
198-4240 Digital Pressure Indicator
Illustration 1 g00296486
1U-5470 Engine Pressure Group
Tool (A) measures the oil pressure in the system. This engine tool group can read the oil
pressure inside the oil manifold.
Note: Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure
Group" for more information. Refer to Operating Manual, NEHS0818, "Using the 198-
4240 Digital Pressure Indicator" for more information.
Oil gallery plug
(1) Plug
1. Install Tool (A) into oil gallery plug (1).
Note: Engine oil pressure to the camshaft and main bearings should be checked on
each side of the cylinder block at oil gallery plug (1).
2. Start the engine. Run the engine with SAE 15W40 oil. Refer to Operation and
Maintenance Manual, "Refill Capacities and Recommendations" for the
recommendations of engine oil.
3. Record the value of the engine oil pressure when the engine is at operating
temperature 100 °C (212 °F).
The minimum engine oil pressure at 1800 rpm should be approximately 275 to 414 kPa
(40 to 59 psi).
Minimum engine oil pressure at low idle rpm (600 to 800 rpm) should be
approximately 68 kPa (10 psi).
4. Compare the recorded engine oil pressure with the oil pressure indicators on the
instrument panel and the engine oil pressure that is displayed on the electronic
service tool.
5. An engine oil pressure indicator that has a defect or an engine oil pressure sensor that
has a defect can give a false indication of a low oil pressure or a high oil pressure. If
there is a notable difference between the engine oil pressure readings make necessary
repairs.
6. If low engine oil pressure is determined, refer to "Reasons for Low Engine Oil Pressure".
7. If high engine oil pressure is determined, refer to "Reason for High Engine Oil Pressure".
Reasons for Low Engine Oil Pressure
NOTICE
NOTICE

containing fluids.

Engine oil level is low. Refer to Step 1.
Engine oil is contaminated. Refer to Step 2.
The engine oil bypass valves are open. Refer to Step 3.
The engine lubrication system is open. Refer to Step 4.
The oil pickup tube has a leak or a restricted inlet screen. Refer to Step 5.
The engine oil pump is faulty. Refer to Step 6.
Engine Bearings have excessive clearance. Refer to Step 7.
1. Check the engine oil level in the crankcase. The oil level can possibly be too far below
the oil pump supply tube. This will cause the oil pump not to have the ability to supply
enough lubrication to the engine components. If the engine oil level is low add engine
oil in order to obtain the correct engine oil level. Refer to Operation and Maintenance
Manual, "Engine Oil" for the recommendations of engine oil.
2. Engine oil that is contaminated with fuel or coolant will cause low engine oil pressure.
High engine oil level in the crankcase can be an indication of contamination. Determine
the reason for contamination of the engine oil and make the necessary repairs. Replace
the engine oil with the approved grade of engine oil. Refer to Operation and
Maintenance Manual, "Engine Oil" for the recommendations of engine oil.
NOTICE
Caterpillar oil filters are built to Caterpillar

specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to the
engine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine
lubricating system. Only use oil filters recommended by
Caterpillar.
3. If the engine oil bypass valves are held in the open position, a reduction in the oil
pressure can be the result. This may be due to debris in the engine oil. If the engine oil
bypass valves are stuck in the open position, remove each engine oil bypass valve and
clean each bypass valve in order to correct this problem. You must also clean each
bypass valve bore. Install new engine oil filters. New engine oil filters will prevent
more debris from causing this problem. For information on the repair of the engine oil
bypass valves, refer to Disassembly and Assembly, "Engine Oil Filter Base -
Disassemble".
4. An oil line or an oil passage that is open, broken, or disconnected will cause low
engine oil pressure. An open lubrication system could be caused by a piston cooling
jet that is missing or damaged. Determine the reason for an open lubrication system
of the engine and make the necessary repairs.
Note: The piston cooling jets direct engine oil toward the bottom of the piston in order
to cool the piston. This also provides lubrication for the piston pin. Breakage, a
restriction or incorrect installation of the piston cooling jets will cause seizure of the
piston.
5. The inlet screen of the oil pickup tube for the engine oil pump can have a restriction.
This restriction will cause cavitation and a loss of engine oil pressure. Check the inlet
screen on the oil pickup tube and remove any material that may be restricting engine
oil flow. Low engine oil pressure may also be the result of the oil pickup tube that is
drawing in air. Check the joints of the oil pickup tube for cracks or a damaged O-ring
seal. Remove the engine oil pan in order to gain access to the oil pickup tube and the
oil screen. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install"
for more information.
6. Check the following problems that may occur to the engine oil pump.
a. Air leakage in the supply side of the oil pump will also cause cavitation and loss
of oil pressure. Check the supply side of the oil pump and make necessary
repairs. For information on the repair of the engine oil pump, refer to
Disassembly and Assembly, "Engine Oil Pump - Remove".
b. Oil pump gears that have too much wear will cause a reduction in oil pressure.
Repair the engine
oil pump. For information on the repair of the engine oil pump, refer to
Disassembly and Assembly, "Engine Oil Pump - Remove".
7. Excessive clearance at engine bearings will cause low engine oil pressure.
Check the engine components that have excessive bearing clearance and
make the necessary repairs.
Reason for High Engine Oil Pressure
NOTICE
NOTICE

containing fluids.

Engine oil pressure will be high if the engine oil bypass valves become stuck in the closed
position and the engine oil flow is restricted. Foreign matter in the engine oil system could be
the cause for the restriction of the oil flow and the movement of the engine oil bypass valves.
If the engine oil bypass valves are stuck in the closed position, remove each bypass valve and
clean each bypass valve in order to correct this problem. You must also clean each bypass
valve bore. Install new engine oil filters. New engine oil filters will prevent more debris from
causing this problem. For information on the repair of the engine oil filter bypass valve, refer
to Disassembly and Assembly, "Engine Oil Filter Base - Disassemble".
NOTICE
Caterpillar oil filters are built to Caterpillar

specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to the
engine bearings, crankshaft, etc., as a result of the larger
waste particles from unfiltered oil entering the engine
lubricating system. Only use oil filters recommended by
Caterpillar.
Engine Crankcase Pressure (Blowby) - Test

SMCS - 1215; 1317
Table 1
Tools Needed
Part Number Part Name Quantity
348-5430 Multi-Tool Gp 1
285-0900 Blowby Tool Group 1
NETG5049 Software License 1
Damaged pistons or rings can cause too much pressure in the crankcase. This condition will
cause the engine to run rough. There will be more than a normal amount of blowby fumes
rising from the crankcase breather. The breather can then become restricted in a short time,
causing oil leakage at gaskets and seals that would not normally have leakage. Blowby can
also be caused by worn valve guides or by a failed turbocharger seal.
348-5430 Multi-Tool Gp
The 348-5430 Multi-Tool Gp, or the 285-0900 Blowby Tool Group is used to check the
amount of blowby. Refer to Tool Operating Manual, NEHS1087, " 348-5430 Multi-Tool Gp "
for the test procedure for checking the blowby.
Finding Top Center Position for No. 1 Piston

SMCS - 1105-531
Table 1
Required Tools
Tool Part Number Part Name Qty
A 208-0888 Engine Turning Tool 1
B 350-7549 Engine Turning Tool 1
C 9S-9082 Engine Turning Tool 1
D 136-4632 Timing Pin 1
E 208-9387 Timing Pin 1
F 208-9388 Adapter 1
G 5P-7305(1) Engine Turning Tool 1
H 456-7526(1) Timing Pin 1
(1) This is for a 966H C11engine
Disassembly and Assembly of the Timing Pin

Use the following procedure in order to assemble the engine timing pin.
(D) 136-4632 Timing Pin
1. Begin with timing pin (D).
Disassembled 136-4632 Timing Pin timing pin
2. Disassemble timing pin (D).
Comparing timing pins
(E) 208-9387 Timing Pin
(F) 208-9388 Adapter
(1) Pin that is removed from 136-4632 Timing Pin
3. Install timing pin (E) and adapter (F) into timing pin assembly (D). Utilize both the
springs that were removed during the disassembly.
(1) Timing pin assembly (D) with the 208-9387 Timing Pin installed
456-7526 Timing Pin
(2) Screw end
(4) 208-9388 Adapter
(5) 3N-6233 Spring
(6) Pin
Procedure for Pin Timing
Flywheel housing
(1) Timing hole
Note: The opposite side of the flywheel housing can be used for this procedure.
When using the opposite side, the shorter timing pin will need to be used to
perform the procedure.
1. Remove plug (1) from the timing hole that is located in the flywheel housing.
Install the assembled timing pin into the timing hole.
Note: If the flywheel is turned beyond the point of engagement, the flywheel must be
turned in the direction that is reverse of normal engine rotation. Turn the flywheel by
approximately 30 degrees. Then turn the flywheel in the direction of normal rotation
until the timing pin engages with the threaded hole. This procedure eliminates the
backlash from the gears when the No. 1 piston is at the top center position.
2. Install tool (A) into the gear in the top left-hand side of the flywheel housing.
Tool (A) is used for turning the flywheel in the flywheel housing. Turn the engine in
the direction of engine rotation. The direction of engine rotation is counterclockwise,
as the engine is viewed from the flywheel end. Turn the engine until the timing pin
engages with the threaded hole in the flywheel.
Note: Tooling (B) or (C) may also be used to turn the flywheel. Either of the three tools
may be used depending on the application and available space.
3. Remove the valve mechanism cover from the engine.
Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
4. The inlet and exhaust valves for the No. 1 cylinder are fully closed if No. 1 piston
is on the compression stroke. Also, the rocker arms can be moved by hand when
the piston is on the compression stroke. If the rocker arms cannot be moved and
the valves are slightly open, the No. 1 piston is on the exhaust stroke.
Note: When the actual stroke position is identified, and the other stroke position is
needed, remove the timing bolt from the flywheel. Then turn the flywheel by 360
degrees in the direction of normal engine rotation and reinstall the timing bolt.
Engine Valve Lash - Inspect/Adjust

SMCS - 1102-025
To prevent possible injury, do not use the starter to turn the flywheel.
Hot engine components can cause burns. Allow

additional time for the engine to cool before measuring
valve clearance.
This engine uses high voltage to control the fuel injectors.
Disconnect electronic fuel injector enable circuit

connector to prevent personal injury.
Do not come in contact with the fuel injector terminals

while the engine is running.
Note: Valve lash is measured between the rocker arm and the bridge for the inlet valves.
Valve lash is measured between the rocker arm and the valve stem for the exhaust valve.
All of the clearance measurements and the adjustments must be made with the engine
stopped. The valves must be fully closed.
Valve Lash Check

Inlet Valves Exhaust Valves
Valve Lash Check 0.38 ± 0.08 mm 0.64 ± 0.08 mm
(Stopped Engine) (0.0150 ± 0.0031 inch) (0.0252 ± 0.0031
inch)
TC Compression Stroke 1-2-4 1-3-5
TC Exhaust Stroke(1) 3-5-6 2-4-6
Firing Order 1-5-3-6-2-4(2)
Table 1
(1) 360° from TC compression stroke
(2) The No. 1 cylinder is at the front of the engine.
An adjustment is not necessary if the measurement of the valve lash is in the acceptable
range. Adjust the valve lash while the engine is stopped. The range is specified in Table
1.
If the measurement is not within this range adjustment is necessary. See Testing And
Adjusting, "Valve Lash And Valve Bridge Adjustment".
Cylinder and Valve location
(A) Exhaust valves
(B) Inlet valves
Valve Lash and Valve Bridge Adjustment
Table 2
Valve Lash
Valves Dimension of Gauge
Inlet 0.38 ± 0.08 mm (0.0150 ± 0.0031 inch)
Exhaust 0.64 ± 0.08 mm (0.0252 ± 0.0031 inch)
Adjust the valve lash while the engine is stopped. Use the following procedure to adjust the
valves:
1. Put the No. 1 piston at the top center position on the compression stroke.
Refer to Testing and Adjusting, "Finding Top Center Position for No. 1
Piston".
Table 3
TC Compression
Stroke
0.38 ± 0.08 mm 0.64 ± 0.08 mm
Valve Lash
(0.0150 ± 0.0031 inch) (0.0252 ± 0.0031 inch)
Cylinders 1-2-4 1-3-5
2. Adjust the valve lash according to Table 3.
a. Lightly tap the rocker arm at the top of the adjustment screw with a soft mallet.
This will ensure that the lifter roller seats against the camshaft's base circle.
b. Loosen the adjustment locknut.
c. Place the appropriate feeler gauge between rocker arm and the valve bridge.
Then, turn the adjustment screw in a clockwise direction. Slide the feeler gauge
between the rocker arm and the valve bridge. Continue turning the adjustment
screw until a slight drag is felt on the feeler gauge. Remove the feeler gauge.
d. Tighten the adjustment locknut to a torque of 30 ± 7 N· m (22 ± 5 lb ft). Do not

allow the adjustment screw to turn while you are tightening the adjustment
locknut. Recheck the valve lash after tightening the adjustment locknut.
3. Remove the timing bolt and turn the flywheel by 360 degrees in the direction of
engine rotation. This will put the No. 6 piston at the top center position on the
compression stroke. Install the timing bolt in the flywheel.
Table 4
TC Exhaust
Stroke(1)
0.38 ± 0.08 mm 0.64 ± 0.08 mm
Valve Lash
(0.0150 ± 0.0031 inch) (0.0252 ± 0.0031 inch)
Cylinders 3-5-6 2-4-6
(1) Position for No. 1 cylinder
4. Adjust the valve lash according to Table 4.
a. Lightly tap the rocker arm at the top of the adjustment screw with a soft mallet.
This will ensure that the lifter roller seats against the camshaft's base circle.
b. Loosen the adjustment locknut.
c. Place the appropriate feeler gauge between rocker arm and the valve bridge.
Then, turn the adjustment screw in a clockwise direction. Slide the feeler gauge
between the rocker arm and the valve bridge. Continue turning the adjustment
screw until a slight drag is felt on the feeler gauge. Remove the feeler gauge.
d. Tighten the adjustment locknut to a torque of 30 ± 7 N· m (22 ± 5 lb ft). Do not

allow the adjustment screw to turn while you are tightening the adjustment
locknut. Recheck the valve lash after tightening the adjustment locknut.
5. Remove the timing bolt from the flywheel after all adjustments to the valve lash
have been made. Reinstall the timing cover.
Compression Brake Lash - Adjust

SMCS - 1129-025

valve clearance.


Note: The valve lash must be adjusted before adjusting the Cat
compression brake lash.
Table 1
Setting Tightening torque for the jam nut
0.7112 ± 0.050 mm (0.028 ± 0.0020 inch) 15 ± 3 N·m (11 ± 2 lb ft)
Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".
Note: The Cat compression brake lash is measured between the Cat compression brake pin
and the exhaust rocker pad. Make all adjustments while the engine is stopped and the
exhaust valves are closed.
Use the following procedure to adjust the slave piston lash on cylinders 1, 3, and 5:
Exhaust rocker arm and actuator piston
1. Put the No. 1 piston at the top center position on the compression stroke.
Refer to Testing and Adjusting, "Finding Top Center Position for No. 1
Piston".
Assembly for the variable valve actuator
(1) Jam nut
(2) Housing for the slave piston
2. Loosen the jam nut (1) .
An example of incorrect centering of the Cat compression brake pin
3. Make sure that the Cat compression brake pin is centered in the housing. Place the
appropriate feeler gauge between the Cat compression brake pin and the exhaust rocker
pad. Then, turn the adjustment screw in a clockwise direction. Slide the feeler gauge
between the Cat compression brake pin and the exhaust rocker pad. Continue turning
the adjustment screw until a slight drag is felt on the feeler gauge. Remove the feeler
gauge.
4. Tighten jam nut (1) to a torque of 15 ± 3 N·m (11 ± 2 lb ft). Recheck the slave
piston lash after tightening the locknut.
To adjust the slave piston lash on cylinders 2, 4, and 6, perform Steps 2 through 4.
6. Remove the timing bolt from the flywheel after all adjustments have been
performed. Reinstall the timing cover.
Refer to Testing and Adjusting, "Electronic Unit Injector - Adjust".
Variable Valve Actuators - Inspect/Adjust

SMCS - 1105-025; 1105-040

valve clearance.


Note: Lash for the Variable Valve Actuator (VVA) is measured between the rocker arm
and the actuator piston. All measurements and adjustments must be made to a cold
engine with the valves closed.
Checking the Variable Valve Actuator Lash

An adjustment is not necessary if the measured lash is in the acceptable range in Table 1. All
engines may not have actuator pistons for both the inlet rocker arm and the exhaust rocker arm.
Check and adjust your lash
setting accordingly.
Table 1
Inlet Rocker Arm
Variable Valve Actuator Lash 0.610 ± 0.075 mm (0.0240 ± 0.0030 inch)
TC Compression Stroke 1-2-4
TC Exhaust Stroke(1) 3-5-6
Firing Order 1-5-3-6-2-4(2)
(1) 360° from TC compression stroke
(2) The No. 1 cylinder is at the front of the engine.
Intake rocker arm and actuator piston
If the measurement is not within this range, an adjustment is necessary. Refer to "Adjusting
the Variable Valve Actuator Lash" for the proper procedure.
Adjusting the Variable Valve Actuator Lash

Note: The valve lash must be set prior to setting the lash for the variable valve actuator.
Use the following procedure to adjust the lash for the variable valve actuator:
1. Put the No. 1 piston at the top center position on the compression stroke. Refer to
Testing and Adjusting, "Finding Top Center Position for No. 1 Piston". The valve
lash must be set before the lash of the variable valve actuator can be adjusted. Also,
the valve cover base must be torqued before the lash of the variable valve actuator
can be adjusted.
Table 2
TC Compression Stroke Inlet Rocker Arm
Cylinders 1-2-4
2. Adjust lash for the variable valve actuator according to Table 2.
a. Loosen the jam nut.
b. Place the appropriate feeler gauge between the actuator piston and the rocker
arm. Then, turn the adjustment screw in a clockwise direction. Slide the feeler
gauge between the actuator piston and the rocker arm. Continue turning the
adjustment screw until the piston of the variable valve Actuator prevents the
feeler gauge from being removed. There should be a tight hold on the feeler
gauge. Turn the adjustment screw counterclockwise in order to loosen the feeler
gauge. Refer to Table 2 for the correct variable valve actuator lash. Remove the
feeler gauge.
c. Tighten the jam nut to a torque of 50 ± 10 N· m (37 ± 7 lb ft). Do not allow the
adjustment screw to turn while you are tightening the jam nut. Recheck the lash
setting after tightening the jam nut.
Table 3
TC Exhaust Stroke Inlet Rocker Arm

Cylinders 3-5-6
4. Adjust lash for the variable valve actuator according to Table 3.
a. Loosen the jam nut.
b. Place the appropriate feeler gauge between the actuator piston and the rocker
arm. Then, turn the adjustment screw in a clockwise direction. Slide the feeler
gauge between the actuator piston and the rocker arm. Continue turning the
adjustment screw until the piston of variable valve actuator prevents the feeler
gauge from being removed. There should be a tight hold on the feeler gauge.
Turn the adjustment screw counterclockwise in order to loosen the feeler gauge.
Refer to Table 3 for the correct variable valve actuator lash setting. Remove the
feeler gauge.
c. Tighten the jam nut to a torque of 50 ± 10 N· m (37 ± 7 lb ft). Do not allow the
adjustment screw to turn while you are tightening the jam nut. Recheck the lash
setting after tightening the jam nut.
5. Remove the timing bolt from the flywheel after all adjustments have been made.
Reinstall the timing cover.
Note: The valve lash must be adjusted before adjusting the compression
brake, if equipped. Refer to Testing and Adjusting, "Electronic Unit
Injector - Adjust".
Power Train Charge System Pressure - Test and Adjust

SMCS - 5117-025-PWT; 5117-081-PWT
Introduction
In order to reduce the risk of personal injury due to

testing and adjusting that is performed on the machine,
use a wireless pressure gauge or a long hose that will
allow personnel to keep away from the machine while the
engine is running.
When testing and adjusting the transmission and power

train, move the machine to an area clear of obstructions,
with safe exhaust ventilation for the exhausts. Sudden
movement of the machine or release of oil under pressure
can cause injury to persons on or near the machine. To
prevent possible injury, do the procedure that follows
before testing and adjusting the transmission and power
train.
Personal injury can result from spring force released

when removing cap screws.
Internal spring force will be released when cylinder

assembly cap screws are removed causing injury.
Always restrain cover as cap screws are loosened.
Follow the established procedure in the Service Manual

to service these parts.
NOTICE

adjusting, and repair of the machine. Be prepared to
containing fluids.
The following procedure is used to test the charge system for the power train.
Specifications
Table 1
Worksheet
Target Pressure Actual Pressure
2480 ± 35 kPa (360 ± 5 psi)
Required Tools
Table 2
Tool Item Qty Part Number Part Name
Pressure Gauge
A1 1 8T-0855
(0 to 4,000 kPa (0 to 580 psi))
A2 1 6V-3989 Fitting
A
A3 2 6V-4143 Quick Connect Coupler
A4 1 177-7862 Hose As
B 198-4240 Digital Pressure Indicator Gp
B1 1 198-4234 Digital Indicator
Pressure Sensor Gp
B2 1 198-4237
(0 to 3,445 kPa (0 to 500 psi))
B3 1 198-4236 Adapter Cable As
Test Preparation
Reference: Before you perform this adjustment, refer to Testing and Adjusting, "Machine
Preparation".
1. Operate the machine until the transmission oil is at operating temperature range
of 75 °C to 90 °C (167 °F to 194 °F).
2. Stop the machine on a hard level surface. Move the transmission control lever to the
NEUTRAL position. Shut off the engine. Place blocks in front of the wheels and
place blocks behind the wheels.
3. Engage the parking brake.
Left side view of the transmission
(1) Main relief valve
Main relief valve
(2) Dust cap
(3) Adjustment screw
(4) Cover
4. Remove dust cap (2). Attach Tooling (A) to the fitting.
Test Procedure
1. Be sure that the transmission control lever is in the NEUTRAL position. Start the
engine and run the engine at high idle.
2. At high idle, the pressure should be 2480 ± 35 kPa (360 ± 5 psi).
Adjustment Procedure
1. If the pressure is not within the specification, stop the engine.
2. Remove cover (4) and turn adjustment screw (3) counterclockwise if the
pressure is above the specification and clockwise if the pressure is below the
specified.
3. Start the engine and check the pressure again. Release and engage the parking brake
again to check if the pressure has changed.
4. Repeat the Steps 1 through 3 until the pressure achieved is 2480 ± 35 kPa (360 ± 5 psi).
5. Stop the engine and install the adjustment screw cover (4).
6. Remove the test equipment. Install dust cap (2).
Transmission Lubrication Oil Pressure - Test

SMCS - 3080-032-PX
Specifications
Table 1
Transmission Lubrication Pressure (Minimum)
Neutral First Gear Forward
LOW Idle 14 kPa (2 psi) 6 kPa (1 psi)
HIGH Idle 275 kPa (40 psi) 135 kPa (20 psi)
Table 2
Transmission Lubrication Pressure
Differential Lock in the "ON" Position
LOW Idle
HIGH Idle
Transmission Lubrication Pressure
Differential Lock in the "OFF" Position

LOW Idle
HIGH Idle
Introduction

engine is running.

train.
NOTICE

containing fluids.
The following procedure is used to test the pressure of the transmission

lubrication oil.
Required Tools
Table 3
Pressure Gauge
A1 1 8T-0854
(0 to 1,000 kPa (0 to 145 psi))
A A2 1 6V-3989 Fitting
A4 1 177-7862 Hose As
D1 1 148-8309 Adapter As
D
D2 1 164-5567 Quick Disconnect Coupler As
Test Preparation
Before you begin this procedure, refer to Testing and Adjusting, "Machine Preparation".
1. Operate the machine until the transmission oil is at operating temperature of 51 °C (124
°F).
2. Stop the machine on a hard level surface. Engage the parking brake. Turn off the engine.
Rear view of the machine
(1) Plug
3. Remove plug (1) from the transmission case. Install Tooling (D) into the port. Attach
Tooling (A) onto Tooling (D).
4. Place the machine on stands so that the rear wheels are off the ground.
Note: Make sure that the All Wheel Drive (AWD) system is turned off.
Note: Support the tandem to prevent the tandem from torquing when the service brake is
applied.
Test Procedure
1. Start the engine.
2. Apply the parking brake. Turn the differential lock to the "ON" position. Operate the
machine in NEUTRAL at low idle. The pressure on the gauge should be a minimum
of 14 kPa (2 psi). Record the gauge reading in Table 2.
3. Operate the machine in NEUTRAL at high idle. The pressure on the gauge should
be a minimum of 275 kPa (40 psi). Record the gauge reading in Table 2.
4. Disengage the parking brake. Operate the machine in FIRST GEAR FORWARD at low
idle. The gauge pressure should be a minimum 6 kPa (1 psi). Record the gauge reading
in Table 2.
5. Operate the machine in FIRST GEAR FORWARD at high idle. The gauge
pressure should be a minimum 135 kPa (20 psi). Record the gauge reading in
Table 2.
6. Repeat Step 2 through Step 5 with the differential lock in the OFF position.
Transmission lubrication pressures that vary with the differential lock in the ON
position indicate leakage in the differential lock system.
7. Stop the machine.
8. Turn off the engine.
9. Remove the stands that were installed under the machine.
10. Remove the test equipment.
11. Install the plug that was removed in Step 3.
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Parking Brake - Test

SMCS - 4267-081
Note: Be sure that the machine has the 352-5716 Power Train Software Gp or newer
before performing this test.
Introduction
Personal injury can result if the machine moves while

testing the parking brake.
If the machine begins to move during the test, reduce the

engine speed immediately and apply the service brakes.
The following test is used to determine if the parking brake is functional. This test is intended
to measure the maximum brake holding effort. The brake holding effort that is required to
prevent a machine from moving at a specific engine rpm varies depending on the machine.
The variations are the differences in the engine setting, in the power train efficiency, and in
the brake holding ability.
Machine Preparation
Note: Be sure that the machine has the correct software for the transmission for this test.
Check the area around the machine. Make sure that the machine is clear of personnel and
clear of obstacles. Test the parking brake on a dry, level surface.
Fasten the seat belt before testing the parking brake.
Test Procedure
1. Start the engine and set the throttle to the HIGH IDLE. Raise the implements slightly.
2. Ensure that the parking brake is engaged.
3. Depress the transmission modulator control (inching pedal).
Note: Do not apply the service brakes.
4. Depress the up shift control four times in order to select "5F". The display should read
"5F".
Note: This step must be completed within 2 seconds.
5. Shift the transmission to the FORWARD direction.
Note: When, the transmission is shifted into "5F" and the parking brake is engaged a
Warning Category 3 will occur.
6. With the engine at high idle, slowly release the pedal until the transmission
automatically shifts to neutral. The engine speed will recover to the initial set
point.
7. Shift the transmission to the NEUTRAL position. Run the engine at 1500 rpm for at
least two minutes in order to cool the transmission oil.
Note: Do not shut down the engine until the oil is cooled properly. Do not repeat the
test procedure until the oil is cooled down properly.
8. Lower the implements to the ground.
9. Stop the engine.
NOTICE
If the machine moved while testing the parking brake,

inspect the parking brake components for wear or
damage. Repair or replace the worn or damaged parking
brake components as required before returning the
machine to service.
Transmission Pressures - Test and Adjust

SMCS - 3030-025-PX ; 3030-081-PX ; 3073-025-PX ; 3073-081-PX ; 3074-025-PX ; 3074-
081-PX
Specifications
Table 1
Transmission Clutch Pressures
Test NEUTRAL FIRST GEAR SECOND GEAR FIRST GEAR
Port FORWARD FORWARD REVERSE
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Table 2
Transmission Clutch Pressures
Test FIRST GEAR SECOND GEAR FIRST GEAR
NEUTRAL
Port FORWARD FORWARD REVERSE
1925 ± 220 kPa
(1) 0.0 kPa (0.00 psi) 0.0 kPa (0.00 psi) 0.0 kPa (0.00 psi)
(280 ± 32 psi)(1)
1925 ± 220 kPa
(280 ± 32 psi)(1)
1925 ± 220 kPa
(280 ± 32 psi)(1)
2480 ± 70 kPa
(360 ± 10 psi)
2480 ± 70 kPa
(360 ± 10 psi)
2480 ± 70 kPa 2480 ± 70 kPa
(6) 0.0 kPa (0.00 psi) 0.0 kPa (0.00 psi)
(360 ± 10 psi) (360 ± 10 psi)
2480 ± 70 kPa 2480 ± 70 kPa 2480 ± 70 kPa
(7) 0.0 kPa (0.00 psi)
(360 ± 10 psi) (360 ± 10 psi) (360 ± 10 psi)
2480 ± 70 kPa
(360 ± 10 psi)
(1) "If you are unable to attain the listed pressures on test port (1), port (2), and port (3), refer to Service
Magazine, M0089983, "New Software is Now Used on Certain M Series Motor Graders"
References
Refer to Service Magazine, M0089983, "New Software is Now Used on Certain M Series
Motor Graders."
Introduction

engine is running.

before testing and
adjusting the transmission and power train.
Personal injury can result from spring force released

when removing cap screws.
Internal spring force will be released when cylinder

assembly cap screws are removed causing injury.
Always restrain cover as cap screws are loosened.
Follow the established procedure in the Service Manual

to service these parts.
NOTICE

containing fluids.
The following test is used to test the transmission pressures.
Required Tools
Table 3
Tool Item Qty Part Number Description
Pressure Gauge
A1 1 8T-0855
(0 to 4,000 kPa (0 to 580 psi))
A2 1 6V-3989 Fitting
A A3 2 6V-4143 Quick Connect Coupler

A4 1 177-7862 Hose As
Pressure Sensor Gp
B2 1 198-4237
(0 to 3,445 kPa (0 to 500 psi))
D D1 1 326-8026 Transmission Test Cover
Test Preparation
Before you begin this procedure, refer to Testing and Adjusting, "Machine Preparation".
1. Operate the machine until the transmission oil is at operating temperature

of 75 °C to 90 °C (167 °F to 194 °F).
2. Stop the machine on a hard level surface. Place the transmission in NEUTRAL.
Turn off the engine. Place blocks in front of the wheels and place blocks behind the
wheels.
(1) Test port for clutch 1 (forward high)
(2) Test port for clutch 2 (forward low)
(3) Test port for clutch 3 (reverse)
(4) Test port for clutch 4 (second speed)
(5) Test port for clutch 5 (third speed)
(6) Test port for clutch 6 (first speed)
(7) Test port for clutch 7 (low range)
(8) Test port for clutch 8 (high range)
Rear view of the transmission

(9) Cover for the transmission control valve
3. Remove cover (9) from the transmission.
4. Remove the drive shaft guard.
5. Remove the differential drive shaft.
6. Assemble Tooling (D) with the 25.4 mm (1.00 inch) bumper.
7. Use the bolt holes for the drive shaft guard to attach Tooling (D) to the parking brake
housing.
Test Procedure
1. With the engine off, attach Tooling (A) or Tooling (B) to test port (5) and port (8).
2. Start the engine and operate the engine at high idle with the transmission in
NEUTRAL. Tooling (A) or Tooling (B) should read 2480 ± 70 kPa (360 ± 10 psi).
Record the pressure readings in Table 1.
3. Stop the engine and remove Tooling (A) or Tooling (B).
4. With the engine off, attach Tooling (A) or Tooling (B) to test port (1), port (6), and port
(7).
5. Start the engine and Operate the engine at high idle with the transmission in FIRST
GEAR FORWARD. Tooling (A) or Tooling (B) should read 1925 ± 220 kPa (280 ±
32 psi) for test port (1). And tooling (A) or (B) should read 2480 ± 70 kPa (360 ± 10
psi) for test port (6) and port (7). Record the pressure readings in Table 1.
6. Stop the engine and remove Tooling (A) or Tooling (B) from test port (1).
7. With the engine off, attach Tooling (A) or Tooling (B) to test port (3), port (6), and port
(7).
8. Start the engine and operate the engine at high idle with the transmission in FIRST
GEAR REVERSE. Tooling (A) or Tooling (B) should read 1925 ± 220 kPa (280 ± 32
psi) for test port (3). And tooling (A) or (B) should read 2480 ± 70 kPa (360 ± 10 psi)
for test ports (6) and (7). Record the pressure readings in Table 1.
9. Stop the engine and remove Tooling (A) or Tooling (B) from test ports (3), and (6).
10. With the engine off, attach Tooling (A) or (B) to test port (2), port (4), and port (7).
11. Start the engine and operate the engine at high idle with the transmission in SECOND
GEAR FORWARD. Tooling (A) or Tooling (B) should read 1925 ± 220 kPa (280 ± 32
psi) for test port (2). And Tooling (A) or Tooling (B) should read 2480 ± 70 kPa (360
± 10 psi) for test port (4) and port (7). Record the pressure readings in Table 1.
12. Stop the engine and remove tooling (A) or Tooling (B).
13. Install the cover (9) and the differential drive shaft.
Note: If all the pressure readings are not within the specified pressure ranges listed in Table
2, the main relief valve may need to be adjusted. Refer to Testing and Adjusting, "Power
Train Charge System Pressure - Test and Adjust" for information about adjusting the main
relief valve. The Testing and Adjusting, "Fill Time for the Transmission Clutch - Calibrate"
procedure will not affect the top pressure of the clutch.
Note: If some of the pressure readings are not within the specified pressure range that is
listed in Table 2, those modulating valves may need to be replaced.
System Pressure - Release

SMCS - 4250-553-PX ; 5050-553-PX
Braking and Hydraulic Fan System
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic

system after the engine has been stopped. Serious injury
can be caused if this pressure is not released before any
service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil

is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped, and the filler cap is cool enough to touch with
your bare hand.
To relieve the pressure from the braking and hydraulic fan system, turn off the machine.
Pump the brakes at least 110 times. Do not assume that all of the pressure is removed from
the system because the brake pedal does not have resistance. Remove the pressure when you
work on any part of the braking and hydraulic fan system.
Service Brake System Pressure - Test

SMCS - 4250-032-PX

engine is running.
Personal injury can result if the machine moves while testing.
If the machine begins to move during test, reduce the

engine speed immediately and engage the parking brake.
Sudden movement of the machine or release of oil under

pressure can cause injury to persons on or near the
machine.
To prevent possible injury, perform the procedure

that follows before testing and adjusting the brake
system.
Specifications
Table 1
Service Brake System Pressures
System pressure prior to starting the engine 0 kPa (0 psi)
Both Left and Right Service Brake Pressures at normal operating 5860 ± 345 kPa
temperature (850 ± 50 psi)(1)(2)
(1) If your machine has 308-9523 Brake Control Valve Gp installed, the maximum bias pressure will be around 207
kPa (30 psi).
(2) If your machine has 355-7411 Brake Control Valve Gp installed, the maximum bias pressure will be around 55
kPa (8 psi).
Introduction
This test will check the service brake pressure at the tandem units.
Required Tools
Tooling (B)
Table 2
Tool Item Qty Part Number Part Name Qty
B1 1 198-4234 Digital Indicator 1
B2 1 251-9600 Pressure Sensor Gp (0 to 68,900 kPa (0 to 10,000 psi)) 1
B3 1 198-4236 Adapter Cable As 1

G 2 6V-3965 Fitting (TEST) 2
H 2 153-4906 O-Ring Seal 2
Test Preparation
1. Move the machine to a smooth, horizontal location. Move the machine away from
other operating machines and away from personnel. Place the transmission direction
control switch in the NEUTRAL position. Engage the parking brake. Lower the work
tools to the ground. Stop the engine and put chocks in front of the wheels and behind
the wheels.
2. Remove the pressure from the brake system by pumping the service brake pedal at a
rate of one second ON and one second OFF. Continue to pump the brakes until a
minimum of 110 applications have been completed. Do not assume that the pressure is
removed from the circuit if the brake pedal has no resistance.
3. Assemble each (G) to each (H).
Left side service brake
4. Remove the plug from the test port (1) for the left service brakes. Install fitting (G)
and tooling (B) onto test port (1).
Right side service brake
5. Remove the plug from the test port (2) for the right service brakes. Install fitting (G)
and tooling (B) onto test port (2).
Test Procedure
1. Look at the pressure gauges. Before you start the engine, the hydraulic oil pressure
should be 0 kPa (0 psi).
2. Start the engine. Allow the hydraulic oil to reach normal operating temperature.
3. Depress the brake pedal. Do not permit the brake pedal to come up. Both the left
service brake and the right service brake pressures must be within 5860 ± 345 kPa
(850 ± 50 psi). If your machine has
308-9523 Brake Control Valve Gp installed, the maximum bias pressure will be around
207 kPa
(30 psi). If your machine has 355-7411 Brake Control Valve Gp installed, the maximum
bias pressure will be around 55 kPa (8 psi).
4. Stop the engine.
6. Remove all test equipment and reinstall the plugs.
If the service brake pressures are not correct, refer to the Testing and Adjusting, "Brake
Accumulator Charging Valve - Test and Adjust".
Parking Brake - Test

SMCS - 4267-081
Note: Be sure that the machine has the 352-5716 Power Train Software Gp or newer
before performing this test.
Introduction
Personal injury can result if the machine moves while

testing the parking brake.
If the machine begins to move during the test, reduce the

engine speed immediately and apply the service brakes.
The following test is used to determine if the parking brake is functional. This test is intended
to measure the maximum brake holding effort. The brake holding effort that is required to
prevent a machine from moving at a specific engine rpm varies depending on the machine.
The variations are the differences in the engine setting, in the power train efficiency, and in
the brake holding ability.
Machine Preparation
Note: Be sure that the machine has the correct software for the transmission for this test.
Check the area around the machine. Make sure that the machine is clear of personnel and
clear of obstacles. Test the parking brake on a dry, level surface.
Fasten the seat belt before testing the parking brake.
Test Procedure
1. Start the engine and set the throttle to the HIGH IDLE. Raise the implements slightly.
2. Ensure that the parking brake is engaged.
3. Depress the transmission modulator control (inching pedal).
Note: Do not apply the service brakes.
4. Depress the up shift control four times in order to select "5F". The display should read
"5F".
Note: This step must be completed within 2 seconds.
5. Shift the transmission to the FORWARD direction.
Note: When, the transmission is shifted into "5F" and the parking brake is engaged a
Warning Category 3 will occur.
6. With the engine at high idle, slowly release the pedal until the transmission
automatically shifts to neutral. The engine speed will recover to the initial set
point.
7. Shift the transmission to the NEUTRAL position. Run the engine at 1500 rpm for at
least two minutes in order to cool the transmission oil.
Note: Do not shut down the engine until the oil is cooled properly. Do not repeat the
test procedure until the oil is cooled down properly.
8. Lower the implements to the ground.
9. Stop the engine.
NOTICE
If the machine moved while testing the parking brake,

inspect the parking brake components for wear or
damage. Repair or replace the worn or damaged parking
brake components as required before returning the
machine to service.
Brake Accumulator Charging Valve - Test and Adjust -

16M

engine is running.


machine.

system.
Introduction
This test provides information on the testing and the adjusting of the accumulator charging
valve.
Required Tools
Tooling (B)
Table 1
B2 2 198-4238 Pressure Sensor Gp (0 to 34,450 kPa (0 TO 5,000 psi))
F 1 5P-1318 Adapter
G 1 1J-9671 O-Ring Seal
H 1 6V-3965 Fitting (TEST)

J 1 153-4906 O-Ring Seal
Machine Preparation
control lever in the NEUTRAL
position. Engage the parking brake. Lower the work tools to the ground. Stop
the engine and put chocks in front of the wheels and behind the wheels.
The control manifold prior to the installation of the adapter and the quick disconnect coupler
3. Remove sensor (2) from manifold (1). Install (G) onto adapter (F). Then install adapter
(F) into the port that held sensor (2).
4. Install (J) onto (H). Then install onto (H) onto (F). Next install (B) onto (H).
Note: Performing this procedure will produce a Warning Category 3, because sensor (1)
has been removed.
Perform the Test

1. Start the engine and run the engine with the transmission in neutral and the
parking brake engaged. Allow the hydraulic oil to reach normal operating
temperature.
Note: The cut in pressure must be adjusted first, because changing the cut in pressure
will also change the cut-out pressure.
2. Pump the service brake pedal. The minimum pressure on the gauges is the cut in
pressure. The cut in pressure should be 9650 ± 661 kPa (1400 ± 96 psi).
3. Loosen locknut (4) and turn setscrew (3) to adjust the cut in pressure. Pump the
service brake pedal. Turn the setscrew clockwise to increase the cut in pressure. Turn
the setscrew counterclockwise to decrease the cut in pressure. Perform this operation
until the correct cut in pressure is achieved. Then tighten locknut (4).
4. Start the engine. Pump the service brake pedal until the pressure in the brake system
decreases to the cut in pressure. The system will recharge and the pump will cut out
at maximum pressure.
5. Repeat Steps 2 through Step 4 until the pressure is within limits.
6. The maximum pressure on the gauges is the cut-out pressure. The cut-out
pressure should be 15858 ± 661 kPa (2300 ± 96 psi).
7. If the cut-out pressure is incorrect, stop the engine.
8. Loosen locknut (6). Turn setscrew (5) clockwise to increase the cut-out pressure.
Turn setscrew (5) counterclockwise to decrease the cut-out pressure. Adjust the
setscrew until the cut-out valve is at the correct pressure setting. Then tighten locknut
(6).
9. Start the engine and check the pressure again.
10. Repeat Step 6 through Step 9 until the pressure is within limits.
11. Stop the engine. Remove the pressure from the brake system by pumping the service
brake pedal at a rate of one second ON and one second OFF. Continue to pump the
brakes until a minimum of 110 applications have been completed. Do not assume
that the pressure is removed from the circuit if the brake pedal has no resistance.
12. Remove the test equipment and reinstall sensor (2) into manifold (1).
Brake Accumulator (Service) - Test and Charge

SMCS - 4263-045; 4263-081; 4263-535
Personal injury or death can result from improper

accumulator charging.
Dry nitrogen is the only gas approved for use in 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.Number 580 connections are used.
When ordering nitrogen gas, be sure that the

cylinders are equipped with CGA Number 580
Connections. Do not use color codes or other methods
of identification to tell the difference between
nitrogen and oxygen cylinders.
Never use an adapter to connect your nitrogen charging

group to a valve outlet used on both nitrogen, oxygen or
other gas cylinders. Be sure you use dry nitrogen (99.8
% purity).

pressure can cause serious injury to persons on or near
the machine.

that follows before testing and adjusting the hydraulic
system.
Cold ambient temperatures could result in the loss of

secondary braking capability due to inadequate hydraulic
accumulator nitrogen precharge. The loss of the
secondary braking system as well as the main hydraulic
pressure will result in little or no braking capability and a

potential for injury or death.
It is recommended to perform a brake accumulator

check anytime the machine has been idle for longer than
two hours below −25 °C (−13 °F). Refer to Operation
and Maintenance Manual before performing any check
of the brake accumulator.
Reference: Refer to Testing and Adjusting, "Machine Preparation for Troubleshooting" before
you begin the test.
Specification
Table 1
Accumulator Precharge Pressure/Temperature Relationship for a Typical 4138 kPa (600 psi) Brake
Accumulator
Temperature Pressure(1)
-10°C (14°F) 3701 kPa (536 psi)
-5°C (23°F) 3771 kPa (547 psi)
0°C (32°F) 3841 kPa (557 psi)
5°C (41°F) 3911 kPa (567 psi)
10°C (50°F) 3982 kPa (577 psi)
15°C (59°F) 4052 kPa (587 psi)
20°C (68°F) 4122 kPa (597 psi)
25°C (77°F) 4193 kPa (608 psi)
30°C (86°F) 4263 kPa (618 psi)
35°C (95°F) 4333 kPa (628 psi)
40°C (104°F) 4404 kPa (638 psi)
45°C (113°F) 4474 kPa (648 psi)
50°C (122°F) 4544 kPa (659 psi)
(1) The tolerance on the nominal pressure is 206 kPa (30 psi).
Introduction
The brake accumulators are mounted behind the cab. The purpose of the accumulator is to
store pressure. The stored pressure allows the machine operator to bring the machine to a stop
in the event of an interruption of pressure from the brake pump.
The following procedure will determine if the accumulator is charged to the appropriate
pressure.
Machine Preparation
other operating machines and away from personnel.
2. Place the transmission direction control switch in the NEUTRAL position. Engage the
parking brake.
3. Lower the work tools to the ground. Stop the engine and place chocks in front of the
wheels and behind the wheels.
Lowering the Piston in Brake Accumulators

In order to charge the accumulator, the piston in the brake accumulator must be on the bottom
of the cylinder. The air temperature outside the accumulator is the ambient temperature.
Before the dry nitrogen pressure in the accumulator can be accurately checked, the
temperature of the accumulator must be equal to the ambient temperature. Before the
accumulator may be correctly charged, the temperature of the accumulator must be equal to
the ambient temperature.
Use table 1 in order to determine the correct charging pressure for the 249-3860 Brake
Accumulator Gp.
Accumulator Charging Procedure

1. Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging
Procedures".
Accumulator Charge Procedure for a Rebuilt Accumulator
NOTICE

containing fluids.

Remove all of the air from the accumulator. After the accumulator is rebuilt, put
approximately 0.9 L (1 qt) of SAE 10W hydraulic oil in the nitrogen chamber of the
accumulator. This oil will be used to help remove the air from the nitrogen chamber of the
accumulator. This hydraulic oil also lubricates the top seal of the piston in the accumulator.
Install the rebuilt accumulator on the machine. Refer to Special Instruction,

REHS5464, "Accumulator Discharging and Charging Procedures" to charge the
rebuilt accumulator.
1. Install the 175-5507 Nitrogen Charging Group.
Brake Control Valve (Service) - Check

SMCS - 4265-535

engine is running.


machine.

system.
Specifications
Table 1
Maximum Amount That The Service Brake Pressure Can Drop After 2 Minutes
140 kPa (20 psi)
Introduction
The brake control valve (service) controls the flow of pressurized oil.
Required Tools
Tooling (B)
Table 2
B2 2 198-4239 Pressure Sensor Gp (0 to 41,369 kPa (0 to 6,000 psi))
G 2 6V-3965 Fitting (TEST)
H 2 153-4906 O-Ring Seal
Test Preparation
control switch in the NEUTRAL
position. Engage the parking brake. Lower the work tools to the ground. Stop
the engine and put chocks in front of the wheels and behind the wheels.
3. Assemble each (G) to each (H).
Left side service brake
(1) Test port
4. Remove the plug from test port (1) for the left service brakes. Install fitting (G) and
Tooling (B) onto the test port (1).
Right side service brake
(2) Test port
5. Remove the plug from the test port (2) for the right service brakes. Install fitting (G)
and Tooling (B) onto the test port (2).
6. Look at the pressure gauges. Before you start the engine, the hydraulic oil pressure
should be 0 kPa (0 psi).
Test Procedure for the Brake Control Valve

1. Start the engine. Allow the hydraulic oil to reach normal operating temperature.
Normal operating is 60° ± 5°C (140° ± 9°F).
2. Depress the brake pedal. Do not permit the brake pedal to come up. Shut off the
engine. Look at the pressure gauges.
3. If service brake pressure drops below 140 kPa (20 psi) after 2 minutes, the brake
control valve must be inspected for the cause of leakage.
removed from the circuit if the brake pedal has no resistance. Remove all test
equipment and reinstall the plugs.
5. Remove all test equipment and reinstall the plugs.
Brake Disc Wear - Check

SMCS - 4255-535
Specification
Table 1
Compensator Settings
Machine Number of turns out Tolerance(1)
14M 2.75 Turns + 60° ± 30 °
16M 4 Turns + 60° ± 30 °
(1) Tolerance is measured in degrees of rotation of the adjustment knob
Introduction
This test determines the amount of wear to the brake discs, which determines if the brake
pack needs to be replaced. The adjustment keeps piston travel to a minimum.
Reference: Refer to the Systems Operation, "Service Brakes" for additional

information concerning the Compensator.
Compensator (4) is preset at the factory. The factory setting will allow compensator (4) to
travel a predetermined amount prior to hitting nut (3).
Note: This test is only valid when piston (2) is fully compressed against brake pack (1).
Required Tooling
Tooling is not required for this procedure.
Check Preparation
1. Lower all implements to the ground, set the parking brake, shut off the engine,
and chock the rear wheels.
Perform the Check Procedure
Cut-away of the brakes
(1) Brake pack
(2) Piston
(3) Nut
(4) Compensator
1. Depress the brake pedal in order to compress piston (2) fully against brake pack (1).
2. Loosen nut (3) completely, until the nut contacts the head of compensator (4).
3. Turn compensator (4) in by hand until the compensator (4) contacts piston (2).
Note: If compensator (4) can be turned in completely and does not contact piston (2),
then brake pack
(1) must be replaced. If compensator (4) contacts piston (2), proceed to the
Testing and Adjusting, "Adjustment Procedure" in this article.
1. Back off compensator (4) according to the specifications that are reflected in the
table. Refer to Table 1.
2. Hold compensator (4) in position from Step 1 and tighten nut to 50 ± 10 N· m (37 ± 7 lb
ft).
Differential Lock Pressure - Check

SMCS - 3272-535-PX
Specifications
Table 1
Worksheet
Target Pressure Actual Pressure
2480 ± 70 kPa (360 ± 10 psi)
Introduction


engine is running.

train.
NOTICE

containing fluids.
The following procedure is used to test the operation of the differential lock.
Required Tools
Table 2
Pressure Gauge
A1 1 8T-0855
(0 to 4,000 kPa (0 to 580 psi))
A A2 1 6V-3989 Fitting
A4 1 177-7862 Hose As
Pressure Sensor Gp
B2 1 198-4237
(0 to 3,445 kPa (0 to 500 psi))
Check Preparation
Reference: Before you perform this adjustment, refer to Testing and Adjusting, "Machine
Preparation".
1. Operate the machine until the transmission oil is at operating temperature

of 75 °C to 90 °C (167 °F to 194 °F).
2. Stop the machine on a hard level surface. Engage the parking brake. Shut off the engine.
Test port (1)
3. Remove the dust cap. Attach Tooling (A) or Tooling (B) to test port (1).
Test Procedure
1. Start the engine and run the engine at high idle.
2. Move the differential lock switch to the ON position.
3. The gauge should read 2480 ± 70 kPa (360 ± 10 psi). If the pressure reading is
too high or if the pressure reading is too low, the transmission relief valve may
need adjusted.
Reference: Refer to Testing and Adjusting, "Power Train Charge System Pressure -
Test and Adjust" for more information about setting the transmission relief valve.
4. If the setting for the transmission relief valve is correct and the pressure reading is
still incorrect, inspect the differential lock valve. If the differential lock valve
appears to be working properly, the differential lock clutch may need serviced.
5. Shut off the engine. Remove the test equipment.
Hydraulic Fan Speed - Test

SMCS - 1386-081-VF ; 1387-081-PX

engine is running.

Make sure all of the work tools have been lowered to the
ground, and the oil is cool before removing any
components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to
touch with your bare hand.

machine.

system.
NOTICE

containing fluids.
Refer to Special Publication, PERJ1017, "Dealer Service

Tool Catalog" for tools and supplies suitable to collect
and contain fluids on Cat® products.
Tooling (D) 9U-7400 Multitach Tool Gp
Table 1

D 9U-7400 Multitach Tool Gp
D1 1 9U-7401 Multitach Tool Gp
D2 1 9U-5140 Photo Pickup
Introduction
This test procedure is intended to determine the maximum and the minimum hydraulic fan
speed.
Preparation for Fan Speed Tests

control switch in the NEUTRAL position.
2. Engage the parking brake. Lower the work tools to the ground. Stop the engine and
put chocks in front of the wheels and behind the wheels.
3. Inspect the hoses for the fan drive for damage. Inspect all the connectors for the fan
drive for damage. Inspect all the components for the fan drive for damage.
4. Check the cooling fan for a piece of reflective tape on one of the fan blades.
Note: If a piece of reflective tape is already visible on one of the fan blades,
proceed to Step 5. If no reflective tape is visible on one of the fan blades, use the
following procedure:
a. Turn the engine start switch to the OFF position.
b. Ensure that the engine start switch is in the OFF position.
View of the rear of the machine
c. Remove the rear grill (1).
d. Clean a small area on the surface of one fan blade near the edge. Position the
tape so that the tape is visible. Place the tape near the edge of the blade.
e. Install the grill assembly (1).
5. Install Tool (D) on the grill assembly (1).
Test for Minimum Fan Speed

1. Start the engine and run the engine at high idle. Use the throttle lock to maintain high
idle.
Note: To ensure the proper operation of the cooling system, the doors for the engine
enclosure should be closed while the test procedures are conducted.
3. Allow the brake accumulators to charge fully.
4. Measure the fan speed before the engine reaches normal operating temperature.
5. The minimum fan speed is 550 ± 50 rpm. If the minimum fan speed is incorrect,
refer to the Testing and Adjusting, "Hydraulic Fan Speed - Calibrate and Adjust".
Test for Maximum Fan Speed

Note: You may not be able to reach maximum fan speed because of the inability of getting the
engine and the hydraulic systems hot enough.
1. Start the engine and run the engine at high idle. Use the throttle lock to maintain high
idle.
Note: To ensure the proper operation of the cooling system, the doors for the engine
enclosure should be closed while the test procedures are conducted.
3. Allow the brake accumulators to charge fully.
4. With the engine at normal operating temperature, measure the speed of the fan.
5. Check Table 2 for the maximum fan speed of your machine. If the maximum fan
speed is incorrect, refer to the Testing and Adjusting, "Hydraulic Fan Speed -
Calibrate and Adjust".
Table 2
Fan Speeds
Maximum
Sales Model Standard High Ambient
14M 1450 ± 50 rpm 1650 ± 50 rpm
16M 1200 ± 50 rpm 1450 ± 50 rpm
Hydraulic Fan Speed - Calibrate and Adjust

SMCS - 1386-025-VF ; 1386-524-VF ; 1387-025-PX ; 7610-MCH
In order to reduce the risk of personal injury

due to testing and adjusting that is performed
on the machine, use a wireless pressure gauge or
a long hose that will allow personnel to keep
away from the machine while the engine is
running.
Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
Make sure all of the work tools have been

lowered to the ground, and the oil is cool before
removing any components or lines. Remove the
oil filler cap only when the engine is stopped,
and the filler cap is cool enough to touch with
your bare hand.
Sudden movement of the machine or release of

oil under pressure can cause injury to persons
on or near the machine.
To prevent possible injury, perform the

procedure that follows before testing and
adjusting the brake system.
NOTICE
Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting, and repair of
the product. Be prepared to collect the fluid
with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Refer to Special Publication, PERJ1017, "Dealer

Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Cat®
products.
Introduction
This procedure is used to set the minimum and the maximum fan speed for your machine.
Required Tools
Tooling D
Table 1
D 9U-7400 Multitach Tool Gp
D1 1 9U-7401 Multitach Tool Gp
D2 1 9U-5140 Photo Pickup
Preparation for Calibration

1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel.
Place the transmission direction control switch in the NEUTRAL position.
2. Engage the parking brake. Lower the work tools to the ground. Stop the engine and place chocks in front of the wheels and behind the wheels.
3. Inspect the hoses for the fan drive for damage. Inspect all the connectors for the fan drive for damage. Inspect all the components for the fan
drive for damage.
4. Check the cooling fan for a piece of reflective tape on one of the fan blades.
Note: If a piece of reflective tape is already visible on one of the fan blades, proceed to Step 5. If no reflective tape is visible on one of the
fan blades, use the following procedure:
a. Turn the engine start switch to the OFF position.
b. Ensure that the engine start switch is in the OFF position.
View of the rear grill
c. Remove the rear grill (1).
d. Clean a small area on the surface of one fan blade near the edge. Position the tape so that the tape is visible. Place the tape near the edge
of the blade.
e. Install the grill assembly (1).
5. Install Tool (D) on the grill assembly (1).
6. Start the engine and run the engine at low idle.
Note: To ensure the proper operation of the cooling system, the doors for the engine enclosure should be closed while the test procedures are
conducted.
7. Connect Caterpillar Electronic Technician (ET) to the machine.
8. Open Cat® ET and check for active diagnostic codes. If there is an active diagnostic code, the calibration procedure will be stopped until the
condition that caused the diagnostic code is corrected.
9. Once any active diagnostic codes are corrected, select the engine Electronic Control Module (ECM) from the available ECM list.
Note: The following information is an example of the calibration procedure. The actual calibration screens may not be for your machine and
the screens may vary as new versions of software are released.
Typical example
10. Select the "Service" menu to begin the calibration procedure. Then select "Calibrations". A second menu will be displayed. Select "Engine
Cooling Fan Calibration" from the second menu.
Typical example
11. Read the warning and select "OK" when you are ready to proceed.
Typical example
12. The next screen allows you to unselect the tests that are not required. Select the box next to the test that is not desired. The check in the check
box will disappear when the test is unselected. The test for the nominal fan speed should not be performed. The test for the nominal fan speed
is used for testing purposes only. The test for the maximum fan speed and the test for the minimum fan speed are the only tests that should
be used. Once the desired tests have been selected, select "Begin".
13. Proceed to "Calibration for Maximum Fan Speed" if the test for the maximum fan speed was selected.
14. Proceed to "Calibration for Minimum Fan Speed" if the test for the minimum fan speed was selected.
Calibration for Fan Speed Solenoid

Calibration for Maximum Fan Speed
Typical example
1. The next screen is the initial calibration screen. The screen displays the instructions for calibration. The top display area displays status
parameters that are monitored during the calibration. The middle display area displays information about the status of the calibration. The
display area on the bottom will display the conditions for the setup and the instructions for the calibration.
Illustration 7 g01286217 Throttle lock
2. The display area will show the following conditions for the setup:
Set the parking brake.
Operate the engine at high idle. Use the throttle lock (4) to operate the engine at high idle.
Ensure that the hydraulic oil temperature exceeds 55 °C (131 °F).
3. Perform the following procedures to satisfy the conditions for setup.
a. Ensure that the parking brake is engaged.
b. Run the engine at high idle with the throttle lock.
c. Monitor the hydraulic oil temperature with the Cat® ET screen and stall a hydraulic function to increase the hydraulic oil
temperature. Stall a hydraulic function by moving the function to the end of travel.
4. When the conditions for setup are satisfied, press the "Next>" button to start the calibration. If the conditions for the setup are not correct, the
condition that is not correct will be display in the middle display area. The calibration will not start. When the conditions are correct, press the
"Next>" button to start the calibration of the fan speed.
Note: When the maximum fan speed is calibrated, the minimum signal will be sent to the hydraulic demand fan solenoid. This minimum
signal will obtain the maximum fan speed.
Note: You can cancel the calibration at any time by pressing the "Cancel" button.
Typical example
5. Record the fan speed. The maximum fan speed for your machine is shown in Table 2. Press button (5) or press button (6) at the bottom of
the screen until the fan speed is approximately 1000 rpm. Then, press the button (5) at the bottom of the screen until the fan speed is
correct.
Note: When button (6) is pressed, the signal to the hydraulic demand fan solenoid will be increased. When the signal is increased, the fan
speed will decrease. When button (5) is pressed, the signal to the hydraulic demand fan solenoid will be decreased. When the signal is
decreased, the fan speed will increase.
Note: When adjusting the maximum fan speed, if the maximum fan speed is exceeded, then decrease the fan speed to 1000 rpm. Repeat
the process of increasing the fan speed to the maximum fan speed in Table 2. This procedure will allow the fan speed to be properly set.
Table 2
Fan Speeds
Maximum
Sales Model Standard AWD High Ambient

14M 1450 ± 50 rpm - 1650 ± 50 rpm
16M 1200 ± 50 rpm - 1450 ± 50 rpm
6. The calibration procedure could be stopped for several reasons. Refer to the following table for the error codes that can be displayed by
Cat® ET. Correct the condition that caused the error code and restart the calibration.
Table 3
Error Codes for the Calibration of the Fan Speed Solenoid
Error
Description Procedure
Code
0002 Active diagnostic present There is an active diagnostic code. Exit the calibration and correct the condition that caused the diagnostic code.
Calibration aborted by
0006
tool/monitor The calibration has been stopped by Cat® ET. Restart the calibration procedure.
0009 Calibration aborted by ECM The calibration has been stopped by the ECM. Restart the calibration procedure.
1010 Engine stopped The engine has stopped. Restart the engine and set the engine to high idle.
1012 Engine rpm incorrect The engine rpm is not correct. Set the engine rpm to high idle.
1018 Parking brake not engaged The parking brake is not engaged. Set the parking brake.
1020 Transmission gear incorrect The transmission gear is not correct. The transmission must be in NEUTRAL.
Hydraulic oil temperature too

1048 The hydraulic oil temperature is too low. Repeat the procedure to increase the hydraulic oil temperature.
low
Hydraulic oil temperature too The hydraulic oil temperature is too high. Decrease engine speed and ensure that the doors for the engine
1054
high enclosure are closed.
1074 Engine rpm too low The engine rpm is too low. Set the engine rpm to high idle.
7. Once the maximum fan speed is correct, press the "Next>" button to complete the test.
Typical example
8. The next screen will show that the test was successful. Select "Continue" to proceed.
9. If the test for the minimum fan speed was selected, proceed to "Calibration for Minimum Fan Speed". If the test for the minimum fan
speed was not selected, disengage the throttle lock and stop the engine.
10. Remove the test equipment unless proceeding to the Testing and Adjusting, "Calibration for Minimum Fan Speed" steps.
Calibration for Minimum Fan Speed
Typical example
1. The next screen is the initial calibration screen. The screen displays the instructions for calibration. The top display area displays status
parameters that are monitored during the calibration. The middle display area displays information about the status of the calibration. The
display area on the bottom will display the conditions for the setup and the instructions for the calibration.
Illustration 11 g01286217 Throttle Lock
2. The display area will show the following conditions for the setup:
Set the parking brake.
Operate the engine at high idle. Use the throttle lock (4) to operate the engine at high idle.
Ensure that the hydraulic oil temperature exceeds 55 °C (131 °F).
3. Perform the following procedures to satisfy the conditions for setup.
a. Ensure that the parking brake is engaged.
b. Run the engine at high idle with the throttle lock.
c. Monitor the hydraulic oil temperature with the Cat® ET screen and stall a hydraulic function to increase the hydraulic oil
temperature. Stall a hydraulic function by moving the function to the end of travel.
4. When the conditions for setup are satisfied, press the "Next>" button to start the calibration. If the conditions for the setup are not correct, the
condition that is not correct will be display in the middle display area. The calibration will not start. When the conditions are correct, press the
"Next>" button to start the calibration of the fan speed.
Note: When the minimum fan speed is being calibrated, the maximum signal will be sent to the hydraulic demand fan solenoid. This
maximum signal will obtain the minimum fan speed.
Note: You can cancel the calibration at any time by pressing the "Cancel" button.
Typical example
5. Record the fan speed. Press button (5) or press button (6) at the bottom of the screen until the fan speed is approximately 1000 rpm. Then, press
the button (6) at the bottom of the screen until the fan speed is correct. The minimum fan speed is 550 ± 50 rpm.
Note: When button (6) is pressed, the signal to the hydraulic demand fan solenoid will be increased. When the signal is increased, the fan
speed will decrease. When button (5) is pressed, the signal to the hydraulic demand fan solenoid will be decreased. When the signal is
decreased, the fan speed will increase.
Note: When adjusting the minimum fan speed, if the minimum speed is exceeded, then increase the speed of the fan to 1000 rpm. Repeat
the process of decreasing the speed of the fan to 550 ± 50 rpm. This procedure will allow the fan speed to be properly set.
6. The calibration procedure could be stopped for several reasons. Refer to the following table for the error codes that can be displayed by
Cat® ET. Correct the condition that caused the error code and restart the calibration.
Table 4
Error Codes for the Calibration of the Fan Speed Solenoid
Error
Description Procedure
Code
0002 Active diagnostic present There is an active diagnostic code. Exit the calibration and correct the condition that caused the diagnostic code.
Calibration aborted by
0006 The calibration has been stopped by Cat® ET. Restart the calibration procedure.
tool/monitor
0009 Calibration aborted by ECM The calibration has been stopped by the ECM. Restart the calibration procedure.
1010 Engine stopped The engine has stopped. Restart the engine and set the engine to high idle.
1012 Engine rpm incorrect The engine rpm is not correct. Set the engine rpm to high idle.
1018 Parking brake not engaged The parking brake is not engaged. Set the parking brake.
1020 Transmission gear incorrect The transmission gear is not correct. The transmission must be in NEUTRAL.
Hydraulic oil temperature too

1048 The hydraulic oil temperature is too low. Repeat the procedure to increase the hydraulic oil temperature.
low
Hydraulic oil temperature too The hydraulic oil temperature is too high. Decrease engine speed and ensure that the doors for the engine
1054
high enclosure are closed.
1074 Engine rpm too low The engine rpm is too low. Set the engine rpm to high idle.
7. Once the minimum fan speed is correct, press the "Next>" button to end the calibration of the fan speed.
Typical example
8. The next screen will show that the test was successful. Select "Continue" to proceed.
9. Disengage the throttle lock and stop the engine.
10. Remove the test equipment.
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Control Manifold (Steering Backup) - Test

SMCS - 5051-081; 5264-081
The machine's batteries must have a normal charge and the

secondary steering electrical system must be okay. A low
charge condition, or any defect in the battery, battery cells,
or electrical circuit can cause loss of secondary steering and
could result in personal injury and/or damage to the
machine.
NOTICE
Once the secondary steering system has been activated,

it should remain ON no more than two minutes. This
should be sufficient time to safely steer the machine to a
stop. When the machine is stopped, turn the key start
switch to the OFF position in order to turn OFF
secondary steering. Prolonged use of the secondary
steering system will cause the electric motor to overheat
and cause damage to it's components.
Introduction
This test verifies that the secondary steering solenoids are functioning properly if the main
steering solenoids fail.
Required Tools
Tools are not required for this test procedure.
Machine Preparation
1. Complete the test procedure Test and Adjusting, "Magnetic Switch (Secondary
Steering Relay) - Test" in order to verify that the secondary steering pump functions
correctly before starting Step 2.
2. The machine should be stationary. Press the implement lockout switch to the ON
position.
3. Activate the parking brake. The key should be in the ON position. Start the engine and
run the engine.
Test Procedure
1. Start the engine and run the engine.
(1) Secondary steering test switch
2. Depress secondary steering test switch (1).
3. While secondary steering test switch (1) is held in the TEST position, provide the
following steering inputs with the left-hand joystick:
Steer left
Steer to the center
Steer right
Verify that the movement of the front wheels aligns with each steering input.
Note: The secondary steering pump will run for a maximum of 10 second intervals.
4. The alert indicator for the secondary steering should remain amber in color during
the test. If the test was not successful, the alert indicator for the secondary steering
will be red in color. Verify that steering faults or events do not occur.
Piston Pump (Brake, Hydraulic Fan) High Pressure Stall

- Test and Adjust - 16M
SMCS - 5070-081-BRK; 5070-081-HFN; 5086-025
S/N - B9H1-UP
S/N - R9H1-UP

engine is running.

Sudden movement of the machine or release of oil under pressure can

cause injury to persons on or near the machine.

system.
Introduction
This procedure will test the setting of the cut-out pressure of the piston pump against a dead
head load.
NOTICE
During this test procedure operation of the engine for

more than 1 minute durations can damage the pump.
Required Tools
Tooling B
Table 1
6V-9511 Plug
F 1
6V-9746 O-Ring Seal
6V-9832 Cap As
G 1
6V-9746 O-Ring Seal
Machine Preparation
1. Run the machine to reach the normal operating temperature.
control lever in the NEUTRAL position. Engage the parking brake. Lower the work
tools to the ground. Stop the engine and put chocks in front of the wheels and
behind the wheels.
View of the brake and hydraulic fan control manifold
4. Remove hydraulic oil line (1) from the Tee (2) and add tooling (F) to the supply hose (1).
Add tooling
(G) to tee (2).
View of the brake and hydraulic fan control manifold
5. Remove the cap from test port (3). Install tooling (B) onto test port (3).
6. Disconnect the wire connector from the fan speed solenoid (4).
Perform the Test
NOTICE
During this test procedure operation of the engine for

more than 1 minute durations can damage the pump.
1. Start the engine. Set the engine speed to high idle.
2. Check the pressure on the gauge. The high-pressure cutoff setting should be
21500 ± 200 kPa (3120 ± 30 psi).
Note: If the high-pressure cutoff setting is incorrect, then the pressure compensator
must be adjusted. Refer to Step 3.
View of bottom left of the 16M engine compartment
3. Perform the following operations to adjust the high-pressure cutoff setting:
a. Stop the engine.
b. Remove cap (5) and loosen locknut (6).
c. Turn the adjustment screw clockwise to increase the high-pressure cutoff setting.
Turn the adjustment screw counterclockwise to decrease the high-

pressure cutoff setting.
d. Tighten locknut (6) and reinstall cap (5).
e. Start the engine and check the pressure again.
f. Perform Steps 1 through 3d until the high-pressure cutoff setting is correct.
4. Stop the engine.
5. Remove tooling (B) from test port (3) and reinstall the cap.
6. Connect the wire connector to the fan speed solenoid (4).
7. Remove tooling (G) and add adapter (2) to the fan motor.
8. Remove tooling (F) and connect hydraulic oil inlet line (1) to adapter (2) on the fan
motor.
9. Install the grill.
Piston Pump (Brake, Hydraulic Fan) Margin Pressure - Test and Adjust - 16M
SMCS - 5070-081-PX ; 5086-081-BRK
S/N - B9H1-UP
S/N - R9H1-UP
In order to reduce the risk of personal injury

due to testing and adjusting that is performed
on the machine, use a wireless pressure gauge
or a long hose that will allow personnel to keep
away from the machine while the engine is
running.
Hydraulic oil pressure can remain in the

hydraulic system after the engine has been
stopped. Serious injury can be caused if this
pressure is not released before any service is
done on the hydraulic system.
Make sure all of the work tools have been

lowered to the ground, and the oil is cool before
removing any components or lines. Remove the
oil filler cap only when the engine is stopped,
and the filler cap is cool enough to touch with

your bare hand.
NOTICE
Care must be taken to ensure that fluids are

contained during performance of inspection,
maintenance, testing, adjusting, and repair of
the product. Be prepared to collect the fluid
with suitable containers before opening any
compartment or disassembling any component
containing fluids.
Refer to Special Publication, PERJ1017, "Dealer

Service Tool Catalog" for tools and supplies
suitable to collect and contain fluids on Cat®
products.
Introduction
This test procedure is intended to measure the margin pressure of the braking and the hydraulic fan pump.
Note: Do not adjust margin pressure to control fan speed unless the calibration for fan speed in Caterpillar electronic Technician (ET) cannot achieve the
minimum desired fan speed or the lowest possible fan speed is within 550 ± 50 rpm.
Required Tools
Tooling B
Table 1
F 1 8T-8902 Tee
G 1 6V-3965 Fitting (TEST)
H 1 153-4906 O-Ring Seal
Optional Tooling
Tooling D
Table 2
D 1U-5796 Pressure Differential Tool Gp
D1 2 177-7861 Hose As (4.3 M (14 FT))
D2 4 6V-4143 Quick Connect Coupler
D3 3 6V-3965 Fitting (TEST)
D4 1 6V-4144 Quick Connect Coupler
Pressure Gauge
D5 1 8T-0859
(0 to 25,000 kPa (0 to 3,600 psi))
Pressure Gauge
D5 1 8T-0861
(0 to 60,000 kPa (0 to 8,700 psi))
D6 1 8C-8431 Tee
D7 1 1U-5793 Oil Filter Pressure Differential Gauge Gp
D8 1 6V-0484 O-Ring Adapter
F 1 8T-8902 Tee
G 6V-3965 Fitting (TEST)
1
H 153-4906 O-Ring Seal
1
Machine Preparation
1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel. Place the
transmission direction
control switch in the NEUTRAL position. Engage the parking brake. Lower the work tools to the ground. Stop the engine and put chocks in front
of the wheels and behind the wheels.
2. Remove the pressure from the brake system by pumping the service brake pedal at a rate of one second ON and one second OFF. Continue
to pump the brakes until a minimum of 110 applications have been completed. Do not assume that the pressure is removed from the circuit
if the brake pedal has no resistance.
3. Assemble tooling (H) onto tooling (G).
Piston pump for the brake and hydraulic fan
4. Install Tool (F) between line (1) and fitting (2). Install Tool (G) into Tool (F).
5. Install Tooling (B) onto test port (G).
Left side of the engine compartment
6. Remove the cap from test port (3). Install Tooling (B) onto pressure test port (3).
7. Use Cat® ET to set the fan speed at 50% of the maximum rpm.
a. Connect Cat® ET to the machine.
b. Open Cat® ET and check for active diagnostic codes. If there is an active diagnostic code, then the calibration procedure will be
stopped until the condition that caused the diagnostic code is corrected.
c. Once any active diagnostic codes are corrected, select the engine Electronic Control Module (ECM) from the available ECM list.
Typical example
d. Then select "Diognostic Tests". A second menu will be displayed. Select "Override Parameters" from the second menu.
Typical example
e. The "Override Parameters" screen will appear. Select the "Engine Fan Bypass" line and place the number 50 in the"value column". Then
select the "Change" button.
Perform the Test

1. Start the engine. Operate the machine until the brake and hydraulic fan system is at the normal operating temperature. The normal operating
temperature of the brake and hydraulic fan system is 60° ± 5°C (140° ± 9°F).
Note: Monitor the system temperature throughout the entire test. Keep the temperature within the 60° ± 5°C (140° ± 9°F) normal operating
temperature range.
2. Operate the engine at high idle.
3. Record the pump discharge pressure from test port (3). Record the signal pressure from test port (G).
Note: When using optional Differential Pressure Gauge (D), connect the high-pressure side of the Differential Pressure Gauge to port (3). Then
connect the low-pressure side of the Differential Pressure Gauge to port (G).
The difference between the pressure at test port (3) and the pressure at test port (G) is margin pressure. The correct margin pressure is 1800 kPa
(260 psi).
View of bottom left of engine compartment
4. If the margin pressure is incorrect, stop the engine.
5. Remove cap (4) and loose locknut (5).
6. Turn the adjustment screw clockwise to increase the margin pressure setting.
Turn the adjustment screw counterclockwise to decrease the margin pressure setting.
7. Tighten the locknut (5) and reinstall the cap (4).
8. Start the engine and check the pressure again.
9. Perform Steps 3 through 7 until the margin pressure setting is correct.
10. Stop the engine.
11. Remove the pressure from the brake system by pumping the service brake pedal at a rate of one second ON and one second OFF. Continue
to pump the brakes until a minimum of 110 applications have been completed. Do not assume that the pressure is removed from the circuit
if the brake pedal has no resistance.
12. Remove all test equipment.
Relief Valve (Secondary Steering) - Test

SMCS - 4322-081-SE
Note: To reduce the risk of injuries due to tests/adjusts performed on the equipment with the
engine running, use a remote pressure reading with a wireless gauge or add long hoses/wires
to keep all personnel away from the machine while the engine is running.
Reference: Before you perform any tests, refer to the Testing and Adjusting, "Machine
Preparation for Troubleshooting" section.
Specification
Table 1
Relief Valve Pressure Setting
17225 kPa (2500 psi)
Introduction
The following procedure will explain the steps for testing the secondary steering relief valve.
Required Tools
Tooling (A)
Tooling (B)
Table 2
Tool Item Part Number Description Qty
A1 8T-0859 Pressure Gauge (0 to 25,000 kPa (0 to 3,600 psi)) 1
A2 6V-3989 Fitting 1
A
A3 6V-4143 Quick Connect Coupler 2
A4 177-7862 Hose As (5.5 m (18 ft)) 1
B 198-4240 Digital Pressure Indicator Gp 1
B1 198-4234 Digital Indicator 1
B2 198-4238 Pressure Sensor Gp (0 to 34,450 kPa (0 to 5,000 psi)) 1
B3 198-4236 Adapter Cable As 1
110-2218 Swivel Tee 1
F
5P-6944 Adapter 1
6V-3965 Fitting 1
Note: Tooling (A) or Tooling (B) may be used to perform these tests.
Test Preparation
(1) Relief valve
(2) Secondary steering pump
(3) Line
1. With the engine off, disconnect line (3) from secondary steering pump (2).
2. Install Tooling (F) to secondary steering pump (2) and connect line (3) to tooling (F).
3. Install Tooling (B) to Tooling (F).
Test Procedure
1. Turn both the battery disconnect switch and the engine start switch to the ON position.
Start the engine and run the engine. Turn the implement lockout switch to the ON
position.
2. Hold the secondary steering test switch in the TEST position until the pressure stops
rising. The pressure should be 17225 kPa (2500 psi). 17225 kPa (2500 psi) is the
correct pressure setting for relief valve (1).
3. If the pressure reading for relief valve (1) is not 17225 kPa (2500 psi), relief valve
(1) must be replaced. Relief valve (1) cannot be adjusted. If the pressure reading is
incorrect, replace relief valve
(1) and repeat Step 2. If the pressure reading for relief valve (1) is correct, remove
Tooling (F) and Tooling (B) and reconnect line (3) to secondary steering pump
(2).
System Pressure - Release

SMCS - 4300-553-PX ; 5050-553-PX
Hydraulic System

Make sure all of the attachments have been lowered, oil

is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped, and the filler cap is cool enough to touch with
your bare hand.
Escaping fluid under pressure, even a pinhole size leak,

can penetrate body tissue, causing serious injury, and
possible death. If fluid is injected into your skin, it must
be treated immediately by a doctor familiar with this
type of injury.
Always use a board or cardboard when checking for a leak.
NOTICE

containing fluids.

Introduction
The following procedure is used in order to relieve hydraulic pressure in the system.
Required Tools
Tools are not required for this procedure.
Machine Preparation
1. Park on a level surface. If you must park on a grade, chock the machine.
2. Apply the service brake in order to stop the machine. Move the transmission
control lever to the NEUTRAL position.
3. Move the speed control lever to the LOW IDLE position.
5. Lower all attachments to the ground.
6. Stop the engine.
Release System Pressure

1. Operate all hydraulic controls through all positions in order to relieve hydraulic
pressure. Repeat this step until all hydraulic pressure is released.
2. Turn the engine start switch to OFF position and remove the key.

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Engine Oil Pressure - Test

Measuring Engine Oil Pressure

Work carefully around an engine that is running. Engine

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained

Refer to Special Publication, NENG2500, "Dealer

Dispose of all fluids according to local regulations and mandates.

1. Install Tool (A) into oil gallery plug (1).

Reasons for Low Engine Oil Pressure

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained

Refer to Special Publication, NENG2500, "Dealer

Dispose of all fluids according to local regulations and mandates.

Engine oil level is low. Refer to Step 1.

Engine oil is contaminated. Refer to Step 2.

The engine oil bypass valves are open. Refer to Step 3.

The engine lubrication system is open. Refer to Step 4.

The engine oil pump is faulty. Refer to Step 6.

Engine Bearings have excessive clearance. Refer to Step 7.

Caterpillar oil filters are built to Caterpillar

of the engine and make the necessary repairs.

Reason for High Engine Oil Pressure

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained

Refer to Special Publication, NENG2500, "Dealer

Dispose of all fluids according to local regulations and mandates.

Caterpillar oil filters are built to Caterpillar

Engine Crankcase Pressure (Blowby) - Test

Finding Top Center Position for No. 1 Piston

Disassembly and Assembly of the Timing Pin

1. Begin with timing pin (D).

2. Disassemble timing pin (D).

Procedure for Pin Timing

3. Remove the valve mechanism cover from the engine.

Engine Valve Lash - Inspect/Adjust

Hot engine components can cause burns. Allow

This engine uses high voltage to control the fuel injectors.

Disconnect electronic fuel injector enable circuit

Do not come in contact with the fuel injector terminals

Valve Lash Check

2. Adjust the valve lash according to Table 3.

b. Loosen the adjustment locknut.

d. Tighten the adjustment locknut to a torque of 30 ± 7 N· m (22 ± 5 lb ft). Do not

4. Adjust the valve lash according to Table 4.

b. Loosen the adjustment locknut.

d. Tighten the adjustment locknut to a torque of 30 ± 7 N· m (22 ± 5 lb ft). Do not

Compression Brake Lash - Adjust

Hot engine components can cause burns. Allow

This engine uses high voltage to control the fuel injectors.

Disconnect electronic fuel injector enable circuit

Do not come in contact with the fuel injector terminals