Testing and Adjusting

990 Series II Wheel Loader 4FR00001-UP (MACHINE) POWERED BY 3412 Engin...
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Product:WHEELLOADER
Model:990IIWHEELLOADER4FR
Configuration:990SeriesIIWheelLoader4FR00001-UP(MACHINE)POWEREDBY3412Engine
Testing and Adjusting

990 & 990 II WHEEL LOADER & 844 WHEEL TRACTOR STEERING SYSTE
Media Number -SENR6649-01 Publication Date -31/03/1995 Date Updated -15/04/2011

SENR66490002
Testing and Adjusting

SMCS - 7566
Important Information
Reference: For specifications with illustrations, make reference to SENR6648, 990 Wheel Loader
Steering System Specifications. If the specifications in SENR6648 are not the same as in the
Systems Operation, Testing And Adjusting module, look at the printing date on the cover of each
book. Use the specifications in the book with the latest date.
Personal injury or death can result from improperly checking for a

leak.
Always use a board or cardboard when checking for a leak. Escaping

fluid under pressure, even a pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is injected into your
skin, it must be treated immediately by a doctor familiar with this type
of injury.
Sudden movement of the machine or release of oil under pressure can

cause injury to persons on or near the machine. To prevent possible
injury, perform the procedure that follows before testing and adjusting
the hydraulic system.
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990 Series II Wheel Loader 4FR00001-UP (MACHINE) POWERED BY 3412 Engin... Page 2 of 21
1. Move the machine to a smooth horizontal location. Move away from working machines and
personnel. Lower the bucket to the ground. Stop the engine.
2. Permit only one operator on the machine. Keep all other personnel either away from the
machine or in view of the operator.
3. Engage the parking brake. Put blocks in front of and behind the wheels.
4. Carefully loosen the fill cap on the hydraulic tank to release the pressure in the tank.
5. Install the steering frame lock link so the machine can not turn.
6. Make sure all hydraulic pressure is released before any fitting, hose or component is loosened,
tightened, removed or adjusted.
7. Tighten the fill cap on the hydraulic tank.
During diagnosis of a hydraulic system, remember that correct oil flow and pressure are necessary
for correct operation. The output of the pump increases with an increase in engine speed and
decreases when engine speed is decreased. Oil pressure is caused by resistance to the flow of oil.
Visual Checks
Make reference to the WARNING on the first page of the steering

system Testing And Adjusting section.
The 4C-4890, 6V-7940, and 8T-5320 Hydraulic Test Groups, or 1U-5481 Pressure Gauge Group,
are used to make the pressure test of the hydraulic system. Before any tests are made, visually
inspect the complete hydraulic system for leakage of oil and for parts that have damage. For some
of the tests, a magnet and a measuring rule (either for inches or millimeters) are usable tools.
When any test is made to the steering hydraulic system, the hydraulic oil must be at the normal
temperature for operation. To increase the oil temperature, start the engine, raise and lower the
bucket, and turn the machine in both directions.
A visual inspection of the steering system and its components is the first step when a diagnosis of
a problem is made. Stop the engine and lower the bucket to the ground. Make the following
inspections:
1. Check the oil level in the sight gauge.
2. Look for air in the oil that is in the tank. Do this immediately after the machine is stopped. Use
a clear bottle or container to obtain a sample of the oil. Look for air bubbles in the oil that is in the
bottle.
3. Remove the filter elements and look for particles removed from the oil by the filter elements. A
magnet will separate ferrous (metallic) particles from nonferrous (nonmetallic) particles.
4. Check all oil lines and connections for damage or leaks.
Performance Tests
Performance tests of the steering system can be used for a diagnosis of poor performance and to
find the source of oil leakage inside the hydraulic system.
This section provides probable causes to a known problem. Since there may be several probable
causes, specific inspections or instrument tests may be recommended. These inspections and tests
will help identify which of the causes is most probable.
Steering System Problems

Problem: Machine turns slowly when STIC control lever is moved.
Probable cause:
1. Oil is cold.
2. Restriction in pilot valve pilot lines.
3. Pilot lines to pilot valve are not connected to proper ports.
4. Steering pump pressure is low.
Problem: Machine responds slowly when steering quickly away from a full turn.
Probable cause:
Not enough clearance between ball check valve and plug assembly in neutralizer valve.
Problem: STIC control lever attempts to turn machine when the machine is at full turn.
Probable Cause:
1. Adjustment of striker for neutralizer valve is not correct.

2. The seat for the ball check valve is worn or damaged.
3. Relief valve opens before striker moves the neutralizer valve stem.
Problem: Machine does not turn smoothly.
Probable Cause:
Control valve spool does not move freely.
Problem: Machine turns too slow in both directions.
Probable Cause:
1. Springs for control valve spool are not adjusted correctly.

2. Not enough flow from primary steering pump.
3. Control valve spool does not move all the way.
Problem: Machine turns too slow in one direction.
Probable Cause:
1. Flow balance adjustment of control valve spool is not correct.

2. Bad seal and/or seat in shuttle valve.
Problem: Machine turns correctly when roading, but is slow in both directions when the
machine turns against a load.
Probable Cause:
1. Leakage past relief valve seat or seals.

2. Leakage past both shuttle seats.
3. The fit of the control valve spool in the bore is not correct.
Problem: Machine turns correctly when roading, but is slow in one direction when the
machine turns against a load.
Probable Cause:
1. Slow right turn: leakage past upper shuttle seat or seal.

2. Slow left turn: leakage past lower shuttle seat or seal.
Problem: Machine does not turn when STIC control lever is moved.
Probable Cause:
1. Control valve spool will not move from the neutral position.
2. Leakage past pilot relief valve seat or seals.
Problem: Machine turns without operator moving the STIC control lever.
Probable Cause:
1. Control valve spool does not return to neutral correctly.

2. The mounting bolts for the steering control valve are too tight.
3. The bolts are too tight for the end covers of the steering control valve.
4. Manufacturing tolerances on the control valve spool in the steering control valve do not
permit the control valve spool to go back to neutral. This can be corrected on some
machines by turning the control valve spool in the steering control valve end for end in its
bore. To do this, the spring, retainer, and shims must be installed on the opposite end of the
control valve spool. An adjustment may be necessary for the steering times.
Problem: Machine turns too fast to make small steering corrections when the machine
moves at fast speeds.
Probable Cause:
1. Control valve spool adjustment is not correct.

2. Control valve spool does not move freely.
3. Metering orifices on control valve spool are filled with foreign material or were not
drilled correctly.
Problem: Pump makes noise and the steering cylinder pistons and rods do not move
smoothly.
Probable Cause:
1. Air in the steering hydraulic circuit.
2. The pump has too much wear.

3. Loose connection of the oil line on the inlet side of the pump.
4. The viscosity of the oil is wrong.
5. The relief valve opens at low oil pressure.
6. The oil level in the tank is low.
Pump Efficiency Check

NOTE: For more information on the hydraulic pump, see SENR6648, Steering System
Specifications.
For any pump test at a given rpm, the pump flow at 690 kPa (100 psi) will be larger than the pump
flow at 6900 kPa (1000 psi). The difference between the pump flow of the two operating pressures
is the flow loss.
Method of finding flow loss:
Flow loss when expressed as a percent of pump flow is used as a measure of pump performance.
Example of finding percent of flow loss:
If the percent of flow loss is more than ten percent, pump performance is not adequate.
*
Numbers in examples are for illustration and are not values for any specific pump or pump
condition. See Specifications for pump flow of a new pump at 690 kPa (100 psi) and 6900 kPa
(1000 psi).
Machine Test
Install a flow meter. For Formula I, measure pump flow at 690 kPa (100 psi) and at 6900 kPa
(1000 psi) with the engine at high idle rpm.
Bench Test
If the test bench can be run at 6900 kPa (1000 psi) and at full pump rpm, find the percent of flow
loss using Formula I.
If the test bench can not be run at 6900 kPa (1000 psi) and at full pump 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 part of Formula II. For the bottom part of the formula, run the pump shaft at 2000
rpm. Measure the pump flow at 690 kPa (100 psi).
Steering Time Check

To check the steering time, put the machine on a dry, hard surface. With the engine at high idle,
the time for a full turn, from stop to stop, must be 3.7 .3 seconds.
With the engine at low idle, the time for a full turn, from stop to stop, must be 7.4 .6 seconds.
With the service brakes off, the difference between the time for a right turn and the time for a left
turn must not be more than .3 second. With the service brakes activated, the time must not
increase more than .2 second.
If the difference between the times for a full right turn and a full left turn with the service brakes
off is more than .3 second:
Steering Control Valve

(1) Control valve spool. (2) Cylinder flow shims. (3) Springs. (4) Pilot port.
1. Remove the fittings from pilot port (4) of the steering control valve.
NOTE: The standard steering control valve is shown, however, the steering control valve for
supplemental steering is similar.
2. Add flow shims (2) for a faster right turn time and slower the left turn time. If the flow balance
shims are removed, the result is opposite.
3. The 4J-8224 flow shims are .25 mm (.010 in) thick. The 5J-4776 flow shims are .30 mm (.012
in) thick. Two shims (one each) will change the steering time at high idle by approximately .1
second each direction.
Example: A check of the steering times shows that the right turn time takes .4 second longer than
the left turn time. Flow shims (2) must be added to decrease the difference between the times. The
addition of four shims (two each) will reduce the right turn time by approximately .2 second and
increase the left turn time approximately .2 second. This will make the right and left turn times
approximately the same.
4. install the fittings and pilot line to port (4).
Pressure Control And Selector Valve
Make reference to the WARNINGS on the first page of the Steering

System Testing And Adjusting section.
Steering Frame Lock Link Installed

(1) Steering frame lock link.
1. Install steering frame lock link (1), so the machine can not turn.
Pilot System Pressure Taps And Relief Valves
(2) Fan drive pump. (3) Steering control valve. (4) Pressure reducing valve. (5) Pressure control and selector valve.
(6) Hose assembly. (7) Pressure taps.
2. Attach the correct hose and pressure gauge to pressure taps (7).
3. Start and run the engine at high idle. With the oil at normal operating temperature, the pressure
reading must equal 3300 400 kPa (480 60 psi).
Cross Section Of Pressure Control And Selector Valve

(8) Spring. (9) Spacers. (10) Adapter.
4. If the pressure reading is not correct, stop the engine.
5. Move the STIC control lever to the center position to release any pilot pressure in the steering
pilot system.
6. Carefully loosen the hydraulic tank fill cap to release any pressure in the hydraulic oil tank.
After releasing the pressure in the hydraulic oil tank, tighten the tank fill cap.
7. Adjust the secondary oil source pressure from the steering system to obtain the primary source
pilot pressure from the fan drive.
8. Locate hose assembly (6), which connects between the fan drive and the pressure control and
selector valve. Completely remove the hose assembly and install a cap on each end of the hose
assembly. Install a plug in the open port on the fan drive unit where the hose assembly was
connected. Install a plug in the open port on the pressure control and selector valve where the hose
assembly was connected.
9. Start the engine. Check the pilot pressure of the secondary source. This pressure should equal
1650 100 kPa (240 15 psi). If the pressure does not equal 1650 100 kPa (240 15 psi),
adjust the valve in the next step.
10. If the pressure needs to be increased, remove adapter (10) and add spacers (9) between spring
(8) and adapter (10). If the pressure needs to be decreased, remove adapter (10) and then remove
spacers (9) as necessary.
990 Series II Wheel Loader 4FR00001-UP (MACHINE) POWERED BY 3412 Eng... Page 10 of 21
NOTE: Be sure to assemble the pressure and selector control valve group so the thick spacer
contacts the spring, and the thin spacer(s) contact adapter (10).
11. Install adapter (10), and repeat Step 9.
12. Install hose assembly (6), and repeat Step 3.
13. If the pressure reading is correct, stop the engine. Remove the test equipment from pressure
tap (7).
14. If the pressure reading is not correct, repeat Steps 5 through 12. If both pressures can not be
obtained, replace the pressure control and selector valve.
Steering System Pressure Tests

Backup Main Relief Valve


1. Install steering frame lock link (1), so the machine can not turn.
Steering System Pump

(2) Pump. (3) Pressure compensator.
Pressure Taps
(4) Left turn pressure tap. (5) Right turn pressure tap.
2. Assemble the necessary hoses and pressure gauges to pressure taps (4) and (5).
NOTE: The relief valve setting is higher than the pressure compensator setting of the steering
pump.
Backup Pressure Relief Valve Location

(6) Pressure relief valve.
Backup Pressure Relief Valve

(7) Locknut. (8) Adjustment screw.
3. Loosen locknut (7), and turn the adjusting screw out exactly one turn to reduce the relief valve
setting by 5170 kPa (750 psi). This will lower the relief valve pressure below the pump's pressure
compensator setting.
4. Start the engine, and operate it at high idle.
5. While observing the gauges, move the STIC control lever in both directions until the relief
valve opens. Note the gauge reading in each direction. With the backup relief valve pressure
adjustment screw turned one revolution out (pressure lowered), the setting should equal 29 325
700 kPa (4255 100 psi).
NOTE: Do not keep the control lever in either turn position while the backup pressure relief valve
is at the relief valve setting for more than five seconds.
6. If the pressure is not the same in both directions, there is a problem in the shuttle valve. If the
pressure is the same in both directions, but the pressure is not correct, the backup main relief valve
must be adjusted.
7. Stop the engine.
8. Loosen locknut (7). To increase the pressure setting, turn adjustment screw (8) clockwise. To
decrease the pressure setting, turn adjustment screw (8) counterclockwise.
9. After screw (8) is adjusted as necessary, tighten locknut (7) to a torque of 50 7 Nm (35 5 lb
ft).
10. Start the engine and operate it at high idle. Repeat Steps 5 and 6.
11. If the pressure is correct, stop the engine.
12. If the pressure is not correct, repeat Steps 7, 8, and 9.
13. After the pressure setting has been adjusted, stop the engine.
14. Set the final relief valve pressure by turning adjustment screw (8), in exactly one turn to
increase the main relief valve pressure setting by 5170 kPa (750 psi). The correct backup relief
valve pressure setting should now equal 34 500 700 kPa (5005 100 psi).
15. Remove the steering frame lock link.
Pressure Compensator Adjustment

1. Install steering frame lock link (1) so the machine can not turn.
Steering System Pressure Tap

(2) Pressure tap. (3) Pressure compensator.
2. Assemble the necessary hoses and pressure gauge to pressure tap (2).
View Of Main Steering Pump With Pressure And Flow Compensator Group
View A-A
(4) Pressure compensator spool. (5) Adjustment screw. (6) Locknut. (7) Cap.
3. Start the engine and operate it at high idle.
4. While observing the gauge, move the STIC control lever in both directions until the relief valve
opens. Note the gauge reading in each direction. The correct pressure compensator setting equals
31 000 400 kPa (4500 60 psi).
NOTE: Do not keep the control lever in either turn position at the relief valve setting for more
than five seconds.
5. If the pressure is not the same in both directions, there is a problem in the shuttle valve. If the
pressure is the same in both directions, but the pressure is not correct, the pressure compensator
needs to be adjusted.
6. Stop the engine.
7. Remove cap (7), and loosen locknut (6). To increase the pressure setting, turn adjustment screw
(5) clockwise. To decrease the pressure setting, turn adjustment screw (5) counterclockwise.
8. After turning adjustment screw (5) to obtain the correct pressure reading, tighten locknut (6),
and replace cap (7).
9. Start the engine and operate it at high idle. Repeat Steps 4 and 5.
10. If the pressure is correct, stop the engine.
11. If the pressure is not correct, repeat Steps 7, 8, and 9.
12. After the correct pressure setting is obtained, stop the engine.
13. Remove the hoses and pressure gauge that was attached to pressure tap (2) in Step 2.
14. Remove the steering frame lock link.
Margin Pressure Adjustment Procedure

1. Install the steering frame lock link.
2. Stop the engine. Move the STIC control lever right and left to release any steering pilot oil
pressure.
3. Slowly loosen the hydraulic oil tank fill cap to relieve any pressure.
NOTE: Pressure may be trapped in the steering cylinders. To relieve any pressure, perform the
following step.
Right And Left Turn Pressure Tap Locations

4. Connect a drain hose equipped with quick disconnects from left turn pressure tap (1), to the
hydraulic oil tank. Connect a drain hose equipped with quick disconnects from right turn pressure
tap (2), to the hydraulic oil tank.
5. Move the STIC control lever all the way to the left, and then all the way to the right. Repeat this
step until there is no wheel movement from side to side.
6. Remove the drain hose assemblies after all steering pressure has been relieved.
Right Side View Of Steering Lines Group

(3) Pump signal line. (4) Steering control valve.
7. Attach a quick disconnect nipple to an 8T-8902 Tee. Install one side of the tee to pump signal
line (3), and the other side of the tee to steering control valve (4).
Right Side View Of Steering Control Valve Group

(5) 6E3985 Cylinder Crossover Relief Valve.
8. Remove cylinder crossover relief valve (5). Install a 9S4190 O-ring Plug and a 2M9780 O-ring
Seal in the open port.
Steering System Pressure Tap Location

(6) Pressure tap.
9. Connect a differential pressure gauge so the high pressure side is connected to steering pump
discharge pressure tap (6). Connect the low pressure side to the tap in the signal pressure line that
was installed in Step 7.
10. Start the engine and run it at high idle.
11. Move the STIC control lever until it is half way to the extreme right position. Check the
differential pressure gauge. The gauge should indicate 2100 100 kPa (305 15 psi).
Location Of Flow Compensator Valve

(7) Cap. (8) Locknut. (9) Adjustment screw.
12. If the differential pressure gauge did not indicate 2100 100 kPa (305 15 psi), the flow
compensator valve located on the main steering pump needs to be adjusted.
If the reading was too high, remove cap (7), loosen locknut (8), and turn adjustment screw (9)
counterclockwise to decrease the margin pressure. If the reading was too low, remove cap (7),
loosen locknut (8), and turn adjustment screw (9) clockwise to increase the margin pressure.
NOTE: One turn of adjustment screw (9) changes margin pressure approximately 7405 kPa (1075
psi).
13. Tighten locknut (8), and replace cap (7).
14. Stop the engine. Move the STIC control lever right and left to release any steering pilot oil
pressure.
15. Slowly loosen the hydraulic oil tank fill cap to relieve any tank pressure.
NOTE: Pressure may be trapped in the steering cylinders. To relieve any pressure, perform the
following step.
Right And Left Turn Pressure Tap Locations

16. Connect a drain hose equipped with quick disconnects from left turn pressure tap (1), to the
hydraulic oil tank. Connect a drain hose equipped with quick disconnects from right turn pressure
tap (2), to the hydraulic oil tank.
17. Move the STIC control lever all the way to the left, and then all the way to the right. Repeat
this step until there is no wheel movement from side to side.
18. Remove the drain hose assemblies after all steering pressure has been relieved.
19. Disconnect and remove the differential pressure gauge.
20. If the tee that was installed in Step 7 is not removed, it should be protected by installing a 6V-
0852 Dust Cap.
21. Remove the 9S-4190 O-ring Plug, and 2M-9780 O-ring Seal that was installed in Step 8.
Right Side View Of Steering Control Valve Group

(5) 6E3985 Cylinder Crossover Relief Valve.
22. Install steering crossover relief valve (5) in the steering control valve group. Tighten relief
valve (5) to a torque of 60 7 Nm (45 5 lb ft).
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990 Series II Wheel Loader 4FR00001-UP (MACHINE) POWERED BY 3412 Engin...

Testing and Adjusting

Testing and Adjusting

Personal injury or death can result from improperly checking for a

Always use a board or cardboard when checking for a leak. Escaping

Sudden movement of the machine or release of oil under pressure can

7. Tighten the fill cap on the hydraulic tank.

Make reference to the WARNING on the first page of the steering

1. Check the oil level in the sight gauge.

4. Check all oil lines and connections for damage or leaks.

Steering System Problems

1. Adjustment of striker for neutralizer valve is not correct.

Problem: Machine does not turn smoothly.

Control valve spool does not move freely.

Problem: Machine turns too slow in both directions.

1. Springs for control valve spool are not adjusted correctly.

Problem: Machine turns too slow in one direction.

1. Flow balance adjustment of control valve spool is not correct.

1. Leakage past relief valve seat or seals.

1. Slow right turn: leakage past upper shuttle seat or seal.

1. Control valve spool does not return to neutral correctly.

1. Control valve spool adjustment is not correct.

1. Air in the steering hydraulic circuit.

2. The pump has too much wear.

Pump Efficiency Check

Method of finding flow loss:

Example of finding percent of flow loss:

Steering Time Check

Steering Control Valve

4. install the fittings and pilot line to port (4).

Pressure Control And Selector Valve

Make reference to the WARNINGS on the first page of the Steering

Steering Frame Lock Link Installed

Pilot System Pressure Taps And Relief Valves

Cross Section Of Pressure Control And Selector Valve

4. If the pressure reading is not correct, stop the engine.

11. Install adapter (10), and repeat Step 9.

12. Install hose assembly (6), and repeat Step 3.

Steering System Pressure Tests

Make reference to the WARNINGS on the first page of the Steering

Steering Frame Lock Link Installed

Steering System Pump

Backup Pressure Relief Valve Location

Backup Pressure Relief Valve

4. Start the engine, and operate it at high idle.

7. Stop the engine.

11. If the pressure is correct, stop the engine.

12. If the pressure is not correct, repeat Steps 7, 8, and 9.

15. Remove the steering frame lock link.

Pressure Compensator Adjustment

Steering Frame Lock Link Installed

Steering System Pressure Tap

3. Start the engine and operate it at high idle.

6. Stop the engine.

10. If the pressure is correct, stop the engine.

11. If the pressure is not correct, repeat Steps 7, 8, and 9.

14. Remove the steering frame lock link.

Margin Pressure Adjustment Procedure

Make reference to the WARNINGS on the first page of the Steering

1. Install the steering frame lock link.

Right And Left Turn Pressure Tap Locations

Right Side View Of Steering Lines Group

Right Side View Of Steering Control Valve Group

Steering System Pressure Tap Location