Systems Operation Testing and Adjusting: TH220B, TH330B, TH360B, TH560B and TH580B Telehandlers Steering System

31200273 December 15, 2006
Systems Operation Testing and Adjusting

TH220B, TH330B, TH360B, TH560B and TH580B Telehandlers Steering System
S/N TBF00100 & After S/N TBG00100 & After S/N TBH00100 & After S/N TBP00100 & After S/N TBJ00100 & After
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. 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 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. 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. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. 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. Caterpillar dealers have the most current information available.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
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Table of
Table of Contents Systems Operation Section
1 Table of Contents
Graphic Color Codes ............................... 3 General Information................................. 4 Steering Arrangement ......................... 4 Introduction.............................................. 6 Location of Electrical Components .......... 7 Selector Switch for the Steering Mode 7 Position Sensors ................................. 7 Electronic Control Module ................... 8 Solenoid for Crab Steer....................... 8 Solenoid for Circle Steer ..................... 8 Relay (Crab Steer) .............................. 8 Relay (Circle Steer) ............................. 9 Location of Hydraulic Components.......... 9 Steering Wheel.................................... 9 Metering Pump .................................. 10 Piston Pump ...................................... 10 Line for the Signal Limiter Valve for the Steering ............................................. 10 Priority Valve ..................................... 10 Control Valve (Steering) .................... 11 Steering Cylinders ............................. 11 Hydraulic Tank .................................. 11 Hydraulic Tank Breather.................... 11 Hydraulic Oil Level Indicator.............. 12 Hydraulic Oil Drain Plugs .................. 12 Electrical Input Components.................. 12 Steering Mode Switch ....................... 12 Position Sensor ................................. 13 Electronic Control Module ..................... 13 Electrical Output Components............... 14 Relays ............................................... 14 Instrument Cluster ............................. 14 Data Link ............................................... 14 CAT Data Link ................................... 14 CAN Data Link................................... 15 Electrical Schematic .............................. 15 Inlet Manifold ......................................... 15 Steering Priority Valve....................... 16 Screens (75 and 100 Micron) ............ 16 Flow Control Valve (Dump valve for the load sensing oil) ................................ 16 Relief Valve (Load sensing oil).......... 16 Check Valve ...................................... 16 Steering Not Activated....................... 17 Steering Activated ............................. 18 Steering System .................................... 19 Steering Control System ................... 19 Steering in Neutral............................. 20
Right Turn in Two-Wheel Steer Mode22 Left Turn in Circle Steer Mode........... 24 Left Turn in Crab Steer Mode ............ 26 Hydraulic Schematic (Steering System). 28 Piston Pump (Implement and Steering) . 29 Piston Pump ...................................... 29 Compensator Valve ........................... 30 Low Pressure Standby....................... 31 Upstroke ............................................ 32 Constant Flow.................................... 33 Destroke ............................................ 34 High Pressure Stall ............................ 36 Solenoid Valve (Steering Mode Selector)................................................. 37 Solenoid Valve................................... 37 Metering Pump (Steering) ...................... 37 Hold ................................................... 39 Right Turn .......................................... 40 Position Sensor (Steering) ..................... 42 Configuration Parameters ...................... 43
Testing and Adjusting Section
Hydraulic Oil Contamination -Test ......... 45 Hydraulic Oil Contamination .............. 45 Flushing the Sampling Valve ............. 45 Obtaining the Sample ........................ 45 Pump Flow - Test ................................... 46 Pump Flow......................................... 46 Test On The Machine ........................ 46 Test On The Bench............................ 47 Steering System Pressures -Test and Adjust ..................................................... 47 Steering System Pressure Tests and Adjustments ....................................... 47 Steering Pressure Test ...................... 48 Steering Pressure Adjustment ........... 48 Margin Pressure Test ........................ 49 Margin Pressure Adjustment ............. 50 Test for the Relief Valve (Load Sensing Oil) ..................................................... 50 Adjustment of the Relief Valve (Load Sensing Oil) ....................................... 51 Test for Pressure Compensator......... 51 Pressure Compensator Adjustment... 52 Low Pressure Standby Test............... 52 Low Pressure Standby Adjustment.... 53 Steering System - Purge ........................ 54 Purging the Steering System ............. 54 Solenoid Valve (Steering Mode Selector) Test ........................................................ 54
2 Table of Contents
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The Solenoid's for the Steering Modes ................................................54 Position Sensor (Steering) -Adjust .........55 Position Sensor ..................................55 Wheel Alignment - Check and Adjust.....57 Checking the Wheel Alignment With Wheels In Place .................................58 Adjusting the Wheel Alignment ..........58 Adjusting the Steering Angle..............59 General Information Table......................60
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3 Systems Operation Section

(A) Red.......................................................... High pressure oil (B) Red Stripes and White Stripes ... First pressure reduction (C) Red Crosshatch ..................... Second pressure reduction (D) Pink .............................................. Third pressure reduction (E) Orange...........................Pilot, signal or torque converter oil (F) Orange Stripes and White Stripes ..................Reduced pilot, signal or torque converter oil (G) Blue.................................................................. Trapped oil (H) Green ............................................ Tank, sump or return oil (I) Brown ............................................................. Lubricating oil (J) Orange Crosshatch ........................... Second reduction in pilot, signal or torque converter oil (K) Yellow............................ Moving or activated components (L) Purple ............................................... Pneumatic pressure (M) Light Gray..................................................... Surface color
Systems Operation Section

Graphic Color Codes
Note: The information that is covered in this manual may not require all of the colors in Illustration 1.
Illustration 1
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General Information
Steering Arrangement
action allows the wheels to turn in the desired direction. Note: The steering mode and the direction of the rotation of the steering wheel will determine the direction of movement of the wheels. The machine may be operated in the following three steering modes: Two-wheel steer Circle steer Crab steer
Two-wheel Steer
When the machine is operated in two-wheel steer, the front wheels are the only active steering wheels. The rear wheels must be in a straight ahead position for proper operation of two-wheel steer. This mode is the only acceptable mode for roading the machine.
Circle Steer
All wheels are steered in this mode. The rear wheels are steered in the opposite direction to the front wheels. This mode provides a shorter turning radius for turns in tight areas.
Crab Steer
All wheels are steered in this mode. The rear wheels are steered in the same direction as the front wheels. This mode enables the machine to move in a sideways manner for maneuverability in confined areas. There are two different arrangements for the steering modes. Manually aligned rear wheels Self-aligning steering Some machines are equipped with a self-aligning feature for the front wheels and the rear wheels. This feature helps to align the wheels in a straight ahead position. The alignment of the wheels is necessary in order to properly operate the machine in two-wheel steer. In addition, the wheels must be aligned when you switch modes from crab steer to circle steer and from circle steer to crab steer. On machines that do not have the self-aligning feature, the wheels must be manually aligned by using the various steering modes. Reference: See the Operation and Maintenance Manual, "Steering Mode Control" for additional information on the operation of the switches.
Illustration 2 (1) Front axle (2) Front steering cylinder (3) Tie rod (4) Steering case (5) Pivot pin (6) Rear steering cylinder (7) Rear axle
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Front axle (1) and rear axle (7) have similar steering arrangements. Front steering cylinder (2) and rear steering cylinder (6) are an integral part of each axle housing. Each cylinder is equipped with two tie rods (3). Each tie rod is mounted to steering case (4) at each wheel. When the steering wheel is being turned, hydraulic oil forces steering cylinders to move tie rods (3). The tie rods act on steering cases (4). The steering cases rotate on pivot pins (5) at each wheel. This
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5 Systems Operation Section When the bottom of the switch is depressed, the contacts for circle steer close. A signal is sent to the machine ECM. The machine ECM sends power to the solenoid for circle steer which is mounted on the control valve for the steering mode. The energized solenoid shifts the spool in order to allow oil flow to the rear steer cylinder for circle steer. Indicator light (9) for circle steer will illuminate when this mode is selected.
Manually Aligned Rear Wheels
Machines With Self-Aligning Steering

The machine may be equipped with self-aligning steering. The self-aligning feature ensures that the front wheels and the rear wheels are aligned before the steering mode is changed.
Illustration 3 (8) Mode select switch g01006730
When steering mode switch (8) is pressed by the operator, the machine will not change to the desired steering mode unless the front wheels and the rear wheels are in the straight ahead position. If steering mode switch (8) is pressed by the operator and the wheels of the machine are not aligned, the current steering mode will remain selected. The indicator for the current steering mode on the display panel will remain ON, and the desired mode indicator will flash. When the front wheels and the rear wheels are moved to the straight ahead position by the operator, the steering mode will then change to the desired mode.
Mode select switch (8) - This switch is a threeposition switch that controls the steering mode. The mode select switch allows the machine to travel in twowheel steer, in crab steer, or in circle steer. Note: Always move the front wheels and the rear wheels to the straight ahead position before you change the steering mode.
Illustration 4 (9) Indicator for circle steer (10) Indicator for crab steer (11) Indicator for two-wheel steer
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When the top of mode select switch (8) is depressed, the contacts for crab steer close. A signal is sent to the machine electronic control module (ECM). The machine ECM sends power to the solenoid for crab steer which is mounted on the control valve for the steering mode. The energized solenoid shifts the spool in order to allow oil flow to the rear steering cylinder for crab steer. Indicator light (10) for crab steer will illuminate when this mode is selected. When the switch is in the center position, the contacts are open and the solenoids on the control valve for the steering mode will not be energized. This will allow the machine to operate in two-wheel steer. Indicator (11) will illuminate when this mode is selected.
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Introduction
Illustration 5
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This module discusses the features and operation of the steering system. The following Telehandlers are covered in this module: TH220B TH330B TH360B TH560B TH580B The steering system on these machines has the following modes of operation: Two-wheel steer Circle steer Crab steer Some machines are equipped with a self-aligning feature for the front wheels and the rear wheels.
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Location of Electrical Components

The steering system consists of the following electronic components: Selector switch for the steering mode Position sensor Electronic control module (ECM) Solenoid for crab steer Solenoid for circle steer Relay for crab steer Relay for circle steer
Selector Switch for the Steering Mode
Illustration 7
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Steering selector switch (1) is located to the left of the instrument panel inside the cab. The selector switch for the steering mode is an input to the Electronic Control Module that controls the steering mode.
Position Sensors
Illustration 8 Front Position Sensor
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Illustration 6 (1) Selector switch for the steering mode (2) Position sensors (3) Electronic control module (4) Solenoid for crab steer (5) Solenoid for circle steer (6) Relay for crab steer (7) Relay for circle steer
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Illustration 9 Rear Position Sensor
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Machines with self-aligning steering are equipped with two steering position sensors (2). One position sensor is attached to the front steering cylinder. The sensor sends a signal to the ECM when the front wheels are in the centered position. The other position sensor is
8 Systems Operation Section attached to the rear steering cylinder. The sensor sends a signal to the ECM when the rear wheels are in the centered position. Reference: See Systems Operation/Testing and Adjusting, "Position Sensor (Steering)" for more information.
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Reference: See Systems Operation/Testing and Adjusting, "Control Valve (Steering Mode)" for more information.
Solenoid for Circle Steer
Electronic Control Module
Illustration 12
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On/Off solenoid (5) for circle steer is located at the front of the cab. Remove the cover from the front of the cab in order to gain access to the solenoid for circle steer. The solenoid for circle steer is attached to the control valve for the steering mode. The solenoid for circle steer shifts the control valve for the steering mode. Reference: See Systems Operation/Testing and Adjusting, "Control Valve (Steering Mode)" for more information.
Illustration 10
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Electronic Control Module (ECM) (3) is mounted to the inner fender under the engine hood. The ECM controls most of the functions of the machine. Reference: See Systems Operation/Testing and Adjusting, "Electronic Control Module" for more information.
Relay (Crab Steer)
Solenoid for Crab Steer
Illustration 13
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Relay (6) for the crab steer is located in the fuse panel. The fuse panel is located behind an access cover in the left side of the cab arrangement. The relay for crab steer enables the solenoid for crab steer to be energized.
Illustration 11 g00903915
On/Off solenoid (4) for crab steer is located at the front of the cab. Remove the cover from the front of the cab in order to gain access to the solenoid for circle steer. The solenoid for crab steer is attached to the control valve for the steering mode. The solenoid for crab steer shifts the control valve for the steering mode.
Reference: See Systems Operation/Testing and Adjusting, "Electrical Output Components" for more information.
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Relay (Circle Steer)
Illustration 14
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Relay (7) for the circle steer is located in the fuse panel. The fuse panel is located behind an access cover in the left side of the cab arrangement. The relay for circle steer enables the solenoid for circle steer to be energized. Reference: See Systems Operation/Testing and Adjusting, "Electrical Output Components" for more information.
Location of Hydraulic Components

The steering system consists of the following hydraulic components: Steering wheel Metering pump Piston pump Line for the Signal Limiter Valve for the Steering Priority valve Control valve for the steering mode Steering cylinders Hydraulic tank Hydraulic tank breather Hydraulic oil level indicator Hydraulic oil drain plugs
Illustration 15 (1) Steering wheel (2) Metering pump (3) Piston pump (5) Priority valve on the main control valve (implement) (6) Control valve for the steering mode (7) Steering cylinders (8) Hydraulic tank (9) Hydraulic tank breather (10) Hydraulic oil level indicator
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Steering Wheel
Illustration 16
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Steering wheel (1) is located in the center of the main operator console. The steering wheel provides input to the metering pump in order to control the direction of the machine.
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Metering Pump
Line for the Signal Limiter Valve for the Steering
Illustration 17
g00903734 Illustration 19 g00874759
Metering pump (2) is located at the front of the cab at the end of the steering rod. Remove the cover from the front of the cab in order to gain access to the metering pump. The metering pump directs oil flow to the steering cylinders. Reference: See Systems Operation/Testing and Adjusting, "Metering Pump (Steering)" for more information.
The line for the signal limiter valve (4) is located at the front of the cab on the left side of the metering pump. Remove the cover from the front of the cab in order to gain access to the line for the signal limiter valve.
Priority Valve
Piston Pump
Illustration 20
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Illustration 18
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Piston pump (3) is located underneath the transmission in the engine enclosure. The piston pump provides hydraulic oil flow to the steering and implement systems. Reference: See Systems Operation/Testing and Adjusting, "Piston Pump (Implement and Steering)" for more information.
Priority valve (5) is located on the inlet manifold on the main control valve. Remove the cover from left side of the machine in order to gain access to the priority valve. The priority valve gives priority to the steering system over the implement system regarding hydraulic oil flow. The priority valve directs hydraulic oil flow to the steering system when the steering system requires oil flow. Reference: See Systems Operation/Testing and Adjusting, "Inlet Manifold" for more information.
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Control Valve (Steering)
Hydraulic Tank
Illustration 23 Illustration 21 g00903903
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Control valve (6) for the steering mode is located at the front of the cab, next to the metering pump. Remove the cover from the front of the cab in order to gain access to the control valve for the steering mode. The control valve for the steering mode directs oil flow for the various modes of steering operation. Reference: See Systems Operation/Testing and Adjusting, "Control Valve (Steering)" for more information.
Hydraulic tank (8) is located on the left side of the machine behind the cab. The hydraulic tank provides a reservoir for the hydraulic oil.
Hydraulic Tank Breather
Steering Cylinders
Illustration 24
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Breather (9) for the hydraulic tank is located on top of the hydraulic tank under the windshield washer reservoir. The hydraulic tank breather vents the tank to the atmosphere.
Illustration 22
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Steering cylinders (7) are attached to the front axle housing and the rear axle housing. The steering cylinders are used in order to turn the tires.
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Hydraulic Oil Level Indicator
Electrical Input Components
Illustration 25
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Hydraulic oil level indicator (10) is located on the left side of the machine behind a protection cover. The hydraulic oil level indicator allows the level of the hydraulic oil tank to be observed.
Hydraulic Oil Drain Plugs

There are two drain plugs for the hydraulic oil system. The drain plugs allow the hydraulic oil to be drained.
Steering Mode Switch
Illustration 26
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Hydraulic tank drain plug (11) is located on the bottom of the hydraulic tank.
The steering mode switch is a three-position switch. The three steering modes crab steer mode, front steer mode, and circle steer mode. A faulty switch can be detected due to the signal pattern of the switch. The CID fault code is number 750 and the FMI code is number 02.
Illustration 27
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Transmission drain plug (12) is located on the bottom of the transmission housing. The transmission drain plug allows the transmission oil to be drained.
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13 Systems Operation Section right side of the machine inside the engine compartment. The ECM sends the information to the Caterpillar Electronic Technician on the CAT data link. Note: The ECM is not serviceable. The ECM must be replaced if the ECM is damaged. Replace the ECM if a failure is diagnosed.
Position Sensor
Inputs
The inputs describe the status of the machine systems. Two types of inputs exist. The inputs can be either a switch type or a sensor type. Switches provide an open, a ground, or a + battery signal to the inputs of the controller. Sensors (frequency, PWM or voltage) provide a changing signal to the sensor inputs of the controller. The inputs to the machine ECM are listed in table 1.
Outputs
The ECM responds to decisions by sending electrical signals to the outputs. The outputs can create an action or the outputs can provide information to the operator or the service technician. The outputs of the machine ECM are listed in table 1.
Illustration 30
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The position sensors are a requirement of the auto align function. There are two steering position sensors. One is located on the front axle and the other sensor is located on the rear axle. The sensors are magnetic position sensors that send a signal to the ECM when the sensors are in the centered position.
Input/Output
The CAT data link is used in order to provide a connection for the service tool for troubleshooting, testing, and calibrations. The data link is bidirectional. The data link allows the ECM to receive information. The data link allows the ECM to send information.
Table 1
Electronic Control Module
Contact Description J2(1) No.( 5 6 24 25 26 27 28

Illustration 31 Electronic Control Module (ECM) g00785019
Function Relay (Circle Steer) Relay (Crab Steer) Switch (Rear Axle Align) Switch (Steer Mode Select - Front) Switch (Steer Mode Select - Circle) Switch (Steer Mode Select - Crab) Switch (Front Axle Align) On/Off On/Off
Type
Switch to Ground Switch to Ground Switch to Ground Switch to Ground Switch to Ground
(1) The ECM responds to an active input only when all the necessary conditions are satisfied. (2) The connector contacts that are not listed are not used.
The electronic control module (ECM) makes decisions that are based on input information and memory information. After the ECM receives the input information, the ECM sends a corresponding response to the outputs. The inputs and outputs of the ECM are connected to the machine harness by two 70 contact connectors (J1 and J2). The ECM is located on the
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Electrical Output Components
Data Link
Illustration 32
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Relays
Illustration 34
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CAT Data Link

The data link is an input and an output of the ECM. The data link is designed to communicate with other electronic control modules through the machine harness. The data link is not a visible component. The data link consists of internal ECM circuits and the connecting harness wiring. The data link is bidirectional. The data link allows the ECM to receive information and the data link allows the ECM to send information. Caterpillar Electronic Technician (ET) also communicates with other ECM modules through the data link. The ET will list the other ECM modules and the available diagnostic information. Note: All electronic control modules (ECM) that use the data link have a module identifier (MID). The MID is listed for each module:
Machine ECM ................................................................... 039 Shift Lever.......................................................................................................117
Illustration 33
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Relay (Circle Steer) and Relay (Crab Steer)

These relays will energize the solenoids that will direct the pressure to the appropriate control valve for the desired steering mode. The relay connects to the ECM through contact J2-5, contact J2-6, and contact J2-8.
Instrument Cluster
The indicators for the steering system are located within the Instrument Cluster (IC). The machine ECM communicates to the IC over the CAN data link. See the appropriate Service Manual for additional information.
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CAN Data Link

The CAN Data Link is used in order to aid the machine ECM with the control of the transmission. The CAN data link is used for communication with the display module.
Electrical Schematic
This is a simplified schematic of the steering system for the machine ECM. This schematic does not show all possible harness connectors. See the appropriate Electrical Schematic, for an accurate schematic of the machine.
Illustration 35
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Inlet Manifold
Reference: See Systems Operation/Testing and Adjusting, "Location of Hydraulic Components" for the location of the inlet manifold on the implement control valve. The inlet manifold includes the following components: Valve Assembly (Steering priority) Screens (75 and 100 micron) Relief Valve (load sensing oil) Flow Control Valve (Dump valve for the load sensing oil)
Check valves
The inlet manifold is part of the main control valve (implement).
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Steering Priority Valve

The flow of oil from the hydraulic piston pump is prioritized by the steering priority valve. The priority valve satisfies the demands from the steering system before the demands from the implement system.
Screens (75 and 100 Micron)

The inlet section of the main control valve (implement) contains three screens. The screens are dedicated to the following circuits: The system for the pilot supply (75 micron) Load sensing oil system for the priority valve (100 micron) Drain for the load sensing oil for the implement system (100 micron)
Flow Control Valve (Dump valve for the load sensing oil)
The Flow Control Valve is installed in order to provide a drain back to the hydraulic tank for the load sensing signal once the load has been reduced on the machine requirements. The signal drain valve is pressure compensated.
Relief Valve (Load sensing oil)

The Relief valve (Load sensing oil) is the main implement pressure relief valve for the hydraulic system. The signal limiter valve limits the maximum pressure in the load signal system. The relief valve has a pressure setting of 22800 kPa (3300 psi).
Check Valve
When the spool in the steering priority valve moves up, pressure from the top side of the spool is exhausted through the check valve. Systems Operation Section
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Steering Not Activated
Illustration 37 This schematic shows the steering priority valve in operation. (1) Check valve (2) Line to implement system (3) Valve As (Steering Priority) (4) Return oil from implement system (5) Spring (6) Orifice (7) Line to metering pump (8) Screen (9) Orifice (10) Line to metering pump (11) Pump supply (12) Load sensing oil from implements (13) Load sensing oil from implement system (14) Relief valve (Load sensing oil) (15) Line to implement system (16) Tank (17) Check valve (Return oil back pressure)
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(18) Flow Control Valve GP (Dump valve for the load sensing oil)
When the steering wheel is stationary, there is no demand from the metering pump for oil. The spool in the steering metering unit is spring centered and the oil is blocked at the spool. This causes an increase in pressure in supply line (10) to the metering pump. The increased pressure acts upon the top of the priority valve spool. The spool proportionally moves down against the force of spring (5). The mid-position of the spool allows oil flow to the steering system and to the implement control system. Further movement of the spool in the steering priority valve closes off the majority of the supply of oil to the steering system. Most of the oil flow through the priority valve is then supplied to the implement system through line (15). Orifice (6) and orifice (9) allow a small leakage from supply line (10) back to the hydraulic tank. This leakage prevents Priority Valve (3) from closing off the
supply passage to the metering pump. Some of the oil through orifice (9) acts with spring (5) in order to work against the pressure above priority valve (3). When steering is activated there is instant response from the metering pump. Some oil in Passage (7) opens check valve (19) and the oil enters the load sensing line (20). The oil in the load sensing oil pressure line (20) flows to the pump compensator and the oil causes the pump to upstroke slightly. The upstroke of the pump will increase the low pressure standby. The higher low pressure standby pressure maintains the pilot supply pressure for the valves of the pilot hydraulic system.
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Steering Activated
Illustration 38 This schematic shows the steering priority valve in operation. (1) Check valve (2) Line to implement system (3) Valve As (Steering Priority) (4) Return oil from implement system (5) Spring (6) Orifice (7) Line to metering pump (8) Screen (9) Orifice (10) Line to metering pump (11) Pump supply (12) Load sensing oil from implements (13) Load sensing oil from implement system (14) Relief valve (Load sensing oil) (15) Line to implement system (16) Tank (17) Check valve (Return oil back pressure)
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(18) Flow Control Valve GP (Dump valve for the load sensing oil)
When the steering wheel is turned, there is a pressure drop in passage (7). Due to the leakage oil past orifice (9) and the force of spring (5), the priority valve (3) moves up rapidly in order to direct supply oil in passage (11) to the metering pump (7). The flow of oil in line (7) is also blocked at the metering pump. This causes a buildup of pressure in line (7). The pressure in the form of a load sensing signal is transmitted through line (7) to a chamber at the bottom of steering priority valve (3). Also, oil flows through Check Valve (9) into signal line (19) in order to signal the pump. The pump increases flow in order to
meet the demand for steering flow. This causes the hydraulic flow to the metering pump to increase. The oil from the piston pump is directed to the metering unit through line (7). When the steering wheel is turned faster, the pressure increases in load signal line (7). The pressure determines the amount of proportional movement of the priority valve spool. If the steering system and another implement are used at the same time, the priority valve can supply oil to both the metering unit and the main control valve
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(implement) once the requirements of the steering flow are met.
Steering System
Steering Control System
The hydraulic pump for the steering system is a variable displacement axial piston type. The pump output is matched to system requirements by a priority valve in the inlet manifold on the main control valve. The priority valve in the inlet manifold is connected by a line to the metering pump. The control valve for the steering mode is a threeposition solenoid operated valve which controls the steering modes. Reference: See Systems Operation/Testing and Adjusting, "Location of Hydraulic Components" for the location of the hydraulic components in the steering system. Reference: See Systems Operation/Testing and Adjusting, "Location of Electrical Components" for the location of the electrical components in the steering system. Reference: See Systems Operation/Testing and Adjusting, "Piston Pump (Implement and Steering)" for operating information. Reference: See Systems Operation/Testing and Adjusting, "Steering Valve (Steering Mode Selector)" for operating information. Reference: See Operation and Maintenance Manual, "Steering Mode" for the operating information of the modes. The four schematics show the Steering System in the following modes of operation: Steering in neutral Right Turn in Two-Wheel Steer Mode Left Turn in Circle Steer Mode
Left Turn in Crab Steer Mode
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Steering in Neutral
Illustration 39 (1) Front steering cylinder (2) Rear steering cylinder (3) Inlet manifold (4) Priority valve (5) Main control valve (implement) (6) Signal limiter valve (implement) (7) Steering selector valve (8) Gerotor pump (9) Metering pump (10) Oil flow to pilot valve (11) Oil flow from implement valve (12) Signal from implement valve (13) Oil flow from control valve (14) Signal drain valve (15) Return to tank (16) Load signal to pump (17) Supply from pump (18) Return to tank (19) Front axle (20) Rear axle (21) Signal limiter valve (steering) (22) Orifice (23) Signal line (24) Check Valve (25) Orifice
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When the steering wheel is stationary the main supply of oil from priority valve (4) is blocked at the spool in the metering pump and there is no flow to the steering cylinders. When the steering is not in operation, a small amount of supply oil flows through orifice (22) and orifice (25). The orifices allow a constant flow of hydraulic oil to flow through signal line (23) to the metering pump and to the tank when the steering wheel is stationary. This leakage prevents the priority valve from closing off the supply passage to the metering pump. When steering is activated there is an instant response from the metering pump. Some oil in Passage (8) opens check valve (24) and the oil enters signal line (2). The oil in signal line (2) flows to the pump compensator and the oil causes the pump to upstroke slightly. The upstroke of the pump will increase the low pressure standby. The higher low pressure standby pressure maintains the pilot supply pressure for the valves of the pilot hydraulic system.
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Right Turn in Two-Wheel Steer Mode
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When the mode select switch is in the center position, the solenoids on steering selector valve (7) for the steering mode are de-energized. The valve spool is then centered by spring force, and the ports that connect rear steering cylinder (2) are blocked. Oil that is locked into the cylinder by the valve spool holds the rear wheels in the straight ahead position and the rear axle operates as a rigid axle. When the steering wheel is turned, the priority valve (4) moves in order to allow oil to flow into metering pump (9). Also, oil flows through Check Valve (24) into signal line (2) in order to signal the pump. The pump increases flow in order to meet the demand for steering flow. This causes the hydraulic flow to the metering pump to increase. The oil from the piston pump is directed to the metering pump. When a right turn is made in two-wheel steer mode, oil flows through gerotor pump (8), through steering selector valve (7) for the steering mode, and to the right side of front steering cylinder (1). Oil that enters the cylinder causes the tie rods to move to the left. This causes the wheels to move to the right. Oil in the left side of the steering cylinder flows to the tank through the metering pump. If the steering cylinder reaches the end of the stroke and the operator continues to turn the steering wheel, pressure in the steering system will increase. The increase in pressure causes signal limiter valve (21) in metering pump (9) to open. The excess signal oil is directed to the tank in order to relieve the pressure. When the steering wheel is turned to the left the flow of oil is reversed. Oil flows directly to the left side of the steering cylinder and return oil is routed through the control valve for the steering mode and back to the tank. Note: If the engine stops and the machine is in motion, the machine can still be steered. When the steering wheel is turned in this situation, the metering section of hand metering pump (9) acts as a pump.
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Left Turn in Circle Steer Mode
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When the bottom of the mode select switch is depressed, and the circle steer mode is selected, solenoid (A) on steering selector valve (7) for the steering mode is energized. The valve spool is offset to the circle steer position. When the steering wheel is turned, the priority valve (4) moves in order to allow oil to flow into metering pump (9). Also, oil flows through Check Valve (24) into signal line (2) in order to signal the pump. The pump increases flow in order to meet the demand for steering flow. This causes the hydraulic flow to the metering pump to increase. The oil from the piston pump is directed to the metering pump. When a left turn is made in circle steer mode, oil flows directly from gerotor pump (8) to the left side of front steering cylinder (1). Oil that is displaced from the right side of the front steering cylinder flows through steering selector valve (7) for the steering mode to the left side of rear steering cylinder (2). Oil that is displaced from the right side of the rear steering cylinder flows through steering selector valve (7) for the steering mode, and metering pump (9) to the tank. The front cylinder rods move to the right. This causes the front wheels to pivot to the left. The rear cylinder rods move to the right. This causes the rear wheels to pivot to the right.
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Left Turn in Crab Steer Mode
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Note: In crab steer, the front wheels and the rear wheels turn in the same direction. Crab steer allows the machine to move in a sideways manner for maneuverability in confined areas. When the top of the mode select switch is depressed, and the crab steer mode is selected, solenoid (B) on steering selector valve (7) for the steering mode is energized. The valve spool is offset to the crab steer position. When the steering wheel is turned, the priority valve (4) moves in order to allow oil to flow into metering pump (9). Also, oil flows through Check Valve (24) into signal line (2) in order to signal the pump. The pump increases flow in order to meet the demand for steering flow. This causes the hydraulic flow to the metering pump to increase. The oil from the piston pump is directed to the metering pump. When the steering wheel is turned counterclockwise in crab steer mode, oil flows directly from gerotor pump (8) to the left side of front steering cylinder (1). Oil that is displaced from the right side of the front steering cylinder flows through the control valve for the steering mode to the right side of rear steering cylinder (2). Return oil from the left side of the rear cylinder flows to the tank through steering selector valve (7) for the steering mode and metering pump (9). The front steer cylinder rods move to the right, and the rear cylinder rods move to the left. This causes the front wheels and the rear wheels to pivot to the left. All the wheels are now turned in the same direction and all wheels are steered.
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Hydraulic Schematic (Steering System)
Illustration 43 Steering system in neutral (1) Steering line relief valves (2) Front axle (3) HAND metering unit (4) Front steering cylinder (5) Rear steering cylinder (6) Rear axle (7) Gerotor pump (8) Inlet Manifold (9) Main hydraulic control valve (10) Signal limiter valve (steering) (11) Priority valve (12) Oil flow to pilot valve (13) Oil flow from implement valve (14) Steering selector valve (15) Signal from implement valve (16) Signal limiter valve (implement) (17) Signal drain valve (18) Oil flow to main control valve (24) Check Valve (25) Orifice
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Piston Pump (Implement and Steering)

Piston Pump
Illustration 44 Steering and Implement Pump (Engine Off) (1) Piston pump (2) Compensator Valve (3) Piston and Barrel Assembly (4) Shaft (5) Bias Spring (6) Swashplate (7) Actuator Piston (8) Load Sensing Oil Pressure (9) Pump Outlet (10) Margin Spring (11) Margin Spool (12) Pump Inlet (13) Adjusting Screw (14) Pressure Cutoff Spool (15) Orifices (16) Passage to Actuator Piston (17) Line to the Control Valve Group (18) Orifice (19) Passage
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Piston pump (1) has the following characteristics: variable displacement load sensing compensation for pressure compensation for flow This piston type pump has variable flow and pressure. The flow and pressure are dependent on the system demands that are sensed by pressure and flow compensator valve (2). Note: Load sensing oil pressure is sometimes referred to as signal oil. The two terms have the same meaning throughout this story. The piston pump has the following components: Piston and barrel assembly (3) - The cylinder barrel contains nine pistons. The cylinder barrel assembly rotates whenever the engine is running. The pistons move oil into the barrel and out of the barrel.
Shaft (4) - The rotation of the pump is counterclockwise when the pump is viewed from the drive end. The piston and barrel assembly is splined to the drive shaft. Bias spring (5) - If there is no pressure on the right side of the actuator piston, the bias spring will hold the swashplate at the maximum angle. Swashplate (6) - The displacement of the pump is controlled by the angle of the swashplate. The angle of the swashplate causes the pistons to move in and out of the rotating barrel. Actuator piston (7) - When oil pressure increases behind the actuator piston, the piston will overcome the force of the bias spring. This causes the angle of the swashplate to be reduced. Pressure and flow compensator valve (2) - The
30 Systems Operation Section pressure and flow compensator valve controls the delivery of oil and the return of oil to the actuator piston. When the engine is OFF, pressure and flow compensator valve (2) does not receive load sensing oil pressure (8) or supply pressure from pump outlet (9). Margin spring (10) pushes flow compensator spool (11) completely downward. Any pressure that is on the right side of actuator piston (7) is vented to the case drain across flow compensator spool (11). When there is no pressure behind actuator piston (7), bias spring (5) is able to hold swashplate (6) at the maximum angle. When the engine is started, shaft (4) starts to rotate. Oil flows into the piston bore from pump inlet (12). Oil is forced out of pump outlet (9) and into the system as the piston and barrel assembly (3) rotates.
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27500 500 kPa (3988 73 psi) if the load sensing oil relief valve fails. Pressure and flow compensator valve (2) has orifice (15) in the load sensing oil passage to actuator piston (16). Orifice (15) is used in order to regulate the response rate of the actuator piston by creating a consistent leak path. The load sensing oil relief valve in the TH330B is set at 22800 kPa (3300 psi) and the margin pressure is set at 2200 kPa (320 psi). The maximum system pressure is 25000 500 kPa (3625 75 psi). Pressure compensator spool (14) is used as a backup to limit the maximum system pressure to 27500 500 kPa (3988 73 psi) on the TH220B and 26000 500 kPa (3770 73 psi) on the TH330B if the load sensing oil relief valve fails. Note: If the load sensing oil relief valve is operating correctly the load sensing oil relief valve controls the maximum system pressure. Maximum system pressure should be the pressure of the load sensing oil relief valve plus the margin pressure. If the load sensing oil relief valve is not adjusted correctly the pressure compensator acts as a backup.
Compensator Valve
Pressure and flow compensator valve (2) is bolted to the top of the piston pump. Pressure and flow compensator valve (2) compensates for pressure variations and flow variations in the implement hydraulic system in order to meet the system demands. Flow compensator spool (11) regulates the pump output flow in response to the following oil pressures: Load sensing oil pressure (8) Supply pressure from pump outlet (9) The load sensing oil is received through the load sensing oil control network for the pump. The flow that is supplied by the hydraulic pump is the amount that is required in order to keep the supply pressure 2200 100 kPa (320 15 psi) above the load sensing oil pressure (8). The difference between load sensing oil pressure (8) from the main hydraulic control valve and the supply pressure from pump outlet (9) is called the margin pressure. Flow compensator spool (11) controls the margin pressure. Margin pressure is equal to the spring force value of margin spring (10). The margin pressure is adjusted by turning adjusting screw (13) on flow compensator spool (11). Note: The maximum system pressure is controlled by the load sensing oil relief valve and the margin pressure. The load sensing oil relief valve in the TH220B is set at 24300 kPa (3524 psi) and the margin pressure is set at 2200 kPa (320 psi). The maximum system pressure is 26500 500 kPa (3843 75 psi). Pressure compensator spool (14) is used as a backup to limit the maximum system pressure to
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Low Pressure Standby
Illustration 45 Steering and Implement Pump (Low pressure Standby) (1) Piston pump (2) Compensator Valve (3) Piston and Barrel Assembly (4) Shaft (5) Bias Spring (6) Swashplate (7) Actuator Piston (8) Load Sensing Oil Pressure (9) Pump Outlet (10) Margin Spring (11) Margin Spool (12) Pump Inlet (13) Adjusting Screw (14) Pressure Cutoff Spool (15) Orifices (16) Passage to Actuator Piston (17) Line to the Control Valve Group (18) Orifice (19) Passage
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When piston pump (1) produces flow, the system pressure begins to increase because the oil flow from pump outlet (9) is blocked at the closed center implement control valves. The supply pressure from pump outlet (9) is felt at the bottom end of flow compensator spool (11). The supply pressure from pump outlet (9) is greater than the combined pressure of load sensing oil pressure (8) and margin spring (10). The flow compensator spool moves upward against the margin spring. This permits system oil to flow to actuator piston (7). When the pressure on actuator piston (7) increases, the force of bias spring (5) is overcome and swashplate (6) is moved to a slight angle. Piston pump (1) produces enough flow in order to compensate for normal system leakage when swashplate (6) is at a slight angle. Also, the piston pump has sufficient pressure in order to provide instantaneous response when an implement is activated.
Even when no implements are being used, the steering system maintains a load sensing oil to the pump. The pressure at pump outlet (9) must overcome the force of margin spring (10) and the dynamic bleed signal. Pressure at pump outlet (9) is called "low pressure standby". Low pressure standby is approximately 4500 kPa (650 psi). The low pressure standby is higher than the margin pressure. The higher pressure is needed to maintain the pilot pressure. When piston pump (1) is at low pressure standby, the supply pressure from pump outlet (9) raises flow compensator spool (11) higher. This will further compress margin spring (10). An increased amount of supply oil from pump outlet (9) will flow to actuator piston (7). This will slightly destroke the hydraulic pump. The low pressure standby can be adjusted by changing the setting of the margin spring.
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Upstroke
Illustration 46 Steering and Implement Pump (Upstroke) (1) Piston pump (2) Compensator Valve (3) Piston and Barrel Assembly (4) Shaft (5) Bias Spring (6) Swashplate (7) Actuator Piston (8) Load Sensing Oil Pressure (9) Pump Outlet (10) Margin Spring (11) Margin Spool (12) Pump Inlet (13) Adjusting Screw (14) Pressure Cutoff Spool (15) Orifices (16) Passage to Actuator Piston (17) Line to the Control Valve Group (18) Orifice (19) Passage
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When an implement hydraulic circuit requires flow, the pressure from pump outlet (9) is reduced. The force of margin spring (10) and load sensing oil pressure (8) is greater than supply pressure from pump outlet (9). The overall force is on the top end of flow compensator spool (11). The spool moves down. The spool blocks the flow of oil to actuator piston (7). Oil that is in the chamber for actuator piston (7) is vented to the case drain across flow compensator spool (11). This allows bias spring (5) to move swashplate (6) to a greater angle. The pump now produces more flow. This condition is known as "upstroking". The following conditions can result in upstroking the pump: If an implement hydraulic circuit is initially activated from low pressure standby, the load sensing load sensing oil increases the pump output flow. This increased pump output flow is routed to the position of a main control spool of a hydraulic control valve that demands the oil.
The hydraulic pump will upstroke when the flow demand increases from changing the position of the main control spool in a hydraulic control valve. If another implement hydraulic circuit is engaged, there is a need for increased pump flow. If the flow demand on the implement hydraulic system remains constant or the flow demand increases, the hydraulic pump will upstroke when the engine speed decreases. Note: The load sensing oil pressure does not need to increase in order to upstroke the hydraulic pump. For example, if one implement hydraulic circuit is activated at an operating pressure of 13800 kPa (2000 psi), the system pressure is 16000 kPa (2320 psi). The pressure of 16000 kPa (2320 psi) is a combination of the margin pressure and the pressure of the load sensing oil. If another implement hydraulic circuit is activated at an initial operating pressure of 6900 kPa (1000 psi), the maximum pressure of the load sensing oil will still be
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13800 kPa (2000 psi). The supply oil pressure will decrease momentarily. The combined force of the load sensing oil pressure (8) and margin spring (10) is now higher than the supply pressure from pump outlet (9) at the bottom end of the spool. Flow compensator spool (11) is pushed to the bottom. This allows oil that is behind actuator piston (7) to be vented to the case drain. The angle of swashplate (6) now increases and the hydraulic pump provides more flow in order to meet the flow demands of both circuits.
Constant Flow
Illustration 47 Steering and Implement Pump (Constant Flow) (1) Piston pump (2) Compensator Valve (3) Piston and Barrel Assembly (4) Shaft (5) Bias Spring (6) Swashplate (7) Actuator Piston (8) Load Sensing Oil Pressure (9) Pump Outlet (10) Margin Spring (11) Margin Spool (12) Pump Inlet (13) Adjusting Screw (14) Pressure Cutoff Spool (15) Orifices (16) Passage to Actuator Piston (17) Line to the Control Valve Group (18) Orifice (19) Passage
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As the pump increases flow or decreases flow in order to match the change in the flow requirements, the forces above the flow compensator spool and below the flow compensator spool will equalize. The following pressures will act on the top end of flow compensator spool (11): Margin spring (10) Load sensing oil pressure (8) The following pressure will act on the bottom end of flow compensator spool (11):
Supply pressure from pump outlet (9) Once the pressures become equal on each end of the spool, flow compensator spool (11) will meter oil to actuator piston (7). Bias spring (5) will be compressed and the system will stabilize. Swashplate (6) is held at a relative constant angle in order to maintain the required flow.
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Destroke
Illustration 48 Steering and Implement Pump (Destroke) (1) Piston pump (2) Compensator Valve (3) Piston and Barrel Assembly (4) Shaft (5) Bias Spring (6) Swashplate (7) Actuator Piston (8) Load Sensing Oil Pressure (9) Pump Outlet (10) Margin Spring (11) Margin Spool (12) Pump Inlet (13) Adjusting Screw (14) Pressure Cutoff Spool (15) Orifices (16) Passage to Actuator Piston (17) Line to the Control Valve Group (18) Orifice (19) Passage
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When less flow is required, piston pump (1) destrokes. The piston pump destrokes when the supply pressure from pump outlet (9) becomes greater than the combined pressure of load sensing oil pressure (8) and margin spring (10). Flow compensator spool (11) is raised. This allows more oil flow to actuator piston (7). Pressure on actuator piston (7) is now increased. The increased pressure overcomes the force of bias spring (5) which moves swashplate (6) to a reduced angle. When the supply pressure at pump outlet (9) matches the combined pressure of load sensing oil pressure (8) and margin spring (10), the flow compensator spool returns to a metering position. Piston pump (1) will return to a constant flow. The following conditions result in destroking the pump: When a main control spool for a hydraulic control valve is moved to the HOLD position the hydraulic pump will destroke.
If the main control spool for a hydraulic control valve is moved to a position that requires less flow, the hydraulic pump will destroke. If multiple hydraulic control valves are being used, the hydraulic pump will destroke when there is a reduction in flow demand from any one of the hydraulic control valves. If the engine speed increases, the piston pump destrokes. When the piston pump destrokes, supply oil pressure from pump outlet (9) decreases on the bottom side of flow compensator spool (11). The force on the top of flow compensator spool (11) is the sum of the following pressures: Margin spring (10) Load sensing oil pressure (8) The following force acts on the bottom of flow compensator spool (11): Supply pressure at pump outlet (9)
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Once the forces become equal on each end of the spool, flow compensator spool (11) will meter oil to actuator piston (7) and the system will stabilize. The system will provide a constant flow until the flow requirements change. Note: Load sensing oil pressure (8) does not need to decrease in order to destroke the hydraulic pump. For example, if two implement hydraulic circuits are activated at operating pressures of 13800 kPa (2000 psi) and 6900 kPa (1000 psi), the system pressure is 16000 kPa (2320 psi). If the implement hydraulic circuit which is activated at 6900 kPa (1000 psi) is returned to the HOLD position, the maximum load sensing oil pressure (8) will still be 13800 kPa (2000 psi). However, the supply pressure at pump outlet (9) is momentarily increased due to the reduced oil flow that is required in the implement hydraulic circuits. Supply pressure at pump outlet (9) raises flow compensator spool (11). This allows more oil flow behind actuator piston (7). The angle of swashplate (6) now decreases and the hydraulic pump provides less flow.
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High Pressure Stall
Illustration 49 Steering and Implement Pump (Maximum System Pressure) (1) Piston pump (2) Compensator Valve (3) Piston and Barrel Assembly (4) Shaft (5) Bias Spring (6) Swashplate (7) Actuator Piston (8) Load Sensing Oil Pressure (9) Pump Outlet (10) Margin Spring (11) Margin Spool (12) Pump Inlet (13) Adjusting Screw (14) Pressure Cutoff Spool (15) Orifices (16) Passage to Actuator Piston (17) Line to the Control Valve Group (18) Orifice (19) Passage
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Note: Relief Valve (Load sensing oil) is sometimes referred to as the signal limiter valve. The two terms have the same meaning throughout this story. Note: This condition will only occur when the load sensing oil relief valve is set below the valve of the pressure compensator. If piston pump (1) is at a high pressure stall or maximum system pressure, the combined pressure of load sensing oil pressure (8) and margin spring (10) is equal to the supply pressure at pump outlet (9). Load sensing oil relief valve (20) limits the maximum system pressure at any pump displacement. Load sensing oil relief valve (20) is set at 22800 kPa (3300 psi). A margin pressure of 2200 100 kPa (320 15 psi) above the load sensing oil is still maintained while piston pump (1) is at a high pressure stall. If the piston pump is at a high pressure stall, the maximum system pressure will be 26500 500 kPa (3843 75 psi) for the TH220B and 25000 500 kPa (3625 75 psi) for the TH330B.
If the load sensing oil relief valve (20) is not adjusted correctly, pressure compensator spool (14) serves as a backup relief in order to protect the hydraulic system. At high pressure stall, the piston pump is at minimum flow and the supply oil at pump outlet (9) is at maximum pressure. These conditions are maintained for a single implement in a stall condition. If multiple implement hydraulic circuits are activated and one circuit is at a stall, the piston pump (1) will upstroke in order to meet the increased flow demands. This flow meets the needs of the other circuits that are operating at a lower work port pressure.
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Solenoid Valve (Steering Mode Selector)

Solenoid Valve
The solenoid valve controls oil flow to the rear steering cylinder. The solenoids are controlled by the switch for the steering mode that is located on the dash panel. Reference: See Systems Operation/Testing and Adjusting, "Location of Hydraulic Components" for the location of the control valve. Reference: See Operation and Maintenance Manual, "Steering Mode" for the operating information of the steering modes. Reference: See Systems Operation/Testing and Adjusting, "Steering System" for further information on the control valve for the steering modes. The solenoid valve has the following characteristics: Three-position Spring centered valve Solenoid operated valve
Metering Pump (Steering)
Illustration 50 (A) Control section (B) Metering section (1) Spool (2) Sleeve (3) Outlet to the tank (4) Makeup valve (5) Inlet (pump supply from priority valve) (6) Check valve (7) Rotor (8) Stator (9) Centering springs (10) Drive pin (11) Left turn port (12) Right turn port (13) Body (14) Drive shaft (15) Signal port
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38 Systems Operation Section The steering metering pump consists of the following two sections: Control section (A) Metering section (B) Section (A) contains a closed center rotary control valve. Metering section (B) is a gerotor pump.
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Illustration 51 Spool and sleeve of the steering metering pump (1) Spool (2) Sleeve (16) Holes for the drive pin (17) Slots for the drive pin (18) Holes (19) Grooves (20) Slots for the centering springs
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The metering pump controls the following actions: Direction of a turn Speed of a turn As the steering wheel is turned faster, there is an increase in the flow of oil to the steering cylinders. The increased flow of oil to the steering cylinders causes the steering cylinder rods to move faster. This causes the machine to make a faster turn. The main components of the metering pump are connected in the following way: The steering column is connected to spool (1) by a splined drive shaft. Sleeve (2), spool (1), and drive shaft (14) are connected by drive pin (10). Drive pin (10) is installed through holes (16) in the sleeve and slots (17) in the spool. The three schematics show the steering system in the following positions: Hold Right Turn Left Turn
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Hold
Illustration 52 (1) Spool (2) Sleeve (4) Makeup valve (6) Check valve (21) Check valve (22) Relief Valve (23) Signal limiter valve (24) Oil flow to left side of front steering cylinder. (25) Pump supply from priority valve (26) Oil flow to load signal network (27) Signal to priority valve (28) Return to tank (29) Oil flow to steering control valve
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When the steering wheel is stationary, centering springs (9) position spool (1) so that the drive pin is in the center of the slots. When the spool and sleeve (2) are in this position, pump supply oil (25) from the priority valve is blocked by the spool. This stops the oil flow between control section (A) and metering section (B). When the steering wheel is stationary, a small quantity of oil is constantly supplied to the metering pump through signal line (27). This creates a slight signal pressure in the metering pump. This signal oil flows through port (15) into the control section of the pump. Oil flows through sleeve (2) and through spool (1). The spool directs the oil to port (3) and oil flows back to the tank. This constant flow allows the oil in the system to warm up. As a result, when the steering wheel is turned, a quicker steering response is achieved. Refer to Illustrations 50, 51 and 52.
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Right Turn
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When the steering wheel is turned to the right, the spool turns. This compresses the centering springs until the drive pin contacts the ends of the slots in the spool, and the sleeve starts to turn. When the spool and the sleeve are in this position, passages are opened through grooves (19) in the spool and holes (18) in the sleeve. This connects control section (A) to metering section (B). Oil is allowed to flow past check valve (6) in inlet port (5) to rotor (7) and stator (8) in gerotor pump (21). When the steering is turned further, drive pin (10) turns drive shaft (14) and the rotor turns inside the stator. This pumps a metered flow of oil back through the spool and sleeve in the control section of the pump. Oil flows through right turn port (12) and the control valve (steering mode) to the steering cylinder. Return oil from the left side of the front steering cylinder flows into the steering metering pump through the following
components to the tank: left turn port (11), spool (1), sleeve (2), and outlet port (3). Refer to Illustration 50, 51 and 53.
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Left Turn
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When a left turn is made, oil flows past check valve (6) in inlet port (5) of the metering valve to gerotor pump (21). The oil is then directed through left turn port (11) to the left side of the front steering cylinder. Return oil from the control valve (steering mode) flows into the steering metering pump through the following components to the tank: right turn port (12), spool (1), sleeve (2), and outlet port (3). If there is a hydraulic pump failure, the metering pump can be manually operated. The metering pump can be manually operated if the engine stops and the engine can not be started again. Makeup valve (4) and check valve (6) allow steering with an inoperable engine. The makeup valve opens in order to allow return oil to flow between the metering pump and steering cylinder. Check valve (6) prevents the oil from returning to the implement and steering pump.
Relief valves (22) are installed in the metering unit in order to reduce the effect of shocks that are transmitted from the road wheels. Note: If a pressure spike occurs in the system due to an outside factor, check valve (6) protects the system from damage. Refer to Illustrations 50, 51 and 54.
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Position Sensor (Steering)
pressure to the appropriate control valve for the desired steering mode. The ECM then sends an input through a CAN data link to the dash panel. A light on the dash panel will illuminate when steering mode is selected. When two-wheel steer is selected the steering position sensor is energized. If the rear wheels are in the straight ahead position, lamp (3) on steering position sensor (2) will be illuminated. The contacts inside the sensor are open and power to the electrical relay for the selector valve is disconnected. Both of the solenoids for the valve are now de-energized regardless of the position of the steering mode select switch.
Illustration 55 Front Position Sensor
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If the rear wheels are not in the straight ahead position, the lamp on the steering position sensor will not be illuminated. The contacts in the steering position sensor will be closed and power is still connected to the electrical relay for the selector valve. The appropriate solenoid on the selector valve remains energized. When the steering wheel is turned, the rear wheels will move in the selected mode until the wheels are in the straight ahead position. The contacts in the steering position sensor are open and the selector valve is deenergized. The spool in the selector valve is then centered by spring force, and the rear wheels remain in the straight ahead position.
Illustration 56 (1) Rear axle (2) Steering position sensor
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When the master steering select switch is moved to the center position, power is disconnected from the electrical circuit for the steering. This position is intended for operation of the machine in two-wheel steer mode. Refer to Systems Operation/Testing and Adjusting, "Position Sensor (Steering) - Adjust" for information on adjusting the sensor. Refer to the Operation and Maintenance Manual, "Steering Alignment" for additional information on adjusting the steering position sensor. Refer to the Systems Operation/Testing and Adjusting, "Location of Electrical Components" for the location of the steering position sensors.
Illustration 57 (2) Steering position sensor (3) Lamp
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Machines with self-aligning steering are equipped with two steering position sensors (2). One position sensor is attached to the front steering cylinder. One sensor is mounted on the rear axle. The steering position sensor is activated when the wheels are in the centered position. The switches are magnetic position sensors that will supply a ground to the ECM when the sensors are in the centered position. The ECM reads the input from the steering position sensor. The ECM will energize the appropriate relay in order to control the solenoid and direct hydraulic
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Configuration Parameters
Illustration 58 This is a summary screen
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Some parameters need to be configured for the machine to operate properly. The configuration screen for the ECM can be accessed by using the Cat Electronic Technician (ET). The configuration screen for each ECM is accessed from the above ECM summary screen by selecting "Configuration" from the "Service" drop-down menu. Reference: Refer to the appropriate service manual for further instructions on configuring the ECM for your machine.
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45 Testing and Adjusting Section 1. Shift the transmission to NEUTRAL and engage the parking brake. 2. Start the engine. 3. Extend the boom and retract the boom several times in order to warm the hydraulic oil. 4. Operate each implement several times in order to circulate the warm oil. Rotate the steering wheel from stop to stop several times. 5. Allow the engine to run on low idle. 6. Open the engine enclosure.
Testing and Adjusting Section

Hydraulic Oil Contamination Test
Hydraulic Oil Contamination
Introduction
The steering system and the transmission system use hydraulic oil from the hydraulic tank. Caterpillar recommends the use of the SOS oil analysis program in order to monitor the condition of your equipment. If the oil becomes contaminated, premature component failure could result. Contaminated oil can also contribute to overheating. Use the following procedure to sample the oil in the system. Reference: See Operation and Maintenance Manual, "SOS Fluid Analysis" for further information about this SOS oil analysis program.
Flushing the Sampling Valve
Illustration 59
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The Hydraulic Oil Sampling Valve is Located in the Engine Compartment.
7. Locate the sampling valve that is positioned at the top of the hydraulic oil filter. Remove the rubber cap from the sampling valve. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates. In order to obtain a representative oil sample, it is first necessary to flush the sampling valve. 8. Attach the 8T-9208 Probe Assembly to the 6K-0713 Hose. 9. Direct the hose into a container for fluid waste. Remove approximately 30 mL (1 fl oz) of fluid from the sampling valve.
Obtaining the Sample
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates. Once the sampling valve has been flushed, carry out the following procedure in order to obtain an oil sample:
Required Tools
Use the following equipment in order to Flush the Sampling Valve:
Table 2
Required Tools Tool Part Number 8T-9208 A 6K-0713 Part Description Probe Assembly Hose Qty 1 1
46 Testing and Adjusting Section
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Required Tools
Use the following equipment in order to obtain the Sample:
Table 3
Table 5
Pump flow at 690 kPa (100 psi) - Pump flow at 6900 kPa (1000 psi)
Required Tools Tool Part Number 177-9343 B 169-7373 = Flow loss Part Description Fluid Sampling Cap and Probe Gp Bottle Qty
Example of determining flow loss

1
Table 6
1 217.6 L/min (57.5 US gpm)
1. Attach the probe from the 177-9343 Fluid Sampling Cap and Probe Gp to a 169-7373 Bottle. 2. Draw a 50 mL (1.7 fl oz) oil sample from the sampling valve.
- 196.8 L/min (52.0 US gpm) = 20.8 L/min (5.5 US gpm)
Maximum Contamination Levels

The level of contaminants that is found in the hydraulic system must meet the ISO 18/15 cleanliness level. The following table contains the maximum acceptable contamination levels:
Table 4
Flow loss is used as a measure of pump performance. Flow loss is expressed as a percentage of pump flow. Method of determining percent of flow loss
Table 7
Flow loss (L/min or US gpm) Hydraulic Oil Contamination Pump flow at 690 kPa (100 psi)
x 100 = Percent of flow loss
Particle Size (Microns) 10 to 20 21 to 50 51 to 100 100 or more
Maximum Number of Particles in a 50 mL (1.7 fl oz) Sample 48000 2580 150 20
Example of determining percent of flow loss

Table 8
20.8 L (5.5 US gal) x 100 = 9.5% 217.6 L/min (57.5 US gpm)
Pump Flow - Test

Pump Flow
Introduction
This test is designed to check a pump for operation within the design parameters. For any pump test, the pump flow at 690 kPa (100 psi) will be larger than the pump flow at 6900 kPa (1000 psi) if the pump is operating at the same rpm. The pump flow is measured in L/min (US gpm). The difference between the pump flow of the two operating pressures is the flow loss. Reference: See the appropriate service manual for specifications of the pump on your machine. Method for determining flow loss
If the percent of flow loss is more than 10%, the pump performance is inadequate. Note: The values in the examples are not set values for any specific pump or for any specific pump condition.
Test On The Machine
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.
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47 Testing and Adjusting Section NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates.
Required Tools
Use the following equipment in order to test the pump flow:
Table 9
Illustration 60 View on the left side of the machine (1) Test fitting for the load signal g00903590
Required Tools Tool A Part Number 5P-3600 Part Description Hydraulic Flow Meter Qty 1
Install tool (A). Run the engine at high idle. Measure the pump flow at 690 kPa (100 psi), and at 6900 kPa (1000 psi). Use these values in the formula that is shown in (Table 8).
Test On The Bench

If the test bench can be run at 6900 kPa (1000 psi) and at 2000 rpm, determine the percent of flow loss by using the following formula (Table 10). If the test bench can not be run at 6900 kPa (1000 psi) and at 2000 rpm, run the pump shaft at 1000 rpm. Measure the pump flow at 690 kPa (100 psi) and at 6900 kPa (1000 psi). Use these values in the top portion of the following formula (Table 9). For the bottom part of the formula, run the pump shaft at 2000 rpm. Measure the pump flow at 690 kPa (100 psi).
Table 10
Illustration 61 View on the right side of the machine (2) Test fitting for the pump supply g00903592
When you check the pressures for the piston pump, several factors must be considered. Outlet pressure for the piston pump should remain approximately 2200 100 kPa (320 20 psi) higher than the maximum implement signal pressure. This difference in pressure is called the margin pressure. Note: Load sensing oil pressure is sometimes referred to as signal oil. The two terms have the same meaning throughout this story.
Pump flow at 690 kPa (100 psi) Pump flow at 6900 kPa (1000 psi) Pump flow at 690 kPa (100 psi) and at 2000 rpm x 100 = Percent of flow loss
Steering System Pressures Test and Adjust

Steering System Pressure Tests and Adjustments
Introduction
The test fittings are located on the control valve at the rear of the machine.
A low pressure setting on the pressure compensator valve will also cause a low high pressure stall. The pressure compensator only functions as a backup to the relief valve (load sensing oil) and to the flow compensator. The pressure compensator should not be set to a lower pressure than the sum of the relief valve (load sensing oil) and the flow compensator. The setting for the relief valve (load sensing oil) must be checked after you adjust the high pressure stall. Reference: See Systems Operation/Testing and Adjusting, "Location of Hydraulic Components" for the location of the hydraulic components on the machine. Reference: See the steering Machine Systems Specifications for your machine.
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Steering Pressure Test

Introduction
The steering system pressure and the margin pressure can be checked at the same time.
4. Divide Tooling (B) into two separate gauge assemblies. Install a pressure gauge on test fitting
(1) and install a pressure gauge on test fitting (2). Refer to Illustrations 60 and 61. 5. Connect Tooling (B) to test fitting (1). Refer to Illustration 60. 6. Start the engine and operate the engine at low idle. Raise the boom until the work tool is off of the ground. Rotate the steering wheel for the full distance of travel. Continue to rotate the steering wheel in order to check the steering pressure. The pressure reading will not be constant. Record the high side of the measured value. If the pressure is not within the specification, adjust the steering relief valve. Refer to Testing and Adjusting, "Steering Pressure Adjustment".
Table 12
Required Tools
Use the following test equipment in order to perform the following procedure: Appropriate pressure gauges Table 11 provides a list of required tools if pressure gauges will be used to perform the following test procedure.
Table 11
Required Tools Tool Part Number 8T-0860 B 6V-3989 177-7861 6V-4143 Part Description Pressure Gauge (0 to 40000 kPa (5800 psi)) Test fitting Hose Coupler Qty 2 2 2 4
Steering Pressure Model TH220B, TH330B, TH360B TH560B with axles 2310707or231-0708 2310709or231-0710 TH580 Pressure 16250 1000 kPa (2350.0 145.0 psi) 17750 1000 kPa (2575.0 145.0 psi) 17750 1000 kPa (2600.0 145.0 psi)
Test Procedure
Personal injury can result from removing hoses or fittings in a system under pressure. Failure to relieve pressure can cause personal injury. Do not remove or disconnect hoses or fittings until all pressure in the hydraulic system has been relieved. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates. 1. Ensure that the hydraulic oil is warm. Refer to the appropriate service manual for further information. 2. Retract the boom and lower the boom. Ensure that the machine is on level ground. 3. Stop the engine. Turn the steering wheel in both directions. This procedure helps purge pressure from the hydraulic system.
7. Straighten the steering wheel and lower the work tool to the ground. 8. If the pressure is within the specification, stop the engine, and proceed to the Testing and Adjusting, Margin Pressure Test.
Steering Pressure Adjustment

Introduction
The steering pressure can be adjusted at the metering pump (steering). Reference: See Systems Operation/Testing and Adjusting, "Location of Hydraulic Components" for the location of the metering pump.
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Adjustment Procedure
Margin Pressure Test

Introduction
The test indicates the difference's between the pump output pressure and the pressure for the load signal. This difference in pressure is called margin pressure.
Required Tools
Test Procedure
Illustration 62 relief valve (load sensing oil or signal oil) (Steering) (3) Plug (4) Adjustment screw
g01001790
Personal injury can result from removing hoses or fittings in a system under pressure. Failure to relieve pressure can cause personal injury. Do not remove or disconnect hoses or fittings until all pressure in the hydraulic system has been relieved. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates. 1. Ensure that the hydraulic oil is still warm. Refer to to the appropriate service manual for further information. 2. Retract the boom and lower the boom. Ensure that the machine is level. 3. Divide Tooling (B) into two separate gauge assemblies. Install a pressure gauge on test fitting (1) and install a pressure gauge on test fitting (2). Refer to Illustrations 60 and 61. 4. Start the engine and operate the engine at low idle. Rotate the steering wheel for the full distance of travel. Subtract the pressure at test fitting (1) from the pressure at test fitting (2). The difference in pressure should be 2200 100 kPa (320 20 psi). This is the margin pressure. If the pressure is not within the specification, refer to Testing and Adjusting, "Margin Pressure Adjustment".
1. Remove plug (3). 2. Use an appropriate sized hex key wrench to turn adjusting screw (4). Turn the screw clockwise in order to increase the pressure setting. Turn the screw counterclockwise in order to lower the pressure setting. Note: Do not turn the adjustment screw more than a half turn at a time. A half turn equals approximately 2480 kPa (360 psi). 3. Recheck the pressure setting. Refer to Testing and Adjusting, "Steering Pressure Test". 4. Install plug (3). Torque the plug to 62.5 2.5 Nm (46.0 2.0 lb ft).
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Margin Pressure Adjustment

Margin pressure should be within the specifications when the steering pressure is within the specification. If the margin pressure is not within the specification, then adjust the low pressure standby on the pump. Refer to Testing and adjusting, "Low Pressure Standby Adjustment" for the proper procedure.
Test Procedure
Personal injury can result from removing hoses or fittings in a system under pressure. Failure to relieve pressure can cause personal injury. Do not remove or disconnect hoses or fittings until all pressure in the hydraulic system has been relieved. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates. Note: Low pressure standby should be within specifications before this test is performed. Note: The test for the relief valve (load sensing oil) and the high pressure stall test can be done at the same time. 1. Ensure that the hydraulic oil is warm. Refer to the appropriate service manual for further information.
2. Retract the boom and lower the boom. Ensure that the machine is level. 3. Stop the engine. Turn the steering wheel in both directions. This procedure helps purge pressure from the hydraulic system. 4. Connect Tooling (B) to test fitting (1). Refer to Illustration 60.
Test for the Relief Valve (Load Sensing Oil)

Introduction
The pressure and flow compensator valve and the relief valve (load sensing oil) will determine the pump output pressure against the load. If the relief valve (load sensing oil) is set below specifications, the high pressure stall will be low. Note: The Relief Valve (Load sensing oil) is sometimes referred to as the signal limiter valve. The two terms have the same meaning throughout this story. Reference: See Systems Operation/Testing and Adjusting, "Location of Hydraulic Components" for the location of the hydraulic components on the machine.
Required Tools
Table 13
Required Tools Tool Part Number 8T-0860 6V-3989 B 177-7861 6V-4143 Part Description Pressure Gauge (0 to 40000 kPa (5800 psi)) Test fitting Hose Coupler Qty 1 1 1 2
5. Start the engine and operate the engine at low idle. Operate the control for the boom retract until the piston pump reaches a stall condition. The pressure at test fitting (1) should be 22800 500 kPa (3300 70 psi). This is the pressure for the load signal. If the relief valve (load sensing oil or signal oil) is not within the specification, adjust the valve before you proceed with any other tests. Refer to Testing and Adjusting, "Relief Valve (Load Sensing Oil or Signal Oil) Adjustment". 6. If the pressure is within the specification, stop the engine and remove Tooling (B).
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Adjustment of the Relief Valve (Load Sensing Oil)

Introduction
Use the following procedure to adjust the setting for the relief valve (load sensing oil or signal oil). The relief valve controls the hydraulic system pressure.
Test for Pressure Compensator

Introduction
The pressure compensator functions as a backup for controlling the high pressure stall. Ensure that all other pressures are within the specifications. A procedure for testing and adjusting the pressure compensator is available. Refer to Testing and Adjusting, "Adjustment for the Pressure Compensator Relief Setting". There is not a simple adjustment for the high pressure stall on this hydraulic system. This is due to the fact that the flow compensator and the relief valve (load sensing oil) control high pressure standby. On this hydraulic system, the pressure compensator serves as a backup.
Test Procedure
Personal injury can result from removing hoses or fittings in a system under pressure. Failure to relieve pressure can cause personal injury. Do not remove or disconnect hoses or fittings until all pressure in the hydraulic system has been relieved. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates. 1. Perform Step 1 through Step 4 in Testing and Adjusting, "Margin Pressure Test".
Illustration 64 (5) Locknut (6) Adjustment screw g01001794
Illustration 63 Relief valve (load sensing oil or signal oil)
g01001360
2. Operate the control for the boom retract until the pump reaches a stall condition. If the margin pressure is correct the pressure at test fitting (1) should be 22800 500 kPa (3300 70 psi). a. If the pressure for the relief valve (load sensing oil) is incorrect at test fitting (1) and the margin pressure is correct, the relief valve (load sensing oil or signal oil) needs to be adjusted. Refer to Testing and Adjusting, "Relief Valve (Load Sensing Oil) Adjustment".
b. If the margin pressure was correct and the pressure
1. Loosen locknut (5). Turn adjusting screw (6) clockwise in order to increase the pressure setting or turn counterclockwise in order to decrease the pressure setting. Note: Do not turn the adjustment screw more than a half turn at a time. 2. Hold adjusting screw (6) in place while you tighten locknut (5). 3. Recheck the pressure setting. Refer to Testing and Adjusting, "Test for the Relief Valve (Load Sensing Oil)". Note: If the signal does not change the pressure at the compensator on the pump needs to be adjusted.
for the relief valve (load sensing oil) was correct, check the pressure at test fitting (2). The pressure should be 26500 500 kPa (3843 70 psi) 25000 500 kPa (3630 70 psi) for the TH330B. This is the high pressure stall reading. If the pressure at test fitting (2) was identical to the signal pressure at test
52 Testing and Adjusting Section fitting (1) then the pressure compensator needs to be adjusted. Refer to Testing and Adjusting, "Pressure Compensator Adjustment". Refer to
Illustrations 60 and 61 for the location of the test fittings.
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4. Turn adjusting screw (8) counterclockwise in order to reduce the setting of the pressure compensator. Turn the screw until the margin pressure begins to drop. 5. When the margin pressure begins to drop, turn adjusting screw (8) clockwise by a 1/4 turn. This ensures that the pressure compensator is set above the adjustment for the relief valve (load sensing oil). 6. Tighten locknut (9) while you hold screw (8) in place. 7. Install seal (10) and cap nut (7). 8. Stop the engine and remove Tooling (B) from the machine.
c. If the high pressure stall reading is low, the pressure compensator needs to be adjusted. Refer to Testing and Adjusting, "Pressure Compensator Adjustment".
Pressure Compensator Adjustment

Low Pressure Standby Test

Introduction
When the machine is not being steered and all implement controls are in HOLD, the piston pump should operate in low pressure standby. The pump output pressure is at a minimum in low pressure standby.
Illustration 65 View on the left side of the machine (1) Test fitting for the load signal g00903590
Reference: See Systems Operation/Testing and Adjusting, "Location of Hydraulic Components" for the location of the hydraulic components on the machine.
Required Tools
Table 14
Required Tools Tool A Part Number 6V-7830 Part Description Pressure Gauge Qty 1
Note: Ensure the use of 6V-7830 Pressure Gauge. During engine start-up, a 17250 kPa (2500 psi) pressure spike is possible.
Illustration 66 (7) Cap nut (8) Adjustment screw (9) Locknut (10) Seal g01001801
Note: Make this adjustment only after trying to make the adjustment of the load sensing valve first. 1. Do not remove Tooling (B). Operate the engine at low idle. 2. Remove cap nut (7) and seal (10). 3. Loosen locknut (9).
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Test Procedure
Low Pressure Standby Adjustment

Introduction
Low pressure standby is controlled by the setting of the flow compensator spool.
Personal injury can result from removing hoses or fittings in a system under pressure. Failure to relieve pressure can cause personal injury. Do not remove or disconnect hoses or fittings until all pressure in the hydraulic system has been relieved. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, 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. Dispose of all fluids according to local regulations and mandates. 1. Ensure that the hydraulic oil is warm. Refer to the appropriate service manual for further information. 2. Retract the boom and lower the boom. Ensure that the frame is level. 3. Stop the engine. Turn the steering wheel in both directions. This procedure helps purge pressure from the hydraulic system. 4. Connect Tooling (A) to test fitting (2). Refer to Illustration 61. Note: Ensure the use of 6V-7830 Pressure Gauge. During engine start-up, a 17250 kPa (2500 psi) pressure spike is possible. 5. 5.Start the engine and operate the engine at low idle. Do not turn the steering wheel and do not operate the implement controls. The output pressure for the piston pump at test fitting (2) should be approximately 4500 1000 kPa (650 150 psi). This is the standby pressure for the piston pump. If the pressure is not within the specification, adjust the standby pressure. Refer to Testing and adjusting, "Low Pressure Standby Adjustment" for the proper procedure. 6. 6. If the pressure is within the specification, stop the engine and remove Tooling (A).
Illustration 67 (11) Locknut (12) Seal (13) Adjustment screw (14) Cap nut
1. Turn off the engine. 2. Remove cap nut (14) and seal (12). Loosen locknut (11). Turn adjusting screw (13) clockwise in order to increase the low pressure standby setting. Turn the adjustment screw counterclockwise in order to decrease the low pressure standby setting. Note: Do not turn the adjustment screw more than a half turn at a time. A half turn equals approximately 8000 kPa (116 psi). 3. Hold adjusting screw (13) in place while you tighten locknut (11). 4. Install seal (12) and cap nut (14). 5. Recheck the pressure setting. Refer to Testing and Adjusting, "Low Pressure Standby Test".
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Steering System - Purge

Purging the Steering System
Introduction
If the steering system has been disassembled or the axles have been removed from the machine the steering system should be purged before the machine is returned to service.
Reference: See the Operation and Maintenance Manual, "Operator Controls" for the location of the service tool connector. 2. Turn on the ignition. 3. Use Caterpillar Electronic Technician (ET) to disable the auto function for the wheel alignment. Reference: See the appropriate service manual for more information. 4. Turn off the ignition. Allow a fifteen second period of time in order for the system to power down. 5. Start the engine. Ensure that all the wheels are aligned with the frame in order to center the wheels into the straight ahead position. 6. Select circle steer mode on the switch for the steering mode. Turn the wheels fully to the right. 7. Select two-wheel steer mode on the switch for the steering mode. Turn the wheels fully to the left. 8. Select crab steer mode on the switch for the steering mode. Turn the wheels fully to the right. 9. Repeat steps 6 through 8 five more times. 10. Select circle steer mode on the switch for the steering mode. Align all the wheels with the frame.
Required Tools
Use the following equipment in order to perform the following procedure: Caterpillar Electronic Technician service tool (ET) The Caterpillar Electronic Technician service tool (ET) is used to access the configuration screen. A message on the ET screen will give instructions that guide the user through the procedure. Refer to the Manual that is provided with the ET software for more information about ET.
Table 15
Required Tools Part Number JEBD3003 171-4401 207-6845 160-0141 Description Caterpillar Electronic Technician (ET) Communications Adapter II Adapter Cable As Adapter Cable As Quantity 1 1 1 1
11. Stop the engine. 12. Turn on the ignition. 13. Use Caterpillar Electronic Technician (ET) in order to enable the auto function for wheel alignment. Reference: See the appropriate service manual for more information. 14. Turn off the ignition. Allow a fifteen second period of time in order for the system to power down. 15. Start the engine. Check that all the steering modes are operating correctly. 16. 16.Disconnect the communications adapter and the computer from the diagnostic service tool connector.
Solenoid Valve (Steering Mode Selector) - Test

The Solenoid's for the Steering Modes
Introduction
The solenoids on the steering selector valve operate on 12 volts that is supplied from the fuse for the steering system.
Illustration 68 Location of the diagnostic service tool connector g00898916
Purging Procedure
1. Connect the communications adapter and the computer to the diagnostic service tool connector.
Reference: See Systems Operation/Testing and Adjusting, "Location of Electrical Components" for the location of the electrical components on the machine.
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Required Tools
Use the following test equipment in order to perform the following procedure: Voltage Tester Digital multimeter Table 16 provides a list of tools that are required to perform the following procedures.
Table 16
Procedure for Checking the Solenoid Resistance

1. Disconnect the electrical connector at the solenoid that is not functioning properly. 2. Use Tooling (B) to check the resistance of the solenoid. Place a lead of the multimeter on each terminal on the solenoid. The resistance should be approximately 4.8 ohms at 20 C (68 F).
Required Tools Tool A B Part Number 5P-7277 6V-7070 Part Description Voltage Tester Digital Multimeter 1 1 Qty
Position Sensor (Steering) Adjust

Position Sensor
Introduction
The position sensor (steering) is installed on machines that are equipped with self-aligning rear steering. The sensor is attached to the rear steering cylinder. Use the following procedure to adjust the sensor. Reference: See Systems Operation, "General Information". Reference: See Testing and Adjusting, "Wheel Alignment - Check and Adjust" for the proper procedure. Reference: See Operation and Maintenance Manual, "Steering Mode Control".
The Procedure for testing the Circuit

Two people are needed to perform this test. Note: Ensure that the battery is fully charged for this check. 1. Turn the start switch ON, but do not start the engine. 2. Use the steering switch on the instrument panel to activate the solenoid circuits. Refer to Systems Operation, "General Information" for operating information on the switch. If a click is heard or if a vibration is felt, the solenoid is being energized. Ensure that both solenoids are checked. If the solenoid did not energize, proceed with the test. 3. Disconnect the electrical connector at the solenoid that is not functioning properly. 4. Use the steering switches on the dash panel in order to activate the disconnected solenoid circuit. 5. Use Tooling (A) to check for voltage on the electrical connector from the steering circuit. Place a lead from the voltage tester on the terminal with the black wire. This is the ground side of the circuit. Place the probe of the voltage tester on the remaining terminal in the connector. This is the battery side of the circuit. The light on the voltage tester should be at full brilliance. 6. If the light on the voltage tester does not illuminate, check the fuse for the steering circuit. If the fuse is not damaged, check the circuit for an open. If the light on the voltage tester is dim, check the circuit for a bad connection. Refer to the Electrical Schematic for your machine.
Personal injury or death can result from machine movement.

Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.
Illustration 69
g00744667
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Illustration 70
g00744669
Illustration 72 (3) Rear axle (4) Position sensor
g00793646
1. In following the above warning, place blocks in front of the wheels and behind the wheels. 2. Attach string (1) to steering stop (2) at the front of the front axle. Attach the string to the steering stop at the rear of the rear axle, as shown.
Illustration 73 (4) Position sensor (5) Clamp
g00793916
6. Slacken two clamps (5) that secure position sensor
(4).
Illustration 71
g00744670
3. Ensure that the wheels are aligned straight ahead. The string should be touching the outer circumference of each wheel in two places. If necessary, move the wheels to a straight ahead position. If the wheels do not touch the string in two places, adjust the wheel alignment. 4. Turn the engine start switch key to the ON position, but do not start the engine. 5. Move the master steering select switch to position 2. Refer to Operation and Maintenance Manual for additional information on the operation of the switches.
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7. Move the sensor to the right until the lamp on the sensor is extinguished. Make a mark on the steering cylinder corresponding to the right hand edge of the sensor. Move the sensor to the left until the lamp on the sensor is extinguished. Make a mark on the steering cylinder corresponding to the right hand edge of the sensor. Move the sensor so that the right hand edge of the sensor is positioned midway between the two marks. This is the optimum position for the sensor. Secure the sensor in place with the existing clamps (5). 8. Turn the engine start switch to the OFF position. 9. Remove the blocks from the wheels.
Wheel Alignment - Check and Adjust

Introduction
Correct steering alignment minimizes tire wear. There should be no toe on either axle. Reference: See the Systems Operation, "General Information". Reference: See the Operation and Maintenance Manual, "Steering Mode". Reference: See the Operation and Maintenance Manual, "Steering Mode Control". Reference: See the Specifications Manual, "Drive and Steering Axles".
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Checking the Wheel Alignment With Wheels In Place
Illustration 75 Steering geometry adjustment (1) Cord lines (2) Locknut (3) Guide rod (4) Knuckle (5) Bolt (6) Locknut
g00795375
1. Park the machine on level ground and align the wheels straight ahead. Move the transmission control to the NEUTRAL position and engage the parking brake. Note: Ensure that the rear wheels are straight ahead. If the steering is not synchronized, the rear wheels may be at an angle when the front wheels are straight. Refer to the Operation and Maintenance Manual, "Steering Mode Control". 2. Lower the boom and retract the boom. Stop the engine and attach a "DO NOT OPERATE" warning tag or similar warning tag to the controls. 3. Place a cord line (1) on each side of the machine. The lines should be parallel with the centerline of the machine. Each cord should be approximately 100 mm (4 inch) from the tires and at a height that corresponds to the centerline of the wheels. Measure the distance between the outer face of the tire and the adjacent cord in order to check that the wheels are parallel. Record the measurement at the front of each wheel and at the back of each wheel. 4. If the wheels are not parallel it will be necessary to adjust the wheel alignment.
Adjusting the Wheel Alignment

1. Loosen locknuts (2). Place an open end wrench on the flats of each guide rod (3). Rotate each guide rod clockwise by an equal amount until the wheels are parallel. Alternatively, rotate each guide rod counterclockwise by an equal amount until the wheels are parallel. The amount of chrome rod that is visible on each side of the steering cylinder must remain equal. Refer to distance (A) in Illustration 75. Tighten the locknuts after the adjustments for the tie rods are complete. Tighten locknuts (2) to the proper torque. See the Specifications Manual, "Drive and Steering Axles" for your machine in order to determine proper torque values. 2. Remove the cord lines.
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59 Testing and Adjusting Section 5. Loosen locknuts (6) on all four stop bolts (5). Turn all four bolts (5) clockwise until the bolts bottom out. 6. Hold a long straight bar (8) against the housing for the steering cylinder.
Adjusting the Steering Angle
Illustration 76 (4) Knuckle (5) Bolt (6) Locknut
g00894957
After the wheels have been correctly aligned the maximum steering angle must be adjusted. Each wheel is equipped with a knuckle (4). The knuckle is equipped with two bolts (5) that act as steering stops. Each bolt is secured in place with a locknut (6). Park the machine on level ground. Move the transmission control to the NEUTRAL position. Lower the boom and retract the boom. Engage the parking brake. 1. Raise the front of the machine in order to lift the front wheels off the ground. Place the jack in a location that will sustain the weight of the machine such as the axle pads. The axle pad should be parallel to the ground. The head of the jack should be against a flat surface. Use a jack which will support the weight of the machine. 2. Remove both of the front wheels.
Illustration 78 Typical Example
g00950064
7. Rotate the left side final drive until the angle that is formed by the two bars measures the correct angle. See table 17.
Table 17
Steering Angles Model TH220B & TH330B TH360B TH560B Front 48 46 46 Rear 50 48 48
8. Apply 154-9731 Thread Lock Compound to the four stop bolts (5). Apply the compound to the threads in the knuckle and apply the compound in the locknuts (6). See Illustration 76. 9. Turn stop bolt (5) on the left side knuckle counterclockwise until the head of the screw contacts the steering stop. Secure the screw in place with locknut (6). Tighten locknuts (6) to a torque of 150 N-m (111 lb ft). See Illustration 75. Note: Use a piece of paper as a go/no-go gauge in order to check that the stop bolts touch the casting. If the paper slides between the bolt and the casting, reset the bolt in order to contact the casting. 10. Repeat step 9 for the stop screw on the right side knuckle that is diagonally opposite.
Illustration 77 Typical Example
g00950065
3. 3. Place bar (7) against the outer flange of the final
Note: The steering stop on the right side knuckle and the steering stop that is directly opposite must make contact with the castings at the same time when the steering is at the maximum angle. 11. Rotate the final drive on the right side until the angle that is formed by the two bars measures the correct angle. See table 17. 12. Turn stop bolt (5) on the right side knuckle counterclockwise until the head of the bolt
drive on the left side. Secure the bar in place with two existing wheel nuts. Repeat the procedure for the final drive on the right side. 4. Clean the four stop bolts (5) and locknuts (6).
60 Testing and Adjusting Section contacts the steering stop. Secure the screw in place with locknut (6). Tighten locknuts (6) to a torque of 150 Nm (111 lb ft). See Illustration 75. Note: Use a piece of paper as a go/no-go gauge in order to check that the stop bolts touch the casting. If the paper slides between the bolt and the casting, reset the bolt in order to contact the casting. 13. 13.Repeat step 12 for the stop screw on the left side knuckle that is diagonally opposite. Note: The steering stop on the left side knuckle and the steering stop that is directly opposite must make contact with the castings at the same time when the steering is at the maximum angle. 14. Remove measuring bars (7) and (8). 15. Replace both wheels and lower the machine to the ground. 16. Repeat the procedure for the rear axle.
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General Information Table

Table 18
Specifications Low Idle (Engine) High Idle (Engine) Torque Stall High Pressure Stall - TH220B High Pressure Stall - TH330B Signal Relief Pressure Low Pressure Standby Margin Pressure Steering Pressure 220B, 330B, and 360B Steering Pressure 560B and 580B
Table 19
950 25 rpm 2350 25 rpm 1985 25 rpm 26500 500 kPa (3843 70 psi) 25000 500 kPa (3630 70 psi) 22800 500 kPa (3300 70 psi) 4500 kPa (650 psi) 2200 100 kPa(32020 psi) 16250 750 kPa (2400 100 psi) 17750 750 kPa (2575 100 psi)
Pressure of the Fan Pump and Speed of the Fan Motor 220B and 330B Machines (Fan Reversing) Engine Low High Speed Idle Idle Pressure 4000 200 kPa (580 30 psi) 15000 200 kPa (2175 30 psi) Fan Motor in Reverse or Counterclockwise Direction Low High Idle Idle 4000 200 kPa (580 30 psi) 14500 200 kPa (2100 30 psi) 1230 50 RPM 2840 50 RPM Fan Speed 1230 50 RPM 2400 50 RPM
Note: Refer to the appropriate Operation & Safety Manual for the proper operation of the reverse switch.
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Index
61 Index A L
Location of Electrical Components Electronic Control Module............................................... 8 Position Sensors............................................................. 7 Relay (Circle Steer) ........................................................ 9 Relay (Crab Steer) .......................................................... 8 Selector Switch for the Steering Mode ........................... 7 Solenoid for Circle Steer ................................................. 8 Solenoid for Crab Steer .................................................. 8 Location of Electrical Components....................................... 7 Location of Hydraulic Components Control Valve (Steering) ............................................... 11 Hydraulic Oil Drain Plugs.............................................. 12 Hydraulic Oil Level Indicator ......................................... 12 Hydraulic Tank.............................................................. 11 Hydraulic Tank Breather ............................................... 11 Line for the Signal Limiter Valve for the Steering ......... 10 Metering Pump ............................................................. 10 Piston Pump ................................................................. 10 Priority Valve................................................................. 10 Steering Cylinders ........................................................ 11 Steering Wheel ............................................................... 9 Location of Hydraulic Components ...................................... 9
Adjustment of the Relief Valve (Load Sensing Oil) Low Pressure Standby Adjustment............................... 53 Low Pressure Standby Test.......................................... 52 Pressure Compensator Adjustment.............................. 52 Test for Pressure Compensator.................................... 51 Adjustment of the Relief Valve (Load Sensing Oil) ............ 51
C
Configuration Parameters .................................................. 43
E
Electrical Input Components Position Sensor............................................................. 13 Steering Mode Switch................................................... 12 Electrical Input Components .............................................. 12 Electrical Output Components CAN Data Link.............................................................. 15 CAT Data Link .............................................................. 14 Data Link....................................................................... 14 Instrument Cluster ........................................................ 14 Relays........................................................................... 14 Electrical Output Components ........................................... 14 Electrical Schematic........................................................... 15 Electronic Control Module .................................................. 13
M
Metering Pump (Steering) Hold .............................................................................. 39 Left Turn ....................................................................... 41 Right Turn ..................................................................... 40 Metering Pump (Steering) .................................................. 37
G
General Information ............................................................. 4 Circle Steer..................................................................... 4 Crab Steer ...................................................................... 4 Machines With Self-Aligning Steering............................. 5 Manually Aligned Rear Wheels....................................... 5 Steering Arrangement..................................................... 4 Two-wheel Steer............................................................. 4 General Information Table ................................................. 60 Graphic Color Codes............................................................ 3
P
Piston Pump (Implement and Steering) Compensator Valve ...................................................... 30 Constant Flow ............................................................... 33 Destroke ....................................................................... 34 High Pressure Stall ....................................................... 36 Low Pressure Standby.................................................. 31 Piston Pump ................................................................. 29 Upstroke ....................................................................... 32 Piston Pump (Implement and Steering) ............................. 29 Position Sensor (Steering) ................................................. 42 Position Sensor (Steering) -Adjust Position Sensor............................................................. 55 Position Sensor (Steering) -Adjust ..................................... 55 Pump Flow - Test Pump Flow .................................................................... 46 Test On The Machine ................................................... 46 Pump Flow - Test ............................................................... 46
H
Hydraulic Oil Contamination -Test Flushing the Sampling Valve ........................................ 45 Hydraulic Oil Contamination ......................................... 45 Obtaining the Sample ................................................... 45 Hydraulic Oil Contamination -Test ..................................... 45 Hydraulic Schematic (Steering System)............................. 28
I
Important Safety Information.................................................ii Inlet Manifold Check Valve.................................................................. 16 Flow Control Valve (Dump valve for the load sensing oil) ........................... 16 Relief Valve (Load sensing oil) ..................................... 16 Screens (75 and 100 Micron) ....................................... 16 Steering Activated......................................................... 18 Steering Not Activated.................................................. 17 Steering Priority Valve .................................................. 15 Inlet Manifold...................................................................... 15 Introduction .......................................................................... 6
S
Solenoid Valve (Steering Mode Selector) Solenoid Valve.............................................................. 37 Solenoid Valve (Steering Mode Selector) - Test The Solenoids for the Steering Modes......................... 54 Solenoid Valve (Steering Mode Selector) - Test ................ 54 Solenoid Valve (Steering Mode Selector) .......................... 37
62 Index
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Steering System Left Turn in Circle Steer Mode...................................... 24 Left Turn in Crab Steer Mode ....................................... 26 Right Turn in Two-Wheel Steer Mode .......................... 22 Steering Control System............................................... 19 Steering in Neutral ........................................................ 20 Steering System - Purge Purging the Steering System ........................................ 54 Steering System - Purge .................................................... 54 Steering System Pressures -Test and Adjust .................... 47 Margin Pressure Adjustment ........................................ 50 Margin Pressure Test ................................................... 49 Steering Pressure Adjustment ...................................... 48 Steering Pressure Test ................................................. 48 Steering System Pressure Tests and Adjustments ...... 47 Test for the Relief Valve (Load Sensing Oil)................. 50 Steering System................................................................. 19 Systems Operation Section.................................................. 3
T
Table of Contents................................................................. 1 Testing and Adjusting Section............................................ 45
W
Wheel Alignment - Check and Adjust Adjusting the Steering Angle ........................................ 59 Adjusting the Wheel Alignment..................................... 58 Checking the Wheel Alignment With Wheels In Place . 58 Wheel Alignment - Check and Adjust................................. 57
Manufactured by JLG under license from Caterpillar

Systems Operation Testing and Adjusting: TH220B, TH330B, TH360B, TH560B and TH580B Telehandlers Steering System

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Systems Operation Testing and Adjusting: TH220B, TH330B, TH360B, TH560B and TH580B Telehandlers Steering System

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31200273 December 15, 2006

Systems Operation Testing and Adjusting

Important Safety Information

3 Systems Operation Section

Systems Operation Section

4 Systems Operation Section

Manually Aligned Rear Wheels

Machines With Self-Aligning Steering

6 Systems Operation Section

7 Systems Operation Section

Location of Electrical Components

Selector Switch for the Steering Mode

Illustration 8 Front Position Sensor

Illustration 9 Rear Position Sensor

Solenoid for Circle Steer

Electronic Control Module

Relay (Crab Steer)

Solenoid for Crab Steer

9 Systems Operation Section

Relay (Circle Steer)

Location of Hydraulic Components

10 Systems Operation Section

Line for the Signal Limiter Valve for the Steering

g00903734 Illustration 19 g00874759

11 Systems Operation Section

Control Valve (Steering)

Illustration 23 Illustration 21 g00903903

Hydraulic Tank Breather

12 Systems Operation Section

Hydraulic Oil Level Indicator

Electrical Input Components

Hydraulic Oil Drain Plugs

Steering Mode Switch

Electronic Control Module

Contact Description J2(1) No.( 5 6 24 25 26 27 28

14 Systems Operation Section

Electrical Output Components

CAT Data Link

Relay (Circle Steer) and Relay (Crab Steer)

15 Systems Operation Section

CAN Data Link

The inlet manifold is part of the main control valve (implement).

16 Systems Operation Section

Steering Priority Valve

Screens (75 and 100 Micron)

Relief Valve (Load sensing oil)

17 Systems Operation Section

Steering Not Activated

18 Systems Operation Section

19 Systems Operation Section

(implement) once the requirements of the steering flow are met.

20 Systems Operation Section

21 Systems Operation Section

22 Systems Operation Section

Right Turn in Two-Wheel Steer Mode

23 Systems Operation Section

24 Systems Operation Section

Left Turn in Circle Steer Mode

25 Systems Operation Section

26 Systems Operation Section

Left Turn in Crab Steer Mode

27 Systems Operation Section