RENR8498-01

July 2007

Specifications
24M Motor Grader
Braking and Hydraulic Fan System
B9K1-Up (Machine)

i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.

RENR8498-01

Table of Contents
Specifications Section
Piston Pump (Brake, Hydraulic Fan) ...................... 4
Pump Control Valve (Brake, Hydraulic Fan) ........... 4
Gear Pump (Differential Lock) ................................ 5
Brake Release Pump and Motor (Parking and
Secondary) ............................................................ 5
Control Manifold (Brake, Hydraulic Fan) ................. 6
Pressure Reducing Valve (Parking Brake) ............. 7
Valve Replacement Kit (Diverter Valve and Relief
Valve) .................................................................... 7
Diverter Valve (Brake Accumulator) ........................ 8
Diverter Valve (Hydraulic Fan) ................................ 8
Relief Valve (Brake, Hydraulic Fan) (Main) ............. 8
Shuttle Valve (Brake, Hydraulic Fan) ...................... 8
Solenoid Valve (Hydraulic Fan) .............................. 9
Pressure Sensor (Hydraulic Fan) ........................... 9
Piston Motor (Hydraulic Fan) .................................. 9
Check Valve (Hydraulic Fan) ................................ 10
Temperature Sensor (Brake Oil, Hydraulic Fan
Oil) ...................................................................... 10
Oil Filter (Hydraulic Fan) ....................................... 10
Oil Cooler (Brake, Hydraulic Fan) .......................... 11
Check Valve (Hydraulic Oil Cooler Bypass) ........... 11
Brake Accumulator ................................................ 11
Pressure Sensor (Brake Oil Accumulator) ............ 12
Shuttle Valve (Brake Accumulator) ....................... 12
Brake Control Valve (Service) ............................... 13
Parking Brake Control .......................................... 13
Check Valve (Parking Brake Release) .................. 14
Check Valve (Parking Brake Release) .................. 14
Solenoid Valve (Parking Brake) ............................ 14
Pressure Switch (Parking Brake) .......................... 14
Service and Parking Brake ................................... 15
Slack Adjuster ...................................................... 16
Oil Filter (Differential Lock) ................................... 17
Relief Valve (Differential Lock) .............................. 17
Solenoid Valve and Mounting (Differential
Lockout) .............................................................. 17

Index Section
Index ..................................................................... 18

3
Table of Contents

4
Specifications Section

RENR8498-01

Specifications Section

i02491577

i02797389

Piston Pump (Brake, Hydraulic

Fan)

Pump Control Valve (Brake,

Hydraulic Fan)
SMCS Code: 5455-BRK; 5455-HFN
Part No.: 285-5240

SMCS Code: 1387-QP; 4268-QP; 5070-BRK;

5070-HFN
Part No.: 291-0061

Illustration 2

g01245219

(1) Pressure change for one turn of nut .... 1600 kPa
(230 psi)
(2) Pressure change for one turn of nut .... 5000 kPa
(725 psi)
Torque for nut (1) and nut (2) .......... 20 Nm (15 lb ft)
Illustration 1

g01243903

Pump displacement ................ 60 cc/rev (3.7 in3/rev)

Low idle speed ............................................. 850 rpm
High idle speed .......................................... 2250 rpm
Rated speed .............................................. 2000 rpm
Rated flow ......................... 120 L/min (31.5 US gpm)

RENR8498-01

5
Specifications Section

i02797407

Gear Pump (Differential Lock)

i02492693

SMCS Code: 3264-NP; 5073

Brake Release Pump and Motor

(Parking and Secondary)

Part No.: 276-2968

SMCS Code: 4354

Part No.: 5T-1060

Illustration 3

Illustration 4

g00103607

Illustration 5

g00103608

g01397591

Pump type .......................................................... gear

The rotation of the shaft is counterclockwise when
the rotation of the shaft is viewed from the drive end.
Pump displacement per revolution ............... 11.3 cc
(0.69 in3)
Maximum rated pressure ........ 21000 kPa (3050 psi)
Maximum rated speed ............................... 3000 rpm

View A-A

Rated flow at 3000 rpm ............................ 30.5 L/min

(8.0572 US gpm)

Rotation of the pump is clockwise when the pump is

viewed from the drive end.

Reference: Refer to the Specifications, Pump

Control Valve (Brake, Hydraulic Fan) for your
machine for information regarding pressure and flow
control.

Bench test requirements: SAE 10W oil must be

stabilized at 82 4C (180 7F) before the test is
performed.
Test information at 24 V:
Output ........................ 2.1 L/min (0.555 US gpm)
Test pressure ........................ 3792 kPa (550 psi)
Current draw .................................... 18 Amperes
(1) Internal relief valve pressure setting .... 4481 kPa
(650 psi)
(2) Torque for the eight bolts ............. 13.6 0.7 Nm
(10 1 lb ft)

6
Specifications Section

RENR8498-01

i02775504

Control Manifold (Brake,

Hydraulic Fan)
SMCS Code: 1359-HFN; 5264-HFN; 5264-BRK
Part No.: 272-0984

g01387256

Illustration 6
The graphic shows the back, top, and right side views of the control manifold group.

(1) Refer to Specifications, Solenoid Valve

(Hydraulic Fan).
(2) Refer to Specifications, Relief Valve (Brake,
Hydraulic Fan) (Main).
(3) Refer to Specifications, Pressure Sensor (Brake
Oil Accumulator).
(4) Refer to Specifications, Valve Replacement Kit
(Diverter Valve and Relief valve) for information
regarding diverter valve (4A) and relief valve (4B).
(5) Refer to Specifications, Diverter Valve (Brake
Accumulator).

(6) Torque for 13 plugs ... 8.1 0.8 Nm (72 7 lb in)

(7) Refer to Specifications, Diverter Valve (Hydraulic
Fan).
(8) Refer to Specifications, Shuttle Valve (Brake,
Hydraulic Fan).
Note: Lubricate all O-rings with the lubricant that is
being sealed prior to assembly.
(9) Torque for the orifice plug ................ 6.7 .7 Nm
(60 6 lb in)

RENR8498-01

7
Specifications Section

(10) Torque for 158-9956 Check Valve Gp .. 41 Nm

(30 lb ft)
(11) Refer to Specifications, Shuttle Valve (Brake
Accumulator).
(12) Torque for 6E-5066 Screen .. 6.5 Nm (60 lb in)
(13) Torque for the orifice plug ............... 4 0.4 Nm
(35 4 lb in)

i02733181

Valve Replacement Kit

(Diverter Valve and Relief
Valve)
SMCS Code: 4263; 5066-BRK; 5117-BRK
Part No.: 282-5396

i02774667

Pressure Reducing Valve

(Parking Brake)
SMCS Code: 5467-BRK
Part No.: 283-9562

Illustration 7

g01386826

(1) Final installation torque ................... 30 3.5 Nm

(22 3 lb ft)
(2) Torque for the nut .... 10 1.5 Nm (90 15 lb in)

Illustration 8

g01370901

Note: This is a dual valve kit that consists of a

diverter valve and a relief valve. These valves must
be replaced as a set.
(1) Installation torque for diverter valve (cut-in for
brake) ............................ 50 5 Nm (37 4 lb ft)
(2) Installation torque for nut ................... 12 1 Nm
(105 9 lb in)
(3) Installation torque for relief valve (cut-out for
brake) ............................ 40 4 Nm (30 3 lb ft)

8
Specifications Section

RENR8498-01

i02794823

Diverter Valve (Brake

Accumulator)

i02778560

SMCS Code: 4263; 5066-BRK

Relief Valve (Brake, Hydraulic

Fan)
(Main)

Part No.: 178-9037

SMCS Code: 5117-HFN; 5117-BRK

Part No.: 245-8355

Illustration 9

g01395637

(1) Installation torque for diverter valve ......... 85 Nm

(65 lb ft)
i02778601

Diverter Valve (Hydraulic Fan)

Illustration 11

g01387904

(1) Torque for the locknut ................ 12 Nm (9 lb ft)

(2) Installation torque for relief valve ....... 50 5 Nm
(37 4 lb ft)
Pressure setting for the relief valve ......... 20700 kPa
(3002 psi)

SMCS Code: 5066-HFN

Part No.: 290-6436

i02590062

Shuttle Valve (Brake, Hydraulic

Fan)
SMCS Code: 5079-HFN; 5079-BRK
Part No.: 239-0618

Illustration 10

g01387917

(1) Installation torque for diverter

valve .......................... 100 10 Nm (75 5 lb ft)
Cracking pressure for diverter valve .......... 1500 kPa
(220 psi)
Illustration 12

g01213965

(1) Shuttle Valve

Torque for shuttle valve assembly .... 9.5 1 Nm
(85 9 lb in)
Operating pressure ........... 42000 kPa (6000 psi)

RENR8498-01

9
Specifications Section

i02590077

Solenoid Valve (Hydraulic Fan)

Note: Install the sensor so that the input pressure

port is lower than the wire end and as close to the
vertical axis as possible.

SMCS Code: 5479-HFN

i02679992

Part No.: 189-8627

Piston Motor (Hydraulic Fan)

SMCS Code: 1386-QP; 5058-HFN
Part No.: 213-5268

Illustration 13

g01214001

Coil
Nominal voltage ...................................... 24 VDC
Maximum current at 100 C
(212 F) ............................................. 1.9 Ampere
Resistance at 25 C (77 F) ............ 5 0.3 ohms
(1) Torque for nut ................ 35 3 Nm (26 2 lb ft)
(2) Torque for adapter ......... 50 7 Nm (37 5 lb ft)

Illustration 15

g01371819

Sectional view of the piston motor

i02419539

Pressure Sensor (Hydraulic

Fan)
SMCS Code: 1408-PXS

The piston motor will rotate in the clockwise direction

or the counterclockwise direction.
(1) 185-0292 Spring
Length ................................. 66.3 mm (2.61 inch)
Outside diameter ..................... 41 mm (1.6 inch)

Part No.: 237-0957

(2) Torque for the four bolts that are holding the end
cap to motor housing ..................... 205 15 Nm
(150 11 lb ft)
Output per revolution .......................... 63 cc (3.8 in3)

Illustration 14

g01214016

Maximum operating pressure .. 34500 kPa (5004 psi)

(1) Final installation torque ................... 20 2.0 Nm
(15 1.5 lb ft)

10
Specifications Section

RENR8498-01

i02482042

i02510726

Check Valve (Hydraulic Fan)

Oil Filter (Hydraulic Fan)

SMCS Code: 5067-HFN

SMCS Code: 5068-HFN

Part No.: 193-9230

Part No.: 249-2307

Illustration 16

g01240112

Maximum pressure ................. 34450 kPa (5000 psi)

Cracking pressure ................................. 0 kPa (0 psi)
i02482883

Temperature Sensor (Brake

Oil, Hydraulic Fan Oil)
SMCS Code: 509T
Part No.: 264-4297

Illustration 18

g01105029

(1) Bypass valve

Pressure setting .......... 345 21 kPa (50 3 psi)
Note: The bypass valve is not adjustable.

Illustration 17

g01213191

Installation torque ................ 20 3 Nm (15 2 lb ft)

Prior to installation, lubricate O-ring (2) lightly with

the lubricant that is being filtered.
(3) Installation torque for housing ........... 55 5 Nm
(41 4 lb ft)
Note: Do not use an air wrench to tighten the
housing.

RENR8498-01

11
Specifications Section

Maximum oil pressure drop ............ 170 kPa (25 psi)

Oil flow rate .......................... 180 L/min (50 US gpm)
i02485050

Check Valve (Hydraulic Oil

Cooler Bypass)
SMCS Code: 5067-BY
Part No.: 200-6311

Illustration 19

g01105030

Section A-A

(4) 7M-1297 Spring

Test length .......................... 50.8 mm (2.00 inch)
Load at test length ......... 175 14 N (40 3.2 lb)
Free length after test .......... 75.7 mm (2.98 inch)
Outside diameter ............ 22.35 mm (0.880 inch)
(5) 133-2198 Spring

Illustration 21

g01180878

Maximum operating pressure .. 34450 kPa (5000 psi)

Cracking pressure ........................... 172 kPa (25 psi)

Test length ...................... 54.41 mm (2.142 inch)

Load at test length ............. 60 3 N (13 0.7 lb)
Free length after test ...... 68.95 mm (2.715 inch)
Outside diameter ................ 16.0 mm (0.63 inch)

i02479616

Brake Accumulator
SMCS Code: 4263

i02483740

Oil Cooler (Brake, Hydraulic

Fan)

Part No.: 219-7282

SMCS Code: 1374

Part No.: 239-8530

Illustration 22

g01238545

Maximum operating pressure .. 20700 kPa (3000 psi)

Maximum operating temperature ..... 100 C (212 F)
Illustration 20

g01240212

Minimum operating temperature ...... 40 C (40 F)

12
Specifications Section

RENR8498-01

(1) Torque for side ...................... 300 Nm (220 lb ft)

i02499241

Pressure Sensor (Brake Oil

Accumulator)
SMCS Code: 4263-PXS

i02594838

Shuttle Valve (Brake

Accumulator)
SMCS Code: 4289-ZJ
Part No.: 257-8414

Part No.: 237-0957

Illustration 23

g01098068

Maximum operating pressure .. 34500 kPa (5000 psi)

Operating voltage ................................ 5 0.25 VDC
(1) Final installation torque ...................... 20 2 Nm
(15 1.5 lb ft)

Illustration 24

g01181445

(1) Shuttle valve

Torque for shuttle valve assembly ........... 40 Nm
(30 lb ft)
Operating pressure ........... 21000 kPa (3050 psi)

RENR8498-01

13
Specifications Section

i02774431

i02510730

Brake Control Valve (Service)

Parking Brake Control

SMCS Code: 4265

SMCS Code: 4257; 4284

Part No.: 294-0978

Part No.: 283-9560

Illustration 26

g01243510

(1) Refer to Specifications, Check Valve (Parking

Brake Release).
(2) Refer to Specifications, Pressure Switch
(Parking Brake).
(3) Refer to Specifications, Pressure Reducing
Valve (Parking Brake).
(4) Refer to Specifications, Solenoid Valve (Parking
Brake).
Illustration 25

g01249496

(A) Height of installed valve ........ 32 mm (1.26 inch)

(B) Height of the valve with the service brake in the
FULLY APPLIED position ... 22.4 mm (0.88 inch)
Service brake pressure ................... 4310 350 kPa
(625 50 psi)
Note: The output pressure of the upper port will
be approximately 100 kPa (15 psi) higher than the
output pressure of the lower port.

14
Specifications Section

RENR8498-01

i02489847

i02489810

Check Valve (Parking Brake

Release)

Solenoid Valve (Parking Brake)

SMCS Code: 5067-BRK

Part No.: 283-9561

SMCS Code: 4282; 4284; 5479

Part No.: 226-5738

Illustration 29
Illustration 27

g01243763

Cracking pressure ............................... 35 kPa (5 psi)

Final installation torque ................... 22 Nm (16 lb ft)
i02479992

Check Valve (Parking Brake

Release)
SMCS Code: 5067-BRK
Part No.: 9T-3096

g01243726

(1) Torque for the nut ... 9.5 1.5 Nm (84 13 lb in)
(2) Final installation torque .. 50 5 Nm (37 4 lb ft)
Operating Voltage ......................................... 24 VDC
Resistance at 20C (68F) ................ 26.96 1 ohms
i02774710

Pressure Switch (Parking

Brake)
SMCS Code: 1408; 4267
Part No.: 229-1537

Illustration 30

Illustration 28

g01249377

Cracking pressure for the check valve ... 35 20 kPa

(5 3 psi)

g01215569

(1) Torque for installing the switch ......... 50 5 Nm

(37 5 lb ft)
Maximum actuation pressure at 40C to +121C
(40F to +250F) ...................... 2100 kPa (305 psi)
Deactuation pressure at 40C to +121C
(40F to +250F) .... 1750 108 kPa (254 16 psi)
Contacts are normally closed below the deactuation
pressure.

RENR8498-01

15
Specifications Section

i02724829

Service and Parking Brake

SMCS Code: 4251; 4267
Part No.: 271-9321, 271-9322

Illustration 31

(1) Torque for six bolts .. 105 20 Nm (75 15 lb ft)

g01366900

16
Specifications Section

Note: Apply 155-0695 Thread Lock Compound to

the threads.
(2) 2G-5681 Spring
Quantity ............................................................ 4
Test Force .................... 670 33 N (150 7.5 lb)
Free length after test ...... 71.882 mm (2.83 inch)
Outside Diameter ..................... 25.4 mm (1 inch)

RENR8498-01

i02482026

Slack Adjuster
SMCS Code: 4261
Part No.: 2G-6535

(3) Friction Disc

Number of discs .............................................. 12
Thickness of one disc ................ 5.08 0.13 mm
(0.200 0.005 inch)
Minimum reusable thickness for one
disk ................................... 4.42 mm (0.174 inch)
Note: Prior to assembly, lubricate the friction discs
with hydraulic oil.
(4) Plate
Number of plates ............................................ 13
Thickness of one plate ....... 2.4130 0.0508 mm
(.0950 .002 inch)
(5) Torque for eight bolts ..................... 270 40 Nm
(200 30 lb ft)
Note: Apply 155-0695 Thread Lock Compound to
the threads.
(6) 4D-5642 Shim Pack
Thickness .... 2.89 .08 mm (0.114 0.003 inch)

Illustration 32

g00291078

(1) 2G-1202 Spring

Quantity ......................................................... two
Test length ............................ 50.8 mm (2.0 inch)
Test force ........................ 45 2 N (10.1 0.5 lb)
Free length after test .......... 76.4 mm (3.01 inch)
Outside diameter ................ 44.5 mm (1.75 inch)

Reference: Refer to the Disassembly and Assembly

for your machine for more information regarding the
installation of these shims

(2) Diameter of piston .......... 82.47 mm (3.247 inch)

(7) Torque for twelve bolts ..................... 60 12 Nm

(44 9 lb ft)

(3) Bore in the housing .................. 82.56 0.04 mm

(3.250 0.002 inch)

Note: Apply 155-0695 Thread Lock Compound to

the threads.
Reference: Refer to the Disassembly and Assembly
for your machine for more information regarding the
installation of these bolts.
(8) The seals and all of the surfaces that are
contacting the seals must be clean and dry at
assembly. Apply a thin film of oil to the metal seal
ring prior to assembly.
Note: Lubricate the seals, and the bores lightly with
the lubricant that is being sealed prior to assembly.

RENR8498-01

17
Specifications Section

i02483806

Oil Filter (Differential Lock)

Pressure setting at 4 L/min (1 US gpm) ..... 2400 kPa

(348 psi)
(1) Pressure change with one revolution of
adjustment screw ...................... 530 kPa (80 psi)

SMCS Code: 5068

Part No.: 191-9784

(2) Torque for nut ............................. 12 Nm (9 lb ft)

(3) Installation torque ..................... 50 Nm (37 lb ft)
i02510741

Solenoid Valve and Mounting

(Differential Lockout)
SMCS Code: 5479-MT
Part No.: 277-8874

Illustration 33

g01157808

Bypass setting ................................ 172 kPa (25 psi)

(1) Installation torque for the indicator
assembly ....................... 29 6 Nm (21 4 lb ft)
(2) Installation torque for the filter ........ 20 to 27 Nm
(15 to 20 lb ft)
i02492800

Relief Valve (Differential Lock)

Illustration 35

SMCS Code: 5117

Position ............................................................ Open

Part No.: 266-1601

Coil

g01244687

Nominal voltage ...................................... 24 VDC

Resistance at 25 5C
(77 9F) ................................. 30.6 1.2 ohms

Illustration 34

g01249358

18
Index Section

RENR8498-01

Index
B

Brake Accumulator ................................................. 11

Brake Control Valve (Service) ............................... 13
Brake Release Pump and Motor (Parking and
Secondary) ............................................................ 5

Service and Parking Brake .................................... 15

Shuttle Valve (Brake Accumulator)........................ 12
Shuttle Valve (Brake, Hydraulic Fan)....................... 8
Slack Adjuster........................................................ 16
Solenoid Valve (Hydraulic Fan) ............................... 9
Solenoid Valve (Parking Brake)............................. 14
Solenoid Valve and Mounting (Differential
Lockout) ............................................................... 17
Specifications Section ............................................. 4

C
Check Valve (Hydraulic Fan) ................................. 10
Check Valve (Hydraulic Oil Cooler Bypass) ........... 11
Check Valve (Parking Brake Release) .................. 14
Control Manifold (Brake, Hydraulic Fan) ................. 6
D
Diverter Valve (Brake Accumulator) ........................ 8
Diverter Valve (Hydraulic Fan)................................. 8
G
Gear Pump (Differential Lock) ................................. 5
I
Important Safety Information ................................... 2
O
Oil Cooler (Brake, Hydraulic Fan)........................... 11
Oil Filter (Differential Lock) .................................... 17
Oil Filter (Hydraulic Fan)........................................ 10
P
Parking Brake Control ........................................... 13
Piston Motor (Hydraulic Fan)................................... 9
Piston Pump (Brake, Hydraulic Fan) ....................... 4
Pressure Reducing Valve (Parking Brake) .............. 7
Pressure Sensor (Brake Oil Accumulator)............. 12
Pressure Sensor (Hydraulic Fan) ............................ 9
Pressure Switch (Parking Brake)........................... 14
Pump Control Valve (Brake, Hydraulic Fan)............ 4
R
Relief Valve (Brake, Hydraulic Fan) (Main) ............. 8
Relief Valve (Differential Lock) .............................. 17

T
Table of Contents..................................................... 3
Temperature Sensor (Brake Oil, Hydraulic Fan
Oil) ....................................................................... 10
V
Valve Replacement Kit (Diverter Valve and Relief
Valve)..................................................................... 7

RENR8498-01

19
Index Section

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All Rights Reserved

Printed in U.S.A.