SERVICE MANUAL 920 & 930 STEERING SYSTEMINTRODUCTION ‘This publication has instructions and procedures for the subject on the tront cover. The information, specifications, and illustrations in this publication are on the basis of information that was current at the time this issue was written, Correct operation, maintenance, test and repair procedures will give this product a long service life, Before starting a test, repair or rebuild job, the serviceman must read the respective sections of the Service Manual, and know all the components he will work on. Your safety, and the safety of others, is at all times very important, When st you sso tis symbol Q) oF this symbol AQ in the manval you m symbols ave warnings. To work safely, you must understand the job you do. Read all instructions to know what is safe and what is not safe. is very important Wy how the weight of parts, Do not lift heavy parte by hand. Use a hoist, Make sure heavy parts have a good stability on the ground. ‘A sudden fall can cause an accident. When lifting part of a machine, make sure the machine has blocks at front and rear. Never let the machine hang on a hoist, put blocks or stands under the weight. When using a hoist, follow the recommendation in the manual, Use correct lift tools as shown in illustrations to get the correct balance of the component you lift, This makes your work safer at all times:940 AND YSU STEERING SYSTEM INDEX SYSTEMS OPERATION Amplifier Steering System 4 Hand Metering Unit (HM) 6 Operation 4 TESTING AND ADJUSTING Hydraulic Steering System 7 Instrument Tests 7 Operation Checks 7 Troubleshooting 8 Visual Checks . ad SPEUIFICA ONS NOTE: For Specifications with illustrations, make reference to the STEER- ING SYSTEM SPECIFICATIONS FOR 920 & 930 WHEEL LOADERS, Form No. REGO1616. If the Specifications in Form REGUL619 are not the same as in the Systems Operation and the esting and Adjusting, look at the printing date on the back cover of each book. Use the Specifications in the book with the latest date,920 AND 930 STEERING SYSTEM SYSTEMS OPERATION AMPLIFIER STEERING SYSTEM , i 4. steering evi Components in the steering system are the small section (cover end) of an engine driven, two section, vane type hydraulic pump, a hand meter- ing unit (16) a steering control (amplifier) valve (2), two hydraulic cylinders (1) and the hydraulic tank. An explanation of the operation can best be given by dividing the system into two parts. These are: the pilot system and the steering (amplifier) system. NOTE: Service information for machines equipped with supplemental steering can be found in SUP- PLEMENTAL STEERING SYSTEM, Form No. REGOO99. Hand metering unit (HMU) (16), which is a small hydraulic pump, is operated with the steering wheel, The hand metering pump sends pilot pres- sure oil to operate steering control (amplifier) valve (2). Steering control valve (2) lets the oil flow from Js. 2. Stesring contra valve, 2 Main spool in steering wale. 4. Valve spoo! in lft neutralizer vale, 5. Valve 0a! 1: Ball check velve fone in each neutralizer valve. 7. Loft neutralize valve, 8, elie valve for main system Il check valve. 11, Ball resolver valve, 12, Flow control lve. 13. Right novtralizer valve, 14 16, Hand metering unit (HM. the engine driven pump go to steering cylinders (1) to tum the machine. At high idle, three full tums of the steering wheel will tum the machine from stop to stop. At low idle, additional tums af the steering wheel are necessary to turn the machine from stop to stop. OPERATION Machine Moving: Engine Running No Steering Action ‘The small section of the two section hydraulic pump sends oil ta steering cantral value (2) The oil cannot go through the valve because main spool (3) for steering is centered. The ail flow then goes in three directions. First, it goes through left neutralizer valve (7) to hand metering unit (16) where it is stopped. Second, it goes to the pistonpeu ANY YSU OTEENING SYSTEM end of selector valve (15). At the selector valve, the oil flow moves selector valve spool (14), apaning passages for oil flow from the hand metering unit (when steering) to the left and right neutralizer valves, Third, the oil goes to the unloading part of Flow control valve (12). The centered main spool (3) in the steering valve keeps the oil in cylinders (1) and lines from coming out. Variable pressures in the cylinders are felt at the spring end of the unloading valve through ball resolver valve (11), The pilot relief valve (8) for main system pressure, will open when the pressute in the cylinders gets to 2500 +25 psi (175.8 + 1.7 kgyem?) mm uo ” i / SELECTOR VALVE IN MANUAL STEERING (Dead Engine! Position [Sint moved to tof, pening passages (21) an! (2211 17. ‘Main cit pressure inlet, 1a, Tole from metering lini steer lelt) 19. Outtat for power steering lef). 20. Inlet from metering unit (steer right). 21. Outlet for manual steering (wg). 28. Outiet for power steering (ight il SELECTOR VALVE IN POWER STEERING POSITION. {Spoo! moved to rght, pening passages (19) and (2311. 17. Main oit pressure inlet. 18. Inlet from metering Unt (steer left, 19. Outlet for power stering (left. 20, Inlet from ing unit (steer right). 21. Outlet for mana steering 281 Outlet for power steering teat) Woh Moving Forward: Engine Running Steering Motion NOTE: The following information is a description of @ right turn, The same principle is used for a left Steering action is controlled by the output of SYSTEMS OPERATION pilot oil from the hand metering unit (HMU). The HMU is a small hydraulic pump that sends pilot oil to the steering valve at the rate of 1.9 gpm (7.2 lit/min) ab one revolution per second of the steering wheel, When the steering wheel is tured to the right, pilot oil is sent from hand metering unit (16), through selector valve (15) to right neutralzer valve (13) where it is sent to the right end of main spool (3) in steering control valve (2). ‘This flow of oil moves the main spool to the right. ‘This action of the main spool opens a passage for oil flow from the pump to the head end of the left cylinder and the rod end of the right cylinder. As main spool (3) moves to the left, small holes (orifices) drilled in the spool let oil flow go through drilled passages to the opposite end of the spool, This Mow of oil through the small holes (orifices) in the main spool causes a decrease in pressure that Is balanced by the centering springs of the main spool. The oil flow that goes to the opposite end of the spool retums to the hand metering unit through left neutralizer valve (7) and selector valve (15), Pressure caused by the flow of oil from the pump 0 steering eylinders (1) is felt through ball resolver valve (11) to the spring chamber of flow control valve (12). As the pressure increases due to road resistance, valve (12) is moved to the left, inctewsing the resistance to the flow of pump oil rough the valve. This causes an increase in the pressure in the cylinders to balance the increase of pressure caused by road resistance, The angle that the machine will turn is limitod by strikers that are installed on both sides of the front frame. As the machine turns to the right (or left) and nears the frame stops the striker makes contact with the valve spool of the right neutralizer valve. This pushes the spool of the neutralizer valve into the budy and stops the flow of oil to the main spool. Stopping the pilot oil lets the main spool, in the steering valve, return to a centered position. ‘This stops the flow of oil from the pump to the cylinders. Steering “off the stop” is possible because the flow of pilot oil is sent around the blocked! passage in the right neutralizer valve. Ib then goes through bypass ball check valve (6) and permits a left tum, If the pressure in the steering cylinders goes higher than 2500 psi (176.8 kg/cm?) pilot relict valve (8) for main system pressure will open. Machine Moving, Dead Engine: Steering When hydraulic pump pressure decreases to less than 30 psi (2.1 kg/cm?) spool (14) in selector valve (15) moves to the left. This stops the flow of pilot oil to either end, of main spool (3) in the steering valve, This same action by spool (14)920 AND 930 STEERING SYSTEM »pens passages (21) and (22) so that the pilot oil will go. to the eylinders. Valves (9) and (10) send oil to the hand metering unit to decrease cavitation and provent road shocks at the steering wheel when moving over rough surfaces This’ steering system lets the operatar keep) control of the machine if the engine stops running, Ii does not provide steering as good as the primary system or a machine equipped with supplemental ering. HAND METERING UNIT ‘The hand metering unit (HMU) is a small, hand operated hydraulic pump, Pressure oil from the main hydraulic pump is sent to the inlet (4) where it stopped when the unit is in the neutral position Sicering action is started hy turning the steering wheel. The control spool is tured by a direct connection with the steering column shaft (9) ‘Turning the spool opens passages that send oil to the metering (pump) (10) ecetion.. The oil that is pumped by the HMU is sent Uhrough connecting lines to the steering valve, The opposite chamber on the HMU is connected to tank HAND METERING UNIT IN NEUTRAL POSITION 1. Meter seetion. 2. Control suction, 3, Column section. & Totot for main system oi, 5, Outlet to tank. Gy Right fm furlot, 7 Lal sm outlet, ‘The faster the steering wheel is turned the faster the machine will turn. This is due to the rate of flow from the HMU, The fastest steering time is when the steering wheel is tured at a rate of 1.1 seconds per revolution with the engine at high idle ‘The fastest time with the engine al low idle is 2.25 to 1.75 seconds per revolution of the steering wheel If the engine should stop when, the machine is moving, the HMU will give the operator the ability SYSTEMS OPERATION AND METERING UNIT IN RIGHT TURN POSITION frm outlet. 7, Lett tara outlet, 8, ll check vale, 9 Stowring column. 10. Metering pump. 11. Spool ana sieve, to manually control the steering until he can come to a stop. When manual steering is used, the HMU sends oil directly to the steering evlinders. Steering pil is kept in the system through the action of bali check valve (8). ED HAND METERING UNIT IN) LEFT TURN POSITION 4, Inlet for main system oll, 5. Outlet t9 tank, 6: Right ‘im outlet, 7- Left tum cutie, CAUTION: Manual steering is slower than power steering. Turning from stop-to-stop is impossible Extra care must be taken by the operator at_all times when this method of steering is used. Pushing the machine is possible but towing should not. be used unless at very slow speeds,920 AND 920 STEERING SYSTEM TESTING AND ADJUSTING HYDRAULIC STEERING SYSTEM During an analysis of the hydraulie steering system, remember that correct oil flow and pres sure are necessary for correct operation. Pump output {oil flow) is a function of engine speed (rpm). Oil pressure is caused by resistance (by th ystem) to the flow of oil Visual checks and measurements are the first ste when troubleshooting a possible problem: Phen do the operation checks and last the instru: mentation tests, ise the 585128 Hydraulic Test Group, a stop wateh and a magnet or the 982000 Flow Meter for basic tests to find: L) The opening pressure of the relief valve for main system pressure, When the opening pressure Mf the relief valve is too low, it will cause a ciecrease in the steering ability’ of the machine. When the opening pressure is too high it will cause a dveroase in the life of hoses and components, 2) Cyele times in the steering circuit. ‘The time needed to steer from straight ahead to either the right or left stop should be approximately the same, Differences in these times will result in poor control of the machine 3) Oil flow in the different parts of the circuit This includes the flow of oil from the pump to the steering valve; from the hand metering unit to the neutralizer valves; from the eelector valve to the steering valve (manual steering), VISUAL CHECKS. Let the oil become cool and do the following inspeetions: 1, Check the level of the oil in the tank. Slowly loosen the tank filler cap, Release all pressure in the tank before removing the cap, Remove the cap, 2, Remove the filter element and cheek for foreign materials. A magnet will separate ferrous metals from non-ferrous materials not made of metal (sealing materials such as piston rings, O-ring seals, ete.) 3. Inspect the hand metering unit, all lines and the steering cylinders for damage or leakage. OPERATION CHECKS. WARNING: When testing and adjusting the hydraulic system, move the machine to a smooth horizontal location on a dirt sur we. Move “away from the job traffic pattern and away from other personnel. Do not let more than fone man on the machine at a time. Keep all other personnel off to one side and in view of the ‘operator at all times. ‘The operation checks of the system 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 time needed to steer from stop to stop can be used to check the condition of the cylinders and the pump. Turn the machine from stop to stop several times, 1, Watch the movement of the cylinders as they are extended and retracted. "The movement must be smooth and regular Listen for noise from the pump, 8. Listen for the sound of the reliof valve opening. The relief valve must not open until the system pressure reaches 2500 £ 25 psi. (175.8 = 1.7 kg/em?} 4. Cheek the time needed to steer the machine from a full left turn to a full right tun. The fastest steering time is when the steering wheel is turned at the rate of one revolution in 1.1 seconds with the engine at high idle. INSTRUMENT TESTS Tools needed: 585123 Hydraulic Testing Group and 952000 Flow Meter ‘Tests can be made with oil at operating tempera. lures of 90° to 120°F, (82° to 49°C). NOTE: ‘Testing with the 982000 Flow Meter should always be done with the oil temperature at 150 45°F (65 C). To keep oil loss to a minimum, remove the filler cap on the tank and replace it before opening the system 1, Install @ © to 4000 psi (0 to 281.2 kg/em®) pressure gage with, necessary fittings and 2. Remove the strikers on both neutralizer valves. NOTE: The safety link can be installed instead of removing the strikers, 3. Get the engine to 2200 rpm. Turn the steering wheel (left or right) until you get a maximum, reading on the pressure gauge920 AND 930 STEERING SYSTEM 4, The gauge must read 2500 + 25 psi (175.8 + Lit kg/cm? ) 5. Keep the engine speed (rpm) at 2200 and turn the steering wheel in the opposite direction ‘The maximum pressure reading must be 2500 £25 psi (175.8 £ 1.7 kg/er 6, Add or remove shims (1) to get the correct pressure CHANGE IN PRESSURE BY REMOVAL [OR ADDITION OF ONE SHIM 7) TESTING AND ADJUSTING 7. Tighten plug (2) to 80 + 8 Ibft. (4.1 0.7 ung) a CHANGE IN psi. shim parT wo, | THICKNESS ‘gion | anasag O10 in. a4 (osm een 337473 005 in, ai. STEERING VALVE Lua) sae 1. Shims, 2. Plug. TROUBLESHOOTING To find the cause of a problem in the steering system, use the following procedures: 1. Check the pilot circuit between hand metering unit (HMU) (12) and spool (6) in_ steering control valve (7) with the engine running A, Remove plug (9) ‘Turn the steering wheel for a right turn ‘The flow of pilot oil must be smooth and free of air, D._ Replace plug (9). Remove plug (4). F, ‘Turn the steering wheel for a left turn. G. The flow of pilot oil must be smooth and free of air. H. Replace plug (4). NOTE: When the plugs are removed, there will be small flow of oil. If the steering wheel is not turned this flow will stop. After the flow has stopped, tum the steering wheel ai a constant rate (2 to 3 seconds per revolution). If the flow of oil does not stop or is not smooth and free of air check the following possible causes. POSSIBLE CAUSE 1 flow is not smooth and has air in it ‘il supply has air in it, Check the lines, valves and tank for an air leak. Check oil level in the tank, Check for restrictions in the drilled passages of the valves or in the pilot lines. HMU is not working correctly. ‘The pull needed to turn the steering wheel should be low, 18 to 22 Ib. in, (20.7 to 25.4 em.kg) when the oil is warm and the wheel is tumed at a rate of 15 to 20 seconds per revolution. If steering is more difficult cheek for a restriction in the pilot lines or the drilled passage ways in the HMU or valves. Check the HMU to be sure it is installed correctly. Il, Cheek the circuit between the HMU (12) and steering cylinders (1) with the engine shut off A. Remove plug (3). B. Turn the steering wheel for a right tum. C. The flow of oil must be smooth and free of air. 1D. Replace plug (3). E, Remove plug (2).SCHEMATIC OF STEERING S¥STEM 1. Steering evinders. 2. Plug, 3:Plug, 4. Plug, 5, Reverse flow ball check valve, 6, Msn spool in steering vale. 7, Steering contol Valve, Pt rele valve, Plug. 10, Ball hack vsive. 11. Ball check waive. 12. Hand metering unit (HMU). 13. & 14. Supply Tine for pilot pressure 0 hand metering unit, 15, Ball resoler valve, 16. Flow contol valve. 17. Spool in selector vale, 18 Pilot line for ight turn, 19, Pilot ine for let torn, 20. Supplementol scoring valve. 21. Supplemental steering pump. P, ‘Tum the steering wheel for a left tum, is more difficult, check for restrictions in the pilot lines or drilled passages in the valves. Check the G. The flow of oil must be smooth and free HMU to be sure it is installed correctly. 7 IL, Cheek the performance of the Hand Metering H. Replace plug (2). Unit (IMU), NOTE: When the plugs are removed, there will he a ‘A, To check the performance of the HMU, small flow of oil. If the steering wheel is not turned loosen fittings on lines (18) and (19). thie flow will stop. After the flow has stopped, Those are the pilot lines for steering right turn the steering wheel at a constant rate, 15 t seconds per revolution. The pull needed to tum t steering wheel should be low 18 to 22 Ib, in, (20.7 B, With the engine running and the steering to 25.4 cm.kg) when the oil is warm. If the steering wheel stationary, there will he a small loss and left respectively. 9920 AND 930 STEERING SYSTEM ‘CHOSE GECTION OF BALL REEOLVER VALVE 15, Bal resolver value, 20, Flow control dampening pin. A ©o LEFT HAND NEUTRALIZER VALVE 4. Plug. 5, Reverse flow bal hack. 10, Ball check valve of oil. The flow should stop after all of the oil in the lines runs out. ©. The amount of pull needed to turn the steering wheel must he low; 18 to 22 Ib, in. (20.7 to 25.4 cm.kg) with warm oil and the wheel is turned at a rate of 15 to 20 seconds per revolution D. Pilot flow at the opened lines must be smooth and free of air when the steering wheel is tumed at 2 to 3 seconds per revolution. . Connect fittings removed in Step IILA IV. The HMU can cause the following problems A. Steering wheel turns by itself with the engine running, 10 TESTING AND ADJUSTING 9, Plog, 17. Ball heck valve, 1. HMU is dirty causing the sleeve valve to stick. (The pull needed to tum the stooring wheel is usually higher than normal). NOTE: If there is dirt. or foreign material in the HMU, the rest of the hydraulic aystem should be flushed. 2. The length of the bolts holding the HMU to the steering column is too Jong. These bolis may not be tight- ened evenly. The surfaces of the HMU and the part it is mounted on are not flat. 3. The centering springs (748010) in the HMU are broken ‘The sleeve valves in the HMU have too tight a fit B. Steering wheel is hard to turn with the engine running, 1. Steering wheel steers normal with cold oil but becomes harder to steer as oil warms up. Check the pilot lines for restrictions,3. ‘The bolts (756835) in the HML assembly are too tight or have not heen Lightened evenly. Correct worque is 20 £1 Ih.ft, (2.8 # 0.14 mkg), 4, Steering pump has a defect. Flow should be 28,0 U.S. gpm, (87.1 lit min) at 1000 psi (70.0 kg/em? ) and 2000 rpm, 5. The clearance between ball cheek valve (10) and spring pin is too small ‘The minimum measurement is .10 in (254 ani) 6. ‘The timing on the HMU drive is not cortect. Drive pin (78009) must be parallel with the groove in the star ear C. Steering wheel is hard to tum when machine is against one of the stops (neu: tralizer valves) The clearance between the reverse flow ball check valves (11) or (5) and spring pin is too small. ‘The minimum measure. ment must be ,10 in. (2.54 mm). ‘Troubleshooting the Steering Control Valve (Engine must be at High Idle unless a ditfere indication is given) A, Machine steering is correct with an empty bucket but it steers slow when the bucket is loaded or the brakes are boing used. 1. The fit between flow control valve (16) and body of the steering contro} valve (7) is t00 loose, ‘One or both of the seats m the ball resolver valve (15) has a leak a. If steering is slow in both direc tions, both seats have a defeet or the fit_between flow control valve (16) and body of the steer ing control valve (7) is too loose The flow control valve may be sticking or there is leakage across pilot relief valve (8) or its seal b. If steering is slow in one ditec- tion only, there is a d i only one of the seats in the ball resolver: right turn slow: upper ball resolver seat, left turn slow lower bail resolver seat 3. Steering pump has a defect. Flow should be 23.0 U.S. gpm (87.1 lit. min) at L000 pst (7.0 kgyem®) and 2000 rpm. B, Steoring wheel turns by itself 1. Check the HMU (See paragraph WA) 2. The alignment of the metering orifice and pump-to-eylinder slots on main control spool (6) with the lands in valve body (7) isnot correet, Remove spool (6) and install it in the reverse direction, Be sure to install the re. tainers and spacers correctly, Steering time from stop-to-stop may need an adjustment. This can be done by using the 6J6517 or 6J6576 Shims. Add” shims to increase right turn cylinder flow. Remove shims to in- crease left turn cylinder flow. 3. Main control spool (6) is sticking in a shifted position, Check the valve for dirt or foreign’ matter, body valve bolt torques that are not the same on each bolt, deep scratches in the bore of the valve body or rough particles ‘on the spool, C. Steering time is too slow in both direc- tions. Normal steering time from stop-to stop is 2.5 to 2.9 seconds with the engine AL high idle and turning, the stooring wheel at I revolution per second 1. Check the steering time with and without brake application, The steer- ing times will be approximately the Make an adjustment to flow control valve (16) by adding 587018 Shims, A maximutn of 10 shims is permitted to Keep the pressure on the pump from being too high in neutral 3. Check the performance of the steer: ing pump. Plow should be 23.0 US pm (87.1 lit/min) at 1000 psi (7.0 Ikg/em? ) and 2000 xprn, 1D, Steering time too slow in one direction only 1, Leakage in one of the ball resolver seats, Check steering with and with- out brake application, (See paragraph VA2) u920 AND 930 STEERING SYSTEM B, 2, Make an adjustment in the shims at the end of the control valve spool (See paragraph V.B.2.) 3. Check the steering wheel slip (move ment of the steering wheel without machine movement) to check the alignment of the control valve spool with the body. Maximum permissible slip (engine at low idle, warm oil, brakes released, bucket off the ground) is 15 seconds per revolution of stecring wheel with a very cmall movement. of the machine. If the steering wheel can be turned faster than 15 seconds per revolution with no movement by the machine, re. move the control valve spool from the steering control valve body and install it in the reverse direction Make a shim adjustment. on the con trol spool until the steering times are the same. Machine does not steer when steering wheel is turned 1. Flow control valve (16) is the open position. stuek in 2. The 198497 Relief Valve has a defect or a failure of a seal. 3, The timing land in the main control valve body is not machined correctly 4, The spline end of the steering column has been pushed into the HMU too far causing the inner and outer sleeve valves to stick 5. Check the performance of the steer- ing pump. Flow should be 23.0 US. gpm (87.1 lit/min) at 1000 psi (7.0 kgiem? ) and 2000 rpm. Machine steering is not smooth . TESTING AND ADJUSTING 1. The flow control valve (16) is not working correctly The flow control dampening pin (20) is not installed, (83430 Valve_on machines 41K1876-UP and 62V 2906—UP). 8. The timing slots and metering orifice of the main control spool are not to specifications, (See paragraph VD. 3). 4, Check the performance of the steer ing pump. Flow must be 23.0 US. gpm (87.1 lit/min) at 1000 psi (7.0 kkgyem? ) and 2000 rpm, Lip seal leakage on the right hand neutral izer valve. The seal can come out of the bore and the stem on the neutralizer valve will not move freely. The relief valve seat may be installed wrong or the O-ring seal is leaking No manual steering; power steering is working correctly. Selector valve spool (17) is stuck in the power steering posi tion. jing wheel can be turned after the e has made contact with a frame stop. 1. The frame stop adjustment is not correct. It does not contact the neu- tralizer valve spool. Valve seat (6) or (11) has a defect or dirt. is keeping it from working cor- rectly Noise caused by vibration, (Can be heard best at lower engine rpm). Replace tube assemblies (13) and (14) with a 1V2774 Hose Assembly (BH caterritcarn Crile, Cat and are Trademarks of Caer Tractor Co CATERPILLAR FUNDAMENTAL ENGLISH