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REG00523-04
December 1979

-;~C.TERPILLAR

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920, 930, 930T & 930T Series II

Wheel Loader Hydraulic System

~.-.-

920

930, 930T &

930T SERIES II

930

41 J1-UP
75J1 UP
62K1-UP
M

71 H1-UP
79J1-UP
41K1-UP
73U1-UP

1781-UP

~~~

'

INTRODUCTION

This pUblication has instructions and procedures for the subject on the front
cover. The information, specifications, and illustrations in this publication
are on the basis of information that was current at the time this issue was
written.
Correct operation, maintenance, test and repair procedures will give this
product a long service life. Before starting a test, repair or rebuild job, the
serviceman must read the respective sections of the Service Manual, and
know all the components he will work on.
Your safety, and the safety of others, is at all times very important. When
you see this symbol
or this symbol
in the manual, you must
know that caution is needed for the procedure next to it. The symbols are
warnings. To work safely, you must understand the job you do. Read all
instructions to know what is safe and what is not safe.
.._"

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It is very important to know the weight of parts. Do not lift heavy parts by
hand. Use a hoist. Make sure heavy parts have a good stability on the ground.
A sudden fall can cause an accident. When lifting part of a machine, make
sure the machine has blocks at front and rear. Never let the machine hang on
a hoist, put blocks or stands under the weight.
When using a hoist, follow the recommendation in the manual. Use correct
lift tools as shown in illustrations to get the correct balance of the
component you lift. This makes your work safer at all times.
40400X3

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LUI-'UI::H HYUHI-'ULIL

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SYSTEMS OPERATION
",
Loader Hydraulic System.....................................................
Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Lift Kickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Main Pressure Relief Valve ....................................... , ... .....
Tilt Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Bucket Position Indicator and Bucket Positioner.. .. .. .. ..... .. .. ... .. .. .. ..
Tilt Circuit Relief Valves..................................................

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4
7
7
5
6
6
6

TESTING AND ADJUSTING

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Loader Hydraulic System

Bucket Position Indicator and Positioner
Bucket Position Indicator
Bucket Positioner
Checking Pump Efficiency
Control Lever Effort
Lift Kickout
Loader System Test Procedures
Lift Circui t Drift
Lift and Tilt Circuit Speeds..................................
Multi-Purpose Bucket Circuit
Tilt Circuit Drift
Main Pressure Relief Valve and Tilt Circuit Relief Valves
Main Pressure Relief Valve
Tilt Circuit Relief Valve (Head Ends)
Tilt Circuit Relief Valve (Rod Ends)
Operational Checks
Visual Checks

8
14
14
14
"
9
15
13
,.' .. 9
10
9
11
10
11
11
12
13
9
8

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to the SPECI

FICATIONS FOR 920 and 930 WHEEL LOADER HYDRAULIC SYS
TEM, Form No. REG01271. If the Specifications given in Form REGOl271
are not the same as given in the Systems Operation and the Testing and
Adjusting, look at the printing date on the back cover of each book. Use
the Specifications given in the book with the latest date.

NOTE: The "C" is an indication of a change from the former issue.

C~:

920 & 930 LOADER HYDRAULIC SYSTEM

SYSTEMS OPERATION

LOADER HYDRAULIC SYSTEM

/"

~1

3~

C?1I4

10~11

13~~~14

~ ,IO:o:::;'i

17

18

I
I

PUMP FL.GW

,_ _

BLOCK~O OIL

SUPPLY OIL

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X~09

LOADER HYDRAULIC SYSTEM IN HOLD POSITION

1. Filter.
2. Lift and tilt control valve
body.
3. Tilt circuit port (connects
to rod ends of tilt
cylinders).
4. Lift circuit port (connects
to rod ends of lift
cylinders) .
5. Make-up valve housing.

6. Lift circuit make-up

valve (rod ends).
7. Lift circuit check valve.
8. Lift circuit control valve
spool.
9. Tilt circuit control valve
spool.
10, Tilt circuit port (connects
to head ends of tilt
cylinders).

The loader hydraulic system consists of a pump,

a hydraulic oil supply tank, the lift and tilt control
valve with attached make-up and relief valves,
control linkage, and the lift and tilt cylinders.
The lift circuit consists of a check valve, valve
spool and make-up valves. When moved to an
operating position, the valve spool directs pump
flow to the lift cylinders. The spool has four posi
tions: RAISE, HOLD, LOWER and FLOAT.
The tilt circuit consists of a check valve, valve
spool, rod end and head end relief valves and make
up valves. When moved to an operating position,
the valve spool directs pump flow to the tilt cylin
ders. The spool has three positions: TILT BACK,
HOLD and DUMP.
The lift system includes a hydraulic lift kick out
circuit. The mechanism in this circuit consists of
a master cylinder mounted on the loader frame
near the hydraulic lift cylinder and a slave cylin
der on the left side of the hydraulic tank to move
the lift control lever linkage. When the lift arms

"1

11. Lift circuit port (connects

to head ends of lift
cylinders).
12. Tilt circuit check valve.
13. Port (connects to pump).
14. Port (blocked).
15. Lift circuit make-up
valve (head ends).
16. Tilt circuit make-u p
valve (rod ends).
17. Tilt cylinders (two).

18. Lift cylinders (two).

19. Tilt circuit relief valve

(rod en~s).

20. Tilt circuit relief valve

(head ends).
21. Tilt circuit make-up valve
(head ends).

22. Oil supply tank.

23. Main pressure relief

valve.
24. Pump.

reach the preset lift height the master cylinder

actuates the slave cylinder, which automatically
moves the lift control lever (and the lift spool in
the control valve in the hydraulic tank) from the
RAISE position detent to the HOLD position.
The tilt system includes either a bucket position
indica tor or a bucket positioner hydraulic circuit.
The mechanism in this circuit consists of a master
cylinder mounted on the right hydraulic tilt cyl
inder and a slave cylinder on the left side of the
hydraulic tank to move the tilt control lever link
age. The master cylinder actuates the slave cyl
inder, which automatically moves the tilt control
lever (and the tilt spool in the control valve in the
hydraulic tank) from the TILT BACK position
detent to the HOLD position at a preset bucket
digging angle.
Oil flow for the hydraulic system is supplied by
the large section of a two section insert vane-type
hydraulic pump.
The oil flow through the hydraulic system when

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. the control levers are in HOLD position is as

follows:
The pump draws supply oil from the tank. The
oil is directed to the lift and tilt control valve in
the tank and flows by the tilt and lift valve spools.
The valve spools are held in HOLD position by
centering springs. The oil leaves the lift and tilt
control valve and flows to the tank. On machines
equipped with an implement control valve, the oil
flows through the implement valve before flo'Ning
to the tank.

MAIN PRESSURE RELIEF VALVE (5J9113)

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ference between these pressures becomes sufficient

to overcome the force of spring (3), the dump valve
(5) is unseated. Pump flow is directed through port
(12) to the tank, preventing any further rise in
pressure.

MAIN PRESSURE RELIEF VALVE (3G2315)

The 3G2315 main pressure relief valve is

mounted to the control valve body. The valve
limits the pressure that can be imposed on the
hydraulic pump. It also protects both the lift and
tilt circuits in all operating positions except
DUMP position. This valve consists of a spring
loaded dump valve and a spring-loaded pilot
valve.

The main pressure relief valve is mounted to the

control valve body. The valve limits the pressure
that can be imposed on the hydraulic pump. It also
protects both the lift and tilt circuits in all opera
ting positions. This valve consists of a spring
loaded dump valve and a spring-loaded pilot valve.

6
7
10

A9831SXl

MAIN PRESSURE RELIEF VALVE

1. Adjustment screw.

10

2. Orifice. 3. Dump v81ve

spring. 4. Dump valve. 5. Dump ports. 6. Pilot valve
spring. 7. Pilot valve. 8. Chamber. 9. Orifice. 10.
Inlet chamber.
.93219

MAIN PRESSURE RELIEF VALVE

1. Shims. 2. Pilot valve spring. 3. Dump valve spring.

4. Orifice. 5. Dump valve. 6. Dump valve seat. 7. In
let chamber. 8. Pilot valve. 9. Pilot valve seat. 10.
Orifice. 11. Chamber. 12. Dump port.

When the pilot valve (8) is seated, the pressure

in chambers (7) and (11) is equal. Dump valve (5)
is held seated by spring (11). The pressure at which
the dwnp valve opens is determined by the shim
adjusted force of spring (2) and force of spring (3).
As the system pressure approaches the relief valve
setting, the pilot valve is unseated slightly opening
orifice (0) to tank. Orifice (10) is larger than
orifice (4). Therefore, as the pilot valve moves
against the spring force, more area of orifice (10)
is exposed. When the exposed area becomes larger
than the area of orifice (4), oil can leave chamber
(11) faster, than the oil can enter chamber (11).
The pressure in chamber (11), at this point, is
lower than pressure in chamber (7). When the dif

When the pilot valve (7) is seated, the pressure

in chamber (8) and inlet chamber (10) is equal.
Dump valve (4) is held seated hy dump valve
spring (3). The pressure at which the dump valve
opens is determined by the shim adjusted force
of pilot valve spring (6) and force of dump valve
spring (3).
As the system pressure approaches the relief
valve setting, the pilot valve is unseated slightly
opening orifice (2) to tank. Orifice (2) is larger
than orifice (9). Therefore, as the pilot valve
moves against the spring force, more area of
orifice (2) is exposed. When the exposed area be
comes larger than the area of orifice (9), oil can
leave chamber (8) faster, than the oil can enter it.
The pressure in chamber (8), at this point, is lower
than pressure in inlet chamber (10). When the
difference between these pressures becomes
sufficient to overcome the force of spring (3), the
dump valve (4) is unseated. Pump flow is directed
through ports (5) to the tank, preventing any
further rise in pressure.

SYSTEMS OPERATION

920 & 930 LOADER HYDRAULIC SYSTEM

TILT CIRCUIT
When the tilt control lever is moved to TILT
BACK position, the tilt control valve spool moves
outward. Pump flow is directed to the tilt circuit
check valve. The check valve remains seated until
pump flow pressure becomes greater than the com
bined force of the oil pressure in the head ends of
the cylinders and the force of the check valve
return spring. The check valve prevents reverse oil
flow and resulting cylinder drift. The oil unseats
the check valve and is directed to the head ends
of the tilt cylinders, tilting the bucket back. Oil
in the rod ends of the cylinders returns through
the control valve to the supply oil in the tank.
When the control lever is moved to DUMP posi
tion, the valve spool is moved into the valve body
and the oil flow is reversed. Oil is directed to the
rod ends of the tilt cylinders, dumping the bucket.
Oil from the head ends of the cylinders returns to
the supply oil in the tank.
The tilt circuit make-up valve housing is mounted
to the lift and tilt control valve body. The make-up
valves will unseat and allow oil from the tank to
supplement pump flow when the piston rods extend
or retract faster than the pump can supply oil to
the cylinders. A make-up valve will also unseat
when the tilt circuit is in HOLD position and the
tilt cylinder piston rods are moved by an excessive
force being exerted on the bucket. In this case, a
tilt circuit relief valve will open to relieve oil
pressure and a make-up valve will unseat to fill the
void of oil in the opposite ends of the cylinders.
Tilt Circuit Relief Valves
When the tilt circuit control valve spool is in
HOLD position, the tilt relief valves (rod ends)
and (head ends) protect the circuit and machine
components by limiting the external force that
can be imposed on the bucket. The tilt relief valves
have higher settings than the main pressure relief
valve. All relief valves are mounted to the tilt
circuit make-up valve housing.
The tilt relief valves are spring-loaded dump
valves. When oil pressure exceeds the tilt relief
valve settings, the springs are compressed and the
dump valves open to the dump ports. The oil flows
through the dump ports and returns to the tank.
The relief valves in the tilt circuit allow excessive
external forces on the bucket to move the tilt
cylinder pistons, thus preventing damage to the
machine components.
Bucket Position Indicator and Bucket Positioner
The bucket position indicator (1) is a strip,
mounted on a tube which moves with the hydraulic
cylinder rod end, and an angle, mounted on the
hydraulic cylinder. As the bucket is moved to
TILT BACK position the strip and angle become
visually aligned. When they are aligned the bucket

BUCKET POSITION INDICATOR AND

POSITIONER ACTUATOR

1. Bucket POSitIon indicators. 2. Bucket positioner

master cylinder. 3. Cam, mounted on a tube connected
to the rod end of the hydraulic cylinder. 4. Roller.

is at the correct digging angle and the tilt control

lever is moved to the HOLD position to stop the
bucket in the digging position.

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X411

8
BUCKET POSITION INDICATOR AND

POSITIONER SYSTEM

1. Bucket position indicators. 2. Bucket pOSitioner

master cylinder. 4. Roller. 5. Hydraulic tank. 6. Right
side hydraulic tilt cylinder. 7. Bucket position slave
cylinder. 8. Hydraulic tube (connects master cylinder
to slave cylinder). 9. Tube assembly.

On machines equipped with the hydraulic bucket

positioner, the bucket positioner automatically
moves the tilt control lever from TILT BACK to
HOLD position. This action stops the bucket
movement at the conect digging position.
With the tilt control lever in TILT BACK posi
tion, the tilt cylinder rod extends to a position
where cam (3) moves under roller (4) and the
roller actuates the piston in the bucket positioner
master cylinder (2). The master cylinder hydraulic
ally actuates the bucket positioner slave cylinder
(7). The action of the slave cylinder moves the
tilt control lever and the spool in the control valve
to the HOLD position. The tilt control lever must
be held in the TILT BACK position to allow the
hydraulic cylinder rod to move the bucket from
the preset digging angle to full tilt back.

The location of cam (3) sets the bucket

tioner for the desired bucket digging angle.

POSl

LIFT CIRCUIT
When the lift control lever is moved to RAISE
position, the lift circuit control valve spool is moved
outward. The oil pressure opens the lift circuit
check valve and pressure oil is directed to the head
ends of the lift cylinders, raising the lift ann. Oil in
the rod ends of the lift cylinders returns back
through the control valve and to the tank.
When the control lever is moved to LOWER
position, the valve spool is moved into the valve
body and pressure oil is directed to the rod ends
of the lift cylinders. The oil in the head ends of the
cylinders returns through the control valve and
to the tank.
When the control lever is moved to FLOAT
position, the head ends, rod ends, pressure cham
bers and return chambers within the valve body are
open to each other. The lift cylinder pistons can
move in either direction depending on the external
forces acting on the bucket. As the pistons move,
all excess oil returns to the tank and make-up oil
is supplied by the pump.
The valve spool is locked in FLOAT position by
the float position detent in the spool. The control
lever must be manually moved out of FLOAT
position.
The lift circuit
make-up valve housing is mounted
.or'.
to the control valve body. The make-up valves will
unseat and allow oil from the tank to supplement
pump flow when the piston rods extend or retract
faster than the pump can supply oil to the cylinders.

The lift kickout automatically returns the lift

control lever (and lift spool in the control valve)
from RAISE to HOLD position when the bucket
reaches a preset height.

When the lift control lever is placed in the

RAISE position, the lift hydraulic cylinder rods
extend and the lift anns raise. As the lift arms
raise past a horizontal attitude the lift hydraulic
cylinder (3) begins to pivot toward the loader
frame. When the lift anns approach the preset
bucket height, the lift cylinder contacts the roller
(5) on the lift kickout master cylinder (4). The
roller pushes the piston in the master cylinder and
the master cylinder hydraulically actuates the lift
kickout slave cylinder (6). The action of the slave
cylinder moves the lift control lever (and the con
trol valve lift spool) to the HOLD position and the
bucket stops at the preset height.

Lift Kickout

X412

LIFT KICKOUT COMPONENTS

1. Hydraulic tank. 2. Loader frame. 3. Hydraulic lift
cylinder. 4. Lift kickout master cylinder. 5. Roller.
6. Lift kickout slave cylinder. 7. Hydraulic tube (con
nects master cylinder to slave cylinder).

920 & 930 LOADER HYDRAULIC SYSTEM

TESTING AND ADJUSTING

LOADER HYDRAULIC SYSTEM

. ~-

It::" WARNING

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Hydraulic oil, under pressures that can be higher than 3000 psi (20700 kPa) can remain in the
hydraulic systems on this machine after the engine and pump have been stopped. Serious injury
can be caused if this pressure is not released before any service is done on the hydraulic systems.
To prevent possible injury, be sure that the pressure is released before any fitting, hose or com
ponent is loosened, tightened, removed or adjusted.
C

When possible, the bucket must always be flat on the ground before service is started. When it
is necessary for the bucket to be raised while tests or adjustments are done, be sure that the lift
arms have correct support and the bucket is in the full dump position.
Always move the machine to a location away from the travel of other machines. Be sure that other
personnel are not near the machine when the engine is running and tests or adjustments are
being made.

\Vhen analyzing the hydraulic system, remember

that propel' oil flow and con'ect oil pressure are
necessary for proper operation. Oil flow is depend
ent on the pumjJ output which is a function of
engine speed. Oil pressure is a result of restriction
to the oil flow.
In all instances, visual checks and measurements
should be made first. Then proceed to operational
checks and finally to instrumentation checks.
Use the 585123 Hydraulic Testing Group, a
stop watch, a magnet, a thermometer and an inch
(mm) scale for basic test to measure;
1. Opening pressure of the main pressure relief
valve and the tilt circuit relief valves. Low
relief valve pressure reduces the lifting and
digging capabilities of the machine. Too high
opening pressures can reduce hose and com
ponent life.
2. Lift and tilt circuit drift rates. Circuit drift
resul ts from leakage past cylinder piston seals,
control valve O-ring seals, poorly seated check
or make-up valves and/or excessive spool-to
valve bore clearances.
3. Lift and tilt circuit cycle times. Excessive
circuit cycle times results from leakage, pump
wear and/or pump speed.

The analysis of a malfunction will be easier and

the conclusion more certain if the following loader
hydraulic system fundamentals are remembered.
The tilt circuit and lift circuit are arranged in a
series circuit. (In bucket dump, pressure oil is not
available to the lift circuit.) The hydraulic pump
and main pressure relief valve are common to both
the lift and tilt circuits. Each circuit has a check
valve to prevent cylinder drift during valve spool
movement. Each circuit also has mal\e-up valves to
supplement pump flow.
".~
Relief valves in the tilt circuit, limit the external
pressure imposed on the circuit when the tilt
control valve is in the HOLD position.

VISUAL CHECKS

A visual inspection of the system with the

engine stopped should be the first step when
trouble-shooting a problem. With the bucket low
ered to the ground and the oil reasonably cool,
perform the following inspections:
1. Check the oil level. Slowly loosen the tank
filler cap. If oil comes out the bleed hole when
the filler cap is loosened, allow tank pressure
to bleed off before removing the filler cap.

install a 9S2000 Flow Meter and follow the FLOW

METER TEE TEST PROCEDURE~II to isolate
the probable leakage source.

2. Remove the filter elements and check for

presence of foreign material. A magnet wil1
separate ferrous metal material from non
ferrous metal and non-metallic sealing material
(piston rings, O-ring seals, etc.).

To adjust components located in the tank, it is

necessary to drain the tank and remove the tank
side cover.

3. Inspect all lines and connections for damage or

leaks.

If basic testing reveals internal circuit leakage,

_._llI._llllla

~ OPERATIONAL CHECKS

The operational check of the system is useful in

detecting possible internal leakage, faulty valves or
a faulty pump. The speed of cylinder operation can
be used as a check of the pump and cylinders.

Example of finding percent of flow loss ...

gpm flow lOSS)

( Pump flow @ 100 psi x 100

1. Observe cylinder extension and retraction for

erratic movement.
or

2. Listen for pump noise.

* 55)
( *57:5 x 100

Percent
of flow
loss

9.5%

If the percent of flow loss is more than 10%,

pump performance is not good enough.

Lift control lever should lock in RAISE.

*Numbers in examples are for illustration and are

not values for any specific pump or pump
condition. See SPECIFICATIONS for pump flow
of a new pump at 100 psi and 1000 psi.

Tilt control lever should lock in TILT BACK.

Test On The Machine

4. Observe bucket positioner and lift kickout

action.

Bucket positioner mechanism should return the

tilt control lever from TILT BACK to HOLD at the
pre-set position.
Lift kickout should return lift control lever from
RAISE to m:rtD at pre-set height.
Test and check adjustment of any area where
incorrect operation is evident or suspected. (See
appropriate section of LOADER SYSTEM TEST
PROCEDURES.)
When or if hydraulic circuit intemal leakage is
determined or suspected, perform pressure checks
first. If operation is still slow or sluggish install a
9S2000 Flow Meter to isolate the suspected
leakage source (See FLOW METER TEE TEST
PROCEDURE-II.)
CHECKING PUMP EFFICIENCY

For any pump test, the pump flow, measured

in gpm (liter/min) at 100 psi (690 kPa) will be
larger than the pump flow at 1000 psi (6900 kPa)
at the same rpm.

ro
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Flow loss when expressed as a percent of pump

flow is used as a measure of pump performance.

Raise, lower, tilt and tiltback the bucket several

times.

3. Listen for relief valve action. Relief valves

should not open except at full cylinder ex
tension or retraction when bucket is em pty.

tiLl

Install a 9S2000 Flow 'Meter. [See subject,

PUMP TESTS (CHART B) in FLOW METER
TEE TEST PROCEDURE II, FORM NO. REG
0080]. Measure pump flow at 100 psi (690 kPa)
and at 1000 psi (6900 kPa) with engine at 2000
rpm.
Formula I:
gpm
(

100 psi - gpm @ 1000

gpm @ 100 psi

PSi)

Percent

x 100 = of flow
loss

Test On The Bench

If the test bench can not be run at 1000 psi

(6900 kPa) at a high rpm, do the first part of the test
with the pump shaft rotation at 1000 rpm. Mea
sure pump flow at 100 psi (690 kPa) and at 1000
psi (6900 kPa). Then in order to measure the
pump flow for the last part of the test, see
SPECIFICATIONS for: Pump rpm at 100 psi
(690 kPa) with the engine at 2000 rpm.

Formula II:
(

gpm @ 100 psi - gpm @ 1000 PSi)

_ Percent
gpm @ 100 psi @ pump rpm
x 100 - of flow
loss

The difference between the pump flow of two

operating pressures is the flow loss.

LOADER SYSTEM TEST PROCEDURES

Method of finding flow loss ...

Lift and Tilt Circuit Speeds

Pump flow at 100 psi'. . 57.5 gpm (liter/min)*

-52.0 gpm (liter/min)*
Pump flow at 1000 psi.
5.5 gpm (liter/min)*
Flow loss
.

The oil must be of recommended viscosity and

at normal operating temperature to obtain accurate
test results. The speed tests are made with the
engine at high idle.

920 & 930 LOADER HYDRAULIC SYSTEM

TESTING AND ADJUSTING

The speeds in the charts are those of a machine

equipped with a general purpose bucket.
System speeds similar to the speeds given,
indicate that th e circuits are operating normally.
Ho wever, the relief valves sho uld be tested to be
certain they are set at the proper ratings.
If only the lift circuit or only the tilt circuit has
slow speeds, check the slow circuit for excessive
drifting.

APPROX.
TIME IN
SECONDS

LIFT CIRCUIT SPEED TESTS

'Raise emply bucket from ground level to lift

kickout height.

6.0

'Same as above but, with loaded bucket.

6.6

'lower empty bucket from lift kickout height to

ground level with control lever In LOWER
Position.

TEST NO.2: Raise the front of the machine off

the ground by lowering the bucket. Shut off en
gine and place the lift control lever in LOWER
position. Observe if lift cylinder rods extend.
TEST NO.3: Raise the empty bucket off the
ground. Place the lift control lever in HOLD posi- C
tion. Shut off engine and observe if the lift cyl
inder rods retract.
TEST NO.4: Raise the empty bucket off the
ground. Shut off engine and place the lift control C
lever in RAISE position. 0 bserve if the lift cy1
inder rods retract.
TEST RESULTS

PROBABLE CAUSE

Drlftin9 occurs only in Tesl

No.1

1. Lift circuit moke-up valve

Drifting occurs only In Test

No.3

1. Lift circuit moke-up volve

Drifting occurs only in Tests

No.1 and No.3

1. Lea kage between pistons

APPROX.
TIME IN
SECONDS

'Move empty bucket from full liltback to full

dump. (Lift arms at maximum heigh!).

1.2

'Some os above bUI, with loaded bucket

104

.9

'If both the liFt and nit c,rcults have extremely slow speeds, check
For pump malFunctioning. Also check the main pressure relief valve
For leakage a r low pressure setting.

Drifting occurs only in Tesls

No.2 and No.4

leaking (Ieakoge between

valve and seat and/or
sea land bodyl.

Drift measurements are the maximum permis

sible during the time interval shown for the oil
temperature in the system.

TILT CYLINDER DRIFT

Drift measurements are the maximum permis

sible during the time interval shown for the oil
temperature in the system.
LIFT CYLINDER DRIFT
Oil
100 to 1 20 F 1 20 0 to 150 F Over 150 F
Temperature (37 0 to 48 C) (48 0 to 65 C) (Over 65 0 CI

'In

",.,.

1. Lift circuit check valve

NOTE: Remember thot on O-ring seal fo;lure in the circuit can

have the some effect os a main componenr failure.

Lift Circuit Drift

Time interval
Minutes

and cylinders.
2. Leakage between lift cir
cuil control valve spool
ond body.

Tilt Circuit Drift

'Move bucket from level to full tiltbock (bucket

on the ground).

Ihead ends) leaking.

3.5

CAUTION: Set the lift kickout so the lift cylinder

piston rods stop .25 in. (6.4 mm) from end of their
strokes.

Maximum
permissible
Drift

(rod ends) lea king.

3.4

Some as above but, with control lever in FLOAT

position.

TILT CIRCUIT SPEED TESTS

TEST NO. 1: Raise the front of the machine off

the ground by lowering the bucket. Place the
lift control lever in HOLD position. Shut off the
engine and observe if lift cylinder rods extend.

in.

mm
9.7

.38

in.

mm

.38

9.7

2.7

in.

mm

.38

9.7

1.7

Oil
1 00 to 1 20 F 120 0 to 150F Over 150 F
Temperature (37 to 48 0 C) (48 to 65CI (Over 65 C)
Maximum
permissible
Drift
Time interval
Minutes

in.

mm

in.

mm

in.

mm

.62

15.8

.62

15.8

.62

15.8

2.7

1.7

TEST NO. L Raise the front of the machine off

the ground by partially dumping the bucket.
Place the tilt control lever in HOLD position.
Shut off engine and observe if the tilt cylinder
rods extend.

920 & !:UU LOADt:H HY[fH-AUlIL ~y~ I t::IVl

<TEST NO.2: Raise the front of the machine off

the ground by partially dumping the bucket.
Shut off engine and place the tilt control lever
in DUMP position. Observe if the tilt cylinder
rods extend.
TEST NO.3: Start the engine. Raise bucket off
the ground (empty with bucket bottom parallel
C to ground). Place the tilt control lever in HOLD
position. Shut off the engine and observe if tilt
cylinder rods retract.
TEST NO.4: Start the engine. Raise bucket off
the ground (empty with bucket bottom parallel
C to ground). Shut off engine and place the tilt
control lever in TILT BACK position. Observe if
tilt cylinder rods retract.
TEST RESULTS
Drifting occurs only in Test
No.1

1. TM

circuit relief valve

(rod ends) damaged ar
leaking.

1. Tilt

circuit relief valve

(head ends) damaged or
leaking.

2. Tilt circuit make-up vqlve

(head ends) leaking.

'M;.'d"

Drifting occurs only in Tests

No.1 and No.3

Drifling occurs anly in Tests

No.2 and No.4

3. Bucket pasilioner hydrau

lic circuli lea king.

1. Leakage between pistons

and cyl inders.
2. Leakage between tilt Cir
cuit valve spool and
body.
circuit check volve
leaking lIeakage between
valve and seal and/or
seat and body.).

l. Tilt

NOTE: Remember that on O-ring seal failure in the circuit can

have the some effect as a major component failure.

Multi-Purpose Bucket Circuit

Drift measurements are the maximum permis

sible during the time interval shown for the oil
temperature in the system.
1. Raise the bucket off the ground.

2. Extend the tilt cylinders fully.

(",,--,..

i'-\,j,'IIl.LJ

MU'..JU.:J' II'WU

MULTIPURPOSE BUCKET CYLINDER DRIFT

Oil
100 to 120 F ~ 20 to 150 F Over 150 F
Temperature (37 to 48 CI (48 t1:l 65 C) (Over 65 C)
Maximum
permissible
Drift
Time interval
Minutes

in.

mm

in.

mm

in.

mm

.31

7.9

.31

7.9

.31

7.9

2.7

1.7

TEST RESULTS

PROBABLE CAUSE

Drifting occurs in
Step N1:I. 3

1. Leakage between pistons and cylinders.

2. Leakage between circuit valve spool
and body.
3. Leakage In circuit check valve.
(Leakage between valve and seat
and/or seat and body).

PROBABLE CAUSE

2. Tilt circuit make-up valve

Irad endslleoking.
Drifting occurs only in Test
No.3

I Lv 1_I"U

3. Extend Multi-Purpose bucket cylinders to

position bowl approximately 1 in. (25.4 mm)
above cutting edge. Stop the engine and ob
serve if the bucket cylinder rods extend.

MAIN PRESSURE RELIEF VALVE AND

TILT CIRCUIT RELIEF VALVES
Tools required to test relief valve: 5S5123 Hy
draulic Testing Group.
The pressure at which the relief valves open
should be checked occasionally and, if necessary,
reset to insure correct operating pressure. The tank
or control valve need not be disturbed to check the
pressure setting.
If the pressures are not within the settings given,
it will be necessary to disassemble the hydraulic
tank to obtain access to the pressure adjusting
shims. Adding shims will decrease the pressure;
removing shims will increase the pressure.

A, WARNING
Use only high pressure testing equipment;
pressure can exceed 2800 psi (19280 kPa).

Before installing test equipment, place the buck

et flat on the ground. With the engine shut ofT,
move the lift and tilt control levers to all positions
to relieve pressure in the hydraulic lines. Return
the control levers to the HOLD position.
Main Pressure Relief Valve

Remove the pressure tap plug (1) and install the

oil pressure test gauge. The test equipment to use
from the 585123 Hydraulic Testing Group is:
788714 Gauge (0 to 4000 psi), 584648 Hose
Assembly and the fittings necessary to connect the
test gauge in the head end pressure tap.
Remove the floor plates. Install test equipment
in the lift circuit line (head ends) .

II

'.

920 & 930 LOADER HYDRAULIC SYSTEM

TESTING AND ADJUSTING

3G2315 MAIN RELIEF VALVE

Tilt Circuit Relief Valve (Head Ends)

LIFT CYLINDER HEAD END PRESSURE TAP
(Located under the loader framel
1. Pressure tap plug.

Start the engine and raise the bucket until the

lift cylinders are at the end of their strokes. With
engine speed at high idle, hold the lift control
lever in the RAISE position. The pressure read
ing on the gauge should be within 2500 2512Si
(17250 170 kPa).

"'l.

TILT CYLINDER HEAD END PRESSURE TAP

.... ,..it!

4. Pressure tap plug:

Remove the head end pressure tap plug (4) and

install the oil pressure test gauge. Test equipment
to use from the 5S5123 Hydraulic Testing Group:

T96145-A

5J9113 MAIN RELIEF VALVE

2. SF 1974 Shims.

3. Plug, shim and spring retainer.

LOWERING THE LIFT ARMS

Torque for plug (3) is 60 2 lb. ft. (80 3 Nm).

PRESSURE CHANGE BY REMOVAL OR ADDITION

OF ONE 8F1974 SHIM

VALVE NO.

SHIM THICKNESS

CHANGE IN psi

5J9113

.005 In. (0.13 mm)

35 psi (240 kPa)

PRESSURE CHANGE FOR 3G2315 VALVE

One turn of adjustment screw.

840 psi (5805 kPa}

5. Bucket (back against blocks).

6. Blocks.

7S8714 Gauge (0 to 4000 psi) (0 to 27500 kPa),

5S4648 Hose Assembly and the fittings neces
sary to connect the test gauge in the head end
pressure tap.
Start the engine. Raise the bucket so lift arms
are horizontal. Tilt bucket (5) back against blocks
(6) to build up pressure in the rod ends of the
tilt cylinders. Return the tilt control lever to
HOLD position.

]2

With the engine speed at high idle, lower the

lift arms. Observe the pressure reading on the
gauge as the tilt cylinder rods are pushed into
their cylinders. The reading should be within
2800 25 psi (19280 170 kPa).

fl ;g4

With engine speed at high idle, place the lift

control lever in RAISE position and observe the
pressure reading on the gauge as the tilt rods are
pulled from the cylinders. The pressure reading
should be within 2800 25 psi (19280 170 kPa).
If it is necessary to correct the rod end relief
pressure, either increase or decrease the shim
thickness in the 5J9106 Relief Valve in the rod end
circuit. The other 5J9106 Relief Valve is in the
head end circuit. See the chart in topic TILT CIR
CUIT RELIEF VALVE (HEAD ENDS) for the
change in relief pressure with either the addition
or removal of shims.

5
T961.:j-A

5J9106 RELIEF VALvE

7. 5J9100 Shims. 8. Plug. shim and spring retainer.
Tighten to 100 5 lb. ft. (135 7 Nm).

PRESSURE CHANGE TO 5J9106VALVE BY REMOVAL

OR ADDITION OF ONE SHIM

SHIM NO.

SHIM THICKNESS

CHANGE IN psi

5J9100

.005 in. (0.13 mm I

29 psi (200 kPa}

.010 in. (0.25 mm)

58 psi (400 kPa)

5J9101
~

'""",

10

x 169?

RAISING LIFT ARM

5. Bucket (in full dump position with tilt levers against
stops on lift arms). 9. Tilt cylinder rod end pressure
tap. 10. Lift arm in horizontal position.

..

Tilt Circuit Relief Valve (Rod Ends)

Remove the rod end pressure tap plug (9) and
install the 788714 Gauge.

LIFT KICKOUT
The lift kickout system should stop the bucket
lift before the lift cylinder rods fully extend.
The initial lift kickout adjustment is made on
the slave cylinder with the bucket on the ground
and the engine stopped.

TILT CYLINDER ROD END PRESSURE TAP

(Located under the tilt cylinderl.
tap plug.

9. Rod end pressure

Start the engine and position the lift ann hori

zontal to the ground. Fully dump the bucket (tilt
levers contact stops on the lift anns) and place the
tilt control lever in HOLD position.

LIFT KICKOUT SYSTEM SLAVE CYLINDER

(Operator's seat has been removed)
1. Control laver. 2. Lift kickout sieve cylinder. 3. Bolt. 4.
Locknut. A. Initial dimension .09 in. (2.29 mml. Minimum
dimension .02 in. (0.51 mm).

13

920 & 930 LOADER HYDRAULIC SYSTEM

1. Remove the seat cushion and place the hand

lift control in the RAISE detent position.
2. Adjust the length of bolt (3) to obtain an
initial dimension (A) of .09 in. (2.29 mm)
between the head of the bolt and control lever

TESTING AND ADJUSTING.

Place the control lever in the TILT BACK

position. Raise the operator's seat and turn the
TILT BACK position lever stop bolt out enough to
prevent the linkage from going into the TILT
BACK detent.

(1 ).

3. Start the engine and raise the bucket until the

lift cylinder rod is .25 in. (6.35 mm) less than
full lift.

4. Stop the engine. Move the hand lift control

into the RAISE detent position. Extend the
length of bolt (3) until it moves control lever
(1) out of the RAISE detent. Tighten lock
nut (4).
5. Start the engine and cycle the lift system.
When the hand lift control is in the RAISE
detent position the minimum dimension be
tween the head of bolt (3) and control lever
(1) is .02 in. (0.51 mm).

BUCKET POSITION INDICATOR

AND POSITIONER
Bucket Position Indicator
The bucket position indicator has two verticle
positioned strips, one mounted on the tilt cylinder
and the other actuated by the movement of the
tilt cylinder rod.
The adjustment is made with the bucket on the
ground and positioned at the desired digging angle.
Align the adjustable strip (l) with strip (2) on the
tilt cylinder.
If the 920 Wheel Loader is not equipped with a
hydraulic bucket positioner, it is necessary to make
an adjustment in the tiltback control linkage.

Bucket Positioner
The bucket positioner will automatically move
the hand tilt control from the TILT BACK detent
position to HOLD when the bucket moves to the
preset digging angle.
The initial bucket positioner adjustments are
made with the bucket on the ground and positioned
at the desired digging angle with the engine
stopped.
1. Loosen cam (4) and move it out from under
roller (5).
2. Remove the seat cushion and place the hand
tilt control in the TILT BACK detent posi
tion.
"....
3. Adjust the length of bolt (8) to obtain an
initial dimension of .09 in. (2.29 mm) between
the head of the bolt and lever (6).
NOTE: Make certain the bolt is fully retracted in
the slave cylinder when this adjustment is made.

---..
-

~
- ~

...

.......... ~

BUCKET POSITION INDICATOR AND

POSITIONER ACTUATOR

1. Adjustable strip.

2. Strip on the tilt cylinder. 3.

Bucket positioner hydraulic master cylinder. 4. Cam.

5. Roller.

14

,.... .
of

".I

.
i<

.,

BUCKET POSITIONER SYSTEM SLAVE CYLINDER

(Operator's seat has baen removed)
6. Lever. 7. Slave cylinder. 8. Bolt. 9. Locknut. A.
Initial dimension .09 in. (2.29 mml. Minimum dimension .02
in. (0.51 mm).

/,,,",,~-

920 & 930 LOADER HYDRAULIC SYSTEM

1. Remove the seat cushion and place the hand

lift control in the RAISE detent position.
2. Adjust the length of bolt (3) to obtain an
initial dimension (A) of .09 in. (2.29 mm)
between the head of the bolt and control lever

TESTING AND ADJUSTING,

Place the control lever in the TILT BACK

position. Raise the operator's seat and turn the
TILT BACK position lever stop bolt out enough to
prevent the linkage from going into the TILT
BACK detent.

(1 ).

3. Start the engine and raise the bucket until the

lift cylinder rod is .25 in. (6.35 mm) less than
full lift.
4. Stop the engine. Move the hand lift control
into the RAISE detent position. Extend the
length of bolt (3) until it moves control lever
(l) out of the RAISE detent. Tighten lock
nut (4).
5. Start the engine and cycle the lift system.
When the hand lift control is in the RAISE
detent position the minimum dimension be
tween the head of bolt (3) and control lever
(1) is .02 in. (0.51 mm).

BUCKET POSITION INDICATOR

AND POSITIONER
Bucket Position Indicator
The bucket position indicator has two verticle
positioned strips, one mounted on the tilt cylinder
and the other actuated by the movement of the
tilt cylinder rod.
The adjustment is made with the bucket on the
ground and positioned at the desired digging angle.
Align the adjustable strip (l) with strip (2) on the
tilt cylinder.
If the 920 Wheel Loader is not equipped with a
hydraulic bucket positioner, it is necessary to make
an adjustment in the tiltback control linkage.

BUCKET POSITION INDICATOR AND

POSITIONER ACTUATOR

1. Adjustable strip.

2. Strip on the tilt cylinder. 3.

Bucket positioner hydraulic master cylinder. 4. Cam.
5. Roller.

14

Bucket Positioner
The bucket positioner will automatically move
the hand tilt control from the TILT BACK detent
position to HOLD when the bucket moves to the
preset digging angle.
The initial bucket positioner adjustments are
made with the bucket on the ground and positioned
at the desired digging angle with the engine
stopped.
1. Loosen cam (4) and move it out from under
roller (5).
2. Remove the seat cushion and place the hand
tilt control in the TILT BACK detent posi
ti~.

3. Adjust the length of bolt (8) to obtain an

initial dimension of .09 in. (2.29 mm) between
the head of the bolt and lever (6).
NOTE: Make certain the bolt is fully retracted in
the slave cylinder when this adjustment is made.

BUCKET POSITIONER SYSTEM SLAVE CYLINDER

(Operator's seat has been removed}
6. Lever. 7. Slave cylinder. 6. Bolt. 9. Locknut. A.
Initial dimension .09 in. (2.29 mm). Minimum dimension .02
in. (0.51 mml.

I,'~':'"~'

;:

ULU U

UUU LU,",ULII I I I UII,",UL,I\, J

I J I LIVI

I~.':> III\I~ ~IIIU ~U.JU;:'

IIIII\.:>

CONTROL LEVER EFFORT

To check the effort needed to pull the lift and

tilt control levers out of the RAISE and TILT
BACK detent positions, a spring scale is needed.

1. Put the lift and tilt control levers in the

RAISE and TILT BACK positions.
2, Disconnect the linkage from the levers at the

hydraulic tank.

-+@

:J

BUCKET POSITIONER CAM ADJUSTMENT

4. Cam, 5. Roller. B. Camtoroller contact maximum

dimension .24 in. (6.1 mml. C. Direction to move cam to
reduce bucket digging angle. D. Direction to move cam
(toward bucket) to increase digging angle.

3. Put a spring scale in the linkage hole in the

levers. The effort needed to pull the levers out
of the RAISE and TILT BACK detent posi
tions is 36 8 lb. (170 36 N).
4. If it is necessary to change the effort needed
to pull the levers back to the HOLD positions,
add 6J6516 Shims to the de tents in the
control valve to increase or remove shims from
the detents to decrease the effort.

4. Move cam (4) under roller (5) un til the

cam-to-roller contact is less than .24 in. (6.1
mm) from the highest edge of the cam.
Tighten the cam in this location.
5. Extend bolt (8) until it moves lever (6) and
the hand tilt control from the TILT BACK
detent to HOLD. Tighten locknut (9).
6. Start the engine and cycle the tilt system.
When th"e hand tilt control is in the TILT
BACK detent position, the minimum di
mension between the head of bolt (8) and
lever (9) is .02 in. (0.51 mm).

15

"\

--

FILTER

~-

L.!J

I~
-

----------

(
I

(,
L_~_.

~.

.,

l
NAME

NO.
1.

CYLINDER RELIEF VALVES

2.

CONTROL VALVE FOR

3.

RELIEF VALVE

'0

MAKE-UP VALVES FOR

5.

ATTACHMENT CONTROL VALVE

6.

TILT CYLINDERS

7 0

MULTIPURPOSE CYLINDERS

.0

FOR MAIN PRESSURE

Ll FT AND TI L T

LiFT CYLINDERS

9.

STEERING CONTROL VALVE

10.

STFERING CYLINDERS

".

"cD

LIFT AND TILT

COOLER

(ATTACHMENT)

12.

HyDRAULIC PUMP

13.

FILTER

1'.

HAND METERING PUMP

15.

OIL SCREEN

1<,.

DIVEHTt::::H VALVE

17.

SUPPLEMENTAL STEERING PUMP

lB.

l O l L SCREEN

PRESSURE TAPS

iMPLEMENT TEE TEST

ROO END PRESSURE IN TILT CIRCUIT

HEAD END PRESSURE IN TILT CIRCUIT

SYSTEM PRESSURE

STEERING TEE TEST

;.

>

17

45369X2