12K Caterpillar Motor Grader Service Manual SZP by quality service repair manual

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Product: MOTOR GRADER

Model: 12K MOTOR GRADER SZP

Configuration: 12K Motor Grader SZP00001-UP (MACHINE) POWERED BY C7 Engine

Disassembly and Assembly C7

Engines for Caterpillar Built Machines Media Number -RENR9218-13

Electronic Control Module - Remove and Install

SMCS - 1901-010

Removal Procedure

Updated -04/06/2014

i02306405

Accidental engine starting can cause injury or death to personnel working on the equipment.

To avoid accidental engine starting, disconnect the battery cable from the negative (-) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

1. Disconnect the battery.

Illustration 1 g01155236

2. Loosen allen head screw (1). Disconnect harness assembly (2) from electronic control module (4) .

3. Remove nuts (3), the washers, the isolation mounts, electronic control module (4), and the ground strap.

Installation Procedure

Illustration 2 g01155236

1. Position the isolation mounts on electronic control module (4). Position the washers, the ground strap, and electronic control module (4) on the engine and install nuts (3) .

2. Connect harness assembly (2) to electronic control module (4). Install allen head screw (1) and tighten to a torque of 6 ± 1 N·m (53 ± 9 lb in).

3. Connect the battery.

Previous Screen

Product: MOTOR GRADER

Model: 12K MOTOR GRADER SZP

Configuration: 12K Motor Grader SZP00001-UP (MACHINE) POWERED BY C7 Engine

Troubleshooting

Shutdown SIS

12K, 140K, 140K Series 2 and 160K Motor Graders Hydraulic and Steering System

Media Number -KENR8423-05

Publication Date -01/09/2014

Hydraulic and Steering System

SMCS - 4300-035; 5050-035

Peformance Checks

Implement System

Problem: The ripper cylinders are failing prematurely.

Probable Cause

Date Updated -16/09/2014

i03351610

• The ripper lines are installed incorrectly. The installation causes the relief valve to be bypassed. The bypass exposes the cylinders to pressure surges. The new hoses and fittings prevent the hoses from being installed incorrectly.

Problem: When you steer the machine, the implement slows down or the implement stops.

Probable Cause

• The low standby pressure of the implement and steering pump is set low. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• The steering priority valve has failed.

• The implement and steering pump has insufficient flow.

Problem: The implement and steering pump does not return to the low standby pressure after the implement is used.

Probable Cause

• The control lever has interference. The control lever does not return to the HOLD position. The signal pressure is still sent to the pressure and flow compensator valve.

• The signal purge valve has malfunctioned in the CLOSED position.

• The steering signal from the steering metering unit is greater than 690 kPa (100 psi). The signal port of the steering metering pump is contaminated. Replace the steering priority valve. Replace the steering metering pump.

• The implement and steering pump has failed or the pressure and flow compensator valve has failed.

Problem: The response of the implements is too fast.

Probable Cause

• An incorrect control stem is installed in the implement control valve.

• The implement control valve has failed.

• The margin pressure is set too high.

Problem: The implements do not work but the steering does work.

Probable Cause

• The combination valve has a failed ball resolver. The combination valve has a failed signal check valve. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• The steering priority valve is stuck. This stops the oil flow to the implements.

• The signal relief valve has failed in the OPEN position or the pressure setting is set incorrectly.

Problem: Too much effort is needed to move the control lever.

Probable Cause

• The lever linkage is restricted or the lever linkage has interference.

• The bias spring in the implement control valve is missing or the bias spring in the implement control valve is incorrect.

• The implement control valve has a sticking control stem or the implement control valve has a failed control stem.

Problem: When the implement is first activated, the implement surges.

Probable Cause

• The slots in the control stem are incorrectly machined.

• Air is in the circuit.

• The margin pressure is set too high.

• The discharge pressure of the implement and steering pump remains too high after the signal pressure drops.

Problem: Any implement moves with the control lever in the HOLD position.

Probable Cause

• The cylinder piston seals have failed or the cylinder piston seals are worn.

• The lock check valve has failed or the port relief has failed.

• The relief valve for the implement line is malfunctioning.

Problem: All of the implement circuits are erratic.

Probable Cause

• The hydraulic oil in the hydraulic system has not reached normal operating temperature.

• The implement and steering pump has failed or the pressure and flow compensator valve has failed.

• Air is in the hydraulic system.

Problem: The performance of the implement is erratic.

Probable Cause

• The implement control valve is contaminated.

• The control valve stem is incorrect for this circuit.

• The margin pressure is set incorrectly.

Problem: Implement circuits will not operate when one cylinder is stalled.

Probable Cause

• The pressure compensator is set too low or the signal relief valve is set too high. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

Problem: The response of all the implements are too slow.

Probable Cause

• Air is in the signal system. Refer to the Testing and Adjusting, "Signal Network - Purge" section in this manual.

• The check valve is leaking or the ball resolver in the signal network is leaking. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• There is contamination in any of the control valves.

• Air is in the system.

• The signal purge valve is stuck open.

• The signal relief valve malfunctions.

• The margin pressure is set too low.

• The implement relief valve is set too low or the implement relief valve leaks.

• The steering priority valve in the combination valve has malfunctioned.

Problem: The response of one implement is too slow.

Probable Cause

• The lever linkage is restricted or the travel is restricted.

• The valve spool that is installed in the control valve is incorrect for the implement.

• The signal check valve in the signal network is functioning incorrectly. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• The implement control valve has failed.

• The implement relief valve is set too low.

• The signal relief valve is set too low.

Steering System

Problem: The steering wheel does not turn the correct number of turns.

Probable Cause

• The steering metering pump is leaking internally.

• The steering cylinders are leaking or the cylinders have incorrect parts.

• An incorrect steering metering pump is installed on the machine.

Problem: The steering does not work but the implements do work.

Probable Cause

• The implement and steering pump is not receiving a signal pressure from the steering system. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering)Test and Adjust" section in this manual.

• The steering priority valve is malfunctioning. The pressure from the implement and steering pump is blocked to the steering circuit.

• There is blockage or damage to the steering circuit or components.

Problem: When the steering wheel is steered against the stop, the steering wheel does not stop.

Probable Cause

• The steering relief valve is set too high. This allows the relief valve to remain open. Refer to the Testing and Adjusting, "Relief Valve (Steering) - Test and Adjust" section in this manual.

• The relief valve in the steering metering pump is set too low.

• The steering metering pump has failed. This allows the wheel to continuously turn.

• The steering cylinder has failed or the steering cylinder is leaking.

• The port is blocked on the steering metering pump or the steering metering pump has a loose connection. This allows air to enter the steering system.

Problem: When the steering wheel is released, the steering wheel oscillates more than three times.

Probable Cause

• The steering metering pump has failed.

• An incorrect steering metering pump has been installed on the machine.

• The steering system relief valve is set too high.

Problem: The steering wheel has a tendency to stick when the steering wheel is against the stop.

Probable Cause

• The steering metering pump has failed and the steering metering pump has trapped pressure in the steering system.

• An incorrect steering metering pump has been installed on the machine.

Problem: The steering wheel kicks back, when the steering wheel is steered against the stop.

Probable Cause

• Air is in the steering cylinders and air is in the steering system. Refer to the Testing and Adjusting, "Steering System - Purge" section in this manual.

• The check valve is missing or the check valve is not working. This check valve is in the steering metering pump at the hydraulic pump pressure port.

Problem: When an implement is used, you can feel hard spots in the steering.

Probable Cause

• The signal resolver in the combination valve has been installed incorrectly after assembly.

Problem: The front wheels vibrate, when you steer the machine.

Probable Cause

• Air is in the steering cylinders and air is in the steering system. Refer to the Testing and Adjusting, "Steering System - Purge" section in this manual.

• The steering metering pump has failed.

• Check the steering priority valve that is in the combination valve.

Hydraulic Pump and the Hydraulic System

Problem: Low standby pressure is too high.

Probable Cause

• All controls are not in the HOLD position. When the controls are in the HOLD position the signal pressure should be less than 690 kPa (100 psi).

• The margin pressure is set too high. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

Problem: The implement and steering pump remains at standby pressure.

Probable Cause

• The implement and steering pump is not receiving a signal. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• The pressure and flow compensator valve is not working.

• The implement and steering pump is not upstroking. The swashplate is blocked.

• When the implements are used or the steering is used, the pump will not upstroke.

Problem: The implement and steering pump has no pressure.

Probable Cause

• The hydraulic system is low on oil.

• The implement and steering pump has malfunctioned or the pump drive shaft has malfunctioned.

• The pressure compensator valve is set incorrectly.

Problem: The pressure of the implement and steering pump is too high.

Probable Cause

• The signal relief valve is set too high. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• The implement and steering pump is not destroking. The actuator piston is stuck or the swashplate is blocked.

Problem: The maximum pressure of the implement and steering pump is too low.

Probable Cause

• The signal relief valve is set too low.

• A leak in the signal network or a plugged signal network

• The pressure compensator valve is set incorrectly. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• The low standby pressure is set low. Refer to the Testing and Adjusting, "Pump Control Valve (Implement, Steering) - Test and Adjust" section in this manual.

• The implement and steering pump is not upstroking. The swashplate is blocked.

Problem: There is a large amount of air in the oil.

Probable Cause

• A leak in the oil line between the hydraulic tank and the implement and steering pump

• The hydraulic system needs to be correctly purged. Refer to the Testing and Adjusting, "Steering System Purge" section in this manual.

• The relief valve constantly opens and the relief valve constantly closes.

• Leakage in the cylinder seals and leakage around the cylinder seals

Problem: The implement and steering pump makes unusual noise.

Probable Cause

• The viscosity of the oil is incorrect.

• The implement relief valve opens at low oil pressure.

• There is a loose oil line connection on the inlet side of the implement and steering pump. Oil aeration.

• The implement and steering pump has too much wear.

• The cylinder rods do not move evenly.

• Air bubbles are in the oil.

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Problem: The temperature of the oil is too hot.

Probable Cause

• The viscosity of the oil is incorrect.

• The signal relief valve is set too high.

• The implement relief valve is set too low.

• The implement and steering pump has too much wear (high leakage).

• There is a restriction in an oil passage.

• The load of the system is too high.

• The signal purge valve has malfunctioned in the CLOSED position. The signal purge valve is in the combination valve.

• Oil aeration.

• Outside air temperature is too hot.