Testing and Adjusting

236B, 246B, 252B and 262B Skid Steer Loaders Hydraulic System
Media Number -RENR4867-03

Publication Date -01/11/2009

Date Updated -24/11/2009

i03177701

Hydrostatic System - Test and Adjust

SMCS - 4350-025; 4350-081
Table 1
Required Tools
Part number

Description

Quantity

6V-4143

Quick Connect Coupler

10

177-7861

Hose As

6V-3989

Fitting As

6V-3966

Fitting As

8T-0855

Pressure Gauge 0 to 4000 kPa (580 psi)

8T-0854

Pressure Gauge 0 to
1000 kPa (145 psi)

8T-0860

Pressure Gauge 0 to
40000 kPa (5802 psi)

186-2613

Pressure Gauge 0 to
70000 kPa (10153 psi)

1U-5796

Pressure Differential Tool Gp

164-3310

Infrared Thermometer

9U-7400

Multitach Tool Gp

1U-6605

Reflective Tape

7X-2444

Swivel Tee

4J-5477

O-Ring Seal

5P-2937

O-Ring Adapter

3J-7354

O-Ring Seal

Install a 6V-4143 Quick Connect Coupler to each end of the 177-7861 Hose As . Install a 6V-3989
Fitting to the 8T-0855 . Install a 6V-3989 Fitting to the 8T-0854 Pressure Gauge . You will also need
to install a 6V-3989 Fitting to the 186-2613 Pressure Gauge .
Install a 6V-3966 Fitting As into both of the 7X-2444 Swivel Tee and the 5P-2937 O-Ring Adapter .

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 power train.

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, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.

Before any tests are performed, prepare the machine. Refer to Testing and Adjusting, "Machine
Preparation". Before any tests are performed, visually inspect the complete hydraulic system for oil
leaks and damaged parts. Refer to Testing and Adjusting, "Visual Inspection".
The tests for the hydraulic system should be done in the following order. In order for the hydrostatic
system to function correctly, each component in the system must be set to the correct specifications.
Some components must be set prior to the testing of other components. A component that is not set
correctly will have an impact on other components in the system.

It is not advisable to bypass preceding tests. Do not perform a test before the tests that precede that
test have been done. Table 1 lists the equipment that is needed to perform testing on the hydrostatic
system. Equivalent tooling may be substituted.
Clearly mark all of the hoses and the corresponding pressure gauges, when the hoses are installed.
The hoses and the pressure gauges will be used multiple times in the testing and adjusting procedures.
Throughout the entire testing procedure, MB pressure refers to the hydraulic oil pressure in the
forward hydrostatic loop. MA pressure refers to the hydraulic oil pressure in the reverse hydrostatic
loop.
Note: The oil in the hydraulic system must be at an operating temperature of 45 5C (113 9 F).
This temperature range is specified for only the standard oil from the factory. Use the 164-3310
Infrared Thermometer or the equivalent to measure this temperature at the hydraulic filter. In order to
increase the hydraulic system temperature, start the engine and operate all hydraulic cylinders for at
least five cycles. Move the machine in the forward and reverse directions. Move the work tool
through the full range of motion.

Baseline for the Hydrostatic System

1. Use cribbing to elevate the machine. The wheels must not touch the ground.
2. Release the hydraulic system pressure. Refer to Testing and Adjusting, "Hydraulic System
Pressure - Release" for the correct procedure.
3. Raise the cab. Refer to Operation and Maintenance Manual, "Cab Support Operation" for the
correct procedure.

Illustration 1

g00788958

(1) Charge pressure tap

4. Install the 177-7861 Hose to the charge pressure tap (1) on the right side of the hydrostatic
piston pump. Connect the 8T-0855 Pressure Gauge to the other end of this hose. Place the hose
in a visible position.

Illustration 2

g00788976

(2) Speed sensing pressure tap

5. Install the 177-7861 Hose to the speed sensing pressure tap (2) . The speed sensing pressure tap
is located on the top of the hydrostatic piston pump. Connect the 8T-0855 Pressure Gauge to
the other end of this hose. Place the hose in a visible position.

Illustration 3

g00592868

6. Install the 9U-7400 Multitach Tool Gp on the rear frame and position the sensor in order to pick
up the reflective tape on the crankshaft pulley.

Illustration 4

g00592874

7. Install the 9U-7400 Multitach Tool Group in the engine compartment and position the sensor in
order to pick up the reflective tape on the fan blade.
8. Route the test hoses so that the cab does not rest on the hoses. Lower the cab. Ensure that the
test hoses and cables do not contact the tires. Securely bolt the cab to the frame.
9. Start the engine and operate each work tool function. Operate the hydrostatic drive forward and
operate the hydrostatic drive rearward until the hydraulic system reaches an operating
temperature of 45 5C (113 9 F).
10. Set the engine to LOW IDLE and verify the engine RPM. Determine if the engine RPM is
within the proper specification. If the engine RPM for LOW IDLE is incorrect, perform the
following adjustments to the cable assembly of the governor control:
Set the throttle to the HIGH IDLE position.
Install the cable assembly to the engine so the cable nuts can be positioned and tightened
in order to set the throttle's bracket. The bracket must make contact with the HIGH IDLE
stop.
Move the throttle to the LOW IDLE position.
Adjust the 6V-7357 Bolt until the low idle stop remains in slight contact with the bracket.
Tighten the 5C-2890 Nut in order to lock the bolt in place.
Note: LOW IDLE and HIGH IDLE have been preset at the factory. The setting of the LOW
IDLE and the HIGH IDLE on these engines should not be adjusted. Adjusting the setting can
void the warranties on the fuel injection pump and the engine. Adjusting the setting can
invalidate the standards for emissions. Adjustment of the LOW IDLE and the HIGH IDLE
should be made only by trained personnel. The LOW IDLE and HIGH IDLE for most engine
applications is given in the Systems Operation, "Engine Design". Some engine applications
may have a different LOW IDLE and HIGH IDLE.
Note: Verify the engine rpm for the LOW IDLE and the HIGH IDLE by referring to the
Technical Marketing Information (TMI) or to the Fuel Setting and Related Information Fiche.

Table 2
Model

Low Idle Engine RPM

236B/ 246B/ 252B/ 262B

1000 50 RPM

11. Record the following items at LOW IDLE: engine RPM, charge pressure and speed sensing
pressure.
Table 3
Model

Charge Pressure

Pressure for Speed Sensing

Oil Temperature Range

45 5C (113 9F)
236B/ 246B/ 252B/ 262B

3100 200 kPa (450 29 psi)

950 200 kPa (138 29 psi)

12. Increase the engine speed to HIGH IDLE.

If the engine speed for HIGH IDLE is incorrect, perform the following checks:
Set the throttle to the HIGH IDLE position.
Install the cable assembly to the engine so the cable nuts can be positioned and tightened
in order to set the throttle's bracket. The bracket must make contact with the high idle
stop.
Move the throttle to the LOW IDLE position.
Adjust the 6V-7357 Bolt until the LOW IDLE stop remains in slight contact with the
bracket.
Tighten the 5C-2890 Nut in order to lock the bolt in place.
Note: Low idle and high idle have been preset at the factory. The setting of the LOW IDLE and
the HIGH IDLE on these engines should not be adjusted. Adjusting the setting can void the
warranties on the fuel injection pump and the engine. Adjusting the setting can invalidate the
standards for emissions. Adjustment of the LOW IDLE and the HIGH IDLE should be made
only by trained personnel. LOW IDLE and HIGH IDLE for most engine applications is given in
the Systems Operation, "Engine Design". Some engine applications may have a different LOW
IDLE and HIGH IDLE.
Table 4
Model

High Idle Engine RPM

236B/ 246B/ 252B/ 262B

2860 50 RPM

13. For machines with a standard fan, record the fan RPM at HIGH IDLE engine RPM.
Table 5
Model

Maximum Fan RPM

236B/ 252B

2000 50 RPM

246B/ 262B

2450 50 RPM

14. For machines with a demand fan, perform the following:

a. Set the engine RPM to HIGH IDLE and install a jumper connector into the plug of the
control module for the demand fan. Allow the completion of the calibration of the fan.
The fan will stabilize. Record the calibrated fan RPM.
Table 6
Model

Calibrated Fan RPM

246B/ 262B

1764 50 RPM

b. Remove the jumper connector from the plug of the control module for the fan.
c. Disconnect the hydraulic oil temperature sensor at the fan motor. Record the maximum
fan RPM.
Table 7
Model

Maximum Fan RPM

246B/ 262B

2400 50 RPM

15. Set the engine RPM on all machines. Refer to the table below. Record the speed sensing
pressure and the charge pressure.
Table 8
Model

Engine RPM

Speed Sensing Pressure

Charge Pressure

Oil Temperature Range

45 5C (113 9F)
236B/ 246B/ 252B/
262B

2300 25
RPM

2000 150 kPa (290

22 psi)

3225 200 kPa (468

29 psi)

Speed Sensing Valve Adjustment

If the speed sensing pressure is low at low idle, perform the following adjustment.

Illustration 5

Remove cap (A) from the speed sensing valve.

g01422109

Illustration 6

g01422113

Adjustment to the speed sensing valve

Loosen locknut (C) on the speed sensing valve.

Turn the adjustment screw (B) on the speed sensing valve counterclockwise.
If the speed sensing pressure is high at low idle, perform the following adjustment.
Turn the adjustment screw (B) on the speed sensing valve clockwise.
If the speed sensing pressure is low at high idle, perform the following adjustments.
Turn the adjustment screw (B) on the speed sensing valve counterclockwise.
Note: If any adjustments have been made to the speed sensing valve, then repeat the test until the
values are within specifications.
Tighten locknut (C) on the speed sensing valve.

Start To Move Test

Perform the start to move test in order to verify that forward and reverse machine movement begins
within specified time after the operator initiates a command.
1. Perform the Hydrostatic System Baseline Test before testing for start to move.
2. Start the engine and operate each work tool function. Operate the hydrostatic drive forward and
operate the hydrostatic drive rearward. Operate until the hydraulic system reaches an operating
temperature of 45 5C (113 9 F).
3. Set the engine speed to LOW IDLE.
4. Quickly move the joystick control for drive into forward to the 12 o'clock position. Capture the
time until the machine moves. Use a stopwatch to measure the specifications. Immediately
return the joystick to the neutral position.
5. Repeat four times. Calculate the average in order to determine the Forward Start to Move time.
6. Quickly move the joystick control for drive into rearward to the 6 o'clock position. Capture the
time until the machine moves. Use a stopwatch to measure the specifications. Immediately
return the joystick to the neutral position.
7. Repeat four times. Calculate the average in order to determine the Forward Start to Move time.
Table 9
Model

Start to Move Forward.

Start to Move Reverse.

236B/ 246B/ 252B/ 262B

1 second max

1.5 seconds max

Pump Neutral Position Test

Perform the test for the neutral position of the pump in order to make sure that the piston pump is
synchronized. If the pump is not synchronized, the machine could drift or the machine could move
with the pilot operated hydraulic control ( hydrostatic) in the NEUTRAL position. If the pump is not
synchronized, the wheel on one side of the machine could start to move before the wheel on the other
side of the machine starts to move.
Note: If the left wheel and the right wheel start to move at the same time, this test is not
required.
1. Use cribbing to elevate the machine. The wheels must not touch the ground. Make sure that all
hoses are out of the way of the rotating wheels.
2. Sit in the operator's seat. Fasten the seat belt and lower the armrest.
3. Start the engine and run the engine at LOW idle.
4. Move the pilot operated hydraulic control ( hydrostatic) slowly forward. Check that the left
wheel and the right wheel start to move at the same time. If the left wheel and the right wheel

start to move at the same time, proceed to the "Maximum Runout"test. If the left wheel and the
right wheel do not start to move at the same time, proceed to step 5.
5. Raise the cab. Refer to Operation and Maintenance Manual, "Cab Support Operation" for the
proper procedure.
Note: Perform the test on rotating group 2 of the piston pump first. Rotating group 2 powers the
piston motor which is on the right side of the machine. Rotating group 2 is farthest from the
engine.

Illustration 7

g01116389

(4) Neutral adjusting bolt for rotating group 2

(5) Neutral adjusting bolt for rotating group 1
(6) MA Port for rotating group 2
(7) MA Port for rotating group 1

6. Remove the plug from the MA port for rotating group 2 (6) . Install 6V-3965 Fitting with 3J1907 O-Ring Seal into the MA port for rotating group 2 (6) . Install 8T-0860 Pressure Gauge (0

to 40000 kPa) to the MA port for rotating group 2 (6) with the following items: 6V-3989
Fitting , two 6V-4143 Quick Connect Couplers and 177-7860 Hose .

Illustration 8

g01116394

(8) MB Port for rotating group 2

(9) MB Port for rotating group 1

7. Install 8T-0860 Pressure Gauge (0 to 40000 kPa) to the MB port for rotating group 2 (8) with
the following items: 6V-3989 Fitting , two 6V-4143 Quick Connect Couplers and 177-7860
Hose .
8. Place the two gauges in an easily visible position.
9. Lower the cab. Route the test hoses so that the cab does not rest on any of the hoses.
10. Fasten the seat belt and lower the armrest.
11. Start the engine and run the engine at LOW idle.
12. Raise the cab.

13. Loosen the locknut for the neutral adjusting bolt. Do not use an impact socket.
14. Turn neutral adjustment screw for rotating group 2 (4) clockwise. Mark the location of the
neutral adjusting bolt when the MB pressure begins to increase.
15. Turn neutral adjustment screw (4) counterclockwise. Mark the location of the neutral adjusting
bolt when the MA pressure begins to increase.
16. Turn the neutral adjustment screw (4) midway between the two marks.
17. Hold the neutral adjustment screw (4) in position as you tighten the locknut to a torque of 30.0
1.5 Nm (22.1 1.1 lb ft).
18. Lower the cab.
Note: In the next step, the wheels will rotate. Make sure that all hoses are out of the way of the
rotating wheels.
19. Move the pilot operated hydraulic control ( hydrostatic) slowly forward. Check that the left
wheel and the right wheel start to move at the same time.
20. If the wheels do not start to move at the same time, then repeat this adjustment procedure for
rotating group 1.

Maximum Runout

Illustration 9

g00560554

Use cribbing to elevate the machine.

1. Use cribbing to elevate the machine. The wheels must not touch the ground.
2. Release the hydraulic system pressure. Refer to Testing and Adjusting, "Hydraulic System
Pressure - Release" for the correct procedure.

3. Raise the cab. Refer to Operation and Maintenance Manual, "Cab Support Operation" for the
correct procedure.

Illustration 10

g00788958

(1) Charge pressure tap

4. Install the 177-7861 Hose to the charge pressure tap (1) on the right side of the hydrostatic
piston pump. Connect an 8T-0855 Pressure Gauge to the other end of this hose. Place the hose
in a visible position.

Illustration 11

g00788976

(2) Speed sensing pressure tap

5. Install the 177-7861 Hose to the speed sensing pressure tap (2) on the top of the hydrostatic
piston pump and connect an 8T-0855 Pressure Gauge to the other end of this hose.

Illustration 12

g01364143

6. Install the 177-7861 Hose to the MB1 (3) and the MB2 (4) onto the pressure ports on the right
side of the hydrostatic piston pump. Connect 186-2613 Pressure Gauge to the other end of these
hoses and place the hoses in a visible position.

Illustration 13

g00592868

7. Install the 9U-7400 Multitach Tool Gp on the rear frame. Position the sensor in order to read
the reflective tape on the crankshaft pulley.
8. Route the test hoses so that the cab does not rest on the hoses. Lower the cab. Ensure that the
test hoses and cables do not contact the tires. Securely bolt the cab to the frame.

Illustration 14

g00726910

The illustration shows the correct placement of the reflective tape.

9. One wheel on each side of the machine will be checked for correct maximum runout. Apply 1U
-6605 Reflective Tape to the wheel studs of each wheel at 90 intervals. Set the sensor to read
the tape strips.
10. Start the machine and set the engine to HIGH IDLE. Verify that the hydraulic oil temperature is
within the specification of 45 5C (113 9 F).
11. Operate the left hydraulic pilot control valve in the forward direction. Hold the hydraulic pilot
control valve in this position.
12. Use the 9U-7401 Multitach Tool Gp to record the wheel speed. Record the wheel speeds for
both sides of the machine. Divide the indicated wheel speed by four in order to calculate the
actual wheel speed.
Table 10
Model

Wheel Speed

236B/ 246B

79 6 RPM

236B and 246B (slow speed)

66 6 RPM

252B/ 262B

74 5 RPM

252B and 262B (slow speed)

61 5 RPM

Note: If the wheels are not within 1 RPM of each other, perform the maximum displacement
stop adjustment procedure. The hystat displacement stops control of the maximum stroke of the
swashplate in each rotating group in the forward direction.

Maximum Displacement Stop Adjustment Procedure

1. To reduce the right wheel speed runout, turn the maximum displacement adjustment screw
clockwise. To increase the right side wheel speed runout, turn the maximum displacement

adjustment screw counterclockwise. The right side maximum displacement adjustment screw is
located on the right side of the hydrostatic pump farthest from the engine. Make adjustments by
turning the screw in increments of 1/8 of a turn and recheck using the maximum runout test.
2. To reduce the left side wheel speed runout, turn the maximum displacement adjustment screw
clockwise. To increase the left side wheel speed runout, turn the maximum displacement
adjustment screw counterclockwise. The left side maximum displacement adjustment screw is
located on the right side of the hydrostatic pump. Make adjustments by turning the screw in
increments of 1/8 of a turn and recheck using the maximum runout test.
3. Once the right and left wheel speeds are within the specification, tighten the adjustment screw
and the adjustment screw locknut to 22 1 Nm (16.2 0.7 lb ft) and install a 6E-5060 Cap
As .

Stall Test

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 power train.

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.

The test can be used in order to identify low power problems with the engine. The test is also used to
identify the crossover relief valves that may be malfunctioning.
1. Raise the cab. Refer to Operations and Maintenance Manual, "Cab Support Operation" for the
correct procedure.

Illustration 15

g00790186

(1) Electrical connection

(2) Brake solenoid

2. Position the machine against an object that will prevent the machine from moving. It is possible
to drive through the brakes. Disconnect the electrical connection (1) for the brake solenoid (2) .
3. The 6V-3121 Multitach or the 9U-7400 Multitach Tool Group should still be installed on the
machine. If a unit is not installed on the machine, reinstall a multitach.

Illustration 16

g01365563

(3) Pressure tap MB for rotating group 1

(4) Pressure tap MB for rotating group 2

4. The two 177-7861 Hose Assemblies should still be attached to the MB pressure ports (3) and
(4) . If the hose assemblies are not installed on the machine, reinstall the hose assemblies.

5. Route the test hoses and cables so that the cab will not rest on the hoses and cables. Properly
secure the cab.
6. Sit in the operator's seat and fasten the seat belt. Lower the armrest.
7. Start the engine and run the engine at LOW IDLE.
8. Slowly increase the engine speed to HIGH IDLE.
9. Push the pilot operated hydraulic control to the FORWARD position until the engine RPM
stabilizes.
Note: Do not continue to stall the hydrostatic system for more than 15 seconds. Damage to the
machine may result.
Note: The wheels should not spin. If the wheels spin, refer to the Testing and Adjusting, "Brake
Test".
10. Record the engine stall speed. Record the MB1 and MB2 pressure values.
Table 11
Model

Engine Stall

236B/ 246B/ 252B/

262B

2700 200
RPM

MB1 Pressure

MB2 Pressure

38300 2000 kPa (5555

290 psi)

38300 2000 kPa (5555

290 psi)

If the engine stall RPM is not correct, refer to the troubleshooting section.
If the MB pressures are not within the specification, the crossover relief valves may need to be
adjusted. Refer to the procedure below.
1. Remove the cap of the crossover relief valve that is not within the specification. Remove the
spring and the crossover relief valve.

Illustration 17

g01365567

2. Place crossover relief valve (5) into a vise.

3. Turn the set screw (6) counterclockwise in order to loosen the setscrew.

Illustration 18

g01365572

4. Place retainer (7) of the crossover relief valve in a vise. Turn adjustment screw (8) in order to
adjust the relief pressure. Turn the adjustment screw clockwise in order to increase the pressure
or turn the adjustment screw counterclockwise in order to decrease the pressure. One full turn
of the adjustment screw is approximately 6400 kPa (928 psi).
Note: When you adjust the crossover relief valve to decrease the pressure, turn the adjustment
screw for an additional 1/4 turn past the estimated adjustment setting. Then, turn the adjustment
screw clockwise for 1/4 turn.
5. Tighten setscrew (6) to a torque of 6.5 Nm (58 lb in).
6. Install crossover relief valve (5) , the spring, and the cap. Tighten the cap to a torque of 160
10 Nm (118 7 lb ft).

Double Stall Test

The test will determine if engine performance is low.
Note: The 6V-3121 Multitach or the 9U-7400 Multitach Tool Group should still be installed on the
machine. If the unit is not installed, reinstall the unit.
1. Position the machine against an object that will prevent the machine from moving. It is possible
to drive through the brakes.
2. Raise the cab. Refer to the Operations and Maintenance Manual, "Cab Support Operation" for
the correct procedure.

Illustration 19

g01356435

(1) Electrical connection

(2) Brake solenoid

3. Disconnect the electrical connection (1) for the brake solenoid (2) .
4. Sit in the operator's seat and fasten the seat belt. Lower the armrest.
5. Start the engine. Run the engine at LOW IDLE and verify that the oil temperature is within the
specification of 45 5C (113 9F).
6. Slowly increase the engine speed to HIGH IDLE.
Note: Do not stall the machine for more than 15 seconds. Damage to the machine could result.
7. Push the pilot operated hydraulic control in the FORWARD direction.
8. At the same time, push the pilot operated hydraulic control ( work tool) to the TILT BACK
position.
9. Record the engine rpm.
Table 12
Model

Double Stall Engine

236B/ 246B/ 252B/ 262B

2300 400 rpm

If the engine stall RPM is not correct, refer to the troubleshooting section.

Test and Adjust - Work Tool System

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
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, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.

NOTICE
Do not adjust the main relief valve above the specified pressure.
Adjustment of the main relief valve above the specified pressure may
cause damage to the gear pump.

Before any tests are performed, prepare the machine for troubleshooting. Refer to Testing and
Adjusting, "Machine Preparation". Before any tests are performed, visually inspect the complete
hydraulic system. Refer to the Testing and Adjusting, "Visual Inspection".
Note: The hydraulic oil temperature during all system tests must be at an operating temperature of 45
5C (113 9 F). Use the 164-3310 Infrared Thermometer or a equivalent to measure this
temperature at the hydraulic filter. In order to increase the hydraulic system temperature, start the
engine and operate all hydraulic cylinders for at least five cycles. Move the machine in the forward
and reverse directions for several minutes.