SPECIFICATIONS - Barrington Diesel Club · 2019. 6. 14. · MANUAL CONTENTS MICROFICHE REG1139F. When the words “use again” are in the description, the specification given can

FORM NO. REG01271-01FOR USE IN SERVICE MANUALS 920 & 930 WHEEL LOADERS,

REG00514VOLUME III SPECIFICATIONS,

REG01650

SPECIFICATIONSFOR

920 & 930 WHEEL LOADER HYDRAULIC SYSTEM

SERIAL NUMBERS 920 93041J1-UP 41K1-UP62K1-UP 71H1-UP75J1-UP 73U1-UP

79J1-UP

BDC for engine manuals and specs https://barringtondieselclub.co.za/

https://barringtondieselclub.co.za/

920 & 930 LOADER HYDRAULIC SYSTEM SPECIFICATIONS

INTRODUCTION

The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1139F.

When the words “use again” are in the description, the specification given can be used to determine if a part

can be used again. If the part is equal to or within the specification given, use the part again.

When the word “permissible” is in the description, the specification given is the “maximum or minimum” tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part.

77200X2

NOTE: For Systems Operation, Testing and Adjusting, make reference to 920 and 930 LOADER HYDRAULIC SYSTEM, Form No. REG00523.

INDEX

Auxiliary Control Valve...................................................................................................................... 12

Cylinders..................................................................................................................................... 13, 14

Double Lever Hand Control ............................................................................................................. 15

Hydraulic Pump..................................................................................................................... 6, 7, 8, 9

Hydraulic Tank.................................................................................................................................. 12

Hydraulic Tank With Auxiliary Control Valve..................................................................................... 13

Lift and Tilt Circuit Make-Up Valves.................................................................................................. 10

Lines Plugs and Fittings..................................................................................................................5, 6

Loader Control Valve ....................................................................................................................... 10

Relief Valve For Main Pressure................................................................................................ 11

Tilt Relief Valve................................................................................................................................. 11

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

2




GENERAL TIGHTENING TORQUE FOR

BOLTS, NUTS AND TAPERLOCK STUDS MT \

The following charts give the standard torque values for bolts, nuts and taperlock studs of SAE Grade 5 or better quality. Exceptions are given in other sections of the Service Manual where needed.

THREAD DIAMETER STANDARD TORQUE

inches millimeters lb. ft. N-m*

Standard---------- 7T77777

hread7mrrrm\

min

Use these torques for bolts and nuts with stan-

[ 11dard threads (conversions are approximate).

1/4 6.35 9 ±3 12 + 45/16 7.94 18 ±5 25 ±73/8 9.53 32 ±5 45 ±77/16 11.11 50 ± 10 70 ± 151/2 12.70 75 ±10 100 ± 159/16 14.29 110 ± 15 150 ± 205/8 15.88 150 ±20 200 ± 253/4 19.05 265 ± 35 360 ± 507/8 22.23 420 ± 60 570 ± 80

1 25.40 640 ± 80 875 ±1001 1/8 28.58 800 ±100 1100+1501 1/4 31.75 1000 ±120 1350 ±1751 3/8 34.93 1200 ±150 1600 ± 2001 1/2 38.10 1500 ±200 2000 ±275

Use these torques for bolts and nuts onhydraulic valve bodies.

5/16 7.94 13 ±2 20 + 33/8 9.53 24 ±2 35 ± 37/16 11.11 39 ±2 50 ± 31/2 12.70 60 ±3 80 ±45/8 15.88 118 ±4 160 ± 6

Taperlock stud

"'ll Use these torques for studs with Taperlock threads.

1/4 6.35 5 ±2 7 ± 35/16 7.94 10 ±3 15 ± 53/8 9.53 20 ±3 30 ± 57/16 11.11 30 ±5 40 ± 101/2 12.70 40 ±5 55 + 109/16 14.29 60 ± 10 80 ±155/8 15.88 75 ±10 100 ± 153/4 19.05 110 ± 15 150 ± 207/8 22.23 170 ±20 230 ± 30

1 25.40 260 ± 30 350 ± 401 1/8 28.58 320 ± 30 400 ± 401 1/4 31.75 400 ± 40 550 ± 501 3/8 34.93 480 ± 40 650 ± 501 1/2 38.10 550 ± 50 750 ± 70

*1 newton meter (N-m) is approximately the same as 0.1 mkg.

3BDC for engine manuals and specs https://barringtondieselclub.co.za/



LINES, PLUGS AND FITTINGS

HYDRAULIC LINE INSTALLATION

1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight.

2. Tighten the bolts at the rigid end.

3. Install the hose and tighten all bolts finger tight.

4. Put the hose in a position so that it does not make contact with the machine or another hose.

5. Tighten the bolts on both connections.

6. Start the engine.

7. Move the implement control levers to all positions.

8. Look at the hose during movement of the implement. Make sure hose is not in contact with the machine or other hoses.

9. Shut off the engine.

10. If necessary, put the hose in a new position where it will not make contact when the implement is moved.

ASSEMBLY OF FITTINGS WITH STRAIGHT THREADS AND O-RING SEALS

This type of fitting is used in many applications. The tube end of the fitting will be different in design so that it can be used in many different applications. However, the installation procedure of the fitting is the same. If the tube end of the fitting body is the same as in the illustration (either an elbow or a straight body) it will be necessary to assemble the sleeve on the tube before connecting the tube to the end.

ELBOW BODY ASSEMBLY

1. End of fitting body (connects to tube). 2. Fitting body.3. Locknut. 4. Backup washer. 5. O-ring seal. 6. End of

fitting that goes into other part.

1. Put locknut (3), backup washer (4) and O-ring seal (5) as far back on fitting body (2) as possible. Hold these components in this position. Turn the fitting into the part it is used on, until backup washer (4) just makes contact with the face of the part it is used on.

2. To put the fitting assembly in its correct position turn the fitting body (2) out (counterclockwise) a maximum of 359°. Tighten locknut (3) finger tight.

NOTE: If the fitting is a connector (straight fitting) the hex on the body takes the place of the locknut. To install this type fitting tighten the hex against the face of the part it goes into.

TORQUES FOR FLARED AND O-RING FITTINGS

The torques shown in the chart that follows are to be used on the nut part of 37° Flared, 45° Flared and Inverted Flared fittings (when used with steel tubing), O-ring plugs, O-ring fittings and swivel nuts when used in applications to 3000 psi (20700 kPa).

A2991 9X2




TORQUES FOR OTHER FITTINGS

Ermeto Tube Fittings

Put nut and sleeve over the tube with head or shoulder end of sleeve next to nut. Push tube into counterbore of fitting body as far as possible. Turn nut clockwise until sleeve holds tube and prevents movement. Tighten the nut 1% turns more to seat sleeve and give a locking action. When necessary to assemble again, put sleeve over tube and tighten nut until a sudden increase in torque is felt. Then tighten 1/6 to 1/3 turn more to seat the sleeve.

Flex Fittings

Put nut and sleeve over tubing and push tube into counterbore of fitting body as far as possible. Tighten the nut until it is against the hex part of the fitting body.

Hi Duty (shear sleeve)Tube Fittings

After tube has been put through the nut and makes contact against the tube shoulder in the fitting body, turn the nut with a wrench until a small decrease in torque is felt. This is an indication that the sleeve has been broken off of the nut. Hold the tube to prevent turning and tighten the nut 1 and 1/2 turns.

Hi Seal Fittings

Put nut and sleeve over the tubing with the short heavy end of the sleeve facing the end of tubing. Put the tube end against the counterbore in the body of the fitting and tighten until nut is over the last thread on the body. The remainder of space is used whenever the fitting is removed and installed again.

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BSts

-^1■H-JA29920X1




HYDRAULIC PUMP(7J1114)

(920)

Rotation is counterclockwise when seen from drive end.

Type of pump: Vane.

For test, use SAE 10W oil at 150° F (65° C).

LARGE SECTION OF THE PUMP (DRIVE END)

Test at Full Speed:

Output.......................................... 31.4 U.S. gpm (119 liter/min)

at a pressure of........................................... 100 psi (690 kPa)

with pump at............................................................. 2000 rpm

with engine at............................................................ 2000 rpm


at a pressure of....................................... 1000 psi (6900 kPa)

with pump at............................................................. 2000 rpm


Test at Half Speed:

Output............................................ 15.5 U.S. gpm (59 liter/min)

at a pressure of.......................................... 100 psi (690 kPa)

with pump at ............................................................. 1000 rpm




with pump at............................................................. 1000 rpm

with engine at ........................................................... 1000 rpm

SMALL SECTION OF THE PUMP (COVER END)

Test at Full Speed:

Output..........................

at a pressure o f . . .

with pump at...........

with engine at . . . .

Output..........................




Test at Half Speed:

Output..........................




Output..........................


with pump at.............

with engine at ..........

(1) Torque for bolts (four)

(2) Torque for bolts (four)

23.7 U.S. gpm (90 liter/min)

.............. 100 psi (690 kPa)

............................. 2000 rpm

............................. 2000 rpm


........... 1000 psi (6900 kPa)

............................. 2000 rpm

............................. 2000 rpm


.............. 100 psi (690 kPa)

............................. 1000 rpm

............................. 1000 rpm


........... 1000 psi (6900 kPa)

............................. 1000 rpm

............................. 1000 rpm

. 45 ± 5 lb. ft. (60 ± 7 N-m)

. 70 ± 5 lb. ft. (95 ± 7 N-m)

6NOTE: FOR TORQUE VALUES NOT GIVEN, SEE THE FIRSTPAGE OF SPECIFICATIONS FOR GENERAL TIGHTENING TORQUES




C HYDRAULIC PUMP(9J5053)

(920)

Rotation is counterclockwise when seen from drive end.

Type of pump: Vane.



Test at Full Speed:

Output.....................

at a pressure of

with pump at ..

with engine at .

Output.....................

at a pressure of

with pump at ..

with engine at .

Test at Half Speed:

Output.....................

at a pressure of

with pump at ..

with engine at .

Output.....................

at a pressure of

with pump at ..

with engine at .

31 U.S. gpm (117 liter/min)

............ 100 psi (690 kPa)

........................... 2000 rpm

........................... 2000 rpm


......... 1000 psi (6900 kPa)

........................... 2000 rpm

........................... 2000 rpm


............ 100 psi (690 kPa)

........................... 1000 rpm

........................... 1000 rpm


.......... 1000 psi (6900 kPa)

........................... 1000 rpm

............................ 1000 rpm


Test at Full Speed:

Output.....................

at a pressure of

with pump at ..

with engine at .

Output.....................

at a pressure of

with pump at ..

with engine at .

Test at Half Speed:

Output.....................

at a pressure of

with pump at ..

with engine at .

Output.....................

at a pressure of

with pump at ..

with engine at .

(1) Torque for bolts ..

(2) Torque for bolts ..


.............. 100 psi (690 kPa)

............................. 2000 rpm

............................. 2000 rpm

. 26 U.S. gpm (98 liter/min)

........... 1000 psi (6900 kPa)

............................. 2000 rpm

............................. 2000 rpm

. 13 U.S. gpm (49 liter/min)

.............. 100 psi (690 kPa)

............................. 1000 rpm

............................. 1000 rpm


........... 1000 psi (6900 kPa)

............................. 1000 rpm

............................. 1000 rpm

. 45 ± 5 lb. ft. (60 ± 7 N-m)

75 ± 5 lb. ft. (100 ± 7 N-m)

7





(930:41 K5272-UP)

Rotation is counterclockwise.

Type of pump: Vane.



Test at Full Speed:

Output.............................................. 41 U.S. gpm (155 liter/min)


with pump at............................................................. 2000 rpm




with pump at............................................................. 2000 rpm


Test at Half Speed:



with pump at............................................................. 1000 rpm




with pump at............................................................. 1000 rpm

with engine at .......................................................... 1000 rpm


Test at Full Speed:

Output.............................................. 28 U.S. gpm (106 liter/min)


with pump at............................................................. 2000 rpm


Output................................................ 26 U.S. gpm (98 liter/min)


with pump at............................................................. 2000 rpm


Test at Half Speed:

Output................................................ 13 U.S. gpm (49 liter/min)


with pump at............................................................. 1000 rpm




with pump at............................................................. 1000 rpm

with engine at ........................................................... 1000 rpm

(1) Torque for bolts................................. 45 ± 5 lb. ft. (60 ± 7 N-m)

(2) Torque for bolts ......................... 100 ± 10 lb. ft. (135 ± 14 N-m)




920 & 930 LOADER HYDRAULIC SYSTEMSPECIFICATIONS


(930: 41K1-41K5271)

Rotation is counterclockwise when seen from drive end.Type of pump: Vane.

For test, use SAE 10W oil at 150° F (65° C),LARGE SECTION OF THE PUMP (DRIVE END)

Test at Full Speed:

Output............................ .. 41.6 U.S. gpm (158 liter/min)at a pressure of...................

with pump at........................

with engine at......................

Output........................ .. 39.1 U.S. gpm (148 liter/min)at a pressure of...................

with pump at........................

with engine at....................Test at Half Speed:

Output.......................... ... 20.6 U.S. gpm (78 liter/min)at a pressure of...................

with pump at......................

with engine at......................

Output.......................... . . 18.1 U.S. gpm (69 liter/min)at a pressure of.....................

with pump at.........................

with engine at....................


Test at Full Speed:

Output........................ .. 23.7 U.S. gpm (90 liter/min)at a pressure of.................

with pump at......................

with engine at..................

Output............................ .. 23.0 U.S. gpm (87 liter/min)at a pressure of.................

with pump at.........................

with engine at....................

Test at Half Speed:

Output..................... .. 11.7 U.S. gpm (44 liter/min)at a pressure of...................

with pump at........................

with engine at ...................

Output.......................... .. 10.8 U.S. gpm (41 liter/min)at a pressure of.................

with pump at................

with engine at ...................

(1) Torque for bolts (four)................... ... 45 ± 5 lb. ft. (60 ± 7 N-m)(2) Torque for bolts (four)............... 150 ± 10 lb. ft. (205 ± 14 N-m)




LOADER CONTROL VALVE(6J9991)

(1) 2A5885 Springs for check valves of lift and tilt circuit:

Length under test force .................................. 2.0 in. (50.8 mm)

Test force..................................... 1.42 to 1.65 lb. (6.3 to 7-4 N)

Free length after test...................................... 3.31 in. (84.1 mm)

Outside diameter .................................................75 in. (19.0 mm)

(2) Torque for relief valves oftilt circuit............................................. 50 ± 3 lb. ft. (70 ± 4 N-m)

(3) Torque for bolts of relief valve______ 65 ± 3 lb. ft. (90 ± 4 N-m)

(4) 6J9998 Springs for valve spools:

Length under test force ................................. 1.69 in. (42.9 mm)

Test force.............................................. 31 ± 1.9 lb. (140 ± 9 N)

Free length after test.................................... 4.82 in. (122.4 mm)

Outside diameter ........................................... 1.54 in. (39.1 mm)

(5) 6J9996 Springs for detent balls (four):

Length under test force........................................ 72 in. (18.3 mm)

Test force................................................ 12 ± 1.1 lb. (53 ± 5 N)

Free length after test....................................... 1.1 in. (27.9 mm)

Outside diameter..................................................20 in. (5.08 mm)

(6) Torque for detents............................. 27 ± 3 lb. ft. (38 ± 4 N-m)

(7) Torque for plugs or bolts(eight).................................................. 9 ± 2 lb. ft. (12 ± 3 N-m)

Effort needed to pull levers, at hydraulic tank, out of RAISEand TILT BACK detent positions............ 36 ± 8 lb. (160 ± 36 N)

Add or remove 6J6516 Shimsunder plugs or bolts (7) to change effort.

LIFT AND TILT CIRCUIT MAKE-UP VALVES

(6J9919)

(1) 6J9098 Springs for make-up valves (four):


Test force................................................60 ± .05 lb. (2.7 ± 0.2 N)


Outside diameter .................................................77 in. (19.6 mm)





RELIEF VALVE FOR MAIN PRESSURE(5J9113)

Opening pressure ....................... 2500 ± 25 psi (17000 ± 170 kPa)

At a flow of........................ 38 ± 1 U.S. gpm (144 ± 4 liter/min)

(1) Thickness of 8F1974 Shim.................................005 in. (0.13 mm)

One shim will change pressure......................... 35 psi (240 kPa)

(2) 2J6089 Spring for pilot valve:

Length under test force.................................. 1.43 in. (36.2 mm)

Test force................................... 64.2 to 70.9 lb. (286 to 315 N)

Free length after test..................................... 1.74 in. (44.1 mm)

Outside diameter ................................................. 49 in. (12.5 mm)

(3) 5J9108 Spring for dump valve:


Test force.......................................... 8.9 to 10.3 lb. (40 to 46 N)


Outside diameter............................ 38 to .42 in. (9.8 to 10.5 mm)

RELIEF VALVE FOR MAIN PRESSURE(3G2350)


At a flow of........................ 38 ± 1 U.S. gpm (144 ± 4 liter/min)

One complete turn of adjustment screw will change opening pressure 840 psi (5805 kPa).

TILT RELIEF VALVE(5J9106)


At a flow of.......................... 10 ± 1 U.S. gpm (38 ± 4 liter/min)

Early Machines..................... 2650 ± 25 psi (18030 ± 170 kPa)(1) 5J9103 Spring (outer):


Test force................................ 144.7 to 169.8 lb. (645 to 755 N)


Outside diameter.......................... 77 to .80 in. (19.6 to 20.3 mm)(2) 5J9104 Spring (inner):


Test force................................... 43.6 to 51.1 lb. (194 to 227 N)


Outside diameter.......................... 42 to .45 in. (10.6 to 11.4 mm)

(3) Thickness of 5J9100 Shim.................................. 005 in. (0.13 mm)

One shim will change pressure............................ 29 psi (200 kPa)

(3) Thickness of 5J9101 Shim.................................. 010 in. (0.25 mm)

One shim will change pressure............................ 58 psi (400 kPa)

(4) Torque for plug.............................. 100 ± 5 lb. ft. (135 ± 7 N-m)




AUXILIARY CONTROL VALVE(6J7364 and 6J9990)

(1) 2A5885 Spring for auxiliary check valve:

Length under test force .................................. 2.0 in. (50.8 mm)

Test force..................................... 1.42 to 1.65 lb. (6.3 to 7.4 N)


Outside diameter.................................................. 75 in. (19.0 mm)

(2) Torque for bolt................................... 24 ± 2 lb. ft. (30 ± 3 Ntti)

(3) 6J9998 Spring for valve spool:


Test force................................................ 31 ± 1.9 lb.(140 ± 9 N)

Free length after test.................................... 4.82 in. (122.4 mm)


HYDRAULIC TANK

(1) Torque for bolt .................................. 45 ± 3 lb. ft. (60 ± 4 Ntti)

(2) 5J2926 Spring for bypass valve:


Test force......................................... 60.6 ± 4.3 lb. (26.8 ± 19 N)



(3) Torque for bolts (two)....................... 65 ± 3 lb. ft. (90 ± 4 Ntti)

(4) Torque for bolts (two)....................... 65 ± 3 lb. ft. (90 ± 4 N-m)

(5) Torque for cover bolts

(thirty-two)............................................ 43 ± 5 lb. ft. (59 ± 7 N-m)

(6) Torque for bolts (twelve).................. 47 ± 3 lb. ft. (63 ± 4 Ntti)

Torque for bolts holding control valve totank (two)................................................. 65 ± 3 lb. ft. (90 ± 4 Ntti)

Torque for bolts connecting linkage tovalve spool............................................... 14 ± 2 lb. ft. (19 ± 3 Ntti)





HYDRAULIC TANK WITH AUXILIARY CONTROL VALVE

(1) Torque for bolt................................... 45 ± 3 lb. ft. (60 ± 4 N-m)

(2) 5J2926 Spring for bypass valve:


Test force........................................... 60.6 ± 4.3 lb. (270 ± 19 N)



(3) Torque for bolts (two)......................... 65 ± 3 lb. ft. (90 ± 4 N-m)




(7) Torque for cover bolts(thirty-two)......................................... 43 ± 5 lb. ft. (59 ± 7 N-m)

(8) Torque for bolts holding auxiliary control valveto tank (eight)..................................... 65 ± 3 lb. ft. (90 ± 4 N-m)

Torque for bolts holding control valveto tank (two) ............................................. 65 ± 3 lb. ft. (90 ± 4 N-m)

Torque for bolts connecting linkage to valvespool ........................................................ 14 ± 2 lb. ft. (19 ± 3 N-m)

CYLINDERS

920 LIFT CYLINDERS (6J8731, 6J8732, 7K9431 and 7K9432)

(1) Torque for nut with lubricanton threads......................... 1200 ± 120 lb. ft. (1620 ± 160 N-m)

(2) Bore in new head................ 2.253 ± .001 in. (57.23 ± 0.02 mm)

Diameter of new rod ... 2.2480 ± .0015 in. (57.10 ± 0.04 mm)

(3) Bore in new cylinder............................. 4.250; +.005 to -.002 in.(107.95; +0.13 to -0.05 mm)

930 LIFT CYLINDERS (6J5677, 6J5678, 7K9433 and 7K9434)





920 TILT CYLINDERS (7J3051, 7J3052, 7K9399 and 7K9400)

(1) Torque for nut with lubricanton threads......................... 1200 + 120 lb. ft. (1620 ± 160 N-m)




1 2

13




Cylinders (Cont.)

930 TILT CYLINDERS (6J5815, 6J5816, 7K9405 and 7K9406)





920 and 930 MULTI-PURPOSE BUCKET CYLINDERS (6J2805, 6J2806, 7J6789 and 9K3157)





920 and 930 SIDE PUMP CYLINDERS (6J5827 and 9K3158)




(3) Bore in new cylinder........................... 4.000; +.005 to -.002 in.(101.60; +0.13 to -0.05 mm)

920 LUMBER FORK CYLINDERS (2K7371 and 9K3156)




(3) Bore in new cylinder............................. 4.000; +.005 to -.002 in.(101.60; +.013 to -0.05 mm)

930 LUMBER FORK CYLINDERS (2K6841 and 9K3164)





930 LOG FORK CYLINDERS (4K501, 4K502, 9K3159 and 9K3160)




(3) Bore in new cylinder(4K501 and 4K502).............................. 4.500; +.005 to -.002 in.

(114.30; +0.13 to -0.05 mm)

(3) Bore in new cylinder(9K3159 and 9K3160) ......................... 5.500;+.005 to-.002 in.

(139.70; +0.13 to -0.05 mm)





C DOUBLE LEVER HAND CONTROL

(1) Distance from side of seatto center of levers....................... 3.54 ± .25 in. (89.9 ± 6.4 mm)

15



E CATERPILLARCaterpillar, Cat and CS are Trademarks of Caterpillar Tractor Co.

CATERPILLAR FUNDAMENTAL ENGLISH FORM NO. REG01271-01

DECEMBER 1979 PRINTED IN U.S.A.



Documents

SPECIFICATIONS - Barrington Diesel Club · 2019. 6. 14. · MANUAL CONTENTS MICROFICHE REG1139F. When the words “use again” are in the description, the specification given can