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Section H

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55 views108 pages

Section H

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Mateus
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Section H Steering Service Manual - Side Engine Loadalls ‘Section 1 - General Information ‘Section 2- Care and Safety ‘Section 3 - Routine Maintenance ‘Section B - Body and Framework ‘Section C- Electrics ‘Section E- Hydraulics ‘Section F - Transmission ‘Section G - Brakes ‘Section H - Steering ‘Section K - Engine ‘Section M - Electronic Data Systems Publication No. 9803/3750-05 od’ Po adie daa ab SRINES ACR ERIES A eee mace, eee sere tee prmsnFanicweaece ny MENON Te TRIAS, C8 eat THR em es So STH ST HSS Section H - Steering Notes: H-0 '9803/3750-05 Ho B Section H - Steering Contents Applications Table Steering SYSTEM Introduction Related Topics Specifications Operation Overview Hydraulic Operation and Schematics Fault Finding Test Procedures Re-phasing the Road Wheels Bleeding the System Proximity Switch - Setting Manual Steer Mode SYSTEM Introduction Related Topics Operation Overview Hydraulic Operation and Schematics Auto Steer Mode SYSTEM Introduction Related Topics ‘Component Location Operation Overview Hydraulic Operation and Schematios (S1) Hydraulic Operation and Schematios (S2) Electrical Operation and Schematics Hydraulic Steering Unit Introduction Related Topics Hydraulic Operation and Schematios Removal and Replacement Priority Valve Introduction Related Topics Removal and Replacement Power Track Rod Introduction Related Topics Removal and Replacement Dismantie and Assemble ‘Steer Rams Introduction Related Topics Removal and Replacement Dismantie and Assemble ‘Steering Column Introduction Page No. Ho-1 Hit H1-2 H1-3 Ht-5 Ht-7 Hin Hie 1-23 1-25 1-27 Ho H2-2 H2-3 H2-6 341 H3-3 3-4 H3-6 H37 H3-13 H3-19 Hat Ha2 Hag Has He H5-2 H63 He H6-2 He-3 H6-7 Hr H7-2 H7-3 Hr-4 He B Section H - Steering Contents Related Topics Removal and Replacement Manual Steer Mode Valve Introduction Related Topics Removal and Replacement Dismantie and Assemble ‘Auto Steer Mode Valve Introduction Related Topics Removal and Replacement Dismantle and Assemble Page No. H8.2 18-3 H9-1 H9-2 H9.3 H9-5 H104 H10-2 H103 H10-7 B Section HO - Steering Applications Important: The machine model names are NOT refered ton the topics. You must refer to the applications table for Applications Table Table the applicable machine models. Table entries shaded grey Indicate @ topic not included in this issue of the manuel, Machine models Topic | Title Variant | 40-170 | 650-140 | 640-140 | 660-170 | 635-125 | 535-140 Ref SAF | 6AG | SAL | 5AM | HiViz | Hiviz SAN | SAP Hf ‘Steering SYSTEM e e e e e e 2 | Manual Steer Mode SYSTEM e e e e e e S| Auto Steer Mode SYSTEM e e e e e e Ha ‘Hydraulic Steering Unit e e e e . e S| Priority Vaive e e e e e e 6 | Power Track Rods e e 7 ‘Steer Rams e e e e S| Steering Column e e e e . e HO |Manual Steer Mode Valve e e e e e e Hi | Auto Steer Mode Valve e e e e e e HO- '9803/3750-05 (AH-00-02) HO-1 Ww Section HO - Steering Applications Table Page left intentionally blank HO2 9000/8750-05 (AH-O0-02) HO-2 Ww Section H1 - Steering Steering SYSTEM Introduction This topic contains information about a machine SYSTEM, The system has some devices that connect either mechanically hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications ‘able, > Related Topics ([)H1-2) Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer tothe relevant topics. 3 Related Topies ([1H1-2) This topic is intended to help you understand what the system does and how it works. Where applicable italso includes procedures such as removal and replacement and dismantle and assemble, 3 Related Topics (P)H1-2 + Specifications ([) H1-3) 3 Steering Pump (1) H1-3) 3 Hydraulic Steering Unit () H1-3) 2 Priority Valve (D)H1-4 = Operation Overview (P)H1-5) 2 Hydraulic Operation and Schematics (() 1-7) + Machines with Steer Rams (T\H1-7) = Machines with Power Track Rods ([) H1-8) 3 Priority Valve Operation (1) H1-9) = Fault Finding (DVH1-14 Fault Finding Tables ([) 1-11 2 Diagnostic “Blink Codes ([}H1-16) 2 Test Procedures (P\H1-16) = Checking for Internal Hydraulic Leakage - Machines with Power Track Rods ([) H1-16) 3 Hydraulic Pressure Tests ([)H1-18) 2 Steer Priority Valve - Cleaning ([) H1-20) Auto Steer Mode Valve - Checking Solenoid Operation ([) H1-21) = Re-phasing the Road Wheels ([)H1-23) = Machines with Solenoid Operated Auto Steer Mode Valve ([)H1-23) = Machines with Manual Steer Mode Valve ([) 1-24) = Bleeding the System ([)H1-26) = Machines with Solenoid Operated Auto Steer Mode Valve ([\H1-25) = Machines with Manual Steer Mode Valve (7) H1-26) 22 Proximity Switeh - Setting ([)H1-27) Hi £$60315750-05 (H-01-01) HI B Section H1 - Steering Steering SYSTEM Related Topics Related Topics Table 1. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles 7 “Applications ALL 7 Service Tools ALL 2 ALL (Care and Safety)” ALL 3 ‘Hydraulic System Checking the Hydraulic Fluid Level E ‘Systems and Schematics E ‘Main Pump ‘Specifications Pressure and Flow Tests - Steering Section B @ Hydraulle Steering Unit (7. H4-1) ALL H Priority Valve (D\H5-1) ALL H > Manual Steer Mode SYSTEM (() H2-1) ALL H '@ Auto Steer Mode SYSTEM (7) H3-1) AL H @ Priority Valve (D)H5-1) ALL B @ Power Track Rod (()HE-1 ALL 4 > Steer Rams (D\HT-1 ALL H @ Steering Column (D)H8-1) ALL (1) You must obey allof the relevant care and safety procedures. Table 2. Service Tools. ‘The table lists the service tools you will need to do Some of the procedures in this topic, Make sure you have the correct service tools BEFORE you Start the procedures Tool Part Number Description ‘88201268 Digital Pressure Gauge 392012710) Hose for Pressure Gauge 1392100253") Hydraulic Pressure Test Kit and Relevant Adaptors (1) Too! available from JCB Service, refer to Section f - Service Tools 60318750-05 Section H1 - Steering Steering SYSTEM Specifications B Specifications Steering Pump Table 3. Steering Pump (Gear pump/Variflow pump "The steering pumo specications are part ofthe main hydraulic pump spectications. > Related Topics (P\H1-2 Type Hydraulic Steering Unit ‘Steer unit with load sensing, complete with integral reliot valve and shock valves. Model Reference: Volumetric Displacement Relief Valve Operating Pressure (at 1600 revsimin) osPc 185 185 cclrev 195 - 200 bar (199 - 204 kaflem?, 2890 - 2000 Ibtin’) ‘Shock Valve Operating Pressure - iffitted 255 bar (280 kgtlem®, 3700 Ibn’) Model Reference: Tea Volumetric Displacement 95 colrev (2: 1 ratio) 195 - 200 bar (198 - 204 katiom?, 2830 - 2900 latin") 2255 bar (280 katlcm, 3700 Ibtin’) Reliel Valve Operating Pressure (at 1600 revsimin) ‘Shock Valve Operating Pressure - if fted H13 £$60315750-05 (H-01-01) H1-3 Ww Section H1 - Steering Steering SYSTEM Specifications Priority Valve The priority valve is mounted on the side of the gear pump. ‘Standby Pressure: [7 bar (71 kgi/om®, 102 Ibfin}) Fig 2 Hi4 £$60315750-05 (H-01-01) H14 B Section H1 - Steering Steering SYSTEM ‘Operation Overview Operation Overview Ilustrations: = Machine with Power Track Rods (1) H1-5) = Machine with Steer Rams (D)H1- The main components of the steering system are the priority valve B, load sensing steer unit C, steer mode Control valve D, and double acting steer rams F or power track rods E as applicable. ‘The priorty valve B is mounted on the side of the gearpump. When the steering wheel is tured, a pressure signal (demand) is generated in the load sense line from the steer Unitto the priorty valve. The prionty valve B then diracts oll from the hydraulic pump A totthe steer unit, which in turn directs the flow to the steer rams F on the axles. ‘When the steering lock is achieved, the pressure signal in the load sense line ceases, The privity valve then directs the oll from the hydraulic pump into the main hydraulic system for operation of the hydraulic services. The maximum steering system pressure is set by a reliat valve housed inside the steer unit C. Fig 3, Machine with Power Track Rods. H15 £$60315750-05 (H-01-01) H15 Steering SYSTEM Section H1 - Steering ‘Operation Overview Fig 4. Machine with Steer Rams H16 £$60315750-05 (H-01-01) H16 Ww Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics Hydraulic Operation and Schematics Macl es with Steer Rams This dagram shows the complete steer cituit For tls agrams of the ciferentstoer modes rete fo the seer mode system topic. => Related Topies (71-2 Component Key: 4 . 7_[Pyeraule Purp TA | Prioty Vaive i 2 | Steer Unt 2A [Rete Vale 2B _[Nen-tetumn Valve 3_| Steer Wade Control Vaive 2 [Steer Rams- Front Axle 3 [Steer Rams Rear Axe T_[Fyerauie Tank HIT S808750-05 (HOOT) HIT B Machines with Power Track Rods ‘This diagram shows the complete steer circuit. For diagrams of the different steer modes refer to the steer mode system topic. = Related Topics ([) H1-2) Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics ‘Component Key: 1 [Hydraulic Pump ta [Priority Valve 2 [Steer Unit 2a _ | Steering System Relief Valve 2b | Shock Valves 3__| Steer Mode Control Vaive 4 _ [Power Track Rod - Front Axle 8 _ [Power Track Rod - Rear Axle Ee 6 | Hydraulic Tank fe. ring Pre Test Poir er X__ | Steering Pressure Test Point § fal Fig 6. H18 '8803/8750-05 H18 B Section H1 - Steering Steering SYSTEM Priority Valve Operation Neutral Fig 7. Note: The illustration is for the purpose of explanation only and is not necessarily an accurate pictorial representation of the vaive. ‘The priorty valve is mounted in on the side of the gearpump The priority valve supplies hydraulic oll to the steering circuiton demand. ‘When the steering is not being operated, flow to the steering cicutt 's dead ended by the ‘closed centre! steering unit 2, and no pressure signal (demand) is generated in the load sense line LS. Pressure trom the purnp outlet at Ais directad tarough onfice B and orifice D, tonto the end of the priority valve spool C. This creates a large pressure difference across the spool, causing it to move up against the force ofthe spring. This allows the ull pump flow to be directed through port EF back to tank (triple pump), oF to the loader control valve (double pump) as applicable. See Section 1 - Hydraulie Schematics Related Topics (1) H1-2) Hydraulic Operation and Schematics H1-9 £$60315750-05 (H-01-01) H1-9 Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics Fig 8. When the steering wheel is tured, @ pressure signal (demand) is generated in the load sense line L$ from the steering unit 2 Pressure is then applied to the spring end of the priority valve spool C. This reduces the pressure difference across the spool, causing itto move down under spring force. This allows some of the pump outlet flow at A to be directed through port P to the steering unit 2, which in turn directs the flow to the corresponding steer rams to tum the wheels The excess flow goes through port EF back to tank (rile pump), or tothe loader contel valve (doube pur) as Bopicable, Seo Section 1 - Hydraulic Schematics 2 Related Topies (1) H1- Wen the steering reaches the required positon, the pressure signal in the load sense line LS fromthe steering Unit ceases, restoring the pressure difierence across the spool G. The spool moves back up, allowing the full pump flow to be directed through port EF back to tank (triple pump), @F to the loader control valve (douible pure) as bofore, The maximum steering system pressure is set by a reliet valve housed inside the steering unit 2 H1-10 £$60315750-05 (H-01-01) H1-10 B Section H1 - Steering Steering SYSTEM Fault Fin: The purpose of this section is to help you trace faults to a faulty unit (valve, actuator, ram, solenoid, proximity switch, etc). Once you have located the fault, refer to the appropriate dismanting, inspecting and test instructions given elsewhere in the steering section To help identity circuits. switches, valves, rams etc. mentioned in the fautt finding procedures, refer also to the electrical schematic diagrams or the hydraulic schematic diagrams.See Section 1 - Hydraulic Schematics or Section C - Harness SYSTEM >. Topies (()H1-2) 1 Before you begin fault finding, read the Safety information at the beginning ofthis manual, 2 Make any relevant electrical checks before moving on to the hydraulics. 3 Make simple checks before say, stripping a major component. 4 Make sure that the hydraulic fluid is at correct working temperature (60 °C, 122 °F). 5 Whatever the fault, check the condition of the hydraulic fluid, Drain and replace necessary 6 Be -sureto remove ALL contamination and if possible identity its ongin. 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 Fault Finding 9 Fault Finding Tables Fault Descriptions: 3 Table 4. Steering wheel difficult to turn. (7) H1-12) 3 Table 6. Steering wheel turns on its own. (DHE) = Table 6. Machine will not turn when the steering wheel turned. (D\H1-12) + Table 8. Steering fails to respond to selected mode (solenoid operated auto mode valve only) (DHI19 + Table 7. Steering ‘drifts' out of phase during ‘operation. (DVH1-13) H1-11 £$60315750-05 (H-01-01) H1-11 B Section H1 - Steering Steering SYSTEM Fault Finding Table 4. Steering wheel difficult to turn. Possible Cause Action Tyres nat inflated to correct pressure. Infiate tyres to correct pressure. Insufficient hydraulic uid ‘Check for leaks and top up the hydraulic tank as required, Leaks in the relevant hoses or component connections. ‘Check hoses and connections for leaks. Airin the hydraulic system. Bleed system - Bleed the lead sense line. Low pump fiow ‘Check pump flaw, f required service or replace purre. ‘Sear relefvave set ncorrectly, Check pressure setting Of steer unit relief valve, adjust as required. ‘Wor or damaged paris inthe steer control vane, Remove and inspect Priority valve not operating correctly, ‘Check ifthe priority valve is sticking (contamination) rectly 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 correctly. ‘Checkif spools sticking, rectify as required Check if solenoids operating, replace solencids as required Mechanical failure, Check for damaged axle components, such as rams, track rods, linkages, etc. Table 8. Steering wh eel turns on its own. missing, Possible Cause Action Dirt in the steer control unit (causing sleeves to stick open) | Clean and inspect unit ‘Steer control valve centring springs damaged, broken or | Check steer unit ‘Steer control valve - position of rotor to shaft sit incorrect. Comect as required > Hydraulic Steering Unit (7) H4-1) ‘Table 6. Machine will not tun when the steering wheel turned. Possible Cause Action Insufficient hydraulic fluid ‘Check for leaks and top up the hydraulic tank as required, Leaks in the relevant hoses or component connections. ‘Check hoses and connections for leaks. Airin the hydraulic system. Bleed system - Bleed the ead sense line. Low pump flow Check pump flow, if required service or replace pure. ‘Seer relefvave set incorrectly (Check pressure setting of steer unit relief valve, adjust as required. ‘Worn or damaged paris inthe steer control vane, Remove and inspect Priority valve not operating correctly ‘Check ifthe priority valve is sticking (contamination) reetity 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 correctly. CCheckif spools sticking, rectify as required ‘Check if solenoids operating, replace solenoids as required H1-12 '860315750-05 (H-07-01) H1-12 B Section H1 - Steering Steering SYSTEM Fault Finding Possible Cause Aetion Mechanical failure, ‘Check for damaged axle components, such as rams, track rods, linkages etc. ‘Seer column splined shaft not fully engaged in steer valve, Check shaft engagement Power track rod failure, Check power track rod for signs of damage, leaks etc, ‘Table 7. Steering ‘drifts’ out of phase during operation. Action Yes. No 7 Does steering go out of phase in less than four hours of [Goto Ensure systemisrephased continuous use? after four hours of continuous use (see Operator's Handbook), 2 Does sieering go out of phase by a small amount and drift |Go to 3 Goto4 no further when changing steer modes? 3 Ensure operator changes steer mode at low engine speed |Done Ensure power track-rod land observes 5 second delay between modes (see piston is centralised and Operator's Handbook), OK now? wheel tracking is correct. Adjust alignment of steer proximity switches to optimise accuracy, ‘4 Bleed steering system to remove air. OK now? Done Gots 3 Check bath front and rear power track rods far intemal [Done Goes leakage. > Checking for internal Hydraulic Leakage - Machines with Power Track Rods ([ 1-16). Check correct seaV/energising ring fitted, check the seal damage, ‘scoring or bore ovality, Re-seal or renew fauity unit(s). OK now? & Strip steer mode valve and inspect spool for scoring or | Done Goto? damage. Renew valve if required. OK now? 7 Check for contamination in the hydraulic system which can |Fier the hydraulic system | itis likely that one of the cause one of the already detailed problems. Is the system preceeding tests was not contaminated? conclusive. Go to 1 H1-13 '860315750-05 (H-07-01) H1-13 B Section H1 - Steering Steering SYSTEM Fault Finding Table 8. Steering fails to respond to selected mode (solenoid operated auto mode valve only) Possible Cause Action Electrical failure Note: The steer mode ECU will generate a blink code for ‘some fault conditions, = Diagnostic ‘Blink’ Codes (DH: Check relevant electrical connectors, f problem stil ppersisis, do @ wiring continuity check on relevant circuits, ‘Selector swich faulty Check selector switch, replace as required Proximity switches not operating correctiy. Check setting of proximity switches, reset or replace switches as required, = Proximity Switch - Setting ()H1-27) ‘Steer mode relay nat operating correctly Renaw relay. ‘Seer mode valve not operating correctly — Check if spools sticking, rectify as required. — Checkit solenoids operating in accordance with made selected. 2 Auto Steer Mode Valve - Checking ‘Solenoid Operation (DAt-21) Leaks in the relevant hoses or component connections. ‘Check hoses and connections for leaks. ECU failure. The ECU is normally a relable component and failure is unlikely. Before renewing the ECU make sure that all relevant electrical connections and components are unctioning correctly. (1) Bonot connecta test meter directly to the pins on the ECU, H1-14 '860315750-05 (H-07-01) H1-14 B Diagnostic ‘Blink’ Codes Machines fitted with a solenoid actuated auto steer mode valve incorporate an electronic control unit (ECU). The ECU has the facility to detect faults with the vaive electrical system. These faults are indicated using the 2WS indicator light 9A in the instrument panel. The blink code sequence Consists of the light being switched ON for approximately one secand followed by @ number of flashes (the code). ‘The sequence is repeated until the faults cleared, Section H1 - Steering Steering SYSTEM Fault Finding Note: Machines with an elecironie instruments system will log an error code, see Section M - Loadail Monitoring SYSTEM, 2 Related Topics (T\H1-2) Figo Blink Code [Cause ation sa —B- ay flash | C'solenod coi or | Check coil and circu faut (open or | related harness short crui) wires and connectors Connectors (Ha 23, Bashes | D'solenod col or | Check coll and circuit fault (open or | related harness short circuit). vires and connectors = Elecirical Connectors (AHS 23) Biiashes [Relay/ade or | Check related relay circuit fault (open or | and related harness: short circuit). wires and connectors 3 Electrical His $8030780-05 HOOT) HIS B Section H1 - Steering Steering SYSTEM Test Procedures Test Procedures Checking for Internal Hydraulic Leakage - Machines with Power Track Rods If hydraulic leaks occur at the steer mode vaNe or power track rods the steering system will go progressively out of pphase, the more the steering is operated the further the front and rear wheels wil drift out of phase. Note: Some drifting out of phase is normal over time and ite getermsnoct eenenirephonel elteatanias the Road Wheels (TH! 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 tod seals, relevant hoses, pipes and adaptors. Internal leakage can occur across power track rod piston seals or within the steer mode vaive. ‘When identifying internal leakage proceed as follows: For 4WS mode faults both front and rear track rods and the steer mode valve must be investigated individually for possible leakage. For 2WS mode faults it's possible to identity if internal leakage is atthe rear power track rod, or steer mode valve without first removing and dismantling components. Proceed as follows: 1 Sop the engine and remove the starter key Disconnect the hydraulic hoses 10-A at the rear ower track rod, Fit an isolating ball valve 10-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, = Bleeding the System ([) H1-26) 3 Set the machine in 2-wheel steer mode and then close the ball valves 10-B, Measure the length of one. side of the track rod 10-C and recotd the value. 4 Drivethe machine, in a circle, inone 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 dueto.a worn or damaged cylinder bore. If the track rod has not moved it can be assumed there is internal leakage at the steer mode valve. Fig 10. Typical Power Track Rod Checking Energiser Seals If having repeated dlificulty in steering the machine and routine fault finding indicates power track rod leakage, itis possible that the power track rod piston head rectangular section piston head seal may have been incorrectly Installed ie. twisted It will be necessary to check both front and rear power track rods. Remove and dismantle the power track rods, 2 Related Topics (M)H1-2) 1 Dismantie ram, remove piston seal 14-A and checkto see if energiser seal 11-B has been installed twisted 6 rolled, Inspect the cylinder bore and piston rod for scoring. nicks and burrs, H1-16 £$60315750-05 (H-01-01) H1-16 Ww Section H1 - Steering Steering SYSTEM Test Procedures Fig 11. 2 Assemble ram using new seals, make sure seal 12-8 is not twisted or rolled, check the whte installation marks. Fig 13. Fig 12. To prevent damage to the seals when fiting the piston rod assembly into the cylinder, clamp the cylinder in the vertical position and lower the piston rod assembly into the cylinder. > Fig 13. (T) 1-17) 3. Fitnew wiper seals (not shown), 4 Refit the power track rod assembly and check the ‘wheel alignment: Related Topies ([1H1-2) 5 Check for correct operation and steer phasing Replenish hydraulic tank as required and check for leaks. aqaz 390815750-05 (FOTO) H1-17 B Section H1 - Steering Steering SYSTEM Hydraulic Pressure Tests Standby Pressure 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 Tum the steering wheel to the left and to the right several times to vent system pressure. A warninc 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. ceva st 3. Disconnect hose D and install a 0 - 70 bar (0 - 1000 lbffin’) pressure test gauge (892101268) into the valve port Position the open end of hose D into a clean Container in order to collect any oil drainage, 4 Disconnect hose A from load sensing port adaptor B and blank off hose A. Do not cap the load sensing port adaptor B. 5. Setthe steering to neutral, i.e. do notturn the steering ‘wheel, and start the engine. Gradually increase the fengine speed to 1000 rpm while checking the ‘maximum pressure gauge reading which should be 5.8 to 87 bar (86 to 126 Ibtin?, If the pressure is outside the limits try cleaning the priority valve, Steer Priority Valve - Cleaning ([3 H1-26) If cleaning the vaive does not rectty, check the steering pump section flow rate and pressure, see Section E - Hydraulics, Service Procedures: Flow and Pressure Tests. = Related Topics (T)H1-2) If the hydraule pump flow and pressure tasts are satisfactory, then the priority valve must be renewed. = Removal and Replacement (() H5-3) Test Procedures Fig 14. Typical Pump H1-18 '860318750-05 (H-07-01) H1-18 B Section H1 - Steering Steering SYSTEM Steering Pressure 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 Tum the steering wheel to the left and to the right several times to vent system pressure. AWarRNING 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. Evatt 3 Connect a 0 to 400 bar (0 to 6000 Ibffin’) pressure gauge (part no, 892/00279) to test point 15-A located on the priority valve 15-B. Fig 15. 4 Run the engine at 1500 rpm and tuin 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 3 Specifications (DHF. 5 Ifnecessary, adjust the pressure setting by removing plug 164A on the hydraulic steer unit Test Procedures 6 Using an allen key, adjust the valve screw 16-B until the correct pressure is shown on the gauge. Fig 16. Note: The pressure adusting screw 16-8 can be accessed through a cut-out at the base of the steering column after first removing the panels. It may be necessary to remove the hydraulic steer unit if access is restricted. 7 Refit the plug 16-4. H1-19 £$60315750-05 (H-01-01) H1-19 B Section H1 - Steering Steering SYSTEM Steer Priority Valve - Cleaning The priority valve spool and spring may be removed for cleaning with the pump in-situ, 4 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 Tum the steering wheel to the left and to the right several times to vent system pressure. A warninc 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. SEN 3. Disconnect hose A from the load sensing port. Blank off the hose to pravent loss of fluid. 4 Unscrew adaptor B and extract the priority valve spring. Remove the blanking plug C and extract the prioity valve spool, Take care not to damage the bore, of the valve. 5 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 fui. 6 Refit the priority valve spool making sure that the spring seat end of the spool faces towards the LS port Refit blanking plug C and torque tighten, 7 Refit the priority valve spring and adaptor B and torque tighten 8 Reconnect the hose to the load sensing port, 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. Table 9. Torque settings Test Procedures Fig 17. Nm Kgfim Tor 100- 105 75-81 102-107 76-83 74-77 55-60 H1-20 '860318750-05 (H-07-01) H1-20 B Section H1 - Steering Steering SYSTEM Auto Steer Mode Valve - Checking Solenoid Operation Note: Machines may be fitted with diferent types of steer mode solenoid valve. Identify the steer mode valve solenoids correctly, =D Steer Mode __Valve Configurations (7) H1-22) The solenoids operate according to the steer mode that is selected. Mode: ‘Solenoia(s) Energised: 2Wheel Steer a 4Wheel Steer BC Crab Steer B,D Operation (energisation) of a solenoid can be easily detected by placing a steel object (e.g. screwdriver blade) close to the outer casing. Amagnetc attraction of the stee! object towards the solenoid indicates energisation If @ solenoid is not energising cary out the following checks: 1 Check the fuse is intact Ifnot, renew and then check that all steer mode solencid combinations function correct, 2 If the fuse is intact remove the electrical connector from the malfunctioning solenoids) 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 solenoic), Renew the solenoid if the reading indicates a short circuit (zero ohms) oF open circuit (infinite resistance). Ita reading somewhere between the two is obtained, reverse the two instrument probes and repeat for a valid check. Note: The electrical connectors at the steer mode valve solenoids are identical, Before uncoupling any of the connectors be sure to label them A B, C or D as applicable, ffs suspected that the connectors have been fitted to the wrong solenoids see the electrical connection data for wire number identification. 2 Electrical Connectors ([)H3-23) Test Procedures H1-21 £$60315750-05 (H-01-01) H1-21 Ww Section H1 - Steering Steering SYSTEM Test Procedures Steer Mode Valve Configurations Fig 18. Key: Fig 18. (DHI-29) 3 ‘Steer mode valve- Machines with power track rods a ‘Steer mode valve - Machines with steer H1-22 {980373750-05 (01-01) H1-22 B Section H1 - Steering Steering SYSTEM Re-phasing the Road Wheels Machines with Solenoid Operated Auto Steer Mode Valve Awarninc Over long period of time, the front and rear axles may get slightly out of phase. At the start of each working Period, before travelling on public roads and at least once a day, or if having difficulty in steering, check and, if necessary, re-align the road wheels, Failure to realign 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. 5264 1 tartthe engine, 2 Select 2 wheel steer B, Proximity switches on the axles prevent the steer mode from changing until the wheels straighten up or pass through the ‘straight ahead’ posttion. Because Of this, there willbe a short period when the indicator, lights do not agree with the switch position, 3 Operate the machine untl the rear wheels straighten up. When the rear wheels straighten up the machine will, 1g0 into 2 wheel steer The indicator lights will show ‘when 2 wheel steer has engages. 4 Select 4 wheel steer A The front and rear wheels are now back in phase. Re-phasing the Road Wheels H1-23 '860318750-05 (H-07-01) H1-23 B Section H1 - Steering Steering SYSTEM Re-phasing the Road Wheels Machines with Manual Steer Mode Valve Awarnine ‘Over along period of time, the front andrear axles may {get slightly out of phase. At the start of each working Period, before travelling on public roads and at least ‘once a day, or if having difficulty in steering, check 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 ead to tyre scuffing and aificutyin steering astraignt Tine. coxa 1 Sartthe engine. 2 Select 4 wheel steer A. Tum the steering wheel until the rear wheels are pointing in the staight ahead position, 3. Select 2 wheel steer B. Tum the steering wheel until the front wheels are pointing in the stright ahead postion, 4 Allwheels are nov pointing straight ahead, select the ‘steer mode required and continue in the normal ‘manner, H1-24 ‘9803/3750-05 [H-01-01) B Section H1 - Steering Steering SYSTEM Bleeding the System Bleeding the System Machines with Solenoid Operated Auto Steer Mode Valve Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows: ‘With the engine running, the following procedure must be carried out in the correct order that is laid down. You must not alter the order of selections and operations, 1 Select 2 Wheel Steer, a Turn steering wheel to left unti front wheels are fully locked to the left. b Tum steering wheel to right, unt front wheels are fully locked to the right 2 Select 4 Wheel Steer, a. Turn steering wheel to left, unt front wheels are. fully locked to the left. 3 Select 2 Wheel Steer, Tum steering whee! to fll ight lock Tum steering wheel to fl lft lock © Tum steering whee! to full ight lock 4 Select Wheel Steer. a Turn steering wheel to left, unt the front wheels, ae fully locked to the left. 5 Select 2 Wheel Steer. Turn steering wheel ofl ight lock Tum steeting whee! to full lft lock Tum steering whee! to fll ight lock 6 Select 4 Wheel Steer. a Turn steering wheel to left unt front wheels are fully locked to the left 7 Select 2 Whee! Steer. ‘a Tum steering wheel to ful right lock. Tum steering wheel ofl ft lock © Tum steering whee! to full right lock 8 Select 4 Whee! Steer. ‘a Tum steering wheel to left, unt the front and rear ‘wheels are fully locked. H1-25 £$60315750-05 (H-01-01) H1-25 B Section H1 - Steering Steering SYSTEM Machines with Manual Steer Mode Valve Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows: This procedure must be carried out in the correct order that is laid down, You must not alter the order of selections and operations, 1 Startthe Engine. 2 Select 2 Wheel Steer, @ Turn steering wheel to left unt front wheels are fully locked to the left. Turn steering wheel to right, unt front wheels are fully locked to the right. & Tum steering wheel to left untifront wheels are in the straight ahead poston. 3 Select 4 Wheel Steer, a Turn steering wheel to left, unt front wheels are fully locked to the left. b Turn steering wheel to right untl front wheels are. in the straight ahead position. 4 Select 2 Wheel Steer. Tum steering whee! to full right lock Turn steering whee! ofl lft lock © Tum steering whee! to fll ight lock d_ Turn steering whee! to left until front wheels are in the straight ahead poston. 5 Select 4 Wheel Steer. a. Turn steering wheel to left, until the front wheels. are fully locked to the left. b Turn steering wheel to right unti front wheels are: in the straight ahead position 6 Select 2 Wheel Steer, a Turn steering wheal to full right lock. Bleeding the System b Tum steering whee! to full left lock. © Tum steering wheel to full ight lock. d_ Tum steering whee! to lft until front wheels are in ‘the straight ahead postion Select 4 Wheel Steer. a. Tum steering wheel to left until front wheels are fully locked to the left b_ Tum steering whee! to right until front wheels are Inthe straight ahead position. Select 2 Whee! Steer. 2 Tum steering whee! to ful right lock Tum steering wheel to fll lock. ¢ Tum steering wheel to ful right lock d_ Tum steering wheel to left until front wheels are in ‘the straight ahead postion Select 4 Wheel Steer. Turn steering wheel to left, until the front and rear wheels are fully lacked ‘Stop the engine and top up the hydraulic tank as required nae 390815750-05 (FOTO) 1-26 B Section H1 - Steering Steering SYSTEM Proximity Switch - Setting Proximity Switch - Setting A WaRNING 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). 1237 Note: The proximty switch setting procedure is the same for both the front and rear axles. The illustration shows a typical axle 1 Align the wheels in the straight ahead position. Check by measuring the steering ram positon, as shown. Set the steering so that dimension X is 129 mm, Fig 21. (D)H4-27) Fig 21. 2 Remove the proximity switch 3 and cover 3 Apply JCB threadlocker to the thread on the locknuts 2 4 Position the proximity switch 3 directly below the target dise 1 on the track rod. 5 Adjust the proximity switch until the dimension ¥ is 3 mm (0.4 ir), 6 Torque tighten the locknuts 2. = Table 10. Torque Settings (D1 H1-27) 7 Do a check of the dimension Y. If this is incorrect repeat steps § and 6. Table 10. Torque Settings Tem Nm kgf m Worf 2 2 25 184 c Fig 22, ae Table 11. Electrical Connections Terminal | Wire Colour |Description a Bue ‘Signal 5 Black Earth c Brown Feed H1-27 £$60315750-05 (H-01-01) H1-27 Ww Section H1 - Steering Steering SYSTEM Proximity Switch - Setting Page left intentionally blank nae 390815750-05 (FOTO) H1-28 Ww Section H2 - Steering Manual Steer Mode SYSTEM Introduction This topic contains information about a machine SYSTEM, The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications ‘able. > Related Topics ([H2-2) Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer tothe relevant topics. 3 Related Topies ([)H2-2) This topic is intended to help you understand what the system does and how it works. Where applicable italso includes procedures such as removal and replacement and dismantle and assemble, 3 Related Topics (P)H2-2 2 Operation Overview (P\H2-3) = Hydraulic Operation and Schematics (() H2-6) aA {90815750-05 (1-08-00) H2-1 B Section H2 - Steering Manual Steer Mode SYSTEM Related Topics Related Topics Table 1. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles ‘Applications ALL Service Tools ALL ALL (Care and Safety)” ALL Hydraulie System Checking the Hydraulic Fluid Level Wheel Alignment ‘Main Pump Pressure and Flow Tests - Steering Section @ Steering SYSTEM (D\H?-1) ALL =) =] m) ef op spay Manual Steer Mode Valve (T1H8-7 AL (1). You must obey all of the relevant care and safety procedures. H22 803087 S0-05 (08-00) H2-2 B Section H2 - Steering Manual Steer Mode SYSTEM ‘Operation Overview Operation Overview Crab Steer With the spool of steer mode valve D in the crab steer position there is a hydraulic connection between the steer Unit C and the front and rear axle steer rams F1 to Fa, (Geer mode valve ports T and A are internally connected, ‘iso ports B and P.) When the steering wheel is tumed (ight tur shown), ois fed to the rear rams F3, Fé andthe displaced oll Is fed to the front rams F1, F2 via the spool assembly, The front rams tum the wheels in the same direction as the rear wheels, causing the machine to crab to the right. Displaced oil returns to tank. Note: Some machines have power track rods instead of steer rams, The method of operation is unchanged. If the steering wheel is turned to the left, the oil fow is reversed and the machine will crab in the opposite direction, Fig 4. Typical Machine Installation H2-3 '860315750-05 (H-08-00) H2-3 B Section H2 - Steering Manual Steer Mode SYSTEM 2Wheel Steer ‘With the spool of steer motle control valve D in the 2-wheel ‘steer position there is @ hydraulic connection between the ‘steer unit C and the front steer rams Ft, F2. (Steer mode control valve ports T and P are internally connacted ) The oilfeed to the rear axle steer rams F3, Fd is blocked by the ‘spool assembly and the axie is held in the straight ahead Position by the locked-up hydraulic il in the rams. Note: Some machines have power track rods instead of steer rams. The method of operation is unchanged. ‘When the steering wheel is turned, only the front axle rams F1, F2 (or front power track rod) are operated by the steering uni C. If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction. ‘Operation Overview | P. ag Fig 2. Typical Machine Installation H24 60318750-05 08-00) H24 B 4Wheel Steer With the spool of steer mode valve D in the 4-wheel steer posttion there is a hydraulic connection between the steer Unit C and the front and rear axle steer rams F1 to Fa. (Seer mode control vave ports T and B are intemally connected, also ports A and P) When the steering wheel is turned (right turn shown), oil is fed to the rear rams F3, F4 and the displaced oils fed to the front rams F1, F2 via the spool assembly, The front rams turn the wheels in the ‘opposite direction to the rear wheels and displaced oi returns to tank, Note: Some machines have power track rods instead of steer rams. The method of operation is unchanged. If the steering wheel is turned to the left, the oil flow is reversed and the machine will tun in the opposite direction. Fig 9. Typical Machine Installation Section H2 - Steering Manual Steer Mode SYSTEM ‘Operation Overview H2-5 60318750-05 08-00) H25 Ww Section H2 - Steering Manual Steer Mode SYSTEM Hydraulic Operation and Schematics Hydraulic Operation and Schematics Refer to the Steering SYSTEM topic for hydraulic operation information. = Related Topics ([)H2.2) H2-6 '$60315750-05 (H-08-00) H26 Ww Section H3 - Steering Auto Steer Mode SYSTEM Introduction This topic contains information about a machine SYSTEM, The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications ‘able, > Related Topics ([)H3-3) Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer tothe relevant topics. Related Topies ([1H3-3) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble, 2 Related Topics (M)H3-3) + Operation Overview (P\H3-6 = Operation - 2-Wheel Steer Selected ([)H3-7) = Operation - 4.Wheel Steer Selected ([)H3-8) 2 Operation - Crab Steer Selected ([) H3-9) 2 Hydraulic Operation and Schematies ($1) ([)H3-7)"" 3 Operation - 2-Wheel Steer Selected ([)H3-7) 2 Operation - 4-Wheel Steer Selected ([)H3-8) = Operation - Crab Steer Selected ([) H3-9) = Schematics (1) H3-10) = Hydraulic Operation and Schematics (S2) (T\H3-13)" = Operation - 2-Wheel Steer Selected ([)H3-13) 2 Operation - 4-Wheel Steer Selected ([)H3-14) 3 Operation - Crab Steer Selected ([)H3-15) = Schematics (1) H3-16) 3 Electrical Operation and Schematics (T)H3-19) 2 Whee! Steer Selected (7) H3-20) 22-4 Whee! Steer Selected ([) H3-21) 2 Crab Steer Selected ([).H3-22) + Electrical Connectors (P) H3-23) (1). Specification variant. Make sure you refer to the correct specification, Table 1. Procedure and Specification Variants (x32) aga {30815750-05 (105-00) H3-1 B Section H3 - Steering Auto Steer Mode SYSTEM Table 1. Procedure and Specification Variants Introduction Procedures, Specifications” Machine Model Application ‘540-170 | 550-140 | 540-140 | 550-170 | 535-125 | 535-140 sar SAG) (SAL 5AM |Hiviz | HiViz SAN | SAP. D Hydraulic Operation and Schemaves. 77) (Machines with power track rods) > Hydraulic Operation and Schematics (S2) (T.H3-13) |@ e e e (Machines with steer rams) (1). The table lists procedure and specification variants and the applicable machine models. Use the table to make sure ‘you refer to the correct information. H3-2 '960315750-05 (7-09-00) H3-2 B Section H3 - Steering Auto Steer Mode SYSTEM Related Topics Related Topics Table 2. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles 7 ‘Applications ALL 2 ALL (Care and Safety)” AL 3 Hydraulie System Checking the Hydraulic Fluid Level gj Electrical Harness SYSTEM ALL ec Fuses and Relays E ‘Systems and Schematics H @ Steering SYSTEM (D\H?-1) ALL B @ Auto Steer Mode Valve (T)H10-7) AL (1). You must obey all of the relevant care and safety procedures. 33 $803780-05 (08-00) 43-3 Ww Section H3 - Steering Auto Steer Mode SYSTEM ‘Component Location Component Location Key. Fig 7. (3-4) [Reve Fig 4. (D1H8-4) 1 ‘Steer mode switch | B ‘Seer mode ECU H3-4 '$60315750-05 (H-08-00) H34 Ww Section H3 - Steering Auto Steer Mode SYSTEM ‘Component Location Key: Fig 2. (DVA3-6) Key: Brig 2 (AS-5) 3 "Steer mode valve- Machines with power 4 ‘Steer mode valve - Machines with steer track rods rams Fig 2. 3-5 S8087SO-05 (000) rs es B Section H3 - Steering Auto Steer Mode SYSTEM Operation Overview Three steering modes are available ~ 2.Wheel Steer (front axle only) = 4-Wheel Seer = Crab Seer In 2.wheel steer mode only the front wheels are steered. In 4-whesl steer mode both axles are steered, guing a smaller turning circle. The crab steer mode allows the machine to be driven diagonally The system is prevented from changing mode until all the wheels are in the straight ahead position. This is detected by proximity sensors on the front and rear axles. If the system is set in 4-wheel steer and 2.wheel steer is selected, the system will stay in 4-wheel steer unt the rear wheels are tured to the straight ahead position, The rear wheels are then hydraulically locked in the straight ahead postion, ‘Operation Overview H3-6 '960315750-05 (7-09-00) H3-6 B Section H3 - Steering Auto Steer Mode SYSTEM Hydraulic Operation and Schematics ($1) Hydraulic Operation and Schematics ($1) Operation - 2-Wheel Steer Selected Note: The illustrations shown are for the purpose of circuit ‘explanation only. Actualinstallations may not be as shown, Fig 3. (13-7). With the spools of steer mode control Valve V in the 2.wheel steer position (colencid A energised) there is a hydraulic connection between the steer unit $ and the front power track rod, F. The oll feed to the rear axle power track rod R is blocked by the spool assembly and the axle is hed in the straight ahead position by the locked-up hydraulic oll in the track rod ram. ‘When the steering wheel is turned, only the front power track rod F is operated by the steering unt S, If the steering whee! is turned to the left, the oil flow is reversed and the machine will tuin in the opposite direction. Fig 3. Typical Machine with Power Track Rods - Right ‘um shown H3-7 '860315750-05 (H-09-00) H3-7 B Section H3 - Steering Auto Steer Mode SYSTEM Operation - 4-Wheel Steer Selected Note: The illustatons shown are fer the purpose of crcult explanation only. Actual installations may not be as shown, Fig 4. (D.H3-8). With the spools of steer mode valve V in the 4-wheel steer positon (solenoids B and D energised) there is a hydraulic connection between the ‘steer unit $ and the front and rear axle power track rods F and R. When the steering wheel is turned (right turn ‘shown), oll is fed to the rear power track rod R and the displaced oil is fed to the front power track rod F via the valve spools. The front power track rod tums the wheels in the opposite direction to the rear wheels and displaced oll returns to tank. If the steering wheel is turned to the left, the oil fow is reversed and the machine will turn in the opposite direction. Hydraulic Operation and Schematics ($1) a» = 3B wn eS [ng Ayo d * aa we = Fig 4. Typical Machine with Power Track Rods - Right ‘urn shown H3-8 60318750-05 08-00) H3-8 B Section H3 - Steering Auto Steer Mode SYSTEM Operation - Crab Steer Selected Note: The illustatons shown are fer the purpose of crcult explanation only. Actual installations may not be as shown, Fig 5. (D)H3-9). With the spools of steer mode valve V in the crab steer position (solenoids B and C energised) there is a hydraulic connection between the steer unit S land the front and rear power track rods F and R. When the ‘steering whee! s turned (night turn shown), oils fed to the rear power track rod R and the displaced oil is fed to the front power track rod F via the valve spools. The front power track rod turns the wheels in the same direction as the rear wheels, causing the machine to crab to the right. Displaced oil returns to tank If the steering wheel is turned to the left, the oil fow is reversed and the machine will crab in the opposite direction. Hydraulic Operation and Schematics ($1) Fig 5. Typical Machine with Power Track Rods - Right ‘urn shown H3-9 60318750-05 08-00) H3-9 Ww Section H3 - Steering Auto Steer Mode SYSTEM Hydraulic Operation and Schematics ($1) Schematics Note: The steer mode valve spools have mechanical detents. Loss of electrical power tothe vaive solencid coils will not cause the system to change steer mode suddenly. ‘Steer Mode 2-Wheel Steer (machines with power track rods) Ports internally connected |F2-F1 Ports internally blocked | R1, R2 Solenoids energised A Key s ‘Steer unit R Oilfiow direction - Fight turn c Oilfiow direction -left turn Vv ‘Steer mode vave FR Front axe H3-10 S8087SO-05 (000) 3-40 B Section H3 - Steering Auto Steer Mode SYSTEM Hydraulic Operation and Schematics ($1) ‘Steer Mode 4 Wheel Steer (machines with power track rods) Ports intemaly connected |F1 - R2 F2-RI orks interaly Blocked |- Solenoids energised [B,D Key 5 Ser unit R Oitfiow direction - right tun v Oilfiow direction - et turn v ‘See’ made vave FR Front axle H3-11 S8087SO-05 (000) 13-11 Ww Section H3 - Steering Auto Steer Mode SYSTEM Hydraulic Operation and Schematics ($1) ‘Steer Mode (Crab Steer (machines with power track rods) Ports internally connected [F1-R1 F2-R2 Parts internally Blocked _|- Solenoids energised BC Key s Steer unit R Oil flow direction - Fight turn C (Oiiow direction eft turn Vv ‘Steer mode vale FR Front axle He-12 S8087SO-05 (000) H3-12 B Section H3 - Steering Auto Steer Mode SYSTEM Hydraulic Operation and Schematics ($2) Hydraulic Operation and Schematics (S2) Operation - 2-Wheel Steer Selected Note: The illustrations shown are for the purpose of circuit explanation only. Actual installations may not be as shown, 2 Fig 3. ()H3-7). With the spools of steer mode control Valve V in the 2-wheel steer position there is a hydraulic connection between the steer unit $ and the front steer rams F1, F2. The oil feed to the rear axle steer rams F3, Fis blocked by the spool assembly and the axle is held in the straight ahead position by the locked-up hydraulic oil in the rams, ‘When the steering wheel is turned, only the front axle rams F4, F2 (or front power track rod) are operated by the steering unit S If the steering wheel is turned to the left, the oil flow is reversed and the machine will tun in the opposite direction, AZ ig — S veg a aD Fig 6. Typical Machine with Steer Rams - Right turn. H3-13 '$60315750-05 (H-08-00) H3-13 B Section H3 - Steering Auto Steer Mode SYSTEM Operation - 4-Wheel Steer Selected Note: The illustatons shown are fer the purpose of crcult explanation only. Actual installations may not be as shown, Fig 4. (D)H3-8). With the spools of steer mode valve V in the 4-wheel steer position there is a hydraulic Connection between the steer unit $ and the front and rear axle steer rams F1 to F4, When the steering whee! is turned (right turn shown), oll is fed to the rear rams F3, Fa and the displaced oll is fed to the front rams F4, F2.via the spool assembly. The front rams turn the whee's in the opposite direction to the rear wheels and displaced oll returns to tank If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction, Hydraulic Operation and Schematics ($2) Fig 7. Typical Machine with Steer Rams - Right turn ‘shown H3-14 '$60315750-05 (H-08-00) H3-14 B Section H3 - Steering Auto Steer Mode SYSTEM Operation - Crab Steer Selected Note: The illustatons shown are fer the purpose of crcult explanation only. Actual installations may not be as shown, Fig 5. (D)H3-9). With the spools of steer mode valve V in the crab steer position there is a hydraulic connection between the steer unit S and the front and rear axle steer rams F1 to F4. When the steering wheel is turned (right turn shown), oil is fed to the rear rams F3, Fé and the displaced oil is fed to the front rams F4, F2 via the spool assembly. The front rams tum the wheels in the same direction as the rear wheels, causing the machine to crab to the right, Displaced oil returns to tank. If the steering wheel is turned to the left, the oil flow is reversed and the machine will crab in the opposite direction, Hydraulic Operation and Schematics ($2) Fig 8. Typical Machine with Steer Rams - Right turn shown H3-16 '$60315750-05 (H-08-00) H3-15 B Section H3 - Steering Auto Steer Mode SYSTEM Schematics Note: The steer mode valve spools have mechanical detents. Loss of electrical power tothe valve solencid coils Hydraulic Operation and Schematics ($2) will not cause the system to change steer mode suddenly. Faulty electrical connections to the solenoid coils (energising the coi) could cause the steer mode to change suddenly with no operator input Seer ode Z- Wheel Seer i (machines with steer . XW \\ rams) ae ‘i ae ors internally connected |F2- Fi eM - Poris eral blocked [RT R2 “cX Saino enegised TA IK Key \ 5 Sear nit z Off aredion wgneurn c iow aver Tek fan v Soar nade VANE FR Frente me 8 hal H3-16 S8087SO-05 (000) Hoe B Section H3 - Steering Auto Steer Mode SYSTEM Hydraulic Operation and Schematics ($2) ‘Steer Mode 4- Wheel Steer (machines with steer rams) Ports internally connected [F1-R2 F2-Ri Parts internally blocked —_|- Solenoids energised BD key s ‘Steer uni R (Oil fiow direction = Fight turn C (Oil flow direction - left tua Vv ‘Steer mode vave FR Front axie H3-17 '860315750-05 (H-09-00) H3-17 B Section H3 - Steering Auto Steer Mode SYSTEM Hydraulic Operation and Schematics ($2) ‘Steer Mode (Crab Steer (machines with steer rams) Ports internally connected [F1-R1 F2-R2 Parts internally Blocked _|- Solenoids energised BC Key s Steer unit R Oil flow direction - Fight turn C (Oiiow direction eft turn Vv ‘Steer mode vale FR Front axle H3-18 '860315750-05 (H-09-00) H3-18 Ww Section H3 - Steering Auto Steer Mode SYSTEM Electrical Operation and Schematics Electrical Operation and Schematics Fig 8. Schematic Circuit (Typical) Gentral to the steer mode system is the electronic control Unit (ECU) 1. When the operator selects a steer mode using the cab mounted selector switch 2, the ECU ‘energises the relevant solenoids C or Don the steer mode valve. Solenoids A and B are energised via a changeover relay 3, which in tum is also controlled by the ECU, Indicator LED's 6, 7 or8 on the instrument pane! iluminate to show the steer mode currently operative Fig 10. Instrument Pane! Note: The steer mode valve spools have mechanical detents. Loss of electrical power to the vaive solencid coils will not cause the system to change steer mode suddenly. Faulty electrical connections to the solenoid coils (energising the coi) could cause the steer mode to change ‘sueldenty with no operator input. 3-19 S8087SO-05 (000) 13-49 Ww Section H3 - Steering Auto Steer Mode SYSTEM Electrical Operation and Schematics 2 Wheel Steer Selected Fig 11. 2Wheel Steer Selected comnpce Centralto the electrical system is the electronic control unt ECU [Function Status 4 (ECU). The table shows the status of the ECU when | pin eee T__ [Selector switch 2input- AWS steer |OFF Table 3. ECU Status, 2-Wheel Steer Selected 8 [Selector swich 2input-crab steer [OFF ECU |Funetion Status] [9 | Rear axle proximity switch input” [ON Pin 40 [High side output- Csolenoid- steer |OFF 1) | Eaethieenneerion, oN mode valve, AWS warning light 6 2 |Relay3 collearth connection (Bsolenoid |OFF 41 [High side output - D solenoid steer OFF + steer mode vaive) mode valve, crab steer warning ight 7 3 [Notused 7 12 _|Power supply ON 4 __|Lowside output- 2WS warning ight [ON 5 |Diagnosticinput- A solenoid- steer [ON (1) 20S will not be selected unti the rear axle returns to mode valve the straight ahead position and an inputat the ECU is © _[Frontaxle proximity switch Sinput___ [OFF ecatied via fra Prax Met 7. 60318750-05 08-00) H3-20 B Section H3 - Steering Auto Steer Mode SYSTEM 4 Wheel Steer Selected Fa Electrical Operation and Schematics Fig 12. 4-Wheel Steer Selected Central to the electrical system is the electronic control unt ECU | Function ‘Status 1 (ECU). The table shows the status of the ECU when | pin eee eee 7 Selector switch 2input-AWS steer [ON Table 4, ECU Status, 4-Wheel Steer Selected 8 Selector swich 2input- crab steer __ [OFF pe Panction status 9 | Rear axle proximity switch 4 input OFF . 70 _|/High side output-Csolenoid- steer [ON 1 [Earth connection on made valve, AWS warning light 6 2 | Relay 3col earth connection (B solenoid [ON i [High side output -D solenoid - steor OFF + steer mode valve) mode valve, crab steer warning light 7 3 |Notused - 72 [Power supply OW 4 [Low side output-2WS warning ight. [OFF % | Diagnosticinput- A-solencid- steer [OFF (1) AWS.will not be selected until the front axle returns 0 mode valve the straight ahoad position and an input atthe ECU is © _ | Frontaxle proxinity switch Sinput” [ONT tecatted Ye te promi sue 5 '808/3750-05 (08-00) H3-21 Ww Section H3 - Steering Auto Steer Mode SYSTEM Electrical Operation and Schematics Crab Steer Selected Fe Fe Fig 13. Crab Steer Selected 7 CCentrato te electrical systemistheelectoniccontrlunt [EGU] Function Sats 1(ECU). The table shows the status ofthe ECU wnen cra | pin steers salected via mace switch 2 7_[Seiecor switch 2input-AWS steer [OFF Table 5. ECU Status, Crab Steer Selected 3 __|Selector swich 2 input- crab steer [ON ECU [Function Status] [9 Rear axle proximity switch 4 input [OFF en 10 | High side output - C solenoid - steer OFF 1 Earth connection ON mode valve, AWS warning light 6 2 [Relay Scoll earth connection (Bsolenoid [ON 71 [High side oulput - D solenoid- deer [ON = sleet mode valve) mode valve, crab steer warning light 7 3 Not used 7 12 | Power supply ON 4 |Low side output 2S warning ight |OFF 5 Diagnostic input - A solenoid - steer OFF (1) Crab steer will not be selected until the front axie mode vaive retuins to the straight ahead position and an inp at 6 Front axle proximity switch 5 input!!! ON EEREDL te rmcmivedl tm fhe arr ewieal 60318750-05 08-00) H3-22 Ww Section H3 - Steering Auto Steer Mode SYSTEM Electrical Operation and Schematics Electrical Connectors ‘Component Key: 3 Fig 14 (T)H3-24) 03 [PanelEarth “OT _| Chassis Earth 102% _| Front Axie Steering Proximity Switch 1085 [Rear Axle Steering Proximity Switch 1044 | Steer Mode Changeover Switch 2044 | Steer Mode Relay 3001 |2 Wheel Steer Solencid [3003 | 4 Wheel Steer Solenoid 3006 | All Wheel Steer Solenoid 3014 | Crab Steer Solenoid 4015 | Steer Mode ECU 8017 [Centre Cluster Waming Lights 7014 | Diode Gate 7048 [Diode Gate {8004 | Panel Hamess to Chassis Harness Connector (0001 [Fuse Box A 60318750-05 08-00) H3-23 ve-eH (0-60) so-osze/e086 ve-eH ey eV sor EFscos Ee)so00 fq ae a Fig 14, Electrical Connectors soneurayog pue uonesado je0170313 WALSAS @pow 138215 ONY Buriaayg - ¢H UODag B Section H3 - Steering Auto Steer Mode SYSTEM. Elect trical Operation and Schematics “The table shows the hamess connectors that connect to the electical devices, The connectors are shown looking at the mating face when disconnected. Remember that the drawings show the harness connectors NOT the device connectors. Use the fable and the relevant electrical schematic to identify the pins in the harness connectors, Continuity checks on the hamess wires can be carried out using a multi-meter. Do not touch ECU connector pins. Do not use a multi-meter on ECU connector pins, Device | Description Location Harness Connector 7021 | Front Axle Stering Located on the Right hand side ofthe front axle Proximity Swatch fa, eo) \e/ 7085 [Rear Axle Steering Located on the rear axle Proximity Switch Toad | Steer Mode Changeover | Loceted on the incrument panel, Remove the Switch 'swich to get access to the connector 2000 | Steer Mode Relay Refer to Section C - Fuses and Relays. > Related Topics ([1H3-3) ‘3001 [2 Wheel Sieer Solenoid | Located on the Steer Mode Valve 3 3003 |4 Wheel Seer Solenoid | Located on the Steer Mode VaNe oH, Ea) ‘3006 |Al Whee! Seer Solenoid [Located on the Steer Mode Valve aa 3014 [Crab Steer Solencid | Located on the Steer Mode Valve 4015 [Steer Mode ECU Located inside the right of the instument panel = behind the load chart mounting. sERSEEO Hopoges) 6017 [Centre Cluster Warning | The display panel connectors are located behind Lights tne parel FEREEEEEER EEEEEEEEEE 60318750-05 08-00) H3-25 Section H3 - Steering Auto Steer Mode SYSTEM Electrical Operation and Schematics To1d [Diode Gate Connects tothe panel harness below he I siGe instrument console. (a) t sees [sresy 7048 [Diode Gate TEA ‘8000 [Harness interconnections |Reler to Section C - Electrical Harness SYSTEM. 3 Related Topics (T.H3-3) 9000 | Fuse boxes Refer to Section C - Fuses and Relays. 2 Related Topics (H3-3) “200 Earth points Referto Section C- Electrical Harmess ‘SYSTEM. 2 Related Topics ([)H3-3) 60318750-05 08-00) H3-26 Ww Section H4 - Steering Hydraulic Steering Unit Introduction This topic contains information about 2 machine DEVICE, Make sure you are referring to the correct device, Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics, ‘This topic is intended to help you understand what the device does and howit works. Where applicable it also includes procedures such as removal and replacement and dismantie and assemble, 2 Related Topics (1 H4-2 = Hydraulic Operation and Schematies (() H4-3) = Removal and Replacement (T)H4-5) + Removal ([YH4-5) 3 Replacement (1) H4-5) H44 '$603/5750-05 (H-02-01) H44 Ww Section H4 - Steering Hydraulic Steering Unit Related Topics Related Topics Table 1. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles 7 “Applications ALL 2 ALL (Care and Safety)” AL 3 Hydraulie System ‘Checking the Hydraulic Fluid Level A @ Steoring SYSTEM (T\HT-1 @ Bleeding the System ([) H7-28) B @ Steering SYSTEM (DHT @ Test Procedures (MHI (1) You must obey all ofthe relevant care and safety procedures, Table 2. Service Tools. "The table lists the Service tools you will need to do Some of the procedures In this tople, Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number Description ‘60087 ‘Spring Installation Tool (1) Eaton Hydraulics Part Number H4-2 '$603/5750-05 (H-02-01) H4-2 Section H4 - Steering Hydraulic Steering Unit Hydraulic Operation and Schematics Hydraulic Operation and Schematics Hydraulic Steering Unit ‘Shock Valves (i fited) ‘Check Vaive Leh FeediRetum Por Right FeediRetum Port Vane inlet Return Line Steer Valve Load Sense Port ‘Steering System Relief Valve: H4-3 '$603/5750-05 (H-02-01) H4-3 Ww Section H4 - Steering Hydraulic Steering Unit Hydraulic Operation and Schematics Fig 1. H44 '860315750-05 (H-02-01) H44 Section H4 - Steering Hydraulic Steering Unit Retnoval and Replacement Removal and Replacement Fig 2. Removal 1 6 Park the machine on level ground, engage the parking brake and set the transmission to neutral Lower the attachments to the ground, Stitch off the engine and remove the starter key. Turn the steering whiee! to the left and to the right several times to vent system pressure, Ensure tat the steering wheel sin the straight ahead position. Disconnect the hydraulic hoses to steering unit 2.A, labelling them to aid reconnection. Plug the ports and hoses to prevent the ingress of ditt and excessive loss of hydraulic ol, Mark the orientation of steering unit 2-8 to splined shat 2B, Remove bolts 2-C (4 off) from inside the cab. At the: same time have an assistant support steering unit 2+ A beneath the machine. ‘Withdraw steering unit 2-8 Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also 1 Torque tighten fixing bolts 2-C, > Table3. Torque Settings (1 H4-5), Make sure that the hoses are refitted in the correct, positions. Note: The steering unit is spring loaded fo the neutral position (i.e. straight ahead). Make eure the steering who! 's in the straight ahead position when reconnecting splined shaft 2-B. 2 Before driving the machine, bleed the steering system = Bleeding the System ([) H1-25) 3. Ifa new steering unit has been fited then the system relief valve must be tested for correct pressure setting. > Hydraulic Pressure Tests ([) H1-18) Table 3. Torque Settings Tem Nm kgf m ag 26 B 46 8 H4-5 '$603/5750-05 (H-02-01) H4-5 Ww Section H4 - Steering Hydraulic Steering Unit Retnoval and Replacement Page left intentionally blank H4-6 '$603/5750-05 (H-02-01) H46 Ww Section H5 - Steering Priority Valve Introduction This topic contains information about 2 machine DEVICE, Make sure you are referring to the correct device, Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics, ‘This topic is intended to help you understand what the device does and howit works. Where applicable it also includes procedures such as removal and replacement and dismantie and assemble, 2 Related Topics (T\H5-2) = Removal and Replacement (DHS; 2 Removal (T)H6-3) = Replacement (1) H6-3) ASA 39081750-05 (FOE) 5-1 B Section H5 - Steering Priority Valve Related Topics Related Topics Table 1. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles 7 ‘Applications ALL 2 ALL (Care and Safety)” AL 3 Hydraulie System Checking the Hydraulic Fluid Level E ‘Main Pump ALL B /@ Steering SYSTEM (DHT. ALL (1) You must obey all ofthe relevant care and safety procedures, H5-2 '$60315750-05 (H-03-01) H5-2 B Section H5 - Steering Priority Valve Removal and Replacement The priority valve assembly is not serviceable beyond the removal of foreign matter. =Stoor Priority Valve - Cleaning ([) H4-20) ‘faulty unit must be replaced, Removal 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 Tum the steering wheel to the left and to the right several times to vent system pressure, A WaRNING 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. Retnoval and Replacement Fig 1. Typical Pump Table 2, Torque Settings Trem Nm kgf m TR 304-4 S404 2H-3 cevet 3. Disconnect hoses A, B and C. Blank off the hoses to prevent loss of fluid and ingress of dirt 4 Remove the three socket head screws D and it the priority valve assembly away from the pump. 5 Remove and discard all 0" ring seals between the ‘mounting faces ofthe prot valve assembly andthe pum Replacement Replacements the opposite ofthe removal procedure During the replacement procedure do this work also Lightly grease and fit new °C’ rings between the mounting faces. Torque tighten socket head screws D evenly and progressively. = Table 2. Torque Sedtings (D)H5-3) H5-3 '$60315750-05 (H-03-01) H5-3 Ww Section H5 - Steering Priority Valve Retnoval and Replacement Page left intentionally blank Ho4 '$60315750-05 (H-03-01) Ho-4 Ww Section H6 - Steering Power Track Rod Introduction This topic contains information about 2 machine DEVICE, Make sure you are referring to the correct device, Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics, ‘This topic is intended to help you understand what the device does and howit works. Where applicable it also includes procedures such as removal and replacement and dismantie and assemble, 2 Related Topics (THE = Removal and Replacement (THE. 2 Removal (T)H6-3) 3 Replacement (1) H6-3) Link Arms (1) H6. = Dismantie and Assemble (1) HE-7 Hel '$60315750-05 (H-07-00) H6-1 Ww Section H6 - Steering Power Track Rod Related Topics Related Topics Table 1. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles 7 ‘Applications ALL 2 ALL (Care and Safety)” AL 3 Routine Maintenance ALL E Ram Dismantle and Assemble ALL B @ Steering SYSTEM (DHT. ALL (1) You must obey all ofthe relevant care and safety procedures, H6-2 '$60315750-05 (H-07-00) H6-2 B Section H6 - Steering Power Track Rod Retnoval and Replacement Removal and Replacement Removal Carry out the general safety procedures detailed under Section 2 - Generaf Procedures, A warninc A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. Before commencing work clean the area around the axle and power track rod 1 As appropriate, use suitable lifting gear to raise the front or rear wheels off the ground and block the, chassis, Remove the left front or right rear wheel as. applicable. 2 Front Axle: Disconnect hoses 1-A and 1-B and then remove adaptor 1-C. Blank off the hoses and plug the: ‘adaptor at 1-A and the port vacated by adaptor 1-C to, prevent the ingress of dir. Rear Axle: Disconnect pipe assembly 1-D from the power track rod at points 1-£ and 1-F. Remove ‘mounting screw 1-G. Lift the pipe assembly clear and blank both open ends to prevent the ingress of ditt Remove adaptor 1-H and plug the port vacated as Well as the port 1-E Note: At this point, if the power track rod is fo be dismantled, loosen the track rod link arms, while the track rod is stil securely clamped, see Link Arms - Removal and Replacement. 3° Remove screw 1-J and pin 4-K at each end of the axle and separate the link ams 1-L from their ‘mounting points. Discard the two web seals seated in the eye of each link arm, 4 Makealignment marks on the cylinder flange and end cover of the power track rod, and on the housing flange ofthe axle 5 Remove the four mounting screws 1-M. 6 Front Axle: Using sultable jacks, support both ends ff the axle and then remove mounting nuts 4-N at both ends, Leave bolts 1-P in position, Lower the jack at the let end sufficient to make room for removal of the power track rod. Using a softfaced hammer, gently tap the closed end of the track rod cylinder to the left and out ofits mounting, Rear Axle: Use 2 sultable jack to raise the lett end of the axla so as to swivel the right end down to make room for removal of the power track rod. Using a soft. faced hammer, gently tap the closed end of the track rod cylinder to the right and out of its mounting Replacement Replacement isthe opposte ofthe removal procedure. During the replacement procedure do this work also 1 Grease and renewthe two web seals in each link arm eye, making Sure they are fited corecty and fully seated 2 Grease the machined external shouiders ofthe power track rod and install by tapping win a softfaced hammeron the mounting ange, 3 Take care to align the marks made at step 4. during removal 4 Before driving the machine, bleed the steering system, see Service Procedures, Bleeding the H6-3 '$60315750-05 (H-07-00) system, Table 2. Torque Settings Tem Nm kgf m Worf 1s 38 37 a TH 36 S7 a oo) 36 ST a ™ 788 7 722 TN 00 oa 420) 1 00 20 a0 H6-3 Ww Section H6 - Steering Power Track Rod lacement w Sect in H6 - Steering Power Track Rod 1k Arms Removal Ifthe power track rod ram Is to be dismantled, or the link ‘arms replaced, proceed as follows: 1 Fix the assembly on a locally made striofrebulld bench.£> Fig 2. (MH6-5). Fig2. 2 Use two suitable open ended spanners at 3-A and 2 B reacting against each other until one ball joint Uunscrews, For the purposes of explanation assume the ball joint at 3-A has unscrewed. ‘3 Unscrew the ball joint until an open ended spanner can be fitted on rod 3-C, Screw the ball joint against the spanner to secure it and to prevent damage tothe rod. ‘Note: The piston rod operates at ful length, any damage {0 the surface wil cause fuid feaks. DO NOT attempt fo ‘orp the rod diameter with pipe grips ete. 4 By reacting against the spanner at 3-C undo the ether ball joint at 3-D. Removal and Replacement Fig 3. 5 Where applicable remove target disc 4-C. Note: I the inner or outer bail joints need to be renewed, then a replacement link arm assembly must be fited. H6-5 '8803/8750-05 (H-07-00), H6E-5 B Section H6 - Steering Power Track Rod Replacement Note: Ifthe power track rod ram is to be dismantled, cary Out the procedure betorereplacing/renewing the link arms. 6.7) Replacement isthe opposite ofthe removal provediure. During the replacement procedure do this work also 1. Remember to fi target aise 4-6 (where applicable) 2 Use JCB Threadlocker and Sealer on the frst three threads of the inner ball joint where it screws into the tend of the track rod, Retnoval and Replacement 3 If the link arms have been renewed, the wheel alignment must be checked. = Fig 5. ([1H6-6) Set the wheels to the straight ahead position and measure dimensions X and ¥ (at the outer edge of the ‘wheel hub). Alignment is correct if the difference between X and ¥ is @ maximum of 1 mm. To adjust the wheel alignment undo the lock nuts 4-E. ‘Turn the threaded adjusters 4-D equally to obtain the correct alignment. Tighten the lock nuts 4-E 4 Check the target disc and proximity switch setting (where applicable) Table 3. Torque Settings tem Nm kgf m Torr aAB | 240-200 | 24-26 | 177-102 aDmE | 240-260 | 24-26 | 177-102 > Figs. Hee '$60315750-05 (H-07-00) H6-6 B Section H6 - Steering Power Track Rod Dismantie and Assemble Dismantle and Assemble Rams = Fig 7. (D)H6-8). The numerical sequence shown on the ilustration is intended as a guide to dismantiing, For assembly the sequence should be reversed Dismantle 1 Fix the ram assembly on a locally manufactured striof rebuild bench, 2 Fig 8. (T) HE-8) 2 Ifnotalready done, remove the two steering Ink arms 7A and 7-8, = DRemoval___and Replacement ([) H6-3) 3 Remove end cap 7-2 and then pull the piston rod assembly 7-5, 7-6, 7-7, 7-8 and 7-9 from the cylinder, Note: Do not aliew the piston rad to cams into contact with the cylinder bore. The cylinder bore may be damaged by careless dismanting 4 Position the piston rod assembly on the bench in place of the ram cylinder. Remove and discard the \wear rings 7-8, 7-7 and seal 7-8/energising ring 7-8. Note: The piston head cannot be removed from the rod. if there (s damage to the rod or piston head, replace the complete assembly, 5 Carefully inspect the bore of the cylinder and the piston rod outer diameter for scoring, nicks and burrs If such damage is visible the components must be renewed Assemble 1 Use a JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and old JCB Mult-Gasket, Allow 15 minutes for solvent to dry before applying fresh JCB Mutt-Gasket Ensure that lubricants used during assembly do not, come into contact with JCB Multi.Gasket 2 Ensure that piston rod seals 7-10 and wiper rings 7- 11 are fitted correctly into the closed end of cylinder 7-B and also into cover 7-2 along with cover seal 7-12. It is very important that energiser ring 6-9 is not twisted. Failure to carry out the installation correctly could lead to hydraulic fluid leakage between the two sides of the power track rod and consequential steering problems. = Fig6 ([H6-7) - after installation check that three white rarks are visible on the outside diameter arrowed before instaling seal 6- 8 Fig. 3. Before installing piston rod assembly 7-5, 7-6, 7-7, 7= 8 and 7-9 apply grease to piston seal 7-8 and to the surfaces of the piston rod. 4 Clamp the cylinder vertically and lower the piston rod assembly in from the top, see, making sure its orientation is correct, i.e, with piston sleeve 7-C nearest the closed end of the cylinder 3 Fig 9. (P}H6-8). Take care not to allow the piston Tod to come into contact with the cylinder bore, Be sure to engage the piston head new wear rings and ‘seals catefully into the cylinder. If the piston head wear rings or seals are damaged during this stage, they must be renewed. Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the track rod 1S operated slowly to its {ull extent in both directions before commencing normal working Table 4. Torque Settings Tem Nm kgf m Tor 78 e78 2 500 H6-7 '$60315750-05 (H-07-00) H6-7 Ww Section H6 - Steering Power Track Rod Dismantie and Assemble Fig 8. Fig 9. H6-8 '960318750-05 (#-07-00) Hes Ww Section H7 - Steering Steer Rams Introduction This topic contains information about 2 machine DEVICE, Make sure you are referring to the correct device, Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics, ‘This topic is intended to help you understand what the device does and howit works. Where applicable it also includes procedures such as removal and replacement and dismantie and assemble, 2 Related Topics (\H7-2 = Removal and Replacement (T\H7-: + Removal (D)H7-3) 3 Replacement (1) H7-3) = Dismantio and Assemble (() H7-4) ATA 390815750-05 (FOS-01) H7-1 Ww Section H7 - Steering Steer Rams Related Topics Related Topics Table 1. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles 7 ‘Applications ALL 2 ALL (Care and Safety)” AL 3 Routine Maintenance ALL E Ram Dismantle and Assemble ALL B @ Steering SYSTEM (DHT. ALL (1) You must obey all ofthe relevant care and safety procedures, H72 S803750-05 (0507) H7-2 Section H7 - Steering Steer Rams Retnoval and Replacement Removal and Replacement Fig 1. Removal Carry out the general safety procedures detailed under Section 2- General Procedures, A Warninc 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. cevert Before commencing work clean the area around the axie and steer ram, The following procedure applies to each of the steering 1 Disconnect the three hoses 1-A. Label each hose before disconnecting to ensure correct replacement, Blank off the hoses and plug the ram ports to pravent, loss of fluid and ingress of dirt 2 Remove screws 4-8 and pins 4-C at each end of the ram and lift the ram clear Replacement Replacements the opposite ofthe removal procedure During the replacement procedure do tis work also: Torque tighten the screws 1-8, > Table2. Torque Settings (T)H7-3) Before driving the machine, bleed the steering system, Bleeding the System (1) H1-25) Table 2, Torque Settings rams on the front and rear axles: Ta = are er 1 36 57 a H7-3 '860315750-05 (H-05-01) H7-3 Ww Section H7 - Steering Steer Rams Disimantle and Assemble Dismantle and Assemble Refer to Section E - Rams, Dismantie and Assemble, Typical Ram. H7-4 '960318750-05 (7-05-01) H74 Ww Section H8 - Steering Steering Column Introduction This topic contains information about 2 machine DEVICE, Make sure you are referring to the correct device, Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics, ‘This topic is intended to help you understand what the device does and howit works. Where applicable it also includes procedures such as removal and replacement and dismantie and assemble, 2 Related Topics (T\H8-2 = Removal and Replacement (T\H8-3) 2 Steering Whee! (1) H8-3) 2 Steering Column Switches ([\H8-3) 3 Steering Column ([)H8-5) eA {90815750-05 (1-06-00) H8-1 Ww Section H8 - Steering Steering Column Related Topics Related Topics Table 1. Related Topics in This Publication ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections [Topic Titles Sub Titles 7 ‘Applications ALL 2 ALL (Care and Safety)” AL (1) You must obey all ofthe relevant care and safety procedures, naa {90815750-05 (1-06-00) H8-2 B Section H8 - Steering Steering Column Retnoval and Replacement Removal and Replacement Steering Wheel Removal 1 Mark the position of the steering wheel 1-£ on the spiined shaft 1. 2 Prise the steering wheel centre cap 1-A from the wheel 4-E. 3 Remove the steering wheel securing nut 1-B. 4 Retrieve the washer 1-C. 5 Pullthe steering wheel 1-E off the splined shaft +-F. 6 Make sure to retain key 1-D, Fig Replacement Replacement is the opposite of the removal procedure, During the replacement procedure do this work also = If key 1-D becomes damaged during the removal procedure, replace with @ new key. — Make sure that the steering wheel lines up with the rmarks created when removing, Steering Column Switches Removal 1 Park the machine and make it safe. Obey the care and safety procedures, 2 Related Topics ([) H8-2) 2 Remove the Wheel (D)H8-3) steering wheel, 2 Steering 3 Remove the two screws on the top of the steering column upper surround 2-C. 4 Remove the two button head screws 2-A, remove the steering column lower surround, 5 Remove the two button head screws 2-B and remove the steering column upper surround, 6 Remove the steering column switch retaining plate scraw3-D. 7 Liftoff the switch retaining plate 3-£ F fitted. 8 Remove the switch covers 3F, 9 Disconnect the harness connectors at 3. 10. Unscrew the retaining screw 3K from the switch collar 36 H8-3 '$60315750-05 (H-06-00) H8-3 Ww Section H8 - Steering Steering Column Removal and Replacement 11 Pullthe column switches 9-H away from the column, Replacement Replacement is the opposite of the removal procedure, During the replacement procedure do this werk also: Make sure that the transmission lever securing bolt 4-4, has 2 washers installed as shown, Fig 2. Hea GERRTED.OS (HOE-OO) He4 B Section H8 - Steering Steering Column Steering Column Note: There are two types of steering column. Type 5X is tit adjustable and type BY is tit and height adjustable, The removal and replacement procedures are the same for both types. Removal 1 Park the machine and make it safe. Obey the care ‘and safety procedures. => Related Topies ([) H8-2) 2 Remove the steering wheel and steering colurm surround. = Steering Wheel ([)H8-3) 3 Remove the column switches. => Steering Column ‘Switches (T) H8.3) Important: The electrical connectors 6-A ard §-B are the same. Record the position of the connectors. 4 Remove the electrical connectors 6-A and §-B. 5 Put aligned marks on the steering shaft 5-D and column 5-E. 6 Remove clips 5-F and pins 5-6. 7 Hold the steering column assembly and remove the lever lock 5-C (if fitted) 8 _Liftthe column assembly clear of the cab. Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also. — Align the marks on the steering shaft and steering ‘column (step 8) — Engage the steeting shaft splines 5-H with the steer valve internal spline, ~ Putelectrical connectors 6-A and §-B in their correct positions, Retnoval and Replacement H8-5 '980315750-05 (4-06-00) H8-5 Ww Section H8 - Steering Steering Column Retnoval and Replacement Page left intentionally blank He-6 '$60315750-05 (H-06-00) H8-6 Ww Section H9 - Steering Manual Steer Mode Valve Introduction This topic contains information about 2 machine DEVICE, Make sure you are referring to the correct device, Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics, ‘This topic is intended to help you understand what the device does and howit works. Where applicable it also includes procedures such as removal and replacement and dismantie and assemble, 2 Related Topics (T\H9-2 = Removal and Replacement (T\H®-: 2 Removal (T)H9-3) 2 Replacement (1) H9-4) = Dismantio and Assemble (() H9-5) 2 Dismantie (T)H9-5) 2 Assemble (D1 H9-6) ag 390815750-05 (FOOT) H9-1 B ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Section H9 - Steering Manual Steer Mode Valve Related Topics Related Topics Table 1. Related Topics in This Publication Sections [Topic Titles Sub Titles 7 ‘Applications ALL 2 ALL (Care and Safety)” AL 3 Hydraulie System Checking the Hydraulic Fluid Level A @ Steoring SYSTEM (T\HT-1 ALL B @ Manual Steer Mode SYSTEM ([) H2-1 ALL (1) You must obey all ofthe relevant care and safety procedures, H9-2 '860315750-05 (H-04-01) H9-2 B Section H9 - Steering Manual Steer Mode Valve Retnoval and Replacement Removal and Replacement Removal 1 Park the machine and make it safe, Fit the boom safety strut Obey the care and safety procedures 3 Related Topics (7) H9-2) 2 Disconnect and cap the four hydraulic hoses from the steer mode valve. Fig 1. (P)H9-3). Label hoses for identification. Fig 3 Remove the fasteners 1-A securing the steer mode valve 1-B to the chassis, 4 Remove the steer mode selector control handle 2-8 (located inside the cab). Fig 2 Remove the nuts 3-8 securing the steer mode selector unit -€ to the cab. = Fig 3. (1 H9-3) Fig 3. ‘The steer mode selector unit, operating cable and valve can now be removed from the machine as a complete assembly. H9-3 '860315750-05 (H-04-01) H9-3 Ww Section H9 - Steering Manual Steer Mode Valve Retnoval and Replacement Note: Before removing the steer mode valve assembly from the machine, observe the routing of the operating cable, Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also — Make sure that the hoses are fitted in the correct position = Bleed the steering system, 2 Bleeding the ‘System (P1H1-25 = Check the hydraulic fluid level, 2 Related Topics (1) H9-2) Hos '860315750-05 (H-04-01) H9-4 Section H9 - Steering Manual Steer Mode Valve Dismantie and Assemble Dismantle and Assemble Dismantle 1 Remove the steer mode valve assembly from the ‘machine. = Removal ([) H8-3) 2 Remove screws A from endcap B. 3. Undo locknut C. Rotating the locknut and endeap B counter.clockwise (so that the parts travel away from the valve) until they disengages the operating cable thread 4 Undo locknut D and disconnect operating cable E from valve adaptor F. Remove screws G from endeap H. Undo locknut J. Rotating the locknut and endeap H ccounter-clockwise (so that the parts travel away from the vaive) until they disengages the operating cable thread Disengage operating cable E from the steer mode selector K H9-5 '860315750-05 (H-04-01) H9-5 Ww Section H9 - Steering Manual Steer Mode Valve Dismantie and Assemble Assemble ‘Assembly isthe opposite of the Dismantling procedure. During the assembly procedure do this work also: Before connecting the operating cable to the valve, set locknut Das shown, = Fig 6. ([ H9-6) In this position the locknut can be used 28 a guide as to how far to wind the operating cable into valve adaptor F (0.4in) Figs. Apply JCB Threadlocker and Sealer to screws A and. H9-6 '860315750-05 (H-04-01) H9-6 Ww Section H10 - Steering Auto Steer Mode Valve Introduction This topic contains information about 2 machine DEVICE, Make sure you are referring to the correct device, Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics, ‘This topic is intended to help you understand what the device does and howit works. Where applicable it also includes procedures such as removal and replacement and dismantie and assemble, 2 Related Topics (T\H10-2) = Removal and Replacement (T\H10-3) = Machines with Power Track Rods ([) H10-3) = Machines with Stoor Rams ([)H10-5) = Dismantio and Assemble (( H10-7) H10-1 '$60315750-05 (H-04-02) H10-1 B ‘The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this: page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Section H10 - Steering Auto Steer Mode Valve Related Topics Related Topics Table 1. Related Topics in This Publication Sections [Topic Titles Sub Titles 7 ‘Applications ALL 2 ALL (Care and Safety)” AL 3 Hydraulie System Checking the Hydraulic Fluid Level A @ Steoring SYSTEM (T\HT-1 ALL B '@ Auto Steer Mode SYSTEM ()A3-1 ALL (1) You must obey all ofthe relevant care and safety procedures, H10-2 '$60315750-05 (H-04-02) H10-2 B Section H10 - Steering Auto Steer Mode Valve Retnoval and Replacement Removal and Replacement Machines with Power Track Rods A WARNING 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. Evatt Awarninc Hydraulic Pressure Hydraulic fluid at system pressure can injure you. 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 hoses, Make sure the engine cannot be started while the hoses are open, inerii2 AwWarRNING 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. Into Removal 1 Park the machine and make it safe, Obey the care and safety procedures, © Related Topies (1) 10-2) 2 Tum the steering wheel to the left and to the right several times to vent system pressure, 3. Disconnecttthe electrical solenoid connections. Label each connector before removal to ensure correct, refitting, The wires should be identfied A. 8, C and D as shown. 4 Disconnect all hytraulic hoses from the steer mode valves assembly. Label the hoses to ensure correct refiting and cap the ends to prevent ingress of dirt. 5 Take hold of the steer mode valves assembly, loosen ‘and remove screws E. Lift the steer mode valves assembly from the machine, Replacement Replacement is the opposite of the removal procedure During the replacement procedure do this work also: H10-3 '$60315750-05 (H-04-02) H10-3 Ww Section H10 - Steering Auto Steer Mode Valve Retnoval and Replacement 1 Make sure that the electrical solenoid connections are refitted in the correct position 2 — Make sure that the hoses are correctly installed 3 Bleed the stearing system. Bleeding the ‘System (DH H10-4 '$60315750-05 (H-04-02) H10-4 B Section H10 - Steering Auto Steer Mode Valve Machines with Steer Rams Removal AWaRNING 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. ceva et AWaRNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. 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 hoses. Make sure the engine cannot be started while the hoses are open. interti2 AWaRNING 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. Intet02 1 Park the machina and make it safe. Obey the care and safety procedures. Related Topies (1) H10-2) 2 Tum the steering wheel to the left and to the right several times to vent system pressure, 3. Disconnect the electrical solenoid connections. Label each connector before removal to ensure correct, rofiting. The wires should be identified A, 8, C and D 15 shown, Retnoval and Replacement Disconnect all hydraulic hoses from the steer mode. valves assembly. Label the hoses to ensure correct Teflting and cap the ends to prevent loss of fluid and ingress of dirt Remove the two nuts E and bolts F and lit the steer mode valves assembly from the machine Fig 2. H10-5 '$60315750-05 (H-04-02) H10-5 Ww Section H10 - Steering Auto Steer Mode Valve Removal and Replacement Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also 1 Make sure that the hoses and solenoid electrical connectors are refitted in the correct positions. 2 Torque tighten the nuts E and bolts F, > Table 2 Torque Settings ([)H10-6) 3 Before driving the machine, bleed the steering system, 2 Bleeding the System ([) H1-26) Table 2. Torque Settings tem Nm ToFin E 35 258 H106 '$60315750-05 (H-04-02) H10-6 B Section H10 - Steering Auto Steer Mode Valve Dismantie and Assemble Dismantle and Assemble Note: The solenoid valves are non-serviceable parts Faulty valves must be renewed. The following procedure details removing and replacing a valve fitted at the ‘manifold block, The procedure is identical forall the valves (2or4 valve assembles depending on machine variant) The procedure assumes that the complete valve and ‘manifold block assembly has been removed from the ‘machine. > Removal and Replacement ([)H10-3) Dismantle 1 Unscrew the knurled cap B and pull off the solenoid call D. Retrieve ‘0’ rings G and E 2 Using @ suitable open enced spanner unscrew the valve stem F from the manifold block A. Retrieve °O" ring 6. Assemble 1. Make sure that all components are perfectly clean. If ‘contamination is suspected make sure that all the collways in the manifold block A are clear of debris, 2 Renewall'O' rings. 3 Lubricate parts with JCB Special Hydraulic fluid before assembling Table 3. Torque Settings item Nm Tofin F TBA TBA. Fig 3. H10-7 '$60315750-05 (H-04-02) H10-7 Ww Section H10 - Steering Auto Steer Mode Valve Dismantie and Assemble Page left intentionally blank H108 '$60315750-05 (H-04-02) H10-8

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