Section H

Steering
Service Manual - Backhoe Loader
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section L - Servo Controls

Publication No.
9803/3290-14

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section H - Steering

Notes:

H-0 9803/3290-14 H-0

 Section H - Steering

Contents Page No.

Service Tools
Numerical List ........................................................................................... H-1
Tool Detail Reference ............................................................................... H-2

Technical Data
Hydraulic Steer Unit .................................................................................. H-3
Priority Valve ............................................................................................. H-4
Priority Valve - 3C Machines (Sideshift) ................................................... H-5

Basic Operation
General Description .................................................................................. H-6
2 Wheel Steer Machines ...................................................................... H-6
4 Wheel Steer Machines ...................................................................... H-7
Steer Circuit Schematics .......................................................................... H-9
2 Wheel Steer Machines ...................................................................... H-9
4 Wheel Steer Machines (Steer Mode Valve Type 1) ......................... H-10
4 Wheel Steer Machines (Steer Mode Valve Type 2) ......................... H-12

Circuit Descriptions
Steer Unit Operation ............................................................................... H-14
Neutral ................................................................................................ H-14
Left Turn ............................................................................................. H-15
Right Turn ........................................................................................... H-16
Right turn, Unassisted ........................................................................ H-17
Shock Valve ........................................................................................ H-18
2 Wheel Steer Mode - Right Turn ....................................................... H-19
Crab Steer Mode - Right Turn ............................................................ H-20
Priority Valve Operation .......................................................................... H-21
Neutral ................................................................................................ H-21
Turning ............................................................................................... H-22
Electrical System .................................................................................... H-23
PCB (Relay) Controlled Steer Mode ................................................... H-23
ECU Controlled Steer Mode ............................................................... H-25
Wires and Connectors ........................................................................ H-27

Fault Finding
Steering System ..................................................................................... H-33
Fault Finding Tables ........................................................................... H-33
Diagnostic `Blink' Codes - if applicable .............................................. H-39

Service Procedures
Hydraulic Pressure Tests ....................................................................... H-40
Standby Pressure ............................................................................... H-40
Steering Pressure ............................................................................... H-41
Steer Priority Valve - Cleaning ................................................................ H-42
2 Wheel Steer Machines ........................................................................ H-43
Bleeding the System .......................................................................... H-43
4 Wheel Steer Machines ........................................................................ H-44
Re-phasing the Road Wheels ............................................................ H-44
Bleeding the System .......................................................................... H-45
Proximity Switch - Setting ................................................................... H-46
Steer Mode Valve - Checking Solenoid Operation ............................. H-47
Checking Components for Internal Hydraulic Leakage ...................... H-48

H-i H-i
 Section H - Steering
Contents

Contents Page No.

Service Procedures - 3C Machines (Sideshift)
Hydraulic Pressure Tests ........................................................................ H-49
Standby Pressure ............................................................................... H-49
Steering Pressure ............................................................................... H-50
Steer Priority Valve - Cleaning ................................................................ H-51

Priority Valve
Removal and Replacement .................................................................... H-52
Dismantle and Assemble ........................................................................ H-53

Priority Valve - 3C Machines (Sideshift)

Removal and Replacement .................................................................... H-54

Power Track Rod

Removal and Replacement .................................................................... H-55
Link Arms ................................................................................................ H-58
Removal and Replacement ................................................................ H-58
Rams ...................................................................................................... H-61
Dismantle and Assemble .................................................................... H-61

Steer Mode Valve (Type 1) - if fitted

Removal and Replacement .................................................................... H-64
Dismantle and Assemble ........................................................................ H-66

Steer Mode Valve (Type 2) - if fitted

Removal and Replacement .................................................................... H-68
Dismantle and Assemble ........................................................................ H-70

Hydraulic Steer Unit

Removal and Replacement .................................................................... H-71
Dismantle and Assemble ........................................................................ H-73
Dismantle ........................................................................................... H-73
Assemble ............................................................................................ H-75

H-ii H-ii
 Section H - Steering

Service Tools
Numerical List

The tools listed in the table are special tools required for Some tools are supplied as kits. Cross references are
carrying out the procedures described in this section. given to tables showing kit contents.
These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is
expected that such general tools will be available in any
well equipped workshop or be available locally from any
good tool supplier.

Part Description Tool Detail

Number Reference
892/00180 Seal Fitting Tool K Fig 1. ( T H-2)
992/09300 Hexagon Spanner K Fig 2. ( T H-2)
992/09400 Hexagon Spanner K Fig 2. ( T H-2)
992/09500 Hexagon Spanner K Fig 2. ( T H-2)
992/09600 Hexagon Spanner K Fig 2. ( T H-2)
992/09700 Hexagon Spanner K Fig 2. ( T H-2)
992/09900 Hexagon Spanner K Fig 2. ( T H-2)
992/10000 Hexagon Spanner K Fig 2. ( T H-2)

H-1 9803/3290-14 H-1

 Section H - Steering
Service Tools
Tool Detail Reference

Tool Detail Reference

Fig 2. Hexagon Spanners

For ram pistons and end caps
992/09300 55mm A/F
Fig 1. 892/00180 - Seal Fitting Tool
992/09400 65mm A/F
Seal Fitting Tool for fitting 'O' ring and back-up ring to
Danfoss Orbitrol Unit. 992/09500 75mm A/F
892/00181 - Replacement Plastic Boss 992/09600 85mm A/F
992/09700 95mm A/F
992/09900 115mm A/F
992/10000 125mm A/F

H-2 9803/3290-14 H-2

 Section H - Steering
Technical Data
Hydraulic Steer Unit

Technical Data
Hydraulic Steer Unit

Steer unit with load sensing, complete with integral relief

valve and shock valves.

Model Reference: 200 OSPC

Volumetric Displacement 200 cc/rev
Relief Valve Operating Pressure (at 1500 revs/min) 120 +/- 3 bar (122 +/- 3.5 kgf/cm2, 1740 +/- 50 lbf/in2)
Shock Valve Operating Pressure 175 - 190bar (178 - 199 kgf/cm2, 2538 - 2756 lbf/in2)

Model Reference: 250 OSPC

Volumetric Displacement 250 cc/rev
Relief Valve Operating Pressure (at 1500 revs/min) 120 +/- 3 bar (122 +/- 3.5 kgf/cm2, 1740 +/- 50 lbf/in2)
Shock Valve Operating Pressure Shock Valve - Not Fitted

Model Reference: 160 OSPC

Volumetric Displacement 160 cc/rev
Relief Valve Operating Pressure (at 1500 revs/min) 120 +/- 3 bar (122 +/- 3.5 kgf/cm2, 1740 +/- 50 lbf/in2)
Shock Valve Operating Pressure 175 - 190bar (178 - 199 kgf/cm2, 2538 - 2756 lbf/in2)

T L

LS
P R

LS

Fig 3.

H-3 9803/3290-14 H-3

 Section H - Steering
Technical Data
Priority Valve

Priority Valve

Standby Pressure: 7 bar (7.1 kgf/cm2, 102 lbf/in2)

18 bar (1) (18.4 kgf/cm2, 261 lbf/in2)

(1) Priority Valve Part No. 35/910066 (if fitted).

LS

LS
CF

EF
P

CF
EF

PP

Fig 4.

H-4 9803/3290-14 H-4

 Section H - Steering
Technical Data
Priority Valve - 3C Machines (Sideshift)

Priority Valve - 3C Machines (Sideshift)

Standby Pressure: 5.6 bar (5.7 kgf/cm2, 81.2 lbf/in2)

LS P EF

S
Fig 6.

Fig 5.

H-5 9803/3290-14 H-5

 Section H - Steering
Basic Operation
General Description

Basic Operation
General Description

2 Wheel Steer Machines

LS

P2

Fig 7.

The main components of the steering system are the The maximum steering system pressure is set by a relief
priority valve A, load sensing steer unit B and double valve housed inside the steer unit B.
acting power track rod ram C mounted on the front axle.

When the steering wheel is turned, a pressure signal

(demand) is generated in the load sense line LS from the
steer unit to the priority valve. The priority valve A directs
oil from the secondary hydraulic pump P2 to the steer unit
B, which in turn directs the flow to the power track rod ram
until the required steering lock is achieved. K Steer
Circuit Schematics ( T H-9).

When the steering lock is held, the pressure signal in the

load sense line LS ceases. The priority valve then directs
the oil from the secondary hydraulic pump P2 into the main
hydraulic system for operation of the hydraulic services.

H-6 9803/3290-14 H-6

 Section H - Steering
Basic Operation
General Description

4 Wheel Steer Machines

LS

E
P2

Fig 8.

The main components of the steering system are the The maximum steering system pressure is set by a relief
priority valve A, load sensing steer unit B, steer mode valve housed inside the steer unit B.
control valve C and double acting power track rod rams D
and E mounted on the front and rear axles. For details of the different steer modes K Steer
Modes ( T H-8).
When the steering wheel is turned, a pressure signal
(demand) is generated in the load sense line LS from the
steer unit to the priority valve. The priority valve A directs
oil from the secondary hydraulic pump P2 to the steer unit
B. When left turn is selected, the steer unit directs the flow
through the steer mode control valve C to the rear power
track rod ram E. When right turn is selected, the steer unit
directs the flow to the front power track rod ram D. K Steer
Circuit Schematics ( T H-9).

When the steering lock is held, the pressure signal in the

load sense line LS ceases. The priority valve then directs
the oil from the secondary hydraulic pump P2 into the main
hydraulic system for operation of the hydraulic services.

H-7 9803/3290-14 H-7

 Section H - Steering
Basic Operation
General Description
Steer Modes

C047511
Fig 9.

Three steering modes are available: The system is prevented from changing mode until all the
wheels are in the straight ahead position. This is detected
– 2-Wheel Steer (front axle only) by proximity sensors E mounted on the front and rear
– 4-Wheel Steer axles. E.g. If the system is set in 4-wheel steer and 2-wheel
steer is then selected, the system will stay in 4-wheel steer
– Crab Steer
until the rear wheels are turned to the straight ahead
position. The rear wheels are then hydraulically locked in
The steering modes are selected from a three position
the straight ahead position.
switch A. The switch sends an electrical signal to a control
unit B, which in turn energises the appropriate steer mode
For details of the electrical circuit and connections, see
control valve solenoid C. Indicator lights D on the
System Operation.
instrument panel illuminate to show the steer mode
currently operative.

In 2-wheel steer mode only the front wheels are steered. In

4-wheel steer mode both axles are steered, giving a
smaller turning circle. The crab steer mode allows the
machine to be driven diagonally.

H-8 9803/3290-14 H-8

 Section H - Steering
Basic Operation
Steer Circuit Schematics

Steer Circuit Schematics

2 Wheel Steer Machines

T B1

L R
B

P2 P1
LS

P T

X B2
CF EF
A
LS

Fig 10.
Component Key:
A Priority valve
B Steer unit
B1 Shock valves
B2 Steering system relief valve
C Power track rod ram (Front axle)
P1 Pump, Main section
P2 Pump, Secondary section
T Hydraulic tank
X Steering pressure test point

H-9 9803/3290-14 H-9

 Section H - Steering
Basic Operation
Steer Circuit Schematics

4 Wheel Steer Machines (Steer Mode

Valve Type 1)
This diagram shows the complete steer circuit. For
diagrams of the different steer modes, K Steer Mode
Valve (Type 1) ( T H-11).

T B1
D

L R
B

P2 P1
LS
C

T B
P T

X P A
CF EF B2
A
LS

E
Fig 11.
Component Key:
A Priority valve
B Steer unit
B1 Shock valves
B2 Steering system relief valve
C Steer mode control valve
D Power track rod ram (Front axle)
E Power track rod ram (Rear axle)
P1 Pump, Main section
P2 Pump, Secondary section
T Hydraulic tank
X Steering pressure test point

H-10 9803/3290-14 H-10

 Section H - Steering
Basic Operation
Steer Circuit Schematics
Steer Mode Valve (Type 1)

2-Wheel Steer
Solenoids energised: A P
T A B
Ports internally connected: P, T
Ports internally blocked: A, B C D
A
B

B T
C
L R
A

A P
D

B
Fig 12.

4-Wheel Steer
Solenoids energised: B, D
Ports internally connected: A, P B T
C A
B, T L R

Ports internally blocked: -

A P
D B

Fig 13.

Crab Steer
Solenoids energised: B, C
Ports internally connected: A, T B A T
B, P L R
C
Ports internally blocked: -

A P
B

Fig 14.

H-11 9803/3290-14 H-11

 Section H - Steering
Basic Operation
Steer Circuit Schematics

4 Wheel Steer Machines (Steer Mode

Valve Type 2)
This diagram shows the complete steer circuit. For
diagrams of the different steer modes, K Steer Mode
Valve (Type 2) ( T H-13).

T B1
D

L R
B

P2 P1 F2 F1

LS
C

P T

X
CF EF B2
A R2 R1
LS

E
Fig 15.
Component Key:
A Priority valve
B Steer unit
B1 Shock valves
B2 Steering system relief valve
C Steer mode control valve
D Power track rod ram (Front axle)
E Power track rod ram (Rear axle)
P1 Pump, Main section
P2 Pump, Secondary section
T Hydraulic tank
X Steering pressure test point

H-12 9803/3290-14 H-12

 Section H - Steering
Basic Operation
Steer Circuit Schematics
Steer Mode Valve (Type 2)

2-Wheel Steer
Solenoids energised: A F2 F1
Ports internally connected: F1, F2
B A
Ports internally blocked: R1, R2
C D

R2 R1

R2 F2
L R

B A

R1 F1
D C

Fig 16.

4-Wheel Steer
Solenoids energised: B, D
Ports internally connected: F1, R2 R2 F2
F2, R1 L R

Ports internally blocked: - B A

R1 F1
D C

Fig 17.

Crab Steer
Solenoids energised: B, C
Ports internally connected: F1, R1 R2 F2
F2, R2 L R

Ports internally blocked: - B A

R1 F1
D C

Fig 18.

H-13 9803/3290-14 H-13

 Section H - Steering
Circuit Descriptions
Steer Unit Operation

Circuit Descriptions
Steer Unit Operation

Neutral

R
P

Fig 19. 4 Wheel steer machine shown

Oil from the priority valve enters the steering unit through
the inlet port (P), opening the non-return valve A. When the
steering wheel is stationary, the inner spool B and outer
sleeve C are held in the neutral position by the centring
springs D. The steering unit is 'closed centre' therefore the
flow from the priority valve is dead ended by the steering
unit.

2 Wheel Steer Machines: On 2 wheel steer machines the

hydraulic steer unit operation is identical to that described
for the 4 wheel steer machines, except the unit pumps oil
out directly to a power track rod ram fitted on the front axle
only. Also, therefore the 2 wheel steer machines do not
have a steer mode control valve.

H-14 9803/3290-14 H-14

 Section H - Steering
Circuit Descriptions
Steer Unit Operation

Left Turn

K
C

E L

T
J
R
P
LS

Fig 20.

The illustration shows the flow through the steering unit in

a left-hand turn condition. Turning the steering wheel
rotates the inner spool B a few degrees relative to the outer
sleeve C, and sends a pressure signal (demand) to relief
valve E, and through the load sense port LS back to the
priority valve.

The relative movement between B and C directs oil

pressure through 6 of the 12 holes in the bottom of outer
sleeve C. The metering unit is linked to the spools by a
cross pin. As the steering is operated the oil is diverted by
the inner spool B into the stator F.

The rotor lobes pump the oil out to one side of the rear
power track rod ram J, turning the rear wheels to the right.
At the same time, the oil displaced from the other side of
the power track rod ram J is directed to the front power
track rod ram K, hence turning the front wheels the
required degree of left turn.

H-15 9803/3290-14 H-15

 Section H - Steering
Circuit Descriptions
Steer Unit Operation

Right Turn

T
J
R
P

Fig 21.

The illustration shows the flow through the steering unit in

a right-hand turn condition. The operation is identical to
that described for a left-hand turn, except that the oil is
diverted by inner spool B to the other side of stator F and
power track rod rams J and K.

H-16 9803/3290-14 H-16

 Section H - Steering
Circuit Descriptions
Steer Unit Operation

Right turn, Unassisted

K
C

L
T
J
R
P
G

Fig 22.

The illustration shows the circuit operation with the engine

stopped. Turning the steering wheel rotates the inner spool
B until the cross pin engages with and rotates outer sleeve
C, metering oil to the stator F, and pumping it out to power
track rod rams J and K under manual pressure only.

As there is no supply from the pump, oil from one side of

the power track rod rams (supplemented by exhaust oil if
necessary), is used to feed the other side via non-return
valve G.

H-17 9803/3290-14 H-17

 Section H - Steering
Circuit Descriptions
Steer Unit Operation

Shock Valve

R
P
X
Y
A

Fig 23.

In normal operation, oil from the priority valve enters the

steering unit through the inlet port (P), opening a spring-
loaded non-return valve A. The flow is directed by the
steering unit to achieve the desired turn (right-hand
shown).

In the event of a pressure shock wave being generated in

the system by an outside force, shock valve H vents this
pressure to exhaust preventing damage to the steering
unit.

Non-return valve X is held on its seat by the generated

pressure and non-return valve A closes to prevent the
shock wave being fed back to the pump. Some of the
excess flows via non-return valve Y to the opposite side of
the power track rod ram to prevent cavitation occurring.

H-18 9803/3290-14 H-18

 Section H - Steering
Circuit Descriptions
Steer Unit Operation

2 Wheel Steer Mode - Right Turn

L
T

Z J
R
P

Fig 24.

The illustration shows the flow through the steering unit in

a right-hand turn condition. The operation is identical to
that described for the 4 wheel steer mode, except the steer
mode control valve Z isolates the oil flow to the rear power
track rod ram J, consequently the rotor lobes pump oil out
to the front power track rod only. The rear wheels are held
in the straight ahead position by the locked-up oil in the
rear power track rod ram.

H-19 9803/3290-14 H-19

 Section H - Steering
Circuit Descriptions
Steer Unit Operation

Crab Steer Mode - Right Turn

Z J
R
P

Fig 25.

The illustration shows the flow through the steering unit in

a right-hand turn condition. The operation is identical to
that described for the 4 wheel steer mode, except the steer
mode control valve Z directs the oil displaced from the front
power track rod ram K to the other side of the rear power
track rod ram J, hence turning the rear wheels in the same
direction as the front wheels, causing the machine to crab
to the right.

H-20 9803/3290-14 H-20

 Section H - Steering
Circuit Descriptions
Priority Valve Operation

Priority Valve Operation

Neutral

B
F

EF

LS

CF
E C D

LS

T
L

P LS
R

A
Fig 26.

When the steering is not being operated, flow to the

steering circuit is dead ended by the `closed centre'
steering unit A, and no pressure signal (demand) is
generated in the load sense line LS.

Pressure from the pump B is directed through an internal

drilling C, onto the end of the priority valve spool D. This
creates a high pressure differential across the spool,
causing it to move to the left against the force of the spring
E. This allows full pump flow to the loader control valve F.

H-21 9803/3290-14 H-21

 Section H - Steering
Circuit Descriptions
Priority Valve Operation

Turning

B
F

EF

LS

CF
E C D

LS

G
T
L

P LS
R

A
Fig 27.

When the steering wheel is turned, a pressure signal The pump output flow available is always greater than the
(demand) is generated in the load sense line LS from the actual flow required to operate the steering system,
steering unit A. therefore flow to the loader valve is never completely cut
off.
Pressure is then applied to the spring end of the priority
valve spool D. This reduces the pressure differential The maximum steering system pressure is set by relief
across the spool, causing it to move to the right under valve G, housed inside the steering unit.
spring force. This allows priority valve flow to the steering
unit A, which in turn directs the flow to the corresponding
power track rod ram until the required steering lock is
reached.

When the steering lock is reached the pressure signal in

the load sense line LS from the steering unit ceases,
restoring the pressure differential across the spool D. The
spool moves back to the left, allowing full pump flow to the
loader control valve F.

H-22 9803/3290-14 H-22

 Electrical System
H-23

PCB (Relay) Controlled Steer Mode With the selector switch 2 in the 4-wheel steer
Component Key:
position, the current energises the 4WS and AWS
micro-relays inside the control unit 1. The relay switch 1 Steer mode control unit (PCB)
The schematic diagrams in this section show how the
electrical circuit works when different functions are contacts 1a and 1b operate to complete the return 1a 2WS/4WS relay switch contacts
operated. circuit for the 4-wheel steer valve solenoid 6 and all-
1b 4WS/Crab relay switch contacts
wheel steer valve solenoid 5 which both energise. The
The wire numbers and colours, where appropriate, relay switch contacts 1a and 1b also complete the 2 Steer mode selector switch - front console
are shown as an aid to identification while fault finding. return circuit for the instrument panel indicator light 3 Proximity switch - front axle
The wires coloured red show the electrical live feeds. which also illuminates.
4 Proximity switch - rear axle
The wires coloured green show the electrical returns
to earth. Crab Steer Selected: K Fig 30. ( T H-24). The front 5 All wheel steer mode valve solenoid
wheels must be in the straight ahead position before 6 4-Wheel steer mode valve solenoid
Before fault finding make sure that you understand crab steer mode is enabled. When the front wheels
are in the straight ahead position, the proximity switch 7 Crab steer mode valve solenoid
how the electrical circuits work. Most potential faults
can be traced using a multimeter to carry out 3 on the front axle operates and lets current flow to the 8 2-Wheel steer mode valve solenoid
continuity checks on wires, switches and solenoids. steer mode selector switch 2.
9803/3290-14

2-Wheel Steer Selected: K Fig 28. ( T H-24). The With the selector switch 2 in the crab steer position,
rear wheels must be in the straight ahead position the current energises the Crab and AWS micro-relays
before 2-wheel steer mode is enabled. When the rear inside the control unit 1. The relay switch contacts 1a
wheels are in the straight ahead position, the and 1b operate to complete the return circuit for the
proximity switch 4 on the rear axle operates and lets crab steer valve solenoid 7 and all-wheel steer valve
current flow to the steer mode selector switch 2. solenoid 5 which both energise. The relay switch
contacts 1a and 1b also complete the return circuit for
Central to the system is the steer mode control unit the instrument panel indicator light which also
(PCB) 1. With the selector switch 2 in the 2-wheel illuminates.
steer position, the current energises the coil of the
2WS micro-relay inside the control unit. The relay
switch contacts 1a operate to complete the return

Section H - Steering
circuit for the 2-wheel steer valve solenoid 8 which
then energises. The relay switch contacts 1a also

Circuit Descriptions
complete the return circuit for the instrument panel
indicator lights which also illuminate.

Electrical System
4-Wheel Steer Selected: K Fig 29. ( T H-24). The
front wheels must be in the straight ahead position
before 4-wheel steer mode is enabled. When the front
wheels are in the straight ahead position, the
proximity switch 3 on the front axle operates and lets
H-23

current flow to the steer mode selector switch 2.

H-24

1 1 1

1a 1a 1a

1b 1b 1b
9803/3290-14

2 2 2
5 5 5

6 7 8 6 7 8 6 7 8

Section H - Steering
3 4 3 4 3 4

Circuit Descriptions
Electrical System
H-24

Fig 28. 2-Wheel Steer Selected Fig 29. 4-Wheel Steer Selected Fig 30. Crab Steer Selected
 ECU Controlled Steer Mode ECU pin 5. The ECU then sends an output on pin 4 to
H-25

Component Key:
illuminate the indicator light on the front console.
1 Steer mode control unit (ECU)
Applicable to 4WS machines from serial no. 1327630.
4-Wheel Steer Selected: K Fig 32. ( T H-26). The 2 Steer mode selector switch - front console
The schematic diagrams in this section show how the front wheels must be in the straight ahead position
3 Proximity switch - front axle
electrical circuit works when different functions are before 4-wheel steer mode is enabled. When the front
operated. wheels are in the straight ahead position, the 4 Proximity switch - rear axle
proximity switch 3 on the front axle operates and 5 4-Wheel steer mode valve solenoid
The wire numbers and colours, where appropriate, sends an electrical input to the steer mode control unit
(ECU) 1 pin 6. 6 Crab steer mode valve solenoid
are shown as an aid to identification while fault finding.
The wires coloured red show the electrical live feeds. 7 All Wheel steer mode valve solenoid
The wires coloured green show the electrical returns With the steer mode selector switch 2 in the 4-wheel 8 2-Wheel steer mode valve solenoid
to earth. steer position, there is an electrical input to the ECU
pin 8. In this condition, the ECU sends an output on 9 Steer mode changeover relay
Before fault finding make sure that you understand pin 10 to energise the 4-wheel steer valve solenoid 5.
how the electrical circuits work. Most potential faults The ECU also completes the return path on pin 2 so Table 1. ECU Connections
can be traced using a multimeter to carry out that the steer mode changeover relay 9 energises. ECU Function:
continuity checks on wires, switches and solenoids. The changeover relay contacts then connect a live Pin
feed to the all-wheel steer valve solenoid 7 which also 1 Earth connection
Important: DO NOT use a multimeter on the ECU energises.
9803/3290-14

2 Earth connection - Steer mode changeover

connector pins. Only test the associated harness
Crab Steer Selected: K Fig 33. ( T H-26). The front relay coil
wiring. Uncouple the harness from the ECU and then
use a multimeter on the pins inside the harness wheels must be in the straight ahead position before 3 Not used
connector as applicable. crab steer mode is enabled. When the front wheels
4 Low side output - 2WS indicator light/Front
are in the straight ahead position, the proximity switch
console
2-Wheel Steer Selected: K Fig 31. ( T H-26). The 3 on the front axle operates and sends an electrical
input to the steer mode control unit (ECU) 1 pin 6. 5 High side input - 2WS mode valve solenoid
rear wheels must be in the straight ahead position
energised
before 2-wheel steer mode is enabled. When the rear
wheels are in the straight ahead position, the With the steer mode selector switch 2 in the crab steer 6 Proximity switch input - Front wheels straight
proximity switch 4 on the rear axle operates and position, there is an electrical input to the ECU pin 7. ahead
sends an electrical input to the steer mode control unit In this condition, the ECU sends an output on pin 11
7 Switch input - Crab steer mode selected
(ECU) 1 pin 9. to energise the crab steer valve solenoid 6. The ECU

Section H - Steering
also completes the return path on pin 2 so that the 8 Switch input - 4WS steer mode selected
With the steer mode selector switch 2 in the 2-wheel steer mode changeover relay 9 energises. The 9 Proximity switch input - Rear wheels straight

Circuit Descriptions
steer position, there is no electrical input to the ECU changeover relay contacts then connect a live feed to ahead
on pin 7 or pin 8. In this condition, the ECU does not the all-wheel steer valve solenoid 7 which also
energises. 10 High side output - 4WS mode valve solenoid
send an output on pin 10 or pin 11, and interrupts the

Electrical System
return path on pin 2 so that the steer mode 11 High side output - Crab steer mode valve
changeover relay 9 is de-energised. The changeover solenoid
relay contacts connect a live feed to the 2-wheel steer 12 Power supply
valve solenoid 8 which then energises. When the
solenoid is energised, an electrical input is sent to the
H-25
H-26

5 6 7 8 5 6 7 8 5 6 7 8

1 9 1 9 1 9
9803/3290-14

2 2 2

Section H - Steering
3 4 3 4 3 4

Circuit Descriptions
Electrical System
H-26

Fig 31. 2-Wheel Steer Selected Fig 32. 4-Wheel Steer Selected Fig 33. Crab Steer Selected
 Section H - Steering
Circuit Descriptions
Electrical System

Wires and Connectors B Rear horn, Rear alarm

G Auxiliary hydraulics
PCB (Relay) Controlled Steer Mode
N Rear lights, Hydraclamp
For components and connector locations
K Fig 34. ( T H-28). Connectors (h3)
Note: The steer mode control unit (PCB) A is mounted on MB1 Earth point
the RH side of the front console. Remove the front console MC Proximity switch - front axle
to gain access. The steer mode control unit is a non-
NH h3 - h2
serviceable part. If it is faulty it must be renewed.

Wires and connectors K Fig 35. ( T H-29). On the Connectors (h4)

electrical diagram the electrical connectors (example, FR)
MA 2-Wheel steer solenoid
are shown looking on the mating face of each connector
when they are disconnected. MB All wheel steer solenoid
MC Crab solenoid
Wires coloured red show the electrical live feeds. Wires
coloured green show the electrical return to earth. MD 4-Wheel steer solenoid
ME h4 - h2
Earth Points MF Proximity switch - rear axle
Faults may be caused by poor earth connections. Although
earth connections are shown, it must be remembered that Splices (h1)
the cab assembly is earthed via further earth strap and
SA
cable connections.
SB
Component Key SD

The following key identifies the component connectors.

Splices (h2)
h1 Harness - Front Console SA
h2 Harness - Side Console/Cab SC
h3 Harness - Engine/Mainframe SD
h4 Harness - Steer SN
Note: For harness drawings see Section C, Electrics. SU
SY
Connectors (h1)
FA h1 - h2 Splices (h3)
FB1 Earth point SA
FC Steer mode control unit (PCB) SD
FR Indicator lights - front console
FS Speedo - if fitted Splices (h4)
FT Steer mode selector switch SA

Connectors (h2)
CA h2 - h3
CB h2 - h1
CCA Fusebox A
CCB Fusebox B
CV Instrument panel
DR2 Earth point
S Steering

H-27 9803/3290-14 H-27

 Section H - Steering
Circuit Descriptions
Electrical System

C047800-C1
Fig 34. Component and Connector Locations - PCB (Relay) Controlled Steer Mode

H-28 9803/3290-14 H-28

H-29

h1 h4 2 1 2 1
h3
822 1 1
FC MB
2 1
MD
2 1

821 2 2 PCB
824B 3
4 5 5 4
3 B D
1 2 1 2
826B 4 4
3 6 6 3
823 5 5 109E 845 109C 826
2 7 7 2
845 6
1 8 8 1
6
MC
825B 7 7 MA A 819 A B
600L 8 8 C C
1 109F 600BW B
A B B A C
109 C
SA 2 1 1 2 2 825

621
600A
FB1 1 109D
SA
2 1 1 2 2 824
MB1
MC C
SD
MF SA 109K

B A 820 819

C C B 600BV
4 41
C B A A B C 109J
12 20 24 28 35 48
ME 1 109B

6 7 2 824

5 8 3 825

4 9 4 826 NH
3 10 5 845

820 1 FT 1 2 11 6 820
9803/3290-14

819A 2 2 1 12 7 600BV 1 13 21 25 29 37
3 4 4 3
823 3 3
2 5 5 2
819B 4 4 12 20 24 28 35 48
1 109B
822 5
1 6 6 1 5 h2 824
SA
6 7 6 7 6 7 6 7 2
821 6 6
5 8 5 8 5 8 5 8 3 825

4 9 4 826
SN
4 9 4 9 4 9

5 845 SU CA
SD 3 10 3 10 3 10 3 10

2 11 2 11 2 11 2 11 6 820
FR 1 12 1 12 1 12 1 12 7 600BV
1 13 21 25 29 37

SB

FUSE A4
106B 1 7
3
6
2
5
1
4 4
1
5
2
6
3
7
N G B S SC 4 41
11 10 9 8 8 9 10 11
825C 5 619
14 13 12 12 13 14
CV
DR2 10 1

FUSE B1
1 10
19
17
15
13
11
9
7
4
3
1
2 11 11 2
CCA 824A 15
3 12 12 3

10
20
18
16
14
12

8
6
4
2
826A 14 4 13 13 4
FS 825A 13
5
6
14
15
14
15
5
6

19
17
15
13
11
9
7
4
3
1
7 16 16 7
4

CCB
4

106A
8

7
8

106B 17 8

Section H - Steering
8 17

10
20
18
16
14
12

8
6
4
2
3
7

18 9
7
3

9 18
4 106N
SD
2
6

6
2
5

109
5
1

106

Circuit Descriptions
1

FA CB
12 24 30 36 48 60 60 48 36 30 24 12
SY
109A

824B 1 1 824B

826B 3 3 826B

Electrical System
845 4 4 845

825D 5 5 825B

819 8 8 819 819

820 9 9 820

106N 46 1 13 25 31 39 49 49 39 31 25 13 1 46 106N
H-29

Fig 35. Wires and Connectors - PCB (Relay) Controlled Steer Mode
 Section H - Steering
Circuit Descriptions
Electrical System
ECU Controlled Steer Mode S Steering
B Rear horn, Rear alarm
For components and connector locations
K Fig 36. ( T H-31). G Auxiliary hydraulics
N Rear lights, Hydraclamp
Note: The steer mode control unit (ECU) A is mounted on
the RH side of the front console. Remove the front console
to gain access. The steer mode control unit is a non- Connectors (h3)
serviceable part. If it is faulty it must be renewed. MB1 Earth point
Wires and connectors K Fig 37. ( T H-32). On the MC Proximity switch - front axle
electrical diagram the electrical connectors (example, FR) NH h3 - h2
are shown looking on the mating face of each connector
when they are disconnected.
Connectors (h4)
Wires coloured red show the electrical live feeds. Wires MA 2-Wheel steer solenoid
coloured green show the electrical return to earth.
MB All wheel steer solenoid
Earth Points MC Crab solenoid
MD 4-Wheel steer solenoid
Faults may be caused by poor earth connections. Although
earth connections are shown, it must be remembered that ME h4 - h2
the cab assembly is earthed via further earth strap and MF Proximity switch - rear axle
cable connections.

Component Key Splices (h1)

SA
The following key identifies the component connectors.
SB
SS
h1 Harness - Front Console
SZ
h2 Harness - Side Console/Cab
TA
h3 Harness - Engine/Mainframe
h4 Harness - Steer
Splices (h2)
Note: For harness drawings see Section C, Electrics.
SA
SC
Connectors (h1)
SD
FA h1 - h2
SN
FB1 Earth point
SU
FC Steer mode control unit (ECU)
SY
FR Indicator lights - front console
TF
FS Speedo - if fitted
FT Steer mode selector switch
Splices (h3)
FZ Steer mode changeover relay
SA
GA Diode gate
SD

Connectors (h2)
Splices (h4)
CA h2 - h3
SA
CB h2 - h1
CCA Fusebox A
CCB Fusebox B
CV Instrument panel
DR2 Earth point

H-30 9803/3290-14 H-30

 Section H - Steering
Circuit Descriptions
Electrical System

FT GA
FS
FC
CB

NH S

FB1

FA CV
CA ME

DR2
C47

FR

h3
MC

MF

MB MA

MC MD

C047810-C1
Fig 36. Component and Connector Locations - ECU Controlled Steer Mode

H-31 9803/3290-14 H-31

H-32

621
h1 h4 h3
SA FB1 2 1 2 1

600L 1 1 2 1 2 1

2 2
MA MD
600DU
FC
3 A D
1 2 1 2
825C 4 7 6 6 7
4

825E 5
8 5 5 8
5 ECU 825 646 826 643

819 6
9 4 4 9
6
MC
821 7
10 3 3 10
7 MC C 819 A B
823 8 8 C C
11 2 2 11 1 824 600BW B
820A 9 9 A B B A C
12 1 1 12 2 1 1 2 2 644 109 C
826B 10 10
824B 11 11
600A
107AS 12 12 1 845
SA MB1
SZ GA 2 1 1 2 2 645

826C 3 3 FZ MB B
2854 2 2
SD
1 1
5 3 MF SA 109K
824C
2 819
TA 1
4
B A 820

C C B 600BV
4 41
107AT 1 C B A A B C 109B
5 4 3
6
845C 2 7 12 20 24 28 35 48
825F 4 2 ME 1 109B
SB 2854 3 8 9 10
1
6 7 2 824

600DU 5 5 8 3 825

4 9 4 826 NH
3 10 5 845
FT 1 2 11 6 820
9803/3290-14

SS 107AU 2 2 1 12 7 600LT 1 13 21 25 29 37
3 4 4 3
823 3 3
2 5 5 2
107AV 4 4 12 20 24 28 35 48
1 109B
1 6 6 1 5 h2 824
SA
6 7 6 7 6 7 6 7 2
821 6 6
5 8 5 8 5 8 5 8 3 825

4 9 4 826
SN
4 9 4 9 4 9

5 845 SU CA
3 10 3 10 3 10 3 10

2 11 2 11 2 11 2 11 6 820
FR 1 12 1 12 1 12 1 12 7 600BV
1 13 21 25 29 37

FUSE A5

FUSE A4
106B 1 7
3
6
2
5
1
4 4
1
5
2
6
3
7
N G B S SC 4 41
11 10 9 8 8 9 10 11
825C 5 619
14 13 12 12 13 14
CV
DR2 10 1

FUSE B1
1 10
19
17
15
13
11
9
7
4
3
1
2 11 11 2
CCA 824A 15
3 12 12 3

10
20
18
16
14
12

8
6
4
2
826A 14 4 13 13 4
FS 825A 13
5
6
14
15
14
15
5
6

19
17
15
13
11
9
7
4
3
1
7 16 16 7
4

CCB
4

106A
8

7
8

106B 17 8

Section H - Steering
8 17

10
20
18
16
14
12

8
6
4
2
3
7

18 9
7
3

9 18
4 106N
SD
2
6

6
2
5

109
5
1

106

Circuit Descriptions
1

FA CB 107 109A

12 24 30 36 48 60 60 48 36 30 24 12 TF SY
824 1 1 824B

826 3 3 826B

845C 4 4 845

Electrical System
825D 5 5 825B

819 8 8 819 819

820A 9 9 820

107 34 34 107H
46 1 13 25 31 39 49 49 39 31 25 13 1
106N 46 106N
H-32

Fig 37. Wires and Connectors - ECU Controlled Steer Mode

 Section H - Steering

Fault Finding
Steering System

The purpose of this section is to help you trace hydraulic Fault Finding Tables
faults to a faulty unit (valve, actuator, ram etc). Once you
have traced the faulty unit, refer to the appropriate
dismantling, inspecting and test instructions given Fault Descriptions:
elsewhere in the steering section. 1 Steering wheel difficult to turn. K Table 2.
( T H-34).
To help identify circuits, valves, rams etc mentioned in the
2 Steering wheel turns on its own. K Table 3.
fault finding procedures, refer to the hydraulic schematic
( T H-35).
diagrams (near the beginning of the Hydraulics Section).
3 Machine will not turn when the K Table 4.
1 Before you begin fault finding, read the Safety steering wheel turned. ( T H-36).
information at the beginning of this manual. 4 Steering fails to respond to selected K Table 5.
mode. (4WS Machines only) ( T H-37).
2 Make simple checks before say, stripping a major
5 Steering fails to phase accurately or K Table 6.
component.
`drifts' out of phase during operation. ( T H-38).
(4WS Machines only)
3 Make sure that the hydraulic fluid is at correct working
temperature (50 °C, 122 °F).

4 What ever the fault, check the condition of the

hydraulic fluid. Drain and replace if necessary.

5 Make any relevant electrical checks before moving on

to the hydraulics.

6 Be sure to remove ALL contamination and if possible

identify its origin. It may be part of a component from
elsewhere in the circuit.

7 Replace any seals such as 'O' rings before re-

assembling hydraulic components.

H-33 9803/3290-14 H-33

 Section H - Steering
Fault Finding
Steering System
Table 2.
Fault Probable Cause Action
Steering wheel difficult to turn. Tyres not inflated to correct pressure Inflate tyres to correct pressure

Insufficient hydraulic fluid. Check for leaks and top up the

hydraulic tank as required.

Leaks in the relevant hoses or Check hoses and connections for

component connections leaks

Air in the hydraulic system. Bleed system - bleed the load sense
line.

Low pump flow. Check pump flow, if required service or

replace pump.

Steer relief valve set incorrectly Check pressure setting of steer unit
relief valve, adjust as required.

Worn or damaged parts in the steer Remove and inspect.

control valve.

Priority valve not operating correctly. Check if the priority valve is sticking,
rectify as required.

Check the load sense line from the

steer unit to the priority valve for signs
of leaking or poor connection.

Steer mode valve not operating Check if spools sticking, rectify as

correctly (4WS Machines only) required

Check if solenoids operating, replace

solenoids as required

Mechanical failure Check for damaged axle components,

such as rams, trackrods, linkages etc.

K Fault Finding Tables ( T H-33).

H-34 9803/3290-14 H-34

 Section H - Steering
Fault Finding
Steering System
Table 3.
Fault Probable Cause Action
Steering wheel turns on its own. Dirt in the steer control unit (causing Clean and inspect unit.
sleeves to stick open)

Steer control valve centring springs Check steer unit.

damaged, broken or missing.
Steer control valve - position of rotor to Refer to Hydraulic Steer Unit -
shaft slot incorrect. Dismantle and Assemble. Correct as
required.

K Fault Finding Tables ( T H-33).

H-35 9803/3290-14 H-35

 Section H - Steering
Fault Finding
Steering System
Table 4.
Fault Probable Cause Action
Machine will not turn when the steering Insufficient hydraulic fluid. Check for leaks and top up the
wheel turned. hydraulic tank as required.

Leaks in the relevant hoses or Check hoses and connections for

component connections leaks

Air in the hydraulic system. Bleed system - bleed the load sense
line.

Low pump flow. Check pump flow, if required service or

replace pump.

Steer relief valve set incorrectly. Check pressure setting of steer unit
relief valve, adjust as required.

Worn or damaged parts in the steer Remove and inspect.

control valve.

Priority valve not operating correctly. Check if the priority valve is sticking,
rectify as required.

Check the load sense line from the

steer unit to the priority valve for signs
of leaking or poor connection.

Steer mode valve not operating Check if spools sticking, rectify as

correctly (4WS Machines only) required

Check if solenoids operating, replace

solenoids as required

Mechanical failure Check for damaged axle components,

such as rams, trackrods, linkages etc.

Steer column splined shaft not fully Check shaft engagement.

engaged in steer valve.

Power track rod failure Check power track rod for signs of
damage, leaks etc.

K Fault Finding Tables ( T H-33).

H-36 9803/3290-14 H-36

 Section H - Steering
Fault Finding
Steering System
Table 5.
Fault Probable Cause Action
Steering fails to respond to selected Selector switch faulty. Check selector switch, replace as
mode (4WS Machines only) required.

Note: Machines with ECU controlled Proximity switches not operating Check setting of Proximity switches,
steer mode will generate a blink code correctly. reset or replace switches as required.
for certain fault conditions,
K Diagnostic `Blink' Codes - if
applicable ( T H-39).

Steer mode valve not operating Check if spools sticking, rectify as

correctly. required.

Check if solenoids operating, replace

solenoids as required.

Leaks in the relevant hoses or Check hoses and connections for

component connections. leaks

Electrical failure. Check relevant electrical connectors, if

problem still persists, do a wiring
continuity check on relevant circuits.

K Fault Finding Tables ( T H-33).

H-37 9803/3290-14 H-37

 Section H - Steering
Fault Finding
Steering System
Table 6.
Fault Probable Cause Action
Steering fails to phase accurately or Incorrect re-phasing procedure. Ensure phasing is carried out correctly
`drifts' out of phase during operation. and at the correct intervals. See
(4WS machines only). Service Procedures, Re-phasing the
Road Wheels.

Note: Where phasing problems are Air in steer hydraulic system. Bleed the system. See Service
limited to 2WS mode, faults will be Procedures, Bleeding the System.
related to the rear power track rod
system. 4WS mode problems require
front and rear track rod systems to be
investigated for possible faults.

Incorrectly set proximity switches. Re-set the proximity switches. See

Service Procedures, Proximity
Switch - Setting.

Power track rod internal or external Check relevant hose and pipework for
hydraulic leaks, see Note. leaks. Check track rod seals for
leakage. Also see Service
Procedures, 4WS Machines -
Checking for Internal Hydraulic
Leakage.

Steer mode valve internal or external Check relevant hose and pipework for
hydraulic leaks, see Note. leaks. Also see Service Procedures,
4WS Machines - Checking for
Internal Hydraulic Leakage.

K Fault Finding Tables ( T H-33).

H-38 9803/3290-14 H-38

 Section H - Steering
Fault Finding
Steering System

Diagnostic `Blink' Codes - if applicable

Applicable to 4WS machines from serial no. 1327630.

The blink codes are applicable to machines fitted with ECU

controlled steer mode only. The ECU has the facility to
detect faults with the steer mode electrical system. These
faults are indicated using the 2WS indicator light A in the
front console. The blink code sequence consists of the light
A
being switched ON for approximately one second followed
by a number of flashes (the code). The sequence is C048691
Fig 38.
repeated until the fault is cleared.
Blink Fault: Action:
Code:
1 Flash `C' solenoid coil or circuit fault (open or short circuit). Check the solenoid coil and related harness wires
and connectors.
2 Flashes `D' solenoid coil or circuit fault (open or short circuit). Check the solenoid coil and related harness wires
and connectors.
3 Flashes Steer mode changeover relay, diode or circuit fault Check the steer mode changeover relay and related
(open or short circuit). harness wires and connectors.

For details of the wires and connectors, see Circuit

Descriptions.

H-39 9803/3290-14 H-39

 Section H - Steering

Service Procedures
Hydraulic Pressure Tests

Standby Pressure

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1
Fig 39.
Make sure that the hydraulic oil is at working temperature,
i.e. 50ºC (122ºF).

1 Turn the steering wheel to the left and to the right

several times to vent system pressure.

2 Disconnect hose A and install a 0 - 40 bar (0 - 580 lbf/

in2) pressure test gauge into the valve port. Position
the open end of hose A into a clean container in order
to collect any oil drainage.

3 Disconnect hose B from load sensing port adaptor C

and blank off.

4 Set the steering to neutral and start the engine.

Gradually increase the engine speed to 1000 rpm
while checking the maximum pressure gauge reading
which should be 5.9 to 8.7 bar (86 to 126 lbf/in2).

If the pressure is outside the limits try cleaning the priority

valve, K Steer Priority Valve - Cleaning ( T H-42).

If cleaning the valve does not rectify, check the hydraulic

pump flow rate, see Section E, Hydraulics, Service
Procedures - Flow and Pressure Testing.

If the hydraulic pump flow and pressure tests are

satisfactory, then the priority valve must be renewed.

H-40 9803/3290-14 H-40

 Section H - Steering
Service Procedures
Hydraulic Pressure Tests

Steering Pressure 4 If necessary, adjust the pressure setting by removing

plug B, on the hydraulic steer unit.

!MWARNING
Make the machine safe before working underneath it. B
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put C
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

Make sure that the hydraulic oil is at working temperature,

i.e. 50ºC (122ºF).

1 Turn the steering wheel to the left and to the right

several times to vent system pressure.

2 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure

gauge to the hydraulic test point A at the outlet from
the pump secondary section (P2) as shown.

A390590

A
Fig 41.

5 Using an allen key C, adjust the valve screw until the

correct pressure is shown on the gauge.

6 Refit the plug B.

Fig 40.

3 Run the engine at 1500 rpm and turn the steering

wheel to full lock. Hold the wheel on full lock and
check the gauge reading. This should be equal to the
relief valve operating pressure, see Technical Data.

H-41 9803/3290-14 H-41

 Section H - Steering
Service Procedures
Steer Priority Valve - Cleaning

Steer Priority Valve - Cleaning

The priority valve spool and spring may be removed for

cleaning.

1 Remove the priority valve from the machine. Refer to

Priority Valve - Removal and Replacement.

2 Unscrew adaptor 9 and extract the priority valve

spring 11.

3 Remove the blanking plug 7. Press out the priority

valve spool 12 using a nylon pin. Take care not to
damage the bore of the valve.

4 Clean these components in clean paraffin paying

particular attention to the orifices at each end of the
spool. Dry off and lubricate with clean hydraulic fluid.

5 Refit the priority valve spool 12 making sure that the

spring seat end of the spool faces towards the LS
port. Refit blanking plug 7 and torque tighten.

6 Refit the priority valve spring 11 and adaptor 9 and

torque tighten.

7 Refit the valve onto the machine. Refer to Priority

Valve - Removal and Replacement.

8 Bleed the load sensing line LS as described below:

a Start the engine, loosen the connection on the

valve, turn and hold the steering wheel fully in
either direction. When bubble free oil flows from
the joint, tighten the connection.

Table 7. Torque Settings

Item Nm kgf m lbf ft Fig 42.
7 50 5.1 37
9 50 5.1 37

H-42 9803/3290-14 H-42

 Section H - Steering
Service Procedures
2 Wheel Steer Machines

2 Wheel Steer Machines

Bleeding the System

When any hydraulic steering component is disconnected
or removed, the system must be bled before driving the
machine.

1 Run the engine at 1500 rpm.

2 Turn and hold the steering wheel fully in both

directions:

a Turn the steering wheel to the left, until the front

wheels are fully locked to the left.

b Turn the steering wheel to the right, until the front

wheels are fully locked to the right.

c Turn the steering wheel to the left, until the front

wheels are in the straight ahead position.

3 Stop the engine.

4 Check the hydraulic tank fluid level, and top-up the

tank if required.

H-43 9803/3290-14 H-43

 Section H - Steering
Service Procedures
4 Wheel Steer Machines

4 Wheel Steer Machines

Re-phasing the Road Wheels

!MWARNING
Over a long period of time, the front and rear axles may
get slightly out of phase. At the start of each working 3
period, before travelling on public roads and at least
once a day, or if having difficulty in steering, check 1
and, if necessary, re-align the road wheels. Failure to
re-align the road wheels at least once per day may
mean a reduction in steering effectiveness. This can
lead to tyre scuffing and difficulty in steering a straight
line.
5-2-6-4

The steering must be re-phased:

– After travelling for 15 miles (24 km) or more on the

road (in 2 wheel steer).
– After carrying out service procedures on any part of
the steering system.

Follow the procedures below for re-phasing the steer 714820

system: Fig 43.
1 Select 2-wheel steer.

Sensors on the axles prevent the steer mode from

changing until the wheels straighten up or pass
through the `straight ahead' position. Because of this,
there will be a short period when the indicator lights
do not agree with the switch position.

2 Operate the machine until the rear wheels

straighten up.

When the rear wheels straighten up the machine will

go into 2-wheel steer. The indicator light will show
when 2-wheel steer has engaged.

3 Select 4-wheel steer again.

The front and rear wheels are now back in phase.

H-44 9803/3290-14 H-44

 Section H - Steering
Service Procedures
4 Wheel Steer Machines

Bleeding the System b Turn the steering wheel to full left lock.

When any hydraulic steering component is disconnected c Turn the steering wheel to full right lock.
or removed, the system must be bled before driving the
machine. 8 Select 4 wheel steer.

With the engine running, the following procedure must be a Turn the steering wheel to the left, until the front
carried out in the correct order that is laid down. You must and rear wheels are fully locked.
not alter the order of selections and operations.
9 Stop the engine.
1 Select 2 wheel steer.
10 Check the hydraulic tank fluid level, and top-up the
a Turn the steering wheel to the left, until the front tank if required.
wheels are fully locked to the left.

b Turn the steering wheel to the right, until the front

wheels are fully locked to the right.

2 Select 4 wheel steer.

a Turn the steering wheel to the left, until the front

wheels are fully locked to the left.

3 Select 2 wheel steer.

a Turn the steering wheel to full right lock.

b Turn the steering wheel to full left lock.

c Turn the steering wheel to full right lock.

4 Select 4 wheel steer.

a Turn the steering wheel to the left, until the front

wheels are fully locked to the left.

5 Select 2 wheel steer.

a Turn the steering wheel to full right lock.

b Turn the steering wheel to full left lock.

c Turn the steering wheel to full right lock.

6 Select 4 wheel steer.

a Turn the steering wheel to the left, until the front

wheels are fully locked to the left.

7 Select 2 wheel steer.

a Turn the steering wheel to full right lock.

H-45 9803/3290-14 H-45

 Section H - Steering
Service Procedures
4 Wheel Steer Machines

Proximity Switch - Setting

E E C
!MWARNING
Raised Equipment
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
13-2-3-7_2 Y

Note: The proximity switch setting procedure is the same

for both the front and rear axles. The illustration shows a
typical rear axle.

1 Align the wheels in the straight ahead position. Check

if straight ahead by measuring the steering ram
position.

Set the steering so that dimension X is equal both

sides.
D A
2 Remove the proximity switch cover C.

3 With the starter switch on, loosen the proximity switch

lock nut D and slide the switch in line with the target
disc A.

4 Loosen the bracket fixing bolts E and adjust the

assembly up or down to bring the switch to the centre
of the target disc. Tighten the fixing bolts E.

Make sure the light emitting diode (L.E.D.) is not A

illuminated (if it is then screw the switch out).
X
Now screw the proximity switch towards the target
disc until the light emitting diode (L.E.D.) on the
B
switch illuminates. Add a further 1 to 1.5 turns of the
A258170
locknut. Tighten the locknut.
Fig 44.

H-46 9803/3290-14 H-46

 Section H - Steering
Service Procedures
4 Wheel Steer Machines

Steer Mode Valve - Checking Solenoid

Operation
The solenoids operate according to the steer mode that is A B
selected.

Mode Solenoid(s) Energised

2-Wheel steer A
4-Wheel steer B, D
Crab steer B, C
C
Operation (energisation) of a solenoid can be easily
detected by placing a steel object (e.g. screwdriver blade)
D
close to the outer casing. A magnetic attraction of the steel
object towards the solenoid indicates energisation.

If a solenoid is not energising carryout the following

checks:

1 Check the fuse is intact. If not, renew and then check Fig 45. Type 1
that all steer mode solenoid combinations function
correctly.

2 If the fuse is intact remove the electrical connector

from the malfunctioning solenoid(s) and check that
the 12V supply is present across the connector pins.
If not, check the supply circuit.

3 Check the solenoid coil resistance which should

measure a few ohms (if unsure of the value compare
with a known good solenoid).
B
Renew the solenoid if the reading indicates a short
circuit (zero ohms) or open circuit (infinite resistance). C
If a reading somewhere between the two is obtained, A
reverse the two instrument probes and repeat for a
valid check.
D

Fig 46. Type 2

H-47 9803/3290-14 H-47

 Section H - Steering
Service Procedures
4 Wheel Steer Machines

Checking Components for Internal bore. See the relevant procedures under Power
Track Rod in this section.
Hydraulic Leakage
If the track rod has not moved it can be assumed
If hydraulic leaks occur at the steer mode valve or power
there is internal leakage at the steer mode valve See
track rods the steering system will go progressively out of
the relevant procedures under Steer Mode Valve.
phase, the more the steering is operated the further the
front and rear wheels will `drift' out of phase.

Note: Some drifting out of phase is normal over time and

the system must be routinely re-phased, K Re-phasing
the Road Wheels ( T H-44).

If the system goes out of phase over short periods of time

it is probable that there is hydraulic leakage. External
leakage is obvious and may occur at track rod seals,
relevant hoses, pipes and adaptors. Internal leakage can
occur across power track rod piston seals or within the
steer mode valve.
C
When identifying internal leakage proceed as follows;

For 4WS mode faults both front and rear track rods and A B
the steer mode valve must be investigated individually for A B
possible leakage. See the relevant procedures under Fig 47.
Power Track Rod and Steer Mode Valve in this section.

For 2WS mode faults it is possible to identify if internal

leakage is at the rear power track rod, or steer mode valve
without first removing and dismantling components.
Proceed as follows:

1 Stop the engine and remove the starter key.

Disconnect the hydraulic hoses A at the rear power
track rod. Fit an isolating ball valve B at each port on
the track rod and then reconnect the hoses.

2 Open the ball valves. Start the engine and bleed the
system, K Bleeding the System ( T H-45).

3 Set the machine in 2-wheel steer mode and then

close the ball valves B. Measure the length of one
side of the track rod C and record the value.

4 Drive the machine, in a circle, in one direction, several

times. Stop the machine and re-measure the track rod
length. Compare the measurements.

If the track rod has moved then it can be assumed

that there is internal leakage across the piston seals
in the power track rod. This may be due to worn or
damaged seals, or due to a worn or damaged cylinder

H-48 9803/3290-14 H-48

 Section H - Steering

Service Procedures - 3C Machines (Sideshift)

Hydraulic Pressure Tests

Standby Pressure
Make sure that the hydraulic oil is at working temperature,
i.e. 50ºC (122ºF).

1 Park the machine on firm level ground, engage the

park brake and set the transmission to neutral. Raise
the loader arms and fit the loader arm safety strut.
Stop the engine and remove the starter key.

!MWARNING
If it is necessary to work with the loader arms raised,
then the loader arm safety strut must be fitted.
4-3-2-8

2 Turn the steering wheel to the left and to the right

several times to vent system pressure. P

3 Working in the engine compartment, disconnect the

hose from priority valve outlet port P. Install a tee
adaptor into the port, then reconnect the hose to the
tee adaptor. Connect a 0 to 40 bar (0 to 580 lbf/in2)
pressure test gauge to the other tee adaptor outlet.

4 Disconnect the hose from priority valve load sensing

port LS, blank off the hose to prevent loss of fluid. In
LS
its place connect a suitable hose to enable any
leakage from the port to be collected in a clean
container. Make sure the end of the hose is in the Fig 48.
container before starting the engine.

5 Set the steering to neutral and start the engine.

Gradually increase the engine speed to 1000 rpm
while checking the maximum pressure gauge reading
which should be 5.6 to 8.7 bar (81 to 126 lbf/in2). A
small amount of oil leakage should be evident from
load sensing port LS.

If the pressure is outside the limits or there is no oil

leakage, try cleaning the priority valve. K Steer
Priority Valve - Cleaning ( T H-51).

H-49 9803/3290-14 H-49

 Section H - Steering
Service Procedures - 3C Machines (Sideshift)
Hydraulic Pressure Tests

Steering Pressure
A
Make sure that the hydraulic oil is at working temperature,
i.e. 50ºC (122ºF). B
1 Park the machine on firm level ground, engage the
park brake and set the transmission to neutral. Raise
the loader arms and fit the loader arm safety strut.
Stop the engine and remove the starter key.

!MWARNING
If it is necessary to work with the loader arms raised,
then the loader arm safety strut must be fitted.
4-3-2-8

2 Turn the steering wheel to the left and to the right

several times to vent system pressure.

3 Working in the engine compartment, connect a 0 to

400 bar (0 to 6000 lbf/in2) pressure gauge to the
hydraulic test point X located on the pump body.

Fig 50.

6 Using an allen key B, adjust the valve screw until the

correct pressure is shown on the gauge.

7 Refit the plug A.

Fig 49.

4 Run the engine at 1500 rpm and turn the steering

wheel to full lock. Hold the wheel on full lock and
check the gauge reading. This should be equal to the
relief valve operating pressure, see Technical Data.

5 If necessary, adjust the pressure setting by removing

plug A, on the hydraulic steer unit.

H-50 9803/3290-14 H-50

 Section H - Steering
Service Procedures - 3C Machines (Sideshift)
Steer Priority Valve - Cleaning

Steer Priority Valve - Cleaning

The priority valve spool and spring may be removed for

cleaning with the pump fitted to the engine.

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.
Raise the loader arms and fit the loader arm safety
strut. Stop the engine and remove the starter key.

!MWARNING
Raised Equipment
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
13-2-3-7_2

2 Turn the steering wheel to the left and to the right

several times to vent system pressure.

3 Working in the engine compartment, disconnect the

hose from priority valve load sensing port LS, blank
off the hose to prevent loss of fluid.
A
4 Unscrew hexagon cap A and extract the priority valve
spring and spool. Take care not to damage the bore LS
of the valve.

5 Clean these components in clean paraffin paying

Fig 51.
particular attention to the orifices at each end of the
spool. Dry off and lubricate with clean hydraulic fluid.
Table 8. Torque Settings
Item Nm kgf m lbf ft
6 Refit the spool and spring making sure that they are
the correct way round. A 103 10 76

7 Refit the hexagon cap A using a new `O' ring and

torque tighten.

8 Reconnect the hose to the priority valve load sensing

port LS, and bleed the load sense line as described
below:

Start the engine, loosen the connection on the valve,

then turn and hold the steering wheel fully in either
direction. When bubble free oil seeps from the joint,
tighten the connection.

H-51 9803/3290-14 H-51

 Section H - Steering

Priority Valve
Removal and Replacement

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

The priority valve is mounted on the right hand side

chassis member, adjacent to the loader valve block. It is
attached to the chassis member by one bolt A, and is
accessible from underneath the machine.

Fig 52.

H-52 9803/3290-14 H-52

 Section H - Steering
Priority Valve
Dismantle and Assemble

Dismantle and Assemble

The numerical sequence shown on the illustration, is

intended as a guide to dismantling.

For assembly the sequence should be reversed.

Note: The priority valve is not serviceable beyond the

removal of foreign matter (Refer to Service Procedures,
Priority Valve - Cleaning). A faulty unit must be replaced.

1 Remove the priority valve from the machine.

2 Unscrew adaptor 9 and extract the priority valve

spring 11.

3 Remove the blanking plug 7. Press out the priority

valve spool 12 using a nylon pin. Take care not to
damage the bore of the valve.

4 Clean these components in clean paraffin paying

particular attention to the orifices at each end of the
spool. Dry off and lubricate with clean hydraulic fluid.

5 Refit the priority valve spool 12 making sure that the

spring seat end of the spool faces towards the LS
port. Renew the aluminium washer 8, then refit
blanking plug 7 and torque tighten, K Table 9.
Torque Settings ( T H-53).

6 Refit the priority valve spring 11. Renew the

aluminium washer 10, then refit adaptor 9 and torque
tighten, K Table 9. Torque Settings ( T H-53).

7 Refit the valve onto the machine.

8 Bleed the load sensing line LS as described below:

Fig 53.
a Start the engine, loosen the connection on the
valve, turn and hold the steering wheel fully in
Table 9. Torque Settings
either direction. When bubble free oil flows from
Item Nm kgf m lbf ft
the joint, tighten the connection.
7 50 5.1 37
Note: All hydraulic adapters that are installed together with 9 50 5.1 37
a bonded sealing washer must also have JCB Threadseal
applied to the threads of the adapter.

H-53 9803/3290-14 H-53

 Section H - Steering

Priority Valve - 3C Machines (Sideshift)

Removal and Replacement

The priority valve housing can be replaced with a new

housing which includes the valve. The housing is an
integral part of the main hydraulic pump. For dismantling
and assembly of the priority valve, see Section E,
Hydraulics, Main Pump - 3C Machines.

The priority valve assembly is not serviceable beyond the

removal of foreign matter, see Service Procedures - 3C
Machines, Steer Priority Valve - Cleaning. A faulty unit
must be replaced.

H-54 9803/3290-14 H-54

 Section H - Steering

Power Track Rod

Removal and Replacement

This procedure is for a typical power steering track rod

removal and replacement.

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

!MWARNING
Raised Equipment
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
A
the control is operated (even with the engine stopped). Fig 54.
13-2-3-7_2

Removal

1 Disconnect and cap hydraulic hoses to prevent loss B

of fluid and ingress of dirt. Label hoses for
identification and correct refitting. C
2 On 4WD machines remove the split pin and nut 54A.
Remove the track rod ball joint from the wheel hub
assembly.

On 2WD machines, remove lock assembly 55B and

pin 55C to remove the track rod pivot from the wheel
hub assemblies.

Fig 55.

H-55 9803/3290-14 H-55

 Section H - Steering
Power Track Rod
Removal and Replacement
3 Remove the four fixing bolts 56D.

D D

D D
Fig 56.

Replacement

Replace the power track rod by reversing the removal

procedure but note the following:

1 On 4WD machines make sure that the split pin is

fitted. If the split pin cannot be fitted after torque
tightening the nut 54A, tighten further to a maximum
of 150Nm until the pin can be inserted.

2 Note the applicable torque values for the track rod

fixing bolts according to axle type, K Table 10.
Torque Settings ( T H-57).

Important: K Fig 59. ( T H-57). On 2WS 4WD axles, the

washers under the heads of the M20 x 110 mm long bolts
G are special washers and must be renewed with the
correct grade JCB hardened washer.

3 After connecting hoses check hydraulic fluid level, if

necessary top up.

4 Bleed hydraulic steering system, refer to Service

Procedures, Bleeding the System.

H-56 9803/3290-14 H-56

 Section H - Steering
Power Track Rod
Removal and Replacement

F G F G
a

Fig 59. 2WS, 4WD Front Axle

E E

A
Fig 57. 4WD Axles

E E
Fig 60. 4WS, 4WD Front Axle

Table 10. Torque Settings

Item Bolt Grade Nm kgf m lbf ft
A - 140 14 103
D - 620 63 457
E, F - 476 48 351
G 10.9 510 52 376

D D Note: The 2WS 2WD front axle is not illustrated. Torque

the bolts to the value given for item D in the table.
D D
Fig 58. 4WS Rear Axle

H-57 9803/3290-14 H-57

 Section H - Steering
Power Track Rod
Link Arms

Link Arms

Removal and Replacement

Removal

1 Fix the assembly on a locally made strip and rebuild

bench as shown in K Fig 61. ( T H-58).

Fig 61.

2 Using two suitable open ended spanners at 62L and

62M react against each other until one ball joint
unscrews.

3 Unscrew the ball joint 62L until an open ended

spanner can be fitted on the rod 62N. Screw the ball
joint against the spanner to secure the spanner and to
prevent damage to the rod.

4 By reacting against the spanner at 62N and 62M undo

the other ball joint.

The track rod spanner flats at 63E are:

Fig 62.
2 Wheel drive machines - 32 mm A/F x 4 mm wide.
4 Wheel drive machines - 40 mm A/F x 4 mm wide.
E
Note: The piston rod operates at full length, any damage
to the surface will cause fluid leaks. DO NOT attempt to
grip the rod diameter with pipe grips etc.

5 Repeat the procedure for the remaining link arm

assembly.

6 Where applicable remove the target disc 63G. G

Fig 63.
Note: If the inner or outer ball joints need to be renewed,
then a replacement link arm assembly must be fitted.

H-58 9803/3290-14 H-58

 Section H - Steering
Power Track Rod
Link Arms
Replacement

Replacement is the reverse of removal but note the

following:

1 Remember to fit the target disc 63G (where

applicable).

2 Use JCB Threadlocker and Sealer on the trackrod

link arms.

3 Note the applicable torque values for the link arms

according to axle type, K Table 11. Torque Settings
( T H-60).

4 If the link arms have been renewed, the wheel

alignment must be checked as follows:

a Set the wheels to the straight ahead position and

measure dimensions 64X and 64Y (at the outer
edge of the wheel hub). Alignment is correct if the
difference between 64X and 64Y is a maximum of
1 mm.

b To adjust the wheel alignment undo the lock nuts

(65H or 66K as applicable). Turn the threaded
adjusters J equally to obtain the correct
alignment. Tighten the lock nuts (65H or 66K as
applicable).

5 Check the proximity switch setting (where

applicable). Refer to Service Procedures, Proximity
Switch - Setting.

H-59 9803/3290-14 H-59

 Section H - Steering
Power Track Rod
Link Arms

Fig 64.

J F K J F

H
Fig 66. 2 Wheel Steer Machines
Fig 65. 4 Wheel Steer Machines

Table 11. Torque Settings

2WS, 4WD C 180 Nm (132 lbf ft) H 45-50 Nm (33-36 lbf ft) F 240-260 Nm (177-184 lbf ft)
2WS, 4WD C 140-150 Nm (103-110 lbf ft) K 300 Nm (221 lbf ft) F 240-260 Nm (177-184 lbf ft)
AWS, 4WD C 270-280 Nm (199-206 lbf ft) H 70-85 Nm (51-62 lbf ft) F 450 Nm (331 lbf ft)
AWS, 4WD C 270-280 Nm (199-206 lbf ft) K 390-410 Nm (287-302 lbf ft) F 450 Nm (331 lbf ft)
2WS, 2WD C N/A K 240-260 Nm (177-184 lbf ft) F 240-260 Nm (177-184 lbf ft)

H-60 9803/3290-14 H-60

 Section H - Steering
Power Track Rod
Rams

Rams

Dismantle and Assemble Assemble

K Fig 67. ( T H-63). The numerical sequence shown on 1 Clean the threads of the end caps 1 and cylinder
the illustration is intended as a guide to dismantling. using a wire brush.

For assembly the sequence should be reversed. 2 Use JCB Cleaner and Degreaser to ensure that all
threads are free from grease, hydraulic oil and
Dismantle sealant. Allow 15 minutes for solvent to dry before
applying JCB Threadlocker and Sealer (High
1 Fix the ram assembly on a locally manufactured strip Strength).
and rebuild bench as shown at A.
Ensure that lubricants used during assembly do not
2 Remove both end caps 1, using a special spanner come into contact with the JCB Threadlocker and
(refer to Service Tools). Pull the piston rod assembly Sealer (High Strength).
from the cylinder.
3 Refer to Section E, Hydraulics, Rams - JCB Ram
Note: DO NOT allow the piston rod to come into contact Sealing Procedure for the correct method of fitting
with the cylinder bore. The cylinder bore may be damaged seals to the end cap and piston head.
by careless dismantling.
4 Clamp the cylinder vertically and lower the piston rod
3 Position the piston rod assembly 2 on a bench in assembly in from the top, as shown at B. Take care
place of the ram cylinder. Remove the seal 4 and not to allow the piston rod to come into contact with
wear rings 3 from the piston head. the cylinder bore. Be sure to engage the piston head
new wear rings and seal carefully into the cylinder. If
Note: The piston head cannot be removed from the rod. If the piston head wear rings or seal are damaged
there is damage to the rod or piston head, replace the during this stage, they must be renewed.
complete assembly.
5 Apply JCB Activator to threads of the end caps 1 and
4 Carefully inspect the bore of the cylinder and the cylinder. Allow Activator to dry for 15 minutes before
piston rod outer diameter for scoring, nicks and burrs. bringing into contact with the JCB Threadlocker and
If such damage is visible the components must be Sealer (High Strength).
renewed.
Note: Neither the JCB Threadlocker and Sealer (High
Note: If burrs are evident on the ends of the piston rod at Strength) nor Activator must be allowed to contact seals,
positions C or D remove by careful filing. bearing rings or `O' rings.

Both end cap assemblies are the same, dismantle as 6 Apply JCB Threadlocker and Sealer (High Strength)
follows: to threads of the ends caps 1, fit new `O' ring 5.

5 Remove the `O' ring 5, end cap seal 6 and wiper seal 7 Ensure that there are no burrs at the ends of the
7. piston rod, K Dismantle ( T H-61), step 4.

6 The bearing bush 8 can be renewed if necessary. 8 Fit an end cap 1 over the piston rod. Apply light hand
However, time will be saved if a complete end cap pressure to the cap to engage the gland seal on the
and bush assembly is obtained. piston rod. DO NOT use excessive force. Screw on
the first end cap and then fix the assembly on the strip
and rebuild bench as shown at A. Fit the remaining
cap and then torque tighten both caps, K Table 12.
Torque Settings ( T H-62).

H-61 9803/3290-14 H-61

 Section H - Steering
Power Track Rod
Rams
Note: If hydraulic oil contacts the uncured JCB
Threadlocker and Sealer (High Strength) a weakening of
the bond will result. Cure times vary according to the
ambient temperature. Allow a minimum of 2 hours
between assembly and filling the ram with oil.

Table 12. Torque Settings

Item Nm kgf m lbf ft
1 678 69.2 500

Note: Cold weather operation. When operating in

conditions which are consistently below freezing, it is
recommended that the track rod is operated slowly to its
full extent in both directions before commencing normal
working.

H-62 9803/3290-14 H-62

 Section H - Steering
Power Track Rod
Rams

7
6
1

8 5
D

3
5 4
C
1
3
6
2 B

Fig 67. Dismantle and Assemble

H-63 9803/3290-14 H-63

 Section H - Steering

Steer Mode Valve (Type 1) - if fitted

Removal and Replacement

!MWARNING E
B
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block A
both sides of all four wheels.

Disconnect the battery, to prevent the engine being C

started while you are beneath the machine.
GEN-4-1_1

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose, E D
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
Fig 68.
Removal
5 Unscrew bolts E and carefully lift the steer mode
The steer mode valve assembly is mounted on the right valve away from the machine.
hand side of the machine in front of the rear axle.
K Fig 68. ( T H-64). Replacement

1 Park the machine on level ground, engage the Replacement is a reversal of the removal sequence, but
parking brake and set the transmission to neutral. note the following:
Lower the attachments to the ground. Stop the engine
and remove the starter key. Make sure that the electrical harness is reconnected
correctly:
2 Turn the steering wheel to the left and to the right
several times to vent system pressure. – Solenoid A = 2-Wheel steer
– Solenoid B = 4-Wheel steer
3 Uncouple the electrical harness from the solenoids. – Solenoid C = Crab steer
Label each connector before disconnecting to ensure
– Solenoid D = All wheel steer
correct replacement. The connectors may already be
identified A, B, C and D as shown.
Check that the correct solenoids energise when the steer
mode selector switch is operated, see Service
4 Disconnect the hydraulic hoses from the steer mode
Procedures, Checking Solenoid Operation.
valve. Label each hose before disconnecting to
ensure correct replacement. Cap the hose ends to
Make sure that the hoses are reconnected correctly:
prevent loss of fluid and ingress of dirt.

H-64 9803/3290-14 H-64

 Section H - Steering
Steer Mode Valve (Type 1) - if fitted
Removal and Replacement
– Port P to hydraulic steer unit (L port)
– Port B to rear power track rod (left side)
– Port A to rear power track rod (right side)
– Port T to front power track rod (right side)

Note: The steer mode valve ports should be stamped 'P',

'B', 'A' and 'T'. Left and right hand are as viewed from the
rear of the machine.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

Before driving the machine, bleed the steering system, see

Service Procedures, Bleeding the System.

H-65 9803/3290-14 H-65

 Section H - Steering
Steer Mode Valve (Type 1) - if fitted
Dismantle and Assemble

Dismantle and Assemble

K Fig 70. ( T H-67). The numerical sequence shown on

the illustration is intended as a guide to dismantling. The
illustration depicts a complete strip down, but to carry out
specific servicing or repair E.g. renewal of one of the
solenoids 3 and 6, it is only necessary to dismantle the
relevant components. 1
For assembly the sequence should be reversed.

Dismantle

1 Before dismantling, match mark the side of the

solenoid valves and the manifold block to ensure
correct assembly.

Note: None of the component parts of the CETOPS valve

assembly can be renewed individually. The extent of
permissible servicing is cleaning and the consequential
renewal of 'O' ring seals. If damage to any component or
distortion of the spool is evident the complete valve
assembly must be renewed.

Important: Take care not to lose the detent balls A from

items 16 and 18.

Assemble
Fig 69.
1 Renew all 'O' rings.

2 Lubricate parts with JCB Special Hydraulic fluid

before assembling.

3 Use the match marks made during the dismantling to

ensure that the valves and the manifold block are
assembled correctly.

Table 13. Torque Settings

Item Nm lbf in
1 7.1 - 9.1 63 - 80

H-66 9803/3290-14 H-66

 Section H - Steering
Steer Mode Valve (Type 1) - if fitted
Dismantle and Assemble

Fig 70. Steer Mode Valve

H-67 9803/3290-14 H-67

 Section H - Steering

Steer Mode Valve (Type 2) - if fitted

Removal and Replacement

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine. B
GEN-4-1_1
C
!MWARNING E A
Hydraulic Pressure E
Hydraulic fluid at system pressure can injure you. D
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing Fig 71.
hoses. Make sure the engine cannot be started while
the hoses are open. 5 Unscrew bolts E and carefully lift the steer mode
INT-3-1-11_2 valve away from the machine.

Removal Replacement

The steer mode valve assembly is mounted on the right Replacement is a reversal of the removal sequence, but
hand side of the machine in front of the rear axle. note the following:
K Fig 71. ( T H-68).
Make sure that the electrical harness is reconnected
1 Park the machine on level ground, engage the correctly:
parking brake and set the transmission to neutral.
Lower the attachments to the ground. Stop the engine – Solenoid A = 2-Wheel steer
and remove the starter key.
– Solenoid B = 4-Wheel steer
2 Turn the steering wheel to the left and to the right – Solenoid C = Crab steer
several times to vent system pressure. – Solenoid D = All wheel steer

3 Uncouple the electrical harness from the solenoids. Check that the correct solenoids energise when the steer
Label each connector before disconnecting to ensure mode selector switch is operated, see Service
correct replacement. The connectors may already be Procedures, Checking Solenoid Operation.
identified A, B, C and D as shown.
Make sure that the hoses are reconnected correctly:
4 Disconnect the hydraulic hoses from the steer mode
valve. Label each hose before disconnecting to
ensure correct replacement. Cap the hose ends to
prevent loss of fluid and ingress of dirt.

H-68 9803/3290-14 H-68

 Section H - Steering
Steer Mode Valve (Type 2) - if fitted
Removal and Replacement
– Port F1 to hydraulic steer unit (L port)
– Port R1 to rear power track rod (left side)
– Port R2 to rear power track rod (right side)
– Port F2 to front power track rod (right side)

Note: The steer mode valve ports should be stamped 'F1',

'F2', 'R1' and 'R2'. Left and right hand are as viewed from
the rear of the machine.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

Before driving the machine, bleed the steering system, see

Service Procedures, Bleeding the System.

H-69 9803/3290-14 H-69

 Section H - Steering
Steer Mode Valve (Type 2) - if fitted
Dismantle and Assemble

Dismantle and Assemble

Note: The solenoid valves are non-serviceable parts. Assemble

Faulty valves must be renewed. The following procedure
details removing and replacing a valve fitted at the 1 Make sure that all components are perfectly clean. If
manifold block. The procedure is identical for all the valves contamination is suspected make sure that all the
(2 or 4 valve assemblies depending on machine variant). oilways in the manifold block A are clear of debris.
The procedure assumes that the complete valve and
manifold block assembly has been removed from the 2 Renew all 'O' rings.
machine. K Removal and Replacement ( T H-68).
3 Lubricate parts with JCB Special Hydraulic fluid
Dismantle before assembling.

1 Unscrew the knurled cap B and pull off the solenoid Table 14. Torque Settings
coil D. Retrieve `O' rings C and E. Item Nm lbf in
F TBA TBA
2 Using a suitable open ended spanner unscrew the
valve stem F from the manifold block A. Retrieve `O'
ring G.

G
F
E

D
C023970
C
B

Fig 72.

H-70 9803/3290-14 H-70

 Section H - Steering

Hydraulic Steer Unit

Removal and Replacement

!MWARNING 1 Replacement is a reversal of the removal sequence.

Make sure that the hoses are correctly installed.
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
!MWARNING
the transmission in neutral and stop the engine. Block Fluid Under Pressure
both sides of all four wheels. Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
Disconnect the battery, to prevent the engine being pressure and wear protective glasses. Hold a piece of
started while you are beneath the machine. cardboard close to suspected leaks and then inspect
GEN-4-1_1 the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
!MWARNING INT-3-1-10_2

Hydraulic Pressure 2 Bleed the steering system. See Service Procedures,

Hydraulic fluid at system pressure can injure you. 4 Wheel Steer Machines - Bleeding the System.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service 3 If a new steering unit has been fitted then the system
hose line must be vented. Make sure the hose service relief valve must be tested for correct pressure
line has been vented before connecting or removing setting. See Service Procedures - Testing the
hoses. Make sure the engine cannot be started while System Pressure.
the hoses are open.
INT-3-1-11_2 Note: All hydraulic adapters that are installed together with
a bonded sealing washer must also have JCB Threadseal
Removal applied to the threads of the adaptor.

K Fig 73. ( T H-72).

1 Park the machine on level ground, engage the

parking brake and set the transmission to neutral.
Lower the attachments to the ground. Stop the engine
and remove the starter key.

2 Turn the steering wheel to the left and to the right

several times to vent system pressure.

3 Disconnect and cap all hydraulic hoses from the

steering unit as shown at A. Label the hoses to
ensure correct refitting.

4 Get an assistant to hold the steering unit, and,

working inside the cab, loosen and remove 4 bolts B.
Lift the steering unit from the machine.

Replacement

H-71 9803/3290-14 H-71

 Section H - Steering
Hydraulic Steer Unit
Removal and Replacement

Fig 73. Hydraulic Steer Unit

H-72 9803/3290-14 H-72

 Section H - Steering
Hydraulic Steer Unit
Dismantle and Assemble

Dismantle and Assemble

Dismantle
K Fig 74. ( T H-74). The numerical sequence shown on
the illustration is intended as a guide to dismantling.

Note: During manufacture, a small mark X will have been

made on sleeve 12 and spool 15, close to one of the slots
for the centring springs 13. Before removing the centring
springs, check that this mark is visible; if not, make a new
mark to ensure correct assembly.

Note: Shock valves (items 29 to 35) are pressure set

during manufacture and the adjusting screw 31 secured
with Loctite. Due to the difficulty of resetting the pressure it
is recommended that the valves are not disturbed. If
dismantling is unavoidable, however, measure and record
the depth of adjusting screw 31 below the top face of the
steering unit before removing the screw.

H-73 9803/3290-14 H-73

 Section H - Steering
Hydraulic Steer Unit
Dismantle and Assemble

Fig 74. Hydraulic Steer Unit

H-74 9803/3290-14 H-74

 Section H - Steering
Hydraulic Steer Unit
Dismantle and Assemble

Assemble
Note: The unit illustrated in the following sequence
represents a typical hydraulic steer valve. The relief valve
(items 25 to 28) and shock valves (items 29 to 35) are not
therefore shown in the following illustrations.

1 Fit spool 15 into sleeve 12, aligning slots for centring

springs 13 and checking that the small marks X are
aligned. Ensure that three slots in spool partially
uncover three holes in sleeve, as at A.

2 Fit two flat centring springs 13 with four curved

springs between them, as shown at B.

3 Fit seal 24 into steer unit body and insert sleeve of

service tool 892/00180. Fit back up ring 20 and seal
21 onto plastic boss, and position on tool spindle, as
shown.

4 Lower steering unit body and tool sleeve over tool

spindle until plastic bush is flush with end of bore.
Assemble sleeves 12 and 15 with cross pin 14 and
centring springs 13. Fit bearing components 16 to 19
with chamfered face of 17 facing away from bearing
18.

5 Remove body from tool leaving plastic bush in

position, and lower body over assembled spool.
Fig 75.
6 Apply downward pressure on body until plastic boss
is forced out of bore, leaving seals correctly located,
K Fig 76. ( T H-75).

Fig 76.

H-75 9803/3290-14 H-75

 Section H - Steering
Hydraulic Steer Unit
Dismantle and Assemble
7 Invert unit and place on a suitable hollow support so 13 Refit the end plate and fit at least one bolt 2 before
that body does not rest on protruding sleeve, thus removing support material.
preventing displacement of the new seals. Place ball
23 into check valve hole and fit bush 22. 14 Fit remaining bolts, ensuring that special bolt 1 is
correctly located. Torque tighten the bolts,
8 Fit new 'O' ring 10. K Table 15. Torque Settings ( T H-76).

9 Fit distributor plate 9 ensuring that holes align. Locate

shaft 11 onto cross-pin 14, noting position of slot B.
When rotor 7 is fitted, slot must align with hollows of
rotor as shown at C.

Fig 78.

Table 15. Torque Settings

Item Nm kgf m lbf ft
1 29 3.0 22
Fig 77. 2 29 3.0 22

10 Use a suitable piece of rigid flat material, 0.25mm 15 Pressure Relief Valve (items 25 to 28),
(0.010 in.) thick, to support the shaft and ensure K Fig 74. ( T H-74).
positive engagement with the splines of rotor 7.
a If removed during the dismantling, clean the
11 Locate rotor onto shaft, ensuring alignment as at C. threads of the adjusting screw 27 and the threads
Fit spacing bush 6 into rotor. in the bore of the steering unit body.
12 Fit 'O' rings 4 and 8 each side of body 5, then position b Assemble the valve into the steer unit body.
body over rotor.

H-76 9803/3290-14 H-76

 Section H - Steering
Hydraulic Steer Unit
Dismantle and Assemble
c Check the relief valve setting after fitting the
steering unit to the machine. See Service
Procedures, 2 and 4 Wheel Steer Machines -
Testing the System Pressure.

16 Shock Valves (items 29 to 35), K Fig 74. ( T H-74).

a If removed during the dismantling, clean the

threads of the adjusting screw 31 and the threads
in the bore of the steering unit body using JCB
Cleaner and Degreaser. Allow to dry.

b Assemble seat 35, ball 34, cap 33 and spring 32

into the steer unit body.

c Apply JCB Threadlocker and Sealer to the

threads of screw 31. Fit the screw to the depth
measured during dismantling.

d Fit plug 29 and washer 30.

H-77 9803/3290-14 H-77

 Section H - Steering
Hydraulic Steer Unit
Dismantle and Assemble

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H-78 9803/3290-14 H-78