200-0762-01 Open Center Compact Valve Custom Installation Guide 602-0575-01 Rev A 2014-12
Overview This guide provides information for completing a custom AutoSteer valve installation on wheeled farm vehicles that are not supported by AutoSteer vehicle specific installation kits. A working AutoSteer valve requires brackets and hoses that correctly fit the vehicle. This manual provides guidelines, specifications and examples of typical AutoSteer valve installations for the purpose of helping AutoSteer dealers accomplish a working installation which is safe and performs satisfactorily. This guide does not cover all possible types of vehicles or even nuances that exist between different brands and models of farm machinery so it is the installer s responsibility to determine if the valve correctly fits the vehicle and performs in a safe manner. The AutoSteer valves provided in this kit is a Compact AutoSteer valve for Open Center Orbitrols with pumps that do not exceed a flow rate of 15 GPM (56 L/Min). For applications that require a higher Orbitrol oil flow, contact your AuroSteer dealer for other higher flow valve options. Note: Do not attempt this installation if you have not received training for the AutoSteer product installation and if you have not completed at least ten (10) standard AutoSteer kit installations. Do not attempt this installation if you do not have complete information and familiarity with the vehicle's steering system and hydraulic system. The installer assumes all responsibility for using good judgment and good fabrication practices when performing this installation. The steering valve installation requires custom hoses to fit each type of vehicle. Use only high quality hydraulic hoses rated for 3000 psi (210 bar) or more. Do not mix hose fittings and hoses of different brands. Assemble hoses and crimp fittings following the hose manufacturer s recommendations. Use only steel hose adapters rated for 3000 psi or more. Use hose fittings that match the type of fittings found on the vehicle. This installation guide describes AutoSteer system installations which use the AutoSteer Open Center compact steering valve for the following hydraulic installation types: Orbitrol Open Center Installation Note: Do not attempt to install the valve on hydraulic systems this manual does not support. 2 Open Center Compact Valve Custom Hardware Installation Guide
Orbitrol Open Center Installation Correct Installation Types: Vehicles with an Open Center non-reactive Orbitrol. Incorrect Installation Types: Very large vehicles requiring a higher oil flow and a larger AutoSteer valve. Large vehicles having Open Center steering gear pump flow that is greater than 15 GPM (56 L/Min). Vehicles with a closed Center load sense steering system. Power beyond closed center load sense installations. Pressure compensated steering systems. Load sense steering systems. Note: The Open Center Orbitrol typically receives oil from a fixed displacement gear pump. Note: For installations on vehicles with reactive steering system, an optional reactive steering kit is required to complete the installation. Reactive steering systems are found mostly on European tractors. Recommended tools: 13mm wrench for the valve mounting screws. 27mm long socket for installing the pressure transducer. 1/8 hex key (Allen key) for removing the orifices and adjusting the relief valve. 6mm hex key for valve long mounting bolts 3/8 wrench for the jam nut on the relief valve. 13/16 wrench for tightening the right and left hose fittings. 15/16 wrench - for tightening the pressure and tank hoses fittings. Pressure gauge with hose and quick coupler for measuring the pump pressure and adjusting the relief valve. 5000psi (350 bar). Pan or bucket for collecting oil Cleaning supplies as necessary for cleaning oil and dirt. This guide contains the following sections: AutoSteer Valve Theory of Operation Steering Valve Installation Overview Prepare the Steering Valve for Installation Mount the Steering Valve Hydraulic Hose Overview Install the Hydraulic Hoses and Fittings Attach Hoses to the Steering Valve Attach Hoses to the Vehicle Connections Hydraulic Installation Checklist Troubleshooting Open Center Compact Valve Custom Hardware Installation Guide 3
AutoSteer Valve Theory of Operation This section describes AutoSteer component functional operations and their interactions when implemented in the Compact valve Open Center installations. This section includes the following sub-sections: Oil Supply Right and left Steering Circuit Manual Override Sensor Plugs and Orifices Oil Supply The Open Center steering valve receives constant oil flow from the vehicle steering gear pump at the PRESSURE IN port and returns this oil flow to the manual steering circuit through the PRESSURE OUT port. The PRESSURE OUT port provides oil to the steering Orbitrol. A built in priority valve generates hydraulic pressure for steering. The pump pressure is adjusted by the priority valve to provide sufficient pressure on demand for steering. A TANK port on the Open Center valve is used to return oil from the steering cylinders towards tank when in AutoSteer mode. The TANK port also provides a low pressure return path for oil from the internal relief valve. A built-in adjustable relief valve limits the maximum steering pressure provided by the Open Center built-in priority valve and protects the pump and steering system from excessive pressure. A diagnostic port with a quick coupler for pressure gauges provides a pressure reading of the pump pressure available at the PRESSURE IN port. Right and Left Steering Circuit A 12 volt proportional valve directs oil to either the Right or Left port for steering the vehicle through the vehicle steering cylinders. To make a left turn, an electrical signal is sent to the Left coil on the proportional valve. The spool inside the proportional valve then allows oil flow between the PRESSURE IN port and the LEFT port while also allowing return oil flow from the RIGHT port to the TANK port. To make a right turn, an electrical signal is sent to the Right turn coil on the proportional valve. The proportional valve then allows oil flow between the PRESSURE IN port and the RIGHT port while also allowing return flow from the LEFT port to the TANK port. Steering speed is controlled by the voltage or PWM (pulse width modulation) signal sent to the proportional valve coils. Higher voltages or higher PWM signals result in more spool movement and a higher oil flow through the proportional valve and a faster steering speed. Pilot operated check valves are present at the Right and Left steer ports, holding the vehicle s steering cylinder in a fixed position between steering commands while also isolating the valve s internal LS circuit from the manual steering pressures while manually steering. Manual Override Sensor A pressure transducer is installed on the valve s TRANS port to provide a manual override (kick-out) electrical signal when the driver turns the steering wheel while AutoSteering. The 4-20mA 3000psi pressure transducer measures the pressure present on the PRESSURE OUT port and detects pressure spikes in the oil provided to the Orbitrol pressure port. 4 Open Center Compact Valve Custom Hardware Installation Guide
Plugs and Orifices The open center valve contains two internal orifices that control the flow of oil in the pilot pressure circuit inside the valve. The valve is also supplied with two additional spare orifices with a diameter of 0.4mm and 0.8mm. These extra orifices allow some adjustments to how the valve behaves. Open Center Valve Installations Overview Open Center Orbitrol Installation The Open Center valve is installed on the pressure line between the steering gear pump and the Orbitrol. The Open Center valve shares the same oil supply used for manual steering. A built in relief valve limits the maximum pump pressure created by the Open Center valve. The Open Center valve tank hose is teed into the Orbitrol tank hose and shares the same return path to tank. The Open Center valve Right and Left steering hoses are teed into the vehicle s right and left steering lines and send oil directly to the steering cylinders. The non-reactive Orbitrol on the vehicle keeps the steering wheel stationary while AutoSteering. Note: Refer to the hose diagrams provided in this manual for an overview of a typical open center steering system. Steering Valve Overview The steering valve installation requires custom hoses to fit each type of vehicle. Use only high quality hydraulic hoses rated for 3000 psi or more. Do not mix hose fittings and hoses of different brands. Assemble hoses and crimp fittings following the hose manufacturer s recommendations. Use only steel hose adapters rated for 3000 psi or more. Use hose fittings that match the type of fittings found on the vehicle (JIC, ORFS, Metric, etc ). This section contains the following sub-sections: Specifications Valve Hose Adapter Connections Valve Mounting Hole Patterns Orifice Locations and Configurations Specifications Table 3. Steering Valve Specifications Function Part Number 200-0762-01 Application Rated Oil Flow Maximum pressure Coil Voltage Pressure transducer Weight Description Wheeled vehicles with 12 volt electrical system requiring steering oil flow up to 6 GPM (22 LPM) 6 GPM (22 L/Min) 3000 psi (210 bar) 12 Vdc 0-3000psi (0-210bar), 4-20mA output, M14x1.5 thread. 12.7 lbs (5.8 kg) Open Center Compact Valve Custom Hardware Installation Guide 5
Valve Hose Adapter Connections The Open Center valve has five threaded hose adapters, one diagnostic port and one thread for installing a pressure transducer. The threads in the valve block are all metric. Table 4. Valve Connections and Fitting Sizes Hose Adapter Valve Block Thread Hose Fitting Size and Type PRESSURE IN (FROM THE GEAR PUMP) M18x1.5-8 ORFS PRESSURE OUT (TOWARDS ORBITROL) M18x1.5-8 ORFS TANK = TANK / RETURN M18x1.5-6 ORFS LEFT = LEFT STEERING CYLINDER M14x1.5-6 ORFS RIGHT = RIGHT STEERING CYLINDER M14x1.5-6 ORFS GP = DIAGNOSTIC PORT M14x1.5 1/8 TRANS = PRESSURE TRANSDUCER M14x1.5 NONE Mounting Hole Patterns Note: The valve may be secured either using four M8x20 screws threaded into the back of the valve or two longer M8x90 socket head cap screws (Allen screws) using the two through holes. 6 Open Center Compact Valve Custom Hardware Installation Guide
Use four M8x20 screws for securing the valve using the above hole pattern on the rear of valve. Use two M8x90 socket head cap screws (Allen screws) for securing the valve using the above hole pattern Open Center Compact Valve Custom Hardware Installation Guide 7
Orifice Plugs The Open Center valve has two internal orifices accessed through the front of the valve that can be changed for adjusting the valve behaviour for specific applications. For most installations these orifices do not need to be changed and the factory default orifices can be used. Use the information provided in Table 5 to configure the orifices to the factory default setting if necessary. Orifice Location and Configuration The figure below shows the location of the two orifices accessible from the front of the valve and identified as 11.1 and 11.2. Table 5 Orifice Plugs Factory Configuration Hydraulic Installation Type 11.1 11.2 Factory Default Configuration (valve as-delivered) 0.6mm Orifice 0.6mm Orifice Below is a description of the orifice functions and instructions for accessing the two orifices and changing them if necessary. 8 Open Center Compact Valve Custom Hardware Installation Guide
Orifice Plug 11.1 1. This is a factory installed 0.6mm diameter orifice that provides a pressure bleed down for the internal load sense signal. This orifice generally does not require any further changes. Installing the larger 0.8mm orifice provided will provide a faster bleed down of the internal pressure signal and will also result is slightly slower steering response. Note: The procedure shown here can also be used for cleaning the orifice if required. If the orifice is dirty and blocked, use compressed air or a needle to clean the hole and rinse with a solvent before re installing. Tools required: 1/8 (3.125mm) hex key (Allen wrench).. 2. To access the orifice you must first remove the external plug shown here using a 1/8 hex key (Allen wrench). 3. The orifice is a small set screw with a 0.6mm hole and is located inside the valve. Use a long 1/8 hex key (Allen wrench) to remove the orifice. 4. Here the orifice plug is shown after being removed. 5. Replace as necessary with a different size orifice, tighten the orifice and replace the external plug. Note: Do not over-tighten the orifice Open Center Compact Valve Custom Hardware Installation Guide 9
Orifice Plug 11.2 1. This is a factory installed 0.6mm diameter orifice that dampens the valve response and prevents chatter or audible noise causes by rapid pressure fluctuations at the priority valve. If audible chatter is observed in specific applications, this orifice can be replaced by the smaller 0.4mm orifice provided to further reduce chatter. Note: The procedure shown here can also be used for cleaning the orifice if required. If the orifice is dirty and blocked, use compressed air or a needle to clean the hole and rinse with a solvent before re installing.. 2. To access the orifice you must first remove the external plug shown here using a 1/8 hex key (Allen wrench). 3. The orifice is a small set screw with a 0.6mm hole and is located inside the valve. Use a long 1/8 hex key (Allen wrench) to remove the orifice. 10 Open Center Compact Valve Custom Hardware Installation Guide
Orifice Plug 11.2 4. Here the orifice plug is shown after being removed. 5. Replace as necessary with a different size orifice, tighten the orifice and replace the external plug. Note: Do not over-tighten the orifice Spare Orifice Storage Two spare orifices having a 0.4mm and 0.8mm diameter are shipped with the valve and are located on the front of the valve in the positions identified as 0.4 and 0.8. To access these spare orifices, first remove the external plugs in position 0.4 or 0.8 using a 1/8 hex key and then remove the internal orifice using the same 1/8 hex wrench. These two spare orifices do not perform any function when they are in the parked position which is used solely for storage. Orifice Maintenance Blocked orifices can result in slow steering response or oil heating. If orifice 11.1 is blocked, oil heating may occur due to sustained high pump pressure. If orifice 11.2 is blocked, the steering may become less responsive due to slow response from the priority valve. To clean an orifice, remove the orifice per the instructions shown above, clean using compressed air or a needle, rinse with a solvent and re install. Open Center Compact Valve Custom Hardware Installation Guide 11
Steering Valve Bracket Installation The AutoSteer kit includes two universal valve brackets and metric hardware fitting most vehicles using existing attachment points. The brackets provide hole and slot features to accommodate a variety of vehicle bolt spacing. Refer to the illustration below. Table 6 Bracket Kit Components Valve Installation Guidelines Item Component Part Number 1. Valve L Bracket 202-0357-02 2. Valve S. Bracket 202-0391-01 3. Bolt Kit Metric 202-0433-01 1. Install the valve on the vehicle in a protected position from tall crops and debris. 2. Install the valve in a position enabling good hose routing and short hoses to the vehicle connection points. 3. Install the valve in a position not interfering with normal vehicle operation and moving parts such as covers, removable shields, wheels, lift arms and implements. 4. Install the valve in a position which provides easy to access for service and hose connections. Do not install the valve in a difficult to reach position. 5. Install the valve on a vehicle structure providing sufficient strength to secure the valve weight plus the mounting bracket and hoses. 6. Secure the valve to the vehicle using existing bolts, threaded holes or through holes on the vehicle. The bracket kit includes a variety of short and long metric bolts and nuts in sizes M8, M10, M12, M16 and M20. 12 Open Center Compact Valve Custom Hardware Installation Guide
Bracket Mounting Examples There are four basic methods for installing steering valve brackets. The following illustrations show the various installation methods using L and S type brackets. (different valve shown). Bracket Mounting Examples L Bracket Installation S Bracket Installation Bracket Installation on Square Frame Steel Pipe Bracket Installation Note: Use the two valve brackets plus the four long screws and locknuts to mount the valve to steel frames up to 4 x4 (100 x 100mm). Note: Use the S bracket and a pair of U-Bolts with locknuts to mount the valve on steel pipes up to 1.5 (38mm) diameter. Open Center Compact Valve Custom Hardware Installation Guide 13
Bracket Mounting Examples S Bracket Completed Installation Example S Bracket Completed Installation Example Example Bracket Installation Procedure Example Bracket Installation Procedure 1. Mount the bracket to the vehicle using the provided hardware. Note: The metric bolts provided in your kit fit most vehicle models. Many tractors have metric threads or holes that can be used for mounting purposes. 14 Open Center Compact Valve Custom Hardware Installation Guide
Example Bracket Installation Procedure 2. Slide the valve onto the bracket. Note: You may leave two mounting screws already threaded into the valve and they slide into the bracket U slots. 3. Insert the two remaining hex screws to secure the valve to the bracket. 4. Tighten the four hex screws using a 13mm ratchet wrench. Steering Valve Installation Procedure Overview 1. Install the AutoSteer valve bracket and valve on the vehicle. 2. Configure the AutoSteer valve internal plug or orifice according to your specific installation type. 3. Connect the hoses between the valve and the vehicle. 4. Check for oil leaks. 5. Adjust the AutoSteer Pressure Relief valve. 6. Perform a functional test to confirm proper valve operation. Open Center Orbitrol Installation Use this valve installation when the vehicle has a Open Center non-reacting Orbitrol. The Open Center Orbitrol will usually get its oil supply from a fixed displacement gear pump. The steering pump oil flow must be less than 15 GPM (56 lpm). An Open Center steering system uses a fixed displacement gear pump for steering and is usually found on some older vehicles, smaller vehicles and some combine harvesters and self-propelled sprayers. An Open Center Orbitrol usually has only four hoses (Pressure, Tank, Right, Left) and does not have a Load Sense hose. The Open Center steering valve is installed on the pressure line between the gear pump and the Orbitrol. The AutoSteer valve shares the same oil supply as the manual steering. The Open Center steering valve has a built in priority valve that divides oil flow between the AutoSteer valve and the manual steering Orbitrol. The AutoSteer Tank hose is teed into the Orbitrol Tank hose and shares the same return to Tank. A Relief Valve inside the AutoSteer Open Center valve limits the maximum pump pressure created by the internal Priority Valve. Open Center Compact Valve Custom Hardware Installation Guide 15
A pressure transducer connected to the PRESSURE OUT port detects a pressure spike in the Orbitrol s pressure line when the steering wheel is turned and kicks-out AutoSteer. The AutoSteer Right and Left steering hoses are teed into the vehicle steering lines and send oil directly to the steering cylinders. The non-reactive Orbitrol keeps the steering wheel stationary while AutoSteering. Do not use this installation with the following vehicle types: Very large vehicles requiring a higher oil flow and a larger AutoSteer valve. Vehicles with a Closed Center LS steering system. Vehicles with a steering pump flow that is greater than 15 GPM (56 lpm). Vehicles with a pressure compensated closed center steering system. Note: Most Pressure compensated Orbitrols also have only four hoses (Pressure, Tank, Right, Left) and no LS hose. This type of Orbitrol can be mistakenly identified as Open Center. You must positively identify the Orbitrol as being Open Center before proceeding with the installation. Note: Inverting the PRESSURE IN and PRESSURE OUT hoses may cause immediate pump damage when the engine is started because the Open Center valve only allows oil flow in one direction. Ensure all hoses are properly oriented and all hose connections are correct and tight before starting the engine. Note: Many Open Center steering systems have their relief valve located inside the Orbitrol and do not have a relief valve located at the pump. These systems are more susceptible to severe pump damage resulting from wrong hose connections and blocked oil flow from the fixed displacement gear pump. 16 Open Center Compact Valve Custom Hardware Installation Guide
Hose Kit Fabrication A custom hose kit must be fabricated to connect the Open Center valve to the vehicle pump and steering system. The hose kit will require five hoses as shown in the two figures below below. Note: The hose adapter type and size must match the types of hose fittings used on the vehicle. (JIC, Metric, ORFS, and so on.) Open Center Compact Valve Custom Hardware Installation Guide 17
Installation Instructions Note: The first illustration below shows the open center steering system prior to Autosteer system installation. The second one shows the completed installation. 18 Open Center Compact Valve Custom Hardware Installation Guide
1. Refer to the illustrations above for a detailed hose diagram and follow the instructions below. 2. Disconnect the pressure hose from the Orbitrol and connect it to the PRESSURE IN port on the Open Center valve. Use an extender hose or threaded adapter as required for completing this hose connection. 3. Connect a hose from the PRESSURE OUT port on the Open Center valve to the pressure port on the Orbitrol. Note: This hose re-establishes pump oil flow for manual steering. 4. Install a tee adapter on the Orbitrol Tank port. It can be installed directly on the Orbitrol tank port or any other position along the Orbitrol tank hose. 5. Connect a hose from the TANK port on the Open Center valve to the tee on the Orbitrol Tank port. Note: You can install this tee anywhere along the tank hose between the Orbitrol and the tank. 6. Connect a hose between the AutoSteer valve Right port and a Tee adapter on the Orbitrol Right steering hose. Note: You may install the tee adapter anywhere along the Right steering line in a convenient location between the Orbitrol and the right steering cylinder. 7. Connect a hose between the AutoSteer valve Left port and a Tee adapter on the Orbitrol Left steering hose. Open Center Compact Valve Custom Hardware Installation Guide 19
Note: You may install the tee adapter anywhere along the left steering line in a convenient location anywhere between the Orbitrol and the left steering cylinder. 20 Open Center Compact Valve Custom Hardware Installation Guide
Orbitrol with tee adapters for TANK, RIGHT, LEFT. Open Center valve fully installed with all hoses connected 8. Individually check each hose connection at both ends and confirm they match the hose diagram in the second illustration above. Note: Wrong hose connections, especially on the pressure and tank lines can cause immediate pump damage when the engine is started. Open Center Compact Valve Custom Hardware Installation Guide 21
9. If the valve has been previously been used on another vehicle, check the internal orifices to confirm that they are installed and are the correct size (diameter) per the table below Type of Installation 11.1 11.2 Factory Default Configuratrion (valve as-delivered) 0.6mm orifice 0.6mm orifice 10. Check all hoses individually and confirm they are correctly connected before starting the engine. 11. Check for leaks and adjust the Relief Valve after the engine is started. 12. Proceed to the calibration and tuning process. Note: Do not start the engine before all hose connections have been checked. Wrong hose connections on vehicle steering systems may cause immediate pump damage when the engine is started. It is especially important to connect the Pressure and Tank hoses correctly. 22 Open Center Compact Valve Custom Hardware Installation Guide
Install the Pressure Transducer Install the Pressure Transducer 1. Identify the pressure transducer threaded port that has a factory installed plastic protective cap. 2. Remove the plastic cap using a screwdriver or wrench. 3. Install the pressure transducer on the threaded port and tighten using a long 27mm hex socket. Note: Do not over tighten the Pressure Transducer. 4. Connect the short Transducer Harness to the Pressure Transducer. Open Center Compact Valve Custom Hardware Installation Guide 23
Install the Pressure Transducer 5. Connect the 4-pin connector and 10-pin connector to the ECU vehicle harness. 6. Note: Secure the transducer cable and connector with cable ties in a protected position. Note: A cable diagram and detailed cable information is provided in your system installation manual. Refer to your system installation manuals for cable connection details. Adjust the AutoSteer Relief Valve The AutoSteer valve has a built-in Load Sense Relief Valve which limits the maximum pump pressure when AutoSteering. The Relief Valve must be adjusted after you have completed the hydraulic installation and before you turn on the AutoSteer. system. The AutoSteer system must be fully installed and functional before you can adjust the Relief Valve. A 1/8 hex key (Allen wrench) and 3/8 (9.52mm) wrench are required for adjusting the relief valve. Note: The Relief Valve in the illustration below is shown on a bench without the hydraulic hoses connected for ease of viewing the adjustment process. When you adjust the Relief Valve, the process is performed with the valve mounted on the vehicle and the hydraulic hoses connected. 24 Open Center Compact Valve Custom Hardware Installation Guide
Open Center Compact Valve Custom Hardware Installation Guide 25
Adjust the AutoSteer Relief Valve 13. Install a 5000 psi pressure gauge on the Open Center AutoSteer valve diagnostics port labeled as GP. Use a short extension hose on the pressure gauge if necessary for easier reading. 14. Put the transmission into Park position and engage the hand brake. 15. Start the engine and leave it at low idle. 16. Immediately check for oil leaks on all hose connections that were opened. 17. Turn the steering wheel full right and then full left and check for the correct manual steering response. Immediately check for oil leaks on all opened hydraulic hose connections. Air in the hoses may cause a slight steering delay when the system is first powered up. 18. Observe the standby pump pressure shown on your pressure gauge. Standby pressure should be very low, or around 300psi (20 bar). Note: If standby pump pressure is zero or less than 100psi (8 bar), you might have inverted the Pressure and Tank hoses. 19. Clear any bystanders from around the vehicle because you will be moving the vehicle steered wheels in the next step. 20. With the Display turned ON access the Hydraulic Valve window from the Steering Components Window and command the steering full Right and full Left. The front wheels will turn towards each of the corresponding directional stops. The maximum pump pressure is indicated on the pressure gauge when the wheels hit the stops. 21. Adjust the AutoSteer Relief Valve so the maximum pump pressure is approximately the same as the maximum manual steering pressure when the wheels hit the stops. Note: The maximum manual steering pressure value can be obtained from the vehicle shop manual or measured by installing a pressure gauge on the open center AutoSteer valve. Note: Most farm vehicles have maximum steering pressure between 2000psi-3000psi. (140bar-210bar). However, some small utility vehicles may have a maximum steering pressure as low as 1200 psi (80 bar). 22. Tighten the jam nut on the Relief Valve once the correct pressure setting has been established. 26 Open Center Compact Valve Custom Hardware Installation Guide
23. Remove your pressure gauge by sliding the sleeve on the quick coupler. Adjust the AutoSteer Relief Valve Note: Turn off the vehicle engine before adjusting the Relief Valve. Turning the engine off will prevent possible vehicle movement or a high pressure fluid hazard. Do not adjust the Relief Valve with the engine running. AutoSteer Hydraulic Installation Checklist 1. The Valve bracket bolts are tight. 2. The Mounting screws securing the valve are tight. 3. The Pressure hose is connected to correct AutoSteer Valve and LS Priority Valve ports. 4. Tank hose is connected to correct AutoSteer valve and vehicle ports. 5. The Right steer hose is connected correctly at both ends. 6. Left steer hose is connected correctly at both ends. 7. The Pressure Transducer is installed and tight. 8. Ensure all hose fittings are tight. 9. Check hose routing and ensure all hoses have cable ties. 10. Ensure all hoses are clear of moving parts, such as levers, the engine drive shaft and front axle shaft. 11. Ensure the ECU vehicle Harness is connected to the two valve connectors. 12. Ensure the relief valve has been adjusted. Troubleshooting This Troubleshooting chapter contains some common system problems, possible causes and corrective actions. Wheels do not turn in AutoSteer Mode Wheels do not Turn in Manual Steering Wheels turn in Opposite Direction in AutoSteer Mode Steering is Slow or Sluggish in AutoSteer Mode Wheels Only Turn in One Direction in AutoSteer Mode Pump Remains Stroked up Too Long or When not AutoSteering Pump Pressure is Always High Valve is Noisy or Chatter Occurs The Wheels Vibrate or Steering is too Twitchy in AutoSteer Mode AutoSteer Does not Kick-Out When Driver Turns the Steering Wheel AutoSteer Kicks-Out Without Turning the Steering Wheel Open Center Compact Valve Custom Hardware Installation Guide 27
Gear Pump That Supplies Oil for Steering System is Damaged Wheels are Wandering or do not Hold Position Wheels Keep Turning Only in One Direction Until they the Hit the Stops The Hydraulic System is Always Noisy When the Engine is Running Wheels do not turn in AutoSteer Mode Valve harness not connected or damaged. Bad harness. Wrong type of vehicle selected in AutoSteer setup. Wrong type of hose hookup to vehicle. Relief Valve pressure set too low. Check maximum pump pressure. Wrong hose connections. Inverted pressure and tank hoses. Compare all hose connections to the correct hose diagram. Severe oil leakage on hose connections. Check all hose connections. Missing orifice in position 11.1 (internal LS draining directly to tank). Wheels do not Turn in Manual Steering Wrong hose connections Low oil level Damaged pump. Check all hoses for correct connections. Check steering oil pressure. Severe oil leakage at pump or steering system. Turn off engine immediately and check all hose connections. Wheels turn in Opposite Direction in AutoSteer Mode Right and Left Steer hoses are inverted. Bad valve cable. Steering direction inverted during system calibration. Pressure and Tank hoses are inverted. This requires immediate attention to avoid possible pump damage. Steering is Slow or Sluggish in AutoSteer Mode Blocked orifice in position 11.2. Remove and clean. Damaged priority valve. Bad shuttle valve. Check O-rings. Replace shuttle valve if necessary. Missing orifice in position 11.1 is allowing excessive oil loss to tank. Wheels Only Turn in One Direction in AutoSteer Mode Bad Wiring Harness Bad valve harness (4-pin connector harness) Bad coil on Proportional Valve Leaking shuttle valve in AutoSteer valve. Jammed spool on Proportional Valve. Could be caused by severe oil contamination. Bad pilot check valve cartridge. Leaking O-ring on one pilot check valve cartridges. 28 Open Center Compact Valve Custom Hardware Installation Guide
Pump Remains Stroked up Too Long or When not AutoSteering Pump Pressure is Always High Blocked bleed-down orifice in position 11.1. (from oil contamination or following service). Wrong hose connections or wrong type of installation for the type of vehicle. Valve is Noisy or Chatter Occurs Hoses are too long. Use shorter hoses. Install valve closer to hookup point to shorten hoses. Loose hoses. Secure hoses or use shorter hoses. Vehicle pump is generating pressure oscillations that create noise. Install hydraulic accumulator. Review complete hydraulic installation. A smaller damper orifice is required in position 11.2. Replace the factory default 0.6mm orifice with the smaller 0.4mm orifice provided with the open center valve. Follow instructions provided in this manual. The Wheels Vibrate or Steering is too Twitchy in AutoSteer Mode Wrong vehicle selected or wrong vehicle type selected. Confirm correct vehicle profile was selected. Wrong calibration. Repeat actuator calibration. Repeat Wheel Angle Sensor calibration. Wrong tuning gains or tuning not done. Steering gain too high. Repeat a complete tuning routine. Response rate slider set too high. Lower the response rate. Wrong settings for 12V valve. Confirm that the AutoSteer system is adjusted for a 12V valve. Bad Wheel Angle Sensor or Wheel Angle Sensor bad cable. Valve flow is too high for the vehicle size. This can happen on very small vehicles. AutoSteer Does not Kick-Out When Driver Turns the Steering Wheel Wrong transducer calibration. Follow correct calibration process. Lower the high pressure limit. Number of samples set too high for the pressure transducer. Lower the number of samples to 1 or 2 for typical Open Center installations. Bad pressure transducer. Wrong type of pressure transducer (must be 3000psi with 4-20mA current output) Bad ECU harness. Wrong transducer selection in application software. AutoSteer Kicks-Out Without Turning the Steering Wheel This can be considered normal if it only occurs immediately after a cold vehicle is powered up in very cold conditions when the oil is more viscous and the standby pump pressure and Return pressure are higher than normal. Allow the oil to warm up slightly before using the AutoSteer system. High pressure limit is set too low. Increase the transducer high pressure limit slightly. Bad pressure transducer or short in transducer harness. Valve response is too twitchy and is causing pressure spikes in the hydraulic system. Repeat the calibration and tuning. Vehicle electrical system is too noisy or has grounding problems. Open Center Compact Valve Custom Hardware Installation Guide 29
Number of samples set to low (never set it to zero). Defective transducer harness on the AutoSteer valve. Replace the short transducer harness. If it kicks-out spontaneously only when acquiring the line, suspect pressure spikes or wrong transducer calibration. If AutoSteer kicks-out spontaneously in a random fashion while steering on the line, suspect electrical problems. Steering Gear Pump is damaged Inverted Pressure and Tank hose connections on the AutoSteer Valve. (inverted hoses eliminate the Relief Valve function) Wrong hose connection. Relief pressure set too high, resulting in pump damage. Wheels are Wandering or do not Hold Position Bad pilot check valve on AutoSteer valve. Bad Wheel Angle Sensor. Bad calibrations for valve (actuator) or Wheel Angle Sensor. Low pump pressure. Pump is not being stroked up. Check maximum pump pressure. Blocked orifice in position 11.2 is preventing the priority valve from working. Clean the orifice. Bad ECU Harness or connectors. Wheels Keep Turning Only in One Direction until they hit the Stops Bad Proportional Valve. Spool in the Proportional Valve is jammed due to dirt from oil contamination. Short on ECU Harness. Defective ECU. Broken ECU Harness. Bad Wheel Angle Sensor. Bad calibration. Repeat Wheel Angle Sensor and actuator calibration. The Hydraulic System is always Noisy When the Engine is running The pump may be stroked up to maximum pressure all the time. Check all hose connections and measure the standby pump pressure. (should be low) Oil level may be low. Defective pump or hydraulic system. Check vehicle hydraulic system. Bleed orifice 11.1 is blocked. High oil temperature The pump may be stroked up to maximum pressure all the time. Check all hose connections and measure the standby pump pressure. (should be low) Oil viscosity is too high. Restrictions in the oil flow path such as thin hoses or dirty filters. 30 Open Center Compact Valve Custom Hardware Installation Guide