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i02024929
Required Tools
Part Number Description Quantity
1U-5796 Pressure Differential Gauge (Group) 2
6V-7830 Pressure Gauge 2
This test is used primarily in order to identify problems in the steering hydraulic circuit. The test can
identify some problems in the circuit for an implement.
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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.
1. Move the machine to a clear area that is level. Lower the implements to the ground. Stop the
engine.
Illustration 1 g00690742
The steering motor is located under the floorplates in the operator's station.
Illustration 2 g00799911
The pressure taps for the steering pilot valve are located below the left console.
2. Remove the floorplate. Install 177-7861 Hoses on pressure taps (A), (B), (J), and (K) .
3. Connect the other ends of the hoses from pressure taps (A) and (B) to two 8T-0861 Pressure
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Gauges .
4. Connect the other ends of the hoses from pressure taps (J) and (K) to two 0 to 4000 kPa (0 to 580
psi) tetragauges.
Note: If only two hoses and gauges are available, install the hoses on pressure taps (A) and (K).
Then, install the hoses on pressure taps (B) and (J) .
6. Place the main display in the operator station in Service Mode of operation in order to monitor the
engine rpm.
7. Start the engine. Operate the engine at HIGH IDLE. The reading should be 2240 40 rpm. Refer
to the Engine Information Plate or refer to the Fuel Settings and Related Information Microfiche.
8. Fully engage the parking brake. Place all controls in the HOLD position. With the engine at HIGH
IDLE, record the pressures on the gauges at pressure taps (A), (B), (J), and (K). The readings on
pressure gauges (J) and (K) should be below 200 kPa (30 psi). If either of the pressures is higher
than 200 kPa (30 psi), the steering pump could be trying to steer in one direction. Check these
possible causes:
9. The reading on pressure gauges at pressure taps (A) and (B) should be 2500 300 kPa (365 45
psi). If the pressures on the gauges at pressure taps (A) and (B) are too high, then the charge
pressure relief valve is improperly adjusted or suspect or the oil temperature is too low. If the
pressures are too low, then check for a problem in the steering charge circuit. Check these possible
causes:
{ The steering pump is worn. Do a pump load test in order to make sure.
10. Release the parking brakes. Fully activate the service brakes. The transmission speed control must
be in the NEUTRAL position. The transmission direction control handle must be in the
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11. With the engine at HIGH IDLE, slowly move the steering control lever to the MAXIMUM
STEER RIGHT position. The steering system is in the STEER STALL CONDITION. Do not
hold the machine in a STEER STALL CONDITION for more than 20 seconds at a time.
Note: The machine must not move. If the machine moves, check the brake system.
12. With the machine in a STEER STALL CONDITION, record pressures (B) and (K). Also record
the engine speed and record the hydraulic oil temperature. Compare the measured pressure with
the pressure in Table 2 below. Use the pressure that is closest to the oil temperature that was
measured. Warm up the oil or allow the oil to cool until the oil more closely matches the values in
Table 2. Repeat the test.
13. Repeat Steps 11 and 12 for a MAXIMUM STEER LEFT condition and record pressures (A) and
(J) .
14. If the measured pressures (A) and (B) match the values in Table 2, the pump is developing the
specified pressure.
Table 2
2240 rpm 40000 1050 kPa (5800 150 psi) 39500 1050 kPa (5730 150 psi)
Note: The above test conditions must be matched as closely as possible. Temperatures or speeds
that are lower than Table 2 may result in higher pressures.
15. If pressures (A) and (B) are not in agreement with Table 2, measure pressures (J) and (K). If
pressures (J) and (K) are not in agreement with the specifications, refer to the topic "Tests and
Adjustments (Steering Pilot Valve)".
If pressures (A) and (B) are higher than the values in Table 2, the pump cutoff pressure needs to
be lowered.
Note: If the pressure cutoff setting can not be lowered, the steering pump or the pressure and flow
compensator valve has failed.
If pressures (A) and/or (B) are lower than the values in Table 2, check these possible causes:
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{ The motor flushing valve is stuck or the valve is not functioning properly.
{ The steering pump is worn or leaking. Do a pump load test in order to make sure.
16. If the engine speed drops more than 30 rpm from HIGH IDLE in one direction or in both
directions during Steps 11 through 13, the corresponding crossover relief/makeup valves may be
leaking or set too low.
Required Tools
Part Number Description Quantity
1U-5796 Pressure Differential Gauge (Group) 1
6V-7830 Pressure Gauge 1
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.
1. Move the machine to a clear area that is level. Lower the implements to the ground. Stop the
engine.
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Illustration 3 g00773866
Pressure control valve
(C) Pressure tap for the discharge line on the charge pump
2. Remove the floorplate. Install one 177-7861 Hose on pressure tap (C) .
3. Connect the other end of the hose to the 0 to 4000 kPa (0 to 580 psi) tetragauge.
5. Start the engine. Operate the engine at HIGH IDLE. With all controls in the NEUTRAL position,
record the pressure at pressure tap (C) .
6. The pressure at pressure tap (C) should be 2500 300 kPa (365 45 psi).
7. If the charge pressure is higher than the specified pressures, then the charge pressure relief valve
could be worn or out of adjustment.
8. If the pressure on the gauge for pressure tap (C) is lower than 2500 300 kPa (365 45 psi)
during a NEUTRAL STEER CONDITION, check these possible causes:
{ The steering pump is worn. Do a pump load test in order to make sure.
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Illustration 4 g00801365
Steering pump
(E) Pressure tap for the signal pressure of the Left Steer position
9. If the charge pressure is correct, check the steering charge circuit. Run the following test. Operate
the engine at HIGH IDLE. Release the parking brakes. Fully activate the service brakes. The
transmission speed control must be in the NEUTRAL position. The transmission direction control
handle must be in the NEUTRAL position. Move the steering lever slowly to the MAXIMUM
STEER LEFT position. Do not hold the machine in a STEER STALL CONDITION for more than
20 seconds at a time.
Note: The machine must not move. If the machine moves, check the brake system.
10. Record the pressure on the gauge for pressure tap (E). If the pressure on the gauge for pressure tap
(E) is lower than 2500 300 kPa (365 45 psi), check these possible causes:
{ The motor flushing valve is stuck open or the valve is leaking excessively.
{ The steering pump is worn. Do a pump load test in order to make sure.
{ The makeup valve is not functioning properly or the valve is set too low.
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Illustration 5 g00491987
Steering pump port plate (front view)
(1) Locknut
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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.
2. Loosen locknut (1) (17 mm (0.67 inch)). Turn adjustment screw (2) (5 mm allen head screw)
clockwise in order to increase the pressure setting or turn the screw counterclockwise in order to
decrease the pressure setting.
Required Tools
Part Number Description Quantity
1U-5796 Pressure Differential Gauge (Group) 2
6V-7830 Pressure Gauge 2
Always move the machine to a location away from the travel of other
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machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
NOTICE
To avoid system damage, make sure that the hydraulic pump is
properly filled with hydraulic oil before start-up.
1. Move the machine to a clear area that is level. Lower the implements to the ground. Stop the
engine.
2. Remove the floorplate. Install 177-7861 Hoses on pressure taps (A) and (B) .
Illustration 6 g00690742
(1) Steering motor
3. Connect the other ends of the hoses from pressure taps (A) and (B) to two 8T-0861 Pressure
Gauges .
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Illustration 7 g00762449
Steering Pump
(E) Pressure tap for the signal pressure for the Left Steer position
(F) Pressure tap for the signal pressure for the Right Steer position
4. Connect one end of a 177-7861 Hose to pressure tap (E). Attach the other end to pressure tap (F)
in order to ensure equal oil pressure on each side of the control.
5. Place the main display in the operator station in Service Mode of operation in order to monitor the
engine rpm.
7. Look at the pressure gauges. Both readings should be the same pressure. The readings should be
equal to the charge pressure.
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Illustration 8 g00492025
Steering Pump Control
(2) Locknut
8. If the pressures are not equal, adjust the neutral position of the pump control. Loosen locknut (2).
Use a hex wrench to turn adjustment screw (1). Turn the screw clockwise or turn the screw
counterclockwise in order to achieve the required spool movement. The pressures on the gauges
should change. Adjust screw (1) until the pressures are equal.
9. Stop the engine. Remove the two 8T-0861 Pressure Gauges and replace the gauges with two 4000
kPa (580 psi) tetragauges.
11. Tighten locknut (2). Remove the pressure gauges, hoses and connectors from pressure taps (A)
and (B). Remove the hose from pressure taps (E) and (F) .
Required Tools
Part Number Description Quantity
1U-5796 Pressure Differential Gauge (Group) 2
6V-7830 Pressure Gauge 2
Do the "Checking and Adjusting Charge Pump Pressure" before doing the test. Also, do the "Mechanical
Adjustment of the Steering Pump Control" before doing the test. This ensures that the mechanical
neutral position of the swashplate is correct.
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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.
1. Move the machine to a clear area that is level. Lower the implements to the ground. Stop the
engine.
2. Remove the floorplate. Install 177-7861 Hoses on pressure taps (A) and (B) .
Illustration 9 g00690742
(1) Steering motor
3. Connect the other ends of the hoses from pressure taps (A) and (B) to two 8T-0861 Pressure
Gauges .
4. Install 177-7861 Hoses on pressure taps (E) and (F). Connect the other ends of the hoses from
pressure taps (E) and (F) to two 0 to 4000 kPa (0 to 580 psi) tetragauges.
5. Place the main display in the operator station in Service Mode of operation in order to monitor the
engine rpm.
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Illustration 10 g00799732
Steering Pump
(3) Locknut
(E) Pressure tap for the signal pressure for the Left Steer position
(F) Pressure tap for the signal pressure for the Right Steer position
7. Look at the pressure gauges that are connected to pressure taps (A) and (B). The readings should
be equal. The pressures should be equal to the charge pressure.
8. Look at the pressure gauges that are connected to pressure taps (E) and (F). Both readings should
be within 345 kPa (50 psi) of each other.
9. If the readings are not within 345 kPa (50 psi), the control valve must be adjusted.
Note: Adjustment screw (2) is an eccentric adjuster. One-half revolution of the screw is the
maximum adjustment. A small amount of movement of screw (2) makes a large pressure
difference.
10. Loosen locknut (3). Turn screw (2) until the pressure gauges have equal readings. Tighten the
locknut.
11. If the control valve can not be adjusted, the control valve must be repaired or replaced.
12. After all tests, adjustments and any needed repairs are completed, remove all test equipment.
Required Tools
Part Number Description Quantity
1U-5796 Pressure Differential Gauge (Group) 2
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Note: Test the steering pump pressure and test the steering pilot pressure before running this test. See
the topic "Diagnostic Instrument Tests of the Steering Hydraulic System".
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.
1. Move the machine to a clear area that is level. Lower the implements to the ground. Stop the
engine.
2. Remove the floorplate. Install 177-7861 Hoses on pressure taps (A) and (B) .
Illustration 11 g00690742
(1) Steering motor
3. Connect the other ends of the hoses from pressure taps (A) and (B) to two 8T-0861 Pressure
Gauges .
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5. Place the main display in the operator station in Service Mode of operation in order to monitor the
engine rpm.
6. Start the engine. Record the rpm. The reading should be 2240 40 rpm.
7. Release the parking brakes. Fully activate the service brakes. The transmission speed control must
be in the NEUTRAL position. The transmission direction control handle must be in the
NEUTRAL position.
8. With the engine at HIGH IDLE, slowly move the steering control lever to the MAXIMUM
STEER RIGHT position. The maximum position puts the steering system in a STEER STALL
CONDITION. Do not hold the machine in a STEER STALL CONDITION for more than 20
seconds at a time.
Note: The machine must not move. If the machine moves, check the brake system.
9. With the machine in a STEER STALL CONDITION, record pressure (B), engine speed and
hydraulic oil temperature. Compare pressure (B) with the pressure in Table 7 that is closest to the
oil temperature in your test. Warm up the oil or allow the oil to cool until the temperature matches
the values in Table 7. Repeat the test.
10. Repeat Steps 8 and 9 in a MAXIMUM STEER LEFT condition. Record pressure (A) .
11. If pressures (A) and (B) during Steps 9 and 10 have the values in Table 7, the pump cutoff valve is
correctly set.
Table 7
2240 rpm
40000 700 kPa (5800 150 psi) 39500 700 kPa (5730 150 psi)
Note: The above test conditions must be matched as closely as possible. Temperatures and speeds
below the specifications may result in pressures higher than the values in Table 7.
12. If one pressure (A) or (B) is low and the other pressure is correct, the problem is probably with the
crossover relief/makeup valve for the side with the low pressure. If pressures (A) and (B) are
higher than the values in Table 7, the pump cutoff pressure needs to be lowered.
If pressures (A) and (B) are lower than the values in Table 7, check these possible causes:
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g. The crossover relief/makeup valves are set too low or the valves are malfunctioning.
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Illustration 12 g00492151
Steering pump port plate (front view)
(1) Locknut
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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.
2. Loosen locknut (1). Turn adjustment screw (2) clockwise in order to increase the pressure setting
or turn the screw counterclockwise in order to decrease the pressure setting.
Required Tools
Part Number Description Quantity
9U-5829 Manifold 1
Note: The crossover relief/makeup valves should not be adjusted on the machine. The test suggests a
procedure to isolate a malfunctioning crossover relief/makeup valve. Also, the test provides instructions
for the bench test of the valve and instructions for the adjustment of the valve.
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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.
Machine Test
1. Move the machine to a clear area that is level. Lower the implements to the ground. Stop the
engine.
2. Place the main display in the operator station in Service Mode of operation in order to monitor the
engine rpm.
3. Start the engine. Operate the engine at HIGH IDLE. The engine speed should be 2240 40 rpm.
4. Place the main display in the operator station in Service Mode of operation in order to monitor the
engine rpm.
5. Release the parking brakes. Fully activate the service brakes. The transmission speed control must
be in the NEUTRAL position. The transmission direction control handle must be in the
NEUTRAL position. Record the engine speed.
6. With the engine at HIGH IDLE, slowly move the steering control lever to the MAXIMUM
STEER RIGHT position. This position puts the steering system in a STEER STALL
CONDITION. Record the engine speed. Do not hold the machine in STEER STALL
CONDITION for more than 20 seconds at a time.
8. If the engine speed drops more than 30 rpm from HIGH IDLE in one direction or both directions
during Steps 6 and 7, the corresponding crossover relief/makeup valves may be leaking or set too
low.
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Illustration 13 g00492154
Steering pump port plate (front view)
Bench Test
The crossover relief/makeup valve has a setting that is higher than the pump cutoff pressure. The valve
cannot be adjusted on the machine. Use the 9U-5829 Manifold to test the crossover relief/makeup valve
on the test bench. The setting for the valve is 45000 500 kPa (6525 75 psi) under the following
conditions:
z 65C (150F)
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Required Tools
Part Number Description Quantity
6V-7830 Pressure Gauge 1
Illustration 14 g00773870
Pressure control valve
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.
1. Move the machine to a clear area that is level. Lower the implements to the ground. Stop the
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engine.
3. Connect the other ends of the hose from pressure tap (D) to a 0 to 1400 kPa (0 to 200 psi)
tetragauge.
6. The gauge reading must be less than 175 kPa (25 psi).
7. If the gauge reading is more than 175 kPa (25 psi), check the hose from the pressure control valve
to the tank for a blockage.
8. Stop the engine. After all tests, adjustments and any needed repairs are completed, remove all test
equipment.
Required Tools
Part Number Description Quantity
6V-7830 Pressure Gauge 1
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Illustration 15 g00492423
Pilot valve
(1) Lever
(2) Hole
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(3) Locknut
(4) Bolt
(5) Plunger
(6) Locknut
(7) Sleeve
Note: If the pilot valve has unequal pressure right to left or unequal steering turn diameter, complete the
following tests:
Illustration 16 g00492426
(1) Lever
(2) Hole
(9) Hole
(10) Housing
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(11) Bolt
(12) Roller
2. Insert a pin of 3.2 mm (0.125 inch) diameter through hole (2) and through hole (9). If the pin does
not go through both holes, adjustment of the alignment is required.
3. If the pin goes through both holes (2) and (9), remove the pin. Release the parking brake, and
insert the pin through holes (2) and (9) again. Do not move the tiller in order to align the holes. If
the pin goes through both holes the alignment of the valve is correct and no further adjustment is
needed. If the pin does not go through both holes, adjustment of the alignment is required.
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.
4. If an adjustment is required, engage the parking brake and disconnect all hydraulic lines to the
pilot valve.
5. Loosen two bolts (11) that hold the pilot valve to mounting plate (8) .
6. Install a pin of 3.2 mm (0.125 inch) diameter into hole (2) in lever (1) and into hole (9) in housing
(10) .
7. Line up the pilot valve so that roller (12) is at the bottom of lever (1) and there is no preload on
either plunger (5). Tighten mounting bolts (11) and remove the pin.
8. Check the adjustment by releasing the parking brake and reinserting the pin through holes (2) and
(9). Do not move the tiller in order to align the holes. If the pin goes through both holes the
alignment of the valve is correct and no further adjustment is needed. If the pin does not go
through both holes, the alignment is not correct and the adjustment should be repeated.
Note: The pilot valve may move if the transmission control cables are too tight or misadjusted.
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10. Connect the hydraulic lines. Start the engine. Remove the air in the pilot circuit.
Actuator Adjustment
1. Shut off the engine. Engage the parking brake. Remove the boot or pull up the boot in order to
allow access to locknut (3) .
2. Loosen two locknuts (3) and adjust two bolts (4) inward until a gap exists between bolts (4) and
plungers (5) on both sides of the valve.
3. Adjust bolts (4) outward in order to remove all free play between bolts (4) and plungers (5). Do
not preload plunger (5) .
Pressure Adjustment
Note: Check the charge pressure before making any adjustments to the pilot pressure.
1. Shut off the engine. Engage the parking brake. Remove the boot or pull up the boot in order to
allow access to locknuts (6) .
Illustration 17 g00799911
The pressure taps for the steering pilot valve are located below the left console.
2. Install a 6V-3081 Hose with a 0 to 4000 kPa (0 to 580 psi) tetragauge on pressure taps (J) and
(K) .
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Illustration 18 g00492486
Angle measurement guide
Illustration 19 g00765773
3. Make a copy of the angle measurement guide. See Illustration 18. With the parking brake
ENGAGED, tape the portion of the guide with the letters to the housing of the tiller. See
Illustration 19. The arrow that corresponds with the letter (N) should be in line with the center of
the stud, as shown. Mark the edge of the tiller so that the mark is aligned with the arrow that
corresponds with the letter (N) .
4. Start and run the engine at LOW IDLE. Read the pressure on the two gauges. The correct pressure
range is between 0 and 200 kPa (0 to 30 psi). If the pressure is greater than 200 kPa (30 psi) on
either gauge, loosen locknut (6) for the side with the high pressure reading. Loosen sleeve (7)
until the pressure on the gauge is less than 200 kPa (30 psi).
5. If the pressure on either gauge reads 0 kPa (0 psi), loosen locknut (6) for the side with no pressure
reading. Tighten sleeve (7) until the pressure is between 0 and 200 kPa (0 and 30 psi).
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7. Place the transmission in NEUTRAL. Firmly depress the service brake pedal and release the
parking brake. The pressure readings on the gauges should not change. If the pressures change, the
pilot valve needs to be aligned.
8. While the service brake pedal is depressed, use the angle measurement guide to shift the tiller so
that positions (A), (B), and (C) in both STEER LEFT and STEER RIGHT are aligned with the
mark on the end of the stud. Note the pressure on each gauge in each position and compare the
pressures to the pressures in Table 11.
Table 11
Pilot Pressure
Position of Tiller J K
(A)
STEER LEFT 745 100 kPa (108 15 psi) 0 to 200 kPa (0 to 29 psi)
(B)
STEER LEFT 1200 170 kPa (174 25 psi) 0 to 200 kPa (0 to 29 psi)
(C)
STEER LEFT 2060 240 kPa (300 35 psi) 0 to 200 kPa (0 to 29 psi)
(A)
STEER RIGHT 0 to 200 kPa (0 to 29 psi) 745 100 kPa (108 15 psi)
(B)
STEER RIGHT 0 to 200 kPa (0 to 29 psi) 1200 170 kPa (174 25 psi)
(C)
STEER RIGHT 0 to 200 kPa (0 to 29 psi) 2060 240 kPa (300 35 psi)
9. If the pressures are low in both directions, increase the engine speed. If the pressures increase,
check for problems in the charge loop.
10. If the pressure is low in one direction only, the pilot valve may be dirty or worn. Check for debris
or for damage in the pilot valve.
Copyright 1993, 2004 Caterpillar Inc. Wed May 26 10:22:01 UTC-0300 2004
All Rights Reserved.
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