Section H

Section H
Steering
Service Manual - 3DX / 4DX Backhoe Loader
Section 1 - General Information
Section 2 - Operator’s Manual
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section D - Controls
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
File Supplied to Mauro Cunha 21/11/2015
Publication No.
9813/2050-4
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Notes:
H-0 9813/2050-4 H-0

Contents
Contents Page No.

Specifications
Technical Data .......................................................................................... H-1
Basic Operation
2 Wheel Steer Machines .......................................................................... H-3
Steer System ........................................................................................ H-3
Hydraulic Operation and Schematics

Neutral Circuit ........................................................................................... H-5
Operation 1 - Neutral ................................................................................ H-6
Right Turn ............................................................................................ H-6
Priority Valve - Neutral ........................................................................ H-10
Load Sensing Dynamic Signal Non Load Reaction ................................ H-12
Specification Data ............................................................................... H-12
VLC Priority Valve (BOPV) ..................................................................... H-13
Service Procedure
Pressure Test .......................................................................................... H-15
Priority Valve - Standby Pressure Testing ........................................... H-16
Priority Valve - Cleaning ..................................................................... H-16
Power Track Rod

Removal and Replacement .................................................................... H-19
Introduction ......................................................................................... H-19
Removal ............................................................................................. H-19
Rams .................................................................................................. H-24

Priority Valve ...................................................................................... H-25
Hydraulic Steer Unit

Removal and Replacement .................................................................... H-27
Removal ............................................................................................. H-27
Replacement ...................................................................................... H-27
Hydraulic Steer Unit (Eaton) ................................................................... H-29
Exploded VIew ................................................................................... H-29
Dismantle and Assemble .................................................................... H-31
Fault Finding
Contents ................................................................................................. H-39
Introduction ......................................................................................... H-39
H-i H-i
Specifications
Technical Data
Specifications
Technical Data
Table 1.
Steer Hydraulics
System Type Full Power Hydrostatic
Hydraulic Supply Main Hydraulic Pump Via Priority Valve
Control Unit Type Load Sensing With integral Relief Valve
Control Unit Relief Valve Operating Pressure 120 + 3.5 bar, 122 + 3.5 kgf/cm2, 1740+ 50 Ibf/in2
(at 1500 revs/mm)
Table 2. 3DX Xtra, 3DX Super and 4DX

Steer Hydraulics
3DX Xtra and Super - From machine serial numbe 1491201 to 15029999
4DX - From machine serial number 1415101 to 1416999
Steering Hydraulic Independent Steering Circuit
Steering Unit Type Open Center Non-reaction
Steering Pump Rexroth Gear Pump
Steering pump Flow 14 cc
Steering Pressure 125 bar
Circuit Refer Hyd. Schematic Drawing
File Supplied to Mauro

Table 3.Cunha 21/11/2015
2 Wheel Drive Machines
Location 1 Ram - Front Axle (RHS)
Bore 63 mm
Rod Diameter 36 mm
Stroke 245 mm
End Cap Assembly A/F 55 mm
Steer Ram(s) Dimension
2 Wheel Drive Machines
Location 1 Ram - Front Axle (LHS)
Bore 75 mm
Rod Diameter 45 mm
Stroke 125 + 125 mm
End Cap Assembly A/F 55 mm
Table 4.
Steer Ram Torque Settings Nm kgf m lbf ft
Piston Head 405 41 300
End Cap 678 69 500
H-1 9813/2050-4 H-1

Specifications
Technical Data
Page left intentionally blank
H-2 9813/2050-4 H-2

Basic Operation
2 Wheel Steer Machines
Basic Operation
Steer System Component

Key:
Schematics 6 In-tank Filter
Table 5. 7 Priority Valve

Component 10 Steer Ram
Key: 42 Steer Unit
P1 Pump, Main Section 43 Shock Valve
P2 Pump, Secondary Section 44 Steer Unit Relief Valve
P2A Pressure Test Point
S Suction Line Note: Hydraulic component port identification letters are
shown in parenthesis, e.g. (LS). The same letters will be
T Tank stamped on the actual component K Fig 1. ( T H-3).
6 T
43
File Supplied
S to Mauro Cunha 21/11/2015
42
10
P2 P1
44
P2A
Fig 1.
H-3 9813/2050-4 H-3

Basic Operation
Hydraulic Operation to the Steer Ram 10 until the required steering lock is
achieved.
The main components of the steering system are the
priority valve 7, load sensing steer unit 42, hydraulic tank When the steering lock is held, the pressure signal LS
T and the Steer ram 10 K Fig 2. ( T H-4). ceases, flow from the hydraulic pump P2 is now distributed
to the main hydraulic circuit via the priority valve 7.
When the steering wheel is turned, a pressure demand is
sensed at the priority valve 7 via load sensing line LS. Maximum steering system pressure is controlled by a relief
valve located in the steering unit 42.
Oil from the hydraulic pump P2 is then distributed via the
priority valve to the steer unit 42, which then directs the oil
LS
P2
10
42
D070930-07
Fig 2.
H-4 9813/2050-4 H-4

Neutral Circuit

Neutral Circuit
Fig 3.
H-5 9813/2050-4 H-5

Operation 1 - Neutral
Flow from the priority valve enters the steering unit through centring springs K. As the unit is 'closed centre' the flow
the bottom right hand port past the non-return valve H. from the pump is dead ended by the steering
When the steering wheel is stationary the inner spool A unit.K Fig 3. ( T H-5).
and sleeve B are held in the neutral position by the
Right Turn
Fig 4.
The illustration shows the flow through the steering unit in pump the oil out to the steering ram E and the required
a right hand turn condition. Turning the steering wheel degree of turn is executed. Exhaust oil returns to tank
rotates the inner spool A a few degrees relative to the outer through the steer unit as shown.
spool B, and sends a pressure signal to the relief valve 44
and through the LS port back to the priority valve.
K Fig 4. ( T H-6). The relative movement between A and
B directs pressure oil through 6 of the 12 holes in the
bottom of sleeve B.The metering unit is linked to the spools
by a cross pin. As the steering is operated the oil is
diverted by inner spool A into the stature D. The rotor lobes
H-6 9813/2050-4 H-6

Left Turn

Fig 5.
Operation 3 - Left Turn
The illustration shows the flow through the steering unit a

left hand turn condition. The operation is identical to that
described on the previous page, except that the oil is
diverted by spool A to the other side of stature D and ram
E. K Fig 5. ( T H-7)
H-7 9813/2050-4 H-7

Left Turn - Unassisted

Fig 6.
The illustration shows the circuit operation with the engine

stopped. Turning the steering wheel rotates the inner spool
A until the cross pin engages with and rotates outer sleeve
B, metering oil to the stator D, and pumping it out to ram E
under manual pressure only. As there is no supply from the
pump, oil from one side of the ram, supplemented by
exhaust oil if necessary, is used to feed the other side via
non-return valve F K Fig 6. ( T H-8).
H-8 9813/2050-4 H-8

Shock Valve
Fig 7.
Operation 5 - Shock Valve
In normal operation, oil flows from the pump, enters the

steering unit via the Right hand port, opening a spring
loaded non-return valve H. The flow is directed by the
steering unit to achieve the desired turn (right hand
shown). In the event of a pressure shock wave being
generated in the system by an outside force, shock valve
G1 vents this pressure to exhaust preventing damage to
the steering unit K Fig 7. ( T H-9).
Non return valve J1 is held on its seat by the generated

pressure and non-return valve H closes to prevent the
shock wave being fed back to the pump. Some of the
excess oil flows via non-return valve J2 to the opposite
side of the ram to prevent cavitation occurring.
H-9 9813/2050-4 H-9

Priority Valve - Neutral
Fig 8.
Turning This reduces the pressure differential across the spool,

causing it to move to the right under spring force. This
As the steering unit 43 is operated, pressure is applied to allows priority valve flow to the steering unit which directs
the spring end of the priority valve spool 2B via sensing the flow to the power track rod rams 40 and 41 until the
line LS from the steering unit K Fig 8. ( T H-10). required steering lock is reached. When the steering lock
H-10 9813/2050-4 H-10

is held the pressure signal across the side port LS of the
steering unit ceases, restoring the pressure differential
across spool 2B. The spool moves back to the left,
allowing full pump flow to the loader control valve 3.
Because the pump output is always greater than the flow

required to operate the steering system, flow to the loader
valve is never completely cut off.
Maximum steering system pressure is controlled by relief

valve 43B, located in the steering unit 43.
Table 6.
Component Key:
LS Load Sensing Port
P From pump
T To Loader Valve
2 Priority Valve
2A Spring
2B Spool
2C Drilling
3 Loader Valve
40 Front Power Track Rod Ram
41 Rear Power Track Rod Ram
43 Steer Unit
43B Relief Valve
H-11 9813/2050-4 H-11

Load Sensing Dynamic Signal Non Load Reaction
Load Sensing Dynamic Signal Non Load Reaction
Input torque
Powered standard.................... 1.7-2.8Nm
Powered low torque................ 1.3-2.2Nm
Non powered ...................... 136Nm
Fig 9.
Specification Data
Max. system pressure.................. 190Bar
Max. back pressure ........................... 10Bar
Rated flow:
50 - 125cc/r.......................... . 7.5- 15LPM
160 - 250cc/r...................... 15- 30LPM
320 - 500cc/r ......................... 30- 45LPM
H-12 9813/2050-4 H-12

VLC Priority Valve (BOPV)
The steering unit uses load sensing power supplies to

achieve load sensing steering. The use of a load sensing
steering unit and a priority valve in a normal power steering
circuit offers the following features:
Provides smooth pressure compensated steering because

load variations in the steering circuit do not affect axle
response or maximum steering rate.
Provides true power beyond system capability by splitting

the system into two independent circuits. Pressure
transients are isolated in each circuit. Only the flow
required by the steering maneuver goes to the steering
circuit. Flow not required for steering is available for use in Fig 11.
the auxiliary circuits.
Provides reliable operation because the steering circuit

always has flow and pressure priority.
The VLC priority valve is designed to be directly mounted

onto the port face of a load sensing steering control unit.
Fig 10.
H-13 9813/2050-4 H-13

Fig 12.
H-14 9813/2050-4 H-14

Service Procedure
Pressure Test
Service Procedure
Pressure Test
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 K Fig 13. ( T H-15).
2 Turn the steering wheel to the left and to the right

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

started while you are beneath the machine.
GEN-4-1_1
3 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge

to test adaptor A.
4 Run the engine at 1500 revs/min. and turn the

steering to full lock. Check the gauge reading which
Fig 13.
D070860-25
should equal the relief valve pressure, refer to

Technical Data K Fig 14. ( T H-15).
Note: The steering wheel must be held on full lock whilst

the gauge reading is being checked.
5 If necessary, adjust the pressure setting by removing

plug B, on the hydraulic steer unit.
6 Adjust screw C using an 'allen key' until the correct.
D070860-24
Fig 14.
H-15 9813/2050-4 H-15

Service Procedure
Pressure Test
maximum pressure gauge reading which should be
5.9 to 8.7 bar (86 to 126 lbf/in2).
If the pressure is outside the limits try cleaning the

priority valve, refer to Priority Valve - Cleaning.
B
If cleaning the valve does not rectify, check the
hydraulic pump flow rate, refer to Section E Main
Pump - Flow and Pressure Testing.
C
If the hydraulic pump flow and pressure tests are
satisfactory, then the priority valve must be renewed.

D070860-27
Fig 16.
D070860-26k Priority Valve - Cleaning

Fig 15.
The priority valve spool and spring may be removed for
Priority Valve - Standby Pressure Testing cleaning.
1 Disconnect hose A and install a 0 - 40 bar (0 - 580 lbf/ 1 Remove the priority valve from the machine. Refer to
in2) pressure test gauge into the valve port. Position Priority Valve - Removal and Replacement
the open end of hose A into a clean container in order K Fig 16. ( T H-16).
to collect any oil drainage.
2 Unscrew adaptor 9 and extract the priority valve
2 Disconnect hose B from load sensing port adaptor C spring 11.
and blank off K Fig 16. ( T H-16).
3 Remove the blanking plug 7. Press out the priority
3 Set the steering to neutral, i.e. do not turn the steering valve spool 12 using a nylon pin. Take care not to
wheel, and start the engine. Gradually increase the damage the bore of the valve.
engine speed to 1000 rev/min. while checking the
4 Clean these components in clean paraffin paying
particular attention to the orifices at each end of the
spool. Dry off and lubricate with clean hydraulic fluid.
H-16 9813/2050-4 H-16

Service Procedure
Pressure Test
5 Refit the priority valve spool 12 making sure that the
spring seat end of the spool faces towards the LS
port. Refit blanking plug 7 and torque tighten.
6 Refit the priority valve spring 11 and adaptor 9 and

torque tighten K Fig 17. ( T H-17).
7 Refit the valve onto the machine. Refer to Priority

Valve - Removal and Replacement.
8 Bleed the load sensing line. Refer to Priority Valve -

Bleeding.
Fig 17.
H-17 9813/2050-4 H-17

Service Procedure
Pressure Test
H-18 9813/2050-4 H-18

Power Track Rod
Removal and Replacement
Power Track Rod

Introduction
This procedure is for a typical power steering track rod
removal and replacement.
!MWARNING

GEN-4-1_1
!MWARNING
A
The loader arm safety strut must be fitted before any
work is done beneath raised loader arms. Make sure B
the shovel is empty, then fit the safety strut as
instructed below.
GEN-1-7
C
Removal
1 Disconnect and cap hydraulic hoses to prevent loss
of fluid and ingress of dirt. Label hoses for
identification and correct refitting
K Fig 18. ( T H-19).
2 On 4WD machines remove the split pin and nut A.

Remove the track rod ball joint from the wheel hub
assembly.
On 2WD machines, remove lock assembly B and pin

C to remove the track rod pivot from the wheel hub
assemblies.
3 Remove the four fixing bolts D.
D
D070860-28
Fig 18.
H-19 9813/2050-4 H-19

Power Track Rod
Replacement Table 7.
Item bolt Nm kgf m lbf ft.
Replace the power track rod by reversing the removal grade
procedure but note the following: A - 140 14 103
1 On 4WD machines make sure that the split pin is D - 620 63 457
fitted. If the split pin cannot be fitted after torque E,F - 476 48 351
tightening the nut A, tighten further to a maximum of
G 8.8 476 48 351
150Nm until the pin can be inserted
K Fig 19. ( T H-20). G 10.9 575 58 424
2 Note the applicable torque values for the track rod

fixing bolts according to axle type. See the Torque
Settings table K Table 7. ( T H-20).
D070860-32
Fig 20.
A
D070860-31
Fig 19.
Note: The 2WS 2WD front axle is not illustrated. Torque

the bolts to the value given for item D in the table.
3 After connecting hoses check hydraulic fluid level, if

necessary top up.
4 Bleed hydraulic steering system.
H-20 9813/2050-4 H-20

Power Track Rod
Link Arms - Removal and Replacement
A
F E
J
M
H G
B F E
K J
X
C C
Y
D070860-29
Fig 21.
H-21 9813/2050-4 H-21

Power Track Rod
Removal Torque Settings
1 Fix the assembly on a locally made strip/rebuild Table 8.

bench as shown K Fig 21. ( T H-21). Item Nm lbf.ft
C 140/150 103/110
2 Using two suitable open ended spanners at L and M
react against each other until one ball joint unscrews. K 300 221
E 240/260 177/184
3 Unscrew the ball joint L until an open ended spanner
can be fitted on the rod N. Screw the ball joint against
the spanner to secure the spanner and to prevent
damage to the rod.
4 By reacting against the spanner at N and M undo the

other ball joint.
Note: 1 Flats at È' are:4 Wheel drive machines - 40 mm

A/F x 4 mm wide.
Note: 2 The piston rod operates at full length, any damage

to the surface will cause fluid leaks. DO NOT attempt to
grip the rod diameter with pipe grips etc.
5 Repeat the procedure for the remaining link arm

assembly.
6 Where applicable remove the target disc G.
Note: 3 If the inner or outer ball joints need to be renewed,

then a replacement link arm assembly must be fitted.
Replacement
Replacement is the reverse of removal but note the
following:
1 Remember to fit the target disc G (where applicable).
2 Use Loctite on the track Rod link arms.
3 If the link arms have been renewed, the wheel

alignment must be checked as follows:
a Set the wheels to the straight ahead position and

measure dimensions X and Y (at the outer edge
of the wheel hub). Alignment is correct if the
difference between X and Y is a maximum of 1
mm.
b To adjust the wheel alignment undo the lock nuts

K. Turn the threaded adjusters J equally to obtain
the correct alignment. Tighten the lock nuts K.
H-22 9813/2050-4 H-22

Power Track Rod
7
6
5
8
3
D
4
5 8
1
2 B B
C
6
7
D070860-30
Fig 22.
H-23 9813/2050-4 H-23

Power Track Rod
Rams 2 Ensure that all threads are free from grease,

hydraulic oil and sealant and apply loctite.
Dismantling and Assembly
Ensure that lubricants used during assembly do not
The numerical sequence shown on the illustration is come into contact with the JCB Thread locker and
intended as a guide to dismantling K Fig 22. ( T H-23). Sealer (High Strength).
For assembly the sequence should be reversed. 3 Correctly fit seals to the end cap and piston head.
Dismantling 4 Clamp the cylinder vertically and lower the piston rod
assembly in from the top, as shown at B. Take care
1 Fix the ram assembly on a locally manufactured strip/ not to allow the piston rod to come into contact with
rebuild bench as shown at A. the cylinder bore. Be sure to engage the piston head
new wear rings and seal carefully into the cylinder. If
2 Remove both end caps. Pull the piston rod assembly the piston head wear rings or seal are damaged
from the cylinder. during this stage, they must be renewed.
Note: 1 DO NOT allow the piston rod to come into contact Note: 4: The loctite must not be allowed to contact seals,
with the cylinder bore. The cylinder bore may be damaged bearing rings or Ò' rings.
by careless dismantling.
5 Apply Sealant (High Strength) to threads of the ends
3 Position the piston rod assembly on a bench in place caps, fit new Ò' ring 5.
of the ram cylinder. Remove the seal and wear rings
from the piston head. 6 Ensure that there are no burrs at the ends of the
piston rod, see Dismantling - Note 3:
Note: 2 The piston head cannot be removed from the rod.
If there is damage to the rod or piston head, replace the 7 Fit an end cap over the piston rod. Apply light hand
complete assembly. pressure to the cap to engage the gland seal on the
piston rod. DO NOT use excessive force. Screw on
4 Carefully inspect the bore of the cylinder and the the first end cap and then fix the assembly on the
piston rod outer diameter for scoring, nicks and burrs. strip/rebuild bench as shown at A. Fit the remaining
cap and then torque tighten both caps.
If such damage is visible the components must be
renewed.
Torque Settings
Note: 3 If burrs are evident on the ends of the piston rod at
positions C or D remove by careful filing. Table 9.
Item Nm kgf m lbf ft
Both end cap assemblies are the same, dismantle as 1 678 69.2 500
follows:
Note: 5 Cold weather operation. When operating in
5 Remove the Ò' ring 5, end cap seal 6 and wiper seal conditions which are consistently below freezing, it is
7. recommended that the track rod is operated slowly to its
full extent in both directions before commencing normal
6 The bearing bush 8 can be renewed if necessary. working.
However, time will be saved if a complete end cap
and bush assembly is obtained.
Assembly
1 Clean the threads of the end caps and cylinder using

a wire brush.
H-24 9813/2050-4 H-24

Power Track Rod
Priority Valve Dismantling and Assembly
Removal and Replacement The numerical sequence shown on the illustration is

intended as a guide to dismantling.
!MWARNING For assembly the sequence should be reversed.

Note: 1 The priority valve is not serviceable beyond the
removal of foreign matter (Refer to Service Procedures,
Priority Valve - Cleaning). A faulty unit must be replaced.
Dismantling
Press out the spool item 12 using a nylon pin. Take care
not to damage the bores of the valve.
GEN-4-1_1
Assembly
Make sure that spring seat of spool 12 faces toward LS

connection.
Clean all parts in clean paraffin.
Lubricate all parts with hydraulic fluid.
Renew aluminium washers 8 and 10.
Note: All hydraulic adaptors that are installed together with

a bonded sealing washer must also have JCB Thread seal
applied to the threads of the adaptor.
File Supplied to MauroTorque
Cunha 21/11/2015
Settings
Table 10.
Item Nm lbf ft
7 50 37
9 50 37
Bleeding
To bleed the LS line, start the engine, loosen the

connection on the valve, turn and hold the steering wheel
fully in either direction. When bubble free oil flows from the
joint, tighten the connection.
Fig 23.
H-25 9813/2050-4 H-25

Power Track Rod
H-26 9813/2050-4 H-26


Removal 2 Bleed the steering system. Refer to Service

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

parking brake and set the transmission to neutral.
Lower the attachments to the ground. Stop the engine
and remove the starter key.
2 Turn the steering wheel to the left and to the right

several times to vent system pressure.
3 Disconnect and cap all hydraulic hoses from the

steering unit as shown at A. Label the hoses to
ensure correct refitting.
Get an assistant to hold the steering unit, and,

working inside the cab, loosen and remove 4 bolts B.
Lift the steering unit from the machine.
Replacement
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3
1 Replacement is a reversal of the removal sequence.

Make sure that the hoses are correctly installed.
H-27 9813/2050-4 H-27

File Supplied to Mauro Cunha 21/11/2015 D070840-23

Fig 24.
H-28 9813/2050-4 H-28

Hydraulic Steer Unit (Eaton)
Exploded VIew
K Fig 25. ( T H-30)
Table 11.
S.No. Description S.No. Description
1 Cap Screw (M10) 22 Dust Seal*
2 End Cap 23 Gland Bushing
3. Anti-Cavitation valve Components (if 24 O-ring 43.2mm ID
included):spring
4. Anti-Cavitation valve Components (if 25 Shaft Seal Kit*
included):plug
5 Anti-Cavitation valve Components (if 26 Needle Thrust Bearing
included): 4mm
6 Seal, O-ring 77.5mm ID* 27 Spring
7 Gerotor 28 Spacer
8 Spacer Plate 29 Inlet Relief valve Components (if included): Plug
9 Drive 30 Inlet Relief valve Components (if included): O-ring 15mm
ID*
10 Housing 31 Inlet Relief valve Components (if included): Spring
11 Cylinder Relief valve Components (if 32 Inlet Relief valve Components (if included): Poppet
included):Valve seat
12
File Supplied to Mauro
Cylinder Relief valve Components (if
included): 5mm
33
Cunha 21/11/2015
Inlet Relief Valve Components (if included): Ball 8.04mm
13 Cylinder Relief valve Components (if 34 Inlet Check Valve (if included)
included): Ball Holder
14 Cylinder Relief valve Components (if 35 Ball 7mm
included): O-ring
15 Cylinder Relief valve Components (if 36 Roll Pin
included): Spring
16 Cylinder Relief valve Components (if 37 Spacer
included):Plug
17 Sleeve 38 Load sense Relief Valve Components (if included):Valve
Sea
18 Spool 39 Load sense Relief Valve Components (if included):Poppet
19 Pin 40 Load sense Relief Valve Components (if included-):Spring
20 Bearing Race 41 Load sense Relief Valve Components (if included):O-ring
7.6454mm ID*
21 Bearing Race 42 Load sense Relief Valve Components (if included):Plug
H-29 9813/2050-4 H-29

Fig 25.
H-30 9813/2050-4 H-30

Dismantle and Assemble

Dismantle
Cleanliness is extremely important when repairing a

steering control unit. Work in a clean area. Before
disconnecting lines, clean port area of unit thoroughly. Use
a wire brush to remove foreign material and debris from
around external joints of the unit.
Note: Although not all drawings show the unit in a vice, we

recommend that you keep the unit in vice during
disassembly. Follow the clamping procedures explained
throughout the manual.
Meter (Gerotor) End
Fig 27.
3 Remove end cap.
4 Remove drive Spacer (If included).
5 Remove seal from Gerotor K Fig 28. ( T H-31).
File Supplied to Mauro6Cunha 21/11/2015

Remove Gerotor Set. Be careful not to drop star.
Fig 26.
1 Clamp unit in vice, Gerotor end up. Clamp lightly on

edges of port facesides (see figure). Use
protectivematerial on vice jaws. Housing distortion
can result if jaws are over-tightened.
2 Remove M10 cap screws.K Fig 27. ( T H-31)
Fig 28.
H-31 9813/2050-4 H-31

7 Remove seal . Note: Do not remove any valves other than manual
steering check valve and anti-cavitationcheck valves. All
8 Remove drive K Fig 29. ( T H-32). other valves are factory preset and are non-serviceable.
13 Carefully remove the spool-sleeve assembly from

housing in upright position.K Fig 31. ( T H-32)
Fig 31.
Note: Do not cock spool-sleeve assembly in housing.

Fig 29.
Rotate spool-sleeve assembly slowly when removing it
from housing.
9 Remove spacer plate.
14 Push pin from spool-sleeve assembly.
10 Remove seal from housing.
11 File Supplied to Mauro15Cunha

Remove housing from vice. 21/11/2015
Remove the bearing race, needle thrust bearing and
bearing race, step by step from the housing
K Fig 32. ( T H-32).
12 Carefully remove anti-cavitationcheck valves and
manual steering check valve(roll pin and ball) from
bolts holes, by tipping.
Fig 32.
16 Remove Shaft seals from seal gland bushing.

Fig 30.
H-32 9813/2050-4 H-32

17 Push spool partially from control end of sleeve, then get into the hydraulic system and cause damage. Do not
carefully remove centering springs from spool by use grit paper or file or grind these parts.
hand. Low input torque unit use four centering springs
and two spacers. Standard input torque unit use six Note: Lubricate all seals with clean petroleum jelly
centering springs. K Fig 33. ( T H-33), (Vaseline). A good service policy is to replace all old seals
K Fig 34. ( T H-33) with new seals. Do not use excessive lubricant on seals for
Gerotor section.
1 Assemble spool and sleeve carefully so that spring

slots line up at the same end. Rotate spool while
sliding parts together. K Fig 86. ( T H-46)
Fig 33.

Fig 35.
Test for free rotation. Spool should rotate smoothly in

sleeve with finger tip force applied at splinedend.
Align spool and sleeve by matching marks, if present.
Otherwise, align spring slots in spool and sleeve and
stand parts on bench.
2 Centering springs for low input torque units have four

arched springs with two flat spacers in the center as
shown in figure.
Fig 34. Centering springs for standard input torque units have
six arched springs.
Assemble
Position centering springs so that the notches line up,
Check all mating surfaces, Replace any parts that have and arched center sections are nested together. Next,
scratches or burrs that can cause leakage. Clean all metal with spring notches facing sleeve, insert one end of
parts in clean solvent. Blow dry with air. Do not wipe dry entire spring set into spring installation tool.
with cloth or paper towel because lint or other matter can
H-33 9813/2050-4 H-33

3 Compress extended end of spring set and push into
spool-sleeve assembly. Keep pressure on spring
ends while withdrawing installation tool and pushing
forward on springs at same time.K Fig 87. ( T H-47)
Fig 36. Fig 37.
4 Center spring set in spring slots. Seat springs down 7 Install two bearing races and needle thrust bearing as
evenly and flush with upper surface of spool and shown in figure.
sleeve
8 Position spool-sleeve assembly so that splinedend of
spool enters open end of housing first
5
Insert pin through spool-sleeve assembly until pin is
within the outside diameter of sleeve. K Fig 89. ( T H-48).
6 Lubricate seal (see parts list) before installation in

seal gland bushing in housing. Use proper seal-
installation tool, to make sure seal enters seal gland
bushing without being cut or nicked. Do not use any
seal that falls freely into counter-bore of seal gland
bushing K Fig 88. ( T H-47).
H-34 9813/2050-4 H-34

Note: Check to insure that spool and sleeve are flush or
slightly below 14-hole surface of housing.Clean upper
surface of housing by wiping with palm of clean hand.
Clean each of the flat surfaces of parts in Gerotor section
in a similar way just before reassembly. Do not use cloth or
paper to clean surfaces.
9 Install 77.5 ID seal in housing.
Fig 38.
Note: While inserting spool-sleeve assembly into housing,

make sure parts do not tilt out of position. Push assembly
gently into place with slight rotating action, keeping pin
from moving out and getting stuck in the internal groove. Fig 40.
Bring spool-sleeve assembly entirely within housing bore.
10 Install Anti-Cavitation check valves and manual
With spool-sleeve assembly in this flush position, check for
free rotation within housing by turning assembly with steering check valve in holes, as shown in figure
K Fig 91. ( T H-48).
fingertip force at splined end.
11 Install spacer plate. Align bolt holes in spacer plate
with tapped holes in housing.
12 Rotate spool and sleeve assembly until pin is parallel

with port face. Install drive, making sure drive is
engaged with pin. To assure proper alignment, mark
drive as shown in figure, When marking drive, note
relationship of slotted end of drive to splinedend of
drive.
13 Align star valleys with pin. Note parallel relationship of

reference lines A, B, C and D in figure.
K Fig 92. ( T H-49)Align bolts holes without
disengaging Gerotor star from drive.
Fig 39.
H-35 9813/2050-4 H-35

Fig 42.
Fig 41.
19 Check for proper timing by turning the spool
14 Lubricate and install 77.5 ID seal in Gerotor ring. The
clockwise and feeling pressure in the “R”port.
lubrication will hold seal in place.
20 Check the manual torque, the steering should turn
15 When used, install drive spacer in Gerotor star.
freely.
16 Lubricate and install 77.5 ID seal in Gerotorring
17 Install end cap on gerotor, aligning holes.
18 File Supplied to Mauro Cunha 21/11/2015

Install 7 dry cap screws in end cap. Pre-tighten
screws to 17Nm, then torque screws to 35-40Nm in
sequence show in figure K Fig 93. ( T H-49).
H-36 9813/2050-4 H-36

Hydraulic Steer Unit (VSP)
Exploded VIew
2
1
4
7
8
3 9
12 5 10
13
14
15
16 11
15
16
17 20
File Supplied to Mauro Cunha
18 21/11/2015
19
21
D071010-01
Fig 43.
Table 12. Item Description

Item Description
16 O-ring
1 Dust Seal Ring
17 End cover
2 Complete relief valve
18 Washer
3 Check valve
19 Screw with Pin
4 Housing spool
20 Screw
5 Ball Ø 6 mm
21 Name plate
6 O- Ring /Roto glyd
7 Bearing assembly
8 Ring
9 Sleeve
10 Cross Pin
11 Set of springs
12 Cardan shaft
13 O-ring
14 Distributor plate
15 Gearwheel set
H-37 9813/2050-4 H-37

Dismantle and Assemble

Dismantle
Cleanliness is extremely important when repairing a

steering control unit. Work in a clean area. Before
disconnecting lines, clean port area of unit thoroughly. Use
a wire brush to remove foreign material and debris from
around external joints of the unit.
1 Remove the screws A (special screw A1) that

attaches the end cover B.
D071000-03
Fig 46.
4 Remove the cardan shaft D.

D071000-01
Fig 44.
2 Remove the end plate B to one side.
D071000-04
Fig 47.
B
5 Remove the distributor plate E.
D071000-02
Fig 45.
3 Lift the gearwheel set (with spacer if installed) C from

the unit and remove the two O-rings.
H-38 9813/2050-4 H-38

D071000-05
Fig 48.
6 Remove the O-ring F. D071000-07

Fig 50.
8 Carefully remove the suction valve (roll pin H and ball

J) from bolts holes, by tipping. K Fig 50. ( T H-39).
Note: On some pins there are two spring. Replace those

springs before reassembly.
9 Keep the cross pin in the sleeve and the spool

File Supplied to Mauro Cunha 21/11/2015 horizontal and press the spool inside. The the sleeve
ring, bearing races and needle bearing will be pushed
out of the housing.
D071000-06
Fig 49.
7 Remove the check valve ball G (Ø 6mm) VSP LS.
D071000-08
Fig 51.
H-39 9813/2050-4 H-39

10 Carefully remove the bearing races K, needle thrust
bearing L and ring W from the spool M, step by step
from the housing.
D071000-08
Fig 52.
11 Push pin N from the spool-sleeve assembly M.
D071000-11
Fig 55.
14 Remove the shock valve plugs R with a 6 mm

hexagon socket spanner. (If Installed)
D071000-09
Fig 53.
12 Push the neutral position springs out of their slots.
D071000-12
Fig 56.
D071000-10
Fig 54.
13 Remove the dust seal P and O-ring /Roto Glyd Q.
H-40 9813/2050-4 H-40

Pressure Relief Valve
1 Remove the plug S and the seal washer T.
D071000-15
Fig 59.
D071000-13
Fig 57. 2 Put the curved springs between the flat spring and
push the three springs in place.
2 Carefully remove the spring U and the piston V by
tipping.

D071000-16
Fig 60.
3 Do the same steps for the other spring set.
4 Press the springs together and align the spring sets in

the centre.
D071000-14
Fig 58.
3 The valve seat is bonded into the housing and cannot

be removed.
D071000-18
Assembly Fig 61.
1 Put the two flat neutral position spring in the slot. 5 Install the ring W over the sleeve and make sure that
the ring must be able to move freely.
H-41 9813/2050-4 H-41

D071000-19
Fig 62. D071000-22
Fig 65.
6 Install the cross pin N into the spool-sleeve assembly
9 Put the outer part of the assembly tool into the bore of
M.
the spool/sleeve. K Fig 65. ( T H-42).
10 Lubricate the O-ring / the roto glyd Q with hydraulic

fluid and put them on the tool.

D071000-20
Fig 63.
D071000-23
7 Install the bearing races K and needle bearing L. Fig 66.
11 Hold the outer part of the assembly tool in the bottom

of the steering unit housing and put the inner part of
the tool right to the bottom.
D071000-21
Fig 64.
8 Turn the steering unit, until the bore is horizontal. D071000-24

Fig 67.
12 Press and turn the O-ring Q into position in the

housing.
H-42 9813/2050-4 H-42

D071000-25
Fig 68.
13 Draw the inner and outer parts of the assembly tool

out of the steering unit bore. D071000-28
Fig 71.
17 The O-ring / Roto Glyd Q are now in position.
18 Turn the steering unit until the bore is vertical again.
19 Put the check valve ball G into the hole.

D071000-26
Fig 69.
14 Leave the guide from the inner part in the bore.

K Fig 69. ( T H-43).
15 Hold the cross pin in the horizontal position and put

the spool-sleeve assembly M into the bore with a light
turning movement. D071000-29
Fig 72.
20 Place a ball J in the two holes. (If Installed)
D071000-27
Fig 70.
16 The spool set will push out the assembly tool guide.
D071000-30
Fig 73.
H-43 9813/2050-4 H-43

21 Place new pins H in the same two holes. (If Installed) 25 Install the distributor plate E. K Fig 76. ( T H-44).
26 Install the cardan shaft D down into the bore so that

the slot is parallel with the connection flange.
D071000-31
Fig 74.
22 Lubricate the O-ring F with mineral oil.
23 Install the O-ring F. D071000-34

Fig 77.
27 Hold the cardan shaft D in position by the mounting

fork X.
D071000-32
Fig 75.
24 Align the distributor plate so that the channel holes

match the holes in the housing.
D071000-35
Fig 78.
28 Lubricate the O-ring with mineral oil and put them in

the grooves of the gear rim.
29 Install the gearwheel set C on the cardan shaft.

K Fig 79. ( T H-45).
D071000-33
Fig 76.
H-44 9813/2050-4 H-44

D071000-36
Fig 79. 31 Install the special screw A1 and the washer.
Note: Fit the gearwheel (rotor) and cardan shaft so that a

tooth base in the rotor is positioned in relation to the shaft
slot. Turn the gear rim so that the seven trough holes
match the holes in the housing.
D071000-39
Fig 81.
32 Install the other six screws A with washers.
D071000-37
Fig 80.
30 Put the end cover B in position.
D071000-40
Fig 82.
33 Torque all the screws to 30 (± 6) Nm.
H-45 9813/2050-4 H-45

34 Install the pressure relief valve piston V and the
spring U.
D071000-41
Fig 83. D071000-42
Fig 85.
35 Install the plug S with seal washer T into the housing
and torque the plug to 65 (± 5) Nm.
D071000-13
Fig 84.
36 Make the pressure setting on a panel or the vehicle.
37 Installed the spring and the valve cones over the two
balls J. (If Installed).
38 Put the dust seal ring P in the housing. The dust seal
ring P must be placed only after the pressure relief
valve has been fitted.
H-46 9813/2050-4 H-46

Fault Finding
Contents
1 Steering wheel difficult to turn K Table 12. ( T H-40).
2 Steering wheel turns on its own K Table 13.

( T H-41).
3 Machine will not turn when the steering wheel turned

K Table 14. ( T H-42).
Introduction
The purpose of this section is to help you trace hydraulic
faults to a faulty unit (valve, actuator, ram etc). Once you
have traced the faulty unit, refer to the appropriate
dismantling, inspecting and test instructions given
elsewhere in the steering section.
To help identify circuits, valves, rams etc. mentioned in the

fault finding procedures, refer to the hydraulic schematic
diagrams (near the beginning of the Hydraulics Section).
1 Before you begin fault finding, read the Safety

information at the beginning of this manual.

2 Make simple checks before say, stripping a major
component.
3 Make sure that the hydraulic fluid is at correct working

temperature (500 C,1220F).
4 What ever the fault, check the condition of the

hydraulic fluid. Drain and replace necessary.
5 Make any relevant electrical checks before moving on

to the hydraulics.
6 Be sure to remove ALL contamination and if possible

identify its origin. It may be part of a component from
elsewhere in the circuit.
7 Replace any seals such as 'O' rings before re-

assembling hydraulic components.
H-39 9813/2050-4 H-39

Fault Finding
Contents
Table 12.
Fault Probable Cause Action
Steering wheel difficult to turn. Tyres not inflated to correct pressure. Inflate tyres to correct pressure
Insufficient hydraulic fluid. Check for leaks and top up the

hydraulic tank as required.
Leaks in the relevant hoses or Check hoses and connections for

component connections. leaks
Air in the hydraulic system. Bleed system - bleed the load sense
line.
Low pump flow. Check pump flow, if required service or

replace pump.
Steer relief valve set incorrectly. Check pressure setting of steer unit
relief valve, adjust as required.
Worn or damaged parts in the steer Remove and inspect.

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

Check the load sense line from the
steer unit to the priority valve for signs
of leaking or poor connection.
Mechanical failure. Check for damaged axle components,

such as rams, track rods, linkages etc.
H-40 9813/2050-4 H-40

Fault Finding
Contents
Table 13.
Steering wheel turns on its own. Dirt in the steer control unit (causing Clean and inspect unit.
sleeves to stick open).
Steer control valve centring springs Check steer unit.

damaged, broken or missing.
Steer control valve - position of rotor to Refer to Hydraulic Steer Unit -
shaft slot incorrect. Dismantle and Assemble. Correct as
required.
H-41 9813/2050-4 H-41

Fault Finding
Contents
Table 14.
Machine will not turn when the Insufficient hydraulic fluid. Check for leaks and top up the
steering wheel turned. hydraulic tank as required.
Leaks in the relevant hoses or Check hoses and connections for

component connections. leaks.
Air in the hydraulic system. Bleed system - bleed the load sense
line.
Low pump flow. Check pump flow, if required service or

replace pump.
Steer relief valve set incorrectly. Check pressure setting of steer unit
relief valve, adjust as required.
Worn or damaged parts in the steer Remove and inspect.

control valve.
Priority valve not operating correctly. Check if the priority valve is sticking,
rectify as required.
Check the load sense line from the

steer unit to the priority valve for signs
File Supplied to Mauro Cunha 21/11/2015 of leaking or poor connection.
Mechanical failure Check for damaged axle components,

such as rams, track rods, linkages etc.
Steer column splined shaft not fully Check shaft engagement.

engaged in steer valve.
Steering ram rod failure Check power track rod for signs of
damage, leaks etc.
H-42 9813/2050-4 H-42

Section H

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Section H

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Section H

File Supplied to Mauro Cunha 21/11/2015

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H-0 9813/2050-4 H-0

Contents Page No.

Hydraulic Operation and Schematics

Power Track Rod

File Supplied to Mauro Cunha 21/11/2015

Hydraulic Steer Unit

Table 2. 3DX Xtra, 3DX Super and 4DX

File Supplied to Mauro

H-1 9813/2050-4 H-1

Page left intentionally blank

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H-2 9813/2050-4 H-2

Steer System Component

Table 5. 7 Priority Valve

H-3 9813/2050-4 H-3

H-4 9813/2050-4 H-4

Hydraulic Operation and Schematics

File Supplied to Mauro Cunha 21/11/2015

H-5 9813/2050-4 H-5

File Supplied to Mauro Cunha 21/11/2015

H-6 9813/2050-4 H-6

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Operation 3 - Left Turn

The illustration shows the flow through the steering unit a

H-7 9813/2050-4 H-7

File Supplied to Mauro Cunha 21/11/2015

The illustration shows the circuit operation with the engine

H-8 9813/2050-4 H-8

File Supplied to Mauro Cunha 21/11/2015

Operation 5 - Shock Valve

In normal operation, oil flows from the pump, enters the

Non return valve J1 is held on its seat by the generated

H-9 9813/2050-4 H-9

Priority Valve - Neutral

File Supplied to Mauro Cunha 21/11/2015

Turning This reduces the pressure differential across the spool,

H-10 9813/2050-4 H-10

Because the pump output is always greater than the flow

Maximum steering system pressure is controlled by relief

H-11 9813/2050-4 H-11

Load Sensing Dynamic Signal Non Load Reaction

Powered standard.................... 1.7-2.8Nm

Powered low torque................ 1.3-2.2Nm

Non powered ...................... 136Nm

File Supplied to Mauro Cunha 21/11/2015

Max. back pressure ........................... 10Bar

50 - 125cc/r.......................... . 7.5- 15LPM

160 - 250cc/r...................... 15- 30LPM

320 - 500cc/r ......................... 30- 45LPM

H-12 9813/2050-4 H-12

VLC Priority Valve (BOPV)

The steering unit uses load sensing power supplies to

Provides smooth pressure compensated steering because

Provides true power beyond system capability by splitting

Provides reliable operation because the steering circuit

The VLC priority valve is designed to be directly mounted

File Supplied to Mauro Cunha 21/11/2015

H-13 9813/2050-4 H-13

File Supplied to Mauro Cunha 21/11/2015

H-14 9813/2050-4 H-14