19/12/22, 15:32 SIS 2.

2011/12/08 Steering Does Not Function (UENR1729-02)

SMCS - 4300 i04316454

Event Codes  
System
Code and Description  Conditions which Generate this Code 
Response 

Malfunction PIP
E192(3) Steering System
There is an active diagnostic code for the steering system. 
The code is
logged. 

in Wrong Direction  -
202 011 1
E256(3) Steering Output Detected
The machine ECM commands steering in a particular direction but the speed
sensor for the steering motor detects motion in the opposite direction. 
The code is
logged. 

2 8
E257(3) Steering Output Detected The machine ECM is not commanding any steering, but the speed sensor for The code is

18: /12/1 791

with No Command Given  the steering motor detects motor speed.  logged. 
E258(3) No Steering Detected with The speed sensor for the steering motor does not detect motor speed in The code is

3
Command Given  response to a steering command from the machine ECM.  logged. 

Table 1

U 2: 9
Probable Causes EN 10-0
© 2 R17 3:00
The oil level in the hydraulic tank is low.

Cat 2 C02
Steering pump controls
29
e
Low charge pump pressure

r
Con pilla terpi a
Crossover relief and makeup valves

fide r: llar
Charge pump flow rate low

Inc
Piston pump (rotating group) flow rate

ntia
Steering pump case drain flow rate

.
lG
The pump or the steering motor has failed.

ree
Faulty Steering tiller handle

Recommended Actions n
Note: Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair
of the machine. You must be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any
component that contains fluid. Dispose of all fluids according to local regulations.

The Oil Level In The Hydraulic Tank Is Low

The hydraulic oil tank has a sight gauge on the outside of the tank. Check the hydraulic oil level with the machine on level ground and the engine
OFF. If oil is NOT seen in the sight glass, the hydraulic oil level is low.

If the hydraulic oil level is low, check for oil leakage.

Inspect the following items of the hydraulic tank for oil leakage:

All of the weld joints

All of the bolted covers and components

All fittings

All hose flange connections

Oil may leak out of the system if:

the welds are damaged

covers and components have the seals or gaskets installed improperly

bolts and fittings are improperly torqued

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Correct any of the problems that are found. Fill the hydraulic tank with the correct oil. Monitor the tank in order to ensure that the leaks have been
stopped.

Refer to Operation and Maintenance Manual, SEBU8408 , "Hydraulic System Oil Level - Check".

Note: Ensure that the strainer is present in the filler tube before adding the recommended hydraulic oil.

The Steering Pump Controls Are Suspect

With the Monitoring System or Caterpillar Electronic Technician (Cat ET), check for event codes associated with the steering lever position sensors.

Any type of failure with the steering position sensors will result in a "Level 3 Warning". A "Level 3 Warning" indicates that the machine must be shut
down immediately, in a safe manner, and in a safe position. Failure to do so will result in damage to the machine or injury to personnel.

Note: Event codes are listed above.

If an event code for the steering system is logged, continue with the following procedures.

1. Check the monitoring system or Cat ET for any fault codes that are related to:

"Steering Position Sensor 1"

"Steering Position Sensor 2"

"Steering Position Sensor 3"

Ensure that a problem with the steering lever position sensors is now causing the steering pump to operate improperly. If the signals from the
steering position sensors are incorrect, the ECM may not be commanding the solenoid to energize properly. Also, the ECM may not be
commanding the solenoid to de-energize properly. Correct any problems with these components, then check to see if the symptom is
resolved.

With the Cat ET, perform the calibration routine for the "Steering Control Position Sensors".

2. With Cat ET, perform the calibration routine for the "Steering Control Position Sensors". After you enter the "Service Password" , the
calibration procedure may be accessed via "Service/Calibrations/Steering Calibrations/Steering Control Position Sensors".
This procedure will calibrate the two position sensors so that the machine ECM can properly interpret the signals from the sensors. This
procedure will also correctly control the steering pump control solenoids.

If these sensors are not properly calibrated, the sensors may be falsely sending signals to the ECM to steer with no steering request. The
sensors may also send signals in one steering direction but not the other.

3. With Cat ET or the monitoring system, check the signal "Duty Cycle" from the steering lever position sensors.
View the status of the steering lever position sensors in order to ensure that the signals are accurate.

The active real-time status of these sensors may be viewed at the following location: "Service/System Status/Steering/Steer Pos Sensor 1
Duty Cycle, Steer Pos Sensor 2 Duty Cycle, Steer Pos Sensor 3 Duty Cycle".

Note: Sensor #2 will show "disabled/not installed". This action is intentional because the two sensor pack has been included on the D6N T4i.
The arrangement is also backward compatible with D6N T3 machines.

Sensor 1 and sensor 3 should be sending a relatively close signal, as follows:

NO STEER - 49% - 51% Duty Cycle

LEFT STEER - 8% - 10% Duty Cycle

RIGHT STEER - 88% - 90% Duty Cycle

If the sensors have been calibrated but are still sending incorrect signals: if no electrical problems are found in the sensor circuits, one or
more of the sensors are bad and must be replaced.

Note: Note: All of the sensors are packaged together as an assembly therefore all of the sensors must be replaced.

After replacing the sensors, repeat Step 2 then retest for the symptom.

Charge Pump Pressure Becomes Low

The charge pump is a fixed displacement gear-type pump. The charge pressure relief valve must open in order to allow enough oil to flow in order
to maintain charge pressure. Oil flow past the charge pressure relief valve will increase as engine RPM increases. However, if the charge pressure
relief valve is stuck open too far, the steering charge pressure cannot be maintained.

The charge pressure relief valve maintains (limits) the charge pressure to approximately 2850 kPa (413 psi) at 2000 engine RPM. Charge pressure
oil is sent to the following:

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drive loop

steering control valve

dual tilt valve (used as pilot oil)

pump actuator piston

Test and adjust the Charge Pressure Relief Valve. Refer to Testing and Adjusting, KENR8558 , "Relief Valve (Charge) - Test and Adjust".

Note: The Cold Oil Relief Valve can also cause similar symptoms. Ensure that the cold oil relief valve is operating properly prior to performing any
test and adjust procedures on the charge pressure relief valve.

Crossover Relief and Makeup Valves

Test and adjust the crossover relief and makeup valves. Refer to Testing and Adjusting, KENR8558 , "Steering Hydraulic Circuit - Test and
Adjust".

Oil from the high-pressure side of the steering loop may leak across to the low-pressure side of the loop under one of the following conditions:

The relief function or the makeup function of one of the valves is stuck open

One of the valves springs is weak

One of the valves springs is broken

One of the valves springs is misadjusted

If one of the conditions listed above exists: the necessary high pressure may not be possible, or maintainable, in one or both sides of the steering
loop.

Test the mechanical neutral position for the steering pump control valve. Refer to Testing and Adjusting, KENR8558 , "Neutral Adjustment
(Steering Pump) - Test and Adjust". If the neutral position of the steering pump control valve is incorrect (off-center while in the NO STEER
condition): the steering pump control valve will command the actuator piston to move off-center when there is no steering request. This condition
may cause the machine to stray from straight-line travel in a NO STEER condition. This condition may also cause the machine to steer more
sharply in one direction than the other.

Charge Pump Flow Becomes Low

If the charge pump becomes too inefficient and cannot produce, the required oil flow then one or more of the following may occur:

steering will be slow to react

turns will not be as sharp

machine may not steer at all

Use a flow meter in order to test the flow rate of the steering charge pump. The charge pump flow rate should be approximately 61.9 L/min
(16.4 US gpm) at 1850 engine RPM.

Piston Pump (Rotating Group) Flow Rate

If the piston pump becomes too inefficient and cannot produce the required oil flow: steering will be slow to react, turns will not be as sharp, or the
machine may not steer at all.

Use a flow meter to test flow rate of the steering pump (flow from the rotating group). The piston pump flow rate should be approximately 276 L/min
(73 US gpm) at 1850 engine RPM. At 2200 engine RPM, the flow rate should be approximately 328 L/min (86.6 US gpm).

Steering Pump Case Drain Flow Rate

Increased or elevated case drain flow rate indicates pump inefficiency.

If the piston pump becomes too inefficient and cannot produce the required oil flow: steering will be slow to react, turns will not be as sharp, or the
machine may not steer at all.

Use a flow meter to test the flow rate of the steering pump case drain. With the flow meter in place and the engine set to 1850 RPM, case drain
flow in a steering stall condition should be no more than approximately 27.6 L/min (7.3 US gpm). That amount is approximately 10% of the piston
pump flow rate. If the case drain flow rate from the steering pump is higher than this 10% specification: the pump should be rebuilt or replaced.

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The Pump Or The Steering Motor Has Failed

Check the case drain flow rate for the steering motor. If there is damage, or excessive wear, of the seal around the steering motor output shaft: the
condition may allow hydraulic case drain oil to leak past the shaft seal. The steering motor is installed in a bore at the top, in front of the main case.
Hydraulic system oil that leaks past the shaft seal will drain directly into the main bevel gear case. The main bevel gear case is the oil reservoir for
power train oil. This condition may cause the power train oil level to increase and at the same time cause the hydraulic oil level to decrease.

Ensure that the steering motor is not worn to the point that the steering system cannot maintain the correct pressures. Wear to the steering motor
rotating group may cause excessive internal (case drain) leakage. This condition may cause the steering motor to operate inefficiently. The
condition will result in wider turns, excessive steering noise, low steering or charge pressures, and hesitation prior to turns.

1. Start the engine and run the engine.

ENSURE THAT THE SERVICE BRAKES ARE FULLY APPLIED THROUGHOUT THIS ENTIRE PROCEDURE.

WARNING: The machine may move during this procedure if the service brakes are released or if the service brakes are weak. When you
move the steering control lever during this procedure: ensure that all personnel are positioned so that no injury can occur due to machine
movement.

Warm the hydraulic oil to 65°± 3°C (150°± 5°F).

2. Stop the engine and disconnect hydraulic hose from the fitting on the manifold of the case drain for the steering motor.

3. Place the end of the hose in a suitable container with a known volume such as a 5-gallon bucket.

4. On the case drain manifold, install a plug at the same place where the case drain line was attached to the steering motor.

5. Start the engine and set engine speed to HIGH IDLE (2200 rpm).

6. Move the steering lever to the full LEFT TURN position. Hold that position long enough to determine the case drain flow rate. Repeat this step
in the full RIGHT TURN position.
The motor case drain flow rate in each direction should be approximately 4 L/min (1 gpm) in either direction.

a. If the motor case drain flow rate is no more than 20% of the specification, the motor can attain the speed/pressure specifications.

b. If case drain flow rate is greater while steering in one direction: a cross port leak on the pressurized side, or the flushing valve is stuck in
one position. A cross port leak will cause the machine to drift from straight travel to the steering side with the greater flow rate.

c. Replace the motor if the flow rate is more than 20% above this specification. The motor is worn and leaking too much. Retest the
system after the motor is replaced.

1. Check The Steering Motor Output Shaft Seal For Damage Or Wear.
Damage, or excessive wear, on the seal around the steering motor output shaft will allow case drain oil to leak past the shaft seal. The
steering motor is installed in a bore at the top, in front of the main case. Hydraulic system oil that leaks past the shaft seal will drain directly
into the main bevel gear case. The main bevel gear case is the oil reservoir for power train oil. This condition may cause the power train oil
level to increase and at the same time cause the hydraulic oil level to decrease.

To determine if the shaft seal is leaking, perform the following steps:

a. Remove the steering motor from the bore in which the motor is installed and wiggle the shaft to see if there is any movement.
If the shaft does not wiggle, disconnect and remove the steering motor from the machine and bench test the motor.

b. Operate the motor at 425 psi in both directions. Observe the shaft seal during bench test operation and look for signs of leakage. If
leakage is observed, replace the shaft seal. Carefully examine the shaft for damage where the seal and shaft contact each other. After
repair and assembly, test the motor again and look for leakage at the shaft before reinstalling the motor.
If the shaft is loose: worn, or failed bearings, have allowed the shaft to wear out the shaft seal.

c. Disassemble The Steering Motor And Inspect For Damage

If you determine that the steering motor is damage, or has excessive internal wear: disconnect both hydraulic lines and electrical
harnesses from the motor and remove the motor from the machine. Disassemble the motor and carefully examine all internal parts (port
plates, rotating group, and bearings). Replace any worn or damaged parts as necessary and bench test, or replace, the worn or
damaged motor with a new motor.

PIP-10118791
2022/12/19
18:29:12-03:00
i04316454
© 2022 Caterpillar Inc.

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Caterpillar:
Confidential Green

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