0/09/30

Testing And Adjusting (SENR7008)

SMCS -

Troubleshooting
Problem 1: Noise from the pump, cylinder movement is not smooth
and regular and a sample of oil from the tank has air bubbles in it.
The probable cause of these problems is air in the system. The noise from the
pump is caused by cavitation (air bubbles at the inlet side); the cylinder that
does not work smoothly is caused by the compression of air; and the bubbles in
the oil are caused by a leak in the system.

1. Check the hose and connections between the tank and the pump for leaks. If
oil can leak out when the machine is setting idle, air can leak in when the pump
is working.

2. Check the level of oil in the hydraulic tank. If the level of the oil is below the
return line, air can get into the oil.

3. Another cause of air in the oil is low oil viscosity. Make reference to the
respective machine LUBRICATION & MAINTENANCE GUIDE.

Problem 2: The oil in the system gets too hot.

There are many factors that can cause heat in the hydraulic system. The
common causes are; low oil level in the tank, a short rapid duty cycle, a
pressure setting on the relief valve that is too low, a restriction in a line that
causes an orifice effect.

1. Low oil level in the hydraulic tank. Check the oil level and if it is low add oil to
the full mark. Check the lines, hoses, connections, valves and cylinders for
leaks.

2. If the duty cycle of the machine is short and fast, the temperature of the oil
can become high. When oil temperature goes above 210° F (98.8° C) it
destroys oil seals in the system.

3. A low setting for relief valve opening will also cause high temperature in the
system oil. This can be corrected by an adjustment to the relief valve that gives
an opening pressure according to specification.

4. A more difficult cause to find is a restriction in an oil line. A restriction in the
pump supply line will reduce the flow of oil to the pump and cause the pump to
become very hot. A restriction in a line that is between the pump and the
implements will cause a reduction in efficiency and high oil temperature.
Removal of the restriction will normally remove the problem.

5. Dirty (sticky) shuttle valve spool. Sticky or leaky pilot valves. Sticky dozer lift
stem.
Problem 3: Oil delivery by the pump is not according to
specification.
There are many reasons why a pump is not delivering oil. Problem 2 shows that
a restriction in the supply line to the pump will reduce the flow of oil. If the
quantity of oil in the system is low, the pump delivery will be low. Low oil level in
the system can cause aeration (air in the oil). Aeration in turn can cause
cavitation at the pump. This will cause less output from the pump. If the
viscosity of the oil is too high, there will be a decrease in the flow of oil from the
pump. A badly worn pump or one that has not been correctly assembled will
also cause less output flow.

1. Check the supply line to the pump for a restriction. Check the tank to be sure
there is not a restriction in the supply line to the pump.

2. Check the level of the oil in the hydraulic tank. Make reference to the
respective machine LUBRICATION & MAINTENANCE GUIDE.

3. Check the type of oil being used in the system. Make reference to the
respective machine LUBRICATION & MAINTENANCE GUIDE.

4. Remove and inspect the pump. Check it for wear and be sure that it is
assembled correctly.

Problem 4: Oil pressure in the system is too low.

This problem is normally caused by leakage in the system, the opening
pressure of the relief valve is too low, or a bad pump.

1. Carefully check the system for leakage. Remember that leakage inside a
control valve can not be easily seen.

2. Check the opening pressures of the two relief valves in this system.

3. Remove and inspect the pump for damage and correct assembly.

NOTE: Low oil flow from the pump will cause low oil pressure in the system.
See Problem 3.

Problem 5: Loss of efficiency in the implement circuits. (Slow

cylinder movement and loss of pressure).
The probable cause for this problem is normally the same as the causes for
Problems 3 and 4. Low oil output from the pump, leakage in the system and the
opening pressure of the relief valve is too low. Check Problems 3 and 4 for
solutions to this problem. Also check all control linkage for free movement and
correct adjustment for full travel of control valve spools.

Problem 6: Cylinder drift that is more than specification.

For the cause of this problem, see the DRIFT TESTS for the different circuits.
Problem 7: Slow (or loss of) movement in the dozer tilt or ripper
circuits.
If this problem is not in the dozer lift circuit, the cause is probably in the pilot
system. The dozer lift control is manually operated through linkage from the
dozer lever. The other implements (dozer tilt and ripper) are operated by
moving their control valves with pilot oil.

1. Check the pressure of the pilot system. See TESTS OF SETTING FOR
RELIEF VALVES. Pilot pressure is caused at the restrictor valve by flow from
the small section of the pump.

NOTE: Remember that pilot pressure can be as high as the relief valve

pressure for the tilt circuit. It must not be less than 100 psi (690 kPa).

2. Check for obstruction in pilot lines.

3. Check the output from the small section of the pump (See Problem 3).

4. Check the restrictor valve for free movement of spools, weak or broken
spring or not enough shims.

Problem 8: Ripper movement is very slow with no down pressure in

either the lift or tip circuits or both.
When one of the pilot valves for the ripper circuits is activated, main oil is sent
to the shuttle valve, in the dozer control valve, to the chamber in back of the
dump valve for main relief pressure. This causes the flow control characteristic
of the dump valve to stop and the valve now becomes a pilot operated relief
valve.

1. Activate the tilt circuit. If the tilt cylinder moves as expected, pilot system
pressure is correct.

2. If the problem is common to both the ripper tip and ripper lift, then the cause
is in the line between the pilot valves and the shuttle valve or in the shuttle
valve. Check the pilot line for restriction or the shuttle valve for damage.

Dozer Hydraulic System

Hydraulic oil, under pressures that can be higher than 2500 psi (17 000
kPa) can remain in the hydraulic systems on this machine after the
engine and pump have been stopped. Serious injury can be caused if
this pressure is not released before any service is done on the hydraulic
systems. To prevent possible injury be sure that the pressure in the
system is released before any fitting, hose or component is loosened,
tightened, removed or adjusted.

When possible, the dozer must always be flat on the ground before
 service is started. When it is necessary for the dozer to be raised while
tests or adjustments are done, be sure that it has the correct support.

Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.

During a diagnosis of the hydraulic system, remember that correct oil flow and
pressure are necessary for correct operation. The output of the pump (pump
flow) increases with an increase in engine rpm and decreases when engine rpm
is decreased. Oil pressure is caused by resistance to the flow of oil.

Visual checks and measurements are the first step when troubleshooting a
possible problem. Then do the Operation Checks and last the Instrument Tests.

Use the 5S5123 Hydraulic Test Group, a stop watch, a magnet and an inch
(mm) ruler for basic tests to measure:

1. The opening pressure of the relief valve for the main system and the relief
valve for the tilt circuit: Relief valve pressures that are too low will cause a
decrease in the lifting and dozing efficiency of the machine. Opening pressures
that are too high will cause a decrease in the life of hoses and components.

2. Drift rates in the lift and tilt circuits: Circuit drift is caused by leakage past
cylinder pistons, O-ring seals in the control valves, check valves or make-up
valves that do not seal correctly or bad adjustment or fit in the control valves.

3. Cycle times in the lift and tilt circuits: Cycle times that are longer than shown
in the charts are the result of leakage, pump wear and/or pump speed (rpm).

The tilt and lift circuits are connected in a modified series circuit for the flow
from the small section of the pump. The lift and ripper circuits are connected in
parallel for flow from the large section of the pump. The output of the two
sections of the pump flow together in the control valve for blade lift. The relief
valve for main system pressure is common to both the blade lift circuit and the
ripper. The tilt circuit has a separate relief valve. Each circuit has a load check
valve to prevent cylinder drift during valve spool movement. The blade lift and
ripper circuits have make-up valves.

Visual Checks
A visual inspection of the system is the first step when troubleshooting a
problem. Make the inspection with the engine turned off and the implements
lowered to the ground.

1. Check the level of oil in the tank. Slowly loosen the tank filler cap and release
the pressure before removal of the cap.
2. Remove the filter element and check it for material that would give an
indication of damage to a component.

3. Inspect all lines and connections for damage or leaks.

4. Inspect control linkage for bent, broken or damaged components.

Operating Checks
The operating checks can be used to find leakage in the system. They can also
be used to find a valve or pump that is not working correctly. The speed of rod
movement when the cylinders are working can be used to check the condition
of the cylinders and the pump.

Raise and lower the blade and ripper several times. Operate the tilt control
valve until the tilt cylinder is fully extended and retracted several times.

1. Watch the cylinders as they are extended and retracted. Movement must be
smooth and regular.

2. Check for noise coming from the pump.

3. Check for the sound of the relief valve opening. The opening pressures of the
relief valves are given in a chart in the subject, TESTS OF SETTINGS FOR
RELIEF VALVES.

Lift And Tilt Circuit Speeds

The oil in the system must be SAE 10 and at a recommended temperature of
150 ± 5° F (65° C) to get correct results. All speed tests are made with the
engine rpm at high idle.

System speeds that are the same as those given in the chart, is an indication
that the circuit operation is normal. The relief valve should be tested to be sure
that the opening pressure of each is correct. (See chart for settings).

If only one of the circuit speeds is slow, check that circuit for cylinder drift.

If the speed tests on all circuits are slow, check the pump for efficiency. (See
CHECKING PUMP EFFICIENCY). Also check the relief valves for leakage or
low pressure settings.
Hydraulic System Test Procedures
Drift Tests for Lift Circuit

TEST NO. 1: Raise the front of the machine off the ground by lowering a level
blade. Put the control lever in HOLD position. Shut off the engine and watch the
lift cylinder rods for movement.

TEST NO. 2: Raise the front of the machine off the ground by lowering a level
blade. Shut off the engine. Hold the lift control lever in LOWER position. Watch
the lift cylinder rods for movement.

TEST NO. 3: Raise the blade off the ground. Put the control lever in HOLD
position. Shut off the engine and watch the lift cylinder rods for movement.

TEST NO. 4: Raise the blade off the ground. Shut off the engine. Hold the lift
control lever in RAISE position. Watch the lift cylinder rods for movement.

Drift Test For Tilt Circuit

TEST NO. 1: Put the blade flat on the ground. Raise the front of the machine off
the ground by lowering the right side of the blade (TILT RIGHT). Put the tilt
circuit in HOLD position. Shut off engine and watch the tilt cylinder rod for
movement.

TEST NO. 2: Put the blade flat on the ground. Raise the front of the machine off
the ground by lowering the left side of the blade (TILT LEFT). Put the tilt circuit
in HOLD position. Shut off the engine and watch the tilt cylinder rod for
movement.

Drift Tests For Ripper Lift Circuit

TEST NO. 1. Raise the rear of the machine off the ground by lowering the
ripper. Put the ripper control lever in HOLD position. Shut off the engine and
watch the ripper cylinder rods for movement.

TEST NO. 2: Raise the ripper off the ground. Put the control lever in HOLD
position. Shut off the engine and watch the ripper cylinder rods for movement.
Tests Of Settings For Relief Valves

Move the machine to a location where the blade can be lowered and will sit
level on the ground (floor). Get the hydraulic oil to operating temperature. Turn
off the engine. Move the control lever for the dozer to each operation position
several times to take the pressure out of the lines.

Dozer Circuit
1. Clean the oil and dirt off of connections and fittings.

2. Install a 9S8093 or 5H4020 Blocking Plate Assembly (1) in the rod end line
for each of the dozer cylinders. Install it as close to the cylinder as possible.

3. Install a 0 to 4000 psi (0 to 27 500 kPa) pressure gauge in pressure tap (2).

4. Start the engine and run it at high idle speed to get full flow from the pump.

 
BLOCKING PLATE ASSEMBLY 
1. Blocking plate assembly.

 
PRESSURE TAP LOCATION 
2. Pressure tap.

5. Move the blade control to RAISE and LOWER positions to get maximum
system pressure.

NOTE: Do not keep the system at relief pressure for more than ten seconds. If
more time is needed, wait one minute and do Step 5 again.

6. Inspect all lines, connections and fittings for leaks.

7. Relief valve pressure must be as shown in Relief Valve Setting Chart.

8. Turn off the engine and move the blade control lever to all positions several
times to release pressures.

9. Remove the Blocking Plate Assemblies and connect lines to cylinders.

10. Check the oil level in the hydraulic tank and add oil if necessary. Make
reference to the respective machine's LUBRICATION & MAINTENANCE
GUIDE.
NOTE: If the machine is equipped with a ripper, the main relief valve setting can
be checked by using the procedure for the ripper circuit.

Tilt And Tilt Pilot Circuits

1. Clean the oil and dirt off of connections and fittings.

2. Install a 0 to 4000 psi (0 to 27 500 kPa) pressure gauge in pressure tap (3).

 
PRESSURE TAP LOCATION 
3. Pressure tap.

3. Start the engine and run it at high idle to get full flow from the pump.

4. Move the blade control to RAISE position until blade is clear of the ground.

5. Move the tilt control lever to TILT LEFT and TILT RIGHT to get maximum
system pressure.

NOTE: Do not keep the system at relief pressure for more than ten seconds. If
more time is needed, wait one minute and do Step 5 again.

6. Inspect all lines, connections, cylinder rod seals, and fittings for leaks.

7. Relief valve pressure must be as shown in the Relief Valve Setting Chart.

Ripper Lift And Ripper Lift Pilot Circuits

1. Clean the oil and dirt off of connections and fittings.

2. Install a 0 to 4000 psi (0 to 27 500 kPa) pressure gauge in pressure tap (2).

3. Start the engine and run it at high idle to get full flow from the pump.

4. Move the ripper control lever to RAISE and LOWER positions to get
maximum system pressure.

NOTE: Do not keep the system at relief pressure for more than ten seconds. If
more time is needed, wait one minute and do Step 4 again.

5. Inspect all lines, connections, cylinder rod seals and fittings for leaks.

6. Relief valve pressure must be as shown in chart.

Ripper Tip And Ripper Tip Pilot Circuits

1. Clean the oil and dirt off of connections and fittings.

2. Install a 0 to 4000 psi (0 to 27 500 kPa) pressure gauge in pressure tap (2).
3. Start the engine and run it at high idle to get full flow from the pump.

4. Move the ripper tip control lever to SHANK IN and SHANK OUT positions to
get maximum system pressure.

NOTE: Do not keep the system at relief pressure for more than ten seconds. If
more time is needed, wait one minute and do Step 4 again.

5. Inspect all lines, connections, cylinder rod seals and fittings for leaks.

6. Relief valve pressure must be as shown in the Relief Valve Setting Chart.

Additional tests can be made by checking the movement of the control valve
spools and the cylinders when a circuit is activated. In all positions of every
control valve, except the FLOAT position of the blade control, the spool must
return freely to the HOLD position when the lever is released. The FLOAT
position on the blade control valve has a detent and must be returned to HOLD
manually. Movement of the cylinders when a circuit is activated must be smooth
and regular.

Push Arm And Brace Group

On bulldozers equipped with the sliding center ball joint, minimum dimensions
must be kept to be sure that the blade parts work smoothly. Install a 1.50 in.
(38.1 mm) block (1) between the blade and cage on the ball joint. Make an
adjustment to link assemblies (2) and (3) until block (1) is held tightly. Remove
block (1) after making final adjustment. Dimensions (4) must be the same.

 
SLIDING CENTER BALL ADJUSTMENT 
1. Block, 1.50 in. (38.1 mm) thick. 2. Link. 3. Link. 4. Dimensions that must be the same.

Procedure To Remove Air From Pump Lines

Whenever it is necessary to remove the oil from the hydraulic tank, an air lock
will develop in the suction line between the pump and the tank. To remove this
air do the following:

1. Fill the tank with hydraulic oil to the correct level.

2. Remove the plugs from the tee test taps.

NOTE: The tee test tap for the large section of the pump is located in the
manifold on the outlet side of the pump. The tee test tap for the small section is
located on the pressure control valve.

3. Let the air escape from the suction line and pump.

4. Replace the plugs as soon as oil starts to run out of the holes.
5. Check and fill the hydraulic tank if necessary.

NOTE: On the D9H it will be necessary to crank the engine with the starter
motor. Be sure the governor control lever is in the "OFF" position. DO NOT LET
THE ENGINE START.

Checking Pump Efficiency

For any pump test, the pump flow, measured in gpm (liter/min) at 100 psi (690
kPa) will be larger than the pump flow at 1000 psi (6900 kPa) at the same rpm.

The difference between the pump flow of two operating pressures is the flow
loss.

If the percent of flow loss is more than 10%, on machine, (15% on the bench)
pump performance is not good enough.

Numbers in examples are for illustration and are not values for any specific pump or
*

pump condition. See SPECIFICATIONS for pump flow of a new pump at 100 psi and
1000 psi.

Test On The Machine

Measure pump flow at 100 psi (690 kPa) and at 1000 psi (6900 kPa) with
engine running at:

D7G Tractor: 2000 rpm.

D8K Tractor: 1280 rpm.

D9H Tractor: 1375 rpm.

Test On The Bench (173 Hydraulic Control)

If the test bench can not be run at 1000 psi at a high rpm, do the first part of the
test with the pump shaft rotation at 1040 rpm. Measure pump flow at 100 psi
(690 kPa) and at 1000 psi (6900 kPa). Then in order to measure the pump flow
for the last part of the test, see SPECIFICATIONS for: Pump rpm at 100 psi with
the bench at 2000 rpm.
Test On The Bench (183 Hydraulic Control)
If the test bench can not be run at 1000 psi at a high rpm, do the first part of the
test with the pump shaft rotation at 1360 rpm. Measure pump flow at 100 psi
(690 kPa) and at 1000 psi (6900 kPa). Then in order to measure the pump flow
for the last part of the test, see SPECIFICATIONS for: Pump rpm at 100 psi with
the bench at 1280 rpm.

Test On The Bench (193 Hydraulic Control)

If the test bench can not be run at 1000 psi at a high rpm, do the first part of the
test with the pump shaft rotation at 1190 rpm. Measure pump flow at 100 psi
(690 kPa) and at 1000 psi (6900 kPa). Then in order to measure the pump flow
for the last part of the test, see SPECIFICATIONS for: Pump rpm at 100 psi with
the bench at 1375 rpm.

PIP-11142838