STEERING HYDRAULICS The steering system is a flow amplified, load sensing, hydraulics arrangement.
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- Conrad Fowler
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1 STEERING HYDRAULICS The steering system is a flow amplified, load sensing, hydraulics arrangement. When the steering wheel is turned, the Steering Metering Pump meters an oil volume proportional to the amount of turn. The steering wheel rotation for the first 9º either direction (approximately 1.12 inches) from it's present stopped position produces no steering result. Beyond the 9º point starts a rapid increase in the volume of oil being directed to the steering cylinders. If the steering wheel is moved in the opposite direction suddenly beyond the 18º point, the steering cylinders will move in the opposite direction. Too much steering wheel movement in opposite directions can result in jerky steering cylinder movements. These movements are not unsafe, but are less comfortable to the operator. The optimum steering wheel action would be to move the steering wheel the minimum amount necessary to position the steering for the present situation. The oil then passes through the flow amplifier where the oil flow is amplified (16 to 1 ratio) and is then led to the appropriate side of the pistons in the steering cylinders. When one cylinder is pushing, the other is pulling. The amplifier are equipped with a built-in priority valve. The priority valve ensures the necessary oil flow is supplied to the Steering Metering Pump and to the flow amplifier spool in all steering situations. There is also a built in back pressure valve which ensures a return pressure of 73 PSI (5 bar) to improve make-up oil to the low pressure side of the steering cylinder pistons during steering. The sole purpose of the pilot relief valve is to protect the steering system. The Steering Metering Pump automatically returns to its neutral position when steering wheel rotation stops. If the oil flow from the accumulator system fails, the Steering Metering Pump automatically functions as a hand pump, i.e. manual steering (emergency steering) of the vehicle is maintained. Max. pressure in steering system 2550 PSI (175 bar) Control spring pressure in priority valve 100 PSI (7 bar) Pressure relief valve setting Shock valve setting 2500 PSI (172 bar) 3250 PSI (223 bar) Counterpressure (backpressure) valve setting 73 PSI (5 bar) STEERING METERING PUMP The steering metering pump (also called the steering unit) is located at the base of the steering column. It is made up of two sections: 1) the control section and 2) the metering section. The two sections are connected inside the unit both hydraulically and mechanically. Hydraulically, oil is supplied to the hand metering unit from the flow amplifier valve. This oil enters the hand metering unit's control section through the inlet P port. When the steering wheel is turned, the control section sends oil to metering section. The metering section is a small 6/20/07 1 FS116821ST1_Br1
2 hydraulic pump and will move a specific volume (metered) proportional to the movement of the steering wheel. The metered oil is then directed back to the control section where it will be directed to either the left turn port L or right turn port R. This oil then becomes pilot oil for the flow amplifier valve. OIL FLOW The control section of the steering metering pump is a closed center type. When the steering wheel is in the NEUTRAL (non-steering) position, there is no alignment between the holes in sleeve and the passages in spool. However, a small amount of pump oil from inlet P is allowed to flow through the center position of the steering metering pump. This small amount of oil flow (thermal bleed) keeps the steering metering pump full and ready for a quick response to steering demands. The thermal bleed also helps keep the pilot oil lines to the steering control valve and the steering metering pump warmed during cold weather operations. If the steering metering pump is taken apart for any reason, it must be put back together with the relationship between rotor and pin as shown in the illustration to the right, otherwise erratic steering will result. LOAD SENSING The steering metering pump has a load sensing port in addition to the ports already described. The load sensing port is connected internally to inlet port P through an orifice. Oil pressure in inlet port P is felt in the load sensing line. This signal pressure is then communicated to the priority valve (2) in the amplifier valve. AMPLIFIER VALVES The amplifier valve is pilot operated through the five hydraulic lines connecting it to the steering metering pump. These lines direct the pilot oil from the steering metering pump to shift the spools in the amplifier valves. The spools control the amount and direction of pressure oil sent to the steering cylinders. The main components of amplifier valve (1) are: 1. Priority spool (Item #2) 2. Amplifier spool 3. Combiner/check spool (inside amplifier spool) 4. Directional spool (Item #6) 5. Relief/makeup valves (Item #5) 6. Backpressure valve (Item #4) 6/20/07 2 FS116821ST1_Br1
3 The following is a list of abbreviations for the ports of the amplifier valve and their meanings for the illustrations in this section. HP High pressure T Tank R Right P Pressure HT Tank L Left LS Load Sensing PP Pilot Pressure CL Cylinder Left steer CR Cylinder Right steer OIL FLOW The amplifier valve has an accumulator incorporated into the system that supplies pressurized oil. Pressure oil from the system flows through port HP of the amplifier valve. This oil then flows by the priority spool (2), and is blocked by the amplifier spool. Pressure oil is communicated to the steering metering pump through port P. Once all passages fill with pressure oil, the priority spool (2) shifts left, but remains slightly open to allow a small amount of oil flow (thermal bleed) to the steering metering pump through port PP. With the vehicle in the neutral (non-steering) position, the left (L) and right (R) pilot oil ports are vented to return to tank oil port (T) in the steering metering pump. With no pilot oil acting on it, the directional spool (6) is maintained in the center position by springs. Any rolling resistance (opposition), acting on the steering cylinders, creates a pressure increase felt in port CL or CR. this pressure increase acts upon the relief/makeup valve (5) in that port. If the pressure increase exceeds kpa (3250 PSI), then the relief/makeup valve (5) allows the excess pressure to bleed into the tank passage to the backpressure valve (4). Pressure greater than 500 kpa (72 PSI) will open the backpressure valve (4) and the oil be allowed to return to tank through port HT. 6/20/07 3 FS116821ST1_Br1
4 STEERING LINES /20/07 4 FS116821ST1_Br1
5 STEERING LINES /20/07 5 FS116821ST1_Br1
6 RIGHT STEER When the steering wheel is turned to the right, hand metering unit sends right turn pilot oil through port R. Pilot oil moves the directional spool (6) to the right. When the directional spool has moved far enough, pilot oil flows to amplifier spool. At the same instant, pressure in pump port P at the steering metering pump is sensed (felt) and communicated to load sensing port LS. The increased pressure in the load sensing line causes the priority spool (2) to move to the right. This allows more oil to flow to the steering metering pump through passage P. Load sensing pressure will vary with steering load (resistance). The priority spool (2) will move accordingly, allowing sufficient oil flow to meet steering requirements. Pilot oil from the directional spool (6) flows to the left end of the amplifier spool through a connecting pin hole and a stabilizing orifice. This causes the amplifier spool to move to the right. Accumulator oil at the spring end (right end) of the amplifier spool flows through a mid-connecting pin to the left side of the amplifier spool and also causes the amplifier spool to move to the right. Pilot oil from the directional spool (6) also flows through orifices into passage of combiner/check spool (inside amplifier spool). Pilot oil is momentarily blocked until the amplifier spool moves far enough right to allow partial oil flow through n orifice (one of eight orifices) to the directional spool (6). When the amplifier spool moves to the right, pressure oil flows through orifices forcing the combiner/check spool left. Pressure oil flows through the balance of orifices (seven of eight orifices) into passage where pilot and pressure oil merge. Oil flows across directional spool (6) (which has already shifted) into port CR for a right turn. This is done by combining the 1 portion of oil coming in as pilot oil from the hand metering unit with 7 portions of pressure oil supply from the accumulator system. The faster the steering wheel is turned, the farther the directional spool (6) and amplifier spool are shifted (moved). A higher flow rate is available to cause the vehicle to turn faster. The ratio of pilot and pressure oil that merge is always the same because one orifice is dedicated to pilot flow and seven orifices are dedicated to pressure flow. Return oil from the cylinders enters port CL, flows across directional spool (6) into the tank passage, around relief/makeup valve (5), forces the backpressure valve (4) open, and returns to tank through port HT. If while turning the vehicle, a front wheel would strike a large obstruction that cannot move, oil pressure in that steering cylinder and it's oil line increase. Oil flow to the cylinder is reversed. This pressure spike (sharp increase) is felt in the amplifier spool. The combiner/check spool moves to the right and closes off (blocks) the seven pressure oil orifices. The amplifier spool moves to the left and blocks the pilot oil orifice. This stops pressure oil flow to the steering cylinders. The pressure spike is not felt at the steering metering pump. If the pressure spike is large enough, the relief/makeup valve (5) will dump the pressure oil to tank as described before. 6/20/07 6 FS116821ST1_Br1
7 RIGHT STEER /20/07 7 FS116821ST1_Br1
8 LEFT STEER LEFT STEER The operation of the amplifier valve for a left hand turn is basically the same as a right hand turn. The only difference is pilot oil from the steering metering pump now is felt in port L. This shifts directional spool left. The machine will now turn left. The rest of the valve operates the same. 6/20/07 8 FS116821ST1_Br1
9 RETURN TO NEUTRAL POSITION When steering effort stops, the steering metering pump returns to the neutral position. Ports L, P, LS, and R are vented (connected) to tank port. Pilot oil flow to the directional spool stops. Oil flow to and from cylinder ports is closed off as springs recenter the directional spool. Loss of pilot oil to the end of amplifier spool allows the spring to shift it to the left. OPERATIONAL CHECKS The front wheels must be on a dry, smooth hard surface, and the hydraulic oil in the steering system must be warm. Test the steering system with the engine at low idle, or off, as directed in the procedures. For this test the engine(s) should be running at low idle with the hydraulic system at 2500 PSI (17,236.9 kpa). Use a stop watch or timer to measure the time it takes for the front wheels to be turned from stop to stop when the steering wheel is turned at a speed of approximately one revolution per second. If the time is more than approximately 10 seconds to turn the wheels from full right to full left or full left to full right, there could be a problem in the hydraulic steering system. Be sure the hydraulic system builds pressure to 2500 PSI (17,236.9 kpa) before each right or left steer test. The test times are to be equal. Position steering linkage against the right hand stop. Build accumulator pressure at 2500 PSI (17,236.9 kpa). Turn both engines off. Steer toward the left turn stops to test the accumulator in this system. The accumulator should provide enough fluid under pressure to the steering system to be able to have short term steering in the event of a total engine shutdown. The failures in the steering system can be one or more of the items that follow: Broken oil line or a leak in an oil line connection Hydraulic pump that is worn Steering metering pump that is worn Relief/makeup valves have wrong pressure setting or leak Spools in the steering control valve do not shift properly Steering cylinders that are worn Accumulator with low Nitrogen precharge TROUBLE SHOOTING Trouble shooting processes usually need to follow a logical and systematic sequence. With that thought in mind, try to complete the steps in number order (or printed order if not numbered) so back-tracking will not be needed. The items immediately following are general maintenance items sometimes easily overlooked. More specific items are listed later in the trouble shooting chart. 6/20/07 9 FS116821ST1_Br1
10 Have a diagram (electrical/hydraulic) of the system you are diagnosing with you when you start. 1. Is the operating oil level correct? 2. Is the state of the oil and the filters acceptable? 3. Are pressures (hydraulic & nitrogen), amounts of flow, and flow directions in accordance with specifications? 4. Is the oil temperature too high or too low (oil viscosity)? 5. Are there undesirable-vibrations or noise (cavitation)? If the operator of the vehicle is present, he should be thoroughly questioned about: 1. The nature of the fault and its effect on the system. 2. How long have forewarnings been noticed? 3. Has someone been tampering with/adjusting the system components? The following quick test method of steering systems is recommendable: 1. Start the motor (pump) and let it operate for a couple of minutes. 2. Drive slowly in a figure eight and notice any percussions or vibrations in steering wheel or steered wheels. Notice whether the steering wheel movements are immediately followed by corresponding corrections of the wheel movements. 3. Stop the vehicle and influence the steering wheel with small, quick movements in both directions. Let go of the steering wheel after each movement. The steering wheel must immediately go to neutral, i.e. no motoring tendencies. The vehicle still being at standstill, turn the steering wheel from stop to stop and count the number of steering wheel turns in both directions: 4. Stop the motor (pump) and turn the steering wheel again from stop to stop. Count the number of steering wheel turns and compare the figures with the previous ones. 5. An important difference (1 turn or more) indicates too much leakage in cylinder, gear-wheel set, shock valves, or suction valves. In large vehicles which can not be emergency steered, the steering wheel movement must be slow with the motor running at low idle speed. 6. If there is leakage, remove a hose from one of the cylinder ends, plug this end and the hose, and influence the steering wheel again. If the steering wheel cannot be turned, the cylinder is defective; in the opposite case, the Steering Metering Pump or perhaps the valve block is defective. When you have identified a defective component for sure, it must be cleaned, together with its closest surroundings, before dismantling. Remove loose paint from lines and fittings in order to prevent dirt and dust from entering the system. All holes, hoses, and pipes must be plugged or covered immediately after dismantling. Never dismantle a hydraulic component in the open air. 6/20/07 10 FS116821ST1_Br1
11 Dismantling should always take place in a work shop, at a clean work table. Cover the table top with newspapers, if necessary. Always make sure to be in possession of a DANFOSS SERVICE MANUAL for the product involved and strictly follow the instructions both for dismantling and reassembly in order to avoid serious errors. For a few assembles special tools are a must! TROUBLESHOOTING: STEERING SYSTEMS WITH OSQA/B AND OSPBX-LS FAULT POSSIBLE REASON CORRECTION Amplification too high 1) Dirty, leaky or missing system relief valve (1) 2) Priority valve (2) piston sticking 1) Clean or replace check valve 2) Clean and check that piston moves easily Amplification too small 1) Priority valve (2) piston sticking 1) Clean and check that piston moves easily No end stop in one or both directions No/low oil pressure buildup Hard point when beginning to turn the steering wheel 1) One or both shock valves (5) set too low 2) One or both suction valves (5) leaky or sticking 3) Missing end stop plate(s) for directional valve (6) 1) LS pressure relief valve adjusted too low 2) Spool and sleeve in OSPBX steering units wrongly composed 3) Emergency steering ball in steering metering pump missing 4) Compensator valve (in accumulator system) pressure setting is too low 5) The accumulator system pump has too much wear 6) Blowdown valve for accumulators is bad 1) Air in LS and/or PP lines 2) Spring force in the priority valve (2) too weak 3) Orifices in LS or PP ports clogged 1) Setting without special equipment is very time consuming. Please contact the closest service shop 2) Clean or replace complete shock/suction valve(s) 3) Fit end stop plates 1) Remove plug and adjust to specified pressure 2) Remove the spool/sleeve set and turn the spool 180 degrees in sleeve. 3) Fit a new ball 4) Readjust 5) Check flow, repair/replace 6) Repair/replace as necessary 1) Bleed the lines 2) Replace with strongerspring. There are 3 sizes: 4-7 and 10 bar. This unit has a 7 bar. 3) Remove and clean orifices 6/20/07 11 FS116821ST1_Br1
12 FAULT POSSIBLE REASON CORRECTION Too much force needed to turn steering wheel Vehicle does not turn when steering wheel is turned Vehicle wanders or steers erratically Vehicle turns too slow in both directions 1) Low oil level in hydraulic oil tank 2) Accumulator system oil pressure is low (worn pump/compensator valve?) 3) Steering metering pump end cover is too tight 4) Steering column components interfere with Steering metering pump (7) shaft 5) Steering metering pump (7) is not working correctly 6) Operation of relief/makeup valves (5) are not correct 7) Oil is cold 8) Load sensing line (LS) is kinked or leaks 9) Dirty orifice in LS-port 10) Dirty orifices in directional valve (6) 11) Dirty orifice in priority valve (2) in PP-port 1) Air in the system 2) Cylinder relief valves (5) malfunction 3) Steering metering pump (7) has a lack of oil or is worn 4) Steering column shaft is disengaged from the steering metering pump (7) 1) Air in the system 2) Steering linkage is worn 3) Worn or loose cylinder piston 4) Cylinder relief valves (5) malfunction 5) Timing of steering metering pump (7) geroter and pin not correct 6) Contamination in steering metering pump (7) 7) Column components interfere with steering metering pump (7) 1) Not enough oil flow from accumulators 2) Cylinder relief valves (5) malfunction 3) Failed accumulator 4) Priority (2), amplifier, or directional (6) spool shift only enough to allow partial flow 1) Add as req'd. 2) Repair as necessary 3) Adjust per Danfoss service manual 4) Check/adjust for proper alignment 5) Check for contamination 6) Clean, repair and/or replace 7) Operate until at operating temperature, then retest 8) Repair/adjust as necessary 9) Clean or replace orifices 10) Clean or replace orifice 11) Clean or replace priority valve 1) Bleed lines and valves 2) Repair/replace as necessary 3) Check accumulator psi and pressure to amplifier valve 4) Repair/replace as necessary 1) Bleed lines and valves 2) Repair/replace as necessary 3) Repair/replace as necessary 4) Replace valves 5) Adjust per instructions 6) Disassemble, clean and assemble per Danfoss service manual 7) Check/adjust for proper alignment 1) Check and repair as req'd 2) Check and repair as req'd 3) Repair 4) Check, clean, replace as necessary 6/20/07 12 FS116821ST1_Br1
13 FAULT POSSIBLE REASON CORRECTION Vehicle turns too slow in one direction Steering wheel does not return to center position correctly Steering wheel turns without operator turning it Steering is soft or spongy 1) Directional spool (6) does not shift fully due to restriction at one end 2) Restriction in steering metering pump (7) 3) Cylinder relief valves (5) malfunction 1) Steering metering pump (7) cover is too tight 2) Steering column components interfere with steering metering pump (7) shaft 3) Restriction between spool and sleeve in steering metering pump (7) 4) Steering metering pump (7) centering springs are damaged or broken 1) Foreign material causes the steering metering pump (7) sleeve/spool to stick 2) Steering metering pump (7) centering (leaf) springs are broken or damaged 1) Air in the steering hydraulic circuit 2) The oil level in the tank is low 3) Accumulator has failed and released nitrogen into the hydraulic system 1) Check, clean, replace as necessary 2) Clean, reassemble, test 3) Check, clean, replace as necessary 1) Adjust per Danfoss service manual 2) Adjust as necessary 3) Check, clean, replace as necessary 4) Repair/replace as necessary 1) Clean, repair/replace as necessary 2) Repair/replace as necessary 1) Bleed lines & valves 2) Add as necessary 3) Repair/recharge 6/20/07 13 FS116821ST1_Br1
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