UENR4816

September 2014

Systems Operation
Testing and Adjusting
AD30 Underground Articulated Truck
Steering System
GXR 1-Up (Machine)

SAFETY.CAT.COM
 i05296198

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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and 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.
A non-exhaustive list of 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. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
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You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
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. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
UENR4816 3
Table of Contents

Table of Contents
Systems Operation Section

General Information..................... ..................... 4

Steering System (Pilot Oil)................ ................ 9
Gear Pump (Hoist, Steering, Brake, and Pilot) 10
Pressure Reducing Valve (Pilot Oil)......... ........11
Oil Filter (Pilot) ........................ .........................11
Solenoid Valve (Implement and Steering) ... ... 12
Steering Metering Pump................. ................ 13
Valve (Steering Lockout)................. ................ 15
Steering Neutralizer Valve ............... ............... 16
Steering System (High Pressure Oil Circuit).. . 18
Steering Control Valve .................. .................. 20
Oil Filter (Steering)..................... ..................... 24
Secondary Steering System.............. ............. 25
Gear Pump (Secondary Steering) ......... ......... 27
Diverter Valve (Secondary Steering) ....... ....... 28

Testing and Adjusting Section

Troubleshooting
Machine Preparation for Troubleshooting ... ... 31
Visual Inspection ...................... ...................... 32
Steering System Troubleshooting ......... ......... 32

Testing and Adjusting

Pump Flow - Test ...................... ...................... 36
Steering System Pressure - Test and Adjust . . 36
Pressure Reducing Valve (Pilot Oil) - Test and
Adjust.............................. .............................. 38
Steering Time - Check .................. .................. 39
Steering Control Valve - Adjust............ ........... 39
Steering Slip - Check and Adjust .......... .......... 40
Valve (Steering Lockout) - Test............ ........... 41
Steering Neutralizer Valve - Check and Adjust 42
Oscillating Hitch - Adjust................. ................ 43

Index Section

Index................................ ............................... 47
4 UENR4816
Systems Operation Section

Systems Operation Section

i05779595

General Information
SMCS Code: 4300

Illustration 1 g03665203
Hydraulic schematic for the steering system
(1) Steering cylinder (6) Steering metering pump
(2) Stem (7) Steering oil filters
(3) Steering control valve (8) Secondary steering diverter valve
(4) Secondary steering pump (9) Steering system pressure tap
(5) Steering neutralizer valve for a right turn (10) Steering lockout valve
UENR4816 5
Systems Operation Section

(11) Breaker relief valve (16) Implement and steering solenoid valve (21) Hydraulic tank
(12) Steering neutralizer valve for a left turn (17) Line to the parking brake circuit (22) Hydraulic oil level sensor
(13) Check valve (18) Brake and pilot pump (23) Pilot oil pressure reducing valve
(14) Primary steering flow switch (19) Steering pump (24) Pilot oil filters
(15) Line to the hoist pilot circuit (20) Screen (25) Line from parking brake control valve

Illustration 2 g03665205
Location of the steering hydraulic system components
(1) Steering cylinders (8) Secondary steering diverter valve (19) Steering pump
(3) Steering control valve (10) Steering lockout valve (21) Hydraulic tank
(4) Secondary steering pump (11) Breaker relief valve (23) Pilot oil pressure reducing valve
(5) Steering neutralizer valve for a right turn (12) Steering neutralizer valve for a left turn (24) Pilot oil filters
(6) Steering metering pump (16) Implement and steering solenoid valve
(7) Steering oil filters (18) Brake and pilot pump
6 UENR4816
Systems Operation Section

The steering hydraulic system is made up of two Illustration 4 g01126506

basic circuits, the pilot circuit and the high-pressure (18) Brake and pilot section of the gear pump
circuit. The high-pressure circuit also incorporates the (19) Steering section of the gear pump
secondary steering system.
The hoist, steering, brake, and pilot gear pump is
The main components of the pilot circuit are hydraulic mounted to the torque converter and updrive housing.
tank (21), brake and pilot pump (18), hydraulic oil The brake and pilot section of gear pump (18) is at
level sensor (22), pilot oil pressure reducing valve the rear of the gear pump. The steering section of
(23), pilot oil filter (24), implement and steering gear pump (19) is in the center of the gear pump.
solenoid valve (16), steering metering pump (6),
steering lockout valve (10), left and right neutralizer
valves (5) and (12), steering control valve (3) and
various lines.
The main components of the high-pressure circuit are
hydraulic tank (21), hydraulic oil level sensor (22),
steering pump (19), steering control valve (3),
steering cylinders (1), steering oil filter (7) and various
lines.
The main components of the secondary steering
system are hydraulic tank (21), hydraulic oil level
sensor (22), secondary steering pump (4), secondary
steering diverter valve (8) and various lines.

Illustration 5 g03665209
(23) Pilot oil pressure reducing valve
(24) Pilot oil filter

Pilot oil pressure reducing valve (23) and pilot oil filter
(24) are mounted on the left side of the front frame, in
the transmission compartment.

Illustration 3 g03665208
(11) Breaker relief valve (behind the guard)
(21) Hydraulic tank
(26) Filler cap

Hydraulic tank (21) is located on the right side of the

machine. The hydraulic tank is the oil reservoir for the
hoist hydraulic system, the steering system, the
braking system, and the brake oil cooling system. Oil
is placed into hydraulic tank (21) through filter cap Illustration 6 g01363877
(26). Breaker relief valve (11) is mounted to the top of (16) Implement and steering solenoid valve
the hydraulic tank behind the guard.
Implement and steering solenoid valve (16) is
mounted on the left side of the front frame, in the
transmission compartment.
UENR4816 7
Systems Operation Section

Illustration 7 g01126518 Illustration 10 g01173953

(6) Steering metering pump (3) Steering control valve

Steering metering pump (6) is located behind the Steering control valve (3) is mounted on the rear of
cover on the front of the cab. the front frame, in the transmission compartment.

Illustration 8 g01363875 Illustration 11 g00918088

(5) Steering neutralizer valve for a right turn (1) Steering cylinder
(12) Steering neutralizer valve for a left turn
Steering cylinders (1) are located on either side of the
Steering neutralizer valves (5) and (12) are located machine articulation hitch.
on the front frame near the upper articulation hitch.

Illustration 12 g01126158
Illustration 9 g01363874
(7) Steering oil filters
(10) Steering lockout valve
Steering oil filters (7) is mounted on the rear of the
Steering lockout valve (10) is mounted on the output crossbeam, in the transmission compartment.
transfer gear case.
8 UENR4816
Systems Operation Section

Illustration 13 g01126532
(4) Secondary steering pump

Secondary steering pump (4) is mounted to the rear

of the output transfer gear case.

Illustration 14 g01126540
(8) Secondary steering diverter valve

Secondary steering diverter valve (8) is mounted on

the right side of the front frame, in the transmission
compartment.
UENR4816 9
Systems Operation Section

i05779826

Steering System (Pilot Oil)

SMCS Code: 4300-PS

Illustration 15 g03665203
Hydraulic schematic for the steering system
(1) Steering cylinder (9) Steering system pressure tap
(2) Stem (10) Steering lockout valve
(3) Steering control valve (11) Breaker relief valve
(4) Secondary steering pump (12) Steering neutralizer valve for a left turn
(5) Steering neutralizer valve for a right turn (13) Check valve
(6) Steering metering pump (14) Primary steering flow switch
(7) Steering oil filters (15) Line to the hoist pilot circuit
(8) Secondary steering diverter valve (16) Implement and steering solenoid valve
10 UENR4816
Systems Operation Section

(17) Line to the parking brake circuit (20) Screen (23) Pilot oil pressure reducing valve
(18) Brake and pilot pump (21) Hydraulic tank (24) Pilot oil filters
(19) Steering pump (22) Hydraulic oil level sensor (25) Line from parking brake control valve

The pilot circuit controls the movement of stem (2) in i02230968

steering control valve (3).
With the engine running, oil is drawn from hydraulic
Gear Pump (Hoist, Steering,
tank (21) by brake and pilot pump (18). Brake and Brake, and Pilot)
pilot pump (18) supplies oil through check valve (13)
to pilot oil pressure reducing valve (23). SMCS Code: 4268; 4306; 5073; 5083; 5085

Pilot oil pressure reducing valve (23) maintains the

pilot system at a constant pressure. Pilot oil pressure
reducing valve (23) relieves excess pilot system
pressure through a line to the hydraulic tank.
Oil from pilot pressure reducing valve (23) flows
through pilot oil filters (24) to implement and steering
solenoid valve (16).
When de-energized, implement and steering solenoid
valve (16) stops pilot oil from flowing to steering
lockout valve (10) and steering metering pump (6).
When energized, implement and steering solenoid
valve (16) directs pilot oil flow to steering lockout
valve (10) and steering metering pump (6).
Illustration 16 g00918522
Steering metering pump (6) is a small hydraulic pump
that is used as a metering valve and as a directional View of the gear pump (hoist, steering, brake and
control valve. When the operator turns the steering pilot)
wheel, a spool and a sleeve will rotate inside the (1) Hoist section of the gear pump
metering pump. The oil flows through steering (2) Steering section of the gear pump
neutralizer valve (5) or steering neutralizer valve (12) (3) Brake and pilot section of the gear pump
to steering lockout valve (10).
Hoist section (1), steering section (2) and brake and
Steering lockout valve (10) stops oil flow from pilot section (3) are part of a three-section, gear type
steering neutralizer valve (5) or steering neutralizer pump that is mounted to the torque converter and
valve (12) to steering control valve (3) when updrive housing.
implement and steering solenoid valve (16) is de-
energized. Hoist section (1) of the gear pump is a fixed
displacement pump that sends oil to the hoist control
When implement and steering solenoid valve (16) is valve. The hoist control valve will send pump oil to
energized, steering lockout valve (10) allows the oil to one of two locations. When the dump body is being
flow from steering metering pump (6) through steering raised or lowered, the hoist cylinders receive the oil. If
neutralizer valve (5) or steering neutralizer valve (12) the hoist is not being used, the oil flows to the oil
when the operator turns the steering wheel. Oil from cooling system for the brakes.
steering neutralizer valve (5) or steering neutralizer
valve (12) can flow through steering lockout valve Steering section (2) of the gear pump is a fixed
(10) to either end of stem (2) in steering control valve displacement pump which sends oil to the steering
(3), causing stem (2) to move. When stem (2) moves, control valve.
high-pressure oil from steering pump (19) can flow to Brake and pilot section (3) of the gear pump is a fixed
steering cylinders (1). displacement pump which sends oil to the service
brake circuit, the parking brake circuit, the hoist pilot
circuit, and the steering pilot circuit. The oil supplied
for the hoist pilot circuit is sent to the pilot control
actuators on the hoist control valve. This oil is used to
move the stem in the hoist control valve.
UENR4816 11
Systems Operation Section

i02349863 i05825278

Pressure Reducing Valve (Pilot Oil Filter (Pilot)

Oil) SMCS Code: 5068-PS; 5092
SMCS Code: 5117; 5467

Illustration 19 g00985722

Illustration 17 g00985443 Pilot oil filters are located on the left side of the front
frame, in the transmission compartment.
The pilot oil pressure reducing valve is located on the
left side of the front frame.
The pilot oil pressure is controlled by the pilot oil
pressure reducing valve. The pilot oil system will
constantly operate at the pressure reducing valve
pressure setting.

Illustration 18 g01173958
(1) Reduced pressure oil outlet port
(2) Outlet port
(3) Pilot oil pressure reducing valve
(4) Inlet port

Pilot oil pressure reducing valve (3) is a cartridge type

valve that maintains a constant pilot pressure to the
steering, and braking circuits.
Pilot oil from the pilot and braking section of the gear
pump enters pilot oil pressure reducing valve (3)
through inlet port (4). Reduced pressure oil flows to
the pilot system through reduced pressure oil outlet
port (1). Excess oil returns to the hydraulic tank
through outlet port (2).
12 UENR4816
Systems Operation Section

Oil from the hydraulic tank flows to the brake and pilot
section of the gear pump. The gear pump sends oil
through the pilot oil pressure reducing valve to the
pilot oil filters.
Oil flows through inlet passage (2). The oil fills the
space between the inside of housings (5) and
elements (4). During normal operation, the oil flows
through elements (4) and out outlet passage (3) to the
remainder of the pilot hydraulic system. Elements (4)
stop any debris that is in the oil.
If filter elements (4) become full of debris, the
restriction to the flow of oil causes a pressure
increase inside the filter. The pressure of the oil
causes bypass valve (6) to move against the force of
spring (7).
The oil then flows past the open bypass valve to the
remainder of the pilot hydraulic system. When the oil
does not flow through the filter elements, the debris in
the oil will damage other components in the hydraulic
system.
Use correct maintenance in order to make sure that
elements (4) do not become full of debris. If elements
(4) are full of debris, the flow of filtered oil to the pilot
hydraulic system is stopped.

i02237781

Solenoid Valve (Implement and

Steering)
SMCS Code: 5479-ZI

Illustration 20 g03686353
Pilot oil filters
(1) Base
(2) Inlet passage
(3) Outlet passage
(4) Elements
(5) Housings

Illustration 22 g01128648

The implement and steering solenoid valve is

mounted on the left side of the front frame, in the
transmission compartment.

Illustration 21 g03686354
Pilot oil filter base
(6) Bypass valve
(7) Spring
UENR4816 13
Systems Operation Section

i05825280

Steering Metering Pump

SMCS Code: 4312

Illustration 23 g01128649
(1) Port to hoist control valve
(2) Port to steering lockout valve
(3) Port to steering metering pump
(4) Implement and steering solenoid valve
(5) Port to parking brake control valve
(6) Port from brake and pilot pump Illustration 24 g03686357
(7) Port from parking brake circuit
Steering metering pump
When implement and steering solenoid valve (4) is (1) Inlet port for the pilot oil
energized, pilot oil from port (6) flows through (2) Return port to the hydraulic tank
implement and steering solenoid valve (4) to ports (3) Outlet port to the right neutralizer valve
(1), (2) and (3). The pilot oil flows from ports (1), (2) (4) Outlet port to the left neutralizer valve
and (3) to the hoist and steering pilot circuits.
When implement and steering solenoid valve (4) is
de-energized, pilot oil flow from port (6) to the hoist
and steering functions is blocked by implement and
steering solenoid valve (4).
Note: If there is a fault with implement and steering
solenoid valve (4) and the valve spool remains in the
de-energized position, pilot oil from the parking brake
control valve will flow to port (7). Pilot oil from port (7)
flows through implement and steering solenoid valve
(4) to the hoist and steering pilot circuits.
Reference: For more information on the implement
and steering solenoid valve refer to Systems
Operation, Troubleshooting, Testing and Adjusting,
Power Train Electronic Control System, “Solenoid
Valves”.

Illustration 25 g03686356
Section A-A
(A) Control section
(B) Metering section
(5) Drive shaft
(6) Oil passage
(7) Spool
(8) Centering springs
(9) Pin
(10) Oil passage for left turn
(11) Oil passage for right turn
(12) Sleeve
(13) Oil passage to metering section
(14) Stator
(15) Rotor
14 UENR4816
Systems Operation Section

The steering metering pump is made up of two When the steering wheel is no longer turning,
sections: control section (A) and metering section (B). centering springs (8) will bring spool (7) and sleeve
The two sections send pilot oil to the steering (12) back to a NO STEER position preventing the
neutralizer valves. From the neutralizer valves, the oil orifices in sleeve (12) from aligning with grooves in
flows to the steering control valve. These spool (7). The flow of oil to metering section (B) is
components control the speed and direction of a turn. blocked causing the steering cylinders to remain in
the current position.
Metering section (B) is a small hydraulic pump. The
metering section produces a specific amount of When the steering is turned clockwise for a right turn,
metered oil flow. Then, the metered oil is directed by pilot oil flows into the steering metering pump through
control section (A). The metered oil flows to either the inlet port (1). From inlet port (1), pilot oil flows through
outlet port to the right neutralizer valve or to the outlet passage (6) to sleeve (12). The oil then flows through
port to the left neutralizer valve. sleeve (12) and spool (7) to passage (11). From
passage (11), the oil flows into metering section (8).
The steering wheel is connected to spool (7) by a
splined shaft assembly. When the steering wheel is The rotation of the steering wheel also causes drive
not being turned, the control section is in the NO shaft (5) to rotate clockwise. Drive shaft (5) causes
STEER position. When the steering wheel is not rotor (15) to rotate in stator (14). This rotation sends a
being turned , most of the flow is blocked by spool (7) metered flow of pilot oil to turn right port (4). Pilot oil
and sleeve (12). A small amount of oil leaks past the then flows to the right neutralizer valve. From the right
spool and back to hydraulic tank. The oil ensures a neutralizer valve, the pilot oil flows to the spool in the
supply of oil at operating temperature is always steering control valve. Return oil from the opposite
available at the metering pump. The pilot oil cannot side of the steering control valve flows into turn left
flow through the metering pump until the steering port (3). The oil then flows back to the hydraulic tank
wheel is turned. through port (2).
The following components will turn when the steering As the steering wheel is turned faster, spool (7) and
wheel is rotated: drive shaft (5), spool (7), pin (9), and sleeve (12) turn further, increasing the size of the
sleeve (12). These components turn in relation with openings between grooves (17) and orifices (19).
each other. Sleeve (12) and spool (7) do not begin This action increases the flow of pilot oil to the right
turning at the same time. neutralizer valve. The increased flow causes the
spool in steering control valve to move faster allowing
a greater flow of high-pressure oil to pass through
steering control valve. The high-pressure oil actuates
the steering cylinders. If the steering wheel is rotated
faster, the machine will turn faster.
When, the steering wheel is turned counterclockwise
the machine makes a left turn. The same components
are used for both the right turn and the left turn. For
these sequences, the same components rotate in the
opposite direction. Oil still comes in through inlet port
(1). Spool (7) and sleeve (12) rotate in the
counterclockwise direction allowing a different set of
grooves (17) and orifices (19) in sleeve (12) to align
with a different set of grooves (17) in spool (7). Pilot
oil flows through passage (10) to metering section
Illustration 26 g03686358 (B).
Spool and sleeve The rotation of the steering wheel also causes drive
(7) Spool shaft (5) to rotate counterclockwise. Drive shaft (5)
(12) Sleeve causes rotor (15) to rotate in stator (14). This rotation
(16) Slots for the centering springs sends metered flow of pilot oil to left turn port (3). Pilot
(17) Grooves for oil flow
(18) Hole in spool for the pin oil then flows to the left neutralizer valve. From the left
(19) Orifices for oil flow neutralizer valve, the pilot oil flows to the spool in the
(20) Hole in sleeve for the pin steering control valve. Return oil from the opposite
side of the steering control valve spool flows into the
The rotation of sleeve (12) is slightly delayed because right turn port (4). The oil then flows back to the
hole (18) is elongated in spool (7). Also, the force of hydraulic tank through port (2).
centering springs (8) prevent sleeve (12) from turning
too rapidly. Both spool (7) and sleeve (12) turn as a
unit.
Spool (7) is permitted to rotate slightly in sleeve (12).
This causes orifices (19) in sleeve (12) to align with
grooves (17) in spool (7) providing a path for the pilot
oil to flow to metering section (B). The pilot oil then
flows to either the right or the left neutralizer valve.
The pilot oil then flows to the steering control valve.
UENR4816 15
Systems Operation Section

Illustration 29 g01128656
(1) Spool
(2) Port from implement and steering solenoid valve
(3) Port to left turn steering neutralizer valve
(4) Port to right turn steering neutralizer valve
(5) Port from steering metering pump
(6) Port from steering metering pump
(7) Steering lockout valve
Illustration 27 g03686355
Gerotor assembly When the implement and steering solenoid valve is
(5) Drive shaft energized, pilot oil flows to port (2). Pilot oil pressure
(9) Pin acts on top of spool (1). Spool (1) moves down. When
(14) Stator the steering wheel is turned to the left, oil from the
(15) Rotor steering metering pump flows to port (5) through
spool (1) to port (3). When the steering wheel is
If the steering metering pump is disassembled, turned to the right, oil from the steering metering
assemble the steering metering pump with the proper pump flows to port (6) through spool (1) to port (4).
relation between rotor (15) and pin (9). Use the above
illustration for the reference. Erratic steering will result When the implement and steering solenoid valve is
if the components are not assembled correctly. de-energized, the implement and steering solenoid
valve stops the supply of pilot oil to port (2). Spool (1)
i02237798
moves up. Oil from the steering metering pump at
port (5) or port (6) is stopped by spool (1).
Valve (Steering Lockout)
SMCS Code: 4307

Illustration 28 g01128655

The steering lockout valve is mounted on the output

transfer gear case.
16 UENR4816
Systems Operation Section

i05825289

Steering Neutralizer Valve

SMCS Code: 4330

Illustration 30 g03686364
Neutralizer valves in the closed position Illustration 31 g03686365

(1) Striker Schematic for the neutralizer valves

(2) Inlet (1) Striker
(3) Ball check valve (2) Inlet
(4) Outlet (3) Ball check valve
(5) Stem (4) Outlet
(6) Spring (5) Stem
(6) Spring
The neutralizer valve stops the flow of pilot oil to the (7) Left neutralizer
steering control valve at the end of a complete turn, (8) Oil line
stopping steering action before the machine turns (9) Oil line
(10) Right neutralizer valve
against frame stops. (11) Drain line
(12) Pilot oil line
Strikers (1) for each valve is mounted on the rear (13) Pilot oil line
frame. Both of the neutralizer valves are mounted on
the front frame. The right and left neutralizer valves Pilot oil flows from the steering metering pump to
and strikers are identical. either the right or left neutralizer valves before flowing
to the steering control valve. Oil flows from the
steering metering pump through line (12) or (13) into
neutralizer valve (7) or (10) through inlet port (2).
Then the oil flows around stem (5) and through outlet
port (4) into line (8) or (9). Then the oil flows to the
steering control valve.
When steering wheel is turned to RIGHT position,
and the machine is turned as far as possible, striker
(1) comes in contact with stem (5) of the right
neutralizer valve. The striker forces the stem to
compress spring (6) and moves the stem until pilot oil
cannot flow from port (2) to port (4) stopping the flow
of pilot oil through line (9).
When the flow of pilot oil stops acting on the spool in
the steering control valve, the control valve spool
returns to the HOLD position causing the steering
action of the machine to stop.
When steering wheel is turned back to the left, return
oil from the end of the steering control valve spool
flows through line (9) into port (4) of the right
neutralizer valve. Because stem (5) has oil flow from
port (2) to port (4) blocked, the oil forces ball check
(3) to the right. The oil now flows out port (2) through
line (13) back to the steering metering pump. The
machine begins to turn to the left.
UENR4816 17
Systems Operation Section

As the machine moves to the left a small amount,

striker (1) will move away from stem (5). Spring (6)
tension acts against stem (5) and moves stem (5)
back into the open position allowing the pilot oil to
flow around the stem again, and ball check valve (3)
closes.
The left neutralizer valve operates in the same
manner as the right neutralizer valve.
18 UENR4816
Systems Operation Section

i05779827

Steering System (High Pressure Oil Circuit)

SMCS Code: 4300-HQ

Illustration 32 g03665203
Hydraulic schematic for the steering system
(1) Steering cylinder (9) Steering system pressure tap
(2) Stem (10) Steering lockout valve
(3) Steering control valve (11) Breaker relief valve
(4) Secondary steering pump (12) Steering neutralizer valve for a left turn
(5) Steering neutralizer valve for a right turn (13) Check valve
(6) Steering metering pump (14) Primary steering flow switch
(7) Steering oil filters (15) Line to the hoist pilot circuit
(8) Secondary steering diverter valve (16) Implement and steering solenoid valve
UENR4816 19
Systems Operation Section

(17) Line to the parking brake circuit (20) Screen (23) Pilot oil pressure reducing valve
(18) Brake and pilot pump (21) Hydraulic tank (24) Pilot oil filters
(19) Steering pump (22) Hydraulic oil level sensor (25) Line from parking brake control valve

The main components of the steering high-pressure

circuit are hydraulic tank (21), screen (20), steering
pump (19), steering control valve (3) and steering
cylinders (1). These components work together to
provide the force needed to turn the machine.
With the engine running, oil flows from hydraulic tank
(21) through screen (20) to steering pump (19).
Steering pump (19) is the center section of a three-
section, gear type pump. The steering section of the
pump provides pressure oil for the steering high-
pressure circuit.
The steering pump sends oil through the check valve
in secondary steering diverter valve (8) to steering
control valve (3).
Check valves in secondary steering diverter valve (8)
control the flow of the oil. When steering pump (19) is
supplying enough oil to steer the machine, the check
valves allow the oil to flow into and through the
secondary steering diverter valve to steering control
valve (3).
When steering pump (19) is not supplying enough oil
to steer the machine, and the machine is moving in
either the forward or reverse direction, the check
valves in the secondary steering diverter valve allow
extra oil from secondary steering pump (4) to flow
through the diverter valve to steering control valve
(3).
If the pilot oil from steering metering pump (6) has
moved stem (2) in steering control valve (3) to either
the right or left turn position, the oil from the steering
pump will flow to steering cylinders (1). The pressure
of this oil in the steering cylinders causes the
machine to turn.
When the machine is in the straight ahead travel
position, the oil in steering control valve (3) cannot
flow past stem (2). This oil flows out of the steering
control valve through steering oil filter (7) and back to
hydraulic tank (21).
20 UENR4816
Systems Operation Section

i05825292

Steering Control Valve

SMCS Code: 4307

Neutral Position

Illustration 33 g03686371
Steering control valve in the NEUTRAL position
(1) Metering orifices. (2) Passage. (3) Passage. (4) Outlet (left turn). (5) Outlet (tank). (6) Outlet (right turn). (7)
Metering orifices. (8) Spring. (9) Inlet (right neutralizer valve). (10) Inlet (left neutralizer valve). (11) Orifice. (12) Stem.
(13) Return passage. (14) Passage. (15) Inlet (steering pump section). (16) Ball resolver valve. (17) Passage. (18)
Flow control valve. (19) Relief valve. (AA) Pressure oil. (BB) Return oil. (CC) Blocked oil.
UENR4816 21
Systems Operation Section

There is no pilot oil flow to either end of valve stem

(12) when the rotation of the steering wheel is
stopped or when the neutralizer valve stops the flow
of oil. After a complete turn, the neutralizer valve
stops the flow of oil. With no pilot oil flow against
either end of the valve spool, spring (8) will keep the
spool in the NEUTRAL position.
When, the steering control valve is in the NEUTRAL
position no pilot oil flows to either inlet (9) or inlet (10).
Spring (8) centers stem (12) and this action blocks
the oil that is flowing from the steering pump.
Because the oil is blocked by the spool, oil pressure
increases in inlet passage (15). This pressure
increase causes flow control valve (18) to move to the
right. When the flow control valve moves, oil can flow
through the orifices and to outlet (5).
When the valve spool is in the NEUTRAL position,
the valve spool blocks the oil in the lines to the
cylinders. The blocked lines cause the steering wheel
to stay in the original stopped position.
The pressure of the oil in blocked outlet (4) or blocked
outlet (6) is felt through ball resolver valve (16) and
against pilot relief valve (19). An increase in pressure
can be caused by a combination of outside forces
that are trying to turn the machine and the valve spool
in the NEUTRAL position. The increase in pressure in
outlet (4) or the increase in pressure in outlet (6)
opens relief valve (19). The pressure in the lines will
not go higher than the relief valve setting.
When pilot flow to one end of the spool stops, part of
the oil on that end of the spool must be removed
before the valve spool can return to the NEUTRAL
position. The oil is moved to the opposite end of the
spool by the force of centering spring (8). The spool
can then move to the NEUTRAL position.
As an example, a left turn is made and pilot oil flows
through inlet (10). The pressure of the oil from inlet
(10) causes stem (12) to move to the right.
When pilot oil flow stops, part of the oil from the left
end of the spool must be removed so that the spool
can move to the NEUTRAL position. The force of
spring (8) causes the spool to move to the left. As the
spool moves, oil that is pushed from the left end of the
spool flows through metering orifices (1).
The oil flows through passage (3) to the spring end of
stem (12). The spool movement continues until the
orifices are blocked and flow through the orifices is
stopped. This movement of the spool stops the flow
of pressure oil to the steering cylinders.
22 UENR4816
Systems Operation Section

Right Turn Position

Illustration 34 g03686372
Steering control valve in the RIGHT TURN position
(1) Metering orifices. (2) Passage. (3) Passage. (4) Outlet (left turn). (5) Outlet (tank). (6) Outlet (right turn). (7)
Metering orifices. (8) Spring. (9) Inlet (right neutralizer valve). (10) Inlet (left neutralizer valve). (11) Orifice. (12) Stem.
(13) Return passage. (14) Passage. (15) Inlet (steering pump section). (16) Ball resolver valve. (17) Passage. (18)
Flow control valve. (19) Relief valve. (AA) Pressure oil. (BB) Return oil. (CC) Blocked oil.
UENR4816 23
Systems Operation Section

When the steering wheel is turned to the right, pilot oil The steering control valve with the relief valve in the
is sent through the right neutralizer valve to inlet (9). open position
The oil flows through inlet (9) into the chamber for (11) Orifice. (16) Ball resolver valve. (17) Passage. (18)
spring (8). Flow control valve. (19) Relief valve.
When pilot oil flows into inlet (9), the force overcomes
the force of spring (8). The force causes stem (12) to The pressure against the flow control valve causes
move to the left. The amount of spool movement is the flow control valve to move to the left. This
increases oil pressure to the cylinders. Pressure
controlled by the rotation of the steering wheel. If the above the relief valve setting will cause the relief
steering wheel is moved slowly there will be less pilot valve to move to the right and the relief valve opens.
oil and less spool movement. A slow turn is the result.
When the relief valve opens, oil flows through
The volume of pilot oil increases by a faster passage (17) and past the relief valve. The flow of oil
movement of the steering wheel. This results in a past orifice (11) causes a lower pressure in the
faster turn. chamber for the flow control spring allowing pressure
Pilot oil flows from the spring chamber across oil in inlet passage (15) to move flow control valve
metering orifices (7). This oil flows through passage (18) to the right.
(2) to the left end of the spool. The oil flows through
the inlet passage from left neutralizer valve (10). The Oil from inlet (15) can now flow through the holes in
oil travels through the left neutralizer valve and to the the flow control valve, which now acts as a dump
metering pump. The metering pump routes the oil valve releasing the extra pressure from the circuit.
back to the hydraulic tank. When the outside force is removed and pressure is
reduced, the springs for the flow control valve and the
With the spool to the left, oil from the steering pump springs for the relief valve return the valves to the
flows from inlet (15) and through the slots in the spool normal positions.
into outlet (6). This oil flows to the head end of the left
steering cylinder, and the rod end of the right steering Return oil from the cylinders enters the outlet for the
cylinder. left turn (4). The oil flows into return passage (13) and
then through outlet (5).
The hydraulic oil pressure extends the left cylinder
rod and the hydraulic oil pressure retracts the right Left Turn Position
cylinder rod causing the machine to turn to the right.
The control valve operation for a left turn is similar to
When the hydraulic oil pressure enters outlet (6), the a right turn. Pilot oil enters inlet passage (10). The
pressure moves ball resolver valve (16). The pilot oil overcomes the force of spring (8). This
hydraulic oil pressure in the cylinders is felt through causes stem (12) to move to the right.
passage (17) and against relief valve (19) and flow
control valve (18). When the spool moves, pump oil from inlet (15) flows
through the slots in the spool to outlet (4). This oil
If an outside force prevents the machine from turning, flows to the head end of the right steering cylinder
the pressure in outlet (6) will increase. This pressure and to the rod end of the left steering cylinder.
increase is also felt against flow control valve (18)
and relief valve (19). The hydraulic oil pressure extends the right cylinder
rodand the hydraulic oil pressure retracts the left
cylinder rod causing the machine to turn to the left.
The valve spool in the left turn position causes the
hydraulic pressure to be felt through passage (14)
and across the ball resolver valve (16). This same
pressure is felt through passage (17) and at relief
valve (19). The remainder of the relief valve operation
for the left turn position is similar to that operation of
the RIGHT TURN position.

Illustration 35 g03686397
24 UENR4816
Systems Operation Section

i05827857 Return oil from the steering control valve flows

through steering oil filters (1) on the way back to the
Oil Filter (Steering) hydraulic tank.
SMCS Code: 4107 Oil flows through inlet passage (3). The oil fills the
space between the inside of housing (5) and the filter
elements. During normal operation, the oil flows
through the filter elements and outlet passage (4) to
the hydraulic tank. The filter elements stop any debris
that is in the oil.
If the filter elements become full of debris, the
restriction of flow of oil causes a pressure increase
inside the filter. This increase of oil pressure causes a
bypass valve in filter base (2) to open.
The oil then flows past the open bypass valve to the
hydraulic tank. When the oil does not flow through the
filter elements, the debris in the oil can damage other
components in the hydraulic system.
Use correct maintenance in order to make sure that
the filter elements do not become full of debris. If the
Illustration 36 g00934923 filter elements are full of debris, the flow of filtered oil
Location of the steering oil filters in the hydraulic system is stopped.
(1) Steering oil filters

Steering oil filters (1) are located at the front of the

front frame, in the transmission compartment.

Illustration 37 g03687441
Steering oil filter
(2) Base
(3) Inlet passage
(4) Outlet passage
(5) Housings
UENR4816 25
Systems Operation Section

i05779828

Secondary Steering System

SMCS Code: 4300-SE; 4300

Illustration 38 g03665203
Hydraulic schematic for the steering system
(1) Steering cylinder (9) Steering system pressure tap
(2) Stem (10) Steering lockout valve
(3) Steering control valve (11) Breaker relief valve
(4) Secondary steering pump (12) Steering neutralizer valve for a left turn
(5) Steering neutralizer valve for a right turn (13) Check valve
(6) Steering metering pump (14) Primary steering flow switch
(7) Steering oil filters (15) Line to the hoist pilot circuit
(8) Secondary steering diverter valve (16) Implement and steering solenoid valve
26 UENR4816
Systems Operation Section

(17) Line to the parking brake circuit (20) Screen (23) Pilot oil pressure reducing valve
(18) Brake and pilot pump (21) Hydraulic tank (24) Pilot oil filters
(19) Steering pump (22) Hydraulic oil level sensor (25) Line from parking brake control valve
UENR4816 27
Systems Operation Section

The purpose of the secondary steering system is to When the machine moves and the engine rpm and
supply oil for steering system should the steering steering pump flow is high, secondary steering
pump system fail, or if engine stops while the diverter valve (8) sends the oil from secondary
machine is moving. The secondary steering system steering pump (4) back to hydraulic tank (21).
also supplements the steering pump oil flow when the Steering pump (19) now provides all of the oil to
engine rpm and pump flow rate is low. steering control valve (3). If, under this condition,
there is a steering pump failure or the engine stops,
secondary steering diverter valve (8) will route
secondary steering pump oil to steering control valve
(3).

i05828147

Gear Pump (Secondary

Steering)
SMCS Code: 4324-GT; 5073-SST

Illustration 39 g01126532
(4) Secondary steering pump

Illustration 41 g00953899

The secondary steering pump is mounted on the front

of the output transfer gear housing, above the rear
drive shaft.

Illustration 40 g01126540
(8) Secondary steering diverter valve

The main components of the secondary steering

system are secondary steering pump (4) and
secondary steering diverter valve (8).
Secondary steering pump (4) is attached to the rear
of the transmission output transfer gears. The pump
is a ground speed driven pump that turns as long as
the machine is moving.
Secondary steering diverter valve (8) is mounted to
the front frame on the right side of the transmission
compartment.
Illustration 42 g03687448
With the engine running, steering pump (19) sends oil Secondary steering pump
to secondary steering diverter valve (8). The oil flows (1) Idler gear
through secondary steering diverter valve (8) to (2) Dive shaft
steering control valve (3). This oil is used to operate (3) Pump housing
the steering cylinders. (4) Drive gear

When the machine starts to move, secondary The secondary steering pump is a ground speed
steering pump (4) also starts to turn. As, the pump driven pump that turns as long as the machine is
turns, oil is drawn from hydraulic tank (21) and sent to moving.
secondary steering diverter valve (8).
28 UENR4816
Systems Operation Section

The secondary steering pump is a gear type pump. i05828149

Drive shaft (2) turns drive gear (4). Drive gear (4)
engages idler gear (1). A seal is formed by the gears
against pump housing (3). As the gears turn, oil
Diverter Valve (Secondary
enters through the inlet port. The oil is trapped Steering)
between the gear teeth and the pump housing. The
oil is pulled around the outside of the gears. The oil is SMCS Code: 4339
then forced out the outlet port.
The oil flows from the secondary steering pump to the
secondary steering diverter valve. When the machine
is moving, the oil always flows to the secondary
steering diverter valve.
If primary steering pump fails to pump oil or if engine
stops, the secondary steering diverter valve will allow
pressure oil from secondary steering pump to flow to
steering control valve.

Illustration 43 g03687461
Diverter valve cutaway (engine at low idle and
machine stopped)
(1) Diverter spool
(2) Return passage to hydraulic tank
(3) Passage
(4) Spring
(5) Outlet to steering control valve
(6) Passage
(7) Orifice
(8) Check valve
(9) Passage
(10) Inlet from steering pump
(11) Check valve
(12) Supply passage for secondary steering pump
(13) Spring
(14) Reversing spool
(15) Passage to left end of reversing spool
(16) Passage
(17) Passage
(18) Passage to right end of reversing spool

The main components of the secondary steering

diverter valve are: diverter spool (1), check valves (8),
and reversing spool (14).
When the engine is running, the oil from the steering
pump flows through inlet (10) and orifice (7) to check
valve (8). The force of the oil opens the check valve.
The oil flows past the check valve and through outlet
(5) to the steering control valve. Check valve (11) will
not allow oil to flow to passage (3).
UENR4816 29
Systems Operation Section

The pressure of oil before orifice (7) is more than the No oil is sent from the secondary steering pump until
pressure of oil after the orifice. These pressures are the machine moves. When the machines moves, the
also felt through passages (9) and (6) respectively. pump is turned by the output transfer gears in the
transmission. Oil from the hydraulic tank is supplied
The oil before orifice (7) flows through passage (9) to to the secondary pump through supply passage (12).
the left side of diverter spool (1). The pressure of the Oil flows from the hydraulic tank through supply
oil after orifice (7) is the same as the pressure of the passage (12), to reversing spool (14).
oil to the right end of diverter spool (1).

Illustration 45 g03687473
Illustration 44 g03687466
Diverter valve cutaway (engine at low idle and
Schematic for the diverter valve machine in forward motion)
(1) Diverter spool (1) Diverter spool
(2) Return passage to hydraulic tank (2) Return passage to hydraulic tank
(3) Passage (3) Passage
(4) Spring (4) Spring
(5) Outlet to steering control valve (5) Outlet to steering control valve
(6) Passage (6) Passage
(7) Orifice (7) Orifice
(8) Check valve (8) Check valve
(9) Passage (9) Passage
(10) Inlet from steering pump (10) Inlet from steering pump
(11) Check valve (11) Check valve
(12) Supply passage for secondary steering pump (12) Supply passage for secondary steering pump
(13) Spring (13) Spring
(14) Reversing spool (14) Reversing spool
(15) Passage to left end of reversing spool (15) Passage to left end of reversing spool
(16) Passage (16) Passage
(17) Passage (17) Passage
(18) Passage to right end of reversing spool (18) Passage to right end of reversing spool

As the engine rpm increases, the oil flow from the When the machine moves in a forward direction, the
steering pump also increases. Due to the increased secondary steering pump sends pressure oil into
oil flow past orifice (7), there is an increase in the passage (17). The pressure of this oil is felt through
difference of the oil pressure before and after the passage (18) to the right end of reversing spool (14).
orifice.
When the force of the oil on left end of diverter spool
(1) is more than combined force of oil and spring (4)
on the right end, diverter spool (1) will move to the
right.
30 UENR4816
Systems Operation Section

The force of this oil moves the reversing spool to the If the engine rpm is high, oil flow from the steering
left. The oil flows through passage (16) to the pump increases. Because of the increased oil flow
secondary steering pump. Oil from the secondary past orifice (7), there is an increase in the difference
pump can then flow from passage (17) into passage of the oil pressure before and after the orifice.
(3). Passage (3) routes the oil to check valve (11) and
diverter spool (1). When the force of the oil on left end of diverter spool
(1) is more than the combined force of the oil and
If the engine rpm is low, diverter spool (1) will be to spring on the right end, diverter spool (1) will shift to
the left. Oil flow past the diverter spool is stopped. the right.
The pressure of the oil in passage (3) increases until
check valve (11) opens. The oil from the secondary steering pump flows into
passage (3). The oil flows around spool (1), into
When check valve (11) opens, oil from secondary passage (2), and back to the hydraulic tank. Only the
steering pump flows past check valve (11) and main steering pump flow is sent to the steering control
combines with the oil from the main steering system valve through outlet (5). Check valve (11) will not let
and flows through outlet (5). This combined oil then the steering pump oil flow into passage (3).
flows to the steering control valve.
If there is a failure of the steering pump, or if the
engine stops, there will be a loss of steering oil flow.
Diverter spool (1) will move to the left. As long as the
machine moves, the flow of oil from the secondary
steering pump will provide oil for the steering
operation.
The oil will flow through passage (3), past check
valve (11), and through outlet (5). Check valve (8) will
prevent the loss of flow through inlet (10) and the
stopped steering pump.
When the machine moves in a reverse direction, the
secondary steering pump turns in the opposite
direction. The pressure oil from the pump is sent
through passage (16) and (15) to left end of reversing
spool (14) causing reversing spool to move to the
right. The pressure oil can then flow through passage
(16) into passage (3). The rest of the oil flow is the
same as when the machine moves forward.

Illustration 46 g03687477
Diverter valve cutaway (engine at high idle and
machine in forward motion)
(1) Diverter spool
(2) Return passage to hydraulic tank
(3) Passage
(4) Spring
(5) Outlet to steering control valve
(6) Passage
(7) Orifice
(8) Check valve
(9) Passage
(10) Inlet from steering pump
(11) Check valve
(12) Supply passage for secondary steering pump
(13) Spring
(14) Reversing spool
(15) Passage to left end of reversing spool
(16) Passage
(17) Passage
(18) Passage to right end of reversing spool
UENR4816 31
Troubleshooting

Testing And Adjusting NOTICE

Section Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
Troubleshooting before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
i02357553
suitable to collect and contain fluids on Caterpillar
products.
Machine Preparation for Dispose of all fluids according to local regulations and
Troubleshooting mandates.

SMCS Code: 4300

When you are analyzing a hydraulic system for poor
performance, remember that correct oil flow and
correct oil pressure are necessary for correct
operation. Oil flow is a function of the pump output.
Hot oil and hot components can cause personal The pump output is a function of engine speed. A
injury. Do not allow hot oil or hot components to restriction to the flow of oil causes oil pressure.
contact the skin.
For any test to the hydraulic system, the hydraulic oil
must be at the normal operating temperature. To
increase the oil temperature, start the engine. Move
the body several times. The oil is at normal operating
temperature when the hydraulic oil temperature
Personal injury or death can result from escaping indicator is between the first mark and the second
fluid under pressure. mark on the temperature gauge.

Escaping fluid under pressure, even a very small Before any tests are performed, visually inspect the
pin-hole size leak, can penetrate body tissue and complete hydraulic system for oil leaks and for
cause serious injury and possible death. If fluid is damaged parts. For some of the tests, a magnet and
injected into your skin, it must be treated immedi- a measuring rule (inches or millimeters) may be used.
ately by a doctor familiar with this type of injury.
Note: Permit only one operator on the machine. Keep
Always use a board or cardboard when checking all other personnel away from the machine or in the
for a leak. operator's sight.

1. Move the machine to a smooth, horizontal location.

Move away from operating machines and away
from other personnel.
Sudden movement of the machine or release of
oil under pressure can cause injury to persons on 2. Move the transmission control to the NEUTRAL
or near the machine. position.

In order to prevent possible injury, perform the 3. Engage the parking brake.
following procedure before testing and adjusting
any of the machine hydraulic systems. 4. Install the steering frame lock.

5. Put wheel blocks in front of the wheels and behind

the wheels.
6. If it is necessary to raise the dump body of the
truck, install the body retaining pins.

7. If it is necessary to work around the tailgate, install

the tailgate retaining pins.

8. Move the hoist control lever to the HOLD position.

9. Stop the engine.

32 UENR4816
Troubleshooting

10. Depress the brake pedal at least 70 times to Visual checks and measurements are the first step
remove the oil pressure from the brake when troubleshooting a possible problem. Then
accumulators. perform the operation checks and last the instrument
tests.
11. Depress the breaker relief valve on the hydraulic Before any operation checks are made to the steering
tank to release the pressure in the hydraulic tank. system, visually inspect the complete system as
follows:
12. Make sure that all oil pressure is released before
any fitting, hose or component is loosened, 1. Check the hydraulic tank oil level. Add oil if
tightened, removed, or adjusted. necessary.

2. Look for air in the oil that is in the hydraulic tank.

i02378231
Perform this immediately after the machine is
stopped. Use a clear bottle or container to obtain a
Visual Inspection sample of the oil. Look for air bubbles in the oil that
SMCS Code: 4300 is in the bottle.
3. Check all oil lines, hoses, and connections for
damage or leaks. Check for loose connections.
Personal injury or death can result from machine
4. Check for restrictions of flow; like sharp bends,
articulation or movement. Machine frames can
move and a person can be crushed. clamps that are not installed correctly and physical
damage to hoses and lines.
Connect the steering frame lock between the front
and rear frames before working on the machine. 5. Remove the filter elements and look for particles
removed from the oil by the filter element. A
magnet will separate ferrous particles from
nonferrous particles (piston rings, O-ring seals,
etc.).
Personal injury or death can result from escaping
fluid under pressure. 6. Check for damage to components.

Escaping fluid under pressure, even a very small

i05828189
pin-hole size leak, can penetrate body tissue,
causing serious injury, and possible death.
Steering System
Always use a board or cardboard when checking
for a leak. Troubleshooting
SMCS Code: 4300
Do not check for pin hole leaks in pump or motor
hoses during a steer stall condition.
If fluid is injected into your skin, it must be treated
by a doctor familiar with this type of injury Personal injury or death can result from machine
immediately.
articulation or movement.
Machine frames can move and a person can be
NOTICE crushed.
Care must be taken to ensure that fluids are con-
Connect the steering frame lock link between the
tained during performance of inspection, mainte-
front and rear frames before working on machine.
nance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid with suitable contain- Do not disconnect the lock link until the machine
ers before opening any compartment or disassem- is made operational and the commissioning pro-
bling any component containing fluids. cedure is completed.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpil-
lar machines.
Dispose of all fluids according to local regulations and
mandates.
UENR4816 33
Troubleshooting

Operation Checks
Personal injury or death can result from escaping Problem: The steering wheel is hard to
fluid under pressure. turn.
Escaping fluid under pressure, even a very small
pin-hole size leak, can penetrate body tissue, Probable Cause
causing serious injury, and possible death.
• The oil is to cold.
Always use a board or cardboard when checking
for a leak. • There is a restriction in the steering metering pump
Do not check for pin hole leaks in pump or motor pilot lines.
hoses during a steer stall condition.
• The pilot lines to the steering metering pump are
If fluid is injected into your skin, it must be treated not connected to the proper ports.
by a doctor familiar with this type of injury
immediately. • There is a restriction across the ball valve at the
steering metering pump supply port in the steering
control valve.
NOTICE
Care must be taken to ensure that fluids are con- • Steering pump pressure is low.
tained during performance of inspection, mainte- • The bolts are too tight for the metering section of
nance, testing, adjusting and repair of the machine. steering metering pump.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpil-
lar machines.
Dispose of all fluids according to local regulations and
mandates.

Performing tests of the steering system can be used

for diagnosis of poor performance and for finding the
source of oil leakage inside the hydraulic system.
This section provides probable causes to a known
problem. Since there may be several probable
causes, specific inspections or specific instrument
tests may be recommended. These inspections and
tests will help to identify the cause that is most
probable.

Note: Make sure that you use hydraulic oil with the Illustration 47 g03687497
correct viscosity for the ambient temperature and for Timing of the metering pump drive
the operating conditions. To determine the correct oil
(1) Pin
viscosity, see the reference that follows. (2) Internal pump gear

Reference: For additional information about the

• The timing of the steering metering pump drive is
various lubricant viscosity for your machine, refer to
not correct. Pin (1) must align with the valley of
the section Operation and Maintenance Manual,
internal pump gear (2).
“Lubricant Viscosities”.
34 UENR4816
Troubleshooting

Problem: The steering wheel is hard to Problem: The truck turns too slow in one
turn when steering quickly away from a direction.
full turn.
Probable Cause
Probable Cause • There is a faulty seal and/or seat in the ball
resolver valve of the steering control valve.
• Not enough clearance between the ball check
valve and the plug assembly in a neutralizer valve. • The flow balance adjustment of the main control
spool is not correct. Refer to System Operation,
Problem: The steering wheel can be Testing and Adjusting, “Steering Time - Check” for
turned when the machine is at a full turn. the machine that is being serviced.

Problem: The machine turns correctly

Probable Cause
when moving, but is slow in both
• Adjustment of strike (stud assembly) for a directions when the machine turns
neutralizer valve is not correct.
against a load (high resistance).
• Seat for the neutralizer ball check valve has a
defect. Probable Cause
• Relief valve opens before striker moves the
neutralizer valve stem. • Oil is leaking past the relief valve seat or seals.
• The control valve spool does not fit correctly in the
Problem: The machine does not turn bore.
smoothly. • Oil is leaking past both seats of the ball resolver
valve.
Probable Cause
Problem: The machine turns correctly
• The steering control valve spool does not move
freely. when moving, but is slow in one direction
when the machine turns against a load
• The steering metering pump supply line has been
installed in the field test port (in the steering control (high resistance).
valve body) instead of the correct location.
Probable Cause
Problem: The truck turns too slow in both
directions. • Slow right turns: Leakage past the upper seat or
seal of the ball resolver valve.
Probable Cause • Slow left turns: Leakage past the lower seat or seal
of the ball resolver valve.
• The steering control valve spool does not move all
the way.

• There is not enough flow from the steering pump.

• The springs for the flow control valve are not
adjusted correctly.
UENR4816 35
Troubleshooting

Problem: The machine does not turn Problem: The machine turns too fast to
when the steering wheel is turned. make small steering corrections when the
machine moves at fast speeds.
Probable Cause
• The flow control valve will not move from the open
Probable Cause
position.
• The flow control valve adjustment is not correct.
• The control valve spool will not move from the Refer to System Operation, Testing and Adjusting,
HOLD position. “Steering Time - Check” for more information.

• Oil is leaking past the relief valve seat or seals. • The control valve spool does not move freely.

• A neutralizer valve stem does not return to the • Metering orifices on the control valve spool are
open position. filled with foreign material or were not drilled
correctly.
• The implement and steering solenoid valve is
sticking or faulty. Problem: The pump makes noise and the
• Steering lockout valve is sticking or faulty. steering cylinder rod does not move
smoothly.
Note: Some Steering slip is normal. Refer to System
Operation, Testing and Adjusting, “Steering Slip -
Check” for further information. Probable Cause
• There is air in the steering hydraulic circuit.
Problem: The machine turns without the
operator turning the steering wheel. • The steering pump has too much wear.
• There is a loose connection of the oil line on the
Probable Cause inlet side of the steering pump.
• The control valve spool does not return to the • The viscosity of the oil is incorrect.
HOLD position.
• The relief valve opens at a low oil pressure.
• The mounting bolts for the steering control valves
are too tight. • The oil level in the tank is low.

• The bolts are too tight for the end covers of the
steering control valve.

• Manufacturing tolerances for the control valve

spool do not permit the spool to return to the HOLD
position.
Note: The problem may be corrected by turning the
spool in the steering control valve around in the bore
(turn end for end). The spring, retainer, and shims
must be installed on the opposite end of the spool. An
adjustment may be necessary for the steering times.

• Steering wheel turns without the operator turning

the steering wheel.
• Foreign material causes the sleeve valves in the
steering metering pump to stick.
• Steering metering pump centering (leaf) springs
are broken or damaged.
36 UENR4816
Testing and Adjusting

Testing and Adjusting Table 4

Example of determining percent of flow loss

20.8 L (5.5 US gal)

217.6 L/min × 100 = 9.5%

i01655538 (57.5 US gpm)

Pump Flow - Test

SMCS Code: 5073-081 Machine Test
Install a flow meter. Run the engine at high idle.
Reference: For additional information on the Measure the pump flow at 690 kPa (100 psi) and at
operation of the hydraulic system, refer to 6900 kPa (1000 psi). Use these values in the formula
Specifications for the machine that is being serviced. in Table 5 .
Table 5
This test is designed to determine whether a pump is
operating within design parameters. This test should Pump flow at 690 kPa
be performed only if all cylinder cycle times are too (100 psi)
slow. Pump flow at 6900 kPa
−
For any pump test, the pump flow at 690 kPa (1000 psi)
Percent of
× 100 =
(100 psi) will be larger than the pump flow at Pump flow at 690 kPa flow loss
6900 kPa (1000 psi) if the pump is operating at the (100 psi)
same rpm. The pump flow is measured in L/min (US
gpm).
The difference between the pump flow of two Bench Test
operating pressures is the flow loss. If the test bench can be run at 6900 kPa (1000 psi)
Note: The values in the examples are not set values and at full pump rpm, use the formula in Table 5 to
determine the percent of flow loss.
for any specific pump or for any specific pump
condition. See the Specification for the pump flow of a If the test bench can not be run at 6900 kPa
new pump at 690 kPa (100 psi) and at 6900 kPa (1000 psi) or at full pump rpm, run the pump shaft at
(1000 psi). 1000 rpm. Measure the pump flow at 690 kPa
Table 1 (100 psi) and at 6900 kPa (1000 psi). Use these
values in the top portion of the formula in Table 6 . For
Method of determining flow loss the bottom part of the formula, run the pump shaft at
2000 rpm. Measure the pump flow at 690 kPa
Pump flow at 690 kPa (100 psi)
(100 psi).
− Pump flow at 6900 kPa (1000 psi) Table 6

Flow loss Pump flow at 690 kPa

(100 psi)
Table 2 Pump flow at 6900 kPa
−
Example of determining flow loss (1000 psi)
Percent of
Pump flow at 690 kPa × 100 =
217.6 L/min (57.5 US gpm) flow loss
(100 psi) and at 2000
− 196.8 L/min (52.0 US gpm) rpm

20.8 L/min (5.5 US gpm)

i05828191
Flow loss that is expressed as a percentage of pump
flow is used as a measure of pump performance. Steering System Pressure -
Table 3 Test and Adjust
Method of determining percent of flow loss
SMCS Code: 4300-025-PX; 4300-081-PX
Flow loss (L/min or US
gpm) Table 7
Percent of flow
× 100 = Required Tools
Pump flow at 690 kPa loss
(100 psi) Part Number Description Qty
177-7861 Hose As 1
6V-4143 Coupler 2

8T-0859 Pressure Gauge 1

UENR4816 37
Testing and Adjusting

Personal injury or death can result from machine

articulation or movement.
Machine frames can move and a person can be
crushed.
Connect the steering frame lock link between the
front and rear frames before working on machine.
Do not disconnect the lock link until the machine
is made operational and the commissioning pro-
cedure is completed.

Illustration 48 g00935388
Steering frame lock installed
Personal injury or death can result from escaping (1) Steering frame lock
fluid under pressure.
1. Install steering frame lock (1) so that the machine
Escaping fluid under pressure, even a very small
pin-hole size leak, can penetrate body tissue, cannot turn.
causing serious injury, and possible death.
Always use a board or cardboard when checking
for a leak.
Do not check for pin hole leaks in pump or motor
hoses during a steer stall condition.
If fluid is injected into your skin, it must be treated
by a doctor familiar with this type of injury
immediately.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid with suitable contain- Illustration 49 g00935390
ers before opening any compartment or disassem- Steering control valve
bling any component containing fluids. (2) Pressure adjusting screw
(3) Pressure tap
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup- 2. Remove the protective cover from pressure tap (3).
plies suitable to collect and contain fluids in Caterpil-
lar machines. Connect a hose assembly with an 8T-0859
Pressure Gauge to pressure tap (3).
Dispose of all fluids according to local regulations and
mandates. 3. Start the engine. Operate the engine at the high
idle rpm with the transmission in NEUTRAL.

4. Turn the machine against the steering frame lock

will cause the relief valve to open.

5. Observe the pressure gauge. The pressure

reading on the gauge should be 17000 ± 520 kPa
(2500 ± 75 psi). Check the reading on the gauge
while attempting to turn the machine in both
directions.
38 UENR4816
Testing and Adjusting

Personal injury or death can result from escaping

fluid under pressure.
Escaping fluid under pressure, even a very small
pin-hole size leak, can penetrate body tissue and
cause serious injury and possible death. If fluid is
injected into your skin, it must be treated immedi-
ately by a doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.

Illustration 50 g03687502
NOTICE
Care must be taken to ensure that fluids are con-
Steering control valve tained during performance of inspection, mainte-
(2) Pressure adjusting screw nance, testing, adjusting and repair of the machine.
(4) Locknut
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
6. If the pressure is not the same in both directions, bling any component containing fluids.
there is a problem in the shuttle valve of the
steering control valve. If pressure is the same in Refer to Special Publication, NENG2500, “Caterpillar
both directions, but pressure is not correct, adjust Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpil-
the spring tension of the relief valve in the steering lar machines.
control valve group. To adjust the relief valve,
perform the following procedure: Dispose of all fluids according to local regulations and
mandates.
• a. Loosen locknut (4).

• b. Turn adjusting screw (2) clockwise to

increase the pressure setting and
counterclockwise to decrease the pressure
setting. Tighten the locknut.

7. After the correct pressure setting is obtained, stop

the engine. Remove the pressure gauge from the
pressure tap. Place the protective cover on the
pressure tap.

8. Remove the steering frame lock.

i03724041

Pressure Reducing Valve (Pilot Illustration 51 g00935397

Location of the pressure tap
Oil) - Test and Adjust (1) Pressure tap for the pilot hydraulic system
SMCS Code: 5117-036
Table 8 1. Remove the protective cover from pressure tap (1).
Connect a hose assembly with an 8T-0856
Required Tools
Pressure Gauge (0 to 6,000 kPa (0 to 870 psi)) to
Part Number Part Description Qty pressure tap (1).
177-7861 Hose As 1
2. With the parking brake engaged, start the engine
6V-4143 Coupler 2 and maintain engine speed above 1500 rpm with
8T-0856 Pressure Gauge 1
the transmission in NEUTRAL.
0 to 6,000 kPa (0 to 870 psi)
3. Observe the pressure on the gauge. The pressure
reading on the gauge with the oil at normal
operating temperature should be 3620 ± 70 kPa
(525 ± 10 psi).
UENR4816 39
Testing and Adjusting

1. Move the machine to a location that is smooth,

level, and hard. The location should also be dry
and free of debris.

Illustration 52 g01176841
Location of the pilot oil pressure reducing valve
(2) Pilot oil pressure reducing valve
Illustration 54 g00935403
Steering frame lock in the stored position
(1) Steering frame lock

2. Move steering frame lock (1) to the STORED

position.
To check the steering time, put the machine on a dry,
hard surface. With the engine at the high idle rpm, the
time for a full turn, from stop to stop, must not be
more than 3.8 ± 0.2 seconds.
With the service brake off, the difference between the
time for a right turn and the time for a left turn must
not be more that 0.3 second. With the service brakes
engaged, the time must not increase by more than
0.2 second.
Illustration 53 g02007733 The difference between the times for a full right turn
(2) Pilot oil pressure reducing valve and a full left turn with the service brake off must not
(3) Locknut be more than 0.3 second. If the steering time is out of
(4) Adjusting screw specification, refer to the following reference.

4. If the pressure reading is not correct, stop the Reference: For additional information on adjusting
engine. Loosen locknut (3) and turn adjusting the steering time, refer to System Operation, Testing
and Adjusting, “Steering Control Valve - Adjust” for
screw (4) on pilot oil pressure reducing valve (2).
the machine that is being serviced.
Turn adjusting screw (4) clockwise to increase the
pressure, and counterclockwise to decrease the
i05828192
pressure.

5. Repeat Step 2 through Step 4 until the correct Steering Control Valve - Adjust
pressure setting is obtained. SMCS Code: 4307-025
6. When this test is complete, stop the engine and Note: Adjustments to the steering control valve
remove the test equipment. Place the protective should only be performed after you complete the
cover on the pressure tap. procedure in the following reference.

Reference: For the correct procedure to check the

i01795580
steering time, refer to System Operation, Testing and
Adjusting, “Steering Time - Check” for the machine
Steering Time - Check that is being serviced.
SMCS Code: 4309-531; 7188-535
40 UENR4816
Testing and Adjusting

2. Add shims (3) to decrease both steering times. If

an increase in the steering times is required,
remove shims.
One 4J-6806 Shims will change the steering
times at high idle by approximately 0.1 second.

3. Install the end cover on the steering control valve.

i02281137

Steering Slip - Check and

Adjust
SMCS Code: 4300-036
Illustration 55 g03687506
Steering control valve To check the steering wheel slip, perform the
(1) Steering control valve following procedure:
(2) Flow balance shims
(3) Cylinder flow shims 1. Put the machine on a dry, hard surface. Disengage
(4) End cover the brakes.
2. Raise the engine speed to 750 rpm, turn the
Steering Time Adjustment steering wheel slowly through one revolution so
1. Remove end cover (4) from steering control valve that there is a minimum of articulation. Perform this
(1). in both directions to get the feel of the steering
action.
2. Add flow balance shims (2) in order to decrease
3. Perform this test three more times in each
the right turn time (steer faster) and increase the
direction. Make a note of the time required for each
left turn time (steer slower). If the flow balance
of the revolutions of the steering wheel.
shims are removed, the result is opposite.
4. Add the three times for each direction. If these
3. Flow balance shims (2) are available in two
totals are 60 seconds or more, the slip is
thicknesses. The 5J-4776 Shims are 0.127 mm
acceptable.
(0.0050 inch) thick. Two 5J-4776 Shims will
change the steering time at high idle by 5. If the totals are less than 60 seconds, remove the
approximately 0.5 second. The 4J-8224 Shims spool from the steering control valve. Turn the
are 0.254 mm (0.010 inch) thick. Two 4J-8224 spool around in its bore (turn it end for end). To do
Shims will change the steering time at high idle by this the spring, retainer, and shims must be
approximately 0.1 second. installed on the opposite end of the spool. In some
cases this will correct the problem of
4. Install the end cover on the steering control valve.
manufacturing tolerances and the slip will then be
Example: A check of the steering times shows that acceptable.
the right turn time is 0.4 second more than the left
turn time. Flow balance shims (2) must be added to
decrease the difference between the times.
The 4J-8224 Shims are 0.254 mm (0.010 inch)
thick. Adding four 4J-8224 Shims will decrease the
right turn time by approximately 0.2 second and
increase the left turn time by approximately 0.2
second. The extra 4J-8224 Shims will make the
right and left turn time approximately the same.

Cylinder Flow Adjustment

Ensure that both steering times (right and left) are 3.8
± 0.2 seconds. If necessary, cylinder flow shims (3)
can be added or removed.
1. Remove the end cover from steering control valve
(1).
UENR4816 41
Testing and Adjusting

i02239852
3. Connect manifold (3) to a hydraulic test bench.
Valve (Steering Lockout) - Test
SMCS Code: 4307

Personal injury or death can result from escaping

fluid under pressure.
Escaping fluid under pressure, even a very small
pin-hole size leak, can penetrate body tissue and
cause serious injury and possible death. If fluid is
injected into your skin, it must be treated 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 con-
tained during performance of inspection, mainte-
nance, 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
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Illustration 57 g01173965
Dispose of all fluids according to local regulations and Steering lockout valves and manifold
mandates. (1) Steering lockout valve for a right turn
(2) Steering lockout valve for a left turn
(5) Port
(6) Port
(7) Port
(8) Port
(9) Port
(10) Port

4. Connect a low pressure oil supply to port (9).

5. Connect a low pressure oil supply to port (10).

6. Connect port (6) to the return port of the hydraulic

test bench.
7. Connect a regulated supply of oil to port (5).

8. Adjust the regulated supply of oil pressure to port

Illustration 56 g01129165 (5) until low pressure oil flows from port (7) and
(1) Steering lockout valve for a right turn port (8).
(2) Steering lockout valve for a left turn
(3) Manifold 9. The pressure required to open steering lockout
(4) Bolts valve (1) and steering lockout valve (2) should be
760 ± 35 kPa (110 ± 5 psi).
Note: Put identification marks on the hose
assemblies for installation purposes. 10. If steering lockout valve (1) does not meet the
1. Disconnect the hose assemblies from manifold (3). required specifications, the valve must be replaced
with a new valve.
2. Remove two bolts (4) and the washers. Remove
manifold (3).
42 UENR4816
Testing and Adjusting

11. If steering lockout valve (2) does not meet the

required specifications, the valve must be replaced
with a new valve.
12. Install manifold (3) to the machine. Install two
bolts (4) and the washers.

13. Connect the hose assemblies to manifold (3).

i02224678

Steering Neutralizer Valve -

Check and Adjust
SMCS Code: 4330-025; 4330-535
Illustration 59 g00935404
Location of the steering frame stop
Check the Steering Neutralizer
(2) Frame stop (one on each side of the machine)
Valves
3. Place a 19 mm (0.75 inch) ball of putty on frame
stop (1) on each side of the machine.

Personal injury or death can result from machine 4. Place the steering frame lock in the stored position.
articulation or movement. Machine frames can
move and a person can be crushed. 5. Start the engine and disengage the parking brake.

Connect the steering frame lock between the front 6. With the engine at high idle, steer rapidly into both
and rear frames before working on the machine. stops.

7. Steer the machine into the straight ahead position

1. Move the machine to a location that is smooth,
and engage the parking brake. Install the steering
level, and hard. The location should also be dry
frame lock and stop the engine.
and free of debris.
8. Measure the thickness of the putty on each side of
the machine. The putty should be pressed to a
thickness of 12 ± 3 mm (0.5± 0.12 inch). This is
the clearance between the frame stop when a full
turn is made.
9. If the clearance is not correct, the steering stop
clearance will need to be adjusted. Refer to “Adjust
the Steering Neutralizer Valves”.

Adjust the Steering Neutralizer

Valves

Illustration 58 g01122117
Personal injury or death can result from machine
articulation or movement. Machine frames can
2. Install steering frame lock (1).
move and a person can be crushed.
Connect the steering frame lock between the front
and rear frames before working on the machine.

1. Ensure the steering frame lock is installed.

UENR4816 43
Testing and Adjusting

i05779829

Oscillating Hitch - Adjust

SMCS Code: 7113-025

1. Park the machine on a hard level surface.

2. Relieve the tension from the oscillating hitch. Block
the rear wheels of the machine and reverse the
machine against the block.

3. Engage the parking brake and stop the engine.

Illustration 60 g01122121
(1) Steering neutralizer valve for a left turn
(2) Striker
(3) Locknut

2. To adjust the steering stop clearance for a left turn,

loosen locknut (3) on striker (2). Turn striker (2)
counter clockwise to increase the steering stop
clearance. Turn striker (2) clockwise to decrease
steering stop clearance.

3. Tighten locknut (3).

Illustration 62 g00992525

4. Remove three bolts (1) and remove locking plate

(2).

Illustration 61 g01122492
(4) Locknut
(5) Striker
(6) Steering neutralizer valve for a right turn

4. To adjust the steering stop clearance for a right

Illustration 63 g00992526
turn, loosen locknut (4) on striker (5). Turn striker
(5) counter clockwise to increase the steering stop 5. Reposition locking plate (2) so that hole (5) is
clearance. Turn striker (5) clockwise to decrease outside of the circumference of thrust flange (3).
steering stop clearance.
6. Install three bolts (1) removed in Step 4. Tighten
5. Tighten locknut (4). three bolts (1) to a torque of 240 ± 20 N·m
6. Check the steering stop clearances. Refer to (175 ± 15 lb ft).
“Check the Steering Neutralizer Valves”. 7. Insert a 3/4 inch square drive through hole (5) so
that the square drive contacts the outside of thrust
flange (3). The square drive will prevent locking
plate (2) from rotating clockwise.
44 UENR4816
Testing and Adjusting

8. Use a suitable wrench on the square drive in order 4. Drive bearing cup (10) down to ensure contact with
to turn thrust flange (3) clockwise until all end play cap (13).
has been removed.
5. Lubricate bearing cones (11) and (9) with SAE 30
9. If necessary, turn thrust flange (3) oil and install.
counterclockwise in order to line up the holes.
Insert the square drive into hole (4) in order to 6. Install cooled bearing cup (8) and drive down to
rotate thrust flange (3) counterclockwise. Rotate ensure light contact pressure on bearing cone (9).
thrust flange (3) as far as the first correct hole
7. Remove three bolts (5) and cap (13) installed in
alignment.
Step 2.
10. Remove the square drive and reposition locking
8. Install the following components: shim pack (7),
plate (2) and bolts (1). Tighten three bolts (1) to a
caps (4) and (13), six bolts (5) and the washers.
torque of 240 ± 20 N·m (175 ± 15 lb ft).
Tighten diagonally opposite bolts (5) to a torque of
Reference: For more information, refer to 100 ± 20 N·m (75 ± 15 lb ft).
Disassembly and Assembly, Machine Systems,
“Front Frame and Rear Frame - Connect”. 9. Install the torquing bolt assembly.

Upper Hitch 10. Apply a torque wrench to the torquing bolt and
read the torque necessary to rotate the bearing
cones.
11. If the torque is within a range of 2.3 to 13.6 N·m
(20 to 120 lb in), remove caps (4) and (13) and
install lip seals (6) and (12). Lubricate the sealing
lips with the lubricant being sealed.

12. Install caps (4) and (13) with six bolts (5) and the
washers, ensuring shims (7) are in place. Apply
Loctite 7649 and then apply Loctite 263 to the
threads of the bolts prior to assembly. Tighten six
bolts (5) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

13. If the torque is LESS THAN 2.3 N·m (20 lb in) or

Illustration 64 g03687507
GREATER THAN 13.6 N·m (120 lb in), remove or
add shims to obtain the correct rotating torque. The
(1) Bolt
(2) Washer removal of shims will increase the torque and the
(3) Pin assembly addition of shims will cause a torque decrease.
(4) Cap
(5) Bolt and washer Reference: For more information, refer to
(6) Lip seal
(7) Shim pack
Disassembly and Assembly, Machine Systems,
(8) Bearing cup “Front Frame and Rear Frame - Connect”.
(9) Bearing cone
(10) Bearing cup
(11) Bearing cone
Procedure to Install the Upper Hitch Pin
(12) Lip seal
(13) Cap
1. Align the upper hitch bores. Install pin (3).

Procedure to Assemble the Upper Hitch 2. Apply Loctite 263 to the thread of bolt (1) prior to
assembly.
1. Apply Loctite C5-A to the bearing cup bores prior
3. Install bolt (1) and washer (2).
to assembly.
Reference: For more information, refer to
2. Install cap (13) with three bolts (5) and the Disassembly and Assembly, Machine Systems,
washers, equally spaced around the cap. “Front Frame and Rear Frame - Connect”.
3. Lower the temperature of bearing cups (8) and (10)
to −75° ± 5°C (−103° ± 9°F). Install cooled bearing
cup (10) in the bearing housing.
UENR4816 45
Testing and Adjusting

Lower Hitch 6. Install cooled bearing cup (7) and drive down to
ensure light contact pressure on bearing cone (8).

7. Remove five bolts (1) and lower cap (12) installed

in Step 2.

8. Install the following components: shim pack (6),

lower cap (12), upper cap (5) and bolts and
washers (1). Tighten diagonally opposite bolts (1)
to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

9. Install the torquing bolt assembly.

10. Apply a torque wrench to the torquing bolt and

read the torque necessary to rotate the bearing
cones.
11. If the torque is within a range of 11.3 to 39.6 N·m
(8.3 to 29.1 lb ft), remove upper cap (5) and lower
cap (12). Install lip seals (4) and (11). Lubricate the
sealing lips with the lubricant being sealed.

12. Install upper cap (5) and lower cap (12) with ten
Illustration 65 g03687508 bolts (1) and the washers, ensuring shim pack (6)
(1) Bolt and washer is in place. Apply Loctite 7649 and then apply
(2) Spacer
(3) Pin
Loctite 263 to the threads of ten bolts (1) prior to
(4) Lip seal assembly. Tighten ten bolts (1) and the washers to
(5) Upper cap a torque of 100 ± 20 N·m (75 ± 15 lb ft).
(6) Shim pack
(7) Bearing cup
(8) Bearing cone
13. If the torque is LESS THAN 11.3 N·m (8.3 lb ft) or
(9) Bearing cone GREATER THAN 39.6 N·m (29.1 lb ft), remove or
(10) Bearing cup add shims to obtain the correct rotating torque. The
(11) Lip seal
(12) Lower cap
removal of shims will increase the torque and the
(13) Bolt and washer addition of shims will cause a torque decrease.
(14) Shim
(15) Bolt and washer Reference: For more information, refer to
(16) Locking plate Disassembly and Assembly, Machine Systems,
(17) Shim pack
(18) Spacer
“Front Frame and Rear Frame - Connect”.

Procedure to Install the Lower Hitch Pin

Procedure to Assemble the Lower Hitch
1. Install spacers (2) and (18).
1. Apply Loctite C5-A to the bearing cup bores prior
to assembly. 2. Align the lower hitch bores. Install pin (1).
Note: Use five 8T-4223 Hard Washers on each bolt 3. Install shim (14), locking plate (16), two bolts (15)
in the next step. and the washers. Tighten two bolts (15) to a torque
2. Install lower cap (12) with five bolts and washers of 900 ± 100 N·m (660 ± 75 lb ft).
(1), equally spaced around the cap.
4. Measure the gap at four equally spaced locations
3. Lower the temperature of bearing cups (7) and (10) between the front frame and locking plate (16).
to −75° ± 5°C (−103° ± 9°F). Install cooled bearing Record the average measurement.
cup (10) in the bearing housing. 5. Install the thickness of shim pack (17) recorded in
4. Drive bearing cup (10) down to ensure contact with Step 4 between locking plate (16) and the front
lower cap (12). frame.
6. Apply Loctite 7649 and then apply Loctite 263 to
5. Lubricate bearing cones (8) and (9) with SAE 30 oil
the threads of the bolts prior to assembly. Install
and install.
two bolts (15) and the washers. Tighten two bolts
(15) to a torque of 900 ± 100 N·m (660 ± 75 lb ft).
46 UENR4816
Testing and Adjusting

7. Apply Loctite 7649 and then apply Loctite 263 to

the threads of the bolts prior to assembly. Install
eight bolts (13) and the washers. Tighten eight
bolts (13) to a torque of 100 ± 20 N·m
(75 ± 15 lb ft).
Reference: For more information, refer to
Disassembly and Assembly, Machine Systems,
“Front Frame and Rear Frame - Connect”.
UENR4816 47
Index Section

Index
D Steering Neutralizer Valve - Check and Adjust
....................................................................... 42
Diverter Valve (Secondary Steering) ............... 28
Adjust the Steering Neutralizer Valves......... 42
Check the Steering Neutralizer Valves ........ 42
G Steering Slip - Check and Adjust ..................... 40
Steering System (High Pressure Oil Circuit).... 18
Gear Pump (Hoist, Steering, Brake, and
Steering System (Pilot Oil)................................. 9
Pilot)............................................................... 10
Steering System Pressure - Test and Adjust ... 36
Gear Pump (Secondary Steering) ................... 27
Steering System Troubleshooting ................... 32
General Information........................................... 4
Operation Checks ........................................ 33
Steering Time - Check ..................................... 39
I Systems Operation Section ............................... 4
Important Safety Information ............................. 2
T
M Table of Contents............................................... 3
Testing and Adjusting ...................................... 36
Machine Preparation for Troubleshooting ....... 31 Testing and Adjusting Section ......................... 31
Troubleshooting............................................... 31
O
Oil Filter (Pilot) ..................................................11 V
Oil Filter (Steering)........................................... 24 Valve (Steering Lockout).................................. 15
Oscillating Hitch - Adjust.................................. 43 Valve (Steering Lockout) - Test........................ 41
Lower Hitch .................................................. 45 Visual Inspection ............................................. 32
Upper Hitch .................................................. 44

P
Pressure Reducing Valve (Pilot Oil)..................11
Pressure Reducing Valve (Pilot Oil) - Test
and Adjust...................................................... 38
Pump Flow - Test ............................................. 36
Bench Test ................................................... 36
Machine Test................................................ 36

S
Secondary Steering System............................ 25
Solenoid Valve (Implement and Steering) ....... 12
Steering Control Valve ..................................... 20
Left Turn Position ......................................... 23
Neutral Position............................................ 20
Right Turn Position....................................... 22
Steering Control Valve - Adjust........................ 39
Cylinder Flow Adjustment ............................ 40
Steering Time Adjustment............................ 40
Steering Metering Pump.................................. 13
Steering Neutralizer Valve ............................... 16
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