JCB 3000 XTRA Series Fastrac Service Repair Manual – PDF Download by www.heydownloads.com

Service Manual 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

World Class Customer Support Copyright ÂŠ 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 General Information Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section 1 - General Information

Notes:

1-0

9803/9970-01

1-0

Section 1 - General Information Contents Page No. Use Introduction ............................................................................................. 1-1-1 Scope ..................................................................................................... 1-1-2 Format .................................................................................................... 1-1-3 Left and Right Sides ............................................................................... 1-1-4 Hydraulic Schematic Codes ................................................................... 1-1-5 Machine Identification Introduction ............................................................................................. 1-2-1 Identifying your Machine ......................................................................... 1-2-2 Torque Settings Introduction ............................................................................................. 1-3-1 Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-3-2 Hydraulic Connections ............................................................................ 1-3-6 `Positional Type' Hydraulic Adaptors .................................................... 1-3-10 Service Tools Numerical List ......................................................................................... 1-4-1 Tool Detail Reference ............................................................................. 1-4-6 Service Consumables Sealing and Retaining Compounds ........................................................ 1-5-1

1-i

Section 1 - General Information Contents

1-ii

Page No.

1-ii

Section 1-1 - General Information

Use Introduction This topic contains information about the structure of the manual and how to use the manual.

K Scope ( T 1-1-2) K Personnel ( T 1-1-2) K Applications ( T 1-1-2) K Newest Data ( T 1-1-2) K Format ( T 1-1-3) K Left and Right Sides ( T 1-1-4) K Hydraulic Schematic Codes ( T 1-1-5) K Colour Codes ( T 1-1-5)

1-1-1

9803/9970-01 (1-01-00)

1-1-1

Section 1-1 - General Information Use Scope

Scope Personnel This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Finally, please remember above all else SAFETY MUST COME FIRST!

Applications This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine.

Newest Data From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue. Always check the on-line JCB data system for relevant technical information.

1-1-2

9803/9970-01 (1-01-00)

1-1-2

Section 1-1 - General Information Use Format

Format The manual is compiled in sections, the first three are numbered and contain information as follows: 1

General Information - general information such as torque settings and service tools.

Care & Safety - includes warnings, cautions and general procedures related to aspects of workshop procedures contained in the manual.

Routine Maintenance - includes service schedules and recommended lubricants for all the machine.

The remaining sections are alphabetically coded and deal with dismantling, overhaul etc. of specific components, for example: A

Attachments

Body and Framework...etc.

The sections contain topics. Each topic is a self contained set of data about a machine SYSTEM or Device. Each topic contains data such as specifications, descriptions, fault finding and test procedures. Device topics also contain removal, replacement, dismantle and assemble procedures. Some topics contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures.

1-1-3

9803/9970-01 (1-01-00)

1-1-3

Section 1-1 - General Information Use Left and Right Sides

Left and Right Sides 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

1-1-4

9803/9970-01 (1-01-00)

1-1-4

Section 1-1 - General Information Use Hydraulic Schematic Codes

Hydraulic Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.

Red

Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.

Pink

Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.

Orange

Blue

Green

Light Green

Yellow

1-1-5

Pilot: Oil pressure used in controlling a device (Pilot).

Neural: Neutral circuit pressure.

Exhaust:

Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

9803/9970-01 (1-01-00)

1-1-5

Section 1-1 - General Information Use Hydraulic Schematic Codes

1-1-6

9803/9970-01 (1-01-00)

1-1-6

Section 1-2 - General Information

Machine Identification Introduction This topic contains information about a machine identification. On the machine and on the machine devices there are identification data plates.

K Machine Identification Plate ( T 1-2-2) K Typical Product Identification Number (PIN) ( T 1-2-3) K Component Identification Plates ( T 1-2-4) K ROPS and FOPS Certification Labels ( T 1-2-5)

1-2-1

9803/9970-01 (1-02-00)

1-2-1

Section 1-2 - General Information Machine Identification Identifying your Machine

Identifying your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. The serial numbers of the machine and its major units are stamped on the plate.

JCB LANDPOWER LIMITED LAKESIDE WORKS, ROCESTER, UTTOXETER, UNITED KINGDOM, ST14 5JP TRACTOR TYPE ENGINE POWER (Kw) @ rpm EEC NUMBER IDENTIFICATION NUMBER

Note: The machine model and build specification is indicated by the PIN. Refer to Typical Product Identification Number (PIN). The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.

TOTAL PERMISSIBLE MASS

(Kg)

PERMISSIBLE FRONT AXLE LOAD *

(Kg)

PERMISSIBLE REAR AXLE LOAD *

(Kg)

UNBRAKED TOWABLE MASS

(Kg)

INDEPENDENTLY BRAKED TOWABLE MASS

(Kg)

INERTIA BRAKED TOWABLE MASS

(Kg)

POWER BRAKED TOWABLE MASS *TYRE DEPENDANT

(Kg)

YEAR OF MANUFACTURE

WEIGHT (Kg) ISO 6016

F AXLE

G BOX

R AXLE

RANGE

PTO BOX

ENGINE

332/W8667

C073810

Fig 2.

The machine and engine serial numbers can help identify exactly the type of equipment you have. JCB LANDPOWER LIMITED LAKESIDE WORKS, ROCESTER, UTTOXETER, UNITED KINGDOM, ST14 5JP

MADE IN THE UK TRACTOR TYPE

ENGINE POWER (Kw) @ rpm EEC NUMBER IDENTIFICATION NUMBER TOTAL PERMISSIBLE MASS

(Kg)

PERMISSIBLE FRONT AXLE LOAD *

(Kg)

PERMISSIBLE REAR AXLE LOAD *

(Kg)

UNBRAKED TOWABLE MASS

(Kg)

INDEPENDENTLY BRAKED TOWABLE MASS

(Kg)

INERTIA BRAKED TOWABLE MASS

(Kg)

YEAR OF MANUFACTURE

WEIGHT (Kg) ISO 6016

POWER BRAKED TOWABLE MASS *TYRE DEPENDANT

(Kg)

F AXLE

G BOX

R AXLE

RANGE

PTO BOX

ENGINE

332/W8724

C073980

Fig 3. C096760

Fig 1. The information on the identification plate will depend on the market for which the machine is built. It will be as shown on one of the following illustrations.

1-2-2

9803/9970-01 (1-02-00)

1-2-2

Section 1-2 - General Information Machine Identification Identifying your Machine Typical Product Identification Number (PIN)

T040900-C1

Fig 4. 1

World Manufacturer Identification (3 Digits)

Engine Type (2 Digits) 27 = QSB 6.7 230Hp (3230) 28 = QSB 6.7 200Hp (3200)

Transmission Type (1 Digit) J = XTRA Drive Transmission

Vehicle Maximum Speed kph (2 Digits) 40 = 40kph 50 = 50kph 60 = 60kph 75 = 75kph

Check Letter (1 Digit) The Check Letter is used to verify the authenticity of the machine's PIN.

Machine Serial Number (8 Digits) Each machine has a unique serial number.

1-2-3

9803/9970-01 (1-02-00)

1-2-3

Section 1-2 - General Information Machine Identification Identifying your Machine

Component Identification Plates Front axle

Gearbox assembly

Rear axle

Engine

B C090820

Fig 5.

1-2-4

9803/9970-01 (1-02-00)

1-2-4

Section 1-2 - General Information Machine Identification Identifying your Machine

ROPS and FOPS Certification Labels The ROPS and FOPS certification label is mounted as shown.

J.C.B. CAB SYSTEMS LAKESIDE WORKS ROCESTER UTTOXETER, STAFFS ST14 5JP ENGLAND

FASTRAC MAX UNLADEN MASS 8000 KG 3000 SERIES

OECD APPROVAL NUMBER 4/0 549 ROPS: COMPLIES TO 79/622/EEC

CAB WA PART No. XXX/XXXXX YEAR OF MANUFACTURE XXXX

CAB WA SERIAL NUMBER

332_V8826

Fig 8. If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer.

C096760-C1

Fig 6. Machines built to Roll Over Protection Structure (ROPS) and Falling Objects Protection Structure (FOPS) standards have the following identification label fitted inside the cab.K Fig 7. ( T 1-2-5)

J.C.B. CAB SYSTEMS LAKESIDE WORKS ROCESTER UTTOXETER, STAFFS ST14 5JP ENGLAND

CAB WA SERIAL NUMBER

FASTRAC MAX UNLADEN MASS 8000 KG 3000 SERIES

OECD APPROVAL NUMBER 4/0 549 FOPS: ROPS: COMPLIES TO COMPLIES TO 79/622/EEC OECD CODE 10

CAB WA PART No. XXX/XXXXX XXXXXXXXXXXXXXX

YEAR OF MANUFACTURE XXXX

332_V8803

Fig 7. The FOPS structure provides impact protection for normal agricultural use, as defined in OECD Code10.

!MWARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17

Machines with a roof hatch fitted have ROPS protection only and have the following label. K Fig 8. ( T 1-2-5)

1-2-5

9803/9970-01 (1-02-00)

1-2-5

Section 1-2 - General Information Machine Identification Identifying your Machine

Page left intentionally blank

1-2-6

9803/9970-01 (1-02-00)

1-2-6

Section 1-3 - General Information

Torque Settings Introduction This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adapters. Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners with different surface treatments. Make sure you use the correct torque figures. Where torques are given in topics within the other sections always use these values.

K Zinc Plated Fasteners and Dacromet Fasteners ( T 1-3-2) K Introduction ( T 1-3-2) K Bolts and Screws ( T 1-3-2) K Hydraulic Connections ( T 1-3-6) K 'O' Ring Face Seal System ( T 1-3-6) K 'Torque Stop' Hose System ( T 1-3-9) K `Positional Type' Hydraulic Adaptors ( T 1-3-10) K Fitting Procedure ( T 1-3-10)

1-3-1

9803/9970-01 (1-05-00)

1-3-1

Section 1-3 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Zinc Plated Fasteners and Dacromet Fasteners T11-002

Introduction

Bolts and Screws

Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.

Use the following torque setting tables only where no torque setting is specified in the text.

The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-3-2).

Torque settings are given for the following conditions:

Fastener Type

Table 1. Fastener Types Colour Part No. Suffix

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners

Zinc and Yellow

Golden finish

'Z' (e.g. 1315/3712Z)

Dacromet

Mottled silver finish 'D' (e.g. 1315/3712D)

Condition 2 – Zinc flake (Dacromet) fasteners

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components

Verbus Ripp Bolts

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

1-3-2

Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

9803/9970-01 (1-05-00)

1-3-2

Section 1-3 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1

Bolt Size

Condition 2

in.

kgf m

lbf ft

kgf m

lbf ft

1/4

6.3

7/16

11.2

1.1

8.3

10.0

1.0

7.4

5/16

7.9

1/2

22.3

2.3

16.4

20.0

2.0

14.7

3/8

9.5

9/16

40.0

4.1

29.5

36.0

3.7

26.5

7/16

11.1

5/8

64.0

6.5

47.2

57.0

5.8

42.0

1/2

12.7

3/4

98.00

10.0

72.3

88.0

9.0

64.9

9/16

14.3

13/16

140.0

14.3

103.2

126.0

12.8

92.9

5/8

15.9

15/16

196.0

20.0

144.6

177.0

18.0

130.5

3/4

19.0

1 1/8

343.0

35.0

253.0

309.0

31.5

227.9

7/8

22.2

1 15/16

547.0

55.8

403.4

492.0

50.2

362.9

25.4

1 1/2

814.0

83.0

600.4

732.0

74.6

539.9

1 1/8

31.7

1 7/8

1181.0

120.4

871.1

1063.0

108.4

784.0

1 1/4

38.1

2 1/4

1646.0

167.8

1214.0

1481.0

151.0

1092.3

Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

kgf m

Condition 2

lbf ft

kgf m

lbf ft

5.8

0.6

4.3

5.2

0.5

3.8

9.9

1.0

7.3

9.0

0.9

6.6

24.0

2.4

17.7

22.0

2.2

16.2

M10

47.0

4.8

34.7

43.0

4.4

31.7

M12

83.0

8.5

61.2

74.0

7.5

54.6

M16

205.0

20.9

151.2

184.0

18.8

135.7

M20

400.0

40.8

295.0

360.0

36.7

265.5

M24

690.0

70.4

508.9

621.0

63.3

458.0

M30

1372.0

139.9

1011.9

1235.0

125.9

910.9

M36

2399.0

244.6

1769.4

2159.0

220.0

1592.4

1-3-3

9803/9970-01 (1-05-00)

1-3-3

Section 1-3 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

kgf m

Condition 2 lbf ft

kgf m

lbf ft

8.1

0.8

6.0

7.3

0.7

5.4

13.9

1.4

10.2

12.5

1.3

9.2

34.0

3.5

25.0

30.0

3.0

22.1

M10

67.0

6.8

49.4

60.0

6.1

44.2

M12

116.0

11.8

85.5

104.0

10.6

76.7

M16

288.0

29.4

212.4

259.0

26.4

191.0

M20

562.0

57.3

414.5

506.0

51.6

373.2

M24

971.0

99.0

716.9

874.0

89.1

644.6

M30

1930.0

196.8

1423.5

1737.0

177.1

1281.1

M36

3374.0

344.0

2488.5

3036.0

309.6

2239.2

Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size

Condition 2

ISO Metric Thread

kgf m

lbf ft

kgf m

lbf ft

9.8

1.0

7.2

8.8

0.9

6.5

16.6

1.7

12.2

15.0

1.5

11.1

40.0

4.1

29.5

36.0

3.7

26.5

M10

80.0

8.1

59.0

72.0

7.3

53.1

M12

139.0

14.2

102.5

125.0

12.7

92.2

M16

345.0

35.2

254.4

311.0

31.7

229.4

M20

674.0

68.7

497.1

607.0

61.9

447.7

M24

1165.0

118.8

859.2

1048.0

106.9

773.0

M30

2316.0

236.2

1708.2

2084.0

212.5

1537.1

M36

4049.0

412.9

2986.4

3644.0

371.6

2687.7

1-3-4

9803/9970-01 (1-05-00)

1-3-4

Section 1-3 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread

kgf m

lbf ft

1.2

0.1

0.9

3.0

0.3

2.0

6.0

0.6

4.5

10.0

1.0

7.5

24.0

2.5

18.0

M10

48.0

4.9

35.5

M12

82.0

8.4

60.5

Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size

1-3-5

ISO Metric Thread

kgf m

lbf ft

2.0

0.2

1.5

6.0

0.6

4.5

11.0

1.1

8.0

19.0

1.9

14.0

46.0

4.7

34.0

M10

91.0

9.3

67.0

M12

159.0

16.2

117.0

M16

395.0

40.0

292.0

M18

550.0

56.0

406.0

M20

770.0

79.0

568.0

M24

1332.0

136.0

983.0

9803/9970-01 (1-05-00)

1-3-5

Section 1-3 - General Information Torque Settings Hydraulic Connections

Hydraulic Connections T11-003

'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45Â° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-3-6

in.

kgf m

lbf ft

1/4

19.0

18.0

1.8

13.0

3/8

22.0

31.0

3.2

23.0

1/2

27.0

49.0

5.0

36.0

5/8

30.0

60.0

6.1

44.0

3/4

32.0

81.0

8.2

60.0

38.0

129.0

13.1

95.0

1 1/4

50.0

206.0

21.0

152.0

Table 9. Torque Settings - SAE Connections SAE Port Hexagon (A/F)

SAE Tube Size

Thread Size

kgf m

lbf ft

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

9803/9970-01 (1-05-00)

1-3-6

Section 1-3 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-3-7

Note: Dimension 2-D will vary depending upon the torque applied.

Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm

1/8

14.0

14.0 - 16.00

1.4 - 1.6

10.3 - 11.8

1/4

19.0

24.0 - 27.0

2.4 - 2.7

17.7 - 19.9

3/8

22.0

33.0 - 40.0

3.4 - 4.1

24.3 - 29.5

1/2

27.0

44.0 - 50.0

4.5 - 5.1

32.4 - 36.9

5/8

30.0

58.0 - 65.0

5.9 - 6.6

42.8 - 47.9

3/4

32.0

84.0 - 92.0

8.6 - 9.4

61.9 - 67.8

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

9803/9970-01 (1-05-00)

kgf m

lbf ft

1-3-7

Section 1-3 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-3-8

in.

kgf m

lbf ft

1/8

20.0

2.1

15.0

1/4

34.0

3.4

25.0

3/8

75.0

7.6

55.0

1/2

102.0

10.3

75.0

5/8

122.0

12.4

90.0

3/4

183.0

18.7

135.0

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

9803/9970-01 (1-05-00)

1-3-8

Section 1-3 - General Information Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-C which is compressed into a 45Â° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque

Stop' Hoses have an additional shoulder 3-D, which acts as a physical stop. Note: Minimum dimension 3-E fixed by shoulder 3-D.

Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F)

1-3-9

in.

kgf m

lbf ft

1/8

14.0

1.4

10.0

1/4

19.0

27.0

2.7

20.0

3/8

22.0

40.0

4.1

30.0

1/2

27.0

55.0

5.6

40.0

5/8

30.0

65.0

6.6

48.0

3/4

32.0

95.0

9.7

70.0

38.0

120.0

12.2

89.0

1 1/4

50.0

189.0

19.3

140.0

1 1/2

55.0

244.0

24.9

180.0

9803/9970-01 (1-05-00)

1-3-9

Section 1-3 - General Information Torque Settings `Positional Type' Hydraulic Adaptors

`Positional Type' Hydraulic Adaptors Fitting Procedure On a typical machine, some hydraulic components may utilise `Positional Type' SAE Hydraulic Adaptors. When fitting `Positional Type' Hydraulic Adaptors it is important to adopt the following procedure. If this procedure is not followed correctly, damage to the `O' ring seal 4-A can occur resulting in oil leaks. 1

Ensure the locknut 4-B is screwed back onto the body of the adaptor as far as possible as shown.

Check the `O' ring backing washer 4-C is a tight fit on the adaptor. Note that the washer should not move freely, if the washer is slack do not use the adaptor.

Check the `O' ring 4-A is fitted and that it is free from damage or nicks. Before fitting the adaptor, smear the `O' ring with clean hydraulic fluid.

Fig 4.

Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used. 4

Screw the adaptor into the port of the hydraulic component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face.

Set the angular position of the adaptor as required, then secure by tightening the locknut 4-B.

Note: When fitted correctly no more than one thread should be visible at 5-Z as shown. 6

Torque tighten the locknut to 81 Nm (60 lbf ft).

Fig 5.

1-3-10

9803/9970-01 (1-05-00)

1-3-10

Section 1-4 - General Informtion

Service Tools Numerical List The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Part Number

Description

Tool Detail Reference

1406/0011

Bonded Washer

K Fig 42. ( T 1-4-16)

1406/0014

Bonded Washer

K Fig 42. ( T 1-4-16)

1406/0018

Bonded Washer

K Fig 42. ( T 1-4-16)

1406/0021

Bonded Washer

K Fig 42. ( T 1-4-16)

1406/0029

Bonded Washer

K Fig 42. ( T 1-4-16)

1604/0003A Adapter

K Fig 35. ( T 1-4-15)

1604/0004A Adapter

K Fig 35. ( T 1-4-15)

1604/0006A Adapter

K Fig 43. ( T 1-4-17)

1604/2055

Adapter

K Fig 35. ( T 1-4-15)

1606/0004

Adapter

K Fig 35. ( T 1-4-15)

1606/0007A Adapter

K Fig 35. ( T 1-4-15)

1606/0008

Adapter

K Fig 35. ( T 1-4-15)

1606/0009

Adapter

K Fig 35. ( T 1-4-15)

1606/0012

Adapter

K Fig 35. ( T 1-4-15)

1606/0014

Adapter

K Fig 35. ( T 1-4-15)

1606/0015

Adapter

K Fig 35. ( T 1-4-15)

1606/0016

Adapter

K Fig 35. ( T 1-4-15)

1606/0017

Adapter

K Fig 35. ( T 1-4-15)

1606/2052

Adapter

K Fig 35. ( T 1-4-15)

1612/2054

Adapter

K Fig 43. ( T 1-4-17)

4104/1310

Hand Cleaner

K Fig 8. ( T 1-4-7)

816/00017

Adapter

K Fig 38. ( T 1-4-16)

816/00189A Blanking Cap

K Fig 40. ( T 1-4-16)

816/00190A Blanking Cap

K Fig 40. ( T 1-4-16)

816/00439

Adapter

K Fig 35. ( T 1-4-15)

816/00440

Adapter

K Fig 35. ( T 1-4-15)

816/15007A Adapter

K Fig 35. ( T 1-4-15)

816/15008

K Fig 35. ( T 1-4-15)

1-4-1

Adapter

9803/9970-01 (1-06-00)

1-4-1

Section 1-4 - General Informtion Service Tools Numerical List Part Number

Description

Tool Detail Reference

816/15118

Adapter

K Fig 36. ( T 1-4-15)

816/20008

Adapter

K Fig 43. ( T 1-4-17)

816/20013

Adapter

K Fig 43. ( T 1-4-17)

816/50005

Adapter

K Fig 38. ( T 1-4-16)

816/50043

Adapter

K Fig 38. ( T 1-4-16)

816/55038

Adapter

K Fig 37. ( T 1-4-15)

816/55040

Adapter

K Fig 37. ( T 1-4-15)

816/55045

Adapter

K Fig 37. ( T 1-4-15)

816/60096

Adapter

K Fig 38. ( T 1-4-16)

816/90022

Blanking Cap

K Fig 40. ( T 1-4-16)

816/90045

Blanking Cap

K Fig 40. ( T 1-4-16)

816/90205

Blanking Cap

K Fig 40. ( T 1-4-16)

816/90274

Blanking Cap

K Fig 40. ( T 1-4-16)

826/01099

Rivet Nut

K Fig 7. ( T 1-4-6)

826/01101

Rivet Nut

K Fig 7. ( T 1-4-6)

826/01102

Rivet Nut

K Fig 7. ( T 1-4-6)

826/01103

Rivet Nut

K Fig 7. ( T 1-4-6)

826/01104

Rivet Nut

K Fig 7. ( T 1-4-6)

826/01105A Rivet Nut

K Fig 7. ( T 1-4-6)

892/00047

Adapter

K Fig 38. ( T 1-4-16)

892/00048

Adapter

K Fig 38. ( T 1-4-16)

892/00049

Adapter

K Fig 38. ( T 1-4-16)

892/00055A Blanking Cap

K Fig 39. ( T 1-4-16)

892/00056A Blanking Cap

K Fig 39. ( T 1-4-16)

892/00057

Blanking Cap

K Fig 39. ( T 1-4-16)

892/00058A Blanking Cap

K Fig 39. ( T 1-4-16)

892/00059A Blanking Cap

K Fig 39. ( T 1-4-16)

892/00060

Blanking Cap

K Fig 39. ( T 1-4-16)

892/00051

Adapter

K Fig 38. ( T 1-4-16)

892/00074

Connector

K Fig 41. ( T 1-4-16)

892/00075

Connector

K Fig 41. ( T 1-4-16)

892/00076

Connector

K Fig 41. ( T 1-4-16)

892/00077

Connector

K Fig 41. ( T 1-4-16)

892/00078

Connector

K Fig 43. ( T 1-4-17)

892/00137

Hose

K Fig 48. ( T 1-4-19)

892/00174

Measuring cup

K Fig 53. ( T 1-4-20)

892/00201

Replacement Gauge

K Fig 45. ( T 1-4-18)

1-4-2

9803/9970-01 (1-06-00)

1-4-2

Section 1-4 - General Informtion Service Tools Numerical List Part Number

Description

Tool Detail Reference

892/00202

Replacement Gauge

K Fig 45. ( T 1-4-18)

892/00203

Replacement Gauge

K Fig 45. ( T 1-4-18)

892/00223

Hand Pump

K Fig 48. ( T 1-4-19)

892/00254

Replacement Hose

K Fig 47. ( T 1-4-18)

892/00255

Adapter

K Fig 36. ( T 1-4-15)

892/00256

Adapter

K Fig 36. ( T 1-4-15)

892/00257

Adapter

K Fig 36. ( T 1-4-15)

892/00258

Adapter

K Fig 36. ( T 1-4-15)

892/00259

Adapter

K Fig 36. ( T 1-4-15)

892/00260

Adapter

K Fig 36. ( T 1-4-15)

892/00261

Adapter

K Fig 36. ( T 1-4-15)

892/00262

Adapter

K Fig 48. ( T 1-4-19)

892/00263

Adapter

K Fig 37. ( T 1-4-15)

892/00264

Adapter

K Fig 37. ( T 1-4-15)

892/00265

Adapter

K Fig 37. ( T 1-4-15)

892/00266

Adapter

K Fig 37. ( T 1-4-15)

892/00267

Adapter

K Fig 37. ( T 1-4-15)

892/00268

Flow Monitoring Unit

K Fig 43. ( T 1-4-17)

892/00269

Sensor Head

K Fig 43. ( T 1-4-17)

892/00270

Load Valve

K Fig 43. ( T 1-4-17)

892/00271

Adapter

K Fig 43. ( T 1-4-17)

892/00272

Adapter

K Fig 43. ( T 1-4-17)

892/00273

Sensor Head

K Fig 43. ( T 1-4-17)

892/00274

Adapter

K Fig 43. ( T 1-4-17)

892/00275

Adapter

K Fig 43. ( T 1-4-17)

892/00276

Adapter

K Fig 43. ( T 1-4-17)

892/00277

Adapter

K Fig 43. ( T 1-4-17)

892/00278

Gauge

K Fig 48. ( T 1-4-19)

892/00279

Gauge

K Fig 47. ( T 1-4-18)

892/00284

Tachometer

K Fig 29. ( T 1-4-12)

892/00285

Hydraulic Oil Temperature Probe

K Fig 28. ( T 1-4-12)

892/00293

Connector Pipe

K Fig 43. ( T 1-4-17)

892/00298

Fluke Meter

K Fig 27. ( T 1-4-12)

892/00311

Brake Test Kit

K Fig 57. ( T 1-4-23)

892/00314

Accumulator Adapter

K Fig 58. ( T 1-4-24)

892/00314

Accumulator and Gas Spring Pressure Test Adapter

K Fig 58. ( T 1-4-24)

892/00318

Hose and Adapter Kit

K Fig 49. ( T 1-4-19)

1-4-3

9803/9970-01 (1-06-00)

1-4-3

Section 1-4 - General Informtion Service Tools Numerical List Part Number

Description

Tool Detail Reference K Fig 53. ( T 1-4-20)

892/00333 892/00347

Connector

K Fig 45. ( T 1-4-18)

892/00706

Test Probe

K Fig 48. ( T 1-4-19)

892/00801

Clutch spanner

K Fig 22. ( T 1-4-10)

892/00802

Rotor puller set

K Fig 24. ( T 1-4-10)

892/00803

Rotor installer set

K Fig 26. ( T 1-4-11)

892/00807

Front plate puller

K Fig 23. ( T 1-4-10)

892/00808

Shaft protector

K Fig 25. ( T 1-4-10)

892/00812

Drive coupling spanner

K Fig 51. ( T 1-4-20)

892/00817

Heavy duty socket

K Fig 53. ( T 1-4-20)

892/00818

Heavy duty socket

K Fig 53. ( T 1-4-20)

892/00819

Heavy duty socket

K Fig 53. ( T 1-4-20)

892/00842

Glass Lifter

K Fig 13. ( T 1-4-8)

892/00843

Folding Stand

K Fig 11. ( T 1-4-7)

892/00844

Long Knife

K Fig 19. ( T 1-4-9)

892/00845

Cartridge Gun

K Fig 9. ( T 1-4-7)

892/00846

Glass Extractor

K Fig 16. ( T 1-4-9)

892/00847

Nylon Spatula

K Fig 20. ( T 1-4-10)

892/00848

Wire Starter

K Fig 14. ( T 1-4-8)

892/00849

Braided Cutting Wire

K Fig 18. ( T 1-4-9)

892/00864

Axle locknut spanner

K Fig 55. ( T 1-4-21)

892/00871

Puller frame - other parts required, see Tool Detail Reference

K Fig 59. ( T 1-4-24)

892/00918

Soild spacer setting tools

K Fig 54. ( T 1-4-20)

892/01033

Data Link Adapter Kit - ABS

K Fig 30. ( T 1-4-12)

892/01092

Hub service kit

K Fig 56. ( T 1-4-22)

992/12300

Mobile Oven

K Fig 10. ( T 1-4-7)

992/12400

Static Oven

K Fig 12. ( T 1-4-8)

992/12600

Static Oven

K Fig 12. ( T 1-4-8)

992/12800

Cut-out Knife

K Fig 15. ( T 1-4-8)

992/12801

‘L’ Blades

K Fig 17. ( T 1-4-9)

992/15500

Rubber Spacer Blocks

K Fig 21. ( T 1-4-10)

993/68101

Slide Hammer

K Fig 6. ( T 1-4-6)

993/68102

End Stops

K Fig 6. ( T 1-4-6)

993/68103

Adapter

K Fig 6. ( T 1-4-6)

993/68104

Adapter

K Fig 6. ( T 1-4-6)

993/68105

Adapter

K Fig 6. ( T 1-4-6)

993/68106

Adapter

K Fig 6. ( T 1-4-6)

1-4-4

9803/9970-01 (1-06-00)

1-4-4

Section 1-4 - General Informtion Service Tools Numerical List Part Number

Description

Tool Detail Reference

993/68107

Bar

K Fig 6. ( T 1-4-6)

993/68108

Adapter

K Fig 6. ( T 1-4-6)

993/68109

Adapter

K Fig 6. ( T 1-4-6)

993/68110

Adapter

K Fig 6. ( T 1-4-6)

993/68111

Adapter

K Fig 6. ( T 1-4-6)

993/69800

Seal Kit

K Fig 45. ( T 1-4-18)

1-4-5

9803/9970-01 (1-06-00)

1-4-5

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated.

Fig 6. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

993/68107

Bar - M20 x M20 X 800 mm

993/68102

End Stops

993/68108

Adaptor - M20 x 7/8" UNF

993/68103

Adaptor - M20 x 5/8" UNF

993/68109

Adaptor - M20 x M12

993/68104

Adaptor - M20 x 1" UNF

993/68110

Adaptor - M20 x 5/8" UNF (Shoulder)

993/68105

Adaptor - M20 x M20

993/68111

Adaptor - M20 x 1/2" UNF

993/68106

Adaptor - M20 x M24 1

826/01099

M6 x 16 mm Rivet Nut

826/01101

M6 x 19 mm Rivet Nut

826/01102

M8 x 18 mm Rivet Nut

826/01103

M8 x 21 mm Rivet Nut

826/01104

M10 x 23 mm Rivet Nut

826/01105A M10 x 26 mm Rivet Nut 2

Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)

Fig 7. Rivet Nut Tool

1-4-6

9803/9970-01 (1-06-00)

1-4-6

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Fig 8. Fig 9. Hand Cleaner - special blend for the removal of polyurethane adhesives.

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

JCB part number - 4104/1310 (454g; 1 lb tub)

JCB part number - 892/00845

Fig 10.

Fig 11. 12V Mobile Oven - 1 cartridge capacity - required to pre- Folding Stand for holding glass - essential for preparing heat adhesive prior to use. It is fitted with a male plug (703/ new glass prior to installation. 23201) which fits into a female socket (715/04300). JCB part number - 992/12300

1-4-7

JCB part number - 892/00843

9803/9970-01 (1-06-00)

1-4-7

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Fig 12. Fig 13. 240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request contact JCB Technical Service.

Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

JCB part number:

JCB part number - 892/00842

992/12400 - 2 Cartridge x 240V9 992/12600 - 6 Cartridge x 240V

Fig 15. Fig 14. Wire Starter - used to access braided cutting wire (below) Cut-Out Knife - used to remove broken glass. through original polyurethane seal. JCB part number - 892/00848

1-4-8

JCB part number - 992/12800

9803/9970-01 (1-06-00)

1-4-8

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Fig 17.

Fig 16. Glass Extractor (Handles) - used with braided cutting wire 'L' Blades - 25 mm (1 in) cut - replacement blades for cut(below) to cut out broken glass. out knife (above). JCB part number - 892/00846

JCB part number - 992/12801 (unit quantity = 5 off)

Fig 18.

Fig 19. Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

Long Knife - used to give extended reach for normally inaccessible areas.

JCB part number - 892/00849 (approx 25 m length)

JCB part number - 892/00844

1-4-9

9803/9970-01 (1-06-00)

1-4-9

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Fig 20.

Fig 21.

Nylon Spatula - general tool used for smoothing sealants - Rubber Spacer Blocks - used to provide the correct set also used to re-install glass in rubber glazing because metal clearance between glass edge and cab frame. tools will chip the glass edge. JCB part number - 892/00847

JCB part number - 992/15500 (unit quantity = 500 off)

Fig 22. Fig 23. 892/00801 Clutch Spanner for air conditioning compressor

892/00807 Font Plate Puller for air conditioning compressor

Fig 25.

Fig 24.

892/00802 Rotor Puller Set for air conditioning compressor 892/00808 Shaft Protector for air conditioning compressor

1-4-10

9803/9970-01 (1-06-00)

1-4-10

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Fig 26. 892/00803 Rotor Installer Set for air conditioning compressor

1-4-11

9803/9970-01 (1-06-00)

1-4-11

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Section C - Electrics

Fig 28. 892/00285 Hydraulic Temperature Probe

Fig 29. 892/00284 Venture Microtach Digital Tachometer

Fig 27. 892/00298 Fluke Meter

892/01033 Data Link Adapter Kit Note: Item A of the Data Link Adapter Kit is unsuitable for use with the Fastrac and must be replaced by the HarnessDiagnostic (J1939) K Fig 31. ( T 1-4-13)

Fig 30.

1-4-12

9803/9970-01 (1-06-00)

1-4-12

Section 1-4 - General Informtion Service Tools Tool Detail Reference 721/10885 Harness - Diagnostic (J1939)

Fig 31. 721/00664 Connecting Lead - Wingst

Fig 32. 892/01066 Combination Lead (alternative to 721/00664, K Fig 32. ( T 1-4-13))

Fig 33.

1-4-13

9803/9970-01 (1-06-00)

1-4-13

Section 1-4 - General Informtion Service Tools Tool Detail Reference 1

Electrical Repair Kit

:7212/0002

2 Way Pin Housing

:7212/0004

2 Way Pin Retainer

:7212/0003

2 Way Socket Retainer

:7212/0001

2 Way Socket Connector

:7213/0002

3 Way Pin Housing

:7213/0004

3 Way Pin Retainer

:7213/0003

3 Way Socket Retainer

:7213/0001

3 Way Socket Connector

:7213/0006

3 Way Pin Housing (DT)

:7213/0008

3 Way Pin Retainer (DT)

:7213/0007

3 Way Socket Retainer (DT)

:7213/0005

3 Way Socket Connector (DT)

:7214/0002

4 Way Pin Housing

:7214/0004

4 Way Pin Retainer

:7214/0003

4 Way Socket Retainer

:7214/0001

4 Way Socket Connector

:7216/0002

6 Way Pin Housing

:7216/0004

6 Way Pin Retainer

:7216/0003

6 Way Socket Retainer

:7216/0001

6 Way Socket Connector

:7218/0002

8 Way Pin Housing

:7218/0004

8 Way Pin Retainer

:7218/0003

8 Way Socket Retainer

:7218/0001

8 Way Socket Connector

:7219/0002

10 Way Pin Housing

:7219/0004

10 Way Pin Retainer

:7219/0003

10 Way Socket Retainer

:7219/0001

10 Way Socket Connector

:7219/0006

14 Way Pin Housing

:7219/0008

14 Way Pin Retainer

:7219/0007

14 Way Socket Retainer

:7219/0005

14 Way Socket Connector

:7210/0001

Dummy Plug

:7210/0002

Wire Seal (1.4 - 2.2 mm dia.)

:7210/0003

Wire Seal (2.2 - 2.9 mm dia.)

1-4-14

Fig 34.

9803/9970-01 (1-06-00)

1-4-14

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Section E - Hydraulics Male Adapters - BSP x BSP 1606/2052

3/8 in. x 1/4 in.

1604/0003A 3/8 in. x 3/8 in. 892/00071

3/8 in. x 3/8 in. taper

1606/0004

1/2 in. x 1/4 in.

1606/0007A 1/2 in. x 3/8 in. 1604/0004A 1/2 in. x 1/2 in.

Fig 35. Male Adaptors

1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

Male Adapters - BSP x NPT (USA only)

1606/0009

3/4 in. x 1/2 in.

816/00439

3/8 in. x 1/4 in.

1604/2055

3/4 in. x 3/4 in.

816/00440

1/2 in. x 1/4 in.

1606/0012

3/4 in. x 1 in.

816/15007A 3/8 in. x 3/8 in.

1606/0014

3/4 in. x 1.1/4 in.

816/15008

1606/0015

1 in. x 1.1/4 in.

892/00255

1/4 in. BSP x Test Point

892/00256

3/8 in. BSP x Test Point

892/00257

1/2 in. BSP x Test Point

892/00258

5/8 in. BSP x Test Point

816/15118

3/4 in. BSP x Test Point

892/00259

1 in BSP x Test Point

892/00260

1.1/4 in. BSP x Test Point

892/00261

5/8 in. UNF x Test Point

816/55045

1/4 in. M BSP x 1/4 in. F BSP x Test Point

816/55038

3/8 in. M BSP x 3/8 in. F BSP x Test Point

816/55040

1/2 in. M BSP x 1/2 in. F BSP x Test Point

892/00263

5/8 in. M BSP x 5/8 in. F BSP x Test Point

892/00264

3/4 in. M BSP x 3/4 in. F BSP x Test Point

892/00265

1 in. M BSP x 1 in. F BSP x Test Point

892/00266

1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point

892/00267

1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point

1/2 in. x 3/8 in.

Fig 36. Pressure Test Adapters

Fig 37. Pressure Test 'T' Adapters

1-4-15

9803/9970-01 (1-06-00)

1-4-15

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Fig 38. 'T' Adapters

892/00047

3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048

1/2 in. BSP (A) x 1/4 in. BSP (B)

892/00049

5/8 in. BSP (A) x 1/4 in. BSP (B)

816/50043

3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051

1 in. BSP (A) x 1/4 in. BSP (B)

816/50005

1/2 in. BSP (A) x 1/2 in. BSP (B)

816/60096

3/4 in. BSP (A) x 3/4 in. BSP (B)

816/00017

1 in. BSP (A) x 1 in. BSP (B)

892/00055A 1/4 in. BSP 892/00056A 3/8 in. BSP 892/00057

1/2 in. BSP

892/00058A 5/8 in. BSP 892/00059A 3/4 in. BSP Fig 39. Female Blanking Caps

892/00060

1 in. BSP

816/90045

1/4 in. BSP

816/00189A 3/8 in. BSP 816/00190A 1/2 in. BSP

Fig 40. Male Cone Blanking Caps

816/90022

5/8 in. BSP

816/90274

3/4 in. BSP

816/90205

1 in. BSP

892/00074

3/8 in. BSP x 3/8 in. BSP

892/00075

1/2 in. BSP x 1/2 in. BSP

892/00076

5/8 in. BSP x 5/8 in. BSP

892/00077

3/4 in. BSP x 3/4 in. BSP

1406/0011

1/4 in. BSP

1406/0018

1/2 in. BSP

1406/0014

5/8 in. BSP

Fig 41. Female Connectors

Fig 42. Bonded Washers

1-4-16

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

9803/9970-01 (1-06-00)

1-4-16

Section 1-4 - General Informtion Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 44. ( T 1-4-17).

892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00273

Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006A Adapter 3/4 in M x 3/4 in M BSP

Fig 43. Flow Test Equipment

1612/2054

Adapter 3/4 in F x 3/4 in M BSP

892/00271

Adapter 3/4 in F x 5/8 in M BSP

892/00272

Adapter 5/8 in F x 3/4 in M BSP

816/20008

Adapter 3/4 in F x 1/2 in M BSP

892/00275

Adapter 1/2 in F x 3/4 in M BSP

892/00276

Adapter 3/4 in F x 3/8 in M BSP

892/00277

Adapter 3/8 in F x 3/4 in M BSP

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

998/11047

600 LPM Flow Turbine with Loading Valve

998/11048

1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors x2

998/11049

Carrying Case for Flow Test Kit

998/11050

Temperature Sensor (125Â°C Max)

Fig 44. 998/11046 JCB ServiceMaster Flow Test Kit

1-4-17

9803/9970-01 (1-06-00)

1-4-17

Section 1-4 - General Informtion Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 46. ( T 1-4-18).

892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in2)

892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in2)

892/00254

Replacement Hose

993/69800

Seal Kit for 892/00254 (can also be used with probe 892/00706)

892/00706

Test Probe

892/00347

Connector - Hose to gauge

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

0-600 Bar Pressure Transduce x2

998/11056

0-100 Bar pressureTransducer x2

998/11057

RPM Tachometer (includes fixed cable, 2 meters)

998/11058

5 Meter Connecting Cable

998/11059

M16 Metric Adaptors for Test Points x4

998/11060

400mm Test Hose 90Â° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

892/00280

Pressure Gauge 0-600 bar (0-9000 lbf/in2)

892/00279

Pressure Gauge 0-400 bar (0-6000 lbf/in2)

892/00346

Pressure Gauge 0-70 bar (0-1000 lbf/in2)

892/00347

Connector

892/00254

Hose

Fig 45. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 46. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

Fig 47. Hydraulic Circuit Test Gauges and Connections

1-4-18

9803/9970-01 (1-06-00)

1-4-18

Section 1-4 - General Informtion Service Tools Tool Detail Reference 892/00223

Hand Pump

892/00137

Micro-bore Hose 1/4 in BSP x 3 metres

892/00274

Adapter 1/4 in M BSP x 3/8 in M BSP Taper

892/00262

1/4 in M BSP x 1/4 in F BSP x Test Point

892/00706

Test Probe

892/00278

Gauge 0 - 40 bar (0 - 600 lbf/in2)

892/00279

Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Fig 48. Hand Pump Equipment

Fig 49. 892/00318 Hose and Adapter Kit To enable flow and pressure test equipment to be connected to adapters fitted with `O' ring face seals. 1

992/09000

Peg spanner for piston head of front hitch ram (including 2 pairs of pegs)

992/09003

Replacement pegs for 7.5 mm holes

992/09004

Replacement pegs for 10 mm holes

Fig 50.

1-4-19

9803/9970-01 (1-06-00)

1-4-19

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Section F - Transmission 892/00812

PTO coupling spanner for yoke type couplings.

Fig 51. Heavy duty sockets 892/00817

17 mm A/F x 3/4in. square drive

892/00818

22 mm A/F x 3/4in. square drive

892/00819

15 mm A/F x 1/2in. square drive

892/00333

19 mm A/F x 3/4in. square drive

892/00174

Measuring cup - axle pinion head bearing

Fig 52.

Fig 53.

2 C

3 4

892/00918

Solid spacer setting kit comprising:

Sleeve for M24 pinion

Adaptor for M30 pinion

Fork

892/00945

Sleeve for M30 pinion

997/11100

Adaptor for M24 pinion

993/70111

Break back torque wrench

Solid spacer - see JCB parts system for correct part number 997/11000

Drive head setting bracket

Fig 54.

1-4-20

9803/9970-01 (1-06-00)

1-4-20

Section 1-4 - General Informtion Service Tools Tool Detail Reference 892/00864

PD90 axle locknut spanner

Fig 55.

1-4-21

9803/9970-01 (1-06-00)

1-4-21

Section 1-4 - General Informtion Service Tools Tool Detail Reference

5 1 6

8, 9

2 3 4

15 19,20 13 14 16

C 18 17 21

Fig 56. 892/01092 Wheel Hub Service Kit A

Bearing Puller

Bearing Press

Seal Dolly Comprises of:

998/10623

Puller beam - 1off

998/1067

Clamp plates - 1off

1315/3731Z

Bolt M16 x 220 - 2off

1370/0601Z

Nut M16 - 2off

998/10614

Reaction tube - 1off

998/10624

Modified wheel stud - 2off

1-4-22

9803/9970-01 (1-06-00)

1-4-22

Section 1-4 - General Informtion Service Tools Tool Detail Reference 7

998/10615

Puller leg - 2off

1370/10701Z

Nut M20 - 4off

1420/0012Z

Washer M20

998/10610

Rod - 2off

1370/0401Z

Nut M12 - 2off

1420/0009Z

Washer M12 - 2off

998/10608

Bearing centre puller- 1off

1315/3414Z

Bolt M10 x 60 - 1off

1370/0301Z

Nut M10 - 1off

998/10606

Reaction tube - 1off

998/10616

Handle nut - 1off

1315/3835Z

Bolt M20 x 300 - 2off

445/12303

Washer - 2off

917/02800

Bearing - 1off

892/00891

Seal dolly - 1off

Section G - Brakes 892/00311

Brake Test Kit 3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in2) 3 x 5 Metre Hoses with Quick Release Adapters 3 x ISO Test Point Adapters

Fig 57.

1-4-23

9803/9970-01 (1-06-00)

1-4-23

Section 1-4 - General Informtion Service Tools Tool Detail Reference

Section S - Suspension 892/00314

Accumulator and Gas Spring Pressure Test Adapter

Fig 58.

892/00918

Pulller adaptercomprising:

892/00871

Frame

892/00874

Brace

C 892/00875

Bar (2 off)

D 892/00876

Block (2 off)

1370/0901Z Nut M24 (2 off)

Use with a 20 tonne hydraulic ram for use with puller bars at 185 mm centres.

Fig 59.

1-4-24

9803/9970-01 (1-06-00)

1-4-24

Section 1-5 - General Informtion Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_4

Table 13. Type

Description

JCB Multi-Gasket

A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB High Strength Threadlocker

A high strength locking fluid for use with threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0601

10 ml

4101/0651

50 ml

A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

A cleaning primer which speeds the curing rate of anaerobic products.

4104/0251

200 ml (Aerosol)

4104/0253

1 ltr (Bottle)

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

400 ml (Aerosol)

Direct Glazing Kit

For one pane of glass; comprises of:

993/55700

JCB Threadlocker and Sealer

Part No.

Quantity

– 1 x Ultra Fast Adhesive (310 ml) – 1 x Active Wipe 205 (30 ml) – 1 x Black Primer 206J (30 ml) – plus applicator nozzle etc. Ultra Fast Adhesive

For direct glazing.

4103/2109

310 ml

Active Wipe 205

For direct glazing.

4104/1203

250 ml

Black Primer 206J

For direct glazing.

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass.

4102/0901

Plastic to Metal Bonder

To seal plastic to metal joints.

4103/0956

50 g

Black Polyurethane Sealant

To finish exposed edges of laminated glass.

4102/2309

310 ml

1-5-1

9803/9970-01 (1-07-00)

1-5-1

Section 1-5 - General Informtion Service Consumables Sealing and Retaining Compounds

Page left intentionally blank

1-5-2

9803/9970-01 (1-07-00)

1-5-2

Section 2 Care and Safety Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section 2 - Care and Safety

Notes:

2-0

9803/9970-01

2-0

Section 2 - Care and Safety Contents Page No. Safety First Important Information ............................................................................. 2-1-1 Safety Check List .................................................................................... 2-1-2 General Procedures Introduction ............................................................................................. 2-2-1 Health and Safety ................................................................................... 2-2-2 Parking the Machine and Making it Safe ................................................ 2-2-6 Releasing the Hydraulic Pressure .......................................................... 2-2-7 Carrying Tools onto the Machine ............................................................ 2-2-8 Connecting/Disconnecting Hydraulic Hoses ........................................... 2-2-9 Quick Release Couplings ..................................................................... 2-2-10 Hydraulic Contamination ...................................................................... 2-2-12 Battery Disconnection/Connection ....................................................... 2-2-14 Removing and Replacing Components ................................................ 2-2-15 Battery Charging System Precautions .................................................. 2-2-16 Hydraulic Rams .................................................................................... 2-2-17

2-i

Section 2 - Care and Safety Contents

2-ii

Page No.

2-ii

Section 2-1 - Care and Safety

Safety First Important Information T1-015

The Operator Manual

Safety Warnings

!MWARNING Study the Operator Manual before starting the machine. You must understand and follow the instructions in the Operator Manual. You must observe all relevant laws and regulations. If you are unsure about anything, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured. INT-1-1-1_2

This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefuly read the message that follows, and inform other operators. In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

Do not operate the machine without an Operator Manual. Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable.

!MDANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1

!MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2

!MCAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3

2-1-1

9803/9970-01 (2-01-00)

2-1-1

Section 2-1 - Care and Safety Safety First Safety Check List

Safety Check List Safety - Yours and Others

General Safety INT-1-3-1_3

All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

!MWARNING

T1-007_3

Operator Manual You and others can be injured if you operate or maintain the machine without first studying the Operator Manual. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB dealer to explain it. Keep the Operator Manual clean and in good condition. Do not operate the machine without an Operator Manual in the cab, or if there is anything on the machine you do not understand. INT-1-3-2_2

!MWARNING

Do not work with the machine until you are sure that you can control it.

Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.

Do not start any job until you are sure that you and those around you will be safe.

INT-1-3-5

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE

!MWARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. INT-1-3-6

!MWARNING Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness. INT-1-3-9_2

2-1-2

9803/9970-01 (2-01-00)

2-1-2

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

!MDANGER

Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with.

Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. 5-1-1-2

8-1-2-4

!MWARNING

!MWARNING Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.

Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor. INT-1-3-10_2

Switch off and do not use your mobile phone when refuelling the machine. INT-3-3-9

!MWARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

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

!MWARNING Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. INT-3-3-7_1

2-1-3

9803/9970-01 (2-01-00)

2-1-3

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

Operating Safety

!MWARNING Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine. INT-2-1-2_2

You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_6

!MWARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-4

!MWARNING

!MWARNING Work Sites Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures. INT-2-2-1

Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. INT-2-1-5

!MWARNING The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open.

!MWARNING Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. INT-2-2-3

5-2-6-5

!MWARNING

!MWARNING Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once and get into fresh air. INT-2-1-10_2

Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly. INT-2-2-4_2

!MWARNING Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse. INT-2-2-5

2-1-4

9803/9970-01 (2-01-00)

2-1-4

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.

Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.

INT-2-2-6

INT-2-1-1

!MWARNING

Safety Barriers Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away.

Reversing Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions.

INT-2-2-8

INT-2-2-9_1

!MDANGER

!MWARNING

Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris.

INT-2-2-10

!MWARNING

5-3-1-12_3

Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor.

!MWARNING Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine. 2-2-3-6

!MWARNING

INT-2-1-14

!MCAUTION Regulations Obey all laws, work site and local regulations which affect you and your machine. INT-1-3-3

Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean. Do not operate the machine if you cannot see clearly. 5-1-4-7

2-1-5

9803/9970-01 (2-01-00)

2-1-5

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

Electrical Power Cables You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables.

Starting/Using the Machine Start only from the operator's seat, with the transmission in neutral. Make sure everyone is clear of the machine before starting or using the machine. 13-2-3_13

You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines.

!MWARNING Do not start the machine until all shields are in place.

Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site.

13-2-3-12

!MWARNING

There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.

Starting/Using the Machine Reduce speed when towing or operating around hazards, on rough ground or steep slopes.

2-2-5-4

13-2-3_14

!MCAUTION

!MWARNING

If you have an attachment which is not covered in the Operator Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed.

Keep Your Hands and Feet Inside the Vehicle When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within the operator compartment while the vehicle is in motion.

5-5-1-1_2

13-1-1-17

!MWARNING

Use only the JCB approved attachments that are specified for your machine. Operating with nonspecified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.

Controls You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated in the machine. 0179

The use of non-approved attachments could invalidate your warranty.

!MWARNING

2-4-5-2_1

!MWARNING Seat Belt Operating the machine without a seat belt can be dangerous. Before starting the engine, make sure your seat belt is fastened. Check the tightness and condition of the seat belt securing bolts regularly (see maintenance schedules). INT-2-1-8_1

Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use selfcontained breathing apparatus. INT-3-2-7_2

2-1-6

9803/9970-01 (2-01-00)

2-1-6

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.

Be aware of the load the machine is carrying or towing and the speed at which you are travelling. Do not corner fast when carrying heavy mounted implements or towing trailers. Reduce speed when towing nonsuspended implements on rough ground. (Consult the implement operator's manual for recommended transport speeds).

INT-2-1-12

!MWARNING

13-2-2-1_1

Passengers Ensure that passengers use the seat provided in the cab. Passengers must not be carried on the rear deck of the vehicle under any circumstances. 13-1-1-1_1

!MWARNING Ensure that any load carried on the rear deck of the machine is firmly secured. 13-1-1-10

!MDANGER The JCB Fastrac is capable of operating at high speeds. Implements or trailers you tow behind the Fastrac may not be designed for high speed operation. BE AWARE of the manufacturer's specified maximum speed rating for any trailers or implements that you tow behind the Fastrac. DO NOT EXCEED THE MAXIMUM DESIGN SPEED OF TRAILERS OR IMPLEMENTS AS INJURY OR DEATH MAY RESULT. 13-2-3-5

!MWARNING The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle. 13-1-1-11_1

!MWARNING Certain tyres fitted as after-market/optional equipment may have maximum permitted speeds below the maximum speed of the vehicle. Brake efficiency is slightly reduced and stopping distance is increased when these tyres are fitted. They will suffer damage if operated at speeds higher than those recommended and may endanger life.

!MWARNING Hitching Trailers and Equipment When the vehicle is approaching a trailer or equipment to be hitched, make sure that no persons are present between vehicle and trailer or equipment. When mounting equipment at the rear of the vehicle, you must ensure that proper steering control is maintained. The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle. 13-1-1-13_1

!MWARNING

13-3-2-5

!MWARNING You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres fitted and do not operate at more than their recommended maximum speed.

Dragged or towed loads should be hitched only to the drawbar. Hitching loads to any other part of the machine can cause machine instability. We recommend that a safety chain is used between the tractor and the implement, as detailed in this manual. 13-2-3-10

!MWARNING

13-2-1-2

Make sure all drawbar pins are properly fitted otherwise an implement or trailer could become detached and cause injury and damage. 13-1-1-30

2-1-7

9803/9970-01 (2-01-00)

2-1-7

Section 2-1 - Care and Safety Safety First Safety Check List

!MCAUTION

Leaving the cab

Trailers with single line hydraulic brakes used in the United Kingdom are subject to a maximum speed of 20 mph (32 kph).

Attempting to attach or detach an implement to or from a PTO shaft or

Working on or cleaning an implement connected to the machine via a PTO shaft.

13-2-2-8

!MCAUTION Trailers with single line air brakes used in the Republic of Germany are subject to a maximum speed of 25 km/ h (15 mph). 13-2-2-13

Always ensure that the PTO shaft and driveline are fully guarded before use. When using stationary PTO equipment, ensure that the park brake is applied. 13-2-1-6

!MWARNING Brakes Do not coast the machine with the engine stopped as the main brakes will only operate for a limited number of applications and trailer brakes may not function at all. Also the steering will become very heavy. 13-1-1-5_2

!MWARNING If the PTO becomes jammed, disengage the PTO, stop the engine and clear the blockage. Wait until the PTO shaft stops before working on the equipment. If the PTO clutch slips, immediately disengage the PTO and stop the engine. 13-2-2-2

!MWARNING When driving the machine on the road, use the accelerator pedal and not the hand throttle to control the engine speed. Always set the hand throttle to 'idle' before using the accelerator pedal.

!MCAUTION Do not use an external PTO button or a joystick button for an emergency PTO stop. 13-3-2-32

13-2-1-8_1

!MWARNING

!MWARNING When driving the machine on the road with an implement or trailer connected to the machine, the transport locks must be engaged to prevent unintentional operation of electronic linkage, front and rear PTO or external hydraulics.

When you hear an audible warning, stop the machine as soon as possible. Get the fault put right before using the machine again. 13-2-1-9

!MWARNING

13-2-4-13

!MWARNING When operating PTO equipment, always observe the following safety precautions:

The cab air filter is designed to remove dirt from the outside air. When using chemicals (e.g. for crop spraying) follow the chemical manufacturer's recommendations for protection from dangerous chemicals. 13-2-3-6

Follow the instructions in the implement Operator Manual. Rotating equipment is dangerous. Do not wear loose fitting clothing when working close to rotating shafts. Always disengage the PTO, stop the engine and wait until the equipment stops, before:

2-1-8

9803/9970-01 (2-01-00)

2-1-8

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

Maintenance Safety

Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. INT-2-1-7_1

!MDANGER Leaving the machine in gear will not prevent it running away. Do not leave the driving seat under any circumstances unless the park brake is on.

!MWARNING Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. INT-3-1-5

!MWARNING

13-2-1-10

!MWARNING The exhaust pipe becomes extremely hot when the engine is running and will remain so for some time after the engine is stopped. If you touch the hot pipe you could be severely burned. 13-2-4-11

Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. GEN-1-5_2

!MWARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses. INT-3-1-3_2

!MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14

2-1-9

9803/9970-01 (2-01-00)

2-1-9

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.

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.

0125

!MWARNING

INT-3-1-10_3

Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8

!MDANGER

!MWARNING 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. INT-3-1-11_2

Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1_3

!MWARNING

!MWARNING Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours. INT-3-1-6

Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first.

!MWARNING Diesel Fuel Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions. INT-3-2-2_1

INT-3-1-9

2-1-10

9803/9970-01 (2-01-00)

2-1-10

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

!MCAUTION

Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

Rams The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion. INT-3-2-10

!MCAUTION

INT-3-2-3

!MCAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants. Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. INT-3-2-14

!MWARNING

INT-3-2-11

!MWARNING When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions. GEN-1-9

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4

!MWARNING Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. INT-3-2-9_1

!MWARNING

!MCAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. INT-3-2-12

!MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: – Damaged hose ends

Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out. GEN-6-2

Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

– Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings. INT-3-3-2

2-1-11

9803/9970-01 (2-01-00)

2-1-11

Section 2-1 - Care and Safety Safety First Safety Check List

!MCAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

Thoroughly wash contaminated detergent and water.

Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

Working Under the Machine Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery.

with

DO NOT BURN FLUOROELASTOMERIC MATERIALS. INT-3-3-5_3

!MWARNING

5-3-1-9

!MWARNING

area

Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks. GEN-1-12

!MWARNING

INT-3-3-8_2

To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.

!MWARNING Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

HYD-1-3_2

!MWARNING

New fluoroelastomeric components at ambient temperature require no special safety precautions.

Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements.

Used fluoroelastomeric components whose temperatures have not exceeded 300째C (572째F) require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA.

If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components.

Used fluoroelastomeric components subjected to temperatures greater than 300째C (572째F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:

Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.

Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable no more than 0.6 metres (2 feet) from the part being welded. INT-3-1-15_2

2-1-12

9803/9970-01 (2-01-00)

2-1-12

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure.

Wheels and tyres are heavy. Take care when lifting or moving them.

0094

Store with care to ensure that they cannot fall and cause injury. 13-3-1-7_1

!MWARNING Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic fluid or gas may cause injury.

!MWARNING You can be killed or injured by moving machinery. Wait for all movement to stop before servicing machinery. 13-3-2-3

!MWARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.

INT-3-1-17

!MWARNING Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.

13-3-2-16

!MWARNING

0147_1

!MWARNING An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work.

The injector solenoids receive high voltage when the engine is operating. To reduce the possibility of personal injury from electrical shock, do not wear jewellery or damp clothing, and do not touch the injector solenoids or the solenoid wires when the engine is operating. GEN-1-19

2-3-2-7_2

!MWARNING

!MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it.

The transmission is in 4 wheel drive until de-selected by hydraulic pressure to 2 wheel drive. If the machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only the rear wheels were raised, the machine could still drive through the front axle. TRANS-8-5

!MCAUTION

INT-3-2-8

!MWARNING Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine.

Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth. 8-3-4-8

INT-3-1-16

2-1-13

9803/9970-01 (2-01-00)

2-1-13

Section 2-1 - Care and Safety Safety First Safety Check List

!MWARNING

Radar Speed Sensor (if fitted) To avoid possible eye damage from microwave signals do not look directly into the sensor face.

When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned.

13-1-1-15

13-3-2-15

Note: For radar speed sensor locationl.

!MWARNING Upon completion of any work on the brake system of machines fitted with ABS, the ABS test within Servicemaster must be run satisfactorily before the machine is driven. It is not sufficient to rely on the ABS self-check which can only check for the presence of components, not that they are correctly installed. 0091

!MWARNING Always renew brake pads and locating pins in complete axle sets, using genuine JCB parts, otherwise braking will be unsafe. 13-3-1-10

!MWARNING Before working on or around the brake system, always observe the following precautions: 1

Stop the engine and block all four wheels.

When the air system is being exhausted, keep hands away from the park brake actuator pushrod and caliper, as they may move and trap your fingers.

Take care if disconnecting an air hose containing pressure as it may whip as air escapes.

Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures.

BRAK-8-3_1

2-1-14

9803/9970-01 (2-01-00)

2-1-14

Section 2-2 - Care and Safety

General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are; parking the machine and making it safe, and venting hydraulic pressure. These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a cross reference to this section so that you can refer to the detailed procedures.

K Health and Safety ( T 2-2-2) K Parking the Machine and Making it Safe ( T 2-2-6) K Releasing the Hydraulic Pressure ( T 2-2-7) K Carrying Tools onto the Machine ( T 2-2-8) K Connecting/Disconnecting Hydraulic Hoses ( T 2-2-9) K Introduction ( T 2-2-9) K Connecting the Hoses ( T 2-2-9) K Disconnecting the Hoses ( T 2-2-9) K Quick Release Couplings ( T 2-2-10) K Hydraulic Contamination ( T 2-2-12) K Hydraulic Fluid Quality ( T 2-2-12) K Effects of Contamination ( T 2-2-12) K Cleaning Operation ( T 2-2-12) K Contaminant Standards ( T 2-2-13) K Filters ( T 2-2-13) K Battery Disconnection/Connection ( T 2-2-14) K Disconnection ( T 2-2-14) K Connection ( T 2-2-14) K Removing and Replacing Components ( T 2-2-15) K Battery Charging System Precautions ( T 2-2-16) K Hydraulic Rams ( T 2-2-17) K Installation ( T 2-2-17) K Caution During Use ( T 2-2-17) K Maintenance, Inspection Points ( T 2-2-17)

2-2-1

9803/9970-01 (2-02-00)

2-2-1

Section 2-2 - Care and Safety General Procedures Health and Safety

Health and Safety Lubricants T3-060_2

Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too.

Hygiene JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

The collection and disposal of used oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

Handling

!MWARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3

Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices. Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1

Avoid prolonged, excessive or repeated skin contact with used oil.

Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin:

Waste Disposal

b Using a nail brush will help. c

INT-3-2-14

All waste products should be disposed of in accordance with all the relevant regulations.

2-2-2

Wash your skin thoroughly with soap and water.

Use special hand cleansers to help clean dirty hands.

d Never use petrol, diesel fuel, or paraffin for washing.

9803/9970-01 (2-02-00)

2-2-2

Section 2-2 - Care and Safety General Procedures Health and Safety 3

Avoid skin contact with oil soaked clothing.

Don't keep oily rags in pockets.

Wash dirty clothing before re-use.

Throw away oil-soaked shoes.

First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice. Skin In the case of excessive skin contact, wash with soap and water.

Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Fires

!MWARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus. 7-3-1-3_1

2-2-3

9803/9970-01 (2-02-00)

2-2-3

Section 2-2 - Care and Safety General Procedures Health and Safety

!MCAUTION

Battery T3-061

!MWARNING

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.

Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12

!MWARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8

Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14

!MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4

!MDANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1_3

2-2-4

9803/9970-01 (2-02-00)

2-2-4

Section 2-2 - Care and Safety General Procedures Health and Safety Warning Symbols

First Aid - Electrolyte

The following warning symbols may be found on the battery.

Do the following if electrolyte: Gets into your eyes

Symbol

Meaning

Immediately flush with water for 15 minutes, always get medical help.

Keep away from children.

Is swallowed A289230-1

Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

Shield eyes.

Gets onto your skin

A289260-1

No smoking, no naked flames, no sparks. Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

2-2-5

9803/9970-01 (2-02-00)

2-2-5

Section 2-2 - Care and Safety General Procedures Parking the Machine and Making it Safe

Parking the Machine and Making it Safe 1

Position the machine on firm level ground. If possible choose an area that is clean and dry. When possible park the machine in a covered area if procedures include work on the hydraulic or fuel systems.

Lower attachments to the ground and if necessary, remove them. Refer to the correct documents and procedures.

Stop the engine and apply the park brake.

Remove the starter key.

Let the machine cool sufficiently before you do work on, or near to, the engine or hydraulic system.

If procedures include work on the electrical system disconnect the battery. K Battery Disconnection/ Connection ( T 2-2-14)

!MWARNING Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and remove the starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels before getting under the machine. 3-3-1-1

INT-3-1-5 C097190

Fig 1.

!MWARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground.

A JCB Service Master diagnostic socket is mounted below the arm rest. This socket is for use by authorised persons for the connection of the Service Master data link only. The use of the socket for any other purpose could damage the machine.

To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. 8-3-1-1

2-2-6

9803/9970-01 (2-02-00)

2-2-6

Section 2-2 - Care and Safety General Procedures Releasing the Hydraulic Pressure

Releasing the Hydraulic Pressure

!MWARNING Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, select float on the relevant external hydraulics control with engiine running, then switch off the engine. Make sure the engine cannot be started while hoses are open. 13-3-2-14

2-2-7

9803/9970-01 (2-02-00)

2-2-7

Section 2-2 - Care and Safety General Procedures Carrying Tools onto the Machine

Carrying Tools onto the Machine When you carry tools onto the machine you must maintain three points of contact with the machine at all times. Lift tools onto the machine in intervals if necessary. Place the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.

2-2-8

9803/9970-01 (2-02-00)

2-2-8

Section 2-2 - Care and Safety General Procedures Connecting/Disconnecting Hydraulic Hoses

Connecting/Disconnecting Hydraulic Hoses Introduction

The following paragraphs describe how to connect and disconnect hydraulic hoses safely.

b For all other hose connections, plug both sides of the connection to prevent loss of fluid.

Connecting the Hoses 1

Connect the hoses. a

For Quick Release Couplings see the procedures Release in this section. K Quick Couplings ( T 2-2-10)

Check for leaks. See step 2, K Connecting the Hoses ( T 2-2-9)

For Quick Release Couplings refer to the correct data. K Quick Release Couplings ( T 2-2-10)

b For all other hose connections, use correct tools and ensure that connections are not crossthreaded. Support the weight of the hose until the connection is made. Do not exceed the recommended torque loading.

!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

Check for leaks as follows: a

Start the engine.

b Operate the controls to pressurise the required hose. c

Switch off the engine. Remove the starter key. Check for signs of leakage at the hose connections.

Disconnecting the Hoses 1

Vent the hydraulic pressure as described on this page.

Disconnect the hoses.

2-2-9

9803/9970-01 (2-02-00)

2-2-9

Section 2-2 - Care and Safety General Procedures Quick Release Couplings

Quick Release Couplings T4-001_2

Connecting and Disconnecting

wedge underneath the sleeve and destroy the coupling.

Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will be fitted with a female coupling A and a male coupling B. The optional attachment hoses will also be fitted with a female coupling A and a male coupling B. K Fig 2. ( T 2-2-11). The quick release couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly. The recommendations listed below should always apply when using flat face quick release couplings. Finally, please read the correct fitting and releasing procedures before installing or removing any optional attachment fitted with quick release couplings.

– Don't damage the faces of the couplings - this can prevent connection and disconnection, or damage seals and cause leakage. – Don't try to dismantle the couplings - they are non serviceable parts. If a coupling is damaged it should be replaced with a new one.

!MWARNING Hydraulic fluid at pressure can injure you. Make the machine safe before connecting or disconnecting quick release couplings; stop the engine and then operate the attachment control a few times to vent residual hydraulic pressure in the attachment hoses. 2-4-1-11

!MWARNING

Quick Release Couplings - Do's and Don'ts – Do wipe the two faces of the coupling and make sure they are clean before connecting. – Do make sure the outside sleeve (female coupling) is pulled back when disconnecting. – Do connect and disconnect a new coupling two or three times to 'work' the PTFE seals - sometimes a new coupling will stick if the seals have not been 'worked'. – Do use a spanner on the hexagon flats of the coupling when fitting adaptors.

The external surfaces of the couplings must be clean before connecting or disconnecting. Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or seriously injured by faulty Quick Release Couplings. 2-4-1-15

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.

– Do use a rubber or hide hammer to disconnect a coupling if it sticks - sticking may occur if there is dirt present in the coupling. – Don't attempt to re-connect a damaged half coupling - this will destroy the seals and necessitate replacing both half couplings. – Don't leave the coupling where it may be run over by a machine or otherwise crushed - this will distort the coupling sleeve and prevent correct connection and disconnection. – Don't clamp on the smooth diameter of the coupling when fitting adaptors - always use the hexagon. – Don't try to turn the sleeve (female coupling) when the coupling has been disconnected - the locking ball will

2-2-10

9803/9970-01 (2-02-00)

2-2-10

Section 2-2 - Care and Safety General Procedures Quick Release Couplings Connecting Quick Release Couplings 1

Remove any residual hydraulic pressure trapped in the service line hose.

Wipe the two faces of the male and female couplings and make sure they are clean.

Make sure that ball 2-C in the female coupling is located in one of its slots.

Fit the male coupling into the female coupling; To ensure that the coupling is not accidentally released, rotate sleeve 2-E half a turn and make sure that the locking ball 2-C does not align with the slot 2-D.

Disconnecting Quick Release Couplings 1

Remove any residual hydraulic pressure trapped in the service line hose.

Align the slot 2-D with ball 2-C.

Pull back sleeve 2-E to release the coupling.

Fig 2.

2-2-11

9803/9970-01 (2-02-00)

2-2-11

Section 2-2 - Care and Safety General Procedures Hydraulic Contamination

Hydraulic Contamination TE-002_3

Hydraulic Fluid Quality

Procedure

This machine uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing. According to a survey conducted by a pump manufacturer, seventy per cent of the causes of problems in hydraulic equipment were attributable to inadequate maintenance of the quality of the hydraulic fluid. Therefore, it is obvious that control of the quality of the hydraulic fluid helps prevent hydraulic equipment problems and greatly improves safety and reliability. Furthermore from an economic angle it extends the life of the hydraulic fluid if quality is maintained.

Connect the cleaning unit in place of the hydraulic filter. K Fig 3. ( T 2-2-12). Run the system for sufficient time to pump all the hydraulic fluid through the unit. Disconnect the cleaning unit and reconnect the filter. Top up the system with clean hydraulic fluid as required.

Effects of Contamination Once inside the system, hydraulic circuit contaminants greatly effect the performance and life of hydraulic equipment. For example, contaminants in a hydraulic pump develop internal wear to cause internal leakage and hence lower discharges. Wear particles generated will circulate with the hydraulic fluid to cause further deterioration in the performance of this and other equipment. Contaminants also enter principal sliding sections of the equipment causing temporary malfunction, scuffing, sticking and leakage and can lead to major problems.The main contaminants can be classified as follows: 1

Solid Particles - sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.

Liquid - usually water and incompatible oils and greases.

Gases - Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid.

S168050-1

Fig 3. Cleaning Unit

These contaminants can appear during manufacture, assembly and operation.

Cleaning Operation The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a cleaning unit. K Fig 3. ( T 2-2-12). General Bulletin 011 also refers.

2-2-12

9803/9970-01 (2-02-00)

2-2-12

Section 2-2 - Care and Safety General Procedures Hydraulic Contamination

Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns. 1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: â&#x20AC;&#x201C; Red Blood Cell = 8 microns (0.008 mm, 0.000315 in) â&#x20AC;&#x201C; Human Hair = 70 microns (0.07 mm, 0.00275 in) â&#x20AC;&#x201C; Grain of Salt = 100 microns (0.1 mm, 0.00394 in) Smallest particle visible to the naked eye is 40 microns (0.00157) approximately. Standards will often be quoted to ISO (International Standards Organisation) for which literature can be obtained.

Filters The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated through use to the required level of cleanliness. The filter must be serviced to the requirements of the machine Service Schedules. To ensure optimum performance and reliability it is important that the machines hydraulic system is serviced periodically in accordance with the manufacturers requirements.

2-2-13

9803/9970-01 (2-02-00)

2-2-13

Section 2-2 - Care and Safety General Procedures Battery Disconnection/Connection

Battery Disconnection/Connection

!MWARNING Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned. 5-2-2-4

Disconnection 1

Get access to the battery. See Section C.

Remove the leads. Disconnect the earth (-) terminal first.

Connection 1

Check the battery. a

If the terminal is dirty, clean the post.

797650

Fig 4. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper. c

After cleaning, apply a thin coat of petroleum jelly to the terminal.

Re-connect the leads. Connect the earth (-) terminal last.

Close and lock the access panels.

2-2-14

9803/9970-01 (2-02-00)

2-2-14

Section 2-2 - Care and Safety General Procedures Removing and Replacing Components

Removing and Replacing Components Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt.

2-2-15

9803/9970-01 (2-02-00)

2-2-15

Section 2-2 - Care and Safety General Procedures Battery Charging System Precautions

Battery Charging System Precautions Obey the procedures below to prevent damage to the alternator and battery. 1

Ensure that the battery negative terminal is connected to the earthing cable.

Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes.

Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator.

When arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables).

If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The slave battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.

2-2-16

9803/9970-01 (2-02-00)

2-2-16

Section 2-2 - Care and Safety General Procedures Hydraulic Rams

Hydraulic Rams Installation 1

Precautions when installing the ram on the machine. a

When installing and removing from the machine, suspend the ram safely.

When painting the machine, mask the ram. a

Secure the piston rod with a band. It is very dangerous if the rod extends unexpectedly. Also, the rod can be damaged and become unusable.

If electric welding is done even at a point away from the ram, there may be sparking inside the ram and it will become necessary to replace the ram with a new one.

Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder.

When stopping or storing, do it at a safe and fixed position. a

If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly and foreign matter and paint can easily enter the ram. This will cause damage to the seals, drastically shortening the life of the ram.

In cold conditions the rod seals may be frozen, so if the ram is operated at maximum pressure and maximum speed, the seals will be damaged.

b There is a large amount of air in a new ram or one which has been left for a long time, so the ram will not operate smoothly. Also, if pressure is applied suddenly without bleeding the air, high temperatures will be generated due to adiabatic compression and the seals may burn.

Welding after installing the ram may result in damage. a

Warm up sufficiently before beginning work. a

b Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder.

The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod.

The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools. Stop or store the machine in a safe and fixed position.

Maintenance, Inspection Points

Install the ram only when it is clean. 1

Carry out daily maintenance and inspection.

Caution During Use a 1

Use only under designated conditions. a

If hydraulic oil other than the designated oil is used, the seals quickly degenerate and become damaged. If the relief valve is set at a value higher than specified, it may cause ram damage and is dangerous.

b In high temperature environments (approx. 90Â°C and above) or low temperature environments (below -20Â°C), seals quickly become damaged. Special seal materials are necessary so check to see if the ram that you are using is suitable or not. 2

2-2-17

The key point for correct long-term ram function is daily maintenance and inspection. Carry out maintenance and inspection so that the ram functions fully at all times. Always remove any mud, water, dust or oil film adhering to the rod and keep it in normal condition. However, when cleaning the wiper ring and seals, do not get them wet with water but wipe clean with a rag. To prevent rust forming during storage, the amount of exposed ram piston rod should be kept to a minimum. If leaving for more than one week, apply a light coating of suitable grease or petroleum jelly to the exposed part of the ram piston rod.

Use genuine JCB parts when replacing parts.

9803/9970-01 (2-02-00)

2-2-17

Section 2-2 - Care and Safety General Procedures Hydraulic Rams a

If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts.

Caution during dismantling and reassembly. a

Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur. Remove the ram from the machine and then dismantle.

b If reassembled with dirty hands, foreign matter can enter the ram causing a shorter life span and also the other hydraulic equipment may be damaged. Reassemble in a clean state. c

Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low, it can cause damage.

2-2-18

9803/9970-01 (2-02-00)

2-2-18

Section 3 Routine Maintenance Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section 3 - Routine Maintenance

Notes:

3-0

9803/9970-01

3-0

Section 3 - Routine Maintenance Contents Page No. Routine Maintenance Introduction ................................................................................................ 3-1 Service Requirements ............................................................................... 3-2 Introduction ............................................................................................3-2 Owner/Operator Support .......................................................................3-2 Service/Maintenance Agreements ........................................................3-2 Initial Service and Inspection .................................................................3-2 Obtaining Replacement Parts ................................................................3-3 Service Schedules ..................................................................................... 3-4 Introduction ............................................................................................3-4 How to Use the Service Schedules .......................................................3-4 Calendar Equivalents ............................................................................3-4 Pre-start Cold Checks, Service Points and Fluid Levels .......................3-5 Functional Test and Final Inspection .....................................................3-9 Fluids, Lubricants and Capacities, Fuel ................................................... 3-11 Coolant Mixtures ................................................................................. 3-11 Fuel .....................................................................................................3-13 Cleaning the Machine .............................................................................. 3-15 Introduction ..........................................................................................3-15 Preparing the Machine for Cleaning ....................................................3-15 Cleaning the Machine ..........................................................................3-16 Checking for Damage .............................................................................. 3-18 Check the Machine Body and Structure ..............................................3-18 Check the Tyres ..................................................................................3-18 Check the Seat and Seat Belt .............................................................3-18 Check the Hydraulic Hoses and Fittings .............................................3-18 Checking the ROPS Structure .............................................................3-19 Greasing .................................................................................................. 3-20 Introduction ..........................................................................................3-20 Drive Shafts .........................................................................................3-21 Front Axle Steering Swivels .................................................................3-22 Agricultural Front 3-Point Linkage (Optional) ......................................3-23 Steering Column Universal Joints .......................................................3-24 Rear Suspension Cylinder Pivots ........................................................3-25 Hydraulic Lift and 3-Point Linkage .......................................................3-26 Rear PTO Drive Shaft Bearing ............................................................3-26 Automatic Trailer Coupling (if fitted) ....................................................3-27 Access Panels ......................................................................................... 3-28 Opening the Engine Cover ..................................................................3-28 Closing the Engine Cover ....................................................................3-28 Air Conditioning and Heater .................................................................... 3-29 Air Conditioning Filters ........................................................................3-29 Cleaning the Heater Filter ...................................................................3-31 Brakes ..................................................................................................... 3-32 Checking the Foot Brake Fluid Level ..................................................3-32 Checking the Trailer Air Tank ..............................................................3-32 Checking the Air Tank Warning Lights .................................................3-33 Checking and Renewing Foot Brake Pads ..........................................3-34 Testing the Park Brake ........................................................................3-36 Checking the Park Brake Pads ...........................................................3-37 Electrical .................................................................................................. 3-38 Battery .................................................................................................3-38 Jump-starting the Engine ....................................................................3-41 Checking the Beam Alignment ............................................................3-43 Fuses and Relays ................................................................................3-44

3-i

Section 3 - Routine Maintenance Contents

Contents Page No. Engine ..................................................................................................... 3-45 Checking the Oil Level ........................................................................3-45 Changing the Oil and Filter ..................................................................3-46 Checking the Coolant Level ................................................................3-48 Draining and Refilling the Coolant .......................................................3-49 Fan Belt ...............................................................................................3-51 Changing the Air Filter Elements .........................................................3-53 Fuel System ............................................................................................. 3-55 Introduction ..........................................................................................3-55 Draining the Fuel Pre-Filter .................................................................3-56 Changing the Fuel Pre-Filter Element .................................................3-57 Changing the Fuel Filter Element ........................................................3-58 Bleeding the Fuel System ...................................................................3-59 Hydraulic System ..................................................................................... 3-60 Introduction ..........................................................................................3-60 Checking the Fluid Level .....................................................................3-61 Changing the Filter Element ................................................................3-62 Changing the Hydraulic Fluid and Cleaning the Suction Strainers ......3-64 Coupling Drains ...................................................................................3-65 Transmission ........................................................................................... 3-66 Checking the Transmission Oil Level ..................................................3-66 Changing the Transmission Oil Filter ..................................................3-67 Changing the Transmission Oil and Cleaning the Strainer ..................3-68 Front Axle ............................................................................................3-70 Rear Axle .............................................................................................3-72 Tyres and Wheels .................................................................................... 3-74 General ................................................................................................3-74 Check the Tyres ..................................................................................3-74 Tyre Inflation ........................................................................................3-75 Wheel Nut Torques ..............................................................................3-76 Adjustable Track Width ........................................................................3-77 Lock Stops ...........................................................................................3-78 Checking and Adjusting the Front Wheel Alignment ...........................3-79 Fender Adjustment ..............................................................................3-81 Windscreen Washer ................................................................................ 3-82 Checking Fluid Level ...........................................................................3-82 Automatic Trailer Coupling (Optional) ..................................................... 3-83 Checking for Wear ...............................................................................3-83

3-ii

Routine Maintenance Introduction This topic contains the service schedules for the machine and the relevant procedures.

K Service Requirements ( T 2) K Service Schedules ( T 4) K Fluids, Lubricants and Capacities, Fuel ( T 11) K Cleaning the Machine ( T 15) K Checking for Damage ( T 18) K Greasing ( T 20) K Access Panels ( T 28) K Air Conditioning and Heater ( T 29) K Brakes ( T 32) K Electrical ( T 38) K Engine ( T 45) K Fuel System ( T 55) K Hydraulic System ( T 60) K Transmission ( T 66) K Tyres and Wheels ( T 74) K Windscreen Washer ( T 82) K Automatic Trailer Coupling (Optional) ( T 83)

9803/9970-01 (3-00)

Routine Maintenance Service Requirements

Service Requirements Introduction T3-095

Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals. This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency. A Service Manual for your machine is available from your JCB Distributor. The Service Manual contains information on how to repair, dismantle and assemble your machine correctly. It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently. JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine.

encounter a problem however, you should contact your Distributor's Service Department who are there to help you! You will have been given the names of the relevant service contacts at your Distributor when the machine was installed. To get the most from your Distributor please help them to satisfy you by: 1

Giving your name, address and telephone number.

Quoting your machine model and serial number.

Date of purchase and hours of work.

Nature of the problem.

Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Distributor is able to offer a variety of programmes covering Warranty, Fixed Price Servicing, Safety Inspections, including weight tests, covering both legal and insurance requirements.

Service/Maintenance Agreements To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB Distributor for details.

A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced. Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced.

Initial Service and Inspection T3-005_2

To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.

Owner/Operator Support JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do

9803/9970-01 (3-00)

Routine Maintenance Service Requirements

Obtaining Replacement Parts T3-096

If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure A Parts Book for your machine is available from your JCB Distributor. The Parts Book will help you identify parts and order them from your JCB distributor. Your dealer will need to know the exact model, build and serial number of your machine. See Identifying Your Machine (Introduction section). The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

9803/9970-01 (3-00)

Routine Maintenance Service Schedules

Service Schedules Introduction

How to Use the Service Schedules

!MWARNING

T3-036_3

Maintenance must be done only by suitably qualified and competent persons.

T3-012_4

In the example shown, A shows all service requirements to be carried out every 10 hours and B shows the requirements to be carried out every 500 hours.

Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground.

Important: Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. Refer to Calendar Equivalents.

To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured.

Important: The intervals given in the schedules must not be exceeded. If the machine is operated under severe conditions (high temperature, dust, water, etc.), shorten the intervals.

8-3-1-1

A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition. Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. When there is no hourmeter fitted, use the calendar equivalents to determine the service intervals. Refer to Calendar Equivalents. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

795390-1

Calendar Equivalents Every 10 Hours = Daily

T3-088

Every 50 Hours = Weekly Every 500 Hours = Six Months Every 1000 Hours = Yearly Every 2000 Hours = 2 Years Every 5000 Hours = 5 Years

9803/9970-01 (3-00)

Routine Maintenance Service Schedules

Pre-start Cold Checks, Service Points and Fluid Levels Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

ENGINE Oil level

- Check

Oil and Filter

Air Cleaner Outer Element Air Cleaner Inner Element

(3)

Air Cleaner Hose and Clamp Security

- Change - Check - Check

Air Compressor Discharge Lines(4)

- Check

Fuel Pre-filter

Fuel Filter

- Drain (3)

(3)

- Change

- Check

Coolant Antifreeze and Coolant Additive Concentration(4)

- Check

Coolant

- Check

(4)

- Check

Fan Belt Tensioner Condition(4)

- Check

Vibration Damper(4)

- Check

Valve Clearances(4)

- Check and Adjust

Crankcase Breather Tube

- Check

Engine Mounting Bolts for Tightness(4)

- Check

Fuel Injection Pump Mounting Bolts for Tightness(4)

- Check

Radiator and Coolers

- Clean

Charge Air Cooler Hose and Clamp Security

- Check

Charge Air Cooler

- Check

Turbocharger(4)

- Check

- Change

Fan Belt Condition

Engine

- Change

Coolant Level

Fan Hub

- Change

Air Compressor Mountings

(4)

Fuel Pre-filter

- Change

(2)(3)

- Steam Clean

9803/9970-01 (3-00)

Routine Maintenance Service Schedules Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

TRANSMISSION, AXLES AND STEERING Transmission Oil Level Transmission Oil

- Check

- Change

(5)

Transmission Strainer

- Clean

Transmission Filter

- Change

Clutch Fluid Level

- Check (6)

Axle Oil Level (incl. Hubs when applicable)

- Check

(7)

Axle Hub Oil

- Change

Axle Beam Oil

- Change

Tyre Pressures/Condition Oil Cooler and Pipework

- Check

- Check and Clean - Security/ Grease

Rear PTO Shaft Bearings

- Grease

Steer Axle Pivots

- Grease

Steering Column Universal Joints

- Grease

Drive Shafts (8)

Steering Axle Wheel Alignment

- Check

Pitman Arm, Drag Link, Track Rod End, Steering Ram and Damper Condition and Security(4)(9)

- Check

Wheel Nut Security

- Check

HYDRAULICS Oil Level Oil(4)

- Sample/ Change

Oil Filter

- Change

Hydraulic System Hydraulic Lift and 3 Point Linkage, Front and Rear Ram Piston Rods Condition Hydraulic Oil Cooler and Pipework

- Check for Leaks

- Check - Check and Clean - Clean

Hydraulic Coupling Drain Reservoir

- Empty

- Grease

Hydraulic Oil Strainer

9803/9970-01 (3-00)

Routine Maintenance Service Schedules Operation 10 Hr 50 Hr Security of Front Weight

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

- Check

- Drain

BRAKES Air System Tank Air System Drier Canister

(4)

- Change

Trailer Brake Control Line Air Filter(4)

- Clean

Brake System Fluid Level

- Check

Brake System Fluid

- Change

Park Brake

- Check and Adjust

Park Brake Pad Condition and Security

- Check

Service Brake Pad Condition and Security

- Check

Battery Electrolyte Level (if applicable)

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

Battery Charge Condition(4)

- Check

Headlamp Alignment

- Check

Calliper Bolt Torque

(4)

Pipework Security ELECTRICS

BODY AND FRAMEWORK Chassis Fabrication

- Visually Inspect for Damage

Seat Belt Condition and Security

- Check

Air Conditioning Condensor

- Clean

ROPS Structure(4)

- Check

Cab Air Intake Filter (standard type only)(10)

- Clean

Door Locks

- Check

Windscreen Washer Fluid Level

- Check

Condition of Paintwork

- Check

Machine Generally

- Check and Clean

9803/9970-01 (3-00)

Routine Maintenance Service Schedules Operation 10 Hr 50 Hr Automatic Trailer Coupling (if fitted)

- Grease

Roller Drawbar (if fitted)

- Grease

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

SUSPENSION Cylinder Pivots Panhard Rod Condition and Torque Tightness

(4)(9)

- Check

Rear Anti-roll Bar Condition and Torque Tightness(4)(9)

- Check

Control Arms Condition and Torque Tightness(4)

- Check

`V' Link Condition and Torque Tightness(4)

- Check

Accumulator Pressure(4)

- Check

Gas Spring Pressure(4)

- Check

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Applies only if recommended oil is available. If this is not available, this job should be carried out every 250 hours. See Fluids, Lubricants and Capacities for suitable alternative oil. (3) If the machine is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F], change engine oil and filter, air and fuel filters at shorter intervals. Shorter maintenance intervals are also required if the machine is operated in a dusty environment or if frequent stops are made. (4) Jobs which should only be done by a specialist. (5) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (6) Check for leaks every 50 hours, check level if leaking. (7) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted. (8) If working in muddy conditions the propshafts and PTO driveshafts must be greased daily. (9) After any of these items are refitted, recheck the torque tightness after a short road test. (10) Heavy duty carbon type filters must be changed at 250 hour intervals.

9803/9970-01 (3-00)

Routine Maintenance Service Schedules

Functional Test and Final Inspection Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

ENGINE - Check

Idle Speed(2) Maximum No Load Speed

- Check

(2)

Exhaust System Security

- Check

Exhaust Smoke (excessive)

- Check

Cooling System for Leaks

- Check

Fuel System for Leaks and Contamination

- Check

Lubrication System for Leaks

- Check

Stop Control

- Check

(2)

TRANSMISSION, AXLES AND STEERING 2WD/4WD/Differential Lock Selection

- Check

Oil Leakage

- Check

Transmission Lubrication Pressure

(2)

- Check

4WD/PTO Supply Pressure (2)

- Check

Differential Lock Pressure Relief Valve(2)

- Check

Neutral Start Operation

- Check

PTO Selection and Operation

- Check

Transmission Calibration(2)

- Check

Selection of Transmission Modes and Ranges

- Check

Steering Operation

- Check

Steering Pressure Relief Valve(2)

- Check

HYDRAULICS Maximum System Pressure(2)

- Check and Adjust

Operation All Services

- Check

System for Oil Leakage

- Check

Oil Cooler and Pipework for Damage or Leakage

- Check

BRAKES Foot Brake - Operation

- Check

Park Brake - Operation

- Check

9803/9970-01 (3-00)

Routine Maintenance Service Schedules Operation Air System Warning Lights ABS

10 Hr

50 Hr

- Check - System Test

(2)

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

ELECTRICS Starter Motor Alternator - Output

- Check - Check

(2)

All Electrical Equipment Operation, (e.g. warning lights, beacon, alarms, horn, wipers etc.)

- Check

Error Codes for all systems, Engine, ABS, Electronic Draft Control, Transmission(2)

- Download and Rectify

Machine Datalog(2)

- Download and Rectify

- Check

Brake Light Switch Input to ABS ECU using computer diagnostic tool(2) SUSPENSION Circuit Pressure(2) Axle to Chassis Clearance Ride Height Operation(2)

(2)

- Check - Check

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist.

9803/9970-01 (3-00)

Routine Maintenance Fluids, Lubricants and Capacities, Fuel

Fluids, Lubricants and Capacities, Fuel Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g.

ITEM

warming up without load). Whilst 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at temperatures below -5ºC (23ºF). Continued use of low viscosity oils can decrease engine life.

Table 1. CAPACITY FLUID/LUBRICANT Litres UK Gal

INTERNATIONAL SPECIFICATION

Fuel Tank

350

Diesel Oil

K Fuel ( T 13)

Engine (Oil)

17.5

3.9

JCB Engine Oil EP 15W/40

API CH-4 or ACEA E3/ B3A3, SAE15W/40

Engine (Coolant)

6.6

JCB High Performance Antifreeze & Inhibitor/ Water

ASTM D6210

Transmission

43.5

9.5

JCB Super Universal Agricultural Oil

API-GL-4, MIL-L-2105

4.4

JCB Gear Oil HP90

API-GL-5, MIL-L-2105C

JCB Gear Oil HP90

API-GL-5, MIL-L-2105C

JCB Brake Fluid Dot 4

SAE J1703 DOT 4

JCB Hydraulic Fluid HP46

ISO VG46

Front Axle - Housing - Hubs x2) Rear Axle

2.5

0.55

Brake System - Front

0.75

0.17

- Rear

0.75

0.17

120

26.4

Hydraulic System(1)

(Above 38ºC,100ºF) JCB Hydraulic Fluid HP32

ISO VG32

(Below 38ºC,100ºF) Grease Points

JCB HP Grease

Lithium complex NLGI No.2 consistency including extreme pressure additives

(1) The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank

Coolant Mixtures T3-009_3

Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period. Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.

!MWARNING Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.

de-ionized water. For further information advice on water hardness, contact your local water authority. The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. 50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F)

7-3-4-4_1

60% Concentration (Extreme Conditions Only) You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use

Protects against damage down to -56 °C (-68 °F)

9803/9970-01 (3-00)

Routine Maintenance Fluids, Lubricants and Capacities, Fuel Important: Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point. If you use any other brand of antifreeze: – Ensure that the antifreeze complies with International Specification ASTM D6210. – Always read and understand the manufacturer's instructions. – Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used. – Ensure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

9803/9970-01 (3-00)

Routine Maintenance Fluids, Lubricants and Capacities, Fuel

Fuel

Acceptable Fuel Specification T3-089

!MCAUTION

Use good quality diesel fuel to get the correct power and performance from your engine.

Recommended Fuel Specification – EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4.

The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also affect the engine performance. GEN-9-3

– BS2869 Class A2. – ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA.

– ASTM D975-91 Class 1-1DA.

– JIS K2204 (1992) Grades 1, 2, 3, and Special Grade 3.

– NATO F63.

Note: Where low sulphur/low aromatic fuels are used it is important that lubricity additives are used. The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. They have not been tested or approved by the engine manufacturer. They should be added by your fuel supplier who should understand the concentration level necessary.

– JP7, MIL T38219 XF63.

Sulphur Content

!MCAUTION A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel system when high sulphur fuels are used. ENG-3-2

Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels.

Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm.

Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%).

Table 2. Percentage of sulphur in Oil Change Interval the fuel (%) Less than 0.5

!MCAUTION Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. GEN-9-2

High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently.

Normal

0.5 to 1.0

0.75 of normal

More than 1.0

0.50 of normal

Aviation Kerosene Fuels Note: Aviation kerosene fuels are not approved and their use may cause damage to components. Warranty will not be allowed on any component where damage is found to have been caused by the use of aviation kerosene.

Low Temperature Fuels Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter.)

9803/9970-01 (3-00)

Routine Maintenance Fluids, Lubricants and Capacities, Fuel Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels Fuel resources such as Rape Methyl Ester and Soybean Methyl ester, collectively known as Fatty Acid Methyl Esters are being used as alternatives and extenders for mineral oil. Fatty Acid Methyl Esters must conform to certain standards to be of acceptable quality, just as mineral oils do at present. Consult your JCB distributor for advice about the use of Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.

9803/9970-01 (3-00)

Routine Maintenance Cleaning the Machine

Cleaning the Machine

!MCAUTION

Introduction T3-062_2

Clean the machine using water and or steam. Do not allow mud, debris etc. to build upon the machine. Before carrying out any service procedures that require components to be removed: 1

Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned. When cleaning is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.

Important: When removing components be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding.

The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system. Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3

Important: Do not aim the water jet directly at bearings, oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors. Use a low pressure water jet and brush to soak off caked mud or dirt. Use a pressure washer to remove soft dirt and oil.

Detergents Avoid using full strength detergent - always dilute detergents as per the manufacturer's recommendations, otherwise damage to the paint finish may occur.

Note: The machine must always be greased after pressure washing or steam cleaning.

Preparing the Machine for Cleaning

!MWARNING

Always adhere to local regulations regarding the disposal of debris created from machine cleaning.

Make sure the engine cannot be started. Disconnect the battery before doing this job.

Pressure Washing and Steam Cleaning

2-3-3-5

!MWARNING When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause serious personal injury. 13-3-2-10_2

Important: Stop the engine and allow it to cool for at least one hour. Do not attempt to clean any part of the engine while it is running. Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape.

9803/9970-01 (3-00)

Routine Maintenance Cleaning the Machine

Cleaning the Machine

h Check for cracks, holes or other damage.

!MWARNING To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components. HYD-1-3_2

Check the charge air piping F for leaks, holes, cracks or loose connections. Tighten the hose clamps if required.

If any damage is found, contact your JCB dealer.

Reposition the coolers and the condensor. Fasten latches A.

Close the engine cover.

!MWARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. 5-3-1-12_3

!MCAUTION Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth.

8-3-4-8

Pay particular attention to the underside. Do not allow mud to build up on the engine and transmission. 1

The radiator and coolers. If the tubes or fins become clogged, the radiator and coolers will be less efficient. a

Stop the engine.

b Open the engine cover. c

Open latches A (one each side) and pull forward the bottom of condensor B.

d Brush off both sides of the condensor and the front of coolers C.

E C090540

Fig 1. e

Brush off the front face of air cooler C.

Brush off the front of the radiator E and rear of coolers D.

g Make sure all the loosened material is brushed out of the cooling area.

9803/9970-01 (3-00)

Routine Maintenance Cleaning the Machine 2

!MWARNING

Engine Do not allow mud to build up on the engine and transmission. Pay particular attention to the exhaust area, remove all combustible material.

Take care with the backrest frame. It may jerk forward and cause injury.

The engine or certain components could be damaged by high pressure washing systems, special precautions must be taken if the engine is to be washed using a high pressure system.

During cleaning, the upholstery should not be soaked through.

13-3-2-9_2

If required, the cushion and backrest can be removed for cleaning by removing screws B.

Important: Do not place the jet nozzle closer than 600mm (24 in) to any part of the engine.

Keep the seat slide runners lightly greased.

Do not attempt to clean any part of the engine while it is running. Stop the engine and allow it to cool for at least one hour. a

Disconnect the battery.

b Do not wash any part of the: i

Fuel injection pump.

Cold start device.

iii Electrical shut off solenoid (ESOS). iv Electrical connections. c

Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by high pressure cleaning system.

B T027040-B2

Fig 2.

Transmission On ABS machines, take special care to avoid directing high power water jets at the electrical connections to the front and rear axle ABS sensors.

Seats Keep the upholstery clean, using a commercially available upholstery or plastic cleaner. Test first for compatibility on a small concealed area of the seat.

9803/9970-01 (3-00)

Routine Maintenance Checking for Damage

Checking for Damage Check the Machine Body and Structure T3-063_4

Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Note damaged paintwork for future repair. Check pivot pins are correctly in place and secured by their locking devices.

Inspect the tyre valve for leaks, when you check the tyre pressures.

Check the Seat and Seat Belt

!MWARNING

T3-008_2

When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years. 2-3-1-7_1

Check steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass and mirrors. Replace damaged items.

Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.

Check all lamp lenses for damage. Check all attachment teeth are undamaged and secure.

Check that the belt mounting bolts are undamaged, correctly fitted and tightened.

Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary.

Check seats are undamaged and secure. Check seat adjustments for correct operation.

Check the Tyres

Check the Hydraulic Hoses and Fittings

!MWARNING

T3-065_2

!MWARNING

You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres fitted and do not operate at more than their recommended maximum speed.

T3-072

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged. INT-3-3-2_4

13-2-1-2

Inspect the hoses regularly for: Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example:

– Damaged hose ends – Chafed outer covers – Ballooned outer covers

– Signs of distortion (bulges)

– Kinked or crushed hoses

– Cuts or wear

– Embedded armouring in outer covers

– Embedded objects (nails, etc.)

– Displaced end fittings

Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre pressures.

Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again.

9803/9970-01 (3-00)

Routine Maintenance Checking for Damage Replacement hoses must be of the same size and standard.

Checking the ROPS Structure

!MWARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_6

Check the structure for damage. Check that the four mounting bolts are installed and undamaged. Check that torque tightness of nuts A and B is correct (see table below). Tighten them to the correct torque if necessary. Dacromet Fasteners (colour: mottled silver) Nm

Kgf m

lbf ft

365

269

C095540

Fig 3.

9803/9970-01 (3-00)

Routine Maintenance Greasing

Greasing Introduction T3-028_2

You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for the correct intervals. Note: The machine must always be greased after pressure washing or steam cleaning. Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient. Stop greasing when fresh grease appears at the joint. Use only the recommended type of grease. Do not mix different types of grease, keep them separate. In the following illustrations, the grease points are numbered. Count off the grease points as you grease each one. Refit the dust caps after greasing. Note: Where applicable, refer to the manufacturers manual for instructions on the maintenance of optional attachments.

9803/9970-01 (3-00)

Routine Maintenance Greasing

Drive Shafts

Front axle drive shaft

!MWARNING

Grease points 5 to 6

Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and remove the starter key. Make sure the park brake is engaged. Disconnect the battery to prevent the engine being started. Block all four wheels before getting under the machine. 3-3-1-1

.Read and follow the procedures in the introduction. K Introduction ( T 20) Note: If working in muddy conditions the propshafts and PTO driveshafts must be greased daily. Note: When greasing the universal joints, you must ensure that grease appears at all four bearing caps. If grease does not appear at any cap, move the shaft from side to side and then re-grease. Wipe away all excess grease.

C071350

Fig 5.

2 3

C071340

Fig 6.

C089830

Fig 4.

Rear PTO drive shaft Grease points 1 to 2

Rear axle drive shaft Grease points 3 to 4

9803/9970-01 (3-00)

Routine Maintenance Greasing

!MWARNING

Front Axle Steering Swivels .Read and follow the procedures in the introduction. K Introduction ( T 20)

Grease points 1 to 4. Note: After initial greasing, turn the wheels from lock to lock, then grease again to ensure full penetration.

C090550

Fig 7.

9803/9970-01 (3-00)

Routine Maintenance Greasing

Agricultural Front 3-Point Linkage (Optional) .Read and follow the procedures in the introduction. K Introduction ( T 20)

!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged. Block all four wheels before getting under the machine. 2-3-2-1

Grease at points 1 to 3.

C090760-C1

Fig 8.

9803/9970-01 (3-00)

Routine Maintenance Greasing

Steering Column Universal Joints .Read and follow the procedures in the introduction. K Introduction ( T 20)

Block all four wheels before getting under the machine. 2-3-2-1

Note: It may be necessary to turn the steering wheel to put the grease nipples A in an accessible position. Grease at point 1 from underneath the machine.

Grease at points 2, 3 and 4 from under the engine cover.

2 A

C097150

Fig 10.

C090560

Fig 9.

9803/9970-01 (3-00)

Routine Maintenance Greasing

Rear Suspension Cylinder Pivots

C093480

Fig 11. .Read and follow the procedures in the introduction. K Introduction ( T 20)

Grease points 1 to 4.

9803/9970-01 (3-00)

Routine Maintenance Greasing

Hydraulic Lift and 3-Point Linkage

Note: Ladder hitch and trailer coupling omitted for clarity.

.Read and follow the procedures in the introduction. K Introduction ( T 20)

Hydraulic lift rams Grease points 3 to 6.

!MWARNING

Three point linkage lift rods

You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Grease at nipples 7, 8, 9 and 10 (lift collars A and B to access nipples 9 and 10). On machines with heavy duty linkage grease points 11 and 12 also.

Stabilizers (standard type) Block all four wheels before getting under the machine.

Grease at point 13.

2-3-2-1

Rear PTO Drive Shaft Bearing Hydraulic lift cross-shaft Grease points 1 and 2.

Grease point 14. Do not exceed 2 to 3 strokes of the grease gun.

C093470

Fig 12.

9803/9970-01 (3-00)

Routine Maintenance Greasing

Automatic Trailer Coupling (if fitted) .Read and follow the procedures in the introduction. K Introduction ( T 20) Note: Whenever the coupling has been pressure-washed it must always be greased. Make sure the coupling is in the open position, i.e. the coupling pin is up and the hand lever A is in its highest position. Grease at points 1 and 2. Operate lever A several times so that the grease is distributed throughout the bearing.

!MCAUTION Keep your hands out of the funnel or you may be injured by the coupling pin as it is forced down by its spring. 13-2-2-17

Grease again and operate the hand lever again.

170201-B1

Fig 13. If driving without a trailer attached, close the coupling to prevent dirt accumulation.

9803/9970-01 (3-00)

Routine Maintenance Access Panels

Access Panels Opening the Engine Cover

!MWARNING

The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open. 5-2-6-5

Engage the park brake, put the transmission in neutral, stop the engine. Remove the starter key. C096810

Fig 15.

Closing the Engine Cover 1

Pull the cover down by means of the strap B. To close the latch, press the cover firmly down.

C095550

Fig 14. 2

Open the left side cab door. Release the engine cover latch by pulling lever A.

9803/9970-01 (3-00)

Routine Maintenance Air Conditioning and Heater

Air Conditioning and Heater Air Conditioning Filters

and pull out the filter D. Check condition of filter and renew if split or worn.

Cleaning the Standard Air Conditioning Filter

If the filter is undamaged, pull foam pre-cleaner 16E (fitted to later filters) out of the filter casing, wash it in low suds detergent and blow dry with compressed air at a maximum pressure of 5.5 bar (80 lbf/in2). Use the same compressed air to blow dirt out of filter 16D in the opposite direction to the arrows marked on the filter.

Check and clean the filter sealing face on the cab body.

Refit the pre-cleaner and fit the filter into the cab aperture using two screws C. Refit the closing panel B.

C035810

Fig 16. Note: The air conditioning system contains environmentally safe R-134A refrigerant. Do not use test equipment or gauges that have contacted R12 refrigerant or the system will be damaged. Note: For crop spraying applications or very dusty conditions, a heavy duty carbon filter can be used in place of the standard filter. Carbon filters must not be cleaned. Keep a log of the hours used and change at 250 hour intervals.

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Unscrew the two quarter-turn fasteners A and remove closing panel B. Remove the two screws C

9803/9970-01 (3-00)

Routine Maintenance Air Conditioning and Heater Changing the Heavy Duty Carbon Filter Note: Carbon filters must not be cleaned. Keep a log of the hours used and change at 250 hour intervals.

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

746220-B1

Fig 18. 2

The new filter is supplied with a separate foam seal K that has a self-adhesive face covered by protective film. Clean the contact face of the new filter L, peel off the protective film from the foam seal and press the foam seal, self-adhesive face downwards, into position on the filter.

Check and clean the seal contact face on the cab body.

Fit the filter into the cab aperture using two screws H. Refit the closing panel G.

C035800

Fig 17. 1

Unscrew the two quarter-turn fasteners F and remove closing panel G. Remove the two screws H and pull out the filter J.

9803/9970-01 (3-00)

Routine Maintenance Air Conditioning and Heater

Cleaning the Heater Filter

!MCAUTION

The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Unscrew fastener A and remove panel B.

Lift out filter C and check for splits or tears. Renew filter if damaged.

If the filter is undamaged, use compressed air at a maximum pressure of 5.5 bar (80 lbf/in2) to blow dirt out of the filter in the opposite direction to the air flow when the filter is installed.

Refit the filter into the cab aperture.

Refit the panel, making sure that the tongue D engages in slot E.

B D E

C096820

Fig 19.

9803/9970-01 (3-00)

Routine Maintenance Brakes

Brakes Checking the Foot Brake Fluid Level 1

Check the fluid level in the reservoirs.

Note: Machines with ABS have three fluid reservoirs. NonABS machines have two fluid reservoirs. The fluid level should be between the two lines A and B moulded into the side of each reservoir. If necessary, add fluid as in Step 2. Note: If the level has fallen below the lower line B, the system must be checked by your JCB distributor. 2

Add the specified brake fluid. Clean the area around the filler cap C. Remove the cap and carefully pour in the recommended fluid until it reaches line B. Avoid spilling the fluid. Wipe up any spillage. Do not allow dirt to enter the reservoir. Fit the cap securely. After the cap is fitted, the level should be to line A.

Note: Do not use ordinary hydraulic fluid.

Checking the Trailer Air Tank Fig 20. 1

Charge the air system by starting the engine. Wait for the tank warning lights to go out. Stop the engine, apply the park brake.

Grip `keyring' fitting D at the bottom of tank E and pull sideways until all water is expelled. The amount of water released is a guide to the functioning of the air dryer. If purging of water takes more than about 5 seconds, or if oil is present, the system must be checked by your JCB distributor.

!MWARNING If the brake fluid warning light comes on, check the brake fluid level immediately. 13-3-1-2_1

!MWARNING Faulty brakes can kill. If you have to top up the brake reservoir frequently, get the brake system checked by your JCB Dealer. Do not use the machine until the fault has been put right. 2-3-2-5_1

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

9803/9970-01 (3-00)

Routine Maintenance Brakes

Checking the Air Tank Warning Lights

FASTRAC

ABS

C039350-B5

Fig 21. 1

Position machine on level ground, apply park brake and stop engine. Block the wheels.

Start and run engine until the air tank warning light B goes out.

Stop engine and turn starter switch to the IGN position.

Press and release brake pedal repeatedly until the air tank warning light comes on.

If the warning light does not operate or go out correctly, you must consult your JCB dealer.

9803/9970-01 (3-00)

Routine Maintenance Brakes

Checking and Renewing Foot Brake Pads

B D B

E C

C E C036480-C1

Fig 22. 1

!MWARNING

Prepare the machine. Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground. Jack up the machine and support it on axle stands. Remove the wheels.

Always renew brake pads and locating pins in complete axle sets, using genuine JCB parts, otherwise braking will be unsafe. 13-3-1-10

!MWARNING

Note: Disc brakes are fitted to all four wheels. The illustration shows a typical calliper.

!MWARNING Oil on the brake disc will reduce brake effectiveness. Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer's safety instructions. If the pads are oily, new ones must be fitted.

Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work. 13-3-1-3

Tap out three pad locating pins B, C and D in direction of the arrow. On later type callipers, collect pin D and clip E which will become loose as pins B and C are removed. Discard the pins and clips.

With a suitable lever, force the worn pads back against the pistons. Remove the pads. Force both pistons fully back, taking care not to damage the seals.

Ensure that the seals are not leaking and that both pistons move freely in the calliper. If not in perfect

2-3-2-3_3

Check the thickness of all the friction pads A and the condition of each disc X. If the friction material is 3 mm (0.12 in) or less on any of the pads, fit a new set. If the surface of the disc is badly warped or pitted, you must consult your JCB distributor.

9803/9970-01 (3-00)

Routine Maintenance Brakes condition, the calliper must be repaired by your JCB distributor. 6

Slide in the new pads and fit new locating pins and clips. Make sure that you fit the same type of pins and clips as those that you have removed.

Before driving the machine, start the engine, wait for air pressure to rise and pump the brake pedal until the brakes are felt to engage at the middle of the pedal travel range.

Try to avoid heavy braking for the first 50 hours of operation after fitting new pads.

Refit the wheels and tighten the wheel nuts, K Wheel Nut Torques ( T 76).

B D B

E C

C E C036480-C1

Fig 23.

9803/9970-01 (3-00)

Routine Maintenance Brakes

!MWARNING

Testing the Park Brake

!MWARNING Before testing the park brake make sure the area around the machine is clear of people.

Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the park brake. 3-2-3-11

2-2-4-5

Note: This routine test applies to all types of brake system but if a trailer fitted with twin-line trailer air brakes is attached and you are parking on an incline, you must also test the park brake for holding on an incline. Refer to the Machine Operator Manual. Test the brake on a level, dry surface.

!MWARNING If the machine starts to move during the following test, immediately apply the foot brake and reduce the engine speed. 2-2-5-1

Ensure that any mounted implements are in the raised position.

Make sure the park brake is engaged.

Start engine and allow to stabilize at idling speed.

Select Powershift mode and change start-off gear to C1. Refer to the Machine Operator Manual.

Depress clutch pedal.

Select forward direction (arrow on touch screen should change to green, gear will be C1).

Slowly release the clutch pedal with engine at idle.

Increase engine speed to no more than 900 rev/min. Machine should not move. Be ready to depress clutch and brake pedal if machine moves.

Note: If the machine moved during the test, have your JCB Distributor inspect the brake.

!MWARNING Do not use a machine with a faulty park brake. 3-2-3-10_2

9803/9970-01 (3-00)

Routine Maintenance Brakes

!MWARNING

Checking the Park Brake Pads

!MWARNING Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work.

Oil on the brake disc will reduce brake effectiveness. Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer's safety instructions. If the pads are oily, new ones must be fitted.

13-3-1-3

2-3-2-3_3

!MWARNING

Before checking the park brake, park on level ground. Put blocks each side of all four wheels. Ensure that all three air tank warning lights are out. Release the park brake, then stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

Check the disc condition If the surface of the disc is badly warped, pitted or showing signs of overheating, you must have it renewed by your JCB Distributor.

13-3-1-4_1

S194341-B1

Fig 24. 1

Check the Pad Condition. Measure pad thickness A. If the thickness of the friction material is 3 mm (0.12 in) or less, the pads must be renewed by your JCB distributor.

9803/9970-01 (3-00)

Routine Maintenance Electrical

Electrical Battery

Close and lock the access panels.

Before carrying out maintenance or leaving the machine unattended for a long period, disconnect the battery earth terminal using the spanner provided with the machine.

Battery Disconnection/Connection T3-019_3

!MWARNING

Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned. 5-2-2-4

Disconnection 1

Get access to the battery. See Access Panels.

Remove the leads. Disconnect the earth (-) terminal first.

Connection 1

Check the battery. a

If the terminal is dirty, clean the post.

Fig 25. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper. c

After cleaning, apply a thin coat of petroleum jelly to the terminal.

Re-connect the leads. Connect the earth (-) terminal last.

9803/9970-01 (3-00)

Routine Maintenance Electrical Checking the Electrolyte Level

Top up if necessary with distilled water or de-ionized water.

Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below.

!MWARNING Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6

Apply the park brake and stop the engine. Remove the battery access panel A. Prize out covers B. Look at the level in each cell. The electrolyte should be 6 mm (0.25 in) above the plates.

Note: When two batteries are fitted on the machine, they are connected in parallel. When fitting the cables, ensure that they are connected as shown on the illustration.

A C090530-C1

Fig 26.

9803/9970-01 (3-00)

Routine Maintenance Electrical Battery Isolator (if fitted)

To disconnect the battery from the machine electrics a battery isolator has been fitted. The battery isolator is located in the battery compartment. The compartment cover 1 can be removed by releasing screws 2.

!MCAUTION Except in an emergency, do not use the battery isolator to switch OFF the engine. Failure to comply may result in damage to the electrical circuits. INT-3-2-13

!MCAUTION Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is fitted. INT-3-1-13

C090530-C2

!MCAUTION

Fig 27.

Ensure that the engine has been stationary for at least 20 seconds before isolating the battery. Failure to do this could result in a loss of data in the ECU. At the end of a working cycle or if the machine is being left unattended, provided the lights are not required, the battery must be isolated. Before attempting to start the engine or use the machine electrics the battery isolator key must be fitted and switched on. Get access to Panels ( T 28)

To isolate the battery turn the battery isolator key A to the horizontal position and remove. Keep the key in a safe place and available for when the machine is next required.

To connect the battery insert the key A and turn in a clockwise direction B.

Close and lock the front grille.

the

front

grille.

K Access

9803/9970-01 (3-00)

Routine Maintenance Electrical

Jump-starting the Engine

!MWARNING

Note: The procedure below should be used if the batteries have become discharged. It is not possible to tow-start or push-start the Fastrac due to the design of the transmission.

Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery fully charged.

Note: The following procedure relates to machines equipped with two batteries connected in parallel.

Do not try to charge a frozen battery or jump-start and run the engine, the battery could explode. Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels. When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This prevents any chance of sparks near the battery. Set all the machine switches to their OFF positions before connecting the external power supply. Even with the starter switch set to off some circuits will be energised when the external power supply is connected. Do not connect the booster (slave) supply directly across the starter motor. Doing this by-passes the neutral gear safety switch. If the machine is in gear, it may 'runaway' and kill or injure bystanders. Use only sound jump leads with securely attached connectors. Connect one jump lead at a time. The machine has a negative earth electrical system. Check which battery terminal is positive (+) before making any connections. Keep metal watch straps and jewellery away from the jump lead connectors and the battery terminals - an accidental short could cause serious burns and damage equipment. Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system.

Engage the park brake. The park brake should have been engaged when the machine was last parked. But if it is not already engaged, engage it now.

Set all switches in the cab to Off.

Note: Although the JCB Fastrac may have two batteries, they are connected in parallel to give 12 Volts. Use a booster supply of 12 Volts (not 24 Volts). 3

Remove panel A to gain access to the batteries and open the bonnet to gain access to the earth connection.

!MWARNING Keep metal watch straps, and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metalwork. If this happens, you can be burned. Make sure that the fuel filler cap is tightly fitted. Make sure that all spilt fuel is cleaned away from the battery area. 2-2-4-2

Connect the booster cables as follows: a

Connect the positive booster cable to the positive (+) terminal on the front battery of the machine.

b Connect the other end of this cable to the positive (+) terminal of the booster supply.

If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. 4-2-2-3_1

9803/9970-01 (3-00)

Routine Maintenance Electrical

A C090530-C1

Fig 28. c

Connect the negative (-) booster cable to the earth connection B which is located against the gearbox housing behind the starter motor. The connections on the machine must be free from paint and dirt. Do not use any other part of the machine for an earth.

d Connect the other end of this cable to the negative (-) terminal on the booster supply.

Do the Pre-Start Checks.

Start the engine.

Disconnect the booster cables. a

C035870-C1

Disconnect the negative (-) booster cable from the earth connection B. Then disconnect it from the booster supply.

b Disconnect the positive (+) booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.

Fig 29.

9803/9970-01 (3-00)

Routine Maintenance Electrical

Checking the Beam Alignment

fitted mark a second horizontal line YY on the wall approximately 1.3 m above XX.

Park the machine on level ground so that the front headlights A are 2.00 m from a wall.

Measure the distance Z from the ground to the centre of the front headlights A. Subtract 25 to 30 mm from this distance and mark a horizontal line XX on the wall at this height. When the auxiliary headlights B are

When the headlights are switched on to dipped beam, the horizontal tops of the light beams should be in line with the horizontal lines X - X and Y - Y on the wall.

To adjust the beam, slightly slacken nut C or D, reposition the light and then tighten the nut.

C090580

Fig 30.

9803/9970-01 (3-00)

Routine Maintenance Electrical

Fuses and Relays Refer to Section C - Fuses and Relays.

9803/9970-01 (3-00)

Routine Maintenance Engine

Engine Checking the Oil Level 1

Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground. Turn the front wheels to full left hand lock.

Stop the engine. Remove the starter key. Before checking the oil level, wait at least 15 minutes to allow the oil to drain down into the sump.

Open the engine cover.

Make sure that the dipstick X is fully in before removing it. Check that the oil level is between the two marks on the dipstick.

Add oil if necessary. If oil is needed, add only the recommended oil at filler Y. K Fluids, Lubricants and Capacities, Fuel ( T 11)

Make sure that the dipstick and filler cap are refitted.

X C090470

Fig 31.

9803/9970-01 (3-00)

Routine Maintenance Engine

Changing the Oil and Filter

C C035790

Fig 32. 1

Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil. Park the machine on firm ground and turn the front wheels to full left hand lock.

the drain plug and its sealing washer. Tighten to 80 Nm (59 lb ft). Open the bonnet. Change the Filter 4

Open the engine cover.

!MWARNING

Unscrew the filter D.

Clean the filter head E, especially on its sealing face.

Note: The old seal can stick to the filter head. Ensure that it is removed. 7

Add clean engine lubricating oil to the new filter. Allow enough time for the oil to pass through the filter element.

Lightly lubricate the seal F on the new element with clean oil. Screw on the new element and tighten by 3/ 4 of a turn after the seal contacts the sealing face, Tighten the element hand-tight only. Overtightening can cause damage to the filter and the seal.

Fill the engine to the upper mark on the dipstick with new oil through the filler. K Checking the Oil Level ( T 45). Refer to the recommended oil grades. K Fluids, Lubricants and Capacities, Fuel ( T 11). Wipe off any spilt oil. Check for leaks. Make sure the filler cap is correctly refitted.

3-3-1-1

!MCAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug. 13-3-1-15

Place a container that can hold at least 18 litres (4 UK gal) beneath the engine to catch the oil.

Remove drain plug C and its sealing washer. Make sure the sealing washer and its mating surfaces are not damaged. Let the oil drain out, then clean and refit

9803/9970-01 (3-00)

Routine Maintenance Engine 10

Connect the battery and run the engine for a few minutes to allow the oil to circulate.

Note: The electronic control unit will prevent the engine from starting until the minimum required oil pressure has been reached. 11

Stop the engine, remove the starter key.and check for leaks. Before checking the oil level, wait at least 15 minutes to allow the oil to drain down into the sump. Recheck the oil level and top up if required.

9803/9970-01 (3-00)

Routine Maintenance Engine

!MWARNING

Checking the Coolant Level

Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze. 7-3-4-4_1

MAX A

MIN

Top-up the Expansion Tank. Use the correct coolant. K Coolant Mixtures ( T 11) Remove filler cap A and add pre-mixed water/ antifreeze solution until the level is up to the line marked `COLD MIN'. Do not overfill.

Note: Check the quality of the antifreeze mixture every year before the cold weather starts. Change it every two years. 6

Refit the Filler Cap Make sure it is tight.

7 C090590

Fig 33.

!MWARNING

Check for Leaks Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and check for leaks.

The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. 9-3-3-1_2

Prepare the Machine Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground.

Stop the Engine Remove the starter key.

Open the engine cover.

Check the Level Visually check that the level of the coolant is up to the line marked `MIN' but below the line marked `MAX'. If the level is low, then continue with steps 5 to 7.

9803/9970-01 (3-00)

Routine Maintenance Engine

Draining and Refilling the Coolant

!MWARNING The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.

9-3-3-1_2

Open the engine cover. Carefully loosen the filler cap. Let any pressure escape. Remove the cap.

!MCAUTION

Fig 34.

Keep your face away from the drain hole when removing the drain plug.

!MCAUTION

C097200

2-3-3-4

Slacken clip E and disconnect the hose. Let the coolant drain out.

Check for damaged hoses and loose or damaged hose clips. Check the radiator for damage and build up of dirt. Clean and repair as required.

The cooling system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented then add the mixture to bring the level to the cold level line. 13-3-2-22

Fill the system slowly with the mixture to prevent air locks. Wait 2 to 3 minutes to allow air to be vented, then top up to the level marked 'COLD MIN'. Do not fit the filler cap at this stage.

Run the engine for 5 minutes at the normal running temperature. Stop the engine and allow to cool.

!MCAUTION

This solution contains no antifreeze. Do not allow the cooling system to freeze during the cleaning operation.

Drain the cooling system, checking that the coolant is not dirty. If it is, repeat the flushing process (steps 5 to 8).

Refill the system as described at step 6 but using the correct pre-mixed water/antifreeze solution. K Coolant Mixtures ( T 11) Do not overfill. Fit the filler cap.

Reconnect hose and tighten clip E.

Prepare a mixture of 23 litres of water and 0.5 kg sodium carbonate (or a commercially available alternative).

13-3-2-17

9803/9970-01 (3-00)

Routine Maintenance Engine Note: A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point. Note: Make sure the heater control is in the hot position before running the engine. This will ensure that the coolant mixture circulates through the entire cooling system. 10

Run the engine and raise the coolant to working temperature. Stop the engine. Check the coolant level again and top up if required. Check for leaks.

9803/9970-01 (3-00)

Routine Maintenance Engine

Fan Belt 1

Stop the engine.

Open the engine cover.

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

!MWARNING Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. 0094

Inspect the belt for damage.

209630-B2

Fig 35. Cracks across the belt width A are acceptable. 4 Cracks across the belt which intersect those in the direction of the belt length B are not acceptable.

The belt tension is automatically maintained by the tensioner G which must be checked at 1000 hour intervals. The belt deflection on the longest run of the belt should be 9.5-12.7 mm (0.375-0.5 in).

Renew the belt if oily or if it has unacceptable cracks or if it is frayed or has pieces of material missing as at C or D. K Removal and Replacement ( T 52) 5

Renew the belt (if damaged, oily or tension incorrect). K Removal and Replacement ( T 52)

Close the engine cover.

Damage can be caused by: a

Incorrect tension

Check the belt tension.

b lncorrect size or length c

Pulley misalignment

d Incorrect installation

Severe operating environment

Oil or grease on the belt

9803/9970-01 (3-00)

Routine Maintenance Engine

!MCAUTION

Removal and Replacement Renew the belt if damaged, oily or tension incorrect. 1

Using a 3/8 in square drive inserted into the square hole in the belt tensioner as shown at F, lever the tensioner roller in the direction of the arrow to allow the belt to be lifted clear. K Fig 36. ( T 52) Do not use excessive force or the tensioner will be damaged.

Applying excessive force in the opposite direction of windup or after the tensioner has been wound up to the positive stop can cause the tensioner arm to break. 13-3-2-20

Note: There is no separate belt for the air conditioning compressor. It is driven by the fan belt.

Before fitting the new belt, check that the tensioner roller and the fan pulley rotate smoothly and that there is no play in the bearings. g Fit the new belt and allow the tensioner to return to its normal position.

Check that bolt G is tightened to 43 Nm (32 lbf ft).

Close the engine cover.

F C035770

Fig 36.

!MCAUTION The belt tensioner is spring-loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. 13-3-2-21

9803/9970-01 (3-00)

Routine Maintenance Engine

Changing the Air Filter Elements

C090430-C1

Fig 37. Note: In a dusty working environment, the outer element may have to be renewed more frequently than the service schedule recommendation. A new inner element must be fitted at latest, every third time the outer element is changed. As a reminder, mark the inner element with a felt tip pen each time you change only the outer element. DO NOT attempt to wash or clean elements - they must be renewed.

!MCAUTION

To prevent dust getting into the engine, disconnect induction hose A at the filter canister F. Cover the hose to prevent rain and dirt getting into the engine. 4

Release the three clips B and remove end cover C.

Pull out the outer element D. Take care not to tap or knock the element as you remove it. Pull out the inner element E.

If necessary remove screw G and disconnect the intake duct H from the filter canister. Make sure the air intake holes J are clear of debris.

Clean the inside of canister F and end cover C.

Carefully insert the new elements into the canister. Make sure they seat correctly, by smearing the seals

The outer element must be renewed immediately if the warning light on the instrument panel illuminates. 2-3-3-1

Turn the front wheels onto full left lock and stop the engine. Remove the starter key.

Open the engine cover.

If changing the inner element disconnect the filter induction hose.

9803/9970-01 (3-00)

Routine Maintenance Engine K and L with grease and checking for a witness mark on the canister base. 9

Connect induction hose A. Fit end cover C onto the canister. Secure the three clips B. Make sure the air filter blocked switch connector M is fitted. Check all hoses for condition and tightness.

9803/9970-01 (3-00)

Routine Maintenance Fuel System

Fuel System Introduction

!MWARNING Fuel Fuel is flammable; keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions. INT-3-2-2_3

!MWARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates your skin, get medical help immediately. 0177

!MCAUTION Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. INT-3-3-12

!MCAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air. 2-3-3-11

9803/9970-01 (3-00)

Routine Maintenance Fuel System

Draining the Fuel Pre-Filter

Stop the engine. Remove the starter key.

Position a suitable container underneath the filter valve A. Unscrew valve A by approximately 31/2 turns until the valve drops down by 25 mm. and draining occurs.

Close the valve when clear fuel, free from water is visible. To close the valve, lift the valve and turn clockwise until it is hand-tight. Do not overtighten or the threads may be damaged.

Dispose of the drained liquid as required by local environmental regulations.

A C035780-C1

Fig 38.

9803/9970-01 (3-00)

Routine Maintenance Fuel System

Changing the Fuel Pre-Filter Element

Block all four wheels before getting under the machine. 2-3-2-1

!MWARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. 13-3-2-16

Stop the engine. Remove the starter key.

Disconnect the electrical connection from the water in fuel sensor Y and unscrew the sensor with `O' ring from the bottom of the element.

Note: Fuel will run from the element. 3

Unscrew the element X.

Screw the sensor Y into the new element, ensuring that the `O' ring is fitted.

Lightly lubricate the seal F of the new element with clean fuel. Screw on the new element and tighten by 3/4 of a turn after the seal contacts the sealing face, Tighten the element hand-tight only. Overtightening can cause damage to the filter and the seal.

Reconnect the electrical connection to the sensor.

Bleed the fuel system. K Bleeding the Fuel System ( T 59) Check for leaks.

Run the engine and ensure that there are no fuel leaks.

9803/9970-01 (3-00)

C035780-C2

Fig 39.

Routine Maintenance Fuel System

Changing the Fuel Filter Element

!MWARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.

13-3-2-16

Stop the engine. Remove the starter key.

C090490-C1

Fig 40. 2

Open the engine cover.

Unscrew the element X.

!MCAUTION Do not pre-fill the engine-mounted fuel filter with fuel. The system must be primed after the fuel filter is installed. Pre-filling the fuel filter can result in debris entering the fuel system and damaging fuel system components. 13-3-2-23

Bleed the fuel system. K Bleeding the Fuel System ( T 59) Check for leaks.

Run the engine and ensure that there are no fuel leaks.

Close the engine cover.

9803/9970-01 (3-00)

Routine Maintenance Fuel System

Bleeding the Fuel System Air in the fuel system could cause misfiring or failure to start. Air will enter the fuel system if the fuel tank has been emptied or if any part of the system has a leak or has been disconnected. In addition, bleeding may be required if the engine has not been started for an extended period.

!MWARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. 13-3-2-16

!MCAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air. 2-3-3-11

Unscrew knob A from the filter head. Do not slacken any fuel pipe connections.

Pump the knob backwards and forwards until resistance to movement is felt.

Screw knob A back into the housing.

C035780-C3

Fig 41.

9803/9970-01 (3-00)

Routine Maintenance Hydraulic System

Hydraulic System

!MCAUTION

Introduction

!MWARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools (less than 40Â°C) before beginning maintenance. 8-3-4-10

Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. INT-3-3-12

INT-3-1-10_3

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

9803/9970-01 (3-00)

Routine Maintenance Hydraulic System

!MCAUTION

Checking the Fluid Level

Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes.

2-3-5-1_2

C095570

Fig 42.

Park the machine on level ground. Apply the park brake. Lower the rear linkage to the ground. Stop the engine. Remove the starter key.

Look at the sight gauge A. Fluid should be visible in the gauge. If the fluid is cloudy, water or air has entered the system. Water or air in the system could damage the hydraulic pump. Contact your JCB distributor if the fluid is cloudy.

If fluid is not visible in the gauge, add recommended fluid at tank cap B.

9803/9970-01 (3-00)

Routine Maintenance Hydraulic System

Changing the Filter Element

C095590

Fig 43.

!MWARNING

d Remove the nut and spring assembly H. Remove the element J from its spindle.

Remove and discard the paper insert Y from metal outer element J.

Clean the metal outer element J.

g Clean the magnets K.

INT-3-1-10_3

Fit the new element as follows:

Fit a new paper insert Y into metal outer element J.

Park the machine on level ground. Apply the park brake. Lower the rear linkage to the ground. Stop the engine. Remove the starter key. Wash off all dirt from around the tank cap B and element cover plate D. Remove the element as follows: a

Remove tank cap B.

b Assemble the refurbished element J on to the spindle, using a new seal L. Ensure that the top lip of the seal locates in the groove inside the filter head M. Fit and tighten the nut and spring assembly H.

b Remove nuts C, cover plate D and 'O' ring E.

d Refit cover plate D and nuts C using a new 'O' ring E.

Remove the element assembly F and 'O' ring G.

9803/9970-01 (3-00)

Fit the element assembly F using a new 'O' ring G.

Routine Maintenance Hydraulic System e

Tighten nuts C to 7 Nm (5 lbf ft).

Top up fluid level at tank cap B and refit cap.

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

9803/9970-01 (3-00)

Routine Maintenance Hydraulic System

!MCAUTION

Changing the Hydraulic Fluid and Cleaning the Suction Strainers

Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

D F

Park the machine on firm, level ground.

Place a container that can hold at least 60 litres (13.5 UK gal) beneath drain plug B. Remove the plug and allow the oil to drain. Refit the drain plug.

!MCAUTION

Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.

2-3-4-2

Remove the strainer G as follows: a

Remove tank cap A.

b Disconnect pipe C from the filter, remove bolts D and take out filter assembly E.

Unscrew strainer G from its spigot and withdraw from the tank via the filter aperture.

C090600

Fig 44.

!MWARNING

Remove the strainer F as follows: a

b Unscrew the strainer and remove it from the rear of the tank. 5

Clean the strainers with a suitable solvent. Follow the solvent manufacturer's instructions on safety.

Refit the strainers, using JCB Activator and JCB Threadlocker and Sealer on the threads. Fit a new â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring J. Refit the filter. Tighten the strainers to 20 Nm (14.7 lbf ft). Reconnect pipe C using Clayton System Seal SC1251 to seal the threads.

Fill the tank with the recommended hydraulic fluid.

INT-3-1-10_3

Disconnect the hose H from the strainer at the rear of the tank.

3-3-1-1

9803/9970-01 (3-00)

Routine Maintenance Hydraulic System

Coupling Drains It is necessary to empty collection reservoir H at regular intervals or more often if necessary. K Service Schedules ( T 4)

B A

C093460

Fig 45.

9803/9970-01 (3-00)

Routine Maintenance Transmission

Transmission Checking the Transmission Oil Level 1

Park the machine on firm, level ground. Engage the park brake. Lower the equipment. Stop the engine.

Check that oil is at the top mark on dipstick X. Add recommended oil, if necessary, at filler Y. K Fluids, Lubricants and Capacities, Fuel ( T 11) After topping up, run the engine for 1 minute, then stop the engine and allow to stand for 2 minutes before re-checking the level.

Note: Do not overfill as this would cause oil to be forced past the oil seals and out of the gearbox.

Y X

194570-B1

Fig 46.

9803/9970-01 (3-00)

Routine Maintenance Transmission

Changing the Transmission Oil Filter Note: If the transmission oil filter warning light comes on when the engine is running and the oil is warm, change the filter element before the time shown in the service schedule. 1

Prepare the machine. Park the machine on firm, level ground.

Remove the element. a

Position a small container to catch the oil when the bowl is removed.

b Unscrew bowl A and take out the element B. 3

Fit the new element (do not wash the old one). a

C090610

Clean the bowl A and filter head D.

Fig 47.

b Make sure that ‘O’ ring C is in position and renew if damaged. Apply a film of oil to the ‘O’ ring. Fit the new element into the bowl and screw the bowl onto the filter head. 4

Tighten the bowl to 30 Nm (22 lbf ft).

Check the oil level and top up if required.

Check for oil leaks a

Run the engine for a few moments to circulate the oil. Check that the transmission oil warning light has gone out. If the light stays on, contact your JCB Distributor.

b Stop the engine and check for leaks around the filter.

9803/9970-01 (3-00)

Routine Maintenance Transmission

Changing the Transmission Oil and Cleaning the Strainer

B C090510

Fig 48. 1

Prepare the machine. Park the machine on firm, level ground.

Note: To make sure all the oil drains out you must drain the oil at plug A because it is lower than the strainer. 5

3-3-1-1

Stop the engine. Disconnect the battery to prevent the engine being started. Block all four wheels before getting under the machine.

Place a container that can hold at least 75 litres (16.5 UK gal) beneath the transmission to catch the oil.

Unscrew strainer B and the sealing washer. Make sure the sealing washer and mating surface are not damaged.

Note: Remove the strainer carefully to avoid dislodging any contamination on the outside of the strainer. 6

Remove drain plug A and the sealing washer. Make sure the sealing washer and mating surface are not damaged. Let the oil drain out, then clean and refit the drain plug and the sealing washer. Tighten to 203 Nm (150 lbf f t).

Clean the strainer with a suitable solvent. Follow the solvent manufacturer's instructions on safety.

9803/9970-01 (3-00)

Routine Maintenance Transmission 7

Refit the strainer and sealing washer. Tighten to 102 Nm (75 lbf f t).

Fill the transmission with the specified oil. K Checking the Transmission Oil Level ( T 66)

9803/9970-01 (3-00)

Routine Maintenance Transmission

Front Axle

Changing the Differential Oil

Checking the Differential Oil Level

Park the machine on firm, level ground.

!MWARNING

Park the machine on firm, level ground.

!MCAUTION

3-3-1-1

Clean the area around the fill/level plug A, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole.

Add recommended oil, if necessary. K Fluids, Lubricants and Capacities, Fuel ( T 11)

Clean the plug and sealing washer before refitting.

Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

B C095600-C1

Fig 50.

A 2

Place a container that can hold at least 30 litres (6.6 UK gal) beneath the drain plug B. Remove the plug and allow the oil to drain. Clean the plug before refitting.

Fill with the recommended oil at fill/level plug A. K Fluids, Lubricants and Capacities, Fuel ( T 11)

C095600

Fig 49.

Oil should be level with the bottom of the fill/level hole. Clean the plug and sealing washer before refitting. Note: Do not overfill as this would cause oil to be forced past the oil seals and out of the axle.

9803/9970-01 (3-00)

Routine Maintenance Transmission Checking the Hub Oil Levels

Changing the Hub Oil

Check each hub separately.

Change the oil in each hub separately.

Park the machine on firm, level ground with the `OIL LEVEL' mark horizontal. K Fig 51. ( T 71)

Park the machine on firm, level ground with the fill/ level plug C at the bottom. K Fig 52. ( T 71).

!MCAUTION

Engage the park brake. Stop the engine and remove the starter key. 2

Clean the area around the fill/level plug Y, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole.

Add recommended oil, if necessary. K Fluids, Lubricants and Capacities, Fuel ( T 11)

Clean the plug before refitting.

Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

Place a container that can hold at least 2.5 litres (0.6 UK gal) beneath the drain plug C. Remove the plug and allow the oil to drain.

Set OIL LEVEL K Fig 51. ( T 71)

mark

the

horizontal.

Fill the hub with recommended axle oil, through the fill/level hole C. K Fluids, Lubricants and Capacities, Fuel ( T 11) Oil should be level with the bottom of the fill/level hole. Clean and refit fill/level plug C.

A435670-B1

Fig 51.

A435670-B2

Fig 52.

9803/9970-01 (3-00)

Routine Maintenance Transmission

Rear Axle

F 160690-C1

Fig 53.

Checking the Oil Level

!MCAUTION The oil level must be checked with the machine level, otherwise a false indication of the amount of oil will be given. 16-3-5-3_2

Note: As the same oil is used right through the rear axle, it is only necessary to check the level at one hub. 1

Park the machine on firm, level ground with the oil level plug Y positioned as shown. K Fig 54. ( T 72) Engage the park brake. Stop the engine and remove the starter key.

418320-B1

Fig 54. 2

Clean the area around the level plug, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. If the level is low proceed to step 3. Otherwise, clean and refit the level plug.

2-3-2-1

9803/9970-01 (3-00)

Routine Maintenance Transmission 3

Clean the area around the filler plug E. Remove plug E. Add the recommended oil until it runs from the hub. K Fluids, Lubricants and Capacities, Fuel ( T 11) Clean the plugs before refitting.

!MCAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

Note: Do not overfill as this would cause oil to be forced past the oil seals and out of the axle.

Place containers beneath the two hub level/drain plugs Y and the axle casing drain plug F. K Fig 53. ( T 72)

Changing the Oil 1

Position level/drain plug Y in both of the hubs at the bottom. K Fig 55. ( T 73)

Note: If the machine has a drawbar or hook it must be removed to get access to the drain plug F. Refer to the relevant operation procedure. Remove the plugs and allow the oil to drain. Refit plug F. 3

Position the drain hole in one of the hubs to the horizontal leaving out the plug Y. K Fig 54. ( T 72) Refit plug Y on the other hub.

Clean the area around the filler plug E. Remove plug E K Fig 53. ( T 72). Add the specified quantity of recommended oil. K Fluids, Lubricants and Capacities, Fuel ( T 11) Stop filling if oil runs from the hub. Clean and refit plug.

Position the drain hole in the other hub to the horizontal. K Fig 54. ( T 72)

Fig 55.

Clean the area around plug Y, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole.

Note: Depending on the phasing of the hubs, it may not be possible to position both hub level/drain plugs at the bottom at the same time. In this case, do Step 2 at one hub, then rotate the axle and drain the other hub.

If necessary add more oil at filler plug E. Clean and refit plugs Y and E.

418320-B2

Note: Do not overfill as this would cause oil to be forced past the oil seals and out of the axle.

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels

Tyres and Wheels

!MWARNING

General The versatility of the JCB Fastrac dictates a range of tyre types which may be operated at differing loads and widely differing speeds. Agricultural type tyres are designated according to both their load carrying ability and their ability to operate at certain speeds.

When ordering tyres, you must specify not only the tyre size but also the speed designation. The correct tyres for the machine are shown in the Tyre Pressures, Speeds and Loads table. On no account should you use tyres of other designations without first gaining approval from the machine manufacturer.

Generally, the speed at which a given tyre can operate depends upon inflation pressure and the load carried.

13-3-1-8_2

See Tyre Pressures, Speeds and Loads in the Operator Manual. This table shows the load carrying capacity per tyre at varying pressures and speeds. All tyres supplied as original equipment may be operated over the full speed range of the vehicle provided the pressure is correct and their loading is no higher than that shown in the table.

Note: If tyres are fitted that are a different size from those previously fitted, ensure that the road speed display is programmed to show the correct speeds for the new tyres (see Instrument Cluster, Programming in theOperator Manual). It may also be necessary to have the speed limiter adjusted (consult your JCB Dealer).

Check the Tyres Note: Whatever the loading, it is desirable to inflate rear tyres to 0.3 bar (4.4 lbf/in2) higher than the pressures given which are for the front tyres. This results in improved handling.

!MWARNING Running tyres outside recommended guidelines may result in failure of the tyres which at high speeds may endanger life. BE WARNED.

!MWARNING

T3-065_2

Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example:

13-3-1-6

!MWARNING Wheels and tyres are heavy. Take care when lifting or moving them.

– Signs of distortion (bulges) – Cuts or wear – Embedded objects (nails, etc.) Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre pressures. Inspect the tyre valve for leaks, when you check the tyre pressures.

Store with care to ensure that they cannot fall and cause injury. 13-3-1-7_1

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels

Tyre Inflation

Before you add air to the tyre, make sure it is correctly fitted on the machine or installed in a tyre inflation cage. K Fig 56. ( T 75).

Introduction

!MWARNING

T3-066

An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work.

Prepare the wheel.

Prepare the equipment. a

2-3-2-7_2

!MWARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury. 13-3-1-7_1

Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 psi) above the recommended tyre pressure. For recommended tyres and pressures for your machine, see Specfications, Tyre Sizes and Pressures.

b Use an air hose fitted with a self-locking air chuck and remote shut-off valve. 3

Add the air. a

Always try to maintain your tyre pressure to the recommended settings. Using your machine with underinflated tyres means:

Make sure that the air hose is correctly connected to the tyre valve. Clear other people from the area. Stand behind the tread of the tyre while adding the air.

b Inflate the tyre to the recommended pressure. Do not over-inflate.

– Decreasing the machines stability – Higher tyre temperatures – Excessive strain of the tyre fabric – More bulging of the sidewalls – Shortens the tyres life. Using the machine with over inflated tyres is dangerous: – It causes excessive tensile loads in the fabric: this makes a tyre more susceptible to cuts and punctures. Do not cut or weld on the rim of an inflated tyre. After checking or amending the tyre pressure always replace and secure the valve cap. Always deflate the tyre before removing foreign obstacles from the tread.

A089570-1

Fig 56.

Procedure T3-067_2

These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job.

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels

Wheel Nut Torques On a new machine check the wheel nut torques every ten hours until they stay correct. K Wheel Nut Torque Setting ( T 76) Every day, before starting work, check that the wheel nuts are tight. If a wheel is being fitted do the following: 1

Do not apply oil to the wheel nut threads.

Use an ordinary hand or power tool to initially tighten the wheel nuts evenly in the sequence shown. Front Wheels. K Fig 57. ( T 76) Rear Wheels. K Fig 58. ( T 76)

T040410

Fig 58. Rear Wheels 3

Then use a torque wrench to tighten all the nuts in a clockwise sequence to the specified torque setting. K Wheel Nut Torque Setting ( T 76)

Recheck the torque setting of the first nut that was torque-tightened. If the nut moves before the correct torque is achieved, retighten all nuts to the correct torque, following the same clockwise sequence as in step 3.

Check the wheel nut torques every ten hours until they stay correct.

Wheel Nut Torque Setting Item

kgf m lbf ft

Front wheels

500

51.0

370

Rear wheels

600

60.0

440

T040400

Fig 57. Front Wheels

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels

Adjustable Track Width To obtain an alternative track width, it is possible to move the wheels from one side of the machine to the other and reverse the wheels on the hubs. The dimensional change to the track width will vary according to the size of wheels and tyres fitted. K Table 3. Track Widths ( T 77)

The 'V' of the tyre tread pattern must always point forward when at the top of the wheel. Tighten the wheel to axle hub nuts as detailed under Checking Wheel Nut Torques. Note: Changing to the wide track setting may result in an overall vehicle width that is greater than that allowed by your local legislation. Make sure you will be obeying all pertinent laws and regulations before using the machine on public roads.

Table 3. Track Widths Tyre Size

Standard Track mm (in)

Wide (Reversed) Track mm (in)

Michelin 495/70R24

1880mm (74)

2095 (82)

Michelin 620/70R26

2165mm (86)

Michelin 620/75R26 + 750/65R26

2165mm (86)

Michelin 620/75R26

2165mm (86)

Trelleborg 680/55R26.5 Trelleborg 600/65R28

2083mm (82)

Rear

2083mm (82)

Front

1940mm (76)

2030mm (81)

Rear

1940mm (76)

1996mm (79)

Front

2015mm (79)

1955mm (77)

Rear

2015mm (79)

1931mm (76)

Trelleborg 540/65R30 + 600/65R28 Front

2015mm (79)

1955mm (77)

Rear

1940mm (76)

1996mm (79)

Trelleborg 540/65R30 + 600/65R28 Front

1880mm (74)

2090mm (82)

Rear

1880mm (74)

2056mm (81)

Trelleborg 540/65R30

Trelleborg 540/65R34 Nokian 440/80R30 Nokian 540/65R30 Dunlop MPT SP T9 455/70R24

Front

2015mm (79)

1959mm (77)

Rear

2015mm (79)

1925mm (76)

Front

2015mm (79)

1955mm (77)

Rear

2015mm (79)

1931mm (76)

Front

2015mm (79)

1955mm (77)

Rear

2015mm (79)

1931mm (76)

Front

1935mm (76)

2035mm (80)

Rear

1930mm (76)

2016mm (79)

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels

Lock Stops To prevent the tyres from fouling on the vehicle chassis, lock stops A must be fitted to the inside of each steering axle swivel. The correct size of lock stop is fitted at the factory to suit the tyre and wheel configuration supplied as original equipment. If a different tyre and wheel configuration is to be used, consult your JCB dealer about the need to change the lock stops and make other essential adjustments to the steering box.

160750-C1

Fig 59.

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels

Checking and Adjusting the Front Wheel Alignment

A B

F D C

G 160762-C1

Fig 60.

!MWARNING

Note: The use of a ball joint splitter will make this job easier.

!MCAUTION Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

3-3-1-1

Position the wheels so that the toe-in measurements are mid-way between the limits given in Checking the Alignment.

Slacken locking nut/bolt G and screw the track rod end E in or out of the track rod as required, ensuring that the taper of the track rod end E aligns with the taper of the steering arm F.

Refit the track rod end and firmly tighten nut D and nut/bolt G. Re-check the toe-in. If correct, tighten nut D to 150 Nm (110 lbf ft, 15 kgf m) and nut/bolt G by means of the nut to 70 - 80 Nm (52 - 59 lbf ft, 7.1 - 8.2 kgf m).

Checking the Alignment 1

Measure the distance A between the leading edge of the front wheel rims at hub height.

Measure the corresponding distance B at the trailing edge.

Distance A should be less than distance B by 0 to 5 mm (0 to 0.2 in). If this is incorrect, proceed to step 2.

Adjusting the Alignment 1

Remove split pin C and nut D. Disconnect the left hand track rod end E from the steering arm F.

Note: Orientate clamp H as illustrated, i.e. so that nut/bolt G is horizontal on the underside of the track rod.

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels 5

Align nut D with the split pin hole by tightening to the next castellation. Fit the split pin C.

9803/9970-01 (3-00)

Routine Maintenance Tyres and Wheels

Fender Adjustment d Tighten screws C into the holes and clamp firmly. e 2

D D A

To maintain the full effectiveness of the fenders when alternative tyres are fitted or if track width is altered the fenders can be moved from side-to-side. K Adjustable Track Width ( T 77) a

Tighten screws B to further clamp support arm A.

Loosen clamping screws D, position the fenders centrally over the tyre treads and then re-tighten screws D.

Note: The illustration shows the front fenders. The rear fenders are mounted on the rear of the chassis but are adjustable in exactly the same way.

C090620

Fig 61.

To accommodate various tyre diameters and working conditions the fenders can be adjusted vertically. Proceed as follows: a

Release support arm A clamping screws B.

b Support the fender and then loosen screws C until support arm A can be moved up and down. c

Adjust the height of the fender, at the same time aligning the holes in support arm A with screws C.

9803/9970-01 (3-00)

Routine Maintenance Windscreen Washer

Windscreen Washer Checking Fluid Level Fill the windscreen washer bottle Y with a suitable liquid. The liquid should contain a de-icing fluid to prevent freezing. Do not use engine coolant antifreeze.

C090520

Fig 62.

9803/9970-01 (3-00)

Routine Maintenance Automatic Trailer Coupling (Optional)

Automatic Trailer Coupling (Optional) Checking for Wear 1

The coupling pin diameter A is either 30 mm (1.18 in) or 38 mm (1.5 in) when new. The 30 mm pin must not wear down below 28 mm (1.1 in) at any point. The 38 mm pin must not show any measurable wear.

The coupling ring diameter B must not be more than 41.5 mm (1.63 in) at any point.

If wear exceeds the above limits, contact your nearest JCB Distributor.

Note: Whenever the coupling has been pressure-washed it must always be greased. Any repair work or fitting of a new coupling must be done in accordance with the Service Manual and inspected by an officially recognised expert.

172210-C1

Fig 63.

9803/9970-01 (3-00)

Routine Maintenance Automatic Trailer Coupling (Optional)

Page left intentionally blank

9803/9970-01 (3-00)

Section A Hitches and Attachments Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section A - Hitches and Attachments

Notes:

A-0

9803/9970-01

A-0

Section A - Hitches and Attachments Contents Page No. Agricultural Front Hitch SYSTEM Introduction ............................................................................................. A1-1 Operation Overview ................................................................................ A1-2 Fault Finding ........................................................................................... A1-3 Position Sensor Removal and Replacement .......................................... A1-4 Position Sensor Calibration .................................................................... A1-5 Rear Hitch Draft Control SYSTEM Introduction ............................................................................................. Operation Overview ................................................................................ Fault Finding ........................................................................................... Draft Pins Removal and Replacement ................................................... Position Sensor Removal and Replacement .......................................... Position Sensor Calibration ....................................................................

A-i

A2-1 A2-2 A2-4 A2-5 A2-6 A2-7

A-i

Section A - Hitches and Attachments Contents

A-ii

Page No.

A-ii

Section A1 - Hitches and Attachments

Agricultural Front Hitch 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.. Descriptions and procedures relate to the system and not the individual devices. 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.

K Operation Overview ( T A1-2) K Fault Finding ( T A1-3) K Position Sensor Removal and Replacement ( T A1-4) K Position Sensor Calibration ( T A1-6)

A1-1

9803/9970-01 (A-02-00)

A1-1

Section A1 - Hitches and Attachments Agricultural Front Hitch SYSTEM Operation Overview

Operation Overview Draft central control ECU (ECU1) controls the front hitch raise and lower functions (implement draft) by energising and de-energising the hitch spool valve solenoids. See Section E, Spool Valves SYSTEM. The operator hitch controls are not connected directly to the draft control ECU. The control signals are processed by the auxiliary control ECU (ACE) transmitted on CAN1. See Section E, Spool Valves SYSTEM. Position sensor B allows the ECU to control the maximum and minimum hitch height as pre-set by the operator.

C096060

Fig 1.

A1-2

9803/9970-01 (A-02-00)

A1-2

Section A1 - Hitches and Attachments Agricultural Front Hitch SYSTEM Fault Finding

Fault Finding – Use JCB Service Master to check for correct draft control operation. Use central controller, front hitch control diagnostic window. – Check the data log for relevant fault codes. – Check that the hitch position sensor installations is correct. – Check related wires and connectors for defects. Use the Service Master help file to identify wires and connectors.

A1-3

9803/9970-01 (A-02-00)

A1-3

Section A1 - Hitches and Attachments Agricultural Front Hitch SYSTEM Position Sensor Removal and Replacement

Position Sensor Removal and Replacement Removal and Replacement The numerical sequence shown on the illustration is intended as a guide to removal. For replacement the sequence should be reversed.

When Removing 1

Slacken the screw 4 and remove the screws 5 to allow the position sensor 6 to be removed.

Locate the shaft of the position sensor 6 in the D shaped hole of the arm 8 before tightening the screw 4.

Before tightening the screws 5, rotate the position sensor 6 so that the screws are in the mid position of the slotted holes in the flange of the position sensor.

Please complete the front hitch position sensor calibration.

Note: This calibration must be done if either the original or a new position sensor has been fittted.

A1-4

9803/9970-01 (A-02-00)

A1-4

Section A1 - Hitches and Attachments Agricultural Front Hitch SYSTEM Position Sensor Removal and Replacement

A1-5

9803/9970-01 (A-02-00)

A1-5

Section A1 - Hitches and Attachments Agricultural Front Hitch SYSTEM Position Sensor Calibration

Position Sensor Calibration Important: Be aware that this process is time critical read all the following steps before commencing. 1

Before the second instrument panel buzzer has finished sounding, slowly cycle the green spool lever 1 from its central neutral position to extend V, then to retract W, and back to neutral N. K Fig 2. ( T A1-6)

Ensure the transport lock T is not engaged, the green spool lever 1 is in its neutral position N, and the touch screen is powered `Off'.

The instrument panel will display a code and begin to count down from 25 seconds. 5

Check that the front hitch spool is correctly configured. A configured front hitch slice is always position 6. Position 5 is for the optional yellow slice (in this example not fitted).

Note: If the slices are configured then DO NOT alter this spool valve configuration screen. Continue the front hitch position sensor calibration procedure as follows: MIRRORS L

C090110-C1

Fig 2.

C071760

Fig 4.

6 Z W N R

4 BS

U D

Fig 3.

Switch the Ignition `On'.

As the first instrument panel buzzer has finished sounding, engage the transport lock T.

C039350-B6

Fig 5. 6

Using button D, scroll down to â&#x20AC;&#x2DC;STARTâ&#x20AC;&#x2122; Start the engine and run at idle.

A1-6

9803/9970-01 (A-02-00)

A1-6

Section A1 - Hitches and Attachments Agricultural Front Hitch SYSTEM Position Sensor Calibration 7

Using button D, scroll down to ‘Tx OFF’.

Disengage the transport lock.

Using button D, scroll down to ‘SLo’ Check hitch depth wheel B is at lowest setting (turned fully forwards). Using the front hitch control A, lower the front linkage to the lowest position. Typical value approximately 150 to 250.

Note: If the value is outside these limits, an error code will be generated when the hitch is operated. 10

Using button D, scroll down to ‘Save’, using the down arrow D. Press button F to save changes and exit calibration mode.

C C096050-C1

Fig 6. Check lift height control C is set to maximum (turned fully clockwise). 8

Using button D, scroll down to ‘SHi’ Using the front hitch control A, raise the front linkage to the highest position. Typical value approximately 750 to 850.

Note: If the value is outside these limits, a fault code will be generated when the hitch is operated. Press button F to save – ‘OK’ displayed. Note: Button F is located in one of two positions.

F C

C096040-C1

Fig 7.

A1-7

9803/9970-01 (A-02-00)

A1-7

Section A2 - Hitches and Attachments

Rear Hitch Draft Control 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.. Descriptions and procedures relate to the system and not the individual devices. 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.

K Operation Overview ( T A2-2) K Automatic Draft Control ( T A2-2) K Fault Finding ( T A2-4) K Draft Pins Removal and Replacement ( T A2-5) K Position Sensor Removal and Replacement ( T A2-6) K Position Sensor Calibration ( T A2-7)

A2-1

9803/9970-01 (A-02-00)

A2-1

Section A2 - Hitches and Attachments Rear Hitch Draft Control SYSTEM Operation Overview

Operation Overview Draft control ECU (EHR-Z) controls the rear hitch raise and lower functions (implement draft) by energising and deenergising the hitch spool valve solenoids. See Section E, Spool Valves SYSTEM. The operator hitch controls are not connected directly to the draft control ECU. The control signals are processed by the auxiliary control ECU (ACE) and the central control ECU (ECU1) and transmitted on CAN1. See Section E, Spool Valves SYSTEM. Position sensor 1 allows the ECU to control the maximum and minimum hitch height as pre-set by the operator.

Automatic Draft Control The implement working depth is automatically controlled. The draft control ECU gets input from load sensors (draft pins 2) in the left and right links of the hitch. When the force from the implement is above pre-set limits the ECU automatically raises the hitch to reduce the force from the implement. As the force reduces the ECU responds by lowering the hitch. The draft control potentiometer (draft mixture control) changes the sensitivity of the automatic draft control. One end of the control scale enables maximum automatic draft control and minumum positional (height) control. At the other end of the control scale there is maximum positional control and minumum automatic draft control. The potentiometer setting is transmitted on CAN1 by the auxiliary control ECU (ACE). When ground radar is present the draft control ECU calculates the amount of wheel slip by comparing the radar calculated ground speed with that from the transmission speed sensors. The result is compared with the maximum allowed wheel slip pre-set by the operator. When the amount of wheel slip is more than the pre-set limit, the draft control ECU responds by raising the hitch. The force from the implement reduces and the amount of wheel slip is less. The draft control ECU transmits the wheel slip value on CAN1. Dashboard ECU (EMS) displays the wheel slip value as percentage (3). The maximum allowed wheel slip value is set by the operator via the touch screen (DECU).

C096190

Fig 1.

A2-2

9803/9970-01 (A-02-00)

A2-2

Section A2 - Hitches and Attachments Rear Hitch Draft Control SYSTEM Operation Overview TRANS SPEED SENSOR

RADAR

POSITION SENSOR

DRAFT PIN L/H

DRAFT PIN R/H

EHR-Z 1

CAN 1

ACE

EMS

DECU

WHEEL SLIP SWITCH

C096200

Fig 2. Draft control network connections 1

Draft control ECU (EHR-Z)

Dashboard ECU (EMS)

Touch Screen ECU (DECU)

Auxiliary controls ECU (ACE)

Transmission speed sensor

Radar unit

Rear hitch position sensor

Draft pin LH (force sensor)

Draft pin RH (force sensor)

Wheel slip control function ON/OFF switch

A2-3

9803/9970-01 (A-02-00)

A2-3

Section A2 - Hitches and Attachments Rear Hitch Draft Control SYSTEM Fault Finding

Fault Finding – Use JCB Service Master to check for correct draft control operation. Use the EHR (draft control ECU) diagnostic window. – Check the data log for relevant fault codes. – Check that the hitch position sensor and draft pin installations are correct. – Check related wires and connectors for defects. Use the Service Master help file to identify wires and connectors.

A2-4

9803/9970-01 (A-02-00)

A2-4

Section A2 - Hitches and Attachments Rear Hitch Draft Control SYSTEM Draft Pins Removal and Replacement

Draft Pins Removal and Replacement TBA

A2-5

9803/9970-01 (A-02-00)

A2-5

Section A2 - Hitches and Attachments Rear Hitch Draft Control SYSTEM Position Sensor Removal and Replacement

Position Sensor Removal and Replacement TBA

A2-6

9803/9970-01 (A-02-00)

A2-6

Section A2 - Hitches and Attachments Rear Hitch Draft Control SYSTEM Position Sensor Calibration

Position Sensor Calibration Calibrate the position sensor 1 after installation. Calibration is done by adjusting the angle of the position sensor. There is no electronic calibration procedure. The sensor must be adjusted so that the arm rest hitch controls (field controls) do not cause the lift rams to extend fully. When the rams extend fully the hydraulic relief valve operates (opens) and the machine is less efficient. Note: Keep clear of the rear hitch and linkage. The rear hitch and linkage can raise or lower suddenly during the procedure. 1

Remove the protective cover to get access to the sensor 1. Start the engine and set the rear hitch controls as follows: a

Set the drop rate control C to maximum.

b Set the raise height control E to maximum. c

Set the draft mixture control H fully towards â&#x20AC;&#x2DC;positionâ&#x20AC;&#x2122;.

d Set the rear working depth to maximum with control wheel G. 2

Use the arm rest rear hitch control B to lower and then raise the rear hitch.

Loosen the sensor mounting screws 2 and slowly rotate the sensor 1 clockwise until the machine hydraulic relief valve operates. Slowly rotate the sensor in the opposite direction until the relief valve closes and the hitch lowers by about 10mm. Tighten the mounting screws.

Press and hold the hitch override switch A to fully raise the hitch. The lift rams should extend a further 10mm. The hydraulic relief valve should operate. Release the switch.

Operate the hitch several times with the arm rest control B, the hydraulic relief valve should not operate. If the relief valve operates (opens) the position sensor adjustment is incorrect.

A2-7

9803/9970-01 (A-02-00)

Fig 3.

A2-7

Section A2 - Hitches and Attachments Rear Hitch Draft Control SYSTEM Position Sensor Calibration

Page left intentionally blank

A2-8

9803/9970-01 (A-02-00)

A2-8

Section C Electrics Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section C - Electrics

Notes:

C-0

9803/9970-01

C-0

Section C - Electrics Contents Page No. Fuses and Relays Introduction ............................................................................................. C1-1 Fuses ...................................................................................................... C1-2 Relays .................................................................................................... C1-6 Schematics Introduction ............................................................................................. C2-1 All Machines ........................................................................................... C2-2 Harness SYSTEM Introduction ............................................................................................. C3-1 Drawings and Interconnection ................................................................ C3-2 Electronics Network SYSTEM Introduction ............................................................................................. C4-1 System Overview .................................................................................... C4-3 Fault Finding ........................................................................................... C4-4 Engine Control ECU ............................................................................... C4-5 Dashboard ECU (EMS) .......................................................................... C4-8 Central Control ECU (ECU1) ................................................................ C4-11 Transmission Control ECU (TECU) ...................................................... C4-14 Draft Control ECU (EHR-Z) .................................................................. C4-17 ABS Control ECU ................................................................................. C4-20 Auxiliary Controls ECU (ACE) .............................................................. C4-23 Touch Screen ECU (DECU) ................................................................. C4-26 Ground Radar SYSTEM Operation Overview ................................................................................ C5-1 Fault Finding ........................................................................................... C5-3 Calibration .............................................................................................. C5-4 Service Master SYSTEM Why Use Service Master? ...................................................................... C6-1 What is Service Master? ......................................................................... C6-2 How to Set Up Service Master ............................................................... C6-3 Connect Service Master to the Machine CANbus ................................ C6-10 Service Master Tools ............................................................................ C6-11 Fault Code SYSTEM Fault Codes ............................................................................................ C7-1 Battery Charging SYSTEM Introduction ............................................................................................. Technical Data ........................................................................................ Electrical Operation and Schematics ...................................................... Test Procedures ......................................................................................

C8-1 C8-2 C8-3 C8-4

Battery Introduction ............................................................................................. C9-1 Specifications ......................................................................................... C9-2 Access .................................................................................................... C9-3 Maintenance ........................................................................................... C9-4 Test Procedures ...................................................................................... C9-7 Battery Disconnection/Connection ......................................................... C9-9 Removal and Replacement .................................................................. C9-10

C-i

Section C - Electrics Contents

C-ii

Page No.

C-ii

Section C1 - Electrics Fuses and Relays Introduction

Fuses and Relays Introduction This topic contains information for identification and location of fuses and relays.

K Relays ( T C1-2) K Access and Location ( T C1-2) K Main Fuses ( T C1-7) K Lighting Fuses ( T C1-8) K Engine-mounted Fuses ( T C1-9) K Relays ( T C1-2) K Access and Location ( T C1-2) K Relays at the Rear of the Cab ( T C1-3) K Relays at the Front of the Cab ( T C1-4) K Relays at the Side of the Cab ( T C1-4) K Relays in Engine Compartment ( T C1-5)

C1-1

9803/9970_01 (C-09-00)

C1-1

Section C1 - Electrics Fuses and Relays Relays

Relays Access and Location Relays are located and accessed as follows:

1 1

2 3

2 C095950

Fig 2. 2

Inside the cab on the left side of the steering column. Undo screws 1 and remove the panel 2. K Relays at the Front of the Cab ( T C1-4)

C095970

Fig 1. 1

Inside the cab at the rear. Remove the trim panel behind the drivers seat. Undo screws 1 and remove the panel 2. K Relays at the Rear of the Cab ( T C1-3) When installing the trim panel be sure to locate the holes 3 on the spigots in the cab floor.

1 2 C089790-C4

Fig 3.

C1-2

Inside the right side of the cab. Open the right side door. Undo screws 1 and remove the panel 2. K Relays at the Side of the Cab ( T C1-4)

Inside the engine compartment. Open the engine cover. K Relays in Engine Compartment ( T C1-5)

9803/9970_01 (C-09-00)

C1-2

Section C1 - Electrics Fuses and Relays Relays

Relays at the Rear of the Cab

MS IWD HSR

ABSD RFWL ORWL APWL OFWL REVL IRWL HDWL IFWL

C092590-C1

Fig 4. Table 1. Item

Description

ABSD ABS diagnostic relay APWL ‘A’ post work lights relay HDWL Headlights relay HSR

Heated screen relay

IFWL

Inner front work lights relay

IRWL

Inner rear work lights relay

OFWL Outer front work lights relay ORWL Outer rear work lights relay REVL

Reverse lights relay

RFWL Rear fender work lights relay BL

Brake lights relay

A/C compressor clutch relay

IWD

Intermittent wiper delay relay

Maintained sensor supply relay

Powershift dump relay

Start inhibit relay

C1-3

9803/9970_01 (C-09-00)

C1-3

Section C1 - Electrics Fuses and Relays Relays

Relays at the Front of the Cab

Relays at the Side of the Cab

STT

IW ETD

TTT

RF RFL

C095940-C1

Fig 5. Table 2. Item

Description

Buzzer relay

ETD

Engine torque de-rate relay

Intermittent wiper relay

Rear fog light relay

RFL

Rear fog light latch relay

STT

Single trailer turn relay (if fitted)

TTT

Twin trailer turn relay (if fitted)

C1-4

C089790-C3

Fig 6. Table 3. Item

Description

Heated screen relay

Ignition relay

9803/9970_01 (C-09-00)

C1-4

Section C1 - Electrics Fuses and Relays Relays

Relays in Engine Compartment

C092610

Fig 7.

438660-C1

Fig 8. Table 4. Item

Description

Inlet manifold heater relay

Fuel injection pump relay

C1-5

9803/9970_01 (C-09-00)

C1-5

Section C1 - Electrics Fuses and Relays Fuses

Fuses Access and Location Fuses are located and accessed as follows:

1 1

2 C095950

Fig 10.

1 2

Inside the cab on the left side of the steering column. Undo screws 1 and remove the panel 2. K Enginemounted Fuses ( T C1-9).

Inside the engine compartment. Open the engine cover. K Engine-mounted Fuses ( T C1-9).

2 C089790-C4

Fig 9. 1

Inside the right side of the cab. Open the right side door. Undo screws 1 and remove the panel 2. K Main Fuses ( T C1-7).

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

If a fuse blows, find out why and rectify the fault before fitting a new one.

C1-6

9803/9970_01 (C-09-00)

C1-6

Section C1 - Electrics Fuses and Relays Fuses

Main Fuses

Radio memory, Side console illumination, Beacon socket, Interior light.

7.5

Hazard warning lamps

â&#x20AC;&#x2DC;Aâ&#x20AC;&#x2122; post front work lights

Headlight bar work lights

Headlamp flasher

Radio power supply

7.5

Auxiliary socket

Cigar lighter

Electronic draft control, Instrument cluster, Hydraulics Electronic Control Unit (ECU 1)

B10

Engine management Electronic Control 30 Unit power supply (ECU)

Reverse lights

Direction indicators

7.5

ISO 11786 socket, Ignition

Instrument cluster, Switch illumination, Speed sensor diff lock cut out relay, Brake light relay

7.5

Radar

Diagnostic connector,

3-pin power socket

3-pin power socket and terminal posts

Air drier

C10

Electronic spool valves

Lights maxi fuse

Transmission

7.5

Fuse Rating (Amps)

Fuse Circuit No

C089790-C2

Fig 11. Table 5. Main Fuses Fuse Circuit No

Fuse Rating (Amps)

Start inhibit

Brake lights

Rear wash/wipe, Seat heating and suspension

Horn, Front windscreen washers and wipers

A4 A5

Engine management Electronic Control 5 Unit (ECU)

Transmission Electronic Control Unit (ECU) power supply

Electronic draft control

Front work lights (outer)

Display Electronic Control Unit (ECU) power supply

A7 A8

Inner front work lights

HVAC unit, AC compressor

Display Electronic Control Unit (ECU) power supply

A10

Hitch/spool valve Electronic Control Unit (ECU)

Display Electronic Control Unit (ECU) power supply

Transmission sensor supply

C1-7

9803/9970_01 (C-09-00)

C1-7

Section C1 - Electrics Fuses and Relays Fuses Fuse Circuit No

Fuse Rating (Amps)

Fuse Circuit No

Fuse Rating (Amps)

Transmission Electronic Control Unit (ECU) power supply

SAFIM trailer brakes

Trailer socket power

Transmission Electronic Control Unit (ECU) bank 3 power supply

Transmission Electronic Control Unit (ECU) bank 2 power supply

J10

Transmission Electronic Control Unit (ECU) bank 1 power supply

Outer rear work lights

Inner rear work lights

Rear fender work lights

Fastrac central controller (ECU1) power 3 supply

Electronic Control Unit (ECU I) sensors 5 power supply

Fastrac central controller (ECU1) bank 1 power supply

7.5

Fastrac central controller (ECU1) bank 4 and 5 power supply

Lighting Fuses

6 2

C095940

Fastrac central controller (ECU1) power 3 supply

Fastrac central controller (ECU1) bank 3 power supply - suspension control

K10

Fastrac central controller (ECU1) bank 2 power supply - PTO, diff lock, 4WD control

Table 6. Optional Equipment Fuses E, F, G Fuse Circuit Fuse No Rating (Amps) E1

Trailer ABS

Tractor ABS

Heated screen RH

Heated screen LH

Heated rear screen

Heated door mirrors

Powered door mirrors

C1-8

Fig 12. Table 7. Lighting Fuses Fuse Circuit No

Fuse Rating (Amps)

Main beam

Dipped beam

Rear Fog lights

LH Side lights

7.5

RH Side lights

7.5

Auxiliary lights switching

Note: Lighting circuits are also protected by fuse H. K Main Fuses ( T C1-7)

9803/9970_01 (C-09-00)

C1-8

Section C1 - Electrics Fuses and Relays Fuses

Engine-mounted Fuses To gain access to the engine-mounted fuses, pull off the relevant plastic cover as shown. The fuses are each retained by two nuts.

C035860

Fig 13. Fuse Circuit No

Fuse Rating (Amps)

100

C1-9

Manifold Heater

9803/9970_01 (C-09-00)

C1-9

Section C1 - Electrics Fuses and Relays Fuses

C1-10

9803/9970_01 (C-09-00)

C1-10

Section C2 - Electrics

Schematics Introduction This topic contains electrical schematics for the complete system.

K Sheets ( T C2-2) K Component Keys ( T C2-15)

C2-1

9803/9970-01 (C-10-00)

C2-1

Section C2 - Electrics Schematics All Machines

All Machines Sheets K Sheet 1 of 12 Ignition Switch, Starter, Alternator, Battery and Fuses ( T C2-3) K Sheet 2 of 12 Ignition Relays, Fuses, ISO Resistors and Warning Buzzers ( T C2-4) K Sheet 3 of 12 Road lighting ( T C2-5) K Sheet 4 of 12 Fastrac Central Controller (FCC) ( T C2-6) K Sheet 5 of 12 JCB 6 x 4 Transmission ( T C2-7) K Sheet 6 of 12 DECU and Unideck Instrument Panel ( T C2-8) K Sheet 7 of 12 CAN Networks ( T C2-9) K Sheet 8 of 12 Air Con/Heater, Mirror Controls, and Heated Screens ( T C2-10) K Sheet 9 of 12 Radio, Worklights, Auxiliary Sockets and Air Drier ( T C2-11) K Sheet 10 of 12 Front and Rear Wash/Wipe, Safim, ABS and EDC Draft Control ( T C2-12) K Sheet 11 of 12 Spool Valves, Hitch Controls and Engine ( T C2-13) K Sheet 12 of 12 Earths ( T C2-14)

C2-2

9803/9970-01 (C-10-00)

C2-2

C2-3

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 1. Sheet 1 of 12 Ignition Switch, Starter, Alternator, Battery and Fuses

332-W9255-1-1

Section C2 - Electrics Schematics All Machines

C2-3

C2-4

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 2. Sheet 2 of 12 Ignition Relays, Fuses, ISO Resistors and Warning Buzzers

332-W9255-1-2

Section C2 - Electrics Schematics All Machines

C2-4

C2-5

9803/9970-01 (C-10-00) C

4 9A

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 3. Sheet 3 of 12 Road lighting

332-W9255-1-3

Section C2 - Electrics Schematics All Machines

C2-5

C2-6

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 4. Sheet 4 of 12 Fastrac Central Controller (FCC)

332-W9255-1-4

Section C2 - Electrics Schematics All Machines

C2-6

C2-7

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 5. Sheet 5 of 12 JCB 6 x 4 Transmission

332-W9255-1-5

Section C2 - Electrics Schematics All Machines

C2-7

C2-8

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 6. Sheet 6 of 12 DECU and Unideck Instrument Panel

332-W9255-1-6

Section C2 - Electrics Schematics All Machines

C2-8

C2-9

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 7. Sheet 7 of 12 CAN Networks

332-W9255-1-7

Section C2 - Electrics Schematics All Machines

C2-9

C2-10

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 8. Sheet 8 of 12 Air Con/Heater, Mirror Controls, and Heated Screens

332-W9255-1-8

Section C2 - Electrics Schematics All Machines

C2-10

C2-11

9803/9970-01 (C-10-00) 2

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 9. Sheet 9 of 12 Radio, Worklights, Auxiliary Sockets and Air Drier

7 6

332-W9255-1-9

Section C2 - Electrics Schematics All Machines

C2-11

C2-12

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 10. Sheet 10 of 12 Front and Rear Wash/Wipe, Safim, ABS and EDC Draft Control

332-W9255-1-10

Section C2 - Electrics Schematics All Machines

C2-12

C2-13

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 11. Sheet 11 of 12 Spool Valves, Hitch Controls and Engine

332-W9255-1-11

Section C2 - Electrics Schematics All Machines

C2-13

C2-14

9803/9970-01 (C-10-00)

K Component Keys ( T C2-15)

K Sheets ( T C2-2)

Fig 12. Sheet 12 of 12 Earths

332-W9255-1-12

Section C2 - Electrics Schematics All Machines

C2-14

C2-15 Front modulator Rear left modulator Rear right modulator

AP2 AP3 AP4

K Table 2. ABS Chassis harness ( T C2-15)

K Table 3. ABS Pannier harness ( T C2-15)

K Table 4. “Arm Rest harness ( T C2-15)

9803/9970-01 (C-10-00)

Tractor ABS6 ECU connector X1

Tractor ABS6 ECU connector X2

ABS CAB bus interconnect

A18

A19

A24

ABS T socket

Engine earth block

Rear LH speed sensor

Rear RH speed sensor

Front RH speed sensor

Front LH speed sensor

ABS1

ABS3

ABS8

ABS9

ABS10

ABS11

Table 2. ABS Chassis harness Key to Connectors:

ABS diagnostic relay

A11

Table 1. ABS6-Cab Harness Key to Connectors:

K Table 14. Front Hitch ( T C2-18)

K Table 13. Transmission harness ( T C2-17)

K Table 12. Safim Valve harness ( T C2-17)

K Table 11. Roof Liner harness ( T C2-17)

K Table 10. Heated Screen and Mirror harness ( T C2-17)

K Table 9. EDC Rear Fender Harness ( T C2-17)

K Table 8. Earth Cables ( T C2-17)

K Table 7. Cab Harness ( T C2-16)

K Table 6. Chassis Harness ( T C2-15)

Turbo request button

Auxiliary lighting relay base

Trailer socket Transmission oil filter blocked switch

C1 C3

Table 6. Chassis Harness Key to Connectors:

AHL9

RH front auxiliary headlamp

LH front auxiliary headlamp

AHL4 AHL5

Auxiliary lights switch

AHL3

Table 5. Auxiliary Lights harness Key to Connectors:

CAR025

Hitch control pot 5 front drop rate

Hitch control pot 4 front max raise

CAR018 CAR019

Hitch control pot 3 rear drop rate

Hitch control pot 2 rear max raise

CAR016 CAR017

Hitch control pot 1 rear mix

CAR015

Hitch/spool valve ECU

CAR012 Rear hitch control

Hand throttle

CAR011

CAR014

Joystick axis Z and Y

CAR010

Front hitch control

Joystick base button

CAR009

CAR013

Joystick buttons 1-7

CAR008

Table 4. “Arm Rest harness Key to Connectors:

Bulkhead connector

AP1

K Table 1. ABS6-Cab Harness ( T C2-15)

K Table 5. Auxiliary Lights harness ( T C2-15)

Table 3. ABS Pannier harness Key to Connectors:

Component Keys

CAN1 engine CAN1 term resistor RH headlight bar worklight

C75 C79 C81

LH rear suspension level sensor

Lower solenoid

Suspension rear right down

C104

Suspension rear right up

Suspension rear left up

C103 C105

Suspension rear left down

RH rear suspension level sensor C102

C101

C100

Diff lock solenoid

Steering angle sensor

C89 C95

Engine ECU earth stud

Engine power

LH front bar headlamp C87

C85

C83

LH headlight bar worklight

Brake reservoir 3

C73

C82

Compressor clutch RH front bar headlamp

C64

Horn

C48 C60

Engine earth block

Front intermittent wiper relay

Air tank 2

Air tank 1

Front wiper motor 2 speed

LH rear light cluster

RH rear light cluster

Front brake reservoir

Rear brake reservoir

Air tank 3

Air drier

C40

C39-E

C34

C33

C30

C19

C18

C14

Key to Connectors:

Section C2 - Electrics Schematics All Machines

C2-15

C2-16

Pilot valve

ECU26

9803/9970-01 (C-10-00)

Powershift dump relay

Brake light relay

CR4-E

Ignition switch

CR3/CR3A

CR4-D

CAN1 transmission ECU

CCA172

Starter relay

Button enter

CCA040

CR4-C

Button down

CCA039

Transmission management relay

Button up

CCA038

Rear wiper relay

Transmission ECU1 Conn C

CAA173

CR4-B

Transmission ECU1 Conn B

CAA172

CR4-A

Transmission ECU1 Conn A

CAA171

Table 7. Cab Harness Key to Connectors:

Auxiliary hydraulic pressure transducer

Spool valve 5

ECU25

ECU32

Spool valve 4

ECU24

Front hitch position sensor

Spool valve 3

ECU23

CAN2 term resistor

Spool valve 2

ECU22

ECU30

Spool valve 1

ECU21

ECU28

CAN2 FCC ECU

ISO 11786 socket

Master buzzer Rear fog light relay Rear fog light relay Engine torque derate relay

CR38 CR39-A CR39-B CR39-C CR39-D

Heater unit

Battery earth 1

CR37

CR40

Rear washer pump

CR36

Flasher relay

Clutch down switch

CR35

CR39-F

Rear RH inner worklight Rear LH outer worklight

CR34

Ignition relay

CR33

Rear LH inner worklight

CR29

Beacon switch

LH number plate light

CR27

CR32

Rear wiper motor

CR26

Auxiliary power socket

RH number plate light

CR25

Beacon socket

Worklight switch

CR24

CR31

Front LH outer worklight

CR21

CR30

Front RH inner worklight

CR14 Front LH inner worklight

Front RH outer worklight

CR11

CR18

Air con unit

CR10

CR16

4WD/Diff lock request switch Rear RH outer worklight

CR9

Front PTO cab switch

CR8

FCC ECU1 Conn B

ECU2

ECU6

Rear PTO cab switch

CR7

Position sensor

E19

ECU2

Rear wiper switch

CR5

Radar speed sensor

E17

CR135

CR134

CR125

CR119

CR117

CR107

CR106

CR94

CR81

CR80

CR78

CR77

CR72

CR71

CR70

CR69

CR68

CR65

CR59

CR58

CR57

CR53

CR48

CR46

CR45

CR44

CR43

CVT display ECU (red)

Binary pressure switch

Battery earth 2

Diagnostic socket

High level brake light

Throttle pedal sensor DECU

Throttle pedal position sensor

Auxiliary power sockets

Air gauge light

RH A post worklight

Rear fog light switch

Main lights switch

Proximity flow switch

RH side repeater

LH side repeater

Trailer 2 flasher unit

Hazard switch

CAN1 EMS

Instrument cluster (Unideck)

LH A post worklight

Park brake switch

Brake light switch

Clutch potentiometer mV

Front washer pump

Maxi lights fuse

Battery positive terminal

LH column switch

RH column switch wipe/wash horn only

RH column switch (indicators only)

RH column switch (main/dip only)

Minor buzzer

CR42

Compressor clutch relay

CR4-F

Raise solenoid

E8 CR43

Key to Connectors:

Section C2 - Electrics Schematics All Machines

C2-16

C2-17

Wheel slip enable switch

Diode

Water valve actuator

Brake pedal switch

EDC draft control ECU bosch EHR Z

LH draft pin

RH draft pin

Area cut out jack socket

Raise/lower switch

ECU connector A

ECU connector B

ECU connector C

CANbus 2

ISO resistor pack

Transport switch

Outer front worklights relay

Inner front worklights relay

A-post worklights relay

Headlight bar worklight relay

Outer rear worklights relay

Inner rear worklights relay

Rear fender worklights relay

Reverse lights relay

CR147

CR149

CR156

E11

ECU1

ECU2

ECU3

ECU4

ECU15

ECU17

RYL1

RYL2

RYL3

RYL4

RYL5

RYL6

RYL7

RYL8

CR143

CAN1 ABS

Driver seat

CR139

CR145

Operator present resistor

CR136

CR144

CAN1 DECU

CVT display ECU (black)

CR135

Key to Connectors:

Chassis earth Engine earth block

M10 M12

RHS EDC lower button

RHS EDC raise button

RH rear fender worklight

RHS PTO request button

LHS EDC lower button

LHS EDC raise button

LH rear fender worklight

LHS PTO request button

9803/9970-01 (C-10-00)

Timer relay Heated screen relay base LH front heated screen RH front heated screen Battery earth Mirror control joystick LH mirror RH mirror Rear heated screen

HS2 HS3 HS6 HS7 HS8 HS10 HS12 HS13 HS17

RH front speaker LH front speaker

RL1 RL2

Table 11. Roof Liner harness Key to Connectors:

Heated front screen switch

HS1

Table 10. Heated Screen and Mirror harness Key to Connectors:

RRF6

RRF5

RRF4

RRF3

LRF8

LRF5

LRF4

LRF3

Table 9. EDC Rear Fender Harness Key to Connectors:

Gearbox earth

Table 8. Earth Cables Key to Connectors: Radio speakers

Panel light

LH interior light

Radio power

SAFIM solenoid

SAFIM valve oil pressure switch

SAFIM light block

SAFIM handbrake pressure switch

540/1000 position sensor PTO rear clutch solenoid

PTO front speed sensor

PFS PR

PTO front brake solenoid

PFB PPS

PTO front clutch solenoid

Powershift Solenoid R

Powershift Solenoid E

Powershift Solenoid D

Powershift Solenoid C

Powershift Solenoid B

Powershift Solenoid A

Main line low oil pressure switch

Master clutch oil temperature sensor

PSR

PSE

PSD

PSC

PSB

PSA

OPS

MCOT

Direction/Speed sensor

Master clutch lube solenoid

MCL DSS

Master clutch brake solenoid

MC MCB

4 wheel drive solenoid Master clutch solenoid

4WD

Table 13. Transmission harness Key to Connectors:

SA12

SA11

SA9

SA3

Table 12. Safim Valve harness Key to Connectors:

RL7

RL5

RL4

RL3

Key to Connectors:

Section C2 - Electrics Schematics All Machines

C2-17

C2-18

Transmission O/P speed sensor

Transmission oil temperature sensor

Range I/P speed sensor

TOS

TOT

TRIS

Front hitch lower

Front hitch raise

Table 14. Front Hitch Key to Connectors:

Range solenoid 1F Low

Rail 2 position sensor

R2S

Range solenoid 1R XLow

Rail 1 position sensor

R1S

R1R XL

PTO rear speed sensor

PRS

R1F L

PTO rear brake solenoid

PRB

Key to Connectors:

Section C2 - Electrics Schematics All Machines

9803/9970-01 (C-10-00)

C2-18

Section C3 - Electrics

Harness 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.. Descriptions and procedures relate to the system and not the individual devices. 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.

K Drawings and Interconnection ( T C3-2)

C3-1

9803/9970-01 (C-03-00)

C3-1

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection

Drawings and Interconnection Harnesses Harness No. 1

Cab Harness 333/P6768

Issue Remarks

K Fig 13. ( T C3-9)

Main components connected to this harness:

Drawing

Air Tanks ECU1 Inputs ECU1 Outputs Transmission ECU Door Connector and Switches Heater and Air Conditioning Mirrors Heated Screens Diagnostic Socket Fuses and Relays Wiper Motors Diff. Lock and PTO Switches Work Lights Number Plate Lights Beacon Socket and Switch Auxiliary Socket Clutch Down switch and Potentiometer Brake Lights Switch Auxiliary Lights Column Switches Instrument Panel Throttle Position Sensor Hazard Switch Armrest Harness Wheel Slip Switch Seat Hitch ECU (EHR draft control) Draft Pins Raise/Lower Switch Transport Switch Cigar Lighter Lighting Switches

C3-2

9803/9970-01 (C-03-00)

C3-2

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection

Chassis Harness 332/W0931

K Fig 23. ( T C3-21)

Main components connected to this harness:

Trailer Socket Heater Motor Fuse Fuel Tank Sender Induction Heaters Horn Alternator Engine ECU Head Lights Work Lights Compressor Clutch Rear Fender Harness Steering Angle Sensor Air Conditioning Pressure Switch Washer Pumps Suspension Sensors Raise and Lower Switches and Solenoids Radar Speed Sensor Spool Valve Solenoids Front Hitch Position Sensor Coolant Level Rear Brake Reservoir Front Brake Reservoir Brake Reservoir 3 Diff. Lock Solenoid Suspension Rear Left Down Solenoid Suspension Rear Left Up Solenoid Suspension Rear Right Down Solenoid Suspension Rear Right Up Solenoid

Arm Rest Harness 333/R1829

K Fig 30. ( T C3-29)

Main components connected to this harness:

Cab Interface DECU ECU (touch screen) Joystick buttons Hand throttle ACE ECU (auxiliary hydraulic control)

ABS Pannier Harness 333/P9127

K Fig 33. ( T C3-33)

Main components connected to this harness:

ABS Chassis/Pannier Interface ABS Front Modulator

C3-3

9803/9970-01 (C-03-00)

C3-3

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection ABS Rear Left Modulator ABS Rear Right Modulator Air Drier Air Tank 3 Air Tank 3 5

ABS 6 Cab Harness 333/P0875

K Fig 34. ( T C3-35)

Main components connected to this harness:

ABS Bulkhead Connector ABS Trailer Socket ABS Chassis/Pannier Interface ABS Fuses ABS ECU

ABS Chassis Harness 333/P9128

K Fig 36. ( T C3-38)

EDC Rear Fender Lighting Harness 333/P0879

K Fig 37. ( T C3-40)

Main components connected to this harness

Chassis Harness interconnect Rear Electronic Draft Control Raise Button Rear Electronic Draft Control Lower Button Rear PTO Request Button Rear Fender Work Light

Heated Front and Rear Screen and Mirrors Harness 333/P0883

K Fig 39. ( T C3-43)

Main components connected to this harness:

Cab harness interface Heated front screen Heated rear screen Heated screen switch Right and left mirrors Mirrors control switch

K Fig 41. ( T C3-46)

Transmission Harness 721/M1991 Main components connected to this harness:

C3-4

Gearbox solenoid control valves

9803/9970-01 (C-03-00)

C3-4

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection

Drawings Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness.

C3-5

9803/9970-01 (C-03-00)

C3-5

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection Cab Harness - 333/P6768 Issue 1

CR1

Table 15. Key to Connectors Rear Bulkhead 1

CR44

Range Column Switch

CR45

Battery Positive

CR46

Maxi Lights Fuse ABS Connector

CR3

Ignition Switch

CR47

CR4

Rear Relays

CR48

Front Washer Pump

CR5

Rear Wiper Switch

CR51

Front Bulkhead

CR7

Rear PTO Switch

CR53

Clutch Potentiometer

CR8

Front PTO Switch

CR57

Brakelight Switch

CR9

4WD/Diff Lock Switch

CR58

Parkbrake Switch

CR10

RRH Outer Worklight

CR59

LH A Post Worklight

CR11

Heater/AC Unit

CR60

RH A Post Worklight

CR12A

Fuse Box A

CR63

Door Switch

CR12B

Fuse Box B

CR65

Instrument Panel

CR12C

Fuse Box C

CR68

Hazard Switch

CR12J

Fuse Box J

CR69

Trailer 2 Relay

CR12K

Fuse Box K

CR70

LH Side Repeater

CR14

FRH Outer Worklight

CR71

RH Side Repeater

CR16

FRH Inner Worklight

CR73

Aux Lights In

CR18

FLH Inner Worklight

CR74

Aux Lights Out

CR21

FLH Outer Worklight

CR77

Main Lights Switch

CR24

Worklight Switch

CR78

Rear Fog Switch

CR25

RH No. Plate Light

CR79

Front Fuse Panel

CR26

Rear Wiper Motor

CR81

Air Gauge Illum

CR27

LH No. Plate Light

CR82

Cigar Lighter

CR29

RLH Inner Worklight

CR85

Aux Lights Supply

CR30

Aux Power Socket

CR94

Aux Power Sockets

CR31

Beacon Socket

CR98

LH Column Switch

CR32

Beacon Switch

CR100

Tractor ABS

CR33

Ignition Relay

CR101

Tractor ABS

CR34

RRH Inner Worklight

CR104

Rear Bulkhead 2

CR35

RLH Outer Worklight

CR106

Throttle Pedal Position Connector

Clutch Down Switch

CR107

Throttle Pedal Idle Validation Switch Connector

CR116

Heated Mirrors Supply

CR117

High Level Brakelight

CR119

Diagnostic Socket

CR120

J1708 Connector

CR125

Battery Negative 2

CR128

Roof Liner Harness Connector

CR36 CR37

Rear Washer Pump

CR38

Battery Negative

CR39

Front Panel Relays

CR40

Heater

CR42

Bleeper

CR43

RH Column Switch

C3-6

9803/9970-01 (C-03-00)

C3-6

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection CR134

ACU Press Switch

IGNS1

Ignition 1

CR135

CVT Display ECU (Red)

IGNS2

Ignition 2

CR136

CVT Display ECU (Black)

ECUIS

ECU1 Switch Sensor Feed

CR142

Armrest Harness Connector

CRIS

Cab Roof Ignition

CR142 CAN

Armrest CAN

PISA4

Panel Ignition A4

TSS1

Transmission Sensor Supply

CR143

Seat

PISC4

Panel Ignition C4

CR144

Wheel Slip Enable

USFS

Undeck Switch Feed Splice

CR146

Diode 2

EDCIS

EDC Ignition

CR147

Diode 3

WLSS

Worklight Supply

CR148

Transmission Bulkhead

BATS1

Battery 1

CR156

Brake Pedal Switch 2

BATS2

Battery 2

Hitch Control

PFSB9

Permanent Feed B9

LH Draft Pin

CRPFS

Cab Roof Permanent Feed

RH Draft Pin

PMLS

Panel Main Lights

Jack Socket

ASS

Alternator Signal

E11

Raise/Lower

RSS2

Radar Signal 2

ECU1

ECU Connector A

TGSRS

True Ground Speed Resistor Splice

ECU2

ECU Connector B

RGSRS

Radar Ground Speed Resistor Splice

ECU3

ECU Connector C

CRES1

Cab Roof Earth 1

ECU4

CAN BUS 2

CRES2

Cab Roof Earth 2

ECU6

ISO 11786 Socket Connector

CRES4

Cab Roof Earth 4

ECU15

ISO 11786 Resistor Connector

ECUES

ECU Earth Splice

ECU 17

Transport Switch

CRES3

Cab Roof Earth 3

CCA038

Button Up

HES

Hitch Earth Splice

CCA039

Button Down

TMES1

Transmission Management Earth 1

CCA040

Button Enter

TMES2

Transmission Management Earth 2

RLY1

Relay Base 1

PES1

Panel Earth 1

RLY2

Relay Base 2

SFPE

Front Panel Earth Splice

RLY3

Relay Base 3

PES3

Panel Earth 3

RLY4

Relay Base 4

SES

Sensor Earth

RLY5

Relay Base 5

CRES6

Cab Roof Earth 6

RLY6

Relay Base 6

OFWLS

Outer Front Worklights

RLY7

Relay Base 7

IFWLS

Inner Front Worklights

RLY8

Relay Base 8

APWLS

A Post Worklights

CCA171

TECU Connector A

ORWLS

Outer Rear Worklights

CCA172

TECU Connector B

RFLS

Rear Foglight Splice

CCA173

TECU Connector C

CDS

Clutch Down Signal

CAR 007

DECU CAN2

FLLS

Foglight Latching Supply

C3-7

9803/9970-01 (C-03-00)

C3-7

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection IRWLS

Inner Rear Worklights

PHLS

Panel Headlights

PLIS

Panel Left Indicator

RHSLS

RH Sidelights

PRIS

Panel Right Indicator

LHSLS

LH Sidelights

PHLS

Panel Headlights

PLIS

Panel Left Indicator

RHSLS

RH Sidelights

PRIS

Panel Right Indicator

LHSLS

LH Sidelights

CRBLS

Cabroof Brakelights

CRBSS

Brake Signal

EDCSSS

EDC Sensor Supply

RLSS

Raise/Lower Switch

MSS1

Maintenance Supply 1

TIPSSS

Transmission Input Speed

TOPSSS

Transmission Output Speed

FFPS

Front Fuse Panel

ACFS

Air Con Feed

C3-8

9803/9970-01 (C-03-00)

C3-8

TO SHEET 4

C 6

A 4

A 2

500

E 8

F 4

E 5

F 2

CR 4

D 6

D 2

C 4

C 2

B 8

B 5

A 6

CR 45

450

F 6

D 4

ITEM HJ

CR 116

CR 42

ITEM HK

CR 58

250

400

C D

IGNS2

CR 47

300

600 350

400

A B D C

BATS2

CR 100

450

IGNS1

CRES6

480

BATS1

360

WLSS

400 500

CR 33

330

S TGSR

28 42

5 7

260

CR 104

CRBLS

290

CR 143

MSS1

20 21

CR 12K

CR 12J

CR 12C

CR 12B

CR 12A

160

180

ECU 6

Fig 13.

TSSS1

LH DRAFT PIN

230

18 0

CR 101

A B

100

HES

150

A B

CR 1

CR 146

300

CRPFS

100

TAPE CR146 TO THIS HARNESS SECTION AS PER JCB STANDARD STD00141

CR 94

PFS39

150

RH DRAFT PIN

120

PISC4

400

3A 1000V

CR 30

APWLS

ACFS 1

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

ITEM EL

ITEM KA

30 0

300 2

ECU 15

8 7 6 5

RE CO AR O NN F EC TO R

CR 148

150

4 3 2 1

13 0

130

110

300 22

0 15

600

x x x x x x x

300

1 2

0 30

CR 3

18 200

x x x x x x x

300

S RGSR

0 20

450

TO SHEET 2

350 50

200

300 250

1950 550 210

SES

0 30

250 100 150

9803/9970-01 (C-03-00)

CDS

EDCSSS

CR 46

200

0 DIO DE

15 10 0

CR BS S

CRIS

CRBSS

180

C3-9 ST

DATUM

100

TMES2

1 2

CR 120

100

150

300

EDCIS

300

TMES1

B J

200

C F

RHSLS

CR 119

CR 142 CAN

31 8

CR 142

22 23

500

ECUIS

0 150

20 CR 38

250

300

CR 125

333-P6768-1 Sheet 1

TO SHEET 3

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

50 100

100

C3-9

600

ECUIS

CR 39

F 6

D 4

F 2

CR 48

F 4

E 8

B 5

CR 37

A 2

A 6

B 8

C 2

C 4

E 5

49a

D 6

D 2

CR 59

100

15 19

CR 70

300

FLLS

ITEM EL

100

10 0

DO NOT FIT HSG. ATTACH TO GAF USING TEARABLE TAPE

CR 79

A 4

C 6

CR 69 23

0 100

950 B

150

150 ITEM EZ

ITEM ES

1000

300

CR 51

CCA 040

1 2

RED TAPE IDENTIFIER

CCA 039

CCA 038

500

175

DOWN

1 2

200

CR 65

120

31 35

26 30 34

25 29 33

CR 156

100

CR 43

230

1 3

CR 40

CR 53

150

2 5 9

0 1

CR 36

CR 147

CANBUS SPLICES SEE SHEET 5

RED TAPE

13 12

6 10

7 11

Fig 14.

ITEM EL

CR 57

200

ITEM HZ (L=300) ALIGN WITH END OF SPACE TAPE

14 18

17 ENTER

7 11

9 13 15

6 10

3A 1000V

TAPE CR146 TO THIS HARNESS SECTION AS PER JCB STANDARD STD00141

DIO DE

CR 81 1 2

TO SHEET 1

2 4

2 5

1 4

CR 107

CR 74

CR 73

450 300

1000 A

YELLOW TAPE IDENTIFIER

CR 106

B A

CR 71

5 37

375

12 5

125

375

10 3 2 1 8

CR 44

CR 98

9 6 5 4 7

DO NOT FIT HSG. ATTACH TO CONDUIT USING TEARABLE TAPE

375

2 5

CR 85

ITEM HZ ALIGN WITH END OF SPACE TAPE

CONNECT CR74 TO CR73

100

XXXXXXXX

RED TAPE IDENTIFIER RED TAPE YELLOW TAPE

CONNECT CR73 TO CR74

950

ITEM EZ

12 0

0 15

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

CR 60

FIT LABELS AS SHOWN SEE NOTE ON SHEET 11 REF. ITEMS AM & AN

CR 63

FFPS

3150

2700

ASS LHSLS RFLS

2625

3350 35 0

3100 3000 2650 2000

3200 3050 2940 2900 2775

PES1 PLIS PRIS PISA4 PMLS

9803/9970-01 (C-03-00) 2600

XX XX XX XX XX XX XX XX XX XX X X XX SFPE

0 55 PES3

C3-10 100 2500

300

2300

10 3 2 1 8

9 6 5 4 7

2 1 8

10 3

CR 68

CR 78

APPLY REAR FOG SWITCH DECAL

CR 77

APPLY MAIN LIGHTS SWITCH DECAL

18 17 5 4 7

APPLY HAZARD SWITCH DECAL

CR 5

APPLY REAR WIPER SWITCH DECAL

CR 32

APPLY BEACON SWITCH DECAL

CR 24

APPLY WORKLIGHT SWITCH DECAL

333-P6768-1 Sheet 2

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-10

TO SHEET 1

300

CRES4

APPLY TRANSPORT SWITCH DECAL

4 3

300

550

2 1

36 35 34 33 32 31 30 29 28 27 26 25

9 6 5 4 7

ECU 17

10 3 2 1 8

500

60 0

8 7

CR 135 6

4 3

2 1

200

CAR 007

250

100

10 3 2 1 8

9 6 5 4 7

100

CR 7

E 11

CR 144

CR 9

CR 82

Fig 15.

APPLY RAISE/LOWER SWITCH DECAL

APPLY WHEEL SLIP SWITCH DECAL

APPLY 4WD SWITCH DECAL

CR 8

100 1700

CR 10

0 10

1730

600

1760

ORWLS

200

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

36 35 34 33 32 31 30 29 28 27 26 25

24 23 22 21 20 19 18 17 16 15 14 13

12 11 10

900

2100 800

12 11 10

CRES1 IFWLS OFWLS

750 700 650

24 23 22 21 20 19 18 17 16 15 14 13

290 270 250 220 200

CR 34

IRWLS

CR 11

100

CR 21

1800

CR 25

1850

300 CRES2

2300

1 3

CR 26 2

100

200

2750

400 400

9803/9970-01 (C-03-00) 700

X X X X X X X

CR 117

X X X X X X X

C3-11 900

3200

CR 27 B

3300 34

3400

CR 29

CR 31

333-P6768-1 Sheet 3

CR 35

WRAP RED TAPE OR HEAT SHRINK AROUND ROUND PORTION OF CONNECTOR BODY FOR IDENTIFICATION

DIA 10 PVC SLEEVE DO NOT TAPE IN PLACE

CR 16

CR 14

SOLID CONDUIT TO SUIT ITEM HC

5 4

CR 128

200

CR 136

CR 18

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-11

9803/9970-01 (C-03-00)

CCA 171

0 27

900

ECU 4

OFWL

850

IFWL

E H

Y RL 2

APWL

100

G F E

B H D

Y RL 3

HDWL

100

0 D

Fig 16.

RL S2

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

CR 145

950

SS PS TO

30 40

TIP

100

A B

CR 134

21 31

30 40

21 31

ECU 3

10 9

200

100

C F

EDC ELECTRONIC CONTROL UNIT

13 19

200 100

DRWL

0 20

0 RLY 5

IRWL

E H

F B

RLY 6

100 J

RLY 7

REVL

B J

TO SHEET 1

RLY 8

JCB CADCAM UGII

RFWL

500

100

ENLARGED VIEW OF CAVITY ID'S FOR E1

CCA 172

CCA 173

ECUES

100

150

10 9

ECU 2

ECU 1

50 RS

C3-12 300

333-P6768-1 Sheet 4

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

100 G

Y RL 4

A J

Y RL 1

C3-12

CR 51

CR 65

GREEN (514F)

OW YELL F) (515

YELLOW (515K )

E WIR AIN ) DR (628K

DRAI NW (628F) IRE

N GREE K) (514

SPLICE WIRE SCRN TO DRAINWIRE/SHIELD AND INSULATE WITH HEATSHRINK AS PER JCB STD 7100/1000. (TYP 7 PLACES)

CANSS1

CANHS1

CANLS1

OW YELL E) (515

GREE (514 N E)

2775 TO DATUM

-L N1

YELL (515 OW E)

EN GRE E) (514

N1 _S

CR 125

CAN1_H

7C 65

CR 145

CANSS3

CANHS3

CANLS3

DRA

IRE

600 TO BRANCH OUT

INW

OW YELL YELL OW

GREE (514B) N

300 TO DATUM

100 MAX (TYP)

CANSS13

CANHS13

E INWIR DRA 28D) (6

YELLOW) (515B YEL (515 LOW D) DR AIN (62 WIRE 8B)

GR (51 EEN 4F)

E IR W AIN DR

CAR 007

9803/9970-01 (C-03-00) CA N_ L

CANLS16

CANHS16

CANSS16

SCRN

YELLOW

CR 119

EEN

Fig 17. K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

GREEN

DRAINWIRE

WIR

AIN

W YELLO YELLO

YELLOW

EEN

W YELLO DR AIN WIR E DRAINWI RE

GREEN

DRA

GRN

YEL

CANSS2

CANHS2

CANLS2

INWIR

CANSS12

CANHS12

CANLS12

100

CAN-H

CAN-

100

YELLOW GREEN SCRN

SCRN

CAN_H

CAN_L

CANBUS 1

CCA 172

CR 142 CAN

YELLOW

CR 1

YELLOW

LO W

E WIR AIN GREEN GREEN YEL

DRAINWIRE

YELLOW

CAN

100

CR 135

DRA IN (628 WIRE E)

GREEN

GRN

CANLS13

GREEN YELLOW

SCRN

YELLOW (515F)

900 TO DATUM

IRE INW DRA (628E)

YELLOW GREEN SCRN

C3-13 EN GRE 4D) (51

CANHS5

N EE GR

E WIR AIN DR EN

GRE GRE

CAN2-H CAN2-L CAN2-S

CANLS5 CANHS1

CANLS1

CANSS1

DRA

IR INW

CANBUS 2

DRA INW IRE

100

CELL 15

CELL 21

ECU 2

ECU 4

333-P6768-1 Sheet 5

CELL 3 CELL 18 CAN1_S CAN1_L CAN1_H

SCRN GREEN YELLOW

CELL 9

CELL 12

APPLY CABLE IDENTIFIERS TO DISTINGUISH CANBUS 2 CABLE

CAN_H CAN_L

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-13

CANSS5

GREEN

C3-14

0.5-2.5

0.5

920C

0.5-2.5

CR4 C2

0.6

1.0

000

IGNS2

CR33 3

6.0

015

014

CR45

4.0

200A

200B

TYPE

DEST

SIZE

WIRE

TERM

P,R

IGNITION SWITCH

CR3

* SEE SHEET 5 FOR CANBUS DETAIL

0.5-2.5

ECU1 6

ECU1 15

0.5

1477

0.5-2.5

0.5

1852

0.5-2.5

CR135 9

9803/9970-01 (C-03-00) 210E

15 16

KV,KW TYPE

1486

KZ LT,LU

ECU1 7 ECU1 13

0.5 0.5

WIRE

805A

610A

DEST ORWLS CRES2

1.0 1.0 GC

TYPE

HG,HH

SIZE

RRH OUTER W/LIGHT

TERM

CR10

W W

0.5

860Z

RHSLS

CRES4

0.5

635W

ECU1 23

0.5

1493

TYPE

ECU1S

0.5

100AA

ECU1 5

DEST

0.5

1494

SIZE

WIRE

TERM

AC,LF

TYPE

ECU1S

KV,KW LT,LU

DEST

0.5

SIZE

4WD/DIFF LOCK SW

1853

CR9

WIRE

FRONT PTO SW

ECU1 3 ECU1 26

0.5 0.5

1854

1475

B LT,LU

LT,LU

ECU1S

6.0 4.0

245 339

19 20

CR82 +

FE FH FH

CR45 CR104 2

PFSB 9

BATS2

CR142 26

2 379

1.0

0.5

1.0

4.0

CCA172 20

CCA172 19

CCA172 14

CCA172 13

CCA172 8

CCA172 7

CCA172 5

TSS1

CR135 2

IGNS2

CR136 23

CR135 1

CR4 A2 CCA172 6

Fig 18.

147B

147A

146B

146A

145B

145A

144

142

103

1.0

0.5

1.0

CR45

TYPE

2.5

FC,FD

015P

378

376

375

CR104 22

DEST

IGNS2

CR104 5

IGNS2

CR94 A

BATS2

FE FF

SIZE

2.0

1.5

1.4

3.0

CR94 B

IGNS1

1.0

CR119 B

1.5

BATS2

EDCIS

PISC4

IGNS2

ECU6 6

IGNS1

CR68 1

IGNS1

RLY8 A

1.0

1.5

0.5

0.6

1.0

1.4

TYPE

FC,FD

FUSE BOX J

101

20 CR12J

015D

195

0.5 1.4

IGNS1

DEST

ECU2 8

1.0

131H

610D

CR14

1.0

SIZE

1.0 1.0

1.0

SIZE

WIRE 860F 610G

TERM A B

0.6

SIZE

RH NO PLT LIGHT

BL AF,AG AF,AG

CRES2

TYPE RHSLS

DEST

CR25

PES1 RHSLS

0.5 0.5

710L 860U

6 7 8

ECUI 16

TYPE

AC,LC

TYPE

0.5

804D

ECUIS

DEST

CRES1

OFWLS

0.5

SIZE

100AC

WIRE

WORKLIGHT SW

600D

800B

WIRE

HG,HH

TYPE

TERM

CR24

TERM DEST

CRES1

1.0

600C

2 FLH OUTER W/LIGHT

1.0

801B

CR21

IFWLS

SIZE DEST

HG,HH

CRES1

TYPE

HG,HH

TYPE

HG,HH

IFWLS

DEST

CRES1

OFWLS

DEST

WIRE

FLH INNER W/LIGHT

801A

SIZE

600B

WIRE

FRH INNER W/LIGHT

600A

800A

WIRE

FRH OUTER W/LIGHT

ECU2 14

TERM

CR18

TERM

CR16

TERM

1.0

880C

010

TERM

CR37

TERM

CR36

TERM

CR35

TERM

CR34

0.6

6.0

SIZE

1.0

SIZE

1.0

SIZE

0.6

SIZE

710H

844

WIRE

1.0

SIZE

REAR WASHER PUMP

810

105

WIRE

K,L

DEST

CRES2

ORWLS

DEST

CRES2

IRWLS

DEST

CRES3

CR3 6

IGNS1

CR45

DEST

PES1

CR5 6

DEST

CDS

TYPE

K,FZ

TYPE

AM,AN

TYPE

HG,HH

TYPE

HG,HH

TYPE

W -

PES1

TYPE

AC,LE

TYPE

HG,HH

AF,AG

TYPE

K,L

2.5

730

CRES4

3.0 2.0 2.0

665A 635 636

CR143- 4

1.5-

750

812C

1.5

812B

863

862

710A

421

417

120B

832

710K

831

830

1546

1427A

1547

1429B

716

C6 D2

2.0

0.6

1.0

0.6

1.0

0.6

1.0

0.5

1.5

1.5 812A

1.5

1.4

1.5

CR68 17

CR69 49

PES1

CR69 C2

CR65 14

PISA4

CR51 26

PES1

CR43 12

CR43 13

CR51 31

CR51 22

CR51 11

CR51 8

FLLS

CR78 5

FLLS

PHLS

CR79 5

PES1

FLLS

333-P6768-1 Sheet 10

AA AA

PMLS

PISC4 1.4

0.6

838G

806

710R

X,Y TYPE

CR65-32

TYPE

0.6

SIZE

360D

160J

A8 B1

1517

WIRE

DEST

CR142 27

2.0

720M

FR. PANEL RELAYS

2.0

637

CR104 21

ECUES

CR85 B CR101 B

3.0

750J 760

CRES6

CR40 4

PES3

PES1

3.0

2.0

CR94 C

3.0 3.0

685 720

CR30 2

3.0

680 710

CR11 7

4.0

CRES2

4.0 2.0 CRES3

DEST CRES1

SIZE 10.0

670

660

WIRE 600 610

BATTERY NEGATIVE

TERM

CR39

CR38 TERM

TYPE K,L

BM,BN

LHSLS

CR31 1

CRPFS

DEST

CR12 A2

CLUTCH DOWN SW

610C

805B

WIRE

RLH OUTER W/LIGHT

610B

835A

WIRE

RRH INNER W/LIGHT

014 660F

3 4

201

IGNITION RELAY 1

WIRE

CR33

0.6

1.0

SIZE

TERM

710D

934

305C

WIRE

1 2

CRES2

CR32 3

1.0 1.0

DEST

SIZE

BEACON SWITCH

610F

934

WIRE

BEACON SOCKET

TERM

CR32

131C

TERM

CR31

CR38

CR12 B14

3.0

330 680

1 2 3.0

DEST

SIZE

CRES2

IRWLS

DEST

WIRE

1.0

131B

1.0

SIZE

CRES2

TERM

835B

AUX POWER SKT

WIRE

1 2 CR30

0.6

RLH INNER W/LIGHT

TERM

CR29

610H

RHSLS

DEST

0.6

860G

CR4 B5

CRIS

CR4 B2

CRES2

DEST

SIZE

LH NO PLT LIGHT WIRE

CR27 TERM

1.0

847

1.0 1.0

846 115B

2 4

1.0

610E

SIZE

WIRE

REAR WIPER MOTOR

CR26 TERM

19 ECU2 13

ECU2 7

1.0

131G

SEE NOTE ***

ECU2 5

15 0.5

ECU2 2

0.5

131L

ECU2 1

0.5

131M

ECU17 2

ECUIS

IGNS2

ECU2 6

BATS2

RLY7 A

131D

1.0

0.5

WLSS

TYPE

FC,FD

131E

2.0

100

10 11

4.0

015N

1.5

311

0.5

323 240H

1.5

WLSS RLY6 A

1.5

RLY5 A

WLSS

DEST

1.5

206G

4 6

322

2.5

321 206F

1.5

206E

SIZE

FUSE BOX K WIRE

TERM

CR12K

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

0.6

2.0

1.4

300

240D

335A 18

CR30 1

3.0

330

14 BATS1

BATS1

3.0

210D

1.4

CR128 3

1.0

165

335

IGNS1

240B

RLY4 A BATS2

1.5

319

WLSS

WLSS RLY3 A

1.5

318 206D

CR43 7

0.5

100AH

206C

FE FF FF

BATS1 CR68 3

CRPFS

1.4

SIZE

2.0

TYPE

BATS2

FC,FD

DEST

CR142 22

IGNS2

1.0

WIRE

CR8

1.0

310

4 2.0

305 210B

2 3

1.0

240A

SIZE

WIRE

FUSE BOX B

0.5

131

015R

TERM

CR12B

CR4 F2

ACFS

IGNS1

170 171

4.0 4.0 2.0

01OG

WLSS RLY2 A

1.5

PIS A4

1.5

RLY1 A

2.5

316 317

206A

13 206B

1.5

135

WLSS

0.6 0.5

015C

11 12

248

IGNS2 E1 24

1.0

130

WIRE

TERM

FE FE

IGNS2 CR104 9

1.0

015G

9 10

355 015B

2.0

120

IGNS1

2.0 2.0

191 240E

115

14 15

010B

CRIS

010E

365A

240F

161

160H

IGNS1

160

106 015E

010K

CR4 E2

1.4 2.0

TYPE

FC,FD

155 145

010F

1.4

SIZE

FUSE BOX C 010D

WIRE

AV -

TERM

CR12C

1.4

AU TYPE

IGNS1

110

1.4

010A

CR36 1

IGNS2

DEST

010C

0.5

105

0.6

015A

SIZE

WIRE

1 2

CR10418

CR38

CR4 F4

325

REAR PTO SWITCH

TERM

4.0 0.5

FUSE BOX A

1528

670

1.0

954

CR40 3

CR40 2

CR40 1

ACFS

DEST

010H

100AG

DEST

2.5 2.5 2.5

876

875

874

4.0

SIZE

HEATER/AC UNIT 170

WIRE

TERM

CR12A

CR11 TERM

TYPE

AC,LG

CR7

LHSLS

PES1

CR4 B6

CR37 1

CR4 B1

CRIS

DEST

CR104 17

CR134 A

CR11 5

CR12A 18

CRBLS

CRES6

CR146 2

CR136 21

CR12A 4

CRES 6

TMES 2

CDS

CR148 40

CR104 28

CRES6

CDS

CR3 7

CRIS

CR5 6

CR26 4

CRES6

X,Y TYPE

TERM

0.6

1.0

0.6

1.0

SIZE

880K

710B

845

844

843

115A

WIRE

REAR WIPER SW

2.0

950

TERM

CR5

1.0 0.5

954

936A

2.0

171

0.5 1.5

883F

750K

0.5

884E

0.5

1.5

0.5

1.0

0.5

1.0

884D

110

750N

744

810A

740

1.0

0.5

750T

182

0.5

810E

1.0

000

0.5

ECU3 7

0.5

1812

1453

0.5-2.5

SES

ECU3 1

0.5

715

1496

0.5-2.5

E1 19

EDCSSS

ECU1-17

RSS2

E11 3

0.5

E11 1

ECU3 11

424

0.5-2.5

501

0.5-2.5

500

0.5-2.5

0.5

929

0.5

923

0.5-2.5

0.5

1418

0.5-2.5

ECU1 38

0.5-2.5

ECU1 35

0.5

1.0

115C

0.6

845

1.0

847

MSS1

TMES1

0.5

750L

ECU3 5

MSS1 CR5 3 CR26 2

0.6 1.0

1.0

CRES6

0.5

CR136 10

ECU3 14

DEST CR12J 2

0.5

846

843

942

750U

944

1.0

SIZE

REAR RELAYS

379

WIRE

ECU3 22

0.5

597

598

0.5-2.5

1810

0.5-2.5

1497

0.5-2.5

675GF

0.5-2.5

0.5

942N

0.5-2.5

CR4

TERM

ECUES

ECUIS

- 8 ECU3

0.5

1.0

ECU3 6

0.5

0.5-2.5

587

1811

636T

0.5-2.5

100V

0.5

1809

0.5-2.5

SFPE

TYPE

JS,JX

D'WIRE

CANLS5

675JF

0.5

*SCRN

0.5-2.5

0.5

*GREEN

0.5-2.5

WIRE

*YELLOW

0.5-2.5

DEST

CANHS5

SIZE

0.5

REAR BULKHEAD 1

CAPAC'Y

CR1

SEE NOTE *** SEE NOTE ***

TERM

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-14

C3-15

M,N

PHLS

CR12B 10

1.4

839

838A

325

M,N

905

881

0.5-2.5

CR51 30

1.0

1425

711F

9803/9970-01 (C-03-00)

H,J

BATS1

BATS2

CR46 1

CR47 C

4.0

6.0

3.0

210

240

250

260

6.0

245

6.0

360

CR43 9

PES1

SIZE

1.0

WIRE

842

710J

CR48

TERM

DEST

CR45

FRONT WASHER PUMP

CR45

3.0

TYPE

AK,AL

AF,AG

TERM

CR63

0.6

720B

PES3

CR135 26

0.5

914B

DEST

CR128 5

0.5

SIZE

914

WIRE

DOOR SWITCH

CR65 23

0.6

3.0

440

270

260

PES3

1.0

720F

IGNS2

APWLS

1.0

804A

TYPE

AH,AG

DEST

1.0

DEST

PES3

APWLS

DEST

BD,BH

CP,CS

TYPE

HG,HH

TYPE

HG,HH

BD,BH

CB,CC

TYPE

EW,EX

TMES1

SIZE

TYPE EW,EX

CCA171 33

015J

SIZE

WIRE

RH A POST W/LIGHT

TERM

CR39 D8

CR43 14

CR43 11

CR43 10

TYPE

WIRE

CR60

720G

1.0

804B

SIZE

WIRE

TERM

TYPE

CR39 E5 PISA4

DEST

CRBSS

PISC4

DEST

PMLS

CR45

DEST

LH A POST W/LIGHT

0.5

TSS1

CCA171 9

TERM

ABS CONNECTOR

6.0

250

SIZE

MAXI LIGHTS FUSE

CR59

1473

675JK

CR12B 19

WIRE

SIZE

PARKBRAKE SWITCH

CR58

TERM

CR100 B

CR12J 1

0.5

884

160L

SIZE

BRAKELIGHT SW

WIRE

3.0

TERM

DEST

TMES1

2.5

265A

1456

CR57

0.5

142P

0.5

CR3 2

GY, BX

SIZE

WIRE

675JG

248

CR47 D

3.0

4.0

270

200B

WLSS

CLUTCH POTENTIOMETER

*** SEE SHEET 6 FOR TWISTED TRIPLE DETAILS

* SEE SHEET 5 FOR CAN BUS DETAILS

TERM

CR33 1

6.0

10.0

201

206

CR53

0.5

1546

0.5-2.5

CR3 1

2.0

841

0.5-2.5

4.0

1.0

834

0.5-2.5

1.0

833

832

0.5-2.5

120C

0.5-2.5

PRIS

PLIS

1.0

CR39 D6 ASS

*YELLOW

*GREEN

*SCRN

403A

1517

409

809D

1425

1422

1424

1423

1492

1491

440

418

838E

1490

0.5

1.0

0.5

0.75

0.5

2.0

1.4

PES3

421

PES3

1.4

720D

CR51 15 CR51 17

866 868 870

4 5 6

AH,AJ

TYPE

AH,AJ

TYPE

809E

PESI

1.5

PES3 PHLS

RFLS

1.0 1.5

0.5

PES3

CR39 C6

1.5 0.5

FLLS

PHLS

DEST

1.5

SIZE

PISC4

PES1

PHLS

PMLS

FFPS

PMLS

DEST

Fig 19.

838C

720J

720T

7 8

716 710AA

5 6

812

838B

0.6

1.0

2.0

SIZE

REAR FOG SW WIRE

TERM

CR78

160C

710F

838

360A

807

360C

WIRE

TERM

MAIN LIGHTS SW

0.6

0.6 CR51 18

CH,FZ

CR51 14

881

CR77

CH,FZ

CR51 13

1.4 0.6 0.6

905

TYPE

AC,LA

TYPE

AC,LB

CH,FZ

CJ,N

CR51 12

1.4

836

SIZE

K,FZ

TYPE

DEST

PRIS

PLIS

M,N K,FZ K,FZ

DK,DL

0.6

RHSLS

LHSLS

CR79 4

AUX LIGHTS OUT

861D

859D

0.6

1.4 0.6

H,J M,N

TYPE

WIRE

904 880D 860C

CR79 2

DEST

TERM

CR74

1.4

SIZE

829

WIRE

AUX LIGHTS IN

CR73 TERM

TYPE

CR81

CR79 12 CR38

0.6

DEST

RHSLS

3.0

SIZE

685

1.0

SIZE

3.0

1.0

SIZE

19 20

362

360B

860

808

880

807A

809

806

904

839

829

418

907

WIRE

0.6

1.5

1.0

1.5

1.0

1.5

1.4

0.6

1.4

SIZE

FRONT FUSE PANEL

665A

448

WIRE

TRACTOR ABS

TERM

CR79

TERM

CR101

CR85 A

PMLS

RHSLS

FFPS

LHSLS

FFPS

RFLS

CR39 B8

CR73 2

CR43 5

CR73 1

CR65 21

CR43 4

DEST

CR38

CR65 12

DEST

(RETURN)

TYPE

FC,FD

AK,AL

AH,AG

TYPE

DG,AG

DJ,AL

CR45 CRBSS

884F 0.5

3.0

265A

DH,AG

IGNS2

1.0

015K

A B

TYPE

DEST

K,L

TYPE

AM,AN

SIZE

(SUPPLY)

CR65 28

SFPE 7

DEST

AK,AL

AH,AG

AK,AL

TYPE

DJ,AL

DG,AG

TYPE

BD,BH

TYPE

WIRE

TRACTOR ABS

1422

711G

WIRE

LH COLUMN SWITCH 2

CR38

DU DV

TYPE

TERM

CR100

TERM

CR98

1.0

191

B 3.0

3.0

355 CR12C 14

DEST CR12C 16

SIZE

WIRE

AUX POWER SKTS

760

362

WIRE

AUX LIGHTS SUPPLY

0.6

CRES3

1.4 1.4

DEST CR12B 16

SIZE

PES3

LHSLS

DEST

TERM

CR94

TERM

CR85

860T

660Z

335

WIRE

+ 3

0.6

CIGAR LIGHTER

720L

0.6

SIZE

AIR GAUGE ILLUM 880G

WIRE

TERM

CR82

TERM

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

PRIS

861A

DEST

1.4

WIRE

SIZE

RH SIDE REPEATER

PES3

PLIS

DEST

CR65 17

CR39 F2

CR43 2

CR68 17

CR68 2

CR39 F6

PES1

DEST

PRIS

TERM

CR71

1.4 1.4

720C

SIZE

859A

WIRE

TERM

0.6

1.0

1.4

2.0

LH SIDE REPEATER

419

CR70

864

865

49a

858

2.0

0.6

710G

31 862

SIZE

TRAILER 2 RELAY WIRE

1.4

CR69

861

TERM

865

CR39 F8 CR69 49a

2.0

863

2.0

720H

0.6

PLIS LHSLS

CR12B 4

CR69 49

CR12C 4

DEST

CANHS1

CANLS1

D'WIRE

ASS

CR39 A

CR51 19

RFLS

CR44 4

CR98 2

CR44 3

CR44 2

CCA040 2

CCA039 2

CR47 B

CR79 2

PHLS 6

CCA038 2

CR69 C3

CR51 20

CR39 F2

CR51 4

CR101 A

CR51 7

CR51 5

CR51 6

0.6

1.4

859 880A

2.0

310

SIZE

858

145

1 2

WIRE

HAZARD SWITCH

TERM

CR68

* SEE SHEET 5 FOR CAN BUS DETAILS

GC -

419

17 18

0.5

411

0.5

417

1.0

448 404

0.5

406 408

0.5

407

SFPE

PRIS

PLIS

0.5 0.5 0.75

859G 711A

CR106 1

CR65 16

CR65 31

CR74 6

CR74 5

1.0

200A

TYPE

K,L

SFPE

DEST

K,L

CR65 29

K,L

TYPE

859B

0.6

403

861B

0.5

1427A

0.5-2.5

0.5

0.6

CR74 4 LHSLS

0.6

CR74 3

CR74 2

1.0

542***

411

409

870

868

0.5-2.5

880F

SIZE

WIRE

CR47

K,L

M,N

WIRE

BATTERY POSITIVE

7210/0001

TERM

CR46

TERM

CR45

1.0

CR65 27

CR65 26

1.0

1423

1424

SFPE

DEST

1.0

SIZE

711E

WIRE

CR44

TERM

RANGE COLUMN SW

CR39 E1

1.0

2.0

830

841

K,L

1.0

831

CR39 E2

K,L

CR51 29

1.0

834

1.0

K,L

PISA4

CR48 1

CR51 28

2.0

1.0

833

0.5-2.5

842

M,N

1.4

836

0.5-2.5

866

CR39 D4

0.5

1547

0.5-2.5

0.6

CR106 3 CR74 1

0.5 1.4

541***

0.5-2.5

CR106 2

0.5

861G

540***

0.5-2.5

CR39 D2

CR65 9

0.5

CR65 11

0.6

408

1429B

0.5-2.5

USFS

PFSB

LHSLS

CR42 +

DEST

0.5

SIZE

0.5-2.5

407

300B 160BB

880B

423

WIRE

INSTRUMENT PANEL

CR65 10

0.6

GT GC

406

CR65 13

D'WIRE

CANLS1

0.6

CR65

TERM

0.5-2.5

120A

M,N

0.5

*SCRN

0.5-2.5

CR79 3

CR79 1

0.5

*GREEN

0.5-2.5

404

TYPE GT

JS,JX

0.5

DEST

SIZE

WIRE

*YELLOW

CANHS1

FRONT BULKHEAD

CAPAC'Y

0.5-2.5

CR51

TERM

1.4

907

M,N

PRIS

1.4

CR69 49a

1.4

864

861C

M,N

TYPE

DX,DY

PLIS

1.4

859C

DEST

SIZE

WIRE

PES3

TYPE

CR65-1

DEST

TERM

RH COLUMN SWITCH

0.5

423

720A

CR43

0.5

WIRE

TERM

SIZE

BLEEPER

CR11 4

2.5

876

CR42

CR11 3

2.5

875

730

CR38

TYPE

CR11 2

2.5

MC/MD

DEST

SIZE

874

HEATER

WIRE

CR40

TERM

CR 116

TERM

CR 107

TERM

CR 106

TERM

CR104

883

1.4

2.0 0.5

101 750JA

0.5

182 504

RHSLS

0.5

SIZE

10J

860N

WIRE

1.0

0.5

SIZE

HEATED MIRRORS SUPPLY

544

942K

675JM

WIRE

THROTTLE PEDAL IDLE VALIDATION SWITCH CONNECTOR

IGNS1

RHSLS

DEST

CR135 14

MSS1

TMES1 8

DEST

EW,EX EW,EX

CR51 9 CR51 10

0.5 0.5

540***

*** SEE SHEET 6 FOR TWISTED TRIPLE DETAILS

541***

0.5

DH,AG

DG,AG

TYPE

EW,EX

TYPE

EW,EX

CR51 21

SIZE

WIRE

TYPE

E1 14

CR4C 8

E1 2

HES

EDCIS

E1 6

CRES6

CR12C 20

CR38

ECU3 21

RLSS

C118

CR4 F8

RLY8 C

ACFS

ECU3 16

RLY4 C

GD GD

CR12A 10

RFLS

HU GD

TYPE

JT,JX

RLY7 C

CRBLS

CR12C 18

CR12B 20

DEST

542***

DEST

0.5 1.0

503

0.5

2.0

660GF

0.5

586

0.5

932 637

0.5

950 1528

924

2.0

877

161C

0.5 0.5

170B

0.5

814

961

1.0 1.5

860L

1.0

130

1.4 1.5

825

809A

1.5

195

4.0

339

THROTTLE PEDAL POSITION CONNECTOR

0.5-1.0

0.5-2.5

0.5-1.0

0.5-2.5

0.5-1.0

0.5-2.5

0.5-1.0

0.5-2.5

0.5-1.0

0.5-2.5

2.5-4.0

SIZE

WIRE

REAR BULKHEAD 2 CAPAC'Y 2.5-4.0

CR 117

0.5

1.0 **560 1.0 ** SEE SHEET 6 FOR TWISTED PAIR DETAILS

**561 1 2

SIZE

J1708 CONNECTOR WIRE

CR 120 TERM

CR119 G CR119 F

333-P6768-1 Sheet 11

CH,L

TYPE

HD,HE

* SEE SHEET 5 FOR CAN BUS DETAILS ** SEE SHEET 6 FOR TWISTED PAIR DETAILS

DEST

GH -

H J

GH GH

CR120 1

1.0

**561

D'WIRE

CANLS3 CR120 2

1.0

0.5 0.5

E **560

*GREEN

GJ GJ GH

*SCRN

*YELLOW

TYPE

GV, GW

CRES4

DEST

HA, HC TYPE

CR12C 12 CANHS3

1.5

CRES2

CRBLS

DEST

SIZE 1.5 0.5

365A

635C

WIRE

DIAGNOSTIC SOCKET

610J

883E

SIZE

HIGH LEVEL BRAKE LIGHT WIRE

TERM

CR 119

TERM

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-15

CR 125

C3-16

CANSS3

TMES2

SFPE

3.0

1.0

3.0

2.5

3.0

1.0

675C

738M

675F

675G

711

661

CR63 1

0.5

936A

660ZE

CR 135 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

WIRE

TERM

CRES3

0.5

9803/9970-01 (C-03-00)

CR142 6 CR142 7 CR107 3 CR142 8 CR142 28 CANLS13 CAR007 A TMES1 CR63 1 CR142 10 CR142 12 TSS1

0.5 0.5 0.5 0.5 0.5 0.5 1.0 2.0 0.5 0.5 0.5 0.5

1.0 1.0

1463 550 544 1439 1459 CAN1_L CAN2_H 676 914B 1449 1465 142N

CAN2_S CAN2_L

CAR007 C CAR007 B

CR142 1 CR142 2 CR1 26 CR142 19 CANHS13 D'WIRE TMES1 CR142 3

0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.0

1464 1535 1453 1438 CAN1_H CAN1_S 675E 549

CVT DISPLAY ECU (RED) WIRE CSA DESTIN 376 1.0 CR12J 6 1.0 CR12J 10 103 -

CR4 F6

DEST

0.5

SIZE

ACU PRESS SWITCH

CR134

914

CRES1

CR12B 12

1.5

165

600N

RHSLS

0.5 1.0

CRPFS

1.0

305G

860E

DEST

SIZE

WIRE

ROOF LINER HARNESS CONNECTOR

HES

TMES1

CR148 26

DEST

SIZE

WIRE

BATTERY NEGATIVE 2

TERM

CR 128

TERM

CW CX TYPE CY,CZ CY,CZ DA DA DA CY,CZ CY,CZ DA CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ DA DA CY,CZ CY,CZ CY,CZ DA CY,CZ CY,CZ CY,CZ CY,CZ CY,DB CY,CZ DA DA CY,CZ CY,CZ CY,CZ DA DA DA CY,CZ CY,CZ

LT,LU

TYPE

LR,LS

TYPE

0.5 0.5 0.5 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 -

0.5 0.5

0.5

1535

549

CR135 7

CR135 6 GH

0.5

1460

1461

2.0

1459

0.5

2.0

335A

720M

GJ GH

CR136 25

CR136 13

CR135 22

CR38

CR12 B16

GH GH GH HU

CR12A 20

GH GH

0.5

131

TMES1

CR136 31

CR135 10

CR136 29 CR136 30

HU HU HU

2.0

0.5

1438

1471

675FF

0.5 0.5

CR136 28

0.5

1469 1470

CR136 26

CR136 27

0.5

1467

1466

1468

CR136 3

0.5

1462

CR135 30

1465

0.5

CR135 21

0.5

1439

CR135 18

0.5

550

0.5

CR135 17

1.0

942G

HU HU

1463

MSS1

CR135 14

1.0

TYPE

LW,JX

CV CX TYPE CY,CZ CY,CZ CY,CZ DA DA DA DA CY,CZ DA CY,CZ DA DA CY,CZ CY,CZ DA DA DA CY,CZ CY,CZ DA CY,CZ DA CY,CZ DA CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ DA DA DA DA

0.5

1464

0.5

SIZE

WIRE

DEST

CR156 1 CR143 1 CR4 E4 CR12J 8 CR142 30 CR142 14 CR142 15 CR142 16 CR142 17 CR142 18 CR142 20 CR144 6 -

CR142 29 ECU6 4

CR4 A4

ARMREST HARNESS CONNECTOR

1541 1455 884D 378 1461 1466 1467 1468 1469 1470 1471 1432 -

1460 1489

944

CVT DISPLAY ECU (BLACK) WIRE CSA DESTIN 675D 1.0 TMES1 0.5 ECU6 3 1488 0.5 CR142 13 1462 0.5 CRBSS 884C

TERM

CR142

CR 136 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1.5

750

CSA DESTIN 0.5 MSS1 0.5 USFS

DIODE 3

CSA DESTIN 0.5 CRBSS 0.5 CR4 E4

DIODE 2

TYPE CB,CC CB,CC

KJ KK TYPE

851

0.5-1.0

524 738M 142B 1495

0.5-1.0 0.5-1.0 0.5-1.0 0.5-1.0

25 26 27 28

0.5-1.0

7210/0052

0.5-1.0

E6 TERM

WIRE

SIZE

DEST. TYPE

TYPE

Fig 20.

725A 0.6 SES JM,CC 426 0.6 E1-18 JM,CC 920A 0.6 EDCSSS JM,CC

WIRE

RH DRAFT PIN

725B 0.6 SES JM,CC 425 0.6 E1-17 JM,CC 920B 0.6 EDCSSS JM,CC

7210/0052

0.5-1.0

LH DRAFT PIN

7210/0052 7210/0052 7210/0052

0.5-1.0

1.0

7210/0052

0.5-1.0

DEST.

0.5-1.0

41 43

740 637G 637H

0.5-1.0

1.0

142K

0.5-1.0 1.0

7210/0052 1484

0.5-1.0

1.0

1443

739

1835

0.5-1.0

0.5-2.5

0.5-1.0

1.0 1.0

7210/0052

0.5-1.0 1834

0.5-1.0 0.5-1.0

ECU3 2

TIPSSS

TMES1

ECU3 3

CCA173 15

ECU3 18

ECU3 19

CCA173 3

CCA173 1

CCA173 13

CCA171 23

CCA173 11

CCA173 22

CCA173 14

ECU17 5

CR4 D2

TSS1

ECU1 22

TOPSSS

TMES2

CCA171 40

CCA171 18

ECU1 19

ECU1 32

TSS1

CR125

CCA171 39

CCA171 8

CCA171 24

TMES2

CCA173 17

ECU3 4

CCA173 21

CCA173 8

CCA173 7

31 32

DEST CCA173 16

CCA173 2

7210/0052

1.0

SIZE

29 1540

1447

0.5-1.0

738 1836

22 0.5-1.0

1826

0.5-1.0

1824

0.5-1.0

19 960

1823

0.5-1.0

18 0.5-1.0

1822

0.5-1.0

1821

1448

0.5-1.0

15 0.5-1.0

675JJ

0.5-1.0

14 16

956

TERM

1 2 3

848

0.5-1.0

E5 1 2 3

1827

0.5-1.0

1825

1830

0.5-1.0

434 1832

0.5-1.0

1829

0.5-2.5 0.5-2.5

1831

0.5-2.5

4 5

963 1833

0.5-1.0

1828

WIRE

TRANSMISSION BULKHEAD CAPACITY

0.5-2.5

TERM

CR148

JACK SOCKET DEST.

ECU1

ECU CONNECTOR A SIZE WIRE DEST

SIZE

DEST.

ECU1 4

300A

135

920 D

*GREEN

928

424

426

425

500B

725

504

920

930

922

*YELLOW

924

403B

1443C

503

660GA

0.5

HITCH CONTROL SIZE WIRE

PFSB

CR12A 12

EDCSSS

CANLS 17

E11 3

CR1 22

E6 2

E5 2

RSS2

SES

CR104 29

EDCSSS

RLSS

E11 1

CANH517

CR104 24

ASS

TOPSSS

CR104 27

HES 2

DEST

922 0.6 E1-10 923 0.6 CR1 17 0.6 RLSS 931 928 0.6 E1-20 929 0.6 CR1 18 660GB 0.6 CRES3 860R 0.6 RHSLS

WIRE

RAISE/LOWER

415 0.6 660GD 0.6 CRES3

WIRE

* SEE SHEET 5 FOR CAN BUS DETAILS

TERM

7 8

TERM

E11

1 2

TERM

TYPE

KL,KN

W W

TYPE

AC LH

BD BD

TYPE

ECU 15

1 2 3 4 5 6 7 8

TERM

7210/0052

100L 536B 100M 534B 536A 537 534A 535

WIRE

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

SIZE

CR1 15

CR1 14

CR148 28

ECU17 3

CR7 C

CR9 3

CR148 37

CR148 31

CR1 20

CR24 3

CR1 28

CR8 C

RSS2

CR8 B

ECUIS RGSRS ECUIS TGSRS RGSRS ECU6-1 TGSRS ECU6-2

DEST

7210/0052 ISO 11786 RESISTOR CONNECTOR

7210/0052

0.5

7210/0052

0.5

7210/0052

1.0

7210/0052

0.5

7210/0052

0.5

7210/0052

0.5

1.0

7210/0052

1.0

0.5

7210/0052

0.5

7210/0052

0.5

CR9 1

E9 1

CR7 B

CR1 27

7210/0052

0.5

598

597

1495

819

1475

1493

1484

1540

501

804D

1477

1486

500AB

1853

1852

1494

415

1854

7210/0052

TERM

K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ

TYPE

DM DN

TYPE

636C

632

CAN1_L

818

CAN1_S

636B

CAN1_H

131C

131B

SCRN(2)

636A

*GREEN(2)

131H

131G

311

131L

*YELLOW(2)

131D

131M

7210/0052

1.0

0.5

7210/0052

1.0

0.5

1.0

7210/0052

0.5

1.0

0.5

1.0

7210/0052

0.5

1.0

0.5

7210/0052

0.5

ECU CONNECTOR B WIRE SIZE

0.5 0.5 -

SIZE

CAN BUS 2 CAN_H CAN_L -

WIRE

6 7 8 9 10

4 5

1 2 3

TERM

ECU 17

1 2 3 4 5 6 7

TERM

ECU6

DEST

1.0 1.0

0.5 0.5 0.5 0.5

SIZE

637G 637H 636U 636P

131A 818 819

WIRE

1.0 1.0 1.0 0.5

1.0 1.0 0.5

SIZE

CR148 41 CR148 42 ECUES ECUES

CR12K 12 ECU2 19 ECU1 28

DEST

CR12 C6 CRES4

ECU15-6 ECU15-8 CR136 2 CR136 14

TRANSPORT SWITCH

106 635ZC

537 535 1488 1489

WIRE

DEST

CANHS5 CANLS5 -

DEST

ECUES

CANLS 11

ECU17 3

D'WIRE

ECUES

CANHS11

CR12K 20

D'WIRE

ECUES

CANLS5

CR12K 18

CR12K18

CR12K 8

CR12K 16

CANHS5

CR12K 14

ISO 11786 SKT CONNECTOR

* SEE SHEET 5 FOR CAN BUS DETAILS

A B C

TERM

ECU4

* SEE SHEET 5 FOR CAN BUS DETAILS

ECU2

TERM

TYPE GC

HW,JX

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

CR 156 BRAKE PEDAL SWITCH 2 CAV WIRE CSA DESTIN 0.5 CR136 18 1 1541 0.5 TMES1 2 675JN

CR 147 CAV WIRE 1 942L 2 160BA

CR 146 CAV WIRE 1 884B 2 884E

* SEE SHEET 5 FOR CAN BUS DETAILS

GA GB TYPE GT GT HU

AC LK TYPE W

KD,KE

EW,EX

CR ABS CANBUS 145 INTERCONNECT WIRE CAV CSA DESTIN 0.5 CANHS16 A CAN H 0.5 CANLS16 B CAN L C

0.5 0.5 0.5 0.5

CSA DESTIN 0.5 EDCIS

TYPE EW,EX

W W W W

635ZA 1432 635ZB 860AA

WIRE 161D

WHEEL SLIP ENABLE

CRIS

1.5

115E CR38

CRES6

0.5

750R

CR136 19

0.5

1455

WIRE

TYPE

LV,MA

CRES4 CR136 32 CRES4 RHSLS

CR 144 CAV 2 4 5 6 7 8

DEST

D'WIRE

SIZE

CANLS2

CANHS2

0.5

DEST

0.5

TERM

C SEAT

GRN

CR143

YLW SCRN

SIZE

ARMREST CAN WIRE

CR142 CAN TERM KT

GA GS

333-P6768-1 Sheet 12

V V W W

W V

TYPE

AC LJ

HL HL

HM HM HM HM

TYPE

GT GT HU

TYPE

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-16

C3-17

1.0

0.5

636D

1418

851

848

RLY3 B

9803/9970-01 (C-03-00)

0.5

SIZE

WIRE

160BC

1492

DEST

USFS 3

CR65 25

SIZE

0.5

BUTTON ENTER

TERM

CCA040

1491

CR65 24

USFS 2

0.5

DEST

SIZE

WIRE

160BD

CR65 19

USFS 1

DEST

TGSRS

TERM

BUTTON DOWN

CCA039

1490

BUTTON UP

WIRE

160BE

TERM

CCA038

7210/0052

534

7210/0052

RLY7 B

RLY2 B

1846

RLY4 B

0.5

1843

1841

RLY1 B

0.5

RGSRS

RLY6 B

RLY8 B

RLY5 B

CR1 9

CR104 20

CR148 10

CR148 11

0.5

1840

7210/0052

1842

0.5

7210/0052

536

7210/0052

0.5

7210/0052

1845

0.5

816

0.5

587

1844

0.5

7210/0052

586

1.0

CR104 14

0.5

961

FIT ITEMS AM,AN WITHOUT SEALS TO CCA038, CCA039, CCA040

801 750XB

C D E

1842

750XC

D E

1843 814 750XD

B C D E

CH,FZ

CH.FZ

TYPE

HD,HE

CH,FZ

CH.FZ

TYPE

HD,HE

CH,FZ

CH.FZ

TYPE

HD,HE

750W

0.5

CRES6

CR104 16

ECU3 24

0.5 0.5

877

816 -

B C

0.5

DEST CR12C 2

SIZE

155

WIRE

CRES6

CR104 8

TERM

0.5

RELAY BASE 8

750XG

E RLY8

0.5 1.5

1846 ECU3 36

CR12K 6

1.5

323 825

DEST

CRES6

IRWLS

SIZE

A B C

0.5

RELAY BASE 7 WIRE

TERM

RLY7

750XF

835

C E

1845

B ECU3 26

1.5

322 0.5 1.5

DEST CR12K 4

SIZE

WIRE

CRES6

TERM

0.5

ORWLS

ECU3 23

2.5 0.5 2.5

DEST CR12K 2

SIZE

CRES6

RELAY BASE 6

750XE

0.5

CR104 11

ECU3 34

CR12B 8

1.5 0.5 1.5

DEST

RLY6

805

1844

321

A B

WIRE

TERM

APWLS

CRES6

SIZE

RELAY BASE 5

319

RLY5

WIRE

TERM

0.5

ECU3 32

CR12B 6

1.5 0.5 1.5

DEST

CRES6

IFWLS

SIZE

RELAY BASE 4

804

318

RLY4

0.5

RELAY BASE 3 WIRE

TERM

RLY3

0.5 1.5

1841

B -

1.5

317 ECU3 35

DEST CR12A 16

SIZE

WIRE

CRES6

TERM

0.5

OFWLS

ECU3 33

CR12A 14

0.5 2.5

2.5

RELAY BASE 2

750XA

800

1840

316

RLY2

DEST

SIZE

RELAY BASE 1 WIRE

CR1 12

0.5

1497

ECUES

CR1 16

CR1 7

7210/0052

1.0

636E

0.5

1811

CR1 25

1812

CR1 5

0.5

1809

CR1 13

0.5

CR148 20

1.0

960

1810

956

CR148 2

963

CR1 24

0.5

1.0

1496

CR148 13

RLY1 TERM

TYPE

DEST

ECU CONNECTOR C WIRE SIZE

ECU3

TERM

1.0 1.0

524 1835 CR148 33

CR148 25

CR58 1

TIPSSS

CR148 23

CR148 6

TIPSSS

TOPSSS

CR148 32

CDS

TOPSSS

CR53 3

Fig 21.

7210/0052

0.5

7210/0052

32 1473

1.0

30 31

7210/0052

29 1448B

7210/0052

1.0

1836

1.0

7210/0052

1.0

7210/0052

1.0

7210/0052

434

1448A

1443B

17 1834

7210/0052 0.5

7210/0052

1.0

7210/0052

0.5

146B

146A

7210/0052

TMES1

1.0

675KE

675CC

CANLS2

1.0 0.5

CR12J 20

CANSS2

TMES1

147B

1.0

0.5

1.0

CANHS2

CR12J 18

7210/0052

0.5

1.0

TMES1

*CAN_L

147A

*SCRN

675FA

*CAN_H

7210/0052

1.0

* SEE SHEET 5 FOR CAN BUS DETAILS

7210/0052

CR12J 16

1.0

CR12J 16

CR12J 4

CR12J 14

TSS1

DEST

1.0

0.5

7210/0052

7210/0052 675JA

145B

1.0 7210/0052

7210/0052

375

6 145A

144

142A

TECU CONNECTOR B WIRE SIZE

TERM

CCA172

1.0 CR148 24

KU TYPE

15 810G

1443A

1456

1447

DEST

7210/0052

TECU CONNECTOR A WIRE SIZE

TERM

CCA171

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

LX TYPE

GL -

1827

1.0

7210/0052 1.0

7210/0052

7210/0052 7210/0052

39 40

7210/0052 7210/0052

7210/0052 37

7210/0052

7210/0052 35 36

7210/0052

7210/0052 33

7210/0052

28 29

7210/0052 7210/0052

26 27

7210/0052

24 25

CR148 3

CR148 7

CR148 1

CR148 4

CR148 19

CR148 21

7210/0052

1.0

TMES2 CR148 5

CR148 12

7210/0052

1.0

7210/0052

1831

1824

1826

1828

1825

1833

1832

1.0 7210/0052

1.0

1829

TMES2

1.0

675KA

675KB

CR148 17 CR148 18

1.0

1823

CR148 9

CR148 16

CR148 8

DEST

1.0

7210/0052 1822

7210/0052

1.0

1830 1821

1 3

TECU CONNECTOR C SIZE WIRE

TERM

CCA173

KT TYPE

TYPE

GA GB TYPE GT GT GT

333-P6768-1 Sheet 13

CAR DECU CAN2 007 WIRE CAV CSA DESTIN 1.0 CR135 24 A CAN2_H B CAN2_L 1.0 CR135 36 C CAN2_S 1.0 CR135 35

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-17

C3-18

6.0 1.4 2.0 2.0 1.4 1.0 1.4 4.0 1.0 1.0 1.0

010 010A 010B 010C 010D 010E 010F 010G 010H 010J 010K

6.0 0.6 1.4 0.6 2.0 1.0 1.0 1.0 1.0 4.0 4.0 0.5

015 015A 015B 015C 015D 015E 015G 015J 015K 015P 015N 015R

DEST

9803/9970-01 (C-03-00)

0.5

160BB

160BA

DEST

2.0

0.5

1.0

0.5

100L

100M

100V

100AA

0.5

100AG

100AH

CR12J 12

CCA172 1

CR148 27

0.5

1.0

0.5

142

142A

142B

142K

142N

CR135 31

CR148 38

CR53 2

SIZE

142P

DEST

CR12A 8 CR43 8 CR39 E8 CR51 27

WIRE

TSS1

TRANSMISSION SENSOR SUPPLY

2.0 2.0 1.0 1.0

120 120A 120B 120C

PANEL IGNITION A4 PISA4

DEST

2.0 1.0 1.0 1.0 1.5

115 115A 115B 115C 115E

DEST

CR12A 6 CR5 2 CR26 3 CR4 B8 CR143 3

SIZE

WIRE

CAB ROOF IGNITION CRIS

CR8 A

CR24 2

CR7 A

0.5

100AC

CR9 2

CR1 6

ECU15 3

ECU15 1

CR12K 10

SIZE

100

CR147 2

CR65 4

CCA040 1

CCA039 1

CCA038 1

DEST

1.5

206F

SIZE

4.0 1.0 1.4 0.6 3.0 1.5 0.5

WIRE

240 240A 240B 240D 240E 240F 240H

CR45 CR12B 1 CR12B 9 CR12B 17 CR12C 15 CR12C 11 CR12K 7

DEST

CR45 CR12B 3 CR12B 13 CR12B 15

4.0 2.0 3.0 1.4

210 210B 210D 210E

BATTERY 2 BATS2

DEST

SIZE

CR12K 1

WIRE

BATTERY 1 BATS1

CR12K 3 CR12K 5

1.5

206E

206G

CR12B 7

CR12B 5

1.5

206D

CR12A 13 CR12A 15

1.5

206A

206B

CR45

10.0

206

206C

EB DEST

SIZE

WLSS

WIRE

WORKLIGHT SUPPLY

EDC IGNITION EB EDCIS CSA DESTIN WIRE 161 0.5 CR12C 10 161C 0.5 CR104 25 161D 0.5 CR144 2

0.5

160BC

0.5

SIZE

160BD

WIRE

SIZE

USFS

WIRE

CR3 5 CR12A 1 CR12C 17 CR12A 11 CR12C 19 CR12C 7 CR12A 9 CR47 A CR100 A CR12J 9 CR12K 9 CR12A 10

WIRE

0.5

160L

UNIDECK SWITCH FEED SPLICE

CR39 A8 CR12C 9

0.5 0.6

160J 160H CR57 1

CR12C 8 CR77 8

160BE

ECUIS

EB DEST

1.0 0.6

SIZE

160 160C

WIRE

PANEL IGNITION C4 PISC4

DEST

CR33 2 CR12A 3 CR12A 7 CR12A 5 CR12C 1 CR12C 13 CR12C 3 CR12A 17 CR12B 11 CR116 B CR12C 5

ECU1 SWITCH SENSOR FEED

SIZE

WIRE

IGNITION 2 IGNS2

SIZE

WIRE

IGNITION 1 IGNS1 CR12B 18 E1 25 CR65 3 -

0.6 0.6 0.6 -

CR46 2 CR77 5 CR79 11 CR77 2 CR39 B2

6.0 2.0 1.5 2.0 1.4

360 360A 360B 360C 360D

0.6 0.6 0.6

403 403A 403B

0.5 0.5 0.5

500 500AB 500B

DEST

CR1 19 ECU1 11 E1 16

DEST

CR51 23 CR65 33 E1 5

DEST

CR38 CR14 2 CR16 2 CR18 2 CR21 2 CR128 4

SIZE

6.0 1.0 1.0 1.0 1.0 1.5

600 600A 600B 600C 600D 600N

WIRE

CAB ROOF EARTH 1 CRES1

RADAR GR'ND SPEED RESISTOR SPLICE EB RGSRS CSA DESTIN WIRE 536 0.5 ECU3 29 536A 0.5 ECU15 5 536B 0.5 ECU15 2

TRUE GROUND SPEED RESISTOR SPLICE EB TGSRS CSA DESTIN WIRE 534 0.5 ECU3 39 534A 0.5 ECU15 7 534B 0.5 ECU15 4

SIZE

WIRE

RADAR SIGNAL 2 RSS2

SIZE

WIRE

ALTERNATOR SIGNAL ASS EB

EB DEST

SIZE

4.0 1.0 1.0 1.0 1.0 1.0 1.0 0.6 0.6 0.5

SIZE

CCA172 11

0.5 1.0 1.0 1.0

675FA 675JA 675CC

0.5 1.0 1.0 -

CSA 2.0 1.0 1.0 1.0 1.0 1.0 0.5

0.5 CR134 B

CR82 2

E9 2

E11 7

CR33 4

CR38

DEST

HITCH EARTH SPLICE HES EB 661 1.0 CR125 660GA 0.5 E1 1 660GF 0.5 CR104 26

660ZE

1.4

0.5

660GD 660Z

0.5

660GB

2.0 0.6

660 660F

SIZE

WIRE

CR1 8 ECU17 6 ECU2 22 -

EB DESTIN CR38 ECU2-11 ECU2-17 ECU2-23 ECU3-10 ECU3-9 ECU17 7

ECU EARTH SPLICE

CR144 5 CR144 7 ECU6 7

CR9 7

CR38 CR119 A

DEST

CCA172 17

1.0

675JG

1.0

675E 1.0

2.5

1.0

1.5

1.0 0.6 1.0 1.0 0.6 0.6

0.6

3.0 0.6 0.6

SIZE

1.0 1.0

711F 711E

3.0

CR125

CR98 1

CR1 4

CR44 1

CR44 5

CR65 8

DEST

CR78 6

CR39 B6

CR77 7 CR69 31 CR37 2 CR48 2 CR39 E4 CR24 7

CR32 7

CR38 CR39 F4 CR5 7

DEST

CR125

CR4 D5

CCA173 9

CCA173 10

Fig 22.

1.0

711

711G

0.5

0.75

711A

675JF

SIZE

WIRE

SFPE

FRONT PANEL EARTH SPLICE

710AA

710R

710F 710G 710H 710J 710K 710L

710D

710 710A 710B

WIRE

PANEL EARTH 1 PES1

675G

744

675KB

675KA

CR148 34

1.0

739

DEST CR148 22

1.0

SIZE

738

WIRE

TMES2

CR136 1

CR135 25

CR135 13

CR142 21

CR125

CR1 11

CR156 2

TRANSMISSION MANAGEMENT EARTH 2

675D

2.0

675FF 676

0.5 3.0

0.5

675JN 675F

0.5

675JM 675GF

CCA172 23 CR107 1

1.0

675KE

CCA172 22

CR53 1

CR148 14

CR58 2

0.5

675JJ

CABROOF EARTH 3 CRES3

636T 636U 632 -

ECUES WIRE 636 636A 636B 636C 636D 636E 636P

0.5 0.5 1.0

0.5

635W 635ZA 635ZB 635ZC

2.0 1.5

635 635C -

SIZE

WIRE

EB DEST

675JK

SIZE

CR38 CR10 2 CR34 2 CR35 2 CR29 2 CR26 1 CR31 2 CR25 B CR27 B CR117 2

TMES1

TRANSMISSION MANAGEMENT EARTH 1 WIRE

EB DEST

CAB ROOF EARTH 4 CRES4

610 610A 610B 610C 610D 610E 610F 610G 610H 610J

WIRE

CAB ROOF EARTH 2 CRES2

0.6 1.0 1.0 0.5

0.6 1.0

3.0 0.6 1.4 1.4 0.6

SIZE

E1 15

0.5

2.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 -

750J 750JA 750K 750L 750N 750R 750T 750U 750W 750XA 750XB 750XC 750XD 750XE 750XF 750XG -

SIZE

2.5 1.0 1.0

WIRE

800 800A 800B

EB DEST

RLY1 C CR14 1 CR21 1

DEST

CR38 CR104 23 CR4 E6 CR4 B4 CR4 D6 CR143 2 CR4 C6 CR4 A6 RLY8 E RLY1 E RLY2 E RLY3 E RLY4 E RLY5 E RLY6 E RLY7 E -

OUTER FRONT WORKLIGHTS OFWLS

SIZE

WIRE

E6 1

E5 1

CR1 23

DEST

0.5 0.5

SIZE

CR81 2 CR60 2 CR59 2 CR78 7

CR68 10 CR78 9

CAB ROOF EARTH 6 CRES6

725A

725B

715

725

WIRE

SES

EB DEST

CR38 CR63 2 CR70 B CR71 B CR42-S

SENSOR EARTH

720L 720F 720G 720T

720H 720J

720 720B 720C 720D 720A

WIRE

PANEL EARTH 3 PES3 1.5 1.0 1.0

SIZE

RLY2 C CR16 1 CR18 1

DEST

1.5 1.0 1.0

804 804A 804B

RFLS

809E

809D

809A

809

WIRE

0.5

1.5

SIZE

EB DEST

CR78 8

CR65 30

CR104 7

CR79 6

DEST

RLY5 C CR10 1 CR35 1

0.6 0.5 0.5 0.5

FLLS

1.5

812C

CR39 C8

CR39 C4

CR78 3

DEST

SIZE

2.0 1.4 1.5 1.5 0.75 1.5

WIRE

838 838A 838B 838C 838E 838G

CR77 6 CR43 6 CR78 2 CR78 10 CR65 20 CR39 C2

DEST

RLY6 C CR34 1 CR29 1

1.5 1.0 1.0 835 835A 835B

PANEL HEADLIGHTS PHLS

DEST

SIZE

WIRE

CR39 B4

INNER REAR WORKLIGHT IRWLS

1.5

812A 812B

1.5

SIZE

812

WIRE

DEST

CR36 2 CR4 D4 CR4 C4 CCA171 16

FOGLIGHT LATCHING SUPPLY

SIZE

WIRE

810 810A 810E 810G

CLUTCH DOWN SIGNAL EB CDS

2.5 1.0 1.0

805 805A 805B REAR FOGLIGHT SPLICE

SIZE

WIRE

DEST

RLY3 C CR60 1 CR59 1

OUTER REAR WORKLIGHT ORWLS

SIZE

WIRE

A POST WORKLIGHTS EB APWLS

801 801A 801B

WIRE

INNER FRONT WORKLIGHTS IFWLS

K Cab Harness - 333/P6768 Issue 1 ( T C3-6)

CR32 2

1.0

305C

WIRE

CR12B 2 CR128 1

1.0 1.0

305 305G

PANEL MAIN LIGHTS PMLS

DEST

SIZE

WIRE

DEST

SIZE

CABROOF PERMANENT FEED CRPFS

300 300A 300B -

WIRE

PERMANENT FEED B9 EB PFSB9 1.4 1.4 1.0 1.4 0.6 0.6

SIZE

1.0 1.0 0.6 0.5 0.6 0.6 0.5 0.6 0.6 0.6 0.5 0.5

860 860L 860C 860E 860F 860G 860N 860R 860T 860U 860Z 860AA

DEST

CR68 5 CR70 A CR51 24 CR43 1 CR73 5 CR65 6

DEST

883E 883F

883

WIRE

0.5 1.5

1.4

SIZE

CR117 1 CR4 E8

CR104 6

DEST

CR51 16 CR81 1 CR5 8 CABROOF BRAKE LTS CRBLS

1.0 0.6 0.6

CR79 8 CR68 8 CR65 2 CR32 8 CR73 3

1.0 0.6 0.6 0.6 0.6 880 880A 880B 880C 880D 880F 880G 880K

DEST

SIZE

WIRE

1.4 1.4 1.0 1.4 0.6 0.6 861 861A 861B 861C 861D 861G LH SIDELIGHTS LHSLS

DEST

CR68 18 CR71 A CR51 25 CR43 3 CR73 6 CR65 7

SIZE

WIRE

CR79 10 CR104 10 CR73 4 CR128 2 CR25 A CR27 A CR116 A E11 8 CR82 3 CR24 8 CR9 8 CR144 8

PANEL RIGHT INDICATOR PRIS

SIZE

WIRE

RH SIDELIGHTS RHSLS

859 859A 859B 859C 859D 859G

WIRE

PANEL LEFT INDICATOR PLIS

1.0

SIZE

EB DEST

CCA171-19 E1 4

1.0 1.0 0.5

1443 1443B 1443C

170B

0.5

4.0

4.0 170A

SIZE 170

AIR CON FEED

1.5

2.0

SIZE

WIRE

ACFS

808

807A

807

WIRE

FFPS

FRONT FUSE PANEL

1.0

CR104 15

CR12 18 CR11 1

EB DEST

CR79 9

CR79 7

CR77 3

EB DEST

CR148 35

CCA171 11

SIZE

WIRE

DEST

CCA171 30

CR148 15

CCA171 21

1443A

TOPSSS

TRANSMISSION OUTPUT SPEED

1448B

1448

1448A

WIRE

TIPSSS

TRANSMISSION INPUT SPEED

MAINT SUPPLY 1 EB MSS1 CSA DESTIN WIRE 942 1.0 CR4 A8 942N 0.5 CR1 10 942G 1.0 CR142 5 942K 0.5 CR107 2 942L 0.5 CR147 1

RAISE/LOWER SWITCH EB RLSS CSA DESTIN WIRE 930 0.5 E1 12 931 0.5 E11 2 932 0.5 CR104 19

EDC SENSOR SUPPLY EB EDCSSS CSA DESTIN WIRE 920 0.5 E1 13 920A 0.5 E6 3 920B 0.5 E5 3 920C 0.5 CR1 2 920D 0.5 E1-22

BRAKE SIGNAL EB CRBSS CSA DESTIN WIRE 884 0.5 CR57 2 884B 0.5 CR146 2 884C 0.5 CR136 8 884F 0.5 CR100 D

333-P6768-1 Sheet 14

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-18

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection Chassis Harness - 332/W0931 Issue 4

Table 16. Key to Connectors Trailer Socket

C87

Engine Earth Stud

C88

Intake Air Heater Megafuse

C89

Steering Angle Sensor Diff Lock Solenoid CVT

Trans Oil Filter

C95

Rear Bulkhead 1

C100

Elec Suspn Potentiometer LH

Air Dryer

C101

Elec Suspn Potentiometer RH

Air Tank

C102

Elec Suspn Solenoid LH Lower

Rear Brake Reservoir

C103

Elec Suspn Solenoid LH Raise

C12

Alternator B+

C104

Elec Suspn Solenoid RH Lower

C14

Front Brake Reservoir

C105

Elec Suspn Solenoid RH Raise

C15

Heater Fuse 1

CCA 114

Water Valve Actuator

C18

RH Rear Light Cluster

Lower Solenoid

C19

LH Rear Light Cluster

Raise Solenoid

C20

Fuel Tank Sender

E17

Radar Speed Sensor

C28

Front Bulkhead

E19

Position Sensor

C30

Front Wiper Motor

ECU 21

Spool Valve 1 Solenoid

C33

Air Tank No. 1

ECU 22

Spool Valve 2 Solenoid

C34

Air Tank No. 2

ECU 23

Spool Valve 3 Solenoid

C39

Starter Motor

ECU 24

Spool Valve 4 Solenoid

C40

Starter Motor Negative

ECU 25

Spool Valve 5 Solenoid

C41

Starter Motor Solenoid

ECU 26

Pilot Valve

C45

Ind. Heater Relay 1

ECU 28

Front Hitch Position Sensor

C47

Ind. Heater Relay Coil 1

ECU 29

Raise/Lower Interconnect

C48

Horn

ECU 30

Terminating Resistor Connector

C49

Alternator D+

ECU 32

Pressure Transducer

C54

Air Filter Switch

BLS

Brake Light Splice

C60

Compressor Clutch

FLS

Fog Light Splice

C63

LH Headlamp

RLS

Reverse Light Splice

C64

RH Headlamp

CES1

Chassis Earth Splice 1

C73

Brake Reservoir 3

CSES

Solenoid Earth

C75

Engine ECU

MBS

Main Beam Splice

C78

Rear Bulkhead 2

FLES

Headlights Earth Splice

C79

Terminating Resistor Connector

CES9

Chassis Earth Splice 9

C81

RH Headlight and Bar Worklight

CES7

Chassis Earth Splice 7

C82

LH Headlight and Bar Worklight

LHIS

LH Indicator Splice

C83

RH Rear Fender Buttons and Worklight

RSLS

Right Side Light Splice

C84

RH Rear Fender Buttons and Worklight

LSLS

Left Side Light Splice

C85

Engine Power

RHIS

Right Hand Indicator Splice

DBS

Dip Beam Splice

C3-19

9803/9970-01 (C-03-00)

C3-19

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection BMS

Brake Malfunction Splice

HBWLS

Headlight Bars Worklights Splice

RFWLS

Rear Fender Worklights Splice

ESLSSS

Sensor Supply

ELSSES

Sensor Earth

RPERS

Rear PTO External Request Splice

EPS

Engine Power Splice

Lower Signal Splice

Raise Signal Splice

VSS

Valve Supply Splice

SWFS

Switch Feed Splice

ESVSS

Electronic Spool Valve Supply Splice

ESVES

Electronic Spool Valve Earth Splice

RS1

Resistor Splice 1

RS2

Resistor Splice 2

C3-20

9803/9970-01 (C-03-00)

C3-20

C75

11 21 31 41

ITEM CT

PIN 41 POSITION

SEE SHT. 3

ITEM HM

ITEM JW

C85

PIN 1 POSITION

ITEM JY

VIEW ON CONNECTOR FACE

250

9803/9970-01 (C-03-00)

C20

ADD WHITE TAPE

C87

C79

950

500

940

ITEM DV CONDUIT TO COVER ALL VISIBLE YELLOW WIRE HEATSHRINK OVER CONDUIT AND RING TERMINAL.

ITEM HF

2 5

3 6

C30

ITEM KN

CANBUS SPLICES SEE SHEET 10

ITEM JU & JV

XXXX

50 MAX

150

10 9

C89

700

1428

00 22

400

RS1

1429

C40

1429B

ITEM KM

ADD WHITE TAPE

700

RS2

320

ITEM CN

ATUM HEATSHRINK

70 130

ADD WHITE TAPE

850

2350

Fig 23.

300

DATUM

C E S 9

1150

200

150

C60

K Chassis Harness - 332/W0931 Issue 4 ( T C3-19)

RES IST OR

C47

1670

C3-21

20 30 40 50

800

C45

1 2

C54

175

150

ITEM ED

ITEM CT

250

C33

C34

CABLE TIE

300

5 29

CCA 114

C28

ITEM EC

C41

18 19

3 8

332-W0931-4 Sheet 1

SEE SHT. 2

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-21

400

ITEM DU

C39

XXX

C88

SEE SHT. 1

ITEM CT

XX XX X X

C15

APPLY RED TAPE FOR IDENTIFICATION

500

X XXXX X XXXX

ITEM GB

C12

ITEM DU

ITEM GB

XX XXX XXX XX XXX XXX ITEM CT

500

700

XXXXXXXXX

C48

XXX

1400

MBS DBS

Fig 24.

1500

ITEM DV

HBWLS

1600

TAPE ITEM FD TO BRANCHOUT

1550

ITEM DV

TAPE ITEM FD TO BRANCHOUT

1650

FLES

C82

C81

1 4

C64

ITEM CT

x x x x x x x x x x

0 130

1320

K Chassis Harness - 332/W0931 Issue 4 ( T C3-19)

XXXXXXXXX

ITEM DV

1350

ITEM DV

XXXXXXXXXX

APPLY LH LABEL 6

C49

XXXXXXXXX

9803/9970-01 (C-03-00) XXXXXXXXX

1200

XXXXXXXXX

XXXXXXXXXX

ITEM GX

XX XXX XXX XX XXX XXX

C63

135

M8 REF LH

ITEM KT

ITEM FA

2 1

ECU 29

XXXX

DETAILED VIEW C12

XXXX

C3-22

400 XXXXXXXXX

110 1260

450

1000

ECU 28

332-W0931-4 Sheet 2

ITEM DV

XXXX XXXX

ITEM GH

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-22

1000

500

C19

3400

*ITEM CT* OR ITEM DY (SEE NOTE)

XXXX

C18

3350

X X X X

XXXX 2100

SWFS

XXXX

C83

120

2000

*ITEM DY* OR ITEM ED (SEE NOTE)

2050

RFWLS

1950

120

E19

ITEM ED

1900

RLS

ITEM HY

ITEM FC

*ITEM JP* OR ITEM KA (SEE NOTE)

1850

X X X X

120 !

ITEM CT

ITEM HG

ITEM DY

1700

XXXX

3 7

4 8

1 2

XXXX

ITEM KP

ITEM ED

ITEM DV

ECU 26

*ITEM DY* OR ITEM ED (SEE NOTE)

NC12-S TYP. 5 PLACES

ECU 21

FLS 1 5

120

MINIMUM

ITEM JT

XXXX

1500

1550

Fig 25.

ITEM CT TO GO TO BACK OF CONNECTOR

*ITEM JR* OR ITEM KB (SEE NOTE)

ECU 32 A C

ITEM KH

ITEM HX* OR ITEM KF (SEE NOTE)

1 2

400

ADD WHITE TAPE

ITEM DV (2 PLACES)

270

ITEM GW (2 PLACES)

K Chassis Harness - 332/W0931 Issue 4 ( T C3-19)

1500

XXXX

X X X X

ECU 22

BLS

X X X X

RPERS

2350

*ITEM HG* OR ITEM KG (SEE NOTE)

ITEM KA (TYP.4 PLACES)

120 240

ECU 23

250

ECU 24

150 100

ECU 30

500

ESVES ESVSS

150

ECU 25

1300

ITEM HK

450

9803/9970-01 (C-03-00) 200

C84

50 REAR OF CONNECTOR

1000

250 200 30

TO SHEET 4

EPS ESLSES ESLSS 0

RSLS

1400

350 0

100

300 150 100

C3-23 50

ITEM JZ (TYP. 5 PLACES)

CES1

LSLS

XXXXXX

C101

ITEM CS

ADD WHITE TAPE

1350

ITEM DV ITEM DV

ITEM FA

ITEM CS

ITEM GY,GZ

VSS

ADD WHITE TAPE

1300

LHIS

1250

1300

600

500

RHIS

1200

332-W0931-4 Sheet 3

TO SHEET 1

ADD WHITE TAPE

E17

1170

C78

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-23

C105

x x x x x C102

CT7

ITEM FD

x x x x x

C103

220 x x x x x

180

ITEM DV

C95

500

ITEM DV

D/L

ITEM DY

Fig 26.

ITEM DV

ITEM FD

x x

170

0 x x

ITEM FA

x x x x x

ITEM DV

200

300

9803/9970-01 (C-03-00) 0

x x x x x

TO SHEET 3

x x x x x

C100

ITEM HD

ITEM DV

NC SPLIT CONDUIT TO SUIT

K Chassis Harness - 332/W0931 Issue 4 ( T C3-19)

C104

CT9

ITEM FD

x x x x x

CT6

ITEM DV

x x x x x x x x x x

450 350

260

x x x x x x x x x x

650

ITEM FD

CT8

x x x x x

ITEM DV

230

S CSE

BMS

200 x

x x x x x

ITEM DV

x x x x x

A B

C73

800

350

750

X X X X x

CES

200

A B

C14

x x x x x

x x x x x x

C3-24 X X X X x

x x x x x

x x x x x x

ITEM FD

A B

ITEM CU (4 PLCS)

332-W0931-4 Sheet 4

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-24

C3-25

CAV

1 2

SIZE

TRANS OIL FILTER

WIRE

DEST.

SIZE

DEST.

SIZE

DEST.

C28 7 CES7

9803/9970-01 (C-03-00)

WIRE

SIZE

DEST.

DESTIN C39

FRONT BRAKE RESERVOIR

CSA 25

TERM

1 2 3 4 5 6

TERM

SIZE

DEST.

620C 1.4 CES1 R,S 861E 0.6 RHIS O,FL 883A 0.6 BLS O,FL 860D 0.6 RSLS O,FL 877B 0.6 RLS O,FL 809A 0.6 FLS O,FL

WIRE

C18 RH REAR LIGHT CLUSTER

383 16.0 C45 X

SIZE

HEATER FUSE 1

WIRE

C15

A 409A 0.5 BMS BH,BI B 640F 0.5 CES7 BH,BI

TERM

C14

WIRE 225

ALTERNATOR B+

A 409B 0.5 BMS BH,BI B 640G 0.5 CES7 BH,BI

SIZE

REAR BRAKE RESERVOIR

408 1.0 640H 1.0

WIRE

AIR TANK NO. 3

195 1.5 C78 5 AI 640K 1.4 CES7 AI

WIRE

AIR DRYER

1852 0.5 C5 27 CP 640C 0.5 CES7 CP

WIRE

TERM

1 2

TERM

C12

1 2

TERM

AA, AB

TYPE

AG,AH KJ,KL

TYPE

CV,CW

O,P R,S R,S O,P O,P R,S O,P Q

TYPE

M,N

TYPE

BF,BG

TYPE FY

TYPE

BF,BG

CD,CE CD,CE

DEST.

LHIS FLS CES1 RHIS RSLS BLS LSLS -

(REF IN BRACKETS REFERS TO FINAL DESTINATION IN A SEPARATE HARNESS)

1.0 1.4 2.0 1.0 1.0 1.4 1.0 -

SIZE

TRAILER SOCKET

WIRE

859F 809C 620A 861F 860A 883C 880H -

TERM

1 (L) 2(54G) 3 (31) 4 (R) 5(58R) 6 (54) 7(58L) 8

1 2

TERM

C20

1 2 3 4 5 6

TERM

C19

SIZE

DEST.

C28 20 C5 4

SIZE

0.5 0.5

WIRE

411 675JF

FUEL TANK SENDER

620B 1.4 CES1 R,S 859E 0.6 LHIS O,FL 883B 0.6 BLS O,FL 880J 0.6 LSLS O,FL 877A 0.6 RLS O,FL 809B 0.6 FLS O,FL

WIRE

LH REAR LIGHT CLUSTER

CP CP

TYPE

CV, CW

TYPE

M,N

* SEE SHEET 10 FOR CANBUS DETAIL

0.5-2.5

0.5 0.5 0.5 0.5 0.5 1.0 0.5 1.0 0.5 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.0 1.5 1.5 1.5 0.5 0.5 1.0 0.5 0.5 -

SIZE

WIRE

CAN_H* CAN_L* SCRN* 675JF 1809 100V 1811 636AC 587 942N 675GF 1497 1810 597 598 1418 923 929 500 501 920C 424 715 1496 1812 1453 1852 1477 -

0.5-2.5

REAR BULKHEAD 1

CAPAC'Y

TERM

DEST

CANHS6 CANLS6 D'WIRE C20 2 C102.1 ESLSSS C104.1 ESLSES ECU28 3 C89 2 C89 1 C101.3 C103.1 ECU29 2 ECU29 3 ECU32 C RS LS E17 1 E17 4 E19 3 E19 2 E19 1 C100.3 C105.1 C89 3 C3.1 RPERS -

HW GG GG GG GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GD GD GD GC GC GC GC GC CQ CQ CQ

TYPE

0.5-2.5

0.5

0.6 1.0

880F 868 870 409 411 542*** 1427A 403 859B 861B 832 120C 833

0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5

16 17 18 19 20 21 22 23 24 25 26 27 28 841 1546

0.5-2.5 0.5-2.5

30 31

C75 31

C48 1

C30 6

C30 5

C30 3

C30 2

RHIS

WIRE

SIZE

DEST.

C28 5 CES9

CSA 25 16

SIZE DEST.

TERM

C45

383 16.0 C15 X

SIZE

CF DEST.

TYPE

1 2 3 4 5 6

TERM

C64

TERM

SIZE

905B 1.0 DBS 836B 1.0 MBS 0.6 866 870 0.6 700B 1.4 FLES

WIRE

DEST.

TYPE

EY GT,GU EY EY

TYPE

GT,GU

TYPE

CQ CP CP CP CP CY

TYPE

KS,KT,DX

CQ CP CP CP CP CY

TYPE

WIRE

SIZE

BRAKE RESERVOIR 3 DEST.

A 409C 0.5 BMS BH,BI B 640P 0.5 CES7 BH,BI

TERM

C73

KS,KT,DX

AM,AN

C28 15 C28 18

RH HEADLAMP

905A 1.0 DBS 836A 1.0 MBS 881 0.6 C28 14 868 0.6 C28 17 700A 1.4 FLES

WIRE

DEST.

C78 17

DEST.

LH HEADLAMP

2.0

950 A C63

SIZE

WIRE

COMPRESSOR CLUTCH TERM

C60

TYPE

404 0.6 C28 4 650G 0.6 CES9 AM,AN

TYPE GA

WIRE

DEST.

C28 23

DEST.

1 2

SIZE

AIR FILTER SWITCH

1.5

SIZE

TYPE

BN,BQ BN,BQ

C28 30

BL, BM

TYPE

DEST.

TERM

C54

403

WIRE

C49 ALTERNATOR D+

2.0 841 690 2.0 C40

1 2

SIZE

HORN WIRE

1 2 3 4

DEST.

**553 1.0C75 40 BK **14271.0C75 42 BK 1427A 1.0C28 22 ** TWISTED PAIR. SEE NOTE.

SIZE

IND. HEATER RELAY COIL 1 WIRE

TERM

C48

1 2

TYPE

IND. HEATER RELAY 1 WIRE

CD,CE CD,CE

TYPE

CD,CE CD,CE

C47 TERM

DEST.

SIZE

1.0

O,P O,P

C78 28

STARTER MOTOR SLND WIRE

182

C41 TERM

M,N TYPE

TYPE

DESTIN C12 C88

620 6.0 CES1 640 3.0 CES7 650 2.0 CES9 690 2.0 C48-2 FLES 700 4.0 636AZ 2.0 CSES -

WIRE

STARTER MOTOR NEGATIVE

WIRE 225 283

STARTER MOTOR +

406 1.0 650D 1.0

TERM

C40

CAV

C39

1 2

TERM

C34 AIR TANK NO.2

C28 6 CES9

407 1.0 650C 1.0

Fig 27.

LHIS

C47 C49 2

C75 23

C20 1

BMS

C64 5

C63 5

LSLS

C64 4

C63 4

DBS

C75 49

MBS

C75 9

RS2 C75 22

C8 1

TYPE

C33 1

C34 1

D'WIRE C54 1

CANLS4

CANHS4

DEST

HV/CR

1 2

DEST.

C28 28 C28 29

SIZE

WIRE

C33 AIR TANK NO.1 TERM

DEST.

O,P C28 26 C28 27

K Chassis Harness - 332/W0931 Issue 4 ( T C3-19)

*** SEE SHEET 6 FOR TWISTED TRIPLE DETAIL

* SEE SHEET 10 FOR CANBUS DETAIL

2.0 1.0

834

0.5-2.5

1.0

1.5

1.0

0.5

0.6

1.0

866

0.6

1.4

0.5-2.5

1.4

1.0

905 881

0.5-2.5

836

0.5-2.5

12 13

1547

0.5-2.5

1.0

541***

540***

0.5-2.5

9 10

1.0 1.0

408

0.5-2.5

1.0

407 1429B

0.5-2.5 0.5-2.5

1.0

0.6

406

404

SCRN*

0.5-2.5

0.5

CAN_L*

0.5-2.5

2 4

0.5

CAN_H*

SIZE

WIRE

0.5-2.5

CAPAC'Y

FRONT BULKHEAD

TERM

C28

WIRE

650A 1.0 CES9 832 1.0 120C 1.0 Q 833 1.0 834 1.0

SIZE

FRONT WIPER MOTOR

TERM

1 2 3 4 5 6

C30

TYPE

BF,BG

C75

C28 10

1.0

C28 9

DB DC

1547

1.0 * CANBUS CABLE. SEE SHEET 10. ** TWISTED PAIR. SEE SHEET 6. *** TWISTED TRIPLE. SEE SHEET 6.

1.0

*CAN_L 47

332-W0931-4 Sheet 7

CANLS4 C28 11

CANHS4

DC 1.0

*CAN_H 46

DB 44

C47 2

DB DB

1.0

C47 1

1.0

C78 9

**1427

**553

40 41

130

1.0

DC 38

D'WIRE

RS2

C28 31

36 1.0

1.0

35 *SCRN

1429

1546

RS1

C28 21

DC 1.0

1.0

26 1428

***542

***540

DC DC

15 16

DC DC DC

DC DC

DC DB

6 8

DC DC

1.0

***541

TYPE

DEST DC

SIZE

ENGINE ECU WIRE

TERM

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-25

C78

C6 1

BLS

FLS

RFWLS

1.5

1.4

195

883

809

2.5-4.0

0.5-2.5

C3-26

9803/9970-01 (C-03-00)

932B 923B 929B 100SB -

620D

825A

1477A

RFWLS

1.5 1.0 0.5 0.5 0.5 0.5 0.5 -

SWFS RS LS ESLSS -

RPERS

CES1

DEST

SIZE

RH REAR FENDER BUTTONS+W/LIGHT

WIRE

C83

TERM

FLES

DEST

700D

HBWLS

814B

1.0 1.0

WIRE

TERM

SIZE

LH HEADLIGHT BAR W/LIGHT

C82

FLES

HBWLS

700C

1.0 1.0

814A

DEST

SIZE

RH HEADLIGHT BAR W/LIGHT

WIRE

C81

TERM

CANLS4

0.5 0.5

CAN_L

CANHS4

CAN_H

DEST

SIZE

WIRE

TERM

TERMINATING RESISTOR CONNECTOR

0.5

504

0.5-1.0

C79

0.5

182

1.0

503

0.5-1.0

0.5-2.5

660GF

0.5-2.5

0.5

1.0

161

0.5-2.5

924

750JA

0.5-1.0

0.5-2.5

0.5-1.0

2.0

101

0.5-2.5

2.0

637

0.5-1.0

0.5

932

586

0.5

1528

0.5-1.0

0.5-2.5

2.0

0.5

877

950

0.5-2.5

0.5

961

0.5-2.5

170B

0.5-2.5

814

0.5-2.5

1.0

1.5

860L

0.5-2.5

1.0

1.5

825

130

0.5-2.5

R,S O,P O,FL O,FL O,FL O,FL O,FL Q

TYPE

AA AB

CP CP

TYPE

CV, CW

CP CP

TYPE

CV, CW

CX CX CQ

TYPE

FJ, DN

E7 1

C41

E8 1

E17 2

E17 3

VSS

CCA114 4

ESVSS

ESVES

ECU26 1

SWFS

CCA114 2

C60 A

RLS

CCA114 1

C95 1

HBWLS

RSLS

C75 39

EPS

4.0

TYPE

339

DEST

2.5-4.0

SIZE

WIRE

REAR BULKHEAD 2

CAPAC'Y

2.5-4.0

TERM

C84

1.5 1.0 0.5 0.5 0.5 0.5 0.5 -

SIZE

WIRE 645A 645B 339A 339B 4.0

CSA 2.5 2.5 4.0

CSA 2.5 2.5 DESTIN C85 1 C85 2

STEERING ANGLE SENSOR CSA DESTIN WIRE CAV 675GF 1.0 C5 11 1 1.0 C5 10 2 942N 1.0 C5 26 3 1453 4 C5 26 5 C5 26 6 C5 26

C89

INTAKE AIR HEATER MEGAFUSE CSA DESTIN WIRE CAV 283 16 C39

C88

WIRE 645A 645B

SWFS RS LS ESLSS -

RPERS

CES1

RFWLS

DEST

DESTIN C87 C87 EPS EPS

ENGINE POWER

932A 923C 929C 100SA -

1477B

620E

825B

WIRE

LH REAR FENDER BUTTONS+W/LIGHT

C87 ENGINE EARTH STUD

CAV 1 2 3 4

C85

TERM

AA AB

CCA WATER VALVE 114 ACTUATOR CSA DESTIN WIRE CAV 0.5 1 170B C78 15 0.5 2 1528 C78 18 3 0.5 4 750JA C78 23

ELEC SUSPN C105 SOLENOID RH RAISE CSA DESTIN WIRE TERM 1812 0.5 C5 25 1 0.5 CSES 2 636AG

ELEC SUSPN SOLENOID RH LOWER CSA DESTIN WIRE TERM 0.5 C5 7 1 1811 0.5 CSES 2 636AF C104

ELEC SUSPN C103 SOLENOID LH RAISE CSA DESTIN WIRE TERM 0.5 C5 13 1 1810 0.5 CSES 2 636AE

ELEC SUSPN C102 SOLENOID LH LOWER CSA DESTIN WIRE TERM 0.5 C5 5 1 1809 0.5 CSES 2 636AD

ELEC SUSPN C101 POTENTIOMETER RH CSA DESTIN WIRE TERM 0.5 ESLSES 1 636AH 0.5 ESLSSS 2 100VA 0.5 C5 12 3 1497

ELEC SUSPN POTENTIOMETER LH CSA DESTIN WIRE TERM 0.5 ESLSES 1 636AK 0.5 ESLSSS 2 100VB 0.5 C5-24 3 1496 C100

DIFF LOCK C95 SOLENOID CVT CSA DESTIN WIRE CAV 0.5 C78 14 1 961 0.5 CSES 2 640W

FG,FH KU TYPE CP CP CQ CP

CV, CW TYPE CP CP

TYPE EW,EX EW,EX EW,EX

CV CW TYPE CP CP

Fig 28.

E17

CSA DESTIN 1.5 C5 23 1.5 C5 22 1.5 C5 21

POSITION SENSOR

RADAR SPEED SENSOR CSA DESTIN 1.0 C5 19 1.0 C78 26 1.0 C78 25 1.0 C5 20

WIRE 500 660GF 161 501

WIRE CAV 1 715 2 424 3 920C

E19

CAV 1 2 3 4 5 6

CSA DESTIN 0.5 C78 27 0.5 VSS

RAISE SOLENOID

WIRE CAV 1 503 2 924A

CSA DESTIN 0.5 C78 29 0.5 VSS

LOWER SOLENOID

WIRE CAV 1 504 2 924B

TYPE GN,GP GN,GP GN,GP

DW DX TYPE CP CP CP CP CQ CQ

TYPE AM,AN AM,AN

K Chassis Harness - 332/W0931 Issue 4 ( T C3-19)

TYPE CP CP CP CQ CQ CQ

DW,DX

TYPE X

TYPE KR KR

FV FW TYPE CZ CZ CZ CZ

R,S O,P O,FL O,FL O,FL O,FL O,FL Q

TYPE

ECU 21

515T

** **

0.5 0.5

0.5

SIZE

0.5

SIZE

0.5

SIZE

TERM

514X**

515X**

WIRE

0.5

SIZE

TERMINATING RESISTOR CONN'R

597 598 ECU 30

0.5 0.5 0.5

101G

1 2 3

SIZE

DEST

KC TYPE

GM,AN

EW,EX

ESLSES ESLSSS C5 9

CANHS10

CANLS10

CX CX CQ

TYPE

FJ DN

O,FL O,FL O,FL

ESVSS C5 14 C5 15

DEST

TYPE

DEST

BC BD

EW,EX

TYPE

GM,AN

C78 20 ESVES

TYPE

KD,KE

TYPE

KD,KE

TYPE

KD,KE

TYPE

KD,KE

TYPE

KD,KE

DEST

ESVSS

CANLS10

CANHS10

ESVES

DEST

ESVSS

CANLS9

CANHS9

ESVES

DEST

ESVSS

CANLS8

CANHS8

ESVES

DEST

ESVSS

CANLS7

CANHS7

ESVES

DEST

ESVSS

CANLS6

CANHS6

ESVES

DEST

RAISE / LOWER INTERCONNECT WIRE TERM

ECU 29

0.5 0.5 587

0.5

636W 100N

1 2

SIZE

WIRE TERM

FRONT HITCH POS'N SENSOR

586 637F

1 2

ECU 28

WIRE TERM

PILOT VALVE

0.5

101E

4 ECU 26

0.5

515W 514W

0.5

SIZE

3 **

WIRE 637E

SPOOL VALVE 5 SOLENOID

101D

514V

637D 515V

WIRE

SPOOL VALVE 4 SOLENOID

101C

514U

637C 515U

WIRE

SPOOL VALVE 3 SOLENOID

0.5

SIZE

2 **

TERM

ECU 25

TERM

ECU 24

3 **

2 **

TERM

ECU 23

514T 101B

2 **

WIRE 637B

3 **

0.5

SPOOL VALVE 2 SOLENOID

101A

514R

637A 515R

SIZE

SPOOL VALVE 1 SOLENOID WIRE

TERM

ECU 22

3 **

2 **

TERM

ECU PRESSURE 32 TRANSDUCER CSA DESTIN WIRE CAV 0.5 ESLSSS A 100P 0.5 ESLSES B 636T 0.5 C5 16 C 1418

FJ DS TYPE CP CP CP

332-W0931-4 Sheet 8

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-26

C3-27 SIZE

BRAKE LIGHT SPLICE WIRE

9803/9970-01 (C-03-00) FL ES

MBS

TERM

CSES

TERM

DEST.

SIZE

DEST.

SIZE

DEST.

WIRE

SIZE

DEST.

SIZE

700 4.0 C40 700A 1.4 C63-6 700B 1.4 C64-6 700C 1.0 C81-2 700D 1.0 C82-2

WIRE

HEADLIGHTS EARTH SPLICE DEST.

TYPE

SIZE

TERM

BMS

DBS

TERM

DEST.

C78 10

SIZE

DEST.

SIZE

DEST.

SIZE

DEST.

409 0.5 C28 19 409A 0.5 C14-A 409B 0.5 C9-A 409C 0.5 C73-A

WIRE

BRAKE MALF'N SPLICE

905A 1.0 C63-2 905B 1.0 C64-2 C28 13 905 1.4

WIRE

DIP BEAM SPLICE

C28 25 1.0 861B 1.0 C1 4 861F 861E 0.6 C18-2

WIRE

RH INDICATOR SPLICE

C28-16 880F 1.0 880J 0.6 C19-4 880H 1.0 C1-7

SIZE

LEFT SIDELIGHT SPLICE WIRE

860A 1.0 C1-5 860D 0.6 C18-4 860L 1.0

WIRE

RIGHT SIDELIGHT SPLICE

LS LS

RH IS

DEST.

C3 2 ----------C73 B -

C8 2

-----------

DEST.

859B 1.0 C28 24 859F 1.0 C1 1 859E 0.6 C19-2

WIRE

LH INDICATOR SPLICE

TERM

RS LS

TERM

LH IS

SIZE

640 3.0 C40 ----------640F 0.5 C14-B 640G 0.5 C9-B 1.0 640H 640K 1.4 C6-2 640C 0.5 ----------640P 0.5 -

WIRE

CE CHASSIS EARTH S7 SPLICE 7 TERM

DEST.

650A 1.0 C30-1 --------------------650 2.0 C40 C33 2 650C 1.0 C34 2 650D 1.0 650G 0.6 C54-2 ---------------------

WIRE

CE CHASSIS EARTH S9 SPLICE 9 TERM

WIRE

SIZE

1.5 1.5 1.5

A DESTIN C5 8 C100 1 C101 1 ECU32 B ECU28 1 -

ENGINE POWER SPLICE A EPS CSA DESTIN WIRE 339 4.0 C78.2 339A 4.0 C85.3 339B 4.0 C85.4

REAR PTO EXTERNAL REQUEST SPLICE A RPERS CSA DESTIN WIRE 1477 0.5 C5 28 1477A 0.5 C83 3 1477B 0.5 C84 3

CSA 1.0 0.5 0.5 0.5 0.5 -

SENSOR EARTH ESLSES WIRE 636AC 636AK 636AH 636T 636W -

DEST.

C78 8 C83-1 C84-1

A CSA DESTIN 1.0 C5 6 0.5 C101 2 0.5 C100 2 0.5 ECU32 A 0.5 ECU28 2 0.5 C84 7 0.5 C83 7 - -

SENSOR SUPPLY

825 825A 825B

ESLSSS WIRE 100V 100VA 100VB 100P 100N 100SA 100SB -

TERM

REAR FENDER RF WLS W'LIGHTS SPLICE

DEST.

C78 11 C81-1 C82-1

SIZE

1.5 1.0 1.0

WIRE

814 814A 814B

HB H'LIGHT BARS WLS W'LIGHTS SPLICE TERM

Fig 29.

TYPE

SWFS WIRE 932 932A 932B

TERM

RS2

TERM

RS1

TERM

ESV ES

TERM

A CSA DESTIN 0.5 C78 24 0.5 E8 2 0.5 E7 2

ECU21-1

ECU25-1

0.5

ECU24-4

0.5

1.0

SIZE

1.0 1.0

WIRE

1429 1429B

RESISTOR SPLICE 2

1428

WIRE

RESISTOR SPLICE 1

637F

C75-32 C28-8

DEST.

C75-28

DEST.

ECU26-2

ECU25-4

ECU23-4

0.5 0.5

0.5

637C 637E

637D

ECU21-4

C78 21

DEST

ECU22-4

0.5

2.0

SIZE

ECU29-1

0.5 637B

637A

637

WIRE

EL'TRONIC SPOOL VALVE EARTH SPLICE

101G

ECU24-1

0.5

101E -

ECU23-1

0.5 0.5

101D

ECU22-1

101C

0.5

C78 22

2.0 0.5

101 101A

DEST

SIZE

101B

WIRE

EL'TRONIC SPOOL VALVE SUPPLY SPLICE

A CSA DESTIN 0.5 C78 19 0.5 C84 4 0.5 C83 4

SWITCH FEED SPLICE

VSS WIRE 924 924A 924B

ESV SS

A CSA DESTIN 0.5 C5 17 0.5 C83 5 0.5 C84 5

VALVE SUPPLY SPLICE

RS WIRE 923 923B 923C

RAISE SIGNAL SPLICE

A CSA DESTIN 0.5 C5 18 0.5 C83 6 0.5 C84 6

LOWER SIGNAL SPLICE LS WIRE 929 929B 929C

K Chassis Harness - 332/W0931 Issue 4 ( T C3-19)

836 1.4 C28 12 836A 1.0 C63-3 836B 1.0 C64-3

WIRE

MAIN BEAM SPLICE

SIZE

C40 C102 2 C103 2 C104 2 C105 2 C95 2

WIRE

636AZ 2.0 636AD 0.5 636AE 0.5 636AF 0.5 636AG 0.5 640W 0.5

SOLENIOD EARTH

620 6.0 C40 620A 2.0 C1-3 620B 1.4 C19-1 620C 1.4 C18-1 620D 1.0 C83-2 620E 1.0 C84-2 -

DEST.

877 0.6 C78 16 877B 0.6 C18-5 877A 0.6 C19-5

WIRE

REVERSE LIGHT SPLICE

809 1.4 C78 7 809A 0.6 C18-6 809B 0.6 C19-6 809C 1.4 C1-2

WIRE

FOG LIGHT SPLICE

C78 6 883 1.4 883A 0.6 C18-3 883B 0.6 C19-3 883C 1.4 C1-6

CE CHASSIS EARTH S1 SPLICE 1

TERM

RLS

TERM

FLS

TERM

BLS

TYPE

332-W0931-4 Sheet 9

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-27

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection Arm Rest Harness - 333/R1829 Issue 1

CAR001 CAR008

Table 17. Key to Connectors Cab Harness 1 Joystick Buttons 1-7

CAR009

Joystick Base Buttons

CAR010

Joystick Axis X and Y

CAR011

Hand Throttle

CAR012

Hitch ECU

CAR013

Front Hitch Control

CAR014

Rear Hitch Control

CAR015

Hitch Control Pot 1 Rear Mix

CAR016

Hitch Control Pot 2 Rear Max Raise

CAR017

Hitch Control Pot 3 Rear Drop Rate

CAR018

Hitch Control Pot 4 Front Max Raise

CAR019

Hitch Control Pot 5 Front Drop Rate

CAR021A

Cigar Lighter Positive

CAR021B

Cigar Lighter Negative

CAR025

Turbo Button

CAR026

CAR027

CCANARM1

Arm Rest CAN Backbone

CCANARM4

CAN1 Term

SMSS3

Maintained Sensor Supply 3

SC1H6

CAN1 High Splice 6

SC1L6

CAN1 Low Splice 6

SC1S6

CAN1 Screen Splice 6

SC1SCR2 SHTSS

Hand Throttle Sensor Supply Splice

STME3

Trans Man Earth Splice

TRBRS

Turbo Request Button Resistor Splice

R1S

Resistor 1 Splice

R2S

Resistor 2 Splice

C3-28

9803/9970-01 (C-03-00)

C3-28

C3-29

9803/9970-01 (C-03-00)

K Arm Rest Harness - 333/R1829 Issue 1 ( T C3-28)

Fig 30.

333-R1829-1 Sheet 1

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-29

Section C3 - Electrics Harness SYSTEM

C3-30

K Arm Rest Harness - 333/R1829 Issue 1 ( T C3-28)

Fig 31.

333-R1829-1 Sheet 2

Drawings and Interconnection

9803/9970-01 (C-03-00)

C3-30

Section C3 - Electrics Harness SYSTEM

C3-31

9803/9970-01 (C-03-00)

K Arm Rest Harness - 333/R1829 Issue 1 ( T C3-28)

Fig 32.

333-R1829-1 Sheet 3

Drawings and Interconnection

C3-31

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection ABS Pannier Harness - 333/P9127 Issue 2

AP1

Table 18. Key to Connectors Bulkhead Connector (Pannier)

AP2

Front Modulator

AP3

Rear Left Modulator

AP4

Rear Right Modulator

C3-32

9803/9970-01 (C-03-00)

C3-32

C3-33

ITEM CH 100

ITEM CC

REAR RIGHT MODULATOR

AP4

ITEM CL

ITEM CE,CF

ITEM E

C TYPE

WIRE

SIZE

DEST.

1 1804 2 1805 3 1803

1.0 1.0 1.0

AP1-9 AP1-11 AP1-10

TERM

ITEM A

A KEY GREY

D D D

ITEM CM 600

BULKHEAD CON' (PANNIER) WIRE

SIZE

DEST.

1808 1807 1806 1801 1800 1802 1804 1803 1805 -

1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 -

AP2-1 AP2-3 AP2-2 AP3-1 AP3-3 AP3-2 AP4-1 AP4-3 AP4-2 -

1 2 3 4 5 6 7 8 9 10 11 12

A,CA TYPE

B B B CB B B B CB B B B CB

ITEM CL

1 2

ITEM CC

100 160

200 RL

AP1 TERM

F 0

ITEM CM

ITEM CM ITEM CJ

ITEM CE,CF

TYP

1 2

10 20

9803/9970-01 (C-03-00)

ITEM CE,CF

FRONT MODULATOR

AP2 WIRE

SIZE

DEST.

1 1808 2 1806 3 1807

1.0 1.0 1.0

AP1-1 AP1-3 AP1-2

TERM

REAR LEFT MODULATOR

AP3 C

WIRE

SIZE

DEST.

1 1801 2 1802 3 1800

1.0 1.0 1.0

AP1-5 AP1-7 AP1-6

TERM

TYPE

D D D

C TYPE

D D D

333-P9127-2 Sheet 1

Fig 33. K ABS Pannier Harness - 333/P9127 Issue 2 ( T C3-32)

Section C3 - Electrics

Harness SYSTEM

Drawings and Interconnection

C3-33

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection ABS 6 Cab Harness - 333/P0875 Issue 1

Table 19. Key to Connectors Power in

Bulkhead

Fuse E1

Fuse E2

Fuse F1

Fuse F4

Tractor ABS Power In

A10

Tractor ABS Return

A11

Tractor ABS Diagnostic Relay

A17

ABS J1708 Diagnostic

A18

Tractor ABS ECU Connector X1

A19

Tractor ABS ECU Connector X2

A21

Bulkhead Connector (Pannier)

A22

Fuse F5

A24

ABS CANBUS Interconnect

A25

Tractor ABS ECU Connector X3

C3-34

9803/9970-01 (C-03-00)

C3-34

C3-35

A21

A J H B K M G L D F E

1000

A2 A1 1

A9 A

B 2

E D

A18

A B

A10

100

2 LITTELFUSE

2 1

C B

A 50

GROMMET 828/00162

200

A17 A4

0 23 5 22

ITEM BE

C D

LITTELFUSE

A24

1150

100

LITTELFUSE

XXXXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXXXX

DATUM 50

400

1250

800

300

9803/9970-01 (C-03-00)

1000

B A C

ITEM BJ A8

2 LITTELFUSE

8 A22

LITTELFUSE

23 22 0 5

A19 6

25 0 ABS DIA

1200 TYP

A11

A25

TO BE SUPPLIED AS PART OF HARNESS TO BLANK UNUSED CONNECTOR ON ECU

K ABS 6 Cab Harness - 333/P0875 Issue 1 ( T C3-34)

C3-35

Harness SYSTEM

333-P0875-1 Sheet 1

Fig 34.

Section C3 - Electrics

11 17

Drawings and Interconnection

12 18

C3-36 A3

SIZE

A1 C A1 D A2 1 -

2.5 2.5 4.0 -

260 270 370 -

9803/9970-01 (C-03-00)

L,Q

M M

SIZE

1.0 1.0 1.0 1.0 1.0 -

TRACTOR ABS ECU CONNECTOR X1 CSA WIRE **561 1.0 CAN_L 0.5 ***564 1.0 ***562 1.0 **560 1.0 CAN_H 0.5 ***565 1.0 ***563 1.0 156 1.0 449 1.0 371 3.0 665A 3.0

1808 1807 1806 1801 1800 1802 1804 1803 1805 -

A B C D E F G H J K L M 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 -

SIZE

A19 13 A19 9 A19 8 A19 15 A19 11 A19 12 A19 16 A19 17 A19 18 -

DEST.

Fig 35.

BD BD BD BD BD BD BD BD BD -

TYPE

L, BN TYPE N N

DESTIN A2 H A2 M A2 K A2 N A9 D A21 C A21 B A21 F A21 G A21 A A21 E A21 J A21 K A21 L

TYPE BA BA BA BA BA BU BU BA BA BU BA BA BA BU BA BA BA BA

TYPE BA BA BA BA BA BA BA BA BA BU BU BA BU BR BR

BS CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

A25

AE AF TYPE AG AG BU

DESTIN

TO BE SUPPLIED AS PART OF HARNESS TO BLANK UNUSED CONNECTOR ON ECU

TRACTOR ABS ECU CONNECTOR X3 CSA WIRE

CAPACTY O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5

A ABS CANBUS 24 INTERCONNECT CSA DESTIN WIRE CAV 0.5 A18 6 A CAN_H 0.5 A18 2 B CAN-L C

DESTIN A17 1 A24 B A2 E A2 F A17 2 A24 A A2 L A2 G A5 2 A11-6 A22 2 A10 B

BC,BF BG,BH

A FUSE F5 22 CSA DESTIN WIRE CAV 3.0 A9 B 1 265A 3.0 A18 14 2 371

WIRE

BULKHEAD CON' (PANNIER)

*** WHEEL SPEED SENSOR WIRE. SEE NOTE

TRACTOR ABS ECU CONNECTOR X2 CSA WIRE ***566 1.0 ***567 1.0 ***568 1.0 ***569 1.0 884F 0.5 1806 1.0 1807 1.0 1800 1.0 1802 1.0 1808 1.0 1801 1.0 1804 1.0 1803 1.0 1805 1.0

CAPACTY O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5

** SERIAL DATA WIRE. *** WHEEL SPEED SENSOR WIRE. SEE NOTE

CAPACTY O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 2.5-4.0 2.5-4.0

TERM

A21

CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

A19

CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A18

TYPE

AT,AU AV,AN AV,AN

SIZE

DEST.

ABS J1708 DIAGNOSTIC WIRE

A17 TERM

561 1.0 A18-1 1** A18-5 560 1.0 2** ** SERIAL DATA WIRE. SEE NOTE

K ABS 6 Cab Harness - 333/P0875 Issue 1 ( T C3-34)

BW BW -

TYPE

DEST.

A11-4 A8-2 A11-2 A10-A A18-12 -

D,E F,G BM

TRACTOR ABS DIAG'C RELAY

TYPE

DEST.

A11-5 A18 15 A13 1

SIZE

WIRE

448 1.0 665A 3.0 665B 1.0

TRACTOR ABS RETURN

TYPE

AD,E BK,G BM BL,C

DEST.

A5-1 A22 1 A19 5

SIZE

15K 1.0 265A 3.0 884F 0.5

TRACTOR ABS POWER IN WIRE

TYPE

DEST.

A5 1 A11-4

L,P

TYPE

L,P

M M

TYPE

L,P

TYPE

J K K K K K K K K K K

TYPE

SIZE

WIRE

153A 153 4 153A 5 448 6 449 8 2

TERM

A TYPE

15KA 1.0 153 1.0

FUSE F4

DEST.

A9 A A8 1 A18 9

SIZE

FUSE F1 WIRE

15K 1.0 15KA 1.0 156 1.0

WIRE

A11

A B C

TERM

A10

A B C D

TERM

1 2

TERM

DEST.

A1 A A2 A

SIZE

1.0 1.0

WIRE

15J 150

1 2

FUSE E2

DEST.

SIZE

FUSE E1 WIRE

A3-2 A4-2 A1-B A18 3 A18 4 A18 8 A19 1 A19 3 A18 7 A19 2 A19 4

DEST.

BULKHEAD WIRE

TERM

DEST.

15J 1.0A4-1 D,E 440 0.5A2-B B,C 260 A3-1 2.5 F,G 270 A3-1 2.5 F,G

SIZE

POWER IN WIRE

4.0 370 1 2 A 150 1.0 B 440 0.5 C D E*** 564 1.0 F*** 562 1.0 G*** 563 1.0 H*** 566 1.0 J K*** 568 1.0 L*** 565 1.0 M*** 567 1.0 N*** 569 1.0 *** WHEEL SPEED SENSOR WIRE. SEE NOTE

TERM

A B C D

TERM

BY TYPE BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU

333-P0875-1 Sheet 2

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-36

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection ABS Chassis Harness

ABS1

Table 20. Key to Connectors ABS T/Socket

ABS2

Cab Bulkhead

ABS3

Bell Housing Bracket (negative)

ABS4

Pannier Bulkhead

ABS8

Rear LH Speed Sensor

ABS9

Rear RH Speed Sensor

ABS10

Front RH Speed Sensor

ABS11

Front LH Speed Sensor

C3-37

9803/9970-01 (C-03-00)

C3-37

9803/9970-01 (C-03-00)

WIRE

BLACK

BROWN

1 2

DEST.

ABS2-12 ABS2-13

SIZE

FA CE

1.0 1.0

REAR RH SPEED SENSOR

AT IN

CE FA

ITEM M

DEST.

ABS2-10 ABS2-11

SIZE

1.0 1.0

TYPE

0 0

900

BRAID OVER CONDUIT AS SHOWN

45 55

ITEM N (SEE DETAIL BELOW) FREE TO SLIDE OVER CONDUIT, TEMPORARILY SECURED USING TEARABLE TAPE.

SPLIT

ITEM N (2 PLACES)

500

ITEM N (SEE DETAIL BELOW) FREE TO SLIDE OVER CONDUIT, TEMPORARILY SECURED USING TEARABLE TAPE.

TYPE

SPLIT

C B B C B

ABS2 1 ABS2-9 ABS3 ABS3 ABS2-28

4.0 1.4 1.4 4.0 1.4

370 150 605 615 440

1 2 3 4

TYPE

A,P DEST.

SIZE

ABS T/SOCKET WIRE

ABS 1 TERM

ITEM T

XXXXXXXXXXXXXXXXXXXXXXXXXXX

ABS2 TERM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

ABS4 TERM 1 2 3 4 5 6 7 8 9 10 11 12

6 5 4 3 2 1 7 8 9 10 11 12

CAPACITY 2.5-4.0 2.5-4.0 2.5-4.0 2.5-4.0 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-2.5 0.5-1.0 0.5-2.5 0.5-1.0 0.5-2.5 0.5-2.5 0.5-1.0 0.5-1.0 0.5-2.5 0.5-2.5 0.5-1.0 0.5-2.5 0.5-1.0

DEST. ABS1-1 ABS10-1 ABS10-2 ABS11-1 ABS11-2 ABS1-2 ABS8-1 ABS8-2 ABS9-1 ABS9-2 ABS4-6 ABS4-5 ABS4-16 ABS4-10 ABS4-9 ABS4-11 ABS4-3 ABS4-2 ABS4-1 ABS1-5 -

DEST. ABS2-26 ABS2-25 ABS2-22 ABS2-15 ABS2-14 ABS2-16 ABS2-19 ABS2-17 ABS2-21 -

Fig 36.

CAB BULKHEAD WIRE SIZE 370 4.0 BLACK 1.0 BROWN 1.0 BLACK 1.0 BROWN 1.0 150 1.5 BLACK 1.0 BROWN 1.0 BLACK 1.0 BROWN 1.0 1800 1.0 1801 1.0 1802 1.0 1803 1.0 1804 1.0 1805 1.0 1806 1.0 1807 1.0 1808 1.0 440 1.5 -

PANNIER BULKHEAD CAPACITY WIRE SIZE 0.5-2.5 1808 1.0 0.5-2.5 1807 1.0 0.5-2.5 1806 1.0 0.5-2.5 0.5-2.5 1801 1.0 0.5-2.5 1800 1.0 0.5-2.5 1802 1.0 0.5-2.5 1804 1.0 0.5-2.5 0.5-2.5 1803 1.0 0.5-2.5 1805 1.0 0.5-2.5 -

ITEM T

D,AE,AF TYPE E AA AA AA F F F F F F F F F F F F F W F W F F W W F F W F W

AB,AC,AD TYPE F F F AA F F F AA F F F AA

1800

K ABS Chassis Harness ( T C3-37)

DATUM

ITEM AE,AF

ITEM V

70 0 BLACK

1 2

BROWN

WIRE

DEST.

ABS2-7 ABS2-8

SIZE

1.0 1.0

FRONT LH SPEED SENSOR TERM

ABS 11

GF AC E

MA TIN

TYPE

1000

ITEM L

E AC GF TIN MA

00 10

TERM

ABS 9

IN AT

WIRE

BLACK

1 2

BROWN

TERM

REAR LH SPEED SENSOR

ABS 8

ITEM AG SUPPLIED LOOSE 320 NC08-S 320 NC08-S 320 NC08-S 320 NC08-S

AX 5M

XXXXXXXXXXXXXXXXXXXXXXXXXXX

ITEM S TO BE CABLE TIED TO TRAILER SOCKET

100

150

500

1200

ITEM T TO EXTEND 50mm PAST THIS JUNCTION AND BE BRAIDED OVER.

0 70

5M AX

ABS 10

SCRAP VIEW (ENLARGED) SHOWING BRAID OVER SEALED CONDUIT ENDS.

1 2

TERM

BROWN

SIZE

1.0 1.0

ITEM R

ITEM L

DEST.

ABS2-5 ABS2-6

TYPE

333-P9128-2 Sheet 1

SCRAP VIEW (ENLARGED) TO SHOW WHEEL SENSOR ARRANGEMENT (2 PLACES)

FRONT RH SPEED SENSOR WIRE BLACK

ITEM R

TYPE

DEST.

ABS1-3 ABS1-4

1350

SIZE

1.4 4.0

WIRE

605 615

ABS BELL HOUSING 3 BRACKET (-VE) TERM

12 APPROX

C3-38 45 55

1700

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

0 32

C3-38

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection EDC Rear Fender Lighting Harness - 333/P0879 Issue 1

RF1

Table 21. Key to Connectors Chassis Harness Interconnect

RF3

PTO Request Button

RF4

Worklight

RF5

EDC Raise Button

RF6

EDC Lower Button

RFSS

Rear Fender Switch Splice

C3-39

9803/9970-01 (C-03-00)

C3-39

C3-40

RF1

50 RFSS

1230

XXXXXX

1300

1350

Fig 37.

RF4

1450

K EDC Rear Fender Lighting Harness - 333/P0879 Issue 1 ( T C3-39)

ITEM AM NOTE: DO NOT TAPE CONDUIT. ADDITIONAL HARNESS TO BE FITTED INTO CONDUIT ON INSTALLATION.

DATUM

1200

100

333-P0879-1 Sheet 1

RF6

RF3

RF5

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

9803/9970-01 (C-03-00)

C3-40

C3-41 CHASSIS HARNESS INTERCONNECT CSA DESTIN WIRE 825A/B 1.0 RF4 1 620D/E 1.0 RF4 2 1477 A/B RF3 2 0.5 932 A/B 0.5 RFSS 923 0.5 RF5 2 929 0.5 RF6 2 100S 0.5 RF3 1

9803/9970-01 (C-03-00) EDC LOWER BUTTON CSA DESTIN 0.5 RFSS 0.5 RF1 6 929 -

RF 6 CAV 1 2 3

M,N

TYPE W,X W,X AC

TYPE D D

A,B

TYPE W,X W,X AC

TYPE P,R P,R P,L P,L P,L P,L P,L U

K EDC Rear Fender Lighting Harness - 333/P0879 Issue 1 ( T C3-39)

Fig 38.

REAR FENDER SWITCH SPLICE AK RFSS WIRE CSA DESTIN 0.5 932A/B RF1 4 932C 0.5 RF5 1 0.5 932D RF6 1

WIRE 932D

EDC RAISE BUTTON CSA DESTIN WIRE 0.5 RFSS 932C RF1 5 0.5 923 -

RF 5 CAV 1 2 3

RF WORKLIGHT 4 CSA DESTIN WIRE CAV 1.0 RF1 1 1 825A/B 1.0 RF1 2 2 620D/E

RF PTO REQUEST 3 BUTTON CSA DESTIN WIRE CAV 0.5 RF1 7 1 100S 0.5 RF1 3 2 1477A/B 3 -

RF 1 CAV 1 2 3 4 5 6 7 8

333-P0879-1 Sheet 2

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-41

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection Heated Front and Rear Screen and Mirror Harness - 333/P0883 Issue 2

HS1

Table 22. Key to Connectors Heated Front Screen Switch

HS2

Timer Relay

HS3

Heated Screen Relay Base

HS4

L/H Screen Fuse

HS5

R/H Screen Fuse

HS6

LH Screen

HS7

RH Screen

HS8

Earth Terminal

HS9

Positive Terminal

HS10

Joystick Control

HS11

Interconnect Cab Roof

HS12

LH Mirror

HS13

RH Mirror

HS14

Mirror Fuse

HS15

Ignition Fuse

HS16

Rear Screen Fuse

HS17

Rear Heated Fuse

HMSS

Heated Mirror Supply Splice

HSIS

Heated Screen Ignition Splice

HSSS

Heated Screen Supply Splice

HSES

Heated Screen Earth Splice

C3-42

9803/9970-01 (C-03-00)

C3-42

HS9

1550

HS11

A B

ITEM AG

LITTELFUSE

HS14

LITTELFUSE

200

9803/9970-01 (C-03-00) HS15

LITTELFUSE

HS5

LITTELFUSE

200

1 LITTELFUSE

HS16

Fig 39.

HSIS

200

D A

100 200

HSES

300

HS8

400

HMSS

1500

6 2

HS10

400 HS17

2300

7 8 4 1 5 2 6 3 9 10

HS1

2 3

5 4

HS13

2 HS6

10 BLACK PVC SLEEVE MUST BE FREE SLIDING. DO NOT TAPE IN POSITION

SEE NOTE 3

2600

300

K Heated Front and Rear Screen and Mirror Harness - 333/P0883 Issue 2 ( T C3-42)

1300

200

HS4

HSSS

450 100

600

100

550

1000

HS3

450

C3-43 200

HS2

300 HS7 SEE NOTE 3

3400

333-P0883-2 Sheet 1

3800

2 5 4

HS12

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-43

C3-44 0.5

790C

10.0 10.0

290 989 988 790D

1 2 3 4

HSES

9803/9970-01 (C-03-00) DEST.

HS5-2 HSES

L,M L,M

TYPE

L,M L,M

TYPE

E E

TYPE

D, F

HS8

DEST.

3 4 5

10J 102

1 2

TYPE

E E

HS11-B HSIS

D, T

E E

TYPE

D, S

AH AF AH AH AF

TYPE

AH AF AH AH AF

TYPE

Y,AA Z,AB

TYPE

AR AR AR AR AR AR AR AR

TYPE

DEST.

HSSS HMSS

DEST.

HS10-4 HMSS HS10-8 HS10-6 HSES

DEST.

Fig 40.

1.0 1.0

SIZE

IGNITION FUSE WIRE

TERM

HS15

1 2

SIZE

WIRE

989C 1.5 993 1.5

TERM

HS14

MIRROR FUSE

0.5 0.75 0.5 0.5 0.75

997 993B 998 996 790H

1 2

DEST.

HS10-3 HMSS HS10-7 HS10-5 HSES

RH MIRROR

0.5 0.75 0.5 0.5 0.75

SIZE

3 4 5

DEST.

HS1-8 HS15-1

LH MIRROR

WIRE

994 993A 995 992 790G

WIRE

TERM

HS13

1 2

TERM

HS12

860N 0.5 10J 1.0

WIRE

SIZE

A B

TERM

HS12-4 HS13-4 HSIS HS13-1 HS12-1 HS12-3 HS13-3 HSES

INTERCONNECT CAB ROOF.

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

SIZE

HS11

WIRE

992 996 102A 997 994 995 998 790F

1 2 3 4 5 6

AN,AP

JOYSTICK CONTROLLER

TERM

HS 10

TYPE

HSES

DEST.

SIZE

10.0

290

TYPE

DEST.

HS3-1

+VE TERM. WIRE

10.0

790 HS9

SIZE

EARTH TERM. WIRE

TERM

993 993A 993B 993C

WIRE

1.5 0.75 0.75 0.5

SIZE

TERM

HS ES

TERM

HS SS

TERM

1.0 0.5 0.5 0.5

SIZE

DEST.

HS8 HS6-2 HS7-2 HS2-E HS3-4 HS1-7 HS10-2 HS12-5 HS13-5 HS17-2

SIZE

790 10.0 790A 2.5 790B 2.5 790C 0.5 790D 0.5 790E 0.5 790F 0.5 790G 0.75 790H 0.75 2.5 790K

WIRE

DEST.

HS3-2 HS4-1 HS5-1 HS14-1 HS16-1

HEATED SCREEN EARTH SPLICE

989 10.0 989A 2.5 989B 2.5 989C 1.5 989D 2.5

WIRE

DEST.

HS15-2 HS10-1 HS2-A HS1-2

HEATED SCREEN SUPPLY SPLICE

102 102A 102B 102C

WIRE

DEST.

HS14-2 HS12-2 HS13-2 HS1-6

HS HEATED SCREEN IS IGNITION SPLICE

TERM

HM HEATED MIRROR SS SUPPLY SPLICE

HS17-2 HSES

DEST.

1 2

SIZE

WIRE

999 790K

TERM

2.5 2.5

DEST.

HSSS HS17-1

REAR HEATED SCREEN

989D 2.5 999 2.5

SIZE

REAR SCREEN FUSE WIRE

HS17

1 2

TERM

HS16

D, F

TYPE

L,M L,M

TYPE

E E

TYPE

K Heated Front and Rear Screen and Mirror Harness - 333/P0883 Issue 2 ( T C3-42)

2.5 2.5

SIZE

991 790B

WIRE

TERM

1 2

DEST.

HS4-2 HSES

RH SCREEN

990 2.5 790A 2.5

SIZE

LH SCREEN WIRE

DEST.

HSSS HS7-1

HS7

1 2

TERM

HS6

989B 2.5 991 2.5

1 2

SIZE

WIRE

HS5 TERM

R/H SCREEN FUSE

E E

TYPE

1 2

DEST.

TERM

HSSS HS6-1

SIZE

WIRE

989A 2.5 990 2.5

HS4

J J H H

TYPE

D, F

HS9 HSSS HS2-C HSES

DEST.

AL AL AL

HSIS HS1-3 HS3-3

L/H SCREEN FUSE

0.5 0.5

SIZE

WIRE

TERM

HS3

0.5 0.5 0.5

102B 520 988

A B C D E

AK TYPE

DEST.

HEATED SCREEN RELAY BASE

SIZE

TIMER RELAY WIRE

TERM

HS2

C C C C C

HSIS HS2-B HMSS HSES HS11-A

0.5 0.5 0.5 0.5 0.5

102C 520 993C 790E 860N

2 3 6 7 8

A TYPE

SIZE DEST.

HEATED FRONT SCREEN SWITCH WIRE

HS1 TERM

333-P0883-2 Sheet 2

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-44

Section C3 - Electrics Harness SYSTEM Drawings and Interconnection Transmission Harness

VBS

Table 23. Key to Connectors Valve Block Splice

PDS

Powershift Dump Splice

RBS

Range Box Splice

PBPS

PTO Brake 12V Splice

SSGS

Speed Sensor Ground Splice

SSPS

Speed Sensor 12V Splice

R1FL

Range Sol 1F-Low

MCL

Master Clutch Lube

R1RXL

Range Sol 1R-Extra Low

4WD

4 Wheel Drive

R2S

Rail 2 Pos Sens H/M

MCOT

M/Clutch Oil Temp

R2RM

Range Sol 2R-Medium

TOS

Trans O/P Spd Sens

R2FH

Range Sol 2F-High

PRS

PTO Rear Speed Sens

TRIS

Range I/P Spd Sens

R1S

Rail 1 Pos Sens L/XL

TOT

Trans Oil Temp

PRB

PTO Rear Brake

MCB

Master Clutch Brake

PPS

PTO 540/1000 Pos Sens

PTO Rear Clutch

PFB

PTO Front Brake

Master Clutch

PSC

Powershift Solenoid C

PSE

Powershift Solenoid E

OPS

Low Oil Pressure Switch

PSB

Powershift Solenoid B

PSD

Powershift Solenoid D

PSR

Powershift Solenoid R

PSA

Powershift Solenoid A

PTO Front Clutch

PFS

PTO Front Speed Sens

C3-45

9803/9970-01 (C-03-00)

C3-45

9803/9970-01 (C-03-00)

DEST PFS B PRS B TRIS B TOS B PPS 2 R2S 2 R1S 2 BH 27

SPEED SENSOR 12V SPLICE WIRE SIZE 142H 1.0 142G 1.0 142D 1.0 142F 1.0 142J 1.0 142C 1.0 142E 1.0 142B 1.0

MASTER CLUTCH LUBE WIRE SIZE 1826 1.0 739B 1.0

RANGE SOL 1R-EXTRA LOW WIRE SIZE DEST 1824 1.0 BH 19 738D 1.0 RBS

4 WHEEL DRIVE WIRE SIZE 960 1.0 738E 1.0

RAIL 2 POS SENS H/M WIRE SIZE 738G 1.0 142C 1.0 1835 1.0 -

M/CLUTCH OIL TEMP WIRE SIZE 524 1.0 738U 1.0

MCL TERM 1 2

R1R XL TERM 1 2

4WD TERM 1 2

R2S TERM 1 2 3 4 5 6

MCOT TERM 1 2

DEST BH 25 SSGS

DEST SSGS SSPS BH 33

DEST BH 20 RBS

DEST BH 21 VBS

RANGE SOL 1F-LOW WIRE SIZE 1823 1.0 738C 1.0

R1F L TERM 1 2

TERM

SSPS

TERM

DEST BH 18 RBS

DEST PFS A PRS A TRIS A TOS A PPS 1 R2S 1 R1S 1 BH 26 MCOT2 TOT 2

SPEED SENSOR GROUND SPLICE WIRE SIZE 738J 1.0 738K 1.0 738F 1.0 738R 1.0 738H 1.0 738G 1.0 738S 1.0 738M 1.0 738U 1.0 738T 1.0

SSGS

DEST BH 38 PFB 1 PRB 1

PTO BRAKE 12V SPLICE WIRE SIZE 142K 1.0 142M 1.0 142L 1.0

PBPS TERM

DEST R2F 2 R2R 2 R1F 2 R1R 2 4WD 2 BH 22

RANGE BOX SPLICE WIRE SIZE 738A 1.0 738B 1.0 738C 1.0 738D 1.0 738E 1.0 738 1.0

RBS TERM

DEST PSC 2 PSE 2 PSB 2 PSD 2 PSR 2 PSA 2 BH 40

POWERSHIFT DUMP SPLICE WIRE SIZE 740C 1.0 740E 1.0 740B 1.0 740D 1.0 740F 1.0 740A 1.0 740 1.0

A,K,N TYPE F F

C,M,P TYPE F F F J J J

A,K,R TYPE F F

A,K,N TYPE F F

A,K,R TYPE F F

12V

TYPE

10C

TYPE

ZZ TYPE

GND

ZZ TYPE

GND

TYPE

PRS TERM A B C

1120

ID LABEL

R2F H

DEST BH 16 RBS

A,K,R TYPE F F

B,L,O TYPE F F F

X+Z

PRS

DEST SSGS SSPS BH 37

R1R XL

180

R2R M

BULKHEAD

PTO REAR SPEED SENS WIRE SIZE 738K 1.0 142G 1.0 1484 1.0

TOT

R1F L

360

RANGE SOL 2F-HIGH WIRE SIZE 1821 1.0 738A 1.0

R2F H TERM 1 2

DEST SSGS SSPS BH 35

A,K,R TYPE F F

R1S TERM 1 2 3 4 5 6

TRIS TERM A B C

B,L,O TYPE F F F

120

RBS

R1S L/XL

DATUM

PLEASE ENSURE PROTECTIVE CAP IS FITTED TO BULKHEAD PRIOR TO DELIVERY

TRANS O/P SPD SENS WIRE SIZE 738R 1.0 142F 1.0 1443 1.0

TOS TERM A B C

120

TERM

DEST BH 17 RBS

1420

PDS

RANGE SOL 2R-MEDIUM WIRE SIZE 1822 1.0 738B 1.0

320

140 470

AO AO

210 SSGS

380

SSPS

DEST SSGS SSPS BH 32

DEST SSGS SSPS BH 15

TOS

TOT TERM 1 2

PBPS

C,M TYPE F F F J J J

B,L,O TYPE F F F

160

DEST BH 24 SSGS

700

Fig 41.

TRANS OIL TEMP WIRE SIZE 1447 1.0 738T 1.0

4WD

TRIS

A,K,N TYPE F F

V+AU

100

PPS

VBS

PSE

PSC

PFB

PRB

MCB

K Transmission Harness ( T C3-45)

R2S H/M

RAIL 1 POS SENS L/XL WIRE SIZE 738S 1.0 142E 1.0 1834 1.0 -

RANGE I/P SPD SENS WIRE SIZE 738F 1.0 142D 1.0 1448 1.0

260

R2R M TERM 1 2

1100

GND

120

AO AO AO

170 200

493 340

PDS

OPS

PSB

PSD

PSR

PSA

MCOT

V+AU

MASTER CLUTCH BRAKE WIRE SIZE 1825 1.0 739A 1.0

MCL

MCB TERM 1 2

PTO REAR BRAKE WIRE SIZE 142L 1.0 851 1.0

200

PRB TERM 1 2

1180

100

PFS

AO AP

ZZ BH DEST

AO AP AP

DEST MCB 2 MC 2 MCL 2 BH 34

VALVE BLOCK SPLICE WIRE SIZE 739A 1.0 739C 1.0 739B 1.0 739 1.0

95 50

436

320 230 140

185

275

AP AP AP AQ AQ AQ AQ

365

865 635 280 235

AP AP AP AQ AQ AQ

190 145 100 55

C3-46 AQ

VBS TERM

DEST BH 12 VBS

DEST PBPS BH 11

A,K,N TYPE F F

MASTER CLUTCH WIRE SIZE 1827 1.0 739C 1.0

POWERSHIFT SOLENOID C WIRE SIZE DEST 1830 1.0 BH 8 740C 1.0 PDS POWERSHIFT SOLENOID E WIRE SIZE DEST 1832 1.0 BH 7 740E 1.0 PDS LOW OIL PRESSURE SWITCH WIRE SIZE DEST 434 1.0 BH 6 675JJ 1.0 BH 14

MC TERM 1 2 PSC TERM 1 2 PSE TERM 1 2 OPS TERM 1 2

POWERSHIFT SOLENOID R WIRE SIZE DEST 1833 1.0 BH 3 740F 1.0 PDS

PSR TERM 1 2

PFS TERM A B C

PF TERM 1 2

PTO FRONT SPEED SENS WIRE SIZE 738J 1.0 142H 1.0 1495 1.0

PTO FRONT CLUTCH WIRE SIZE 963 1.0 637G 1.0

DEST SSGS SSPS BH 28

DEST BH 2 BH 41

POWERSHIFT SOLENOID A WIRE SIZE DEST 1828 1.0 BH 1 740A 1.0 PDS

POWERSHIFT SOLENOID D WIRE SIZE DEST 1831 1.0 BH 4 740D 1.0 PDS

PSD TERM 1 2

PSA TERM 1 2

POWERSHIFT SOLENOID B WIRE SIZE DEST 1829 1.0 BH 5 740B 1.0 PDS

PSB TERM 1 2

DEST BH 9 VBS

DEST PBPS BH 10

PTO FRONT BRAKE WIRE SIZE 142M 1.0 848 1.0

PFB TERM 1 2

DEST BH 13 BH 42

DEST SSGS SSPS BH 31

PTO REAR CLUTCH WIRE SIZE 956 1.0 637H 1.0

PTO 540/1000 POS SENS WIRE SIZE 738H 1.0 142J 1.0 1540 1.0 -

PR TERM 1 2

PPS TERM 1 2 3 4 5 6

721-M1991-4 Sheet 1

B,L,O TYPE F F F

A,K,N TYPE F F

D,Q,AK TYPE G,H G,H

A,K,N TYPE F F

C,M,P TYPE F F F J J J

Section C3 - Electrics Harness SYSTEM

Drawings and Interconnection

C3-46

Section C4 - Electrics

Electronics Network 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.. Descriptions and procedures relate to the system and not the individual devices. 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.

K System Overview ( T C4-3) K Fault Finding ( T C4-4) K Engine Control ECU ( T C4-5) K Inputs/Outputs ( T C4-6) K Removal and Replacement ( T C4-7) K Dashboard ECU (EMS) ( T C4-8) K Setup ( T C4-8) K Inputs/Outputs ( T C4-9) K Removal and Replacement ( T C4-10) K Central Control ECU (ECU1) ( T C4-11) K Inputs/Outputs ( T C4-12) K Access ( T C4-13) K Removal and Replacement ( T C4-13) K Transmission Control ECU (TECU) ( T C4-14) K Inputs/Outputs ( T C4-15) K Access ( T C4-19) K Draft Control ECU (EHR-Z) ( T C4-17) K Inputs/Outputs ( T C4-18) K Access ( T C4-19) K Removal and Replacement ( T C4-19) K ABS Control ECU ( T C4-20) K Inputs/Outputs ( T C4-21) K Access ( T C4-22) K Removal and Replacement ( T C4-22) K Auxiliary Controls ECU (ACE) ( T C4-23) K Inputs/Outputs ( T C4-24) K Access ( T C4-25) K Removal and Replacement ( T C4-25)

C4-1

9803/9970-01 (C-08-00)

C4-1

Section C4 - Electrics Electronics Network SYSTEM Introduction K Touch Screen ECU (DECU) ( T C4-26) K Inputs/Outputs ( T C4-27) K Service Calibration Mode ( T C4-28) K Engine Throttles Calibration ( T C4-30) K PTO Speed Selection Calibration ( T C4-34) K Joystick Calibration ( T C4-36) K Transmission Calibration ( T C4-40) K Steering Angle Calibration ( T C4-42) K Screen Calibration ( T C4-43) K Access ( T C4-44) K Removal and Replacement ( T C4-44)

C4-2

9803/9970-01 (C-08-00)

C4-2

Section C4 - Electrics Electronics Network SYSTEM System Overview

System Overview The electronics network system consists of electronic devices which communicate with each other over CAN bus networks. In this way the devices interact with each other to control machine systems in response to inputs from operator controls and remote sensors and switches

– CAN 1 - uses the J1939 communication protocol. – CAN 2 - uses the J1939 communication protocol. – J1708 bus - diagnostics link for the ABS ECU. CanBus systems use two wires (and also a shield wire) to provide data communication. Devices are connected in parallel. Each end of the CAN bus connects to a terminating resistor.

There are three separate CAN bus networks:

CAN 2

SPOOL VALVES

EMS

ECU1

EHR-Z

ACE

DECU

CAN 1

ENGINE

TECU

ABS

DLA

DIAGNOSTICS CONNECTOR

10 J1708 BUS

C096020

Fig 1. Network Device

K Touch Screen ECU (DECU) ( T C4-26)

CAN enabled auxiliary valve spool solenoids Refer to Section E, Spool Valves

K Engine Control ECU ( T C4-5)

K Dashboard ECU (EMS) ( T C4-8)

Diagnostic connector. Service Master SYSTEM

K Central Control ECU (ECU1) ( T C4-11)

K Transmission Control ECU (TECU) ( T C4-14)

DLA - diagnostic data link adaptor (service tool). Service Master SYSTEM

K Draft Control ECU (EHR-Z) ( T C4-17)

K ABS Control ECU ( T C4-20)

Personal computer with JCB Service Master software (service tool). Service Master SYSTEM

K Auxiliary Controls ECU (ACE) ( T C4-23)

C4-3

9803/9970-01 (C-08-00)

C4-3

Section C4 - Electrics Electronics Network SYSTEM Fault Finding

Fault Finding Use JCB Service Master to help identify faults with the CAN bus wiring or connectors. Look at the vehicle/CAN diagnostics screen to see CAN bus activity in real time. Look at the Data Log to see fault codes relating to CAN bus communication faults. BEFORE testing the CAN bus system with a multimeter, disconnect the Service Master Laptop and DLA from the diagnostic socket and switch the Ignition â&#x20AC;&#x2DC;OFFâ&#x20AC;&#x2122;. DO NOT touch electronic control unit electrical connector pins. DO NOT use a multimeter on electronic control unit connector pins. Remember that there are two separate CAN bus networks on the machine. In addition the ABS ECU connects to the diagnostics socket by a separate CAN bus Locations of CAN bus connectors and terminating resistors are given in the applicable Service Master help file.

C4-4

9803/9970-01 (C-08-00)

C4-4

Section C4 - Electrics Electronics Network SYSTEM Engine Control ECU

Engine Control ECU

C096120

Fig 2. The engine ECU is located on the left side of the engine. The ECU manages engine fuelling to control engine speed, emissions and torque. This ECU has a hardwired secondary throttle pedal sensor to allow limp home operation if the CAN bus communication with the DECU is lost. There are three electrical connectors on the ECU: 1

Power supply connector

Machine device connector

Engine device connector

C4-5

9803/9970-01 (C-08-00)

C4-5

Section C4 - Electrics Electronics Network SYSTEM Engine Control ECU

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is also given in the applicable Service Master help file. Section Topic

SPN91

Accelerator pedal position sensor (Yellow)

Throttle Position Sensors (TPS)

SPN97

Water in fuel sensor

Water in Fuel Sensor

SPN100

Engine oil pressure switch

Sensors and Actuators

SPN102

Engine inlet manifold pressure sensor

Sensors and Actuators

SPN105

Engine inlet manifold temperature sensor

Sensors and Actuators

SPN108

Barometric pressure sensor

Sensors and Actuators

SPN110

Engine coolant temperature sensor

Sensors and Actuators

SPN111

Coolant level sensor

Sensors and Actuators

SPN190

Engine speed sensors

Sensors and Actuators

EEM5

Engine inlet manifold grid heater relay

Cold Start SYSTEM

CAS

Camshaft sensor

Sensors and Actuators

CRS

Crankshaft sensor

Sensors and Actuators

FRS

Injection fuel rail pressure sensor

Sensors and Actuators

Fuel pump actuator

Sensors and Actuators

C4-6

9803/9970-01 (C-08-00)

C4-6

Section C4 - Electrics Electronics Network SYSTEM Engine Control ECU

Removal and Replacement The ECU is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty. Do not replace the ECU with one from another machine. They may look the same but the electronic software can be different. After replacement make sure that the ECU is connected to the machine systems correctly. Use JCB Service Master.

C4-7

9803/9970-01 (C-08-00)

C4-7

Section C4 - Electrics Electronics Network SYSTEM Dashboard ECU (EMS)

Dashboard ECU (EMS)

1 ))

5.0 km/h

)

750 rpm

02.26PM 000004km JCB FASTRAC

ABS

2 C039350-B10

Fig 3. The EMS 1 has a multi-function display. The operator can select display information from a list by use of the push buttons 2. Refer to the machine Operator Handbook for more information. The EMS gets inputs from devices connected directly and as CAN bus messages. Data is processed and results displayed. The EMS also transmits data as CAN bus messages.

Setup The EMS stores information about the machine variant and its configuration. If the EMS or related components are replaced the EMS must be setup as follows: Replaced Component

Procedure

EMS Unit

Use the correct Service Master Setup tool to store related vehicle data in the EMS

Tyres

Changes to tyre size specifications will change the calculated vehicle speed. Use the Service Master Setup tool to change the tyre size specification used by the EMS

C4-8

9803/9970-01 (C-08-00)

C4-8

Section C4 - Electrics Electronics Network SYSTEM Dashboard ECU (EMS)

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is also given in the applicable Service Master help file. Section Topic

EMS53-55 LH column lever status (if fitted) EMS57

Alternator charge signal

EMS59-62 Vehicle turn signals ON (digital input) EMS63-64 Vehicle lights ON (digital input) EMS65

Tractor ABS warning ON (digital input)

EMS66

Trailer ABS fault warning ON (digital input)

EMS67

Air tank 1 pressure switch

Brake SYSTEM (Non -ABS), Brake SYSTEM (ABS)

EMS68

Air tank 2 pressure switch

Brake SYSTEM (Non -ABS), Brake SYSTEM (ABS)

EMS69

Air tank 3 pressure switch

Brake SYSTEM (Non -ABS), Brake SYSTEM (ABS)

EMS73

Air filter blocked switch

EMS74

Brake fluid level switches

Brake SYSTEM (Non -ABS), Brake SYSTEM (ABS)

EMS78

Area cutout signal (CAN1 message)

EMS99

LH column lever end button/ LH steering column button (digital input)

EMS110

Radar present input (CAN1 message)

Ground Radar SYSTEM

EMS111

Radar speed (CAN1 message)

Radar SYSTEM

EMS112

Fuel tank level sender input

Fuel Tank

EMS114

EMS dashboard buzzer output

C4-9

9803/9970-01 (C-08-00)

C4-9

Section C4 - Electrics Electronics Network SYSTEM Dashboard ECU (EMS)

C4-10

9803/9970-01 (C-08-00)

C4-10

Section C4 - Electrics Electronics Network SYSTEM Central Control ECU (ECU1)

Central Control ECU (ECU1)

C0092890-C1

Fig 4. The Fastrac central control (ECU1) 1 is located under the passenger seat. The ECU communicates on both CAN1 and CAN2

C4-11

9803/9970-01 (C-08-00)

C4-11

Section C4 - Electrics Electronics Network SYSTEM Central Control ECU (ECU1)

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is also given in the applicable Service Master help file. Section Topic

FCC1

Valve slice status (CAN2 message)

Spool Valve SYSTEM

FCC2

Front hitch settings (CAN1 message)

Spool Valve SYSTEM

FCC8

Spool slice operating mode (CAN1 message)

Spool Valve SYSTEM

FCC11

Spool slice time/flow mode setting: (CAN1 message) E

Spool Valve SYSTEM

FCC14

Spool slice temperature (CAN2 message)

FCC15

Current active valve slice blink code (CAN2 message) E

Spool Valve SYSTEM

FCC16

Spool movement (CAN2 message)

Spool Valve SYSTEM

FCC18

Front linkage external ‘raise’ control (digital input)

Spool Valve SYSTEM

FCC19

Front linkage external ‘lower’ control (digital input)

Spool Valve SYSTEM

FCC26

Front hitch position sensor

Agricultural Front Hitch

FCC31

Spool valve block pilot valve

Spool Valve SYSTEM

FCC41

Transport switch

Spool Valve SYSTEM

FCC119

4WD solenoid

6x4 Smoothshift Transmission SYSTEM

FCC120

Diff lock solenoid

Differential Lock SYSTEM

FCC156

Radar speed output - implement socket

Radar SYSTEM

FCC157

Theoretical ground speed output - implement socket

FCC164

Spool valve inlet pressure sensor

Spool Valve SYSTEM

FCC1903

Front PTO cab control switch

6x4 Smoothshift Transmission SYSTEM

FCC1904

Diff lock switch

Differential Lock SYSTEM

FCC1906

Rear PTO external stop switch

6x4 Smoothshift Transmission SYSTEM

FCC1907

2WD/4WD switch

6x4 Smoothshift Transmission SYSTEM

FCC1911

Rear PTO cab control switch

6x4 Smoothshift Transmission SYSTEM

FCC1921

Front PTO external stop switch

6x4 Smoothshift Transmission SYSTEM

FCC200

Rear suspension ride height potentiometers

Rear Suspension SYSTEM

FCC204

Rear suspension control valves

Rear Suspension SYSTEM

FCC227

Rear PTO clutch solenoid

6x4 Smoothshift Transmission SYSTEM

FCC228

Rear PTO brake solenoid

6x4 Smoothshift Transmission SYSTEM

FCC229

Front PTO clutch solenoid

6x4 Smoothshift Transmission SYSTEM

FCC230

Front PTO brake solenoid

6x4 Smoothshift Transmission SYSTEM

FCC231

PTO rear speed sensor

6x4 Smoothshift Transmission SYSTEM

FCC232

PTO front speed sensor

6x4 Smoothshift Transmission SYSTEM

FCC233

PTO 540/1000 position sensor

6x4 Smoothshift Transmission SYSTEM

FCC191b3 Transmission oil filter blocked switch

C4-12

9803/9970-01 (C-08-00)

C4-12

Section C4 - Electrics Electronics Network SYSTEM Central Control ECU (ECU1)

Access

Removal and Replacement

!MCAUTION Electronic Control Unit The electronic control unit under the passenger's seat is protected by a cover. Do not use the machine with the cover removed.

The ECU is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty.

0103

Get access under the passenger seat: Undo four bolts 1 and lift out the passenger seat complete with base plate 3. Do not remove cover 2.

Do not replace the ECU with one from another machine. They may look the same but the electronic software can be different. After installation of a new ECU do the following: – Make sure that the ECU is connected to the machine systems correctly. Use JCB Service Master.

– Configure the spool valve slices. – Calibrate the spool controls.

– Calibrate the front hitch position sensor.

3 C095860

Fig 5.

C4-13

9803/9970-01 (C-08-00)

C4-13

Section C4 - Electrics Electronics Network SYSTEM Transmission Control ECU (TECU)

Transmission Control ECU (TECU)

C092890-C2

Fig 6. The transmission control (ECU1) 1 is located to the rear of the passenger seat. The ECU communicates on CAN1.

C4-14

9803/9970-01 (C-08-00)

C4-14

Section C4 - Electrics Electronics Network SYSTEM Transmission Control ECU (TECU)

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is also given in the applicable Service Master help file. Section Topic

Transmission bulk oil temperature sensor

Master clutch oil temperature sensor

Clutch pedal position sensor

T12

Clutch pedal activation switch

T13

Transmission oil pressure switch

T14

Transmission output shaft speed sensor

T15

Transmission intermediate shaft speed sensor

T70

Parkbrake switch

T10100

Transmission rail position sensors

T10102

Range solenoids

T10300

Master clutch pedal sensor

T10302

Master clutch solenoid

T10303

Master clutch brake solenoid

T10304

Master clutch lubrication solenoid

T10401

Transmission power shift relay

T10500

Powershift/reverse solenoid valves

C4-15

9803/9970-01 (C-08-00)

6x4 Smoothshift Transmission SYSTEM

C4-15

Section C4 - Electrics Electronics Network SYSTEM Transmission Control ECU (TECU)

Access

Removal and Replacement

!MCAUTION Electronic Control Unit The electronic control unit under the passenger's seat is protected by a cover. Do not use the machine with the cover removed.

The ECU is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty.

0103

Do not replace the ECU with one from another machine. They may look the same but the electronic software can be different.

Get access under the passenger seat: Undo four bolts 1 and lift out the passenger seat complete with base plate 3. Do not remove cover 2.

After installation of a new ECU do the following: â&#x20AC;&#x201C; Make sure that the ECU is connected to the machine systems correctly. Use JCB Service Master. â&#x20AC;&#x201C; Calibrate the transmission.

1 2

3 C095860

Fig 7.

C4-16

9803/9970-01 (C-08-00)

C4-16

Section C4 - Electrics Electronics Network SYSTEM Draft Control ECU (EHR-Z)

Draft Control ECU (EHR-Z)

C092890-C3

Fig 8. The draft control (EHR-Z) 1 is located to the rear of the passenger seat. The ECU controls the position of the rear hitch according to operator commands and adjusts working depth if required depending on draft force and wheel slip. The ECU communicates on CAN1.

C4-17

9803/9970-01 (C-08-00)

C4-17

Section C4 - Electrics Electronics Network SYSTEM Draft Control ECU (EHR-Z)

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is also given in the applicable Service Master help file. Section Topic

EHR1

Position sensor

EHR2

Draft sensor left

EHR3

Draft sensor right

EHR5

Radar speed sensor

EHR30

Rear linkage ‘raise’ solenoid

EHR31

Rear linkage ‘lower’ solenoid

EHR33

Rear linkage ‘raise’ over-ride buttons

EHR34

Rear linkage ‘lower’ over-ride buttons

C4-18

9803/9970-01 (C-08-00)

Draft Control SYSTEM

C4-18

Section C4 - Electrics Electronics Network SYSTEM Draft Control ECU (EHR-Z)

Access

Removal and Replacement

!MCAUTION Electronic Control Unit The electronic control unit under the passenger's seat is protected by a cover. Do not use the machine with the cover removed.

The ECU is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty.

0103

Do not replace the ECU with one from another machine. They may look the same but the electronic software can be different.

Get access under the passenger seat: Undo four bolts 1 and lift out the passenger seat complete with base plate 3. Do not remove cover 2.

After installation of a new ECU do the following: â&#x20AC;&#x201C; Make sure that the ECU is connected to the machine systems correctly. Use JCB Service Master.

1 2

3 C095860

Fig 9.

C4-19

9803/9970-01 (C-08-00)

C4-19

Section C4 - Electrics Electronics Network SYSTEM ABS Control ECU

ABS Control ECU

C092890-C4

Fig 10. The ABS control ECU 1 is located to the rear of the passenger seat. The ECU controls the ABS modulator valves in response to inputs from wheel rotation sensors. The ECU communicates on CAN1.

C4-20

9803/9970-01 (C-08-00)

C4-20

Section C4 - Electrics Electronics Network SYSTEM ABS Control ECU

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is also given in the applicable Service Master help file. Section Topic

ABS1

Front left hand wheel speed sensor

ABS2

Front right hand wheel speed sensor

ABS3

Rear left hand wheel speed sensor

ABS4

Rear right hand wheel speed sensor

ABS5

Front modulator

ABS6

Rear left modulator

ABS7

Rear right modulator

ABS8

Brake light switch

C4-21

Brake SYSTEM (ABS), ABS Sensors (ABS)

Brake SYSTEM (ABS), Pressure Modulating Valves (ABS)

9803/9970-01 (C-08-00)

C4-21

Section C4 - Electrics Electronics Network SYSTEM ABS Control ECU

Access

Removal and Replacement

!MCAUTION Electronic Control Unit The electronic control unit under the passenger's seat is protected by a cover. Do not use the machine with the cover removed.

The ECU is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty.

0103

Do not replace the ECU with one from another machine. They may look the same but the electronic software can be different.

Get access under the passenger seat: Undo four bolts 1 and lift out the passenger seat complete with base plate 3. Do not remove cover 2.

1 2

3 C095860

Fig 11.

C4-22

9803/9970-01 (C-08-00)

C4-22

Section C4 - Electrics Electronics Network SYSTEM Auxiliary Controls ECU (ACE)

Auxiliary Controls ECU (ACE)

1 C095850

Fig 12. The auxiliary control ECU 1 is located in the arm rest assembly. The ECU gets inputs from the auxiliary service operator controls as follows: – Front and rear hitch controls – Spool lever controls – Spool parameter controls located under the arm rest The inputs are converted into CAN messages. The ECU communicates on CAN1.

C4-23

9803/9970-01 (C-08-00)

C4-23

Section C4 - Electrics Electronics Network SYSTEM Auxiliary Controls ECU (ACE)

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is given in the applicable Service Master help file. Section Topic

ACE3 -7 Spool levers position (input)

Spool Valve SYSTEM

ACE10R Rear hitch maximum raise height control (input) ACE10F

Front hitch maximum raise height control (input)

ACE11R Rear hitch draft mixture control (input) ACE12R Rear hitch drop rate control (input) ACE12F

Front hitch drop rate control (input)

ACE14R Rear hitch controls (input) ACE14F

C4-24

Front hitch controls (input)

9803/9970-01 (C-08-00)

C4-24

Section C4 - Electrics Electronics Network SYSTEM Auxiliary Controls ECU (ACE)

Access

After installation of a new ECU do the following:

The ACE ECU is fixed to the upper armrest console. The spool control levers are part of the ECU assembly.

â&#x20AC;&#x201C; Make sure that the ECU is connected to the machine systems correctly. Use JCB Service Master.

Removal and Replacement

â&#x20AC;&#x201C; Calibrate the hitch and spool controls. Use JCB Service Master.

The ECU is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty.

C096680

Fig 13. To get access to the ECU electrical connector B remove control panel A. Do not replace the ECU with one from another machine. They may look the same but the electronic software can be different.

C4-25

9803/9970-01 (C-08-00)

C4-25

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Touch Screen ECU (DECU)

C096090

Fig 14. The touch screen display (DECU) is a colour VGA liquid crystal display with touch screen. It provides a graphical interface to keep the operator informed of the vehicle status. The operator can access various menus to configure the machine in different ways. The DECU has a service mode. This enables service personnel to calibrate various machine control devices. K Service Calibration Mode ( T C4-28) The ECU communicates on CAN1.

C4-26

9803/9970-01 (C-08-00)

C4-26

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Inputs/Outputs Code

Device/Input/Output

Related Topics Note: Detailed information about each device is given in the applicable Service Master help file. Section Topic

DECU6

Steering angle sensor

Axle Differential Lock SYSTEM

DECU10 12 volt transmission (6x4) sensor supply

6x4 Smoothshift Transmission SYSTEM

DECU16 Neutral button

6x4 Smoothshift Transmission SYSTEM

DECU17 Joystick trigger button

6x4 Smoothshift Transmission SYSTEM

DECU18 Joystick button A

6x4 Smoothshift Transmission SYSTEM

DECU19 Joystick button B

6x4 Smoothshift Transmission SYSTEM

DECU20 Joystick headland button

6x4 Smoothshift Transmission SYSTEM

DECU21 Joystick resume button

6x4 Smoothshift Transmission SYSTEM

DECU22 Joystick button C

6x4 Smoothshift Transmission SYSTEM

DECU23 Joystick button D

6x4 Smoothshift Transmission SYSTEM

DECU41 Maintained 12 volt supply relay (transmission management relay)

6x4 Smoothshift Transmission SYSTEM

DECU50 Foot throttle

Foot Throttle Position Sensors

DECU51 Hand throttle

Hand Throttle Control

DECU61 Joystick - forward/back

6x4 Smoothshift Transmission SYSTEM

DECU62 Joystick - left/right

6x4 Smoothshift Transmission SYSTEM

DECU90 Armrest decrease button (-)

Touch Screen (DECU)

DECU91 Armrest increase button (+)

Touch Screen (DECU)

DECU28 Brake pedal switch DECU29 Operator present switch DECU39 Brake light relay

DECU93 Slip control ON/OFF switch

C4-27

9803/9970-01 (C-08-00)

C4-27

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Service Calibration Mode The touch screen allows service personnel to access calibration procedures. Access the service calibration mode as follows: 1

Switch on the ignition but do not start the engine.

Press icon S and then icon T on the touch screen to access the level 1 programming screen. C096100

Fig 17. 3

Press and hold buttons X and Y at the same time. Press icon D when it changes from grey to blue. The service calibration menu screen displays.

Fig 15.

C070660-B2

Fig 18. Service Calibration Menu Screen C070200-C2

Fig 16. Level 1 Programming Screen

C4-28

9803/9970-01 (C-08-00)

C4-28

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU) Device Calibration The programming and service calibration screens allow access to device calibration procedures as follows: Icon

Devices/Calibration

Procedures

B - Engine

Foot throttle positions

K Foot Throttle Calibration ( T C4-32)

Hand throttle positions

K Hand Throttle Calibration ( T C4-30)

PTO lever position

K PTO Speed Selection Calibration ( T C4-34)

D - Joystick

Joystick positions

K Joystick Calibration ( T C4-36)

E - Transmission

Park brake position

K Transmission Calibration ( T C4-40)

C - PTO

Clutch pedal position Gearbox clutch operation F - Steering angle

Steer angle potentiometer position

K Steering Angle Calibration ( T C4-42)

G - Touch screen

Touch position alignment

K Screen Calibration ( T C4-43)

C070660-B1

Fig 19. Service Calibration Menu Screen

C4-29

9803/9970-01 (C-08-00)

C4-29

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Engine Throttles Calibration Hand Throttle Calibration Access the Calibration Menu K Service Calibration Mode ( T C4-28)

C070920

Fig 21. 3

Select the hand throttle icon G.

C070660-C3

Fig 20. Service Calibration Menu Screen 2

Select the engine calibration icon B.

C4-30

9803/9970-01 (C-08-00)

C4-30

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

J 868 96 96 868

C070930

Fig 22. 4

Select the top icon J to program the hand throttle `Idle' position. It will become highlighted green

Move the hand throttle to its idle position and check the value.

Store the value in the memory by pressing the save icon K.

Select the lower icon L to program the hand throttle maximum position.

Move the hand throttle to the maximum engine speed position and check the value.

Store the value in the memory by pressing the save icon K.

In order to return to settings screen, press the `Return' icon R.

C4-31

9803/9970-01 (C-08-00)

C4-31

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU) Foot Throttle Calibration Access the Calibration Menu K Service Calibration Mode ( T C4-28)

C070920

Fig 24. 3

Select the foot throttle icon H.

C070660-C3

Fig 23. Service Calibration Menu Screen 2

Select the engine calibration icon B.

C4-32

9803/9970-01 (C-08-00)

C4-32

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

J 784

181

C070930-B1

Fig 25. 4

Select the top icon J to program the foot throttle `up' position. It will become highlighted green

With the foot throttle at the top of its travel, check the value shown in the box is the highest possible value in the foot throttle's range.

Store the value in the memory by pressing the save icon.

Select the lower icon L to program the foot throttle `down' position.

Move the foot throttle to the maximum engine speed position. Check the value is the lowest in the sensor's range.

Store the value in the memory by pressing the save icon.

In order to return to settings screen, press the `Return' icon R.

C4-33

9803/9970-01 (C-08-00)

C4-33

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

PTO Speed Selection Calibration Calibration is necessary after replacement of any of the following transmission or PTO related items: – Fastrac Central Controller (ECU 1) – Wiring – Valves – Position sensors – Speed sensors Note: Ensure PTO is not set to auto-disengage with linkage position as this will prevent front PTO starting up. Ensure transmission oil is warm. Access the Calibration Menu. K Engine Throttles Calibration ( T C4-30)

C090170-C1

Fig 27.

Important: Make sure PTO speed lever A is in neutral position N before you start calibration. 3

With engine stopped, press the top icon T. K Fig 28. ( T C4-35) The number in this icon indicates the steps in the calibration. This should change to 1. Grey park brake icon (a) will appear.

C070660-C3

Fig 26. Service Calibration Menu Screen 2

Select the PTO calibration icon C.

C4-34

9803/9970-01 (C-08-00)

C4-34

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

A Z C090170-C1

Fig 29. C071480

Fig 28. 4

Make sure park brake is on. Icon (a) will turn grey.

When icon (b) is grey ‘LO’, move lever A to 540.

When PTO lever is confirmed in 540, icon (b) will turn green, then change to grey ‘HI’.

When icon (b) is grey ‘HI’, move lever A to 1000. Icon (b) will turn green.

When calibration is complete, number 8 in the top icon T indicates calibration OK.

Grey icon (b) will appear. 5

When PTO lever is confirmed in neutral, icon (b) will turn green, then change to grey ‘LO’.

Number 15 and a cross in the top icon indicates calibration failed and a fault code will be generated. 10

To access fault codes, press icon Z. Possible faults: a

Mechanical selector fault, e.g. cable.

b Potentiometer fault (inside gearbox). c

Potentiometer wiring fault.

d ECU fault.

C4-35

9803/9970-01 (C-08-00)

C4-35

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Joystick Calibration

G Joystick Centre Position Access the Calibration Menu K Service Calibration Mode ( T C4-28)

C070960-B1

Fig 31. 3

Select icon G to access the joystick central position calibration menu.

C070660-C3

Fig 30. Service Calibration Menu Screen 2

Select the joystick calibration icon D.

C4-36

9803/9970-01 (C-08-00)

C4-36

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

J 484 492

C070940-B1

Fig 32. 4

Check that movement of the joystick in either axis registers a change in the numbers displayed in the box J.

Ensure that the joystick is in the middle position and both values are similar.

Store the value in the memory by pressing the save icon K.

C4-37

9803/9970-01 (C-08-00)

C4-37

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU) Joystick Left/Right Positions

Important: Calibrate the joystick centre position before calibrating the joystick left and right positions. Access the Calibration Menu. K Engine Throttles Calibration ( T C4-30)

G C070960-B1

Fig 34. 3

Select icon G to display the joystick left/right position calibration values as stored. K Fig 35. ( T C4-39)

C070660-C3

Fig 33. Service Calibration Menu Screen 2

Select the joystick calibration icon D.

C4-38

9803/9970-01 (C-08-00)

C4-38

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

M 611

347

C070950-B1

Fig 35. 4

Select icon M and check that the values change as the joystick is moved from side to side.

Hold the joystick to the right.

Store the value in the memory by pressing the save icon K.

Select box N, it will become green.

Pull the joystick to the left.

Store the value in the memory by pressing the save icon K.

C4-39

9803/9970-01 (C-08-00)

C4-39

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Transmission Calibration

Calibration is necessary after replacement of any of the following transmission related items:

b Transmission in neutral. c

– Transmission ECU

Park brake OFF.

Clutch pedal up.

d Start engine and set to 1500 rpm on the hand throttle.

– Wiring – Valves – Position sensors – Speed sensors 1

It is ESSENTIAL that the transmission oil is warm (approximately 55 deg C).

Note: A fault code will occur if you do try to do the calibration at too low a temperature (e.g. 25 deg C). 2

Stop engine. Switch on the ignition and access the Throttles Calibration Menu. K Engine Calibration ( T C4-30)

Select the transmission icon E. The calibration screen will appear.

C071000

Fig 37. 5

Press box W. All icons on the touch screen will then be green. The number in the box will then count up as calibration progresses. There is a fault if any calibration step takes longer than 5 minutes.

When the number in box W changes to 2 the park brake icon will change to grey. Apply the park brake, the icon will change back to green and the calibration will continue.

When number in box W is 3 and icon c is blue, press clutch pedal and hold down.

When icon c is yellow, release pedal.

C070660-C3

Fig 36. Service Calibration Menu Screen 4

Before starting prerequisites:

C4-40

calibration,

set

the

following

9803/9970-01 (C-08-00)

C4-40

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU) 9

Various transmission clutches will engage and disengage as the number in box W counts up from 4 through to 7

If calibration is successful, a green tick will appear at step 8. If calibration is unsuccessful , a red cross icon will appear, step 15 will be displayed and fault code(s) will be generated.

Go to the fault code screen, check for and fix any faults that have occurred during calibration

C4-41

9803/9970-01 (C-08-00)

C4-41

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Steering Angle Calibration Access the calibration menu K Service Calibration Mode ( T C4-28)

713

489

248

T V W

K C071110-C1

Fig 39. C070660-C3

Fig 38. Service Calibration Menu Screen 2

Press screen calibration button G. The following screen will appear.

C4-42

Select icon T to turn it green and display the calibration value. With the arrow pointing left selected, start the engine and turn the steering to full left lock. Check that the value changes as the steering turns.

Store the value in the memory by pressing the save icon K.

Select icon V to turn it green and display the calibration value. Turn the steering to straight ahead. Check that the value changes as the steering turns.

Store the value in the memory by pressing the save icon K.

Select icon W to turn it green and display the calibration value. Turn the steering to full right lock. Check that the value changes as the steering turns.

Store the value in the memory by pressing the save icon K.

9803/9970-01 (C-08-00)

C4-42

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Screen Calibration Access the calibration menu K Service Calibration Mode ( T C4-28)

C070900

Fig 41. 3 C070660-C3

Press each of the three small icons in turn. If screen calibration is OK, the screen will automatically return to the calibration menu.

Fig 40. Service Calibration Menu Screen 2

If calibration is not correct, a black cross on a blue background will appear.

Press screen calibration button G. The following screen will appear.

C070910-C1

Fig 42. 4

C4-43

If calibration failure occurs repeatedly, contact JCB Landpower.

9803/9970-01 (C-08-00)

C4-43

Section C4 - Electrics Electronics Network SYSTEM Touch Screen ECU (DECU)

Access

Removal and Replacement

Remove the rear plastic housing. Remove the DECU earth strap and and its fixings.

The ECU is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty. Do not replace the ECU with one from another machine. They may look the same but the electronic software can be different. After installation of a new ECU do the following: – Make sure that the ECU is connected to the machine systems correctly. Use JCB Service Master. – Calibrate the Calibration ( T C4-43)

screen.

K Screen

– Calibrate the devices controlled by the DECU. K Device Calibration ( T C4-29)

C4-44

9803/9970-01 (C-08-00)

C4-44

Section C5 - Electrics

Ground Radar SYSTEM Operation Overview The radar present icon displays 2 on the dashboard (EMS) together with the radar calculated speed (speeds less than 20mph (32km/h)). At higher speeds the EMS displays a speed value calculated from transmission speed sensor inputs. The EMS ‘area worked’ display function uses the calculated radar distance travelled. The draft control ECU uses the input from the radar and compares it to the transmission speed sensor calculated speed value to calculate wheel slip. The touch screen (DECU) enables calibration of the radar unit.

C096150

Fig 1. A radar system measures ground speed when the machine travels at speeds less than 20mph (32km/h). Radar unit 1 is fixed under the machine facing to the rear at an angle of 35° to the ground. The unit will not work correctly at other angles. The output of the unit is a digital pulse. The frequency of the pulse can is used to determine vehicle speed. The pulses are summed to determine distance traveled The signal from the radar unit is input to the central control ECU (ECU1) and the draft control ECU (EHR-Z). ECU1 automatically detects the radar device. There is no ‘setup’ option for radar in JCB Service Master. ECU1 outputs the radar speed signal to the ISO11786 socket for use by compatible attachements.

C5-1

9803/9970-01

C5-1

Section C5 - Electrics Ground Radar SYSTEM Operation Overview

RADAR 1

1 2

EMS

ECU1

EHR-Z

DECU

CAN 1

CAN 1 C096140

Fig 2. Radar network connections 1

Radar unit

Radar unit pulse signal

Radar unit ‘present signal’

Dashboard ECU (EMS)

Central control ECU (ECU1)

Draft control ECU (EHR-Z)

Touch screen ECU (DECU)

C5-2

9803/9970-01

C5-2

Section C5 - Electrics Ground Radar SYSTEM Fault Finding

Fault Finding – Use JCB Service Master to check for correct radar operation. The EHR (draft control ECU) and central controller (ECU1) diagnostic windows display the radar signal if present. – Check the data log for relevant fault codes. – Check that the radar unit is at the correct angle to the ground and its mountings are secure. – Check related wires and connectors for defects. Use the Service Master help file to identify wires and connectors.

C5-3

9803/9970-01

C5-3

Section C5 - Electrics Ground Radar SYSTEM Calibration

Calibration Calibrate the radar after installation of the radar unit or its mounting bracket. The unit must also be calibrated after installation of a new draft control or central control ECU. 1

Switch on the ignition but do not start the engine.

Press icon S and then icon T on the touch screen to access the level 1 programming screen. Press the radar icon C. The radar calibration screen appears.

Press box R to zero the counter. Drive the machine along the course to the point where the wheel hub is directly above the mark made at 100 metres from the start position. It advised that someone walks alongside the machine to ensure the final position is accurate.

When the 100 metre mark is reached press the calibration button R a second time.

The display R will show a value. Divide the value by 100 to get the radar pulses per metre. The result should be with in 10% of the set value shown at S:

132.2 pulses/metre (UK machines), 131.8 pulses/ metre (ROW machines).

Fig 3. If necessary adjust the value at S to match the calculated radar pulse rate. Use the arm rest + or buttons to change the value at S.

C P

R 24560

S 132.6

C070200-C4

Fig 4. Level 1 programming screen 3

Accurately measure a distance along the ground of 100 meters in a straight line from a point directly below the centre of a wheel hub.

Start the engine. Press the calibration icon P, box R will appear.

C5-4

9803/9970-01

Fig 5. Radar calibration screen

C5-4

Section C6 - Electrics Service Master SYSTEM Why Use Service Master?

Service Master SYSTEM Why Use Service Master? Introduction

operate correctly. This can only be done with Service Master.

JCB machines now use the latest developments in electronic management of machine systems. This means that machine systems such as service hydraulics, engine, transmission and steering are controlled using electronic control units (ECUs). The ECUs process inputs from electrical sensors and then output signals to electrical actuators on the applicable devices. The ECUs are also connected to the machine CANbus electronic communication system.

Fault Finding Faults with ECU controlled systems can be difficult or impossible to trace using traditional methods. In addition to the primary function of machine control the ECUs are also able to detect possible faults with sensors and actuators. The faults are `logged' using a code system. Use Service Master to see and understand these codes.

Re-Programming ECUs The ECU's use pre-loaded Flash ECUs with the correct software to compute responses to inputs from sensors. If an ECU is replaced the correct software must be programmed (`flashed') into the ECU memory. New software may also be issued by JCB Service to improve machine operation. This will also require the ECU to be re-programmed. This can only be done with Service Master.

Summary With the latest Service Master software loaded on your laptop and you can: – Fault find – For fast, effective fault finding. – Check maintenance standards – See if the machine has been abused.

In addition Service Master has direct links to relevant onscreen help information about relevant devices. This information is designed to help you identify, test, and if applicable, remove and replace devices.

– View and change machine set up data – This can only be done with Service master. – Flash ECUs with the correct software – This can only be done with Service master.

Identify Poor Maintenance System faults that are present, or have happened in the past can be seen. This is not only useful when fault finding but can also identify poor standards of maintenance. For example a log showing a history of water in fuel detected. Use Service Master to see and understand these codes.

Access Machine Set Up Data Machine parameters such as tyre sizes, gear shift points and engine injector calibration codes are all stored and used by the relevant control ECU's. During the life of the machine it will be necessary to change some of these parameters. Without the correct data the machine will not

C6-1

9803/9970-01

C6-1

Section C6 - Electrics Service Master SYSTEM What is Service Master?

What is Service Master? Introduction JCB Service master is software for use with Microsoft Windows and a laptop personal computer.

The laptop computer is connected to the machine `diagnostic socket' using special cables and an adapter. Use Service master software to: â&#x20AC;&#x201C; Display data from machine ECUs â&#x20AC;&#x201C; Change data stored in ECUs

CANbus Communications System Fig 1. C

Controller

Area

Network

Tool Sets Service master software communicates with the machine ECUs using the CAN.

Tool sets 1C are different for each machine range. A typical tool set includes:

CAN is an electronic communications system that connects compatible machine ECUs to one pair of data wires called the CANbus. Coded data is sent to and from the ECUs on the CANbus. By connecting Service master software to the CANbus this data is seen and decoded for use by an engineer.

Service Master Structure

Vehicle Setup tool

Diagnostics tool

Flash Programmer tool

Data Logger tool

Service master software is supplied as part of the JCB Service data DVD 1A issued to JCB dealers. The DVD includes all the software tools for all applicable JCB machines. A selector window 1B is used to choose the correct software tool set 1C for each machine range.

Service History Each tool is specific to the chosen machine range. The tool icons are `short-cuts' to the tool software files. Detailed information about how to use the tools is given in the applicable machine documentation.

C6-2

9803/9970-01

C6-2

Section C6 - Electrics Service Master SYSTEM How to Set Up Service Master

How to Set Up Service Master Note: The procedures that follow describe how to set up Service master for USB compatible equipment. There are other procedures and options. These are described in detail in the Service master help files contained on the JCB Service Information DVD.

Load the DLA laptop driver software

Configure the DLA type and communications port

Make sure that the DLA flash memory contains the latest firmware file

Connect Service master to the machine CANbus

Before you set up Service master make sure you have: – A Microsoft Windows compatible laptop computer with a DVD drive and a USB port (2A) Note: Service master is compatible with Windows 98, 2000, ME and XP. – The latest Service master software (JCB Service Information DVD) (2B) – A JCB compatible data link adapter (DLA) (2C) (See Service Tools in Section1.) – The correct connection cables (2D) (See Service Tools in Section1.)

K Install Service Master ( T C6-4) K Start Service Master ( T C6-5) K Load the DLA Laptop Driver Software ( T C6-6) K Configure the DLA Type and Communications Port ( T C6-7) K Check the DLA Firmware File ( T C6-8) K Connect Service Master to the Machine CANbus ( T C6-10)

Important: DO NOT connect any cables at the laptop, DLA or machine now.

A C

D B Fig 2. To set up Service master for the first time: 1

Install Service master

Start Service master

C6-3

9803/9970-01

C6-3

Section C6 - Electrics Service Master SYSTEM How to Set Up Service Master

Install Service Master 1

Exit all open programs on your laptop computer.

Insert the `JCB Service Information Pack DVD' into the DVD drive. The chooser screen will open. Click on the `S4' icon. K Fig 3. ( T C6-4)

Fig 5. a

At the `installer' K Fig 6. ( T C6-4)

screen

click

`Next'.

Fig 3. 3

The S4 chooser screen will open. Click on the Service master Icon. K Fig 4. ( T C6-4)

Fig 6. b At the `destination location' screen click `Next'. c

At the `installation type' screen click `Next'. (A full installation is recommended.)

d At the `installation complete' screen, click `Finish'. Fig 4. 4

The Service master set up screen will open. Click on the `Install' button. K Fig 5. ( T C6-4). The installation process now starts:

C6-4

9803/9970-01

C6-4

Section C6 - Electrics Service Master SYSTEM How to Set Up Service Master

Start Service Master 1

Double click on the Service master icon. K Fig 7. ( T C6-5). (The icon is found on the desktop or in the `Start' menu -`Programs' - 'JCB'.)

Fig 7. 2

The Service master chooser window will open. K Fig 8. ( T C6-5)

Fig 9.

Fig 8. 3

Open the drop down menu to see the machines and components supported by Service master tools. K Fig 9. ( T C6-5)

C6-5

9803/9970-01

C6-5

Section C6 - Electrics Service Master SYSTEM How to Set Up Service Master

Load the DLA Laptop Driver Software To use Service master for the first time you must load the DLA driver software. You will not have to do the procedure again. Important: DO NOT connect the DLA or cables at the laptop or machine now. 1

Start the Service master software on your laptop computer. K Start Service Master ( T C6-5)

Select `DLA' from K Fig 10. ( T C6-6)

the

drop

down

menu.

Fig 12.

Fig 10. 3

Double click on icon.K Fig 11. ( T C6-6)

the

USB

driver

Fig 11. Note: Drivers are also available for computers with serial ports (no USB) and other versions of Microsoft Windows. If your laptop does not have a USB port, double click on the correct driver icon. 4

The driver installer window will open. K Fig 12. ( T C6-6). Follow the on-screen installation instructions to complete the installation.

C6-6

9803/9970-01

C6-6

Section C6 - Electrics Service Master SYSTEM How to Set Up Service Master

Configure the DLA Type and Communications Port

Note: Older DLAs and laptop computers may not be compatible with USB ports. Choose the `Parallel/Serial DLA' device in the DLA chooser.

To use Service master for the first time you must make sure that the correct DLA and laptop port is selected to communicate with the DLA. You will not have to do the procedure again. 1

Start the Service master software on your laptop computer. K Start Service Master ( T C6-5)

Select `DLA' from the Service master drop down menu. K Fig 10. ( T C6-6)

Double click the K Fig 13. ( T C6-7)

COM

Port

Chooser

icon.

Fig 13. 4

The DLA Chooser window will open. Select the `USB/ Serial DLA' device and then click `Apply'. K Fig 14. ( T C6-7)

Fig 14.

C6-7

9803/9970-01

C6-7

Section C6 - Electrics Service Master SYSTEM How to Set Up Service Master

Check the DLA Firmware File Important: Do not connect the DLA to the machine until this procedure has been completed. The DLA has software embedded in its own flash memory. This file must be replaced with a new one when new firmware is released. You will only have to Check the DLA firmware file version if you receive a new Service master version or use a different DLA. 1

Connect a 'USB PC Cable' to the DLA and a free port on your laptop computer.

Note: Connect the USB cable directly to the laptop computer. DO NOT connect the cable via a USB hub.

Fig 16. 6

Note: Older DLAs and laptop computers may not be compatible with USB ports. Use a serial PC cable to connect the DLA to the laptop serial port. 2

Start the Service master software on your laptop computer. K Start Service Master ( T C6-5)

Select `DLA' from K Fig 10. ( T C6-6)

Double click on the USB DLA Flash Loader icon. K Fig 15. ( T C6-8)

the

drop

down

Check for a new firmware file: Click on the browse button 16A and locate the file stored within the JCB Service master directory on your laptop hard drive. a

Click the `Open' button. The selected file appears in the `Firmware File Name' field together with its release date and application version, for example 2.01.K Fig 18. ( T C6-8)

menu.

Fig 15. Fig 17. Note: Older DLAs and laptop computers may not be compatible with USB ports. Double click the `Flash loader for Serial/Parallel DLA' icon. 5

The device flash update tool window opens. The details of the firmware in the DLA are displayed including the application version, for example 1.04.

A Fig 18.

C6-8

9803/9970-01

C6-8

Section C6 - Electrics Service Master SYSTEM How to Set Up Service Master 7

Load a new firmware file: If the firmware in the DLA is not up to date, load the new file. Click the `Start' button 18A and follow the on-screen instructions.

When the update is complete disconnect the DLA and close the service master application.

Important: The computer must be restarted before the updated software can be used.

C6-9

9803/9970-01

C6-9

Section C6 - Electrics Service Master SYSTEM Connect Service Master to the Machine CANbus

Connect Service Master to the Machine CANbus For all data log, diagnostics and programming using JCB Service Master, use the Data Link Adapter (DLA) kit part number 892/01174 to connect the machine to your laptop or PC. (See Service Tools in Section1.) Note: Make sure the DLA is running the latest Firmware file. K Check the DLA Firmware File ( T C6-8). Use the USB cable 718/20235 between the PC and the DLA. Remove cap 2 to get access to diagnostic socket 1. Make sure you connect cable 718/20237 to the diagnostic socket 1. Note: Cable 721/10885 can be used as an alternative to 718/20237.

C095910

Fig 19.

C6-10

9803/9970-01

C6-10

Section C6 - Electrics Service Master SYSTEM Service Master Tools

Service Master Tools Summary Tool

Icon

Description

Guide

Enables ECU setup for machine configuration.

3000 Setup Tool

C075490-C1

Enables calibration of auxiliary hydraulic spool controls.

ACE Setup Tool

C095830

View operating parameters in real K 3000 Diagnostics Tool Content Guide ( T C6-12) time for all the machine ECU controlled systems including engine, transmission, ABS brake system, suspension system and hydraulic controls.

3000 Diagnostics

C087940

3000 DataLogger

View data logs for main machine systems incliding fault code logs.

C095810

Flashloader Tool

Enables download and upload of data files between a laptop computer and ECU flash memory.

3000 Help

Comprehensive information about machine electrical and electronic devices.

C047140-C1

C6-11

9803/9970-01

C6-11

Section C6 - Electrics Service Master SYSTEM Service Master Tools

3000 Diagnostics Tool - Content Guide The tool contains several main system tabs. The tab opens a set of ‘diagnostic windows’. Each window enables the user to monitor electrical and electronic devices for a specific machine function. ABS Diagnostic Windows ABS system test ABS fault codes Modulators and speed sensors Engine Diagnostic Windows Engine management Fuel and cold start heaters

Central Controller Diagnostic Windows Green slice (V) (hydraulic valve spool control) Blue slice (V) (hydraulic valve spool control) Brown slice (V) (hydraulic valve spool control) Grey slice (V) (hydraulic valve spool control) Yellow slice (V) (hydraulic valve spool control) Front hitch control (U) (hydraulic valve spool control) Rear suspension control General Information (ground radar, area cutout, ECU power supply status) Manual mode ACE Diagnostic Windows ACE (auxiliary control ECU)

Engine controls Engine fault codes

Vehicle/CAN Diagnostic Windows Vehicle identification

Transmission Diagnostic Windows Master clutch control

Version information CAN bus statistics

Powershift control Range control Available gears Transmission controls 6x4 calibration values PTOs/Implement Connector Diagnostic Windows PTO’s/Implement connector 4WD and Diff Diagnostic Windows 4WD and diff lock EHR Diagnostic Windows EHR draft controller

C6-12

9803/9970-01

C6-12

Section C7 - Electrics

Fault Code SYSTEM Fault Codes ABS ECU Code

Description

A0101

No ABS faults

A0201

Front Left Wheel Speed Sensor Excessive Air Gap

A0202

Front Left Wheel Speed Sensor Output Low at Drive-Off

A0203

Front Left Hand Wheel Speed Sensor Open or Shorted

A0204

Front Left Hand Wheel Sensor Loss of Sensor Signal

A0205

Front Left Hand Wheel End Fault

A0206

Front Left Wheel Speed Sensor Erratic Signal

A0207

Front Left Wheel Speed Sensor Tyre Size Calibration

A0301

Front Right Wheel Speed Sensor Excessive Air Gap

A0302

Front Right Wheel Speed Sensor Output Low at Drive-Off

A0303

Front Right Hand Wheel Speed Sensor Open or Shorted

A0304

Front Right Hand Wheel Sensor Loss of Sensor Signal

A0305

Front Right Hand Wheel End Fault

A0306

Front Right Wheel Speed Sensor Erratic Signal

A0307

Front Right Wheel Speed Sensor Tyre Size Calibration

A0401

Rear Left Wheel Speed Sensor Excessive Air Gap

A0402

Rear Left Wheel Speed Sensor Output Low at Drive-Off

A0403

Rear Left Hand Wheel Speed Sensor Open or Shorted

A0404

Rear Left Hand Wheel Sensor Loss of Sensor Signal

A0405

Rear Left Hand Wheel End Fault

A0406

Rear Left Wheel Speed Sensor Erratic Signal

A0407

Rear Left Wheel Speed Sensor Tyre Size Calibration Fault

A0501

Rear Right Wheel Speed Sensor Excessive Air Gap

A0502

Rear Right Wheel Speed Sensor Output Low at Drive-Off

A0503

Rear Right Hand Wheel Speed Sensor Open or Shorted

A0504

Rear Right Hand Wheel Sensor Loss of Sensor Signal

A0505

Rear Right Hand Wheel End Fault

A0506

Rear Right Wheel Speed Sensor Erratic Signal

A0507

Rear Right Wheel Speed Sensor Tyre Size Calibration

A0601

Battery Voltage Too Low, As measured by the ABS ECU

A0602

Battery Voltage Too High, As measured by the ABS ECU

C7-1

9803/9970-01

C7-1

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

A0603

Battery Voltage Too Low During ABS as measured by the ABS ECU

A0604

Battery Voltage Input Open Circuit

A0605

Ignition Voltage Too Low

A0606

Ignition Voltage Too High

A0607

Ignition Voltage Too Low During ABS

A0608

Input Voltage Has Temporary Excessive Noise

A0609

Input Voltage Has Excessive Noise

A0901

Rear Left PMV REL Solenoid Shorted to Ground

A0902

Rear Axle Left Hand PMV REL Solenoid Shorted to Voltage

A0903

Rear Axle Left PMV REL Solenoid Open Circuit.

A0904

Rear Axle Left Hand PMV HLD Solenoid Shorted to Ground

A0905

Rear Axle Left Hand PMV HLD Solenoid Shorted to Voltage

A0906

Rear Axle Left Hand PMV HLD Solenoid Open Circuit

A0907

Rear Axle Left Hand PMV CMN Open Circuit

A0908

Rear Axle Left Hand PMV CMN Open Circuit

A1001

Rear Right PMV REL Solenoid Shorted to Ground

A1002

Rear Axle Right Hand PMV REL Solenoid Shorted to Voltage

A1003

Rear Axle Right PMV REL Solenoid Open Circuit.

A1004

Rear Axle Right Hand PMV HLD Solenoid Shorted to Ground

A1005

Rear Axle Right Hand PMV HLD Solenoid Shorted to Voltage

A1006

Rear Axle Right Hand PMV HLD Solenoid Open Circuit

A1007

Rear Axle Right Hand PMV CMN Open Circuit

A1008

Rear Axle Right Hand PMV Configuration Error

A1101

J1939 Serial Link

A1102

J1939 Retarder

A1103

J1939 Engine Communications

A1201

Brake Pedal Switch Not Detected

A1202

Brake Pedal Switch fault

A1203

Dynamometer Test Mode

A1204

Retarder Relay Open Circuit or Shorted to Ground

A1205

Retarder Relay Circuit Shorted to Voltage

A1206

ABS Warning Lamp Circuit Fault

A1210

Front and rear wheel speeds implausible

A1218

ABS ECU recorded a fault in the previous power on cycle

A9999

Wheel Speed Sensor Tyre Size Calibration Fault

C7-2

9803/9970-01

C7-2

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Fastrac Central Controller - ECU1

Code

Description

C0120

ECU1 battery voltage too low

C0121

ECU1 Battery voltage too high

C0122

ECU1 sensor reference voltage too low

C0123

ECU1 sensor reference voltage too high

C0130

Valve Block Pilot Valve driver Open circuit

C0131

Valve Block Pilot Valve driver short circuit

C0132

Pilot Valve driver fault

C0150

Valve Block Pressure sensor open circuit

C0151

Valve Block Inlet Pressure Sensor signal low

C0152

Valve Block Inlet Pressure Sensor output high

C0170

Four Wheel Drive Open Circuit

C0171

Four Wheel Drive Over Current

C0172

Four Wheel Drive General Fault

C0175

Diff Lock Open Circuit

C0176

Diff Lock Over Current

C0177

Diff Lock General Fault

C0200

ECU1 loaded an EEPROM value during power up

C0202

ECU1 Software Fault

C0205

PTO Front Brake Solenoid Open Circuit

C0206

PTO Front Brake Solenoid Short Circuit

C0207

PTO Front Brake General Fault

C0210

PTO Front Clutch Solenoid Open Circuit

C0211

PTO Front Clutch Solenoid Short Circuit

C0212

PTO Front Clutch General Fault

C0213

PTO Front Clutch Circuit: output over range

C0214

PTO Front Clutch Circuit: Output under range

C0220

PTO Rear Brake Solenoid Open Circuit

C0221

PTO Rear Brake Solenoid Short Circuit

C0222

PTO Rear Brake General Fault

C0225

PTO Rear Clutch Solenoid Open Circuit

C0226

PTO Rear Clutch Solenoid Short Circuit

C0227

PTO Rear Clutch General Fault

C0228

PTO Rear Clutch Circuit: Output over range

C0229

PTO Rear Clutch Circuit: Output under range

C0235

PTO Control Message from DECU Timeout

C7-3

9803/9970-01

C7-3

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

C0236

PTO Control Message from DECU Plausibility Error

C0237

Front PTO Configuration Change While PTO Running

C0238

PTO Speed Selection Lever moved when PTO running

C0239

Front PTO speed has not increased when PTO On

C0240

PTO 540/1000 Selector Position Sensor: signal under range

C0241

PTO 540/1000 Selector Position Sensor: invalid position

C0242

PTO 540/1000 Selector Position Sensor: invalid position

C0243

PTO 540/1000 Selector Position Sensor: invalid position

C0244

PTO 540/1000 Selector Position Sensor: invalid position

C0245

PTO 540/1000 Selector Position Sensor: invalid position

C0246

PTO 540/1000 Selector Position Sensor: invalid position

C0247

PTO 540/1000 Selector Position Sensor: signal over range

C0248

PTO Calibration General Fault

C0249

PTO Calibration Failed

C0250

Rear PTO speed hasn't increased when PTO On

C0251

Front PTO speed present when PTO Off

C0252

Rear PTO speed present when PTO Off

C7-4

9803/9970-01

C7-4

Section C7 - Electrics Fault Code SYSTEM Fault Codes

EMS Dashboard

Code

Description

D0001

EMS Memory Error

D0002

EMS Memory Error

D0003

EMS CanBus switched off due to error

D0004

EMS executed COP watchdog reset

D0005

EMS Application ROM Error

D0042

EMS detected vehicle voltage exceeded 16V

D0227

Air Filter Blocked

D0228

Trailer ABS fault

D0229

Alternator not charging (engine speed over 1000rpm)

D0230

Brake fluid level low

D0231

Air tank 1 pressure low

D0232

Air tank 2 pressure low

D0233

Air tank 3 pressure low

D0234

Handbrake on when moving

D0236

Radar speed signal inconsistent with Gearbox speed

D0240

EMS has reset due to CanBus error

C7-5

9803/9970-01

C7-5

Section C7 - Electrics Fault Code SYSTEM Fault Codes

DECU (Touch Screen)

Code

Description

P0000

This fault code is for information only

P0001

CAN error: EMS stops communicating with the DECU

P0002

CAN error: ABS stops communicating with the DECU

P0003

CAN error: Engine ECU stops communicating with the DECU

P0004

CAN error: ECU1 stops communicating with the DECU

P0005

CAN error: EHR stops communicating with the DECU CAN error: Gearbox ECU stops communicating with the DECU

P0007

DECU Service Master Settings Failed To Save

P0008

Trip Min / Max Log reset by the service laptop

P0009

Min / Max Log has been reset by the service laptop

P0010

Transmission Operating Characteristics reset by the service laptop

P0011

Engine Operating Characteristics reset by the service laptop

P0012

DECU calibration value reset on power up

P0013

DECU calibration value failed to save.

P0014

Hand Throttle Idle Position Calibration Failed

P0015

Hand Throttle Maximum Speed Calibration Failed

P0016

Foot Throttle Idle Position Calibration Failed

P0017

Foot Throttle Maximum Speed Calibration Failed

P0018

Joystick Centre Position Calibration Failed

P0029

DECU Front PTO Configuration failed to load

P0030

DECU Rear PTO Configuration failed to load

P0031

DECU Front PTO Configuration failed to save

P0032

DECU Rear PTO Configuration failed to save

P0033

DECU 4WDConfiguration failed to save

P0034

DECU 4WDConfiguration failed to load

P0035

DECU Area Cutout Configuration failed to save

P0036

DECU Area Cutout Configuration failed to load

P0037

Steering Angle Left Calibration Failed.

P0038

Steering Angle Right Calibration Failed.

P0039

Rear PTO Calibration Failed

P0040

Rear PTO Calibration Passed

P0041

Front PTO Calibration Failed

P0042

Front PTO Calibration Passed

P0043

Joystick Calibration Value Failed To Save

P0044

Joystick Calibration Value Failed To Load

C7-6

9803/9970-01

C7-6

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

P0045

DECU User Settings Failed to Save

P0046

DECU User Settings Failed to Load

P0047

DECU Internal Temperature Sensor low

P0048

DECU Internal Temperature Sensor under range

P0049

DECU Internal Temperature Sensor high

P0050

DECU Internal Temperature Sensor over range

P0051

Hand Throttle 5 volt Sensor Supply low

P0052

Hand Throttle 5 volt Sensor Supply under range

P0053

Hand Throttle 5 volt Sensor Supply high

P0054

Hand Throttle 5 volt Sensor Supply over range

P0059

DECU detected Ignition Supply Voltage is Low

P0060

DECU detected Ignition Supply Voltage is Low

P0061

DECU detected Ignition Supply Voltage is High

P0062

DECU detected Ignition Supply Voltage is High

P0063

Steering Angle Straight Ahead Calibration Failed

P0064

DECU Spool Value Configuration Load Failed

P0065

DECU Spool Configuration Failed To Save

P0066

DECU Transmission Control Configuration Load Failed

P0067

DECU Transmission Control Configuration Value Failed To Save

P0070

DECU lost CanBus communication with MVEC

P0099

DECU Service Master Settings Failed To Load

P0130

Foot Throttle Signal Under Calibration

P0131

Foot Throttle Signal Under Range

P0132

Foot Throttle Signal Over Calibration

P0133

Foot Throttle Signal Over Range

P0150

Hand Throttle Signal Under Calibration

P0151

Hand Throttle Signal Under Range

P0152

Hand Throttle Signal Over Calibration

P0153

Hand Throttle Signal Over Range

P0163

Clutch Pedal Signal Over Range

P0170

Steering Angle Sensor Under Calibration

P0171

Steering Angle Sensor Under Range

P0172

Steering Angle Sensor Over Calibration

P0173

Steering Angle Sensor Over Range

P0180

Joystick Forwards / Backwards Under Calibration

P0181

Joystick Forward / Backwards Under Range

P0182

Joystick Forward / Backwards Over Calibration

P0183

Joystick Forward / Backwards Over Range

C7-7

9803/9970-01

C7-7

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

P0190

Joystick Left / Right Under Calibration

P0191

Joystick Left / Right Under Range

P0192

Joystick Left / Right

P0193

Joystick Left / Right Over Range

P0300

Foot Throttle Sensor Signal Plausibility Error

P0303

Engine Speed Signal Plausibility Error

P0304

Maximum vehicle speed occurred information only

P0305

Maximum engine speed occurred information only

P0306

Maximum vehicle voltage occurred information only

P0307

Maximum Engine Coolant Temperature occurred information only

P0308

Maximum Transmission temperature occurred information only

P0309

DECU reached maximum internal temperature information only

P0310

DECU internal temperature reached limit information only

P0311

DECU LCD display shut down because the temperature was too hot

P0312

Hand Throttle signal Plausibility error

P0313

Engine speed received by the DECU out of range or not updated.

P0320

Front PTO Cab Switch signal plausibility error

P0321

Rear PTO Cab Switch signal plausibility error

P0322

Control Panel Switch signals not received by DECU

P0350

Automatic Door Lock system: DECU (Air Solenoid Valve) Driver Supply error

P0400

6x4 Transmission: Direction Plausibility error

P0401

6x4 Transmission: failed to change Neutral within time out

P0402

6x4 Transmission: failed to change gear within time out

P0403

6x4 Transmission: failed to respond to gear request

P0404

6x4 Transmission: TECU gear is out of range

P0405

Transmission current gear is invalid

P0406

Transmission failed to change Range within the specified time

P0410

Transmission Output Shaft Speed Sensor fault

P0411

Transmission Output Shaft speed invalid to available gears

P0415

Mismatch between the VIN number and DECU software.

P0417

Gearbox Not Calibrated At Correct Temperature

P0420

12V Transmission sensor supply fault

P0421

Brake Pedal Signal plausibility fault detected by DECU

P0422

6X4 transmission not compatible with engine ID

P0423

6X4 transmission: Calibration mode entered unexpectedly

P0424

6X4 transmission software: DECU requested gear out of range

P0425

6X4 transmission software:

P0426

6X4 transmission software:

C7-8

9803/9970-01

C7-8

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

P0427

Transmission calibration successfully passed.

P0428

Transmission calibration failed.

P0429

The operator left the seat during the calibration sequence.

P0430

Speed Limiter exceeded for more than 5 minutes continuously

P0431

The 2 brake pedal switches do not agree.

P0435

Operator Controls have not entered Neutral at start-up

P0436

Vehicle Speed implausible to selected gear

P0438

Insufficient Vehicle Deceleration During a Reversal.

P0439

Gearbox Speed Signal indicates implausible or erratic vehicle speeds

P0440

DECU Touch Screen Calibration fault

P0445

The absolute gearbox energy count limit has been exceeded during reversals.

P0446

A reversal has been requested while the gearbox energy count was too high.

P0448

Excessive clutch slip when using clutch pedal

P0460

The DECU is incorrectly configured.

P0470

Front PTO speed implausible to engine speed

P0471

Rear PTO speed implausible to engine speed Range Gears Synchronizer: protection warning

P0480

Engine stalled Power Down DECU before restarting

P0484

Clutch system plausibility error.

P0485

Transmission Master Clutch Slipping as Clutch Pedal not fully returned.

P0486

Transmission Master Clutch Slipping.

P0487

Clutch Excessive Slip Energy Warning

P0488

Clutch Excessive Slip Energy Limit.

P0489

Clutch Excessive Slip Time Warning.

P0490

Transmission Oil filter blocked

P0495

Transmission Oil Temperature has not changed.

P0496

Transmission Bulk Oil Temperature above normal operating level

P0497

Master Clutch Oil Temperature above normal operating level

P0498

Transmission Oil temperature difference above normal operating level when the engine is running

P0499

Transmission Oil Temperature difference above normal operating level at Engine start up

C7-9

9803/9970-01

C7-9

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Engine ECU (6.7 QSB)

Code

Description

Q0111

Engine ECU internal failure

Q0115

Engine Crankshaft and Camshaft Sensor signals Erratic, Intermittent, or Incorrect

Q0122

Intake Manifold Pressure Sensor Circuit Voltage Above Normal, or Shorted to High Source

Q0123

Intake Manifold Pressure Sensor Circuit Voltage below Normal, or Shorted to Low Source

Q0124

Intake Manifold Pressure High

Q0131

Accelerator Pedal Position Sensor - Voltage Above Normal, or Shorted to High Source

Q0132

Accelerator Pedal Position Sensor - Voltage Below Normal, or Shorted to Low Source

Q0133

This Fault Code should not occur on an 7000 Fastrac

Q0134

This Fault Code should not occur on an 7000 Fastrac

Q0135

Engine Oil Pressure Sensor Circuit - Voltage Above Normal or Shorted to High Source

Q0141

Engine Oil Pressure Sensor Circuit - Voltage Below Normal or Shorted to Low Source

Q0143

Engine Oil Pressure Low

Q0144

Coolant Temperature Sensor Circuit Voltage above Normal or Shorted to High Source

Q0145

Coolant Temperature Sensor Circuit Voltage below Normal, or Shorted to Low Source

Q0146

Coolant Temperature High

Q0151

Coolant Temperature High

Q0153

Intake Manifold Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source

Q0154

Intake Manifold Air Temperature Sensor Circuit - voltage Below Normal, or Shorted to Low Source

Q0155

Intake Manifold Air Temperature High

Q0187

Engine Sensor Supply #2. Voltage below Normal or shorted to Low Source

Q0221

Barometric Pressure Sensor Circuit Voltage Above Normal, or Shorted to High Source

Q0222

Barometric Pressure Sensor Circuit Voltage Below Normal, or Shorted to Low Source

Q0227

Engine Sensor Supply #2. Voltage above Normal, or Shorted to High Source

Q0234

Engine Speed High

Q0238

Sensor Supply Voltage #3 Circuit Voltage Below Normal, or Shorted to Low Source

Q0241

Vehicle Speed Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Q0242

Vehicle Speed Sensor Circuit Abnormal Rate of Change

Q0249

Ambient Air Temperature Sensor Circuit - Voltage Above Normal, or Shorted to High Source

Q0256

Ambient Air Temperature Sensor Circuit - Voltage below Normal, or Shorted to Low Source

Q0268

Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Q0271

High Fuel Pressure Solenoid Valve Circuit Voltage Below Normal, or Shorted to Low Source

Q0272

High Fuel Pressure Solenoid Valve Circuit Voltage Above Normal, or Shorted to High Source

Q0275

Fuel Pumping Element (Front) Mechanical System Not Responding Properly or Out of Adjustment

Q0281

High Fuel Pressure Solenoid Valve #1 Mechanical System Not Responding Properly or Out of Adjustment

C7-10

9803/9970-01

C7-10

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

Q0284

Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit - Voltage Below Normal, or Shorted to Low Source

Q0285

SAE J1939 Multiplexing PGN Timeout Error - Abnormal Update Rate

Q0286

SAE J1939 Multiplexing Configuration Error Out of Calibration

Q0287

SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error - Received Network Data In Error

Q0288

SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Error - Received Network Data In Error

Q0291

J1939 Datalink Error (Vehicle Datalink) รณ Abnormal Update Rate.

Q0292

Auxiliary Temperature Sensor Input 1 Fault

Q0293

Auxiliary Temperature Sensor Input #1 - Voltage Above Normal or Shorted to High Source

Q0294

Auxiliary Temperature Sensor Input #1 - Voltage Below Normal or Shorted to Low Source

Q0295

Barometric Pressure Sensor Circuit - Data Erratic, Intermittent or Incorrect

Q0319

Real Time Clock Power Interrupt - Data Erratic, Intermittent, or Incorrect

Q0322

Injector Solenoid Cylinder #1 Circuit Current Below Normal or Open Circuit

Q0323

Injector Solenoid Cylinder #5 Circuit Current Below Normal or Open Circuit

Q0324

Injector Solenoid Cylinder #3 Circuit Current Below Normal or Open Circuit

Q0325

Injector Solenoid Cylinder #6 Circuit Current Below Normal or Open Circuit

Q0331

Injector Solenoid Cylinder #2 Circuit Current Below Normal or Open Circuit

Q0332

Injector Solenoid Cylinder #4 Circuit Current Below Normal or Open Circuit

Q0334

Coolant Temperature Sensor Circuit Data Erratic, Intermittent, or Incorrect

Q0341

Engine Control Module data lost - Data Erratic, Intermittent, or Incorrect

Q0343

Engine Control Module Warning internal hardware failure - Bad Intelligent Device or Component

Q0351

Injector Power Supply - Bad Intelligent Device or Component

Q0352

Sensor Supply Voltage #1 Circuit Voltage Below Normal, or Shorted to Low Source

Q0386

Sensor Supply Voltage #1 Circuit Voltage Above Normal, or Shorted to High Source

Q0387

Accelerator Pedal Position Sensor Supply. Voltage Above Normal or Shorted to High Source

Q0415

Oil Pressure Low Data Valid but Below Normal Operating Range.

Q0418

Water in Fuel Indicator High - Data Valid but Above Normal Operating Range.

Q0426

SAE J1939 data link - cannot transmit

Q0427

CanBus Datalink - Abnormal Update Rate

Q0428

Water in Fuel Sensor Circuit - Voltage Above Normal or Shorted to High Source

Q0429

Water in Fuel Sensor Circuit - Voltage Below Normal or Shorted to Low Source

Q0431

This Fault Code should not occur on an 7000 Fastrac

Q0432

This Fault Code should not occur on an 7000 Fastrac

Q0433

Intake Manifold Pressure Sensor. Data Erratic, Intermittent, or Incorrect

Q0434

Engine ECU Power Lost without Ignition Off

Q0435

Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Q0441

Battery Voltage Low - Data Valid but Below Normal Operational Range

Q0442

Battery Voltage High - Data Valid but Above Normal Operational Range

C7-11

9803/9970-01

C7-11

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

Q0443

Accelerator Pedal Supply Voltage Below Normal or Shorted to Low Source

Q0449

Fuel Pressure High - Data Valid but Above Normal Operational

Q0451

Injector Metering Rail Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source

Q0452

Injector Metering Rail Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source

Q0471

Engine Oil Level รณ Data Valid But Below Normal Operational Range รณ Least Severe Level

Q0488

Intake Manifold Temperature - Data Valid but Above Normal Operational Range

Q0553

Injector Metering Rail Pressure High Data Valid but Above Normal Operational Range

Q0554

Fuel Pressure Rail Sensor Error - Data Erratic, Intermittent, or Incorrect

Q0559

Injector Metering Rail Pressure Low Data Valid but Below Normal Operational Range

Q0595

Turbocharger Speed High - Data Valid but Above Normal Operational Range

Q0596

Electrical Charging System Voltage High Data Valid but Above Normal Operational Range

Q0597

Electrical Charging System Voltage Low Data Valid but Below Normal Operational Range

Q0598

Electrical Charging System Voltage Very Low Data Valid but Below Normal Operational Range

Q0649

Change Lubricating Oil and Filter.

Q0687

Turbocharger Speed Low - Data Valid but Below Normal Operational Range

Q0689

"Primary Engine Speed Sensor Error Data Erratic, Intermittent, or Incorrect"

Q0691

Turbocharger Compressor Inlet Temperature Sensor Circuit Voltage Above Normal, or Shorted to High Source

Q0692

Turbocharger Compressor Inlet Temperature Sensor Circuit Voltage Below Normal, or Shorted to Low Source

Q0731

Engine Speed/Position Sensors: Camshaft and Crankshaft Sensors misaligned.

Q0753

Engine Camshaft Speed/Position sync error - Data Erratic, Intermittent, or Incorrect

Q0757

Engine ECU (ECM) data lost

Q0778

Engine Camshaft Speed Sensor Error Data Erratic, Intermittent, or Incorrect

Q0951

Engine Cylinder power imbalance

Q1117

Engine ECU Power Lost With Ignition On

Q1139

Injector Cylinder #1 - Mechanical System Not Responding Properly or Out of Adjustment

Q1141

Injector Cylinder #2 - Mechanical System Not Responding Properly or Out of Adjustment

Q1142

Injector Cylinder #3 - Mechanical System Not Responding Properly or Out of Adjustment

Q1143

Injector Cylinder #4 - Mechanical System Not Responding Properly or Out of Adjustment

Q1144

Injector Cylinder #5 - Mechanical System Not Responding Properly or Out of Adjustment

Q1145

Injector Cylinder #6 - Mechanical System Not Responding Properly or Out of Adjustment

Q2185

Yellow Accelerator Pedal Position Sensor Supply Voltage Above Normal, or Shorted to High Source

Q2186

Yellow Accelerator Pedal Position Sensor Supply Voltage Below Normal, or Shorted to Low Source

Q2195

Auxiliary Equipment Sensor Input Engine Protection

Q2215

Fuel Pump Delivery Pressure Data valid but below Normal Operating Range

Q2216

Fuel Pump Delivery Pressure - Data valid but above Normal Operating Range

Q2217

Engine ECU (RAM) Memory Corrupt - Condition Exists

Q2249

Injector Metering Rail 1 Pressure. Data valid but Below Normal Operating Range.

Q2292

Fuel Inlet Meter Device - Data Valid but Above Normal Operational Range

C7-12

9803/9970-01

C7-12

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

Q2293

Fuel Flow Demand Lower Than Expected.

Q2311

Fuel Actuator Circuit Error Condition Exists

Q2321

Crankshaft Speed / Position Sensor - Data Erratic, Intermittent, or Incorrect

Q2322

Camshaft Speed / Position Sensor - Data Erratic, Intermittent, or Incorrect

Q2347

Turbocharger Compressor Outlet Temperature (Calculated) - Data Valid but Above Normal Operational Range

Q2449

Injector Metering Rail 1 Pressure. Data valid but Below Normal Operating Range.

Q2555

Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source

Q2556

Intake Air Heater #1 Circuit - Voltage Below Normal, or Shorted to Low Source

Q2963

Engine Coolant Temperature High - Data Valid but Above Normal Operational Range

Q2964

Intake Manifold Temperature High - Data Valid but Above Normal Operational Range

Q2973

Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

C7-13

9803/9970-01

C7-13

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Rear Hitch

Code

Description

R0101

Rear Hitch Solenoid Valve: Raise Fault

R0102

Rear Hitch Solenoid Valve: Lower Fault

R0103

Rear Hitch Raise/Lower Solenoid Valve circuit shorted

R0104

Rear Linkage Raise Over-ride Control fault

R0105

Rear Linkage Lower Over-ride Control fault

R0106

Rear Hitch Draft Control (EHR) supply fault

R0107

Rear Hitch Draft Control (EHR) Battery Voltage Too High

R0108

Rear Hitch Main Control Switch fault

R0202

Rear Hitch Position Sensor Fault

R0203

Rear Hitch Control Working Depth Potentiometer Fault

R0204

Rear Hitch Control Maximum Lift Height Potentiometer Fault

R0205

Rear Hitch Draft Control (EHR) CanBus Fault

R0206

Rear Hitch Draft Control (EHR): external sensor fault.

R0207

Rear Hitch Draft Control (EHR) lost CanBus communication with DECU

R0301

Rear Hitch Right Draft Pin Fault

R0302

Rear Hitch Left Draft Pin Fault

R0303

Rear Hitch Draft Control (EHR) Battery Voltage Too Low

R0304

Rear Hitch Control: Working Depth Potentiometer Fault

R0306

Rear Hitch Controls: Draft Mixture Potentiometer Fault

R0307

Rear Hitch failed to move to required position.

R0401

Radar Speed Signal Fault detected by EHR Draft Control

R0402

EHR detected a fault with the Transmission Crown wheel Speed signal

R0500

Rear Hitch Working Depth Control: Signal Plausibility fault

R0501

Rear Hitch Draft Mixture Control: Signal Plausibility fault

R0502

Rear Hitch Maximum Raise Height Controls: Signal Plausibility Fault

R0503

Rear Hitch Drop Rate: Signal Plausibility Fault

R0504

Rear Hitch Draft Mixture Potentiometer: Signal 1 Open or Shorted

R0505

Rear Hitch

R0506

Rear Hitch Drop Rate Controls: Signal 1 Open or Shorted

R0507

Rear Hitch Draft Mixture Controls: Signal 2 Open or shorted

R0508

Rear Hitch Maximum Raise Height Controls: Signal 2 Open or Shorted

R0509

Rear Hitch Drop Rate Controls: Signal 2 Open or Shorted

R0510

Rear Hitch Working Depth Control: Signal 1 Open or Shorted

R0511

Rear Hitch Working Depth Control: Signal 2 Open or Shorted

R0512

Rear Linkage Main Raise/Lower Switch: Signal 1 Open or Shorted

C7-14

9803/9970-01

C7-14

Section C7 - Electrics Fault Code SYSTEM Fault Codes Code

Description

R0513

Rear Linkage Main Raise/Lower Switch : Signal 2 Open or Shorted

R0514

Rear Linkage Main Raise/Lower Switch : Signal 3 Open or Shorted

C7-15

9803/9970-01

C7-15

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Suspension

S0001

Rear Left Suspension Ride Height Potentiometer over range

S0002

Rear Left Suspension Ride Height Potentiometer under range

S0003

Rear Right Suspension Ride Height Potentiometer over range

S0004

Rear Right Suspension Ride Height Potentiometer under range

S0007

Rear Left Suspension value less than the allowable limit for calibration

S0008

Rear Left Suspension value greater than the allowable limit for calibration

S0009

Rear Right Suspension signal less than the allowable limit for calibration

S0010

Rear Right Suspension signal greater than the allowable limit for calibration

S0020

Rear Left Suspension Raise Solenoid valve: open or shorted to supply

S0021

Rear Left Suspension Raise Solenoid valve: short circuit

S0022

ECU1 Internal fault: Rear Left Suspension Driver fault

S0030

Rear Left Suspension Lower Solenoid Valve: open or shorted to supply

S0031

Rear Left Suspension Lower Solenoid valve: short circuit

S0032

ECU1 Internal fault: Rear Left Suspension Driver fault

S0040

Rear Right Suspension Raise Solenoid Valve: open or shorted to supply

S0041

Rear Right Suspension Raise Solenoid valve: short circuit

S0042

ECU1 Internal fault: Rear Right Suspension Driver fault

S0050

Rear Right Suspension Lower Solenoid Valve: open or shorted to supply

S0051

Rear Right Suspension Lower Solenoid valve: short circuit

S0052

ECU1 Internal fault: Rear Right Suspension Driver fault

C7-16

9803/9970-01

C7-16

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Gearbox 6x4

T1000

Transmission

T1001

Transmission Output Shaft Speed Sensor: signal over-range

T1002

Transmission speeds plausibility fault

T1010

Transmission Intermediate shaft speed sensor: signal under range

T1011

Transmission Intermediate shaft speed sensor over-range

T1012

Transmission Intermediate Shaft Speed not plausible to engine speed and intended gear

T1020

Transmission Rail 1Range Position Sensor: signal under range

T1021

Transmission Rail 1Range Position Sensor: over-range

T1022

Transmission Rail 1Range Position Sensor: signal not plausible

T1030

Transmission Rail 2Range Position Sensor: signal under range

T1031

Transmission Rail 2Range Position Sensor: signal over-range

T1032

Transmission Rail 2Range Position Sensor: signal not plausible

T1040

Transmission Oil Temperature Sensor: signal under range

T1041

Transmission Bulk Oil Temperature sensor: signal over-range

T1044

Transmission Bulk Oil Temperature exceeded limit

T1050

Master Clutch Temperature Sensor: signal under range

T1051

Master Clutch Oil Temperature Sensor: signal over-range

T1052

Master Clutch Oil Temperature Sensor: signal value has not changed.

T1053

Transmission Oil Temperature signal plausibility fault

T1054

Master Clutch Oil Temperature exceeded limit

T1060

Clutch Pedal Position Sensor: signal under range

T1061

Clutch Pedal Position Sensor: signal over-range

T1062

Powershift Relay not disengaged when Clutch Pedal is fully depressed

T1070

Clutch Activation Switch not detected when Clutch Pedal at 0%

T1071

Clutch Activation Switch On when Clutch Pedal above 60%

T1080

Transmission Oil Pressure Low

T1200

Powershift Solenoid Valve A: short-circuit

T1201

Powershift Solenoid Valve A: open-circuit

T1210

Powershift Solenoid Valve B: short-circuit

T1211

Powershift Solenoid Valve B: open-circuit

T1220

Powershift Solenoid Valve C: short-circuit

T1221

Powershift Solenoid Valve C: open-circuit

T1230

Powershift Solenoid Valve D: short-circuit

T1231

Powershift Solenoid Valve D: open-circuit

T1240

Powershift Solenoid Valve E: short-circuit

T1241

Powershift Solenoid Valve E: open-circuit

C7-17

9803/9970-01

C7-17

Section C7 - Electrics Fault Code SYSTEM Fault Codes T1250

Powershift Solenoid Valve Reverse: short-circuit

T1251

Powershift Solenoid Valve Reverse: open-circuit

T1260

Master Clutch Solenoid Valve: short-circuit

T1261

Master Clutch Solenoid Valve: open-circuit

T1270

Master Clutch Lubrication Valve: short-circuit

T1271

Master Clutch Lubrication Valve: open circuit

T1280

Master Clutch Brake Solenoid Valve: short-circuit

T1281

Master Clutch Brake Solenoid valve: open-circuit

T1290

Range Solenoid B: short-circuit

T1291

Range Solenoid B: open-circuit

T1300

Range Solenoid A: short-circuit

T1301

Range Solenoid A: open circuit

T1310

Range Solenoid D: short-circuit

T1311

Range Solenoid D: Open-circuit

T1340

Range Solenoid C: short-circuit

T1341

Range Solenoid C: open-circuit

T1400

Transmission Range Change failed

T1401

Invalid CanBus message received by TECU

T1402

Invalid CanBus message received by TECU

T1403

Invalid CanBus message received by TECU

T1404

Invalid CanBus message received by TECU

T1405

Invalid CanBus message received by TECU

T1406

Transmission ECU Control software fault

T1407

Transmission ECU Control software fault

T1408

Transmission ECU Control software fault

T1409

Transmission ECU Control software fault

T1410

Transmission ECU Control software fault

T1411

Transmission ECU Control software fault

T1412

Transmission ECU Control software fault

T1413

Transmission ECU Control software fault

T1414

Transmission ECU Control software fault

T1415

Transmission Speed Signal plausibility error

T1416

Intermediate Shaft Speed and engine speed not plausible

T1417

Transmission Speed Sensor fault during Start-up check

T1418

Transmission Master Clutch has been slipping excessively

T1419

Transmission ECU Software fault

T1420

Transmission ECU Software fault

T1421

TECU detected engine RPM exceeds 3750RPM

T1422

TECU detected Engine RPM has not changed in 2 minutes.

C7-18

9803/9970-01

C7-18

Section C7 - Electrics Fault Code SYSTEM Fault Codes T1423

TECU detected Engine RPM message has not been received in 2 seconds

T1424

TECU detected Engine torque has exceed 125%

T1425

TECU detected Engine torque has not changed in 2 minutes

T1426

TECU detected Engine torque message has not been received in 2 seconds

T1427

TECU detected DECU communication had not been received in 2 seconds

T1450

Transmission fault detected for DECU information

T1451

Transmission fault detected for DECU information

T1452

Transmission ECU Software fault (Invalid gear request)

T1453

Invalid value set in for Double de-clutching message.

T1454

During double de-clutching the range box rails took too long to get to Neutral.

T1500

Transmission Range Calibration Fault: Clutch Pedal Down Value too low

T1501

Transmission Range Calibration Fault: Clutch Pedal Down Value too high

T1502

Transmission Range Calibration Fault: Clutch Pedal Up value too low

T1503

Transmission Range Calibration Fault: Clutch Pedal Up value too high

T1510

Transmission Range Calibration Fault: Rail 1(point 1) too low

T1511

Transmission Range Calibration Fault: Rail 1(point 1) too high

T1512

Transmission Range Calibration Fault: Rail 1(point 2) too low

T1513

Transmission Range Calibration Fault: Rail 1(point 2) too high

T1520

Transmission Range Calibration Fault: Rail 2(point 1) too low

T1521

Transmission Range Calibration Fault: Rail 2(point 1) too high

T1522

Transmission Range Calibration Fault: Rail 2(point 2) too low

T1523

Transmission Range Calibration Fault: Rail 2(point 2) too high

T1530

Transmission Clutch Calibration Fault: Master Clutch bite point current too low

T1531

Transmission Clutch Calibration Fault: Master Clutch bite point current too high

T1532

Transmission Clutch Calibration Fault: Master Clutch time too low

T1533

Transmission Clutch Calibration Fault: Master Clutch time too high

T1534

Transmission Calibration Fault: Powershift Valve A bite point too low

T1535

Transmission Calibration Fault: Powershift Valve A bite point too high

T1536

Transmission Calibration Fault: Powershift Valve B bite point too low

T1537

Transmission Calibration Fault: Powershift Valve B bite point too high

T1538

Transmission Calibration Fault: Powershift Valve R bite point too low

T1539

Transmission Calibration Fault: Powershift Valve R bite point too high

T1540

Transmission Calibration Fault: Powershift Valve C bite point too low

T1541

Transmission Calibration Fault: Powershift Valve C bite point too high

T1542

Transmission Calibration Fault: Powershift Valve D bite point too low

T1543

Transmission Calibration Fault: Powershift Valve D bite point too high

T1544

Transmission Calibration Fault: Powershift Valve E bite point too low

T1545

Transmission Calibration Fault: Powershift Valve E bite point too high

T1550

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve A

C7-19

9803/9970-01

C7-19

Section C7 - Electrics Fault Code SYSTEM Fault Codes T1551

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve B bite point

T1552

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve R bite point

T1553

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve C bite point

T1554

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve D bite point

T1555

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve E bite point

T1556

Transmission calibration Fault: failed to achieve high range for PS calibration.

T1560

Transmission ECU not calibrated

T1570

Transmission Calibration failed: Handbrake is disengaged

T1571

Transmission Calibration failed: Output Shaft Speed is not zero

T1572

Transmission Calibration failed: engine RPM outside calibration range

T1573

Transmission Calibration occurred when oil temperature too low

T1574

Transmission Calibration occurred when oil temperature too high

T1575

Transmission Calibration Fault: change in engine torque not detected for Master Clutch

T1576

Transmission Calibration Fault: change in engine torque not detected for Master Clutch

T1580

Transmission Calibration Fault:

T1581

Transmission Calibration Fault:

T1582

Transmission Calibration Fault:

T1583

Transmission Calibration Fault:

T1584

Transmission Calibration Fault:

T1585

Transmission Calibration Fault:

T1586

Transmission Calibration Fault:

T1590

Transmission Calibration Fault:

T1591

Transmission Calibration Fault:

T1592

Transmission Calibration Fault:

T1593

Transmission Calibration Fault:

T1596

Transmission Calibration Fault:

T1597

Transmission Calibration Fault:

T1598

Transmission Calibration Fault:

T1599

Transmission Calibration Fault:

T1600

Transmission Calibration Fault:

T1601

Transmission Calibration Fault:

T1602

Clutch Activation Switch On when Clutch Position percentage too low

T1603

Clutch Activation Switch On when Clutch Position signal voltage too high

T1610

Transmission Calibration Fault:

T1611

Transmission Calibration Fault:

T1650

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve A cal time

T1651

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve B cal time

T1652

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve R cal time

T1653

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve C cal time

C7-20

9803/9970-01

C7-20

Section C7 - Electrics Fault Code SYSTEM Fault Codes T1654

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve D cal time

T1655

Transmission Calibration Fault: change in engine torque not detected for Powershift Valve E cal time

C7-21

9803/9970-01

C7-21

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Front Hitch Slice

U0000

Valve block CanBus Communication fault - Front Hitch Slice

U0001

Valve block CanBus Communication fault Front Hitch Slice

U0002

Implausible CanBus Data Received Message - Front Hitch Slice

U0003

Implausible CanBus receive Message Front Hitch Slice

U0004

Front Hitch Slice internal fault

U0005

EEPROM Inconsistent - Front Hitch Slice

U0006

No faults but valve has switched off for >4 seconds - Front Hitch Slice

U0007

Valve Slice Supply Voltage < 11 volts: Front Hitch Slice

U0008

Valve Slice Supply Voltage > 16 volts Front Hitch Slice

U0009

Spool Movement Too short - Front Hitch Slice

U0010

Excessive Internal Spool Movement - Front Hitch Slice

U0011

Internal Spool Float Position Not Reached - Front Hitch Slice

U0012

Spool Valve Operated Manually - Front Hitch Slice

U0013

Supply Voltage < 8 Volts - Front Hitch Slice

U0014

Supply > 36 but < 45 volts - Front Hitch Slice

U0015

High Over Voltage Supply > 45 volts - Front Hitch Slice

U0016

Output Stage Fault - Front Hitch Slice

U0017

Valve block internal Position transducer fault Front Hitch Slice

U0018

Spool Valve Cannot return To The Neutral Position Front Hitch Slice

U0019

Spool Not In Neutral When Powered Up Front Hitch Slice

U0020

Program Memory Error Front Hitch Slice

U0021

Spool valve Off Line: Front Hitch Slice

U0066

Front Hitch Position Sensor: signal over-range

U0067

Front Hitch Position Sensor: signal under-range

U0068

Front Hitch Position Sensor input open circuit.

U0071

Spool Valve very high temperature Front Hitch Slice

U0124

Front Hitch Controls message from ACE not received by ECU1

U0201

Spool movement too short Front Hitch Slice

U0203

Spool valve very high temperature Front Hitch Slice

U0500

Front Hitch Working Depth Control: Signal Plausibility Fault

U0502

Front Hitch Maximum Raise Height Controls: Signal Plausibility Fault

U0503

Front hitch Drop Rate : signal plausibility fault

U0505

Front Hitch Maximum Raise Height Controls: Signal

U0506

Front Hitch Drop Rate Controls: Signal 1 Open or Shorted

U0508

Front Hitch Maximum Raise Height Controls: Signal 2 Open or Shorted

U0509

Front Hitch Drop Rate Controls: Signal 2 Open or Shorted

C7-22

9803/9970-01

C7-22

Section C7 - Electrics Fault Code SYSTEM Fault Codes U0510

Front Hitch Working Depth Control: Signal 1 Open or Shorted

U0511

Front Hitch Working Depth Control: Signal 2 Open or Shorted

U0512

Front Hitch Main Raise/Lower Switch: Signal 1 Open circuit or Shorted

U0513

Front Hitch Main Raise/Lower Switch : Signal 2 Open circuit or Shorted

U0514

Front Hitch Main Raise/Lower Switch : Signal 3 Open or Shorted

C7-23

9803/9970-01

C7-23

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Green Slice

Code

Description

V0000

Valve block CanBus Communication fault - Green Slice

V0001

Valve block CanBus Communication fault Green Slice

V0002

Implausible CanBus Data Received Message - Green Slice

V0003

Implausible CanBus Data Received Message Green Slice

V0004

Potentiometer / PWM Fault - Green Slice

V0005

EEPROM Inconsistent - Green Slice

V0006

No faults but valve has switched off for >4 seconds - Green Slice

V0007

Valve Slice Supply Voltage < 11 volts: Green Hitch Slice

V0008

Valve Slice Supply Voltage > 16 volts - Green Slice

V0009

Spool Movement Too short - Green Slice

V0010

Excessive Internal Spool Movement - Green Slice

V0011

Internal Spool Float Position Not Reached - Green Slice

V0012

Spool Valve Operated Manually - Green Slice

V0013

Supply Voltage < 8 Volts - Green Slice

V0014

Supply > 36 but < 45 volts - Green Slice

V0015

High Over Voltage Supply > 45 volts - Green Slice

V0016

Output Stage Fault - Green Slice

V0017

Valve block internal Position transducer fault Green Slice

V0018

Spool Valve Cannot return To The Neutral Position Green Slice

V0019

Spool Not In Neutral When Powered Up Green Slice

V0020

Program Memory Error Green Slice

V0021

Spool valve Off Line: Green Slice

V0050

Main lever electrical input too low Green slice

V0051

Main lever electrical input too high Green slice

V0054

Flow or duration control driver open circuit -Green slice

V0055

Flow or duration control too low. - Green slice

V0056

Flow or duration control too high. - Green slice

V0070

Implausible main control lever position Green Slice

V0071

Spool valve very high temperature Green Slice

V0100

Green Slice Spool Lever : Signal Plausibility Fault

V0101

Green Slice Spool Lever : Signal Fault

V0102

Green Slice Spool Lever : Signal Fault

V0124

Green Slice Controls message from ACE not received by ECU1

V0201

Spool Movement Too short - Green Slice

V0203

Spool valve very high temperature Green Slice

C7-24

9803/9970-01

C7-24

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Blue Slice

W0000

Valve block CanBus Communication fault - Blue Slice

W0001

Valve block CanBus Communication fault Blue Slice

W0002

Implausible CanBus Data Received Message - Blue Slice

W0003

Implausible CanBus Data Received Message - Blue Slice

W0004

Potentiometer / PWM Fault - Blue Slice

W0005

EEPROM Inconsistent - Blue Slice

W0006

No faults but valve has switched off for >4 seconds - Blue Slice

W0007

Valve Slice Supply Voltage < 11 volts: Blue Slice

W0008

Valve Slice Supply Voltage > 16 volts - Blue Slice

W0009

Spool Movement Too short - Blue Slice

W0010

Excessive Internal Spool Movement - Blue Slice

W0011

Internal Spool Float Position Not Reached - Blue Slice

W0012

Spool Valve Operated Manually - Blue Slice

W0013

Supply Voltage < 8 Volts - Blue Slice

W0014

Supply > 36 but < 45 volts - Blue Slice

W0015

High Over Voltage Supply > 45 volts - Blue Slice

W0016

Output Stage Fault - Blue Slice

W0017

Valve block internal Position transducer fault Blue Slice

W0018

Spool Valve Cannot return To The Neutral Position Blue Slice

W0019

Spool Not In Neutral When Powered Up Blue Slice

W0020

Program Memory Error Blue Slice

W0021

Spool valve Off Line: Blue Slice

W0050

Main lever electrical input too low Blue slice

W0051

Main lever electrical input too high Blue slice

W0054

Flow or duration control driver open circuit. - Blue slice

W0055

Flow or duration control too low. Blue slice

W0056

Flow or duration control too high. Blue slice

W0070

Implausible main control lever position Blue Slice

W0071

Spool valve very high temperature Blue Slice

W0100

Blue Slice Spool Lever : Signal Plausibility Fault

W0101

Blue Slice Spool Lever : Signal Fault

W0102

Blue Slice Spool Lever : Signal Fault

W0124

Blue Slice Controls message from ACE not received by ECU1

W0201

Spool movement too short Blue Slice

W0203

Spool valve very high temperature Blue Slice

C7-25

9803/9970-01

C7-25

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Brown Slice

Code

Description

X0000

Valve block CanBus Communication fault - Brown Slice

X0001

Valve block CanBus Communication fault Brown Slice

X0002

Implausible CanBus Data Received Message - Brown Slice

X0003

Implausible CanBus Data Received Message - Brown Slice

X0004

Potentiometer / PWM Fault - Brown Slice

X0005

EEPROM Inconsistent - Brown Slice

X0006

No faults but valve has switched off for >4 seconds - Brown Slice

X0007

Valve Slice Supply Voltage < 11 volts: Brown Slice

X0008

Valve Slice Supply Voltage > 16 volts - Brown Slice

X0009

Spool Movement Too short - Brown Slice

X0010

Excessive Internal Spool Movement - Brown Slice

X0011

Internal Spool Float Position Not Reached - Brown Slice

X0012

Spool Valve Operated Manually - Brown Slice

X0013

Supply Voltage < 8 Volts - Brown Slice

X0014

Supply > 36 but < 45 volts - Brown Slice

X0015

High Over Voltage Supply > 45 volts - Brown Slice

X0016

Output Stage Fault - Brown Slice

X0017

Valve block internal Position transducer fault Brown Slice

X0018

Spool Valve Cannot return To The Neutral Position Brown Slice

X0019

Spool Not In Neutral When Powered Up Brown Slice

X0020

Program Memory Error Brown Slice

X0021

Spool valve Off Line: Brown Slice

X0050

Main lever electrical input too low Brown slice

X0051

Main lever electrical input too high Brown slice

X0054

Flow or duration control driver open circuit. - Brown slice

X0055

Flow or duration control too low. - Brown slice

X0056

Flow or duration control too high. - Brown slice

X0070

Implausible main control lever position Brown Slice

X0071

Spool valve very high temperature Brown Slice

X0100

Brown Slice Spool Lever : Signal Plausibility Fault

X0101

Brown Slice Spool Lever : Signal Fault

X0102

Brown Slice Spool Lever : Signal Fault

X0124

Green Slice Controls message from ACE not received by ECU1

X0201

Spool movement too short Brown Slice

X0203

Spool valve very high temperature Brown Slice

C7-26

9803/9970-01

C7-26

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Grey Slice

Code

Description

Y0000

Valve block CanBus Communication fault - Grey Slice

Y0001

Valve block CanBus Communication fault Grey Slice

Y0002

Implausible CanBus Data Received Message - Grey Slice

Y0003

Implausible CanBus Data Received Message Grey Slice

Y0004

Potentiometer / PWM Fault - Grey Slice

Y0005

EEPROM Inconsistent - Grey Slice

Y0006

No faults but valve has switched off for >4 seconds - Grey Slice

Y0007

Valve Slice Supply Voltage < 11 volts: Grey Slice

Y0008

Valve Slice Supply Voltage > 16 volts - Grey Slice

Y0009

Spool Movement Too short - Grey Slice

Y0010

Excessive Internal Spool Movement - Grey Slice

Y0011

Float Position Not Reached - Grey Slice

Y0012

Spool Valve Operated Manually - Grey

Y0013

Supply Voltage < 8 Volts - Grey Slice

Y0014

Supply > 36 but < 45 volts - Grey Slice

Y0015

High Over Voltage Supply > 45 volts - Grey Slice

Y0016

Output Stage Fault - Grey Slice

Y0017

Valve block internal Position transducer fault Grey Slice

Y0018

Spool Valve Cannot return To The Neutral Position Grey Slice

Y0019

Spool Not In Neutral When Powered Up Grey Slice

Y0020

Program Memory Error Grey Slice

Y0021

Spool valve Off Line Grey Slice

Y0050

Main lever electrical input too low Grey slice

Y0051

Main lever electrical input too high Grey slice

Y0054

Flow or duration control driver open circuit. -Grey slice

Y0055

Flow or duration control too low. - Grey slice

Y0056

Flow or duration control too high. - Grey slice

Y0070

Implausible main control lever position Grey Slice

Y0071

Spool valve very high temperature Grey Slice

Y0100

Grey Slice Spool Lever : Signal Plausibility Fault

Y0101

Grey Slice Spool Lever : Signal Fault

Y0102

Grey Slice Spool Lever : Signal Fault

Y0124

Grey Slice Controls message from ACE not received by ECU1

Y0201

Spool movement too short Grey Slice

Y0203

Spool valve very high temperature Grey Slice

C7-27

9803/9970-01

C7-27

Section C7 - Electrics Fault Code SYSTEM Fault Codes

Page left intentionally blank

C7-28

9803/9970-01

C7-28

Section C8 - Electrics

Battery Charging 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.. Descriptions and procedures relate to the system and not the individual devices. 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.

K Technical Data ( T C8-2) K Electrical Operation and Schematics ( T C8-3) K Test Procedures ( T C8-4)

C8-1

9803/9970-01 (C-01-00)

C8-1

Section C8 - Electrics Battery Charging SYSTEM Technical Data

Technical Data

System Type

12 Volt, negative earth

Alternator

150 Amp nominal output

C8-2

9803/9970-01 (C-01-00)

C8-2

Section C8 - Electrics Battery Charging SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics With the 6-speed gearbox lever set to neutral and starter switch A turned to 'IGN', the battery supply is fed via fuse Ca and the 6-speed gearbox neutral switch C (now closed as shown on the diagram) to the solenoids of the two inhibit start relays D and E. To eliminate the need to select neutral in the 6-speed gearbox, an alternative supply route to the solenoids of the start inhibit relays is provided via Ba the clutch depressed switch H. With the front and rear power take off (PTO)

switches F and G turned to the braking position, as shown in the diagram, an earth return is provided for the inhibit start relay solenoids, causing them to energise. When the starter switch is turned to the start ('HS') position, the battery supply is fed via fuse Bb and the relay contacts of the inhibit start relays D and E to the starter solenoid J, which energises and connects the battery supply to the starter motor K.

O IGN

A Bb

J K1

K K2

41843

418430-C1

Fig 1.

C8-3

9803/9970-01 (C-01-00)

C8-3

Section C8 - Electrics Battery Charging SYSTEM Test Procedures

Test Procedures Alternator Charging Test

B A

418400-C1

Fig 2. 1

Ensure that all battery and alternator connections are in place, secure and making good metal - to - metal contact, especially the 'earth' connections to chassis and engine.

Make sure that the alternator drive belt tension is correct.

If the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test.

Disconnect the positive lead B from battery number 2 and install a 100 amp open - type shunt between the battery positive lead and the battery number 2 positive terminal C.

C8-4

Connect a multimeter positive lead to machine side of the shunt and negative lead to battery side of the shunt.

Connect the leads to the meter and set the meter to the relevant range as follows.

9803/9970-01 (C-01-00)

C8-4

Section C8 - Electrics Battery Charging SYSTEM Test Procedures AVO 2002

– Red lead to volts (middle) socket on meter.

Faults d, e, and f may be checked only by removing and dismantling the alternator for further testing.

– Black lead to negative on meter. – RH slider to DC voltage. – LH slider. K Fig 2. ( T C8-4). AVO 2003

– Red lead to amps socket (marked A) on the meter. – Black lead to negative on meter. – RH slider to DC voltage – LH slider to 200 Shunt

FLUKE 85

– Red lead to volts socket (marked V) on meter. – Black lead to COM socket on meter. – Set dial to mV.

Start the engine and run at maximum speed (see K Technical Data ( T C8-2)). Meter should show maximum alternator output in Amps (see K Technical Data ( T C8-2)).

Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly. 8

A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability. a

Defective suppression capacitor.

b Dirty slip rings or worn brushes. c

Defective regulator.

d Defective rectifier. e

Open or short - circuited field (rotor) windings.

Open or short - circuited power (stator) windings.

To check for fault a, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary.

To check for faults b and c, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the slip rings using extra-fine glass paper. The regulator may only be checked by substitution.

C8-5

9803/9970-01 (C-01-00)

C8-5

Section C8 - Electrics Battery Charging SYSTEM Test Procedures

C8-6

9803/9970-01 (C-01-00)

C8-6

Section C9 - Electrics

Battery Introduction

This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Descriptions and procedures relate to the device and not related systems. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Specifications ( T C9-2) K Battery Connections ( T C9-2) K Access ( T C9-3) K Maintenance ( T C9-4) K Test Procedures ( T C9-7) K Battery Load Testing ( T C9-7) K Specific Gravity Testing ( T C9-8) K Battery Disconnection/Connection ( T C9-9) K Removal and Replacement ( T C9-10)

C9-1

9803/9970-01 (C-05-00)

C9-1

Section C9 - Electrics Battery Specifications

Specifications Twin 12 v battery installation. Batteries connected in parallel to provide 12 v electrical system. Battery (single battery)

- Cold crank amps for 1 minute to 1.4 volts per cell at -18 900 A 0C (0 0F) Capacity 20H

110 Ah

Battery Connections

7 ALTERNATOR BOOT

M8 M8

6 GRID HEATER

BOOT

M12

BOOT

+VE

BATTERY 1 -VE

BATTERY 2

STARTER MOTOR M12

5 4

-VE M12

BELL HOUSING C095900

Fig 1. Item

Description

Cab harness

Battery 1

Battery 2

Engine flywheel housing

Starter motor

Cold start heater

Alternator

C9-2

9803/9970-01 (C-05-00)

C9-2

Section C9 - Electrics Battery Access

Access Get access to the batteries as follows:

1 1

1 2 C089790-C4

Fig 2. â&#x20AC;&#x201C; Open the right side door. Undo screws 1 and remove the panel 2.

C9-3

9803/9970-01 (C-05-00)

C9-3

Section C9 - Electrics Battery Maintenance

Maintenance To ensure that the battery provides optimum performance the following steps should be observed: 1

Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.

When applicable - never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates. Use only distilled water for topping up.

Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) - this condition makes recharging the battery very difficult.

â&#x20AC;&#x201C; Never boost-charge a maintenance free battery. â&#x20AC;&#x201C; Never charge a maintenance free battery at a voltage in excess of 15.8 Volts. â&#x20AC;&#x201C; Never continue to charge a maintenance free battery after it begins to gas.

Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery:

!MWARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12

C9-4

9803/9970-01 (C-05-00)

C9-4

Section C9 - Electrics Battery Maintenance

!MCAUTION

Battery T3-061

!MWARNING

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14

!MWARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4

C9-5

9803/9970-01 (C-05-00)

C9-5

Section C9 - Electrics Battery Maintenance Warning Symbols

First Aid - Electrolyte

The following warning symbols may be found on the battery.

Do the following if electrolyte: Gets into your eyes

Symbol

Meaning

Immediately flush with water for 15 minutes, always get medical help.

Keep away from children.

Is swallowed A289230-1

Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

Shield eyes.

Gets onto your skin

A289260-1

No smoking, no naked flames, no sparks. Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

C9-6

9803/9970-01 (C-05-00)

C9-6

Section C9 - Electrics Battery Test Procedures

Test Procedures Battery Load Testing

This test is to determine the electrical condition of the battery and to give an indication of the remaining useful `life'. Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27Â°C).

Set the CHECK/LOAD switch 3-A to LOAD and hold down for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

Note: Do not hold the switch in the LOAD position for more than 10 seconds. 6

K Table 1. Fault Diagnosis ( T C9-7), foregoing tests are unsatisfactory.

the

Ensure that the battery is completely disconnected from the vehicle. Connect up the battery tester as follows: 1

Set the CHECK/LOAD switch 3-A to OFF.

Set rocker switch 3-B to the battery voltage (12V).

Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.

Set the CHECK/LOAD switch 3-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts.

239510-1

Battery Tester Readings 1

Fig 3. Battery Tester

Table 1. Fault Diagnosis Remedy

CHECK: 0 - 12.6 Volts

Renew battery

LOAD: less than 6 Volts 2

CHECK: 6 - 12.4 Volts

Recharge and re-test. If tests still unsatisfactory renew battery.

LOAD: less than 9 Volts and falls steadily but remains in yellow zone. 3

CHECK: less than 10 Volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

LOAD: less than 3 Volts 4

CHECK: more than 11 Volts

Charge battery which will probably recover.

LOAD: 6 - 10 Volts steady

C9-7

9803/9970-01 (C-05-00)

C9-7

Section C9 - Electrics Battery Test Procedures

Specific Gravity Testing The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15°C (60°F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing.

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15°C (60°F) a 'correction factor' must be applied to the reading obtained. Add 0.07 per 10°C (18°F) if the temperature is higher than 15°C (60°F) and subtract the same if the temperature is lower.

Table 2. Specific Gravity at 15°C (60°F) Fully Charged Half Discharged

Fully Discharged

Ambient temperature up to 27°C (80°F)

1.270 - 1.290

1.190 - 1.210

1.110 - 1.130

Ambient temperature above 27°C (80°F)

1.240 - 1.260

1.170 - 1.190

1.090 - 1.110

C9-8

9803/9970-01 (C-05-00)

C9-8

Section C9 - Electrics Battery Battery Disconnection/Connection

Battery Disconnection/Connection

Disconnection 1

Get access to the battery.

Remove the leads. Disconnect the earth (-) terminal first.

Connection 1

Check the battery. a

If the terminal is dirty, clean the post.

797650

Fig 4. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper. c

After cleaning, apply a thin coat of petroleum jelly to the terminal.

Re-connect the leads. Connect the earth (-) terminal last. For twin battery installations make sure that the interconnection leads are installed correctly.

Close and lock the access panels.

C9-9

9803/9970-01 (C-05-00)

C9-9

Section C9 - Electrics Battery Removal and Replacement

Removal and Replacement

!MCAUTION

Make sure that all battery connection wires are clear of battery terminals.

Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

Undo the clamp nuts 1 and clamping brackets 2.

INT-3-1-14

Using handles 3 remove battery from compartment.

!MWARNING

Replacement

Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth.

Replacement is the opposite of the removal procedure. Reconnect the batteries. Follow the correct procedure. K Battery Disconnection/Connection ( T C9-9)

When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

3 1 1

3 1

C095890

Fig 5.

Removal 1

Get access to the batteries. K Access ( T C9-3)

Follow the procedure for disconnection of the batteries. Disconnect both batteries to avoid the risk of short circuit. K Battery Disconnection/ Connection ( T C9-9)

C9-10

9803/9970-01 (C-05-00)

C9-10

Section E Hydraulics Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section E - Hydraulics

Notes:

E-0

9803/9970-01

E-0

Section E - Hydraulics Contents Page No. Schematic Circuits Introduction ............................................................................................. E1-1 Introduction to Hydraulic Schematic Symbols ........................................ E1-2 Complete Machine Circuit with Power Beyond Service .......................... E1-8 External Hydraulics SYSTEM Introduction ............................................................................................. E2-1 Technical Data ........................................................................................ E2-2 Pressure Testing ..................................................................................... E2-3 Spool Valve SYSTEM Introduction ............................................................................................. E3-1 Operation Overview ................................................................................ E3-2 Configuration .......................................................................................... E3-5 Calibration - Auxiliary and Hitch Control Parameters ............................. E3-9 Fault Finding ......................................................................................... E3-10 Removal and Replacement ................................................................... E3-11 Dismantle and Assemble ...................................................................... E3-12 Variable Flow Pump Introduction ............................................................................................. E4-1 Removal and Replacement .................................................................... E4-2 Dismantling and Assembly ..................................................................... E4-4 Gear Pump (Suspension and Steering) ................................................ E4-12 Gear Pump (Suspension and Steering) Introduction ............................................................................................. E5-1 Removal and Replacement .................................................................... E5-2 Dismantling and Assembly ..................................................................... E5-4

E-i

Rear Hitch Ram Introduction ............................................................................................. Removal and Replacement .................................................................... Dismantling and Assembly ..................................................................... Testing ....................................................................................................

E6-1 E6-2 E6-3 E6-5

Front Hitch Ram Introduction ............................................................................................. Removal and Replacement .................................................................... Dismantling and Assembly ..................................................................... Testing ....................................................................................................

E7-1 E7-2 E7-3 E7-5

E-i

Section E - Hydraulics Contents

E-ii

Page No.

E-ii

Section E1 - Hydraulics

Schematic Circuits Introduction This topic contains hydraulic schematics for the complete system. Detailed schematics for individual systems are given throughout the manual.

K Introduction to Hydraulic Schematic Symbols ( T E1-2) K Complete Machine Circuit with Power Beyond Service ( T E1-8)

E1-1

9803/9970-01 (E-00-00)

E1-1

Section E1 - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols

Introduction to Hydraulic Schematic Symbols TE-001

General (Basic and Functional Symbols) Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.

Table 2. Rams Single acting

Double acting There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components. Table 1. General

Double ended

Double acting with damping at rod area end

Table 3. Pumps and Motors Variable capacity pump two directions of flow

Spring Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow Fixed capacity motor two directions of flow

Indication of rotation

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

E1-2

Variable capacity motor one direction of flow

9803/9970-01 (E-00-00)

E1-2

Section E1 - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols Table 4. Control Valves Used to enclose several valves indicating they are supplied as one unit

Throttling orifice - normally closed

3-Position, 4-port spring centered pilot operated valve

Throttling orifice - normally open

3-position, 6-port spring centered pilot operated valve

3-Position, 4-port spring centered solenoid & pilot pressure operated valve 3-Position, 4-port spring centered detent hand operated valve

Relief valve

Variable restrictor

Non-return valve

Non-return valve with back pressure spring

Pilot operated non-return valve

One way restrictor

High pressure selector (shuttle valve)

E1-3

9803/9970-01 (E-00-00)

E1-3

Section E1 - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning Working line, return or feed

Reservoir - return line below fluid level

Pilot control Drain lines Header tank Flexible pipe

Pressure sealed tank Line junction

Accumulator

Crossing lines

Filter or strainer

Water trap Air bleed

Line plugged, also pressure test point Line plugged with take off line

Cooler - with no indication of coolant flow

Cooler - indicating direction of coolant flow

Quick release couplings connected Heater Quick release couplings disconnected

Reservoir - return line above fluid level

E1-4

9803/9970-01 (E-00-00)

E1-4

Section E1 - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols Table 6. Control Mechanisms Solenoid one winding

Rotating shaft - one direction

Solenoid two windings

Rotating shaft - two directions

Detent

Locking device

Electric motor operated

Internal pressure pilot operated

Over centre device External pressure pilot operated Simple linkage Pressure operated spring release General control Pilot operated by solenoid pilot valve Push button operated Pilot operated by a solenoid or seperate pilot valve Lever operated Pressure guage Pedal operated Pressure switch Stem operated

Spring operated

Roller operated

Roller trip operated (one directional)

E1-5

9803/9970-01 (E-00-00)

E1-5

Section E1 - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols

Control Valves Control valves are usually represented by one or more square boxes. K Fig 1. ( T E1-6) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes - 3 positions etc).

Fig 4. Fig 1. K Fig 2. ( T E1-6) - In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).

It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. K Fig 4. ( T E1-6) shows a 'D' type spool.

Fig 2. K Fig 4. ( T E1-6) shows a valve described as a 3position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked.

K Fig 5. ( T E1-6) - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.

Fig 5. K Fig 6. ( T E1-6) - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port

Fig 3. If the valve spool was moved to Position 1, movement of the spool would connect Port P1 to Port P2, and Port P3 to Port P4. K Fig 4. ( T E1-6). If the valve spool was moved to Position 3, movement of the spool would connect Port P1 to Port P4, and Port P3 to Port P2. K Fig 4. ( T E1-6).

E1-6

9803/9970-01 (E-00-00)

Fig 6.

E1-6

Section E1 - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

Fig 7. Simple Schematic Circuit Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit. K Fig 7. ( T E1-7). Hydraulic tank 7-A is a pressurised tank with an internally mounted strainer 7-B on the suction line to the fixed displacement pump 7-C. System pressure is limited to the setting of relief valve 7-D. Valve spool 7-E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.

Example Circuit Key 7-A

Hydraulic Tank

7-B

Strainer

7-C

Fixed Displacement Pump

7-D

Relief Valve

7-E

Spool

7-F

One Way Valve

7-G

Double Acting Hydraulic Ram

If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram 7-G. Notice that the fluid must first open one way valve 7-F before flowing to the ram.

E1-7

9803/9970-01 (E-00-00)

E1-7

E1-8

Hydraulic Trailer Brake Valve (optional)

Steering Circuit Cooler

Main Filter

Front Lift Rams

Rear Auxiliary Circuits

One-way Restrictor

Relief Valve

Pump - External Hydraulics

Pump - Suspension and Trailer Brake Valve

Pump - Steering

Power Beyond Pressure Connection

Power Beyond Load Sense Connection

Power Beyond Tank Connection

Drop Flow Control Valve (front lift rams) (optional)

Rear Lift Rams

Suspension Cylinders

Steering Box

PBL

PBT

EP - Pilot pressure shut off valve

WV5 - Front hitch slice

WV4 - Auxiliary valve slice - Grey

WV3 - Auxiliary valve slice - Brown

WV2 - Auxiliary valve slice - Blue

WV1 - Auxiliary valve slice - Green

EHR - Rear draft control slice

External Hydraulics/Draft Control Valve

K Fig 8. ( T E1-9)

Component Key Suspension/Differential Control Valve

Hydraulic Trailer Brake Connector

Rear Axle Differential Lock

CT8 - CT11 Suspension height solenoid control valves

CT7 - Diff lock solenoid pilot valve

CT6 - Pressure relief valve (diff lock)

CT4 - Diff lock control valve

CT1 - Pressure maintenance valve

Tank

Complete Machine Circuit with Power Beyond Service

Section E1 - Hydraulics Schematic Circuits

Complete Machine Circuit with Power Beyond Service

9803/9970-01 (E-00-00)

E1-8

Section E1 - Hydraulics Schematic Circuits

N SB

Fig 8.

Green

Blue

Brown

Grey

C096860

Complete Machine Circuit with Power Beyond Service

E1-9

9803/9970-01 (E-00-00)

E1-9

Section E1 - Hydraulics Schematic Circuits Complete Machine Circuit with Power Beyond Service

Page left intentionally blank

E1-10

9803/9970-01 (E-00-00)

E1-10

Section E2 - Hydraulics

External Hydraulics 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. Descriptions and procedures relate to the system and not the individual devices. 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.

K Technical Data ( T E2-2) K Flow Rates ( T E2-2) K Pressures ( T E2-2) K Spool Valve ( T E2-2)

K Pressure Testing ( T E2-3) K Maximum System Pressure ( T E2-3) K Pilot Stand-by Pressure ( T E2-4)

E2-1

9803/9970-01 (E-01-00)

E2-1

Section E2 - Hydraulics External Hydraulics SYSTEM Technical Data

Technical Data Flow Rates

Total Pump Flow at maximum system pressure and 2200 engine rev/min. Note: When checking flow, be aware of the maximum flow through the spools (see below). Standard Pump

127 litres/min

28 UK gal/min

33.5 US gal/min

100 litres/min

22 UK gal/min

26.4 US gal/min

Maximum system pressure at 1500 engine rev/min

210 bar

214 kgf/cm2

3045 lbf/in2

Pilot stand-by pressure - no service selected

18 bar

18.4 kgf/cm2

260 lbf/in2

Maximum flow from each spool Standard Spool Valve

Pressures

Spool Valve All external hydraulics spools

Electronic, 4 position double acting with provision for timed hydraulic kick-out and flow control.

Other Hydraulic Circuits Note: For technical data of other hydraulic systems, refer to the following sections of the Service Manual: Section F - Transmission Section H - Steering Section S - Suspension

E2-2

9803/9970-01 (E-01-00)

E2-2

Section E2 - Hydraulics External Hydraulics SYSTEM Pressure Testing

Pressure Testing Maximum System Pressure

C097220

Fig 1. Connect a 0-400 bar (0-6000 lbw/in2) pressure gauge to test point P on the end section of the spool valve slices. Disable the time and pressure controlled kick-out on the spool to be operated. Ensure that there is no implement connected to the relevant quick release couplings so that the closed coupling can hold the M.R.V. pressure.

low and cannot be corrected by screw B. In this case, valve C can be removed, cleaned and refitted. Make sure that all the parts of the valve are refitted in their original positions (including any shims S).

Run the engine at 1500 r.p.m., select the spool to ram extend or retract position. Check the gauge reading against the maximum system pressure setting in Technical Data. If necessary, adjust the setting at screw B on the piston pump. Important: Do not try to increase the pressure above the specified setting as the pressure is also controlled by valve C. Increasing the pressure above the recommended setting will cause severe overheating of the hydraulic system. Do not disturb valve C unless the pressure is very

E2-3

9803/9970-01 (E-01-00)

E2-3

Section E2 - Hydraulics External Hydraulics SYSTEM Pressure Testing

Pilot Stand-by Pressure

D C070540-B5

Fig 2. Connect a 0-40 bar (0-600 lbw/in2) pressure gauge in place of plug D. Operate any spool to activate the load sensing system, then select neutral. Important: The gauge reading must be checked within 1 minute of the spool having been operated otherwise the reading will not be correct. Check the gauge reading with the engine running at low idle against the pilot stand-by pressure setting in Technical Data.

E2-4

9803/9970-01 (E-01-00)

E2-4

Section E2 - Hydraulics External Hydraulics SYSTEM Pressure Testing

Power Beyond Operation The operation of the power beyond is intended to be completely independent of the Boast auxiliary valve. The power beyond can take 100% of the pump output and is intended for use with implements that have their own valve block to control the complete implement hydraulic system and only need an oil supply from the tractor. A problem will arise if you try to use the Boast valve and the power beyond simultaneously - the amount of oil required increases and the path of least resistance applies. The Boast valve does not know that the power beyond is fitted to the tractor or if it is selected or not. the Boast valve will meter the oil as described above assuming it has all the pump output for itâ&#x20AC;&#x2122;s own use. If the Boast valve requires all the available oil being produced and it is the path of least resistance (lower pressure services), then all the oil will flow to the Boast valve. only when the engine speed is increased and more oil flow is produced does the power beyond start to work. The opposite can also happen, if the Bosch valve is set up to flow oil to one or more services that need high pressure then the power beyond is operated opening the lower pressure path then the Bosch valve will reduce or stop flowing oil. It is important to realise that the two systems are independent regarding their control but operating one will affect the other as they are intended to be used separately not simultaneously

E2-5

9803/9970-01 (E-01-00)

E2-5

Section E3 - Hydraulics

Spool Valve 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. Descriptions and procedures relate to the system and not the individual devices. 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.

K Operation Overview ( T E3-2) K Configuration ( T E3-5) K Calibration - Auxiliary and Hitch Control Parameters ( T E3-9) K Fault Finding ( T E3-10) K Removal and Replacement ( T E3-11) K Dismantle and Assemble ( T E3-12)

E3-1

9803/9970-01 (E-06-00)

E3-1

Section E3 - Hydraulics Spool Valve SYSTEM Operation Overview

Operation Overview

2A 3A

4A 6A

E A2

C B

4 2 3

C096010

Fig 3. Electronically controlled spool valves control front and rear hitches and auxiliary hydraulic services for operation of hydraulic implements.

Pilot pressure solenoid cut off valve

Filter (pilot oil)

Machines can have up to six spool valves depending on the specification. Item

Description

Green service auxiliary spool valve slice

Blue service auxiliary spool valve slice

Brown service auxiliary spool valve slice

Grey service auxiliary spool valve slice

Front hitch service spool slice

1A - 6A

CAN enabled proportional solenoid pilot control valves

A1 - A2

Solenoid pilot control valves

Rear hitch (draft control) service spool slice

Inlet/outlet end section

Pressure transducer (main system pressure)

E3-2

9803/9970-01 (E-06-00)

E3-2

Section E3 - Hydraulics Spool Valve SYSTEM Operation Overview

Control Network

CAN 2

CAN 2 D

C A2

6 34 2 1

AC1

AC3 AC2

A1 EHR-Z

ECU1

ACE AC4

CAN 1

CAN 1 C096030

Fig 4. Control

Process

AC1 - Auxiliary spool control levers

Up to four levers operate auxiliary spools 1-4. The levers are part of the auxiliary control ECU (ACE). The ECU processes the inputs from the levers and transmits a signal on CAN 1. The signal is received by the central control ECU (ECU1) which then controls the spool valve solenoid pilot control valves via CAN 2.

AC3 - Front hitch spool controls Front hitch controls are connected to the auxiliary control ECU (ACE). The ECU processes the inputs from the controls and transmits a signal on CAN 1. The signal is received by the central control ECU (ECU1) which then controls the front hitch spool valve (6) solenoid pilot control valves via CAN 2. AC2 - Rear hitch spool controls Front hitch controls are connected to the auxiliary control ECU (ACE). The ECU processes the inputs from the controls and transmits a signal on CAN 1. The signal is received by the draft control ECU (EHR-Z) which then controls the hitch spool valve solenoid pilot control valves A1 and A2 via direct electrical connections. AC4 - Hitch spool parameter controls

The controls are connected to the auxiliary control ECU (ACE). When the hitch control operates the ECU adjusts the CAN signal depending on the parameter control setting.

C - Pressure transducer

The output from pressure transducer C is a function of the main hydraulic system pressure. ECU1 processes the output from the sensor to control spool kick out times and to ensure reliable pilot oil pressure.

E3-3

9803/9970-01 (E-06-00)

E3-3

Section E3 - Hydraulics Spool Valve SYSTEM Operation Overview D - Pilot pressure cut off solenoid valve

The pilot cut off valve is controlled by and output from ECU1. The ECU prevents spool operation by die-energising the solenoid valve D and isolating the pilot oil supply to the spools. The valve is de-energised when the transport switch is set to ON or if there is a hydraulic fault.

Configuration Spools 1,2, 3, 4 and 6 are digitally assigned by ECU1. If replacement spools or a new ECU 1 is installed the spools must be re-assigned before the system will function. K Configuration ( T E3-5)

Calibration The lever controls for the spools are electronically calibrated to record the neutral, full flow and detent positions. The hitch maximum and minimum parameter controls are also electronically calibrated. Do the calibration procedures if replacement controls are installed. K Calibration ( T E3-4)

E3-4

9803/9970-01 (E-06-00)

E3-4

Section E3 - Hydraulics Spool Valve SYSTEM Configuration

Configuration Spools controlled by ECU 1 must be configured. Until each spool slice is configured, the tractor cannot identify the 5 spool slices.

The Slice Configuration process is carried out on the instrument panel and the valve slices are each assigned a number (1 to 6) which is stored in the valve slice memory. Table 1. Slice Number Spool Slice Description 1

Green

Blue

Brown

Grey

Yellow (spool not fitted)

Front Hitch

MIRRORS L

C090110-C1

Fig 5.

Note: The rear hitch spool is controlled directly by the EHR Draft ECU. The rear hitch spool is NOT controlled by ECU 1. Note: The spools are not interchangeable with those fitted to earlier Fastrac models.

Accessing the Configuration Mode

Z W N R Important: Be aware that this process is time critical read all the following steps before commencing. 1

Ensure the transport lock T is not engaged, the green spool lever 1 is in its neutral position N, and the touch screen is powered `Off'.

Fig 6. 2

Switch the Ignition `On'.

As the first instrument panel buzzer has finished sounding, engage the transport lock T.

E3-5

9803/9970-01 (E-06-00)

E3-5

Section E3 - Hydraulics Spool Valve SYSTEM Configuration

Valve Slices Currently Configured Upon accessing Configuration Mode the spool valve slices which are connected and configured will be displayed on the instrument panel. Slices configured are identified by the prefix `H'. Some examples of valve slice configuration that may be seen on the instrument panel are as follows: C071760

Fig 10. Slices 1, 2, 3, 4 and 6 (front hitch) configured. Slice 5 either not fitted or not connected.

C071750

Fig 7. One or more slices connected but none yet configured. (‘0’ indicates Bosch state) C071730

Fig 11. Either: No slices connected, CAN2 wiring or supply fuse fault or non-compatible slice connected. Slices each need returning to Bosch state first using the following method:

Configuring `Bosch' Slices

C071740

Fig 8. All six slices connected and configured correctly.

The object of this procedure is to make sure that each valve slice is correctly identified to its proper position number on the Fastrac. K Table 1. ( T E3-5) When configured, each valve slice will store this identity even if it is unplugged. To wipe the slice memory it must be restored to Bosch state, K Returning Configured Slices to Bosch State ( T E3-8) As with earlier machines, only one new valve slice can be configured at a time.

C071800

Fig 9. A Bosch default slice is connected (‘0’) and can be configured as either slice 2 or 5. Slices have been connected and configured to positions 1, 3. 4 and 6.

Configuration is very quick. To avoid confusion it is best to work methodically through the configuration process and configure all valve slices.

Configuration Procedure In this procedure valve slices are connected one at a time, configured from their Bosch state and then disconnected again before proceeding.

E3-6

9803/9970-01 (E-06-00)

E3-6

Section E3 - Hydraulics Spool Valve SYSTEM Configuration Note: Having more than one unconfigured slice connected makes it possible to store several slices as the same number. 1

With all Valve Slices connected enter configuration the Configuration mode. K Accessing Mode ( T E3-5)

Disconnect all slices. K Fig 12. ( T E3-7)

b If H0 appears the slice is in default Bosch mode. K Fig 14. ( T E3-7)

C071750

Fig 14. Slowly cycle the green spool lever until the first dash ("-") is flashing. To assign and save the slice to position 1, press button C. K Fig 15. ( T E3-7) Note: Button C is located in one of two positions.

C096000

Fig 12. 3

Reconnect the green K Fig 12. ( T E3-7)

slice

number

1. C096040

The green slice is correctly assigned as slice 1 if H1 appears. K Fig 13. ( T E3-7) Proceed to step e.

Fig 15. The display will then show that the connected slice has been assigned to position 1. K Fig 16. ( T E3-7) Proceed to step e.

C071770

Fig 13. C071790

Fig 16.

E3-7

9803/9970-01 (E-06-00)

E3-7

Section E3 - Hydraulics Spool Valve SYSTEM Configuration c

If the green slice is assigned incorrectly to a different number (for example number 4) the following display will appear. K Fig 17. ( T E3-8)

only 5 slices (or fewer). If a 5th (yellow) spool is not fitted, position 5 will remain blank (-). To Exit Configuration

Cycle to the number 4 on the display by slowly moving the green spool lever. Press button C once to return the connected slice to a Bosch state. Then repeat step b.

Scroll down to ‘Save’, using the down arrow D.

U C071780

Fig 17.

d There is a fault if the display shows only dashes. K Fig 18. ( T E3-8)

Z C039350-B6

Fig 19. 2

Press button C. K Fig 15. ( T E3-7)

Returning Configured Slices to Bosch State Already configured slices will appear numbered on the menu list. C071730

Fig 18. Check the CAN2 wiring through the cab bulkhead connector to the spool valve for an open circuit, crossed wires or a terminating resistor fault. Check the supply and ground wiring to the spool valve connector. If the wiring is OK then it is likely the spool valve is not in Bosch mode – contact JCB Landpower. e

By returning them to Bosch state the selected slice memory is wiped and it can be reassigned to another position or machine. The following procedure should be used: 1

Slowly cycle the green spool lever to select the required slice. (There is no need to disconnect the slices.)

If a slice is connected and configured, pressing button C returns that slice to the default Bosch setting.

Green slice is now configured. Now disconnect the green slice and repeat the procedure to configure the other slices individually, starting with the blue spool.

Note: The front hitch must always be assigned to position 6 on the instrument panel even if the spool valve fitted has

E3-8

9803/9970-01 (E-06-00)

E3-8

Section E3 - Hydraulics Spool Valve SYSTEM Calibration - Auxiliary and Hitch Control Parameters

Calibration - Auxiliary and Hitch Control Parameters The spool controls must be calibrated to ensure correct spool operation. Do the calibration procedures if replacement controls are installed. Use JCB Service Master and the Fastrac ACE calibration tool. For more information about the calibration procedure refer to JCB Service Master.

F G

The calibration tool sets the following control parameters: Control

Z W N R

Parameter

Spool levers 1- 4 (1) N - Neutral position

W - Forward detent position Z - Forward maximum position R - Backward detent position V - Backward maximum position Front hitch drop rate control - A

Minimum position

Front hitch height control - B

Minimum position

Frint hitch depth control wheel - F

Maximum position

Rear hitch drop rate control - C

Minimum position

Rear hitch lift height control - E

Minimum position

Rear hitch mixture (draft control) - H

Minimum position

Rear hitch depth control wheel - G

Maximum position

Maximum position Maximum position

H C096050

Minimum position

Fig 20.

Maximum position Minimum position Maximum position Minimum position

(1) The spool flow rate and detent time parameters are set by the operator by use of the touch screen.

E3-9

9803/9970-01 (E-06-00)

E3-9

Section E3 - Hydraulics Spool Valve SYSTEM Fault Finding

Fault Finding The ECUâ&#x20AC;&#x2122;s controlling the spool valves log fault codes in the event of system faults. The codes are diplayed on the instrument panel and stored in the fault code log. Refer to Section C for fault code explanantions. Use the Service Master diagnostic tools and help information to identify system faults.

LED Blink Codes Each spool valve slice has an LED inside the electrical connector 1. When the ignition is ON and the valve is operating correctly the LEDs are ON constantly. If there is a fault the LED flashes to form a blink code. For an explanation of the codes refer to the Service Master help information.

C096080

Fig 21.

E3-10

9803/9970-01 (E-06-00)

E3-10

Section E3 - Hydraulics Spool Valve SYSTEM Removal and Replacement

Removal and Replacement TBA

E3-11

9803/9970-01 (E-06-00)

E3-11

Section E3 - Hydraulics Spool Valve SYSTEM Dismantle and Assemble

Dismantle and Assemble TBA

E3-12

9803/9970-01 (E-06-00)

E3-12

Section E3 - Hydraulics Spool Valve SYSTEM Dismantle and Assemble

Page left intentionally blank

E3-13

9803/9970-01 (E-06-00)

E3-13

Section E4 - Hydraulics

Variable Flow Pump Introduction

K Removal and Replacement ( T E4-2) K Dismantling and Assembly ( T E4-4) K Control Valve ( T E4-4) K Sealing the Driveshaft ( T E4-5) K Pump ( T E4-6)

E4-1

9803/9970-01 (E-11-00)

E4-1

Section E4 - Hydraulics Variable Flow Pump Removal and Replacement

Removal and Replacement

14 15

11 9 10

16 20 B 5

17 T

7 Fig 22.

Removal The numerical sequence shown on the illustration is intended as a guide to removal. Blank off all open ports and hoses to prevent excessive oil loss and entry of dirt.

If the values are low, renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, dismantle the pump for re-sealing only.

Replacement Reverse the removal sequence.

Gear Pump A (Suspension and Steering) Gear Pump A (Suspension and Steering) Before removing and dismantling the pump, check the flow and pressure for each section of the pump (see Section H, Steering and Section S, Suspension - Technical Data).

E4-2

Before fitting adapter 10, make sure the pump gear teeth are well oiled.

9803/9970-01 (E-11-00)

E4-2

Section E4 - Hydraulics Variable Flow Pump Removal and Replacement Torque Settings Item

kgf m

lbf ft

2.5

0.9

47.5

4.9

Piston Pump B (External Hydraulics) Important: If fitting a new pump or one that has been drained of oil, it is essential that the pump is filled with hydraulic oil via port T before starting the engine. Torque Settings Item

kgf m

lbf ft

133

13.6

8.2

200

20.4

148

E4-3

9803/9970-01 (E-11-00)

E4-3

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly

Dismantling and Assembly Control Valve

Dismantling and Assembly

Removal and Replacement

Note: Before dismantling, measure dimensions X and Y . K Fig 23. ( T E4-4)

and

record

If required, the control valve can be dismantled for cleaning and reassembled. K Fig 24. ( T E4-4)

Make sure that dimensions X and Y are as recorded.

G H J

Fig 23. 1

Remove caps E, measure and record dimensions X and Y.

Remove screws F and lift off control valve G.

Check `O' rings H and sealing surface J.

Fit the control valve using new seals. Make sure that dimensions X and Y are as recorded. Fig 24.

E4-4

9803/9970-01 (E-11-00)

E4-4

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly

Sealing the Driveshaft

C A B Fig 25. 1

Wrap tape around shaft A to protect the seal from damage. Remove circlip B and seal C.

B C D Fig 26. 2

Make sure that the shaft is not damaged. Grease the new seal C and insert it as far as washer D. Refit circlip B.

E4-5

9803/9970-01 (E-11-00)

E4-5

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly

Pump

4 5 6 8 9

17 19

11 12

15 18

3 2 1 20 22

Fig 27. K Dismantling ( T E4-7)

E4-6

9803/9970-01 (E-11-00)

E4-6

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly Dismantling

Inspection

Follow the numerical sequence K Fig 27. ( T E4-6).

14 15

Fig 28.

To allow removal of piston 14 and swash plate 15, turn swash plate slightly along axis Z K Fig 28. ( T E4-7).

Fig 29. Check for wear on surfaces indicated by the arrows K Fig 29. ( T E4-7)

E4-7

9803/9970-01 (E-11-00)

E4-7

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly

Fig 33. Make sure there are no grooves or signs of wear.

Fig 30. Check that the retaining plate is free from grooves and that there is no wear in the slipper pad area K Fig 30. ( T E4-8).

Fig 34. Check that cylinder sliding surface (arrowed) is free of grooves, wear and embedded foreign particles. Check that there are no scratches on the control plate D. Fig 31.

Check that there are no scratches or metal deposits on sliding surfaces A. Check that there is no end-play in direction of arrows.

Fig 35. Check that surface E is undamaged.

Fig 32. Check cylinder bores B and splines C.

E4-8

9803/9970-01 (E-11-00)

E4-8

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly Assembly

4 5 6 8 9

17 19

11 12

15 18

3 2 1 20 22

Fig 36. Reverse the dismantling sequence K Fig 36. ( T E4-9).

E4-9

9803/9970-01 (E-11-00)

E4-9

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly

14 Z

0 - 0,05 Fig 37. Taper bearings must have a preload of 0 - 0.05 mm, measured at the housing joint face K Fig 37. ( T E4-10). If necessary, grind the shim washer 9 to achieve correct preload. Renew all seals.

Fig 38. Before fitting swash plate 15 and piston 14, hold bearings 16 and spring 17 in position with grease. Make sure that swash plate locates correctly on spring and piston. Apply JCB Threadlocker and Sealer to plug 11 and tighten to 320 Nm (236 lbf ft).

E4-10

9803/9970-01 (E-11-00)

E4-10

Section E4 - Hydraulics Variable Flow Pump Dismantling and Assembly

Fig 39. When inserting the cylinder and pistons assembly 10, use an `O' ring as shown to keep the pistons in position K Fig 39. ( T E4-11). When fitting the end plate 5, make sure index marks are aligned on end plate and housing. Tighten capscrews 4 to 310 Nm (230 lbf ft).

E4-11

9803/9970-01 (E-11-00)

E4-11

Section E4 - Hydraulics Variable Flow Pump Gear Pump (Suspension and Steering)

Gear Pump (Suspension and Steering)

Fig 40.

E4-12

9803/9970-01 (E-11-00)

E4-12

Section E4 - Hydraulics Variable Flow Pump Gear Pump (Suspension and Steering)

Dismantling and Assembly

is permissible. If the wear is greater than 0.3mm (0.01 in), renew the pump.

The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 40. ( T E4-12). Before removing and dismantling the pump, check the flow and pressure for each section of the pump (see Section H, Steering and Section S, Suspension - Technical Data). If the values are low, renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, dismantle the pump for re-sealing only. Note: If the steering flow rate is low, make sure that there is no dirt in the end cover 12 and that the spool 10 moves freely. The size of washer 9 controls the steering flow rate (see Technical Information Bulletin 10/183).

The bores and side faces of the bearing blocks and gears are coated with Teflon during manufacture. If the coating is worn away, or if the bearing surfaces are scored or damaged the pump must be renewed. If the faces of the gear teeth are damaged the pump must be renewed. DO NOT use any abrasives on the bearing blocks or gears as this would destroy critical manufacturing dimensions It is only worth reassembling (with new seals) if the body, bearings, bushes and gears are in perfect condition.

When Assembling Renew all seals and `O' rings. Pack between lips of the shaft seals with grease. Protect the lips of the shaft seals from damage using a tapered sleeve, or, alternatively, by wrapping tape around the shaft splines whilst they are passing through the seal.

For assembly the sequence should be reversed.

When Dismantling Mark housings and covers to ensure correct re-assembly. Remove sharp edges and burrs from shafts to avoid seal damage.

Note the correct orientation of bearing blocks and use of dowels.

Remove all the seals.

Note the location of dowels 21 (2 off), 32 (2 off) and 37 (2 off).

Keep bearing blocks 25, 27, 38, 40 and gears 26 and 39 together in sets to ensure refitting of the bearing blocks in their original positions.

Ensure that the ends of seals 14, 23, 34 and 41 and backup rings 15, 24, 35 and 42 do not overhang the bearing blocks to become trapped in the housings.

Inspection

Torque Settings

Clean all the components using a proprietary washing agent (do not use trichloroethylene or similar as this will damage the seals). Dry the components immediately afterwards with compressed air. Be sure to blow out the ports and cross drillings in the end cover 12. Inspect the flow control valve spool 10 for signs of wear or damage. Inspect the spool bore in end cover 12. Make sure the flow control components 1 to 10 are free from dirt.

Item

kgf m

lbf ft

7.6

47-55

4.8-5.6

35-41

12-16

1.2-1.6

9-12

12-16

1.2-1.6

9-12

E4-13

9803/9970-01 (E-11-00)

E4-13

Section E4 - Hydraulics Variable Flow Pump Gear Pump (Suspension and Steering)

Page left intentionally blank

E4-14

9803/9970-01 (E-11-00)

E4-14

Section E5 - Hydraulics

Gear Pump (Suspension and Steering) Introduction

K Removal and Replacement ( T E5-2) K Dismantling and Assembly ( T E5-4)

E5-1

9803/9970-01 (E-11-00)

E5-1

Section E5 - Hydraulics Gear Pump (Suspension and Steering) Removal and Replacement

Removal and Replacement

14 15

11 9 10

16 20 B 5

17 T

7 Fig 41.

Removal The numerical sequence shown on the illustration is intended as a guide to removal. Blank off all open ports and hoses to prevent excessive oil loss and entry of dirt.

Replacement Reverse the removal sequence.

E5-2

Before fitting adapter 10, make sure the pump gear teeth are well oiled.

9803/9970-01 (E-11-00)

E5-2

Section E5 - Hydraulics Gear Pump (Suspension and Steering) Removal and Replacement Torque Settings Item

kgf m

lbf ft

2.5

0.9

47.5

4.9

kgf m

lbf ft

133

13.6

8.2

200

20.4

148

E5-3

9803/9970-01 (E-11-00)

E5-3

Section E5 - Hydraulics Gear Pump (Suspension and Steering) Dismantling and Assembly

Dismantling and Assembly

Fig 42. The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 42. ( T E5-4).

E5-4

Before removing and dismantling the pump, check the flow and pressure for each section of the pump (see Section H, Steering and Section S, Suspension - Technical Data).

9803/9970-01 (E-11-00)

E5-4

Section E5 - Hydraulics Gear Pump (Suspension and Steering) Dismantling and Assembly If the values are low, renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, dismantle the pump for re-sealing only. Note: If the steering flow rate is low, make sure that there is no dirt in the end cover 12 and that the spool 10 moves freely. The size of washer 9 controls the steering flow rate (see Technical Information Bulletin 10/183). For assembly the sequence should be reversed.

DO NOT use any abrasives on the bearing blocks or gears as this would destroy critical manufacturing dimensions It is only worth reassembling (with new seals) if the body, bearings, bushes and gears are in perfect condition.

When Dismantling Mark housings and covers to ensure correct re-assembly. Remove sharp edges and burrs from shafts to avoid seal damage.

Note the correct orientation of bearing blocks and use of dowels.

Remove all the seals.

Note the location of dowels 21 (2 off), 32 (2 off) and 37 (2 off).

Keep bearing blocks 25, 27, 38, 40 and gears 26 and 39 together in sets to ensure refitting of the bearing blocks in their original positions.

Ensure that the ends of seals 14, 23, 34 and 41 and backup rings 15, 24, 35 and 42 do not overhang the bearing blocks to become trapped in the housings.

Inspection

Torque Settings

Item

kgf m

lbf ft

7.6

47-55

4.8-5.6

35-41

12-16

1.2-1.6

9-12

12-16

1.2-1.6

9-12

Inspect all components for damage or signs of wear. It is normal for the gears to have cut a slight track in the body bore on the inlet (large port) side. A groove up to 0.3mm (0.01 in) deep across the full width of the gear teeth is permissible. If the wear is greater than 0.3mm (0.01 in), renew the pump. The bores and side faces of the bearing blocks and gears are coated with Teflon during manufacture. If the coating is worn away, or if the bearing surfaces are scored or damaged the pump must be renewed. If the faces of the gear teeth are damaged the pump must be renewed.

E5-5

9803/9970-01 (E-11-00)

E5-5

Section E5 - Hydraulics Gear Pump (Suspension and Steering) Dismantling and Assembly

Page left intentionally blank

E5-6

9803/9970-01 (E-11-00)

E5-6

Section E6 - Hydraulics

Rear Hitch Ram Introduction

K Removal and Replacement ( T E6-2) K Dismantling and Assembly ( T E6-3) K Testing ( T E6-5)

E6-1

9803/9970-01 (E-20-00)

E6-1

Section E6 - Hydraulics Rear Hitch Ram Removal and Replacement

Removal and Replacement Note: The procedure given is for the right hand ram. The procedure for the left hand ram is similar.

Removal 1

Ensure that lift rams are fully closed as pressure cannot be vented by operating controls with engine stopped.

Support the weight of the lift arm on the same side as the ram to be removed.

Disconnect and blank the hydraulic connections A and B.

Remove bolt C and keep plate D and drive out pin E.

Support the ram, remove bolt F and keep plate G and extract pin H, using a slide hammer and a suitable M12 bolt in the threaded hole in the end of pin H.

Replacement Reverse the removal procedure. Make sure that flats on pins E and H are aligned with the flats on the keep plates D and G. Fig 43.

E6-2

9803/9970-01 (E-20-00)

E6-2

Section E6 - Hydraulics Rear Hitch Ram Dismantling and Assembly

Dismantling and Assembly

Fig 44.

E6-3

9803/9970-01 (E-20-00)

E6-3

Section E6 - Hydraulics Rear Hitch Ram Dismantling and Assembly

Dismantling K Fig 44. ( T E6-3) Heat the threaded area of end cap A to a minimum of 300째C (570째F) to release the locking sealant and unscrew the end cap using a suitable peg spanner located in holes B. Withdraw the piston rod C from the cylinder D complete with all of the internal parts. Heat the threaded area of piston head E to a minimum of 300째C (570째F) to release the locking sealant and unscrew the piston head using a suitable peg spanner. Removal of the piston head will allow end cap A to slide off the piston rod.

Fig 45. 2

Close the tool. K Fig 46. ( T E6-4) The seal must form a reniform (kidney shape).

Remove and discard the sealing components F to M. Take extreme care not to damage the cylinder bore or the grooves in the end cap A and piston head E.

Assembly Before assembling, check the components for damage and wear, especially the cylinder bore. Renew the complete assembly if necessary.

Fig 46. 3

Renew all items in the seal kit. Lightly oil the seals with JCB Hydraulic Fluid. Fit wiper seals F and G as described below. K Wiper Seal Fitting Procedure ( T E6-4) Apply JCB Retainer (High Strength) to the threads of end cap A and piston head E. Tighten both to the specified torque setting.

Locate the seal in the end cap groove. When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool.

Torque Settings

Item

kgf m

lbf ft

400

295

550

405

Wiper Seal Fitting Procedure The size (diameter) and position of pins P is determined by the diameter and radial width of the wiper seal being fitted. The pins are screwed into threaded holes in the tool body. The spacing of the holes is designed to suit small or large diameter wiper seals. 1

Open the tool. K Fig 45. ( T E6-4) Insert the new wiper seal. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

E6-4

9803/9970-01 (E-20-00)

E6-4

Section E6 - Hydraulics Rear Hitch Ram Testing

Testing Using a hydraulic hand pump (see Service Tools), check for smooth operation of the ram. With the ram extended, pressurise to 250 bar (3625 lbf/in2) and check for leakage. No leakage is permitted.

E6-5

9803/9970-01 (E-20-00)

E6-5

Section E6 - Hydraulics Rear Hitch Ram Testing

Page left intentionally blank

E6-6

9803/9970-01 (E-20-00)

E6-6

Section E7 - Hydraulics

Front Hitch Ram Introduction

K Removal and Replacement ( T E7-2) K Dismantling and Assembly ( T E7-3) K Testing ( T E7-5)

E7-1

9803/9970-01 (E-20-00)

E7-1

Section E7 - Hydraulics Front Hitch Ram Removal and Replacement

Removal and Replacement TBA

E7-2

9803/9970-01 (E-20-00)

E7-2

Section E7 - Hydraulics Front Hitch Ram Dismantling and Assembly

Dismantling and Assembly

Fig 47.

E7-3

9803/9970-01 (E-20-00)

E7-3

Section E7 - Hydraulics Front Hitch Ram Dismantling and Assembly

Dismantling

Torque Settings

K Fig 47. ( T E7-3)

Assembly Wiper Seal Fitting Procedure

Item

kgf m

lbf ft

400

295

550

405

The size (diameter) and position of pins P is determined by the diameter and radial width of the wiper seal being fitted. The pins are screwed into threaded holes in the tool body. The spacing of the holes is designed to suit small or large diameter wiper seals. 1

Open the tool. K Fig 48. ( T E7-4) Insert the new wiper seal. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

Fig 48. 2

Close the tool. K Fig 49. ( T E7-4) The seal must form a reniform (kidney shape).

Fig 49. 3

Locate the seal in the end cap groove. When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool.

E7-4

9803/9970-01 (E-20-00)

E7-4

Section E7 - Hydraulics Front Hitch Ram Testing

E7-5

9803/9970-01 (E-20-00)

E7-5

Section E7 - Hydraulics Front Hitch Ram Testing

Page left intentionally blank

E7-6

9803/9970-01 (E-20-00)

E7-6

Section F Transmission Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section F - Transmission

Notes:

F-0

9803/9970-01

F-0

Section F - i Contents

Contents Page No. 6 x 4 Smoothshift Transmission SYSTEM Introduction .............................................................................................. F1-1 Technical Data ......................................................................................... F1-3 Flow Rate and Pressures ....................................................................F1-3 Transmission Technical Data Checklist ...............................................F1-4 Component Identification ......................................................................... F1-6 External Components ..........................................................................F1-6 Internal Components ...........................................................................F1-8 Hydraulic Circuit .................................................................................... F1-10 Electrical and Electronic Network .......................................................... F1-13 Ratio and Drive Control ......................................................................... F1-14 Joystick Controller .............................................................................F1-14 Column Switch ..................................................................................F1-14 Touch Screen Control ........................................................................F1-15 Calibration .........................................................................................F1-16 Master Clutch Control ............................................................................ F1-17 Clutch Pedal Position Sensor ............................................................F1-17 PTO Control ........................................................................................... F1-18 Speed Change Lever Control ............................................................F1-18 Drive Paths ............................................................................................ F1-19 Solenoid Identification .......................................................................F1-19 Clutch Packs - Identification ..............................................................F1-20 Forward/First + High Range ..............................................................F1-22 Forward/Second + Medium Range ....................................................F1-24 Forward/Third + Low Range ..............................................................F1-26 Forward/Fourth + Extra Low Range ..................................................F1-28 Forward/Fifth + Low Range ...............................................................F1-30 Forward/Sixth - Medium Range .........................................................F1-32 Reverse/First - High Range ...............................................................F1-34 Fault Finding .......................................................................................... F1-36 Complete Transmission .....................................................................F1-36 Wet Master Clutch .............................................................................F1-37 Power Take Off Clutches ...................................................................F1-39 4/2 Wheel Drive .................................................................................F1-40 Test Procedures ..................................................................................... F1-41 Gearbox Pressure Test Procedure ....................................................F1-42 6 x 4 Smoothshift Gearbox Introduction .............................................................................................. F2-1 Charge Pump .......................................................................................... F2-2 Removal ..............................................................................................F2-2 Replacement .......................................................................................F2-2 Dismantling ..........................................................................................F2-3 Control Valve ........................................................................................... F2-4 Removal ..............................................................................................F2-4 Replacement .......................................................................................F2-4 P.T.O. Position Sensors ........................................................................... F2-5 Removal ..............................................................................................F2-5 Replacement .......................................................................................F2-6 Dismantling and Assembly ..................................................................F2-7 Gearbox ................................................................................................... F2-9 Removal ..............................................................................................F2-9 Replacement .....................................................................................F2-11 Dismantling and Assembly ................................................................F2-11

F-i

Section F - i Contents

Contents Page No. Front Axle Introduction .............................................................................................. F3-1 Removal and Replacement - Differential Oil Seal ................................... F3-2 Removal and Replacement ..................................................................... F3-4 Removal ..............................................................................................F3-5 Replacement .......................................................................................F3-6 Dismantling and Assembly - Hub and Drive Shaft ................................... F3-7 Dismantling ..........................................................................................F3-8 Assembly ...........................................................................................F3-10 Removal and Replacement - Drive Head .............................................. F3-14 Removal ............................................................................................F3-14 Replacement .....................................................................................F3-15 Dismantling and Assembly - Drive Head ............................................... F3-16 Dismantling ........................................................................................F3-17 Assembly ...........................................................................................F3-17 Pinion Depth ......................................................................................F3-19 Solid Spacer Installation ....................................................................F3-20 Crown Wheel and Pinion Adjustment ................................................F3-22 Dismantling and Assembly - Differential ................................................ F3-23 Dismantling ........................................................................................F3-24 Assembly ...........................................................................................F3-24 Rear Axle Introduction .............................................................................................. F4-1 Removal and Replacement - Differential Oil Seal ................................... F4-2 Dismantling and Assembly - Rear PTO Drive Shaft ................................ F4-4 When Dismantling ...............................................................................F4-5 Assembly .............................................................................................F4-5 Installation - Rear PTO Output Shaft ....................................................... F4-6 General ................................................................................................F4-6 Fitting ...................................................................................................F4-6 Removal and Replacement ..................................................................... F4-7 Removal ..............................................................................................F4-8 Replacement .......................................................................................F4-9 Dismantling and Assembly - Hub and Drive Shaft ................................. F4-10 Dismantling ........................................................................................F4-11 Assembly ...........................................................................................F4-11 Removal and Replacement - Drive Head .............................................. F4-13 Removal ............................................................................................F4-14 Replacement .....................................................................................F4-14 Dismantling and Assembly - Drive Head ............................................... F4-15 Dismantling ........................................................................................F4-16 Assembly ...........................................................................................F4-17 Pinion Depth ......................................................................................F4-19 Solid Spacer Installation ....................................................................F4-20 Crown Wheel and Pinion Adjustment ................................................F4-22 Dismantling and Assembly - Differential ................................................ F4-23 Dismantling ........................................................................................F4-24 Assembly ...........................................................................................F4-24 Propshafts Introduction .............................................................................................. F5-1 Removal and Replacement ..................................................................... F5-2 Removal ..............................................................................................F5-2 Replacement .......................................................................................F5-4

F-ii

Section F - i Contents

Contents

F-iii

Page No.

F-iii

Section F1 - Transmission

6 x 4 Smoothshift Transmission 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.. Descriptions and procedures relate to the system and not the individual devices. 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.

K Technical Data ( T F1-3) K Flow Rate and Pressures ( T F1-3) K Transmission Technical Data Checklist ( T F1-4) K Component Identification ( T F1-6) K External Components ( T F1-6) K Internal Components ( T F1-8) K Hydraulic Circuit ( T F1-10) K Electrical and Electronic Network ( T F1-13) K Ratio and Drive Control ( T F1-14) K Joystick Controller ( T F1-14) K Column Switch ( T F1-14) K Touch Screen Control ( T F1-15) K Calibration ( T F1-16) K Master Clutch Control ( T F1-17) K Clutch Pedal Position Sensor ( T F1-17) K PTO Control ( T F1-18) K Speed Change Lever Control ( T F1-18) K Drive Paths ( T F1-19) K Solenoid Identification ( T F1-19) K Clutch Packs - Identification ( T F1-20) K Forward/First + High Range ( T F1-22) K Forward/Second + Medium Range ( T F1-24) K Forward/Third + Low Range ( T F1-26) K Forward/Fourth + Extra Low Range ( T F1-28) K Forward/Fifth + Low Range ( T F1-30) K Forward/Sixth - Medium Range ( T F1-32) K Reverse/First - High Range ( T F1-34)

F1-1

9803/9970-01 (F-05-00)

F1-1

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Introduction K Fault Finding ( T F1-36) K Complete Transmission ( T F1-36) K Wet Master Clutch ( T F1-37) K Power Take Off Clutches ( T F1-39) K 4/2 Wheel Drive ( T F1-40) K Test Procedures ( T F1-41) K Gearbox Pressure Test Procedure ( T F1-42)

F1-2

9803/9970-01 (F-05-00)

F1-2

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Technical Data

Technical Data Flow Rate and Pressures Note: The following figures are measured with the transmission oil at operating temperature. Transmission Charge Pump Litres/min Maximum flow rate @ 2200 engine rev/min

67 - 71

UK Gal/min

US Gal/min

14.7 - 15.6

17.7 - 18.8

Transmission Pressures

Engine rev/min

bar

lbf/in2

Main Line Pressure

800

12.4 - 13.8

180- 200

1600

13.1 - 14.5

190 - 210

2200

13.1 - 14.5

190 - 210

800

0 - 0.1

0 - 1.5

2200

1-2

14.5 - 2.9

800

2.7

2200

145

Wet Master Clutch Operating Pressure

800

Mainline less 0.7

Mainline less 10

Clutch A Operating Pressure

1600

Mainline less 0.7

Mainline less 10

Clutch B Operating Pressure

1600

Mainline less 0.7

Mainline less 10

Clutch C Operating Pressure

1600

Mainline less 0.7

Mainline less 10

Clutch D Operating Pressure

1600

Mainline less 0.7

Mainline less 10

Clutch E Operating Pressure

1600

Mainline less 0.7

Mainline less 10

Clutch R Operating Pressure

1600

Mainline less 0.7

Mainline less 10

High Range Selector Operating Pressure

800

Mainline less 0.5

Mainline less 7

Medium Range Selector Operating Pressure

800

Mainline less 0.5

Mainline less 7

Low Range Selector Operating Pressure

800

Mainline less 0.5

Mainline less 7

Extra Low Range Selector Operating Pressure

800

Mainline less 0.5

Mainline less 7

Four Wheel Drive Disconnect Operating Pressure

1600

Mainline less 0.5

Mainline less 7

Front Power Take Off Brake Release Operating Pressure

800

Mainline less 0.5

Mainline less 7

Rear Power Take Off Brake Release Operating Pressure

800

Mainline less 0.5

Mainline less 7

Lubrication Pressure Wet Clutch High Pressure Lubrication

Front Power Take Off Clutch Operating Pressure

1600

Mainline less 0.5

Mainline less 7

Rear Power Take Off Clutch Operating Pressure

1600

Mainline less 0.5

Mainline less 7

Transmission Brake Operating Pressure

800

Mainline less 0.5

Mainline less 7

360

Differential Lock Operating Pressure

F1-3

9803/9970-01 (F-05-00)

F1-3

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Technical Data

Transmission Technical Data Checklist Reference Data The following Technical Data Checklist introduced by JCB Transmissions is available from the Technical Service Team and should be saved to the computer hard drive. It can then used in conjunction with the fault finding and Technical Data published in this Service Manual. If necessary this form may also be copied from the manual and completed by the engineer. Correct completion of the checklist will assist the engineer in diagnosing gearbox/transmission abnormalities. Completed Checklists may then be saved as required and if necessary forwarded to the Technical Service Team for further assistance via email or preferably a Techweb call. Important: In the event of a complete transmission replacement under warranty (due to performance related issues), the dealer is expected to supply a completed copy of the checklist. This will be used to support the claim and assist fault finding on the returned unit. Important: For safety the procedures detailed in the Service Manual MUST be followed.

F1-4

9803/9970-01 (F-05-00)

F1-4

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Technical Data Transmission Technical Data Checklist Company

Contact Name

Transmission Serial Number

Email Address/Tel. Number

Machine Make/Model

Installation Date

Machine Serial Number

Machine Hours

Oil Used

Oil Sample 1. Pressures at 500C

Wet Clutch In

Test Point 3

Wet Clutch Lubrication

Test Point 14

Mainline

Test Point 1

Lubrication

Test Point 2

High Range

Test Point 8

Medium Range

Test Point 9

Low Range

Test Point 10

Extra Low Range

Test Point 11

Clutch A

Test Point 15

Clutch B

Test Point 4

Clutch C

Test Point 6

Clutch D

Test Point 5

Clutch E

Test Point 7

Clutch R

Test Point 17

4 WD Disconnect

Test Point 12

Front PTO Brake Release

Test Point 16

Rear PTO Brake Release

Test Point 18

Front PTO Clutch

Test Point 19

Rear PTO Clutch

Test Point 21

Trans Brake Release

Test Point 20

2. Transmission Flow Testing at 500C

Yes ..................No...............

1000 Rev/min

l/min in Neutral at 1000 Rev/min

2000 Rev/min

Gal/min in Neutral at 2000 Rev/min

Measured at pump outlet 3. Summary of Symptoms / Fault / Previous History

Signature

F1-5

Date

9803/9970-01 (F-05-00)

F1-5

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Component Identification

Component Identification External Components K Fig 1. ( T F1-7) 1

Wet clutch casing

Rear casing

Intermediate casing

Front casing

Range box casings

Front P.T.O. assembly

Rear P.T.O. assembly

Park brake disc and rear axle driveshaft coupling

Charge pump

Solenoid control valve block

P.T.O. ratio position sensor

Front axle driveshaft coupling

Speed sensors

Range box selector position sensors

Range box selector solenoid control valves

Pump drive interface

F1-6

9803/9970-01 (F-05-00)

F1-6

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Component Identification

15 15 15

14 14

12 3

4 5

8 6 2 7

3 C090310

Fig 1. External Components

F1-7

9803/9970-01 (F-05-00)

F1-7

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Component Identification

Internal Components Note: The component locations shown are different to actual locations in the gearbox. The illustrations identify the main components and their locations relative to the different gearbox casings. It is not possible to show actual component positions within each casing. For example; We can see that components C,E and D are located in the rear casing 4. The actual relative positions of C,E and D inside the casing is not shown. K Fig 2. ( T F1-9) 1

Wet clutch casing

Rear casing

Intermediate casing

Front casing

Range box casings

Wet clutch assembly

P.T.O. input shaft (engine driven)

Centre bearing shaft

Mainshaft

Range box mainshaft

Range box output shaft

P.T.O. idler shaft

P.T.O. ration selector shaft

Rear P.T.O. clutch

P.T.O. intermediate gear shaft

P.T.O. selector rail and fork

Pump drive shaft

Transmission brake assembly

Wet clutch driven gear

Idler shaft and gear

Ratio clutch pack A

Ratio clutch pack B

Ratio clutch pack C

Ratio clutch pack D

Ratio clutch pack E

Reverse clutch pack R

Four wheel drive de-selector clutch pack

F1-8

9803/9970-01 (F-05-00)

F1-8

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Component Identification

1 20

3 S 5

39 6

14 15 16

17 18

19 15 14 6

C090320

Fig 2. Internal Components

F1-9

9803/9970-01 (F-05-00)

F1-9

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Hydraulic Circuit

Hydraulic Circuit This JCB Smoothshift full power shifting transmission is made up of three distinct assemblies. 1

Wet Clutch Assembly

Smoothshift Gearbox Assembly, incorporating Splitter Box and independent drive to Front and Rear Power Take Off drives.

Range Box Assembly

All three assemblies are hydraulically supplied by charge pump 4 via suction strainer 5 located in the sump of the transmission assembly. Pump 4 is driven by the engine via an idler gear meshing with the gearbox main input shaft. This crescent gear type pump delivers oil to selector valve 6. A cold start by-pass valve 7 is located in the body of the pump and whilst the oil is cold, vents excess pressure back to pump suction line to protect mainline components, such as air blast oil cooler 8, from over pressurisation on initial start-up. Pump delivery flows via external hoses and pipework first to oil cooler 8 which maintains a temperature of 50 deg C over ambient. From the cooler, pump flow enters pressure filter 9 which cleans all oil flow. The filter has a safety bypass valve to ensure pump flow is still available at the transmission even if the filter element becomes blocked. There are two sensors fitted in this area. Temperature sensor 30 monitors oil temperature exiting the cooler. Pressure sensor 31 monitors pressure of the oil leaving the filter. A significant pressure drop here would indicate a blocked filter. Cooled and filtered pump delivery enters control valve 6 where pressure sensor 32 checks available pressure for system lubrication purposes. The lubrication circuit is teeâ&#x20AC;&#x2122;d off main pump flow through check valve supplying wet clutch 1 via solenoid 12 and the remaining clutch packs via various spray bars in the transmission casing. Downstream of sensor 32 is the pressure maintenance sequencing valve 10, this valve is held open by spring force, ensuring a positive oil supply to wet clutch 1 and to the lubrication circuit. As pump supply pressure rises, it is sensed through filtered pilot line controlling sequence valve 10, overcomes spring force and closes the valve. This pressure fills

F1-10

central gallery of selector valve 6 so that it is available to all ratio and direction solenoid valves. Simultaneously supplying solenoids controlling gearbox speed ranges and four wheel drive de-selection in the range box 3. Pressurised flow to control valve is teeâ&#x20AC;&#x2122;d off to fill the pressure accumulator 11. This ensures that there is a sufficient pressurised volume of oil to immediately fill clutch packs as they are selected. The selection of the clutch packs in Smoothshift gearbox 2 are progressively damped by the proportional operation of solenoids 13, 14, 15, 16, 17, 18, 19, 22 and 23. The remaining solenoids, operating transmission input brake L and Front and Rear Power Take Off Brakes G and H and range box remotely mounted solenoids 25, 26, 27, and 28 are direct acting types. Item

Component

Transmission Pump

Suction Strainer

Selector Valve

By-pass Valve

Oil Cooler

Oil Filter

Pressure Maintenance Sequencing Valve

Pressure Accumulator

Wet Master Clutch Lubrication Solenoid

Clutch A Solenoid

Clutch B Solenoid

Clutch C Solenoid

Clutch D Solenoid

Clutch E Solenoid

Reverse Clutch Solenoid

Wet Master Clutch Solenoid

Front Power Take Off Brake Solenoid

Rear Power Take Off Brake Solenoid

Front Power Take Off Solenoid

Rear Power Take Off Solenoid

Transmission Input Brake Solenoid

Extra Low Range Solenoid

9803/9970-01 (F-05-00)

F1-10

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Hydraulic Circuit Item

Forward

Component

Low Range Solenoid

Medium Range Solenoid

Reverse

Ratio

Clutches Selected

Ratio

Clutches Selected

High Range Solenoid

3rd

A and D

3rd

R and E

Four Wheel Drive Clutch Solenoid

4th

B and D

Temperature Sensor

5th

A and E

Filter Condition Sensor

6th

B and E

Low Pressure Lubrication Warning Sensor

Pump Delivery Pressure Sensor

PTO Ratio Sensor

Medium/High Range Sensor

Low/Extra Low Range Sensor

Item

Transmission Clutches/Brakes

Clutch A

Clutch B

Clutch C

Clutch D

Clutch E

Reverse Clutch

Wet Master Clutch

Front Power Take Off Brake

Rear Power Take Off Brake

Front Power Take Off Clutch

Rear Power Take Off Clutch

Transmission Input Brake

Extra Low Range Selector Rail Piston

Low Range Selector Rail Piston

Medium Range Selector Rail Piston

High Range Selector Rail Piston

Four Wheel Drive Clutch

The Smoothshift transmission ratios are achieved by the following clutch pack selection combinations. Forward

Reverse

Ratio

Clutches Selected

Ratio

Clutches Selected

1st

A and C

1st

R and C

2nd

B and C

2nd

R and D

F1-11

9803/9970-01 (F-05-00)

F1-11

F1-12

Section F1 - Transmission

C059000

Fig 3.

F1-12

Hydraulic Circuit

6 x 4 Smoothshift Transmission SYSTEM

6 23

9803/9970-01 (F-05-00)

29 13

33 18

25 7

S 5 L

36 N 4

35 3 A 19

D 15

M F

Q R 1 16 14

28 27 C B J 17 10

K 30 9 12

31 32

H G 8

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Electrical and Electronic Network

Electrical and Electronic Network TBA

F1-13

9803/9970-01 (F-05-00)

F1-13

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Ratio and Drive Control

Ratio and Drive Control Joystick Controller

Removal and Replacement The joystick is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty. Removal 1

Park the machine and make it safe. Disconnect the batteries.

Pull up the bottom of gaiter 1.

Undo four screws 2.

Lift out the joystick and uncouple its electrical connectors.

Replacement Replacement is the opposite of the removal procedure. After installation of a new joystick controller do the following: C096130

Fig 4. The joystick contoller moves in two axis and controls the transmission drive mode and gear selection. The buttons on the joystick are programmable. K Touch Screen Control ( T F1-15)

â&#x20AC;&#x201C; Calibrate the movement of the joystick. Use the touch screen, (see Section C - Electronic Network SYSTEM).

Column Switch TBA

F1-14

9803/9970-01 (F-05-00)

F1-14

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Ratio and Drive Control

Touch Screen Control

N A CB

A C039840-B1

Fig 6. C071210-B4

Fig 5. The touch screen (DECU) enables the operator to select a transmission drive mode (see the Operator Handbook).

F1-15

The touch screen also enables programing of the joystick buttons for operation of transmission modes (see the Operator Handbook).

9803/9970-01 (F-05-00)

F1-15

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Ratio and Drive Control

Calibration The transmission electronic control system calibration ensures correct operation of drive and ratio selection. Calibration is necessary after replacement of any of the following transmission related items: – Transmission ECU – Wiring – Control valves – Position sensors – Speed sensors Use the touch screen to do the calibration procedure, (see Section C - Electronics Network SYSTEM).

F1-16

9803/9970-01 (F-05-00)

F1-16

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Master Clutch Control

Master Clutch Control Clutch Pedal Position Sensor

C056110-C1

Fig 7.

C097000

Fig 8.

Proportional solenoid control valve 2 controls the position of the master clutch depending on the position of the clutch pedal. The solenoid valve is located in the gearbox solenoid control valve block 1.

F1-17

The transmission ECU gets an input from clutch pedal position potentiometer A. The transmission must be calibrated after installation or adjustment of the sensor A. Use the touch screen, (see Section C - Electronics Network SYSTEM).

9803/9970-01 (F-05-00)

F1-17

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM PTO Control

PTO Control The gearbox front and rear power take off clutches are engaged electrically by switches in the cab and on the outside of the machine.

The switches 3 and 4 must be calibrated after installation or adjustment of control cable 5. Use the touch screen, (see Section C - Electronics Network SYSTEM).

Speed Change Lever Control

2 3

4 5

C096990

Fig 9. The speed control lever 1 moves to enable selection of N (no PTO drive), high or low speed. When the lever moves to select high speed metal lever arm 2 moves between the faces of switch 3. When the lever moves to select low speed the lever arm moves between the faces of switch 4. In this way the machine electrical system detects when the PTO is set to neutral, low or high speed. Control cable 5 connects to lever arm 2 and engages the gearbox PTO gears via interface 6.

F1-18

9803/9970-01 (F-05-00)

F1-18

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Drive Paths Solenoid Identification

The annotations identifying the selector solenoids are the same as detailed on the Transmission Hydraulic Circuit Description as follows. Solenoid

Solenoid Description

Clutch A Solenoid

Clutch B Solenoid

Clutch C Solenoid

Clutch D Solenoid

Clutch E Solenoid

Reverse Clutch Solenoid

Wet Master Clutch Solenoid

Front P.T.O. Brake Solenoid

Rear P.T.O. Brake Solenoid

Front P.T.O. Solenoid

Rear P.T.O. Solenoid

Transmission Brake Solenoid

17 16

19 15

20 21

The Smoothshift transmission ratios are achieved by the following solenoid selection combinations. C056110

Fig 10. Forward

Reverse

Ratio

Solenoids Selected

Ratio

Solenoids Selected

1st

13 and 15

1st

18 and 15

2nd

14 and 15

2nd

18 and 16

3rd

13 and 16

3rd

18 and 17

4th

14 and 16

5th

13 and 17

6th

14 and 17

Note: If selector valves 13 to 24 are renewed then a full recalibration must be performed on transmission.

F1-19

9803/9970-01 (F-05-00)

F1-19

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Clutch Packs - Identification The following illustrations showing clutch pack identification and range/ratio power flows have the shafts illustrated to easily show respective gear constant mesh trains. In reality the shafts are not arranged vertically above one another, consequently it is necessary to show idler shaft 39 engaging with input shaft gear 37 illustrated in two positions. Power Take Off selector shaft and clutch drums have been omitted for clarity.

Ratio Clutch Pack B

Ratio Clutch Pack C

Ratio Clutch Pack D

Ratio Clutch Pack E

Reverse Clutch Pack R

Four Wheel Drive De-selector Clutch Pack

37 38

40 39

43 C057310

Fig 11. The illustration shows a more accurate shaft orientation viewed from the front Wet Clutch end of the transmission, as can be seen shaft 38 driven by the wet clutch assembly has clutch pack gear 37 splined to it. Gear 37 is in constant mesh with idler shaft 39 which in turn is in constant mesh with gear 43, and gear 56. This splits the drive between shafts 40 and 47 of the Smoothshift gearbox.K Fig 11. ( T F1-20) 37

Input Shaft Gear

Clutch R support shaft

Idler Shaft

Clutch A support shaft

Free to spin Clutch A drive gear

Clutch B/C support shaft

Free to spin Clutch B drive gear

Ratio Clutch Pack A

F1-20

9803/9970-01 (F-05-00)

F1-20

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

F1-21

Fig 12.

C057280

Drive Paths

9803/9970-01 (F-05-00)

F1-21

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Forward/First + High Range Description Engine power and torque has been transmitted via the Wet Clutch assembly 1 and spins input shaft and clutch pack gear 37. Because Reverse clutch pack R is disengaged the drum spins freely on its support shaft 38. Power is transmitted via Idler gear 39 and free to spin gear 43 to shaft 40 carrying clutch packs A and D.

constant mesh with mainshaft gear 45 which is also free to spin on its shaft. Its mating gear 46 splined to support shaft 47 is now locked to gear 48 via selected piston 42 in clutch C. Consequently shaft 47 spins and rotates gear 48. The constant mesh gear train transmits the drive through gears 48, 49 and 50.

17 16

19 15

20 21

C057300

Fig 14.

With High Range direct acting solenoid 28 also energised, selector fork operates synchromesh hub 52 which locks high range gear 53 to range box mainshaft transmitting drive directly to output shaft 54 to which output flange 55 is splined. Also identified are range box solenoids numbered 25 Extra Low Range, 26 Low Range, 27 Medium Range, 28 High Range and 29 Four Wheel Drive De-selection.

C056110

Fig 13. The operator has selected forward first on the control panel which has energised proportional solenoid valves 13 and 15 in the selector valve block 6. These solenoids progressively select and direct controlled main line pressure to the selected clutch pack operating pistons 41 and 42 engaging both clutch packs A and C in a controlled cushioned manner. As soon as clutch A engages, clutch drum gear 43 is locked to shaft 40 transmitting the drive through splined coupling and via gear 44 on clutch pack D. Gear 44 is in

F1-22

9803/9970-01 (F-05-00)

F1-22

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

45 46

Fig 15.

C057280-C1

Drive Paths

F1-23

9803/9970-01 (F-05-00)

F1-23

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Forward/Second + Medium Range Description Engine power and torque has been transmitted via the Wet Clutch assembly 1 and spins input shaft and clutch pack gear 37 mounted in the Smoothshift Gearbox 2. Because Reverse clutch pack R is disengaged the drum spins freely on its support shaft 38. Power is transmitted via Idler gear 39 through free to spin clutch pack gear 56.

coupling to clutch pack C shaft. Selected clutch C locks gear 48 to shaft 47. Gear 48 is in permanent mesh with mainshaft gear 49 which is fixed to gear 64 causing the shaft to rotate along with gear 50. The constant mesh gear train continues to transmit the drive via gear 51 to the mainshaft of the range box 3.

17 26 16

19 15

20 21

C057300

Fig 17. With Medium Range direct acting solenoid 27 also energised, selector fork operates synchromesh hub 52 which locks medium range gear 58 to range box mainshaft transmitting drive directly to output shaft 54 to which output flange 55 is splined.

Fig 16. The operator has selected forward second on the control panel which has energised proportional solenoid valves 14 and 15 in the selector valve block. These solenoids progressively select and direct controlled main line pressure to the selected clutch pack operating pistons 42 and 57 engaging both clutch packs B and C in a controlled cushioned manner. As soon as clutch B operates, clutch drum gear 56 is locked to shaft 47 transmitting the drive via splined

F1-24

9803/9970-01 (F-05-00)

F1-24

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

Fig 18.

54 38 37 39

C057280-C2

Drive Paths

F1-25

9803/9970-01 (F-05-00)

F1-25

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Forward/Third + Low Range Description Engine power and torque has been transmitted via the Wet Clutch assembly 1 and spins input shaft and clutch pack gear 37 mounted in the Smoothshift Gearbox 2. Because Reverse clutch pack R is disengaged the drum spins freely on its support shaft 38. Power is transmitted via Idler gear 39 which is in constant mesh with free to spin clutch gear 59 on shaft 40. This shaft carries clutch packs A and D.

As soon as clutch A operates, clutch drum gear 59 is locked to shaft 40 transmitting the drive via splined connection 62 to shaft on which clutch pack D is mounted. Selected clutch D locks gear 63 to shaft. Gear 63 is in constant mesh with mainshaft gear 64 which in turn is splined to shaft causing the shaft to rotate along with gear 49. The constant mesh gear train transmits the drive via gears 50 and 51 to the mainshaft of the range box 3.

17 16

19 15

20 21

C057300

Fig 20.

With Medium/High Range direct acting solenoids 27 and 28 deselected, selector fork operates synchromesh hub 52 in to the neutral position. Solenoid valve 26 is energised causing low/extra low selector shaft to push synchromesh hub 65 across which locks low range gear 67 to range box output shaft 54 transmitting drive across low range gear sets 66 and 67 directly to the gearbox output flange 55.

C056110

Fig 19. The operator has selected forward third on the control panel which has energised proportional solenoid valves 13 and 16 in the selector valve block. These solenoids progressively select and direct controlled main line pressure to the selected clutch pack operating pistons 60 and 61 engaging both clutch packs in a controlled cushioned manner.

F1-26

9803/9970-01 (F-05-00)

F1-26

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

Fig 21.

59 40

39 38

C05728-C3

Drive Paths

F1-27

9803/9970-01 (F-05-00)

F1-27

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Forward/Fourth + Extra Low Range Description Engine power and torque has been transmitted via the Wet Clutch assembly 1 and spins input shaft and clutch pack gear 37 mounted in the Smoothshift Gearbox 2. Because Reverse clutch pack R is disengaged the drum spins freely on its support shaft 38.

As soon as clutch B operates, clutch drum gear 56 is locked to shaft 47 transmitting the drive via splined connection 47 to shaft on which clutch pack C is mounted, driving splined clutch gear 46 through constant mesh mating of gears 45 and 44. Gear 44 splined to shaft rotates shaft. Selected clutch D locks gear 63 to shaft. Gear 63 is in constant mesh with mainshaft gear 64 which in turn is splined to shaft causing the shaft to rotate along with gear 50. The constant mesh gear train transmits the drive via gear 51 to the mainshaft of the range box 3.

Power is transmitted via Idler gear 39 which is in constant mesh with free to spin shaft gear 56 on shaft 47. This shaft carries clutch packs B and C.

28 6

17 16

19 15

C057300

Fig 23.

With Medium/High Range direct acting solenoids 27 and 28 deselected, selector fork operates synchromesh hub 52 to the neutral position. Solenoid valve 26 is energised causing low/extra low selector shaft to push synchromesh hub 65 across transmitting drive across extra low range gear sets 68 and 69 transmitting drive directly to the output flange 55.

C056110

Fig 22. The operator has selected forward fourth on the control panel which has energised proportional solenoid valves 14 and 16 in the selector valve block. These solenoids progressively select and direct controlled main line pressure to the selected clutch pack operating pistons 57 and 61 engaging both clutch packs in a controlled cushioned manner.

F1-28

9803/9970-01 (F-05-00)

F1-28

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

47 46

Fig 24.

C057280-C4

Drive Paths

F1-29

9803/9970-01 (F-05-00)

F1-29

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Forward/Fifth + Low Range Description Engine power and torque has been transmitted via the Wet Clutch assembly 1 and spins input shaft and clutch pack gear 37 mounted in the Smoothshift Gearbox 2. Because Reverse clutch pack R is disengaged the drum spins freely on its support shaft 38. Power is transmitted via Idler gear 39 which is in constant mesh with free to spin shaft gear 59 on shaft 40. This shaft carries clutch packs A and D.

As soon as clutch A operates, clutch drum gear 59 is locked to shaft 40 transmitting the drive via splined connection 62 to shaft on which clutch pack D is mounted. Clutch D is de-selected and gear 63 is free to rotate on shaft. Gear 44, splined to shaft is in constant mesh with mainshaft gear 45. This is locked to shaft 71 by selected piston 70 rotating shaft 71 and gear 64. The constant mesh gear train transmits the drive via gears 50 and 51 to the mainshaft of the range box 3.

17 16

19 15

C057300

Fig 26. With High/Medium range direct acting solenoids 27 and 28 deselected, selector fork pushes synchromesh hub 52 into the neutral position. Solenoid valve 26 is energised causing low/extra low selector shaft to push synchromesh hub 65 across transmitting drive across low range gear sets 66 and 67 locking low range gear 67 to range box output shaft 54 transmitting drive directly to the output flange 55.

C056110

Fig 25. The operator has selected forward fifth on the control panel which has energised proportional solenoid valves 13 and 17 in the selector valve block. These solenoids progressively select and direct controlled main line pressure to the selected clutch pack operating pistons 60 and 70 engaging both clutch packs A and E in a controlled cushioned manner.

F1-30

9803/9970-01 (F-05-00)

F1-30

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

Fig 27.

71 59

64 49

C057280-C5

Drive Paths

F1-31

9803/9970-01 (F-05-00)

F1-31

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Forward/Sixth - Medium Range Description Engine power and torque has been transmitted via the Wet Clutch assembly 1 and spins input shaft and clutch pack gear 37 mounted in the Smoothshift Gearbox 2. Because Reverse clutch pack R is disengaged the drum spins freely on its support shaft 38. Power is transmitted via Idler gear 39 which is in constant mesh with free to spin shaft gear 56 on shaft 47. This shaft carries clutch packs B and C.

As soon as clutch B operates, clutch drum gear 56 is locked to shaft 47 transmitting the drive via splined connection and constant mesh gear train gears 46 and 45. Clutch pack E is connected to gear 45 and once selected locks gear 64 to shaft. The constant mesh gear train transmits the drive via gears 50 and 51 to the mainshaft of the range box 3.

17 26 16

19 15

20 21

C057300

Fig 29. With Medium range direct acting solenoid 27 selected, selector fork pushes synchromesh hub 52 into the medium range position. This transmits drive across medium range gear sets 58 and 59 transmitting drive directly to the output flange 55.

C056110

Fig 28. The operator has selected forward sixth on the control panel which has energised proportional solenoid valves 14 and 17 in the selector valve block. These solenoids progressively select and direct controlled main line pressure to the selected clutch pack operating pistons 57 and 70 engaging both clutch packs B and E in a controlled cushioned manner.

F1-32

9803/9970-01 (F-05-00)

F1-32

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

Fig 30.

47 46

52 58 3

C057280-C6

Drive Paths

F1-33

9803/9970-01 (F-05-00)

F1-33

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Drive Paths

Reverse/First - High Range Description Engine power and torque has been transmitted via the Wet Clutch assembly 1 and spins input shaft and clutch pack gear 37 mounted in the Smoothshift Gearbox 2. When in neutral, Reverse clutch pack R is disengaged the drum spins freely on its support shaft 38. Power is transmitted via Idler gear 39 which is in constant mesh with free to spin shaft gear 56 on shaft 47. This shaft carries clutch packs B and C.

As soon as clutch R operates, clutch drum gear 37 is locked to shaft 38 transmitting the drive through main shaft centre bearing assembly 73 to constant mesh gear train gears 45 and 46. This rotates shaft 47 and clutch C. Clutch pack C is connected to gear 48 and once selected locks gear to shaft. The constant mesh gear train transmits the drive via gears 49, 50 and 51 to the mainshaft of the range box 3.

17 16

19 15

20 21

C057300

Fig 32.

With High range direct acting solenoid 28 selected, selector fork pushes synchromesh hub 52 into the high range position. This transmits drive across high range gear sets 53 and 54 transmitting drive directly to the output flange 55.

C056110

Fig 31. The operator has selected Reverse first on the control panel which has energised proportional solenoid valves 18 and 15 in the selector valve block. These solenoids progressively select and direct controlled main line pressure to the selected clutch pack operating pistons 72 and 42 engaging both clutch packs R and C in a controlled cushioned manner.

F1-34

9803/9970-01 (F-05-00)

F1-34

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM

Fig 33.

C057280-C7

Drive Paths

F1-35

9803/9970-01 (F-05-00)

F1-35

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Fault Finding

Fault Finding Complete Transmission Table 1. CHECK

ACTION

Has the tractor software just been reprogrammed?

Make sure the correct software has been used.

Does the touch screen (DECU) show a gear and direction selected?

Check all transmission ECU fuses.

Check the powershift dump relay.

Check for tractor error codes.

Monitor the clutch pedal position (%) and activation switch using Service Recalibrate if necessary. Master or the DECU Information.

Using Service Master, check that the selected powershift solenoids are energised.

Using Service Master, monitor the selected range gear and rail position (%).

Using Service Master, monitor the transmission intermediate and output speed sensors.

Download datalog.

10 Check transmission oil level and oil grade are correct. 11 Check that mainline oil pressure is correct. K Gearbox Pressure Test Procedure ( T F1-42) 12 Check the relevant wet clutch, powershift and range oil pressures. K Gearbox Pressure Test Procedure ( T F1-42) 13 Do axle drive shafts rotate when a gear is selected? (Test with 4WD selected.)

F1-36

9803/9970-01 (F-05-00)

Isolate mechanical components and investigate.

F1-36

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Fault Finding

Wet Master Clutch Clutch fails to engage, slips or engages erratically: Table 2. CHECK

ACTION

Check for active fault codes using Service Master.

Download datalog.

Monitor the clutch pedal position (%) and activation switch using Service Recalibrate if necessary. Master.

Monitor the wet clutch solenoid current using Service Master.

Check transmission oil level and oil grade are correct.

Check that mainline oil pressure is correct.K Gearbox Pressure Test Procedure ( T F1-42)

Check the wet clutch pressure. K Gearbox Pressure Test Procedure ( T F1-42)

Clutch fails to disengage correctly when machine is in motion: Table 3. CHECK

ACTION

Check for active fault codes using Service Master.

Download datalog.

Monitor the clutch pedal position (%) and activation switch using Service Recalibrate if necessary. Master.

Check that powershift dump relay is energised when clutch pedal is fully Renew the potentiometer. down.

Recalibrate the gearbox.

Check that mainline oil pressure is correct. K Gearbox Pressure Test Procedure ( T F1-42)

Check the wet clutch pressure. K Gearbox Pressure Test Procedure ( T F1-42)

F1-37

9803/9970-01 (F-05-00)

F1-37

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Fault Finding CHECK

ACTION

The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox. 7

Is the clutch piston check valve faulty?

Renew the check valve.

Are steps visible in the drive tangs on the clutch drum?

Renovate or renew the drum as required.

Are the clutch return springs worn or broken?

Renew the springs. Always renew the springs even if they appear serviceable.

F1-38

9803/9970-01 (F-05-00)

F1-38

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Fault Finding

Power Take Off Clutches PTO Clutch does not engage: Table 4. CHECK

ACTION

Check the operator settings for PTO cutout such as linkage height settings, which will prevent the PTO from engaging (flashing PTO icon).

Check for active fault codes.

Download datalog.

Is the PTO speed selector fully engaged?

Monitor the selector values in the gearbox using Service Master.

Monitor the PTO On/off switch in the cab using Service Master.

Monitor the external PTO cut-out switch using Service Master. (A fault will prevent PTO start-up.)

If 2WD cannot be selected, check the relevant fuses.

Monitor the PTO clutch solenoid being energised using Service Master.

Check the PTO clutch solenoid is actually being energised.

Measure the PTO clutch oil pressure. K Gearbox Pressure Test Procedure ( T F1-42)

10 Check the correct PTO option is set using the Set-up Tool (Service Master). 11 Check for mechanical drive line failure in the PTO system. 12 Recalibrate the transmission. (This also calibrates the PTO speed selector position.) Note: The PTO brake will not affect PTO clutch operation.

F1-39

9803/9970-01 (F-05-00)

F1-39

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Fault Finding PTO continues to rotate when the PTO switch is at stop Note: The PTO brake is applied 5 seconds after the PTO is switched off.

The PTO brake is low power - it prevents the PTO from rotating when not the PTO is not engaged. It is much less powerful than the PTO clutch and will not affect heavy inertia PTO implements during run down.

Table 5. CHECK

ACTION

Check for active fault codes.

Download datalog.

Monitor the PTO switch position and PTO solenoid state using Service Master.

Check the brake solenoid is being energised after 5 seconds.

Check the supply fuses are correct.

Check the solenoid for faults or internal spool sticking

Strip and inspect the pto brake friction plates.

4/2 Wheel Drive Table 6. CHECK

ACTION

Check for operator cut-out settings which will prevent 4WD engaging (such as speed, linkage height or steer angle).

Check for tractor fault codes.

Monitor 4WD switch and 4WD solenoid using Service Master.

Check if the 4WD solenoid is actually energised. (Solenoid on = 4WD.)

Check for mechanical 4WD driveline faults.

Check 4WD operating pressure. K Gearbox Pressure Test Procedure ( T F1-42)

F1-40

Download datalog.

9803/9970-01 (F-05-00)

F1-40

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Test Procedures

Test Procedures Prior to pressure testing, transmission fluid levels should be checked and adjusted. (See Section 3) If a thorough transmission pressure testing sequence is to be undertaken, precautions must be made to prevent the machine from moving. It may therefore be necessary to disconnect both front propshaft A and rear propshaft B from the transmission output flanges. All personnel unconnected with this pressure testing operation must be kept clear of the work area.

C057350

Fig 34.

F1-41

9803/9970-01 (F-05-00)

F1-41

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Test Procedures

Gearbox Pressure Test Procedure

Compare recorded pressures with the figures in Technical Data.

Operate machine to correct transmission operating temperature.

Lubrication Pressure

Note: When pressure gauge C is connected to remote pressure testing points numbered 1 - 12 a delay can be experienced as pressure builds in the microbore hoses connecting test points to transmission control valve block.

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 2. With transmission in neutral, start engine and allow to idle, once stabilised note pressure. Progressively increase engine speed to maximum rev/min and note pressure.

The following illustrations identify the microbore connections at the transmission and also the self seal couplings which may be used to check pressures controlling other transmission functions.

Compare recorded pressures with the figures in Technical Data.

Item No

Pressure Measured

Mainline Pressure

Lubrication Pressure

Wet Clutch Operating Pressure

Clutch B Operating Pressure

Clutch C Operating Pressure

Clutch D Operating Pressure

Clutch E Operating Pressure

High Range Selector Operating Pressure

Medium Range Selector Operating Pressure

Low Range Selector Operating Pressure

Extra Low Range Selector Operating Pressure

Four Wheel Drive Disconnect Clutch Operating Pressure

Rear Valve Block Pressures, see Section E

Wet Clutch High Pressure Lubrication

Clutch A Operating Pressure

Front PTO Brake Release Operating Pressure

Clutch R Operating Pressure

Rear PTO Brake Release Operating Pressure

Front PTO Clutch Operating Pressure

Transmission Brake Release Operating Pressure

Rear PTO Clutch Operating Pressure

Mainline Pressure Position 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 1. With transmission in neutral and at normal operating temperature run engine at idle, allow recorded pressure to stabilise, note pressure. Progressively increase engine speed to maximum rev/min and note pressure.

F1-42

C057320

Fig 35.

Wet Master Clutch - Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 3. With personnel kept clear of transmission output flanges, start engine and allow to idle, press clutch pedal to full travel, note pressure. Compare recorded pressures with the figures in Technical Data Section.

Clutch B Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 4 this will record operating pressure in clutch B only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage second gear, this will pressurise both B and C clutches. Progressively increase engine speed to 1600 rev/min and note pressure. Compare recorded pressures with the figures in Technical Data.

9803/9970-01 (F-05-00)

F1-42

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Test Procedures Clutch D Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 6. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage third gear, this will pressurise both A and D clutches. Progressively increase engine speed to 1600 rev/min and note pressure.

14 4

To monitor pressure in clutch A it will be necessary to relocate pressure gauge G. Stop engine and move pressure gauge G to pressure test point 15 located on the transmission selector valve block. Access is best achieved from under the LHS of the machine. Progressively increase engine speed to 1600 rev/min and note pressure. Compare recorded pressures with the figures in Technical Data.

Clutch E Operating Pressure

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 7 this will record operating pressure of clutch E only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage third gear, this will pressurise both A and D clutches. Progressively increase engine speed to 1600 rev/min and note pressure.

1 16

18 20

Compare recorded pressures with the figures in Technical Data.

19 17

Clutch R Operating Pressure

D C057330

Fig 36.

Clutch C Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 5. This will record operating pressure in clutch C only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage second gear, this will pressurise both B and C clutches. Progressively increase engine speed to 1600 rev/min and note pressure. Compare recorded pressures with the figures in Technical Data.

F1-43

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 17 located on the transmission selector valve. Access is best achieved from under the LHS of the machine. This will record operating pressure of reverse clutch R only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select reverse first. This will engage clutches R and C. Progressively increase engine speed to 1600 rev/min and note pressure. Compare recorded pressures with the figures in Technical Data..

High Range Selector Piston - Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 8 located on top of the range box. This will momentarily record operating pressure of high range selector piston only, once selected the operating

9803/9970-01 (F-05-00)

F1-43

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Test Procedures pressure will decay as the range is held selected by detents in the selector hub. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage third gear high range, this will pressurise both A and D clutches and also high range selector piston. Compare recorded pressures with the figures in Technical Data..

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 10 located on top of the range box. This will momentarily record operating pressure of low range selector piston only, once selected the operating pressure will decay as the range is held selected by detents in the selector hub. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage third gear low range, this will pressurise both A and D clutches and also low range selector piston. Compare recorded pressures with the figures in Technical Data.

Extra Low Range Selector Piston - Operating Pressure

11 10

C057360

Fig 37.

Medium Range Selector Piston - Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 9 located on top of the range box. This will momentarily record operating pressure of medium range selector piston only, once selected the operating pressure will decay as the range is held selected by detents in the selector hub. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage third gear medium range, this will pressurise both A and D clutches and also medium range selector piston. Compare recorded pressures with the figures in Technical Data.

F1-44

Low Range Selector Piston - Operating Pressure

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 12 located on top of the range box. This will momentarily record operating pressure of extra low range selector piston only, once selected the operating pressure will decay as the range is held selected by detents in the selector hub. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage third gear extra low range, this will pressurise both A and D clutches and also extra low range selector piston. Compare recorded pressures with the figures in Technical Data.

Four Wheel Drive Disconnect Clutch Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 12 located on top of the range box. This will record operating pressure of 4WD disconnect clutch only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select transmission forward and engage sixth gear high range, this will pressurise both B and E clutches and also high range selector piston which automatically selects 4WD disconnect clutch. Progressively increase engine speed to 1600 rev/min and note pressure. Compare recorded pressures with the figures in Technical Data..

9803/9970-01 (F-05-00)

F1-44

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Test Procedures Wet Clutch High Pressure Lubrication

Forward Power Take Off Brake Operating Pressure

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 14 located beside wet clutch lubrication selector solenoid on the wet clutch housing. Operate clutch pedal to full travel, this will record operating pressure of wet clutch high pressure lubrication only. With personnel kept clear of transmission output flanges, start engine and allow to idle. Progressively increase engine speed to maximum rev/min and note pressure. Compare recorded pressures with the figures in Technical Data..

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 16 located on the transmission selector valve. Access is best achieved from under the LHS of the machine. This will record operating pressure of front PTO brake application only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select front PTO. Progressively increase engine speed to 1600 rev/min and note pressure. Compare recorded pressures with the figures in Technical Data..

Rear Power Take Off Brake Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 18 located on the transmission selector valve. Access is best achieved from under the LHS of the machine. This will record operating pressure of rear PTO brake application only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select front PTO. Progressively increase engine speed to 1600 rev/min and note pressure.

14 4

Compare recorded pressures with the figures in Technical Data..

Front Power Take Off Clutch Operating Pressure

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 19 located on the transmission selector valve. Access is best achieved from under the LHS of the machine. This will record operating pressure of front PTO clutch only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select front PTO. Progressively increase engine speed to 1600 rev/min and note pressure.

1 16

18 20

Compare recorded pressures with the figures in Technical Data..

Transmission Brake Operating Pressure

19 17

Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 20 located on the transmission selector valve. Access is best achieved from under the LHS of the machine. This will record operating pressure of transmission brake release only. With personnel kept clear of transmission output flanges, start engine and allow to

D C057330

Fig 38.

F1-45

9803/9970-01 (F-05-00)

F1-45

Section F1 - Transmission 6 x 4 Smoothshift Transmission SYSTEM Test Procedures idle, press clutch pedal to full travel, this will automatically engage transmission brake application pressure. Compare recorded pressures with the figures in Technical Data..

Rear Power Take Off Clutch Operating Pressure Stop engine and move 0-40 bar (0-600 lbf/in2) pressure gauge G to test point 21 located on the transmission selector valve. Access is best achieved from under the LHS of the machine. This will record operating pressure of rear PTO clutch only. With personnel kept clear of transmission output flanges, start engine and allow to idle, select rear PTO. Progressively increase engine speed to 1600 rev/min and note pressure. Compare recorded pressures with the figures in Technical Data..

F1-46

9803/9970-01 (F-05-00)

F1-46

Section F2 - Transmission

6 x 4 Smoothshift Gearbox Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. 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 how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Charge Pump ( T F2-2) K Removal ( T F2-2) K Replacement ( T F2-2) K Dismantling ( T F2-3) K Control Valve ( T F2-4) K Removal ( T F2-4) K Replacement ( T F2-4) K P.T.O. Position Sensors ( T F2-5) K Removal ( T F2-5) K Replacement ( T F2-6) K Dismantling and Assembly ( T F2-7) K Gearbox ( T F2-9) K Removal ( T F2-5) K Replacement ( T F2-6) K Dismantling and Assembly ( T F2-7)

F2-1

9803/9970-01 (F-09-00)

F2-1

Section F2 - Transmission 6 x 4 Smoothshift Gearbox Charge Pump

Charge Pump Removal

Replacement

The numerical sequence is a guide to removal, for replacement the sequence should be reversed.

Replacement is a reverse of removal with the following precautions.

The transmission pump may be removed with the transmission in situ.

Renew ‘O’ ring seals 4, grease ‘O’ ring seals to secure in place as the pump 3 is offered into position.

Ensure transmission has been drained of oil and if removed from machine, is securely mounted on manipulator.

With the pump casing spigot located in aperture in transmission casing, it may be necessary to carefully shock load pump with a plastic mallet to fully engage spigot.

Retain pump with washers and capscrews 2 as shown.

Disconnect pressure feed hose 1 from pump adapter, plug hose and cap adapter to prevent ingress of dirt.

1 2

3 4

C066140-C1 C066140-C1

Fig 1. 2

Remove capscrews 2 securing pump to transmission casing and withdraw pump 3.

Collect and discard ‘O’ ring seals 4.

F2-2

9803/9970-01 (F-09-00)

F2-2

Section F2 - Transmission 6 x 4 Smoothshift Gearbox Charge Pump

Dismantling

The numerical sequence is a guide to dismantling. For assembly the sequence may be reversed. 1

Grip the pump body in a vice fitted with soft jaws.

Undo capscrews 1 and remove along with their washers.

Lift cover 2 from pump. If necessary flow relief valve may be dismantled for cleaning. Release plug 3 and discard bonded seal 4. Remove poppet valve 5 and its spring. Inspect valve for nicks or scoring. Discard â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring seal 6.

Press gear shaft 7 from pump body. Release circlip 8 and withdraw needle bearing race 8. Inspect bearing and if showing sign of wear, discard.

Lift pump rotor 10 from pump body along with annulus ring 11.

Release large circlip 12 from the underside of pump body and withdraw ball bearing race 13. Inspect bearing race for wear or damage, discard if necessary.

5 4 3 6 10 11

C055560

Fig 2.

F2-3

9803/9970-01 (F-09-00)

F2-3

Section F2 - Transmission 6 x 4 Smoothshift Gearbox Control Valve

Control Valve Removal

The numerical sequence is a guide to removal, for replacement the sequence should be reversed. Note: Prior to removal pressure wash dirt and debris from the external casings of the transmission. Be sure to protect electrical and hydraulic connections from any chemicals used in the wash equipment. 1

Disconnect wiring connectors from each of the solenoid selector valves 1.

Disconnect hydraulic hose 2, plug hose and cap adapter.

The illustration shows self seal pressure testing points 3 positioned on the valve, on production, these are replaced with microbore hoses and the pressure testing points are remotely located. Mark for correct replacement, remove the hoses from these pressure points, plug hoses and cap adapters to prevent ingress of dirt.

Note: When releasing fixing screws 6 slacken progressively and in a logical opposing sequence to prevent the aluminium valve block distorting.

2 4 6 C066250 C066250

It is recommended that bolts 3 and 4 be removed prior to the slackened remainder. These bolts may be replaced with studs to help support the valve block as the remaining fixings are removed. Remove and discard gasket between valve block and transmission casing.

Fig 3.

Replacement Replacement is a reverse of removal with the following precautions. – Position new gasket over support studs left in casing. – Offer valve block to transmission over studs in position 3 and 4. Run fixing screws into remaining positions, remove studs 3 and 4 and replace with correct screws. Tighten in an opposing pattern to prevent valve becoming distorted. – Reconnect hydraulic hoses 2 to pressure testing points in correct positions as marked on removal. – On completion use the touch screen to calibrate the transmission , see Section C - Electronics Network SYSTEM.

F2-4

9803/9970-01 (F-09-00)

F2-4

Section F2 - Transmission 6 x 4 Smoothshift Gearbox P.T.O. Position Sensors

P.T.O. Position Sensors The front and rear P.T.O. position sensors record the position of the P.T.O. selector rail and is located underneath the Smoothshift gearbox casing at A.

4 2

3 1 C057250

Fig 4.

Removal

The numerical sequence is a guide to removal.

Note: If position sensors are renewed then a full recalibration must be performed on transmission.

F2-5

9803/9970-01 (F-09-00)

F2-5

Section F2 - Transmission 6 x 4 Smoothshift Gearbox P.T.O. Position Sensors

Replacement

2 E

C055290-C1 C055290-C1

Fig 5. Offer electric sensor body 2 into housing of selector sensor. To ensure correct timing of electric sensor 2 position flat E of drive spindle towards semi-circular segment D of selector sensor shank. Retain in place with screws 1. On completion do the PTO calibration procedure, use the touch screen, see Section C - Electronics Network SYSTEM.

F2-6

9803/9970-01 (F-09-00)

F2-6

Section F2 - Transmission 6 x 4 Smoothshift Gearbox P.T.O. Position Sensors

Dismantling and Assembly The numerical sequence is a guide to dismantling, for assembly the sequence should be reversed.

B 4

C055310-C1

Fig 7. Important: DO NOT attempt to fit position sensor to casing with selector sensor 2 already fitted. Some pressure will be required to fit ‘O’ ring sealed body 4 into casing, and plastic bodied selector sensor may be damaged.

Fit to gearbox casing with fork end of shank lever locating over dowel B in selector fork. Retain in position with screw 3.

C055300-C1

Fig 6. Renew ‘O’ rings 8 on shank 7 of selector fork sensor. Lubricate ‘O’ rings and push selector fork shank 7 into housing 4. Retain with grub screw 6. Renew housing ‘O’ ring 5.

F2-7

9803/9970-01 (F-09-00)

F2-7

Section F2 - Transmission 6 x 4 Smoothshift Gearbox P.T.O. Position Sensors

C055730-C1 C055730-C1

Fig 8. Engage flat bladed screwdriver C in slot D of shank and attempt to rotate it backwards and forwards. If fork on shank 7 has engaged with dowel B correctly then no rotation should be apparent. However, if shank rotates remove sensor body 4 from casing and re-engage fork of shank 7 correctly over dowel .

F2-8

9803/9970-01 (F-09-00)

F2-8

Section F2 - Transmission 6 x 4 Smoothshift Gearbox Gearbox

Gearbox Removal

1 6 A

21 A

17 13

5 4 18

11 9 2

3 C056810

Fig 9.

F2-9

9803/9970-01 (F-09-00)

F2-9

Section F2 - Transmission 6 x 4 Smoothshift Gearbox Gearbox

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Drain hydraulic tank, remove suction hoses 9 and 10 and pressure hoses 11 and 12 from the main hydraulic pumps.

With cab removed electrical connections to the transmission will be disconnected at the main multi pin plug, consequently the transmission loom 13 may be left connected to the solenoid valves and sensors fitted to the transmission as shown.

Note: If any part of the transmission wiring harnesses are renewed then a full recalibration must be performed on transmission. 9

Remove transmission filter and housing 14 complete.

Disconnect, plug and label all pressure test point hoses from the transmission selector valve.

Remove transmission dip stick, tube and filler tube.

Arrange suitable overhead crane with spreader bar and adjustable length chains A connected to front two lifting points 15 and 16 on top of transmission. Adjust chain lengths to give an even lift. Fit block and tackle B to rear most transmission lifting bracket 17, adjust block and tackle so that it is sharing the load with the two front chains A.

Allow overhead crane to take weight.

Arrange a jack to support the rear of the engine. Remove crossmember 1 supporting transmission.

With the load adequately supported, remove all wet clutch housing to flywheel housing bolts 18. With the transmission hanging on the hoists, push it backwards clear of the engine.

BF-4-1_1

Note: 2/4 wheel drive and front and rear P.T.O. functions are ECU controlled, consequently if incorrect operation is reported, error codes and Service Master should be used to investigate possible electrical reasons for this prior to the transmission being removed from the machine. The numerical sequence is a guide to removal, for replacement the sequence should be reversed. 1

Remove cab. See Section B

Drain oil from transmission. See Section 3.

Remove all protection plates and cross members, except transmission mounting cross member 1, across chassis obstructing access to transmission fittings.

Remove rear axle drive propshaft 2 and rear PTO drive shaft 3.

Remove four wheel drive propshaft to front axle (not illustrated) and front PTO drive shaft from yoke 4.

Note: As hydraulic hoses are disconnected from the transmission, they should be plugged and their associated adapters capped to prevent ingress of dirt. The hoses should also be clearly marked for correct replacement. 6

Remove transmission cooler hoses 5 from steel pipes under engine bulkhead. Disconnect the other end of these hoses from their fittings, one on filter head 7 and the second one from transmission pump outlet. Remove hose 8 from filter to selector valve.

F2-10

9803/9970-01 (F-09-00)

F2-10

Section F2 - Transmission 6 x 4 Smoothshift Gearbox Gearbox

Replacement

Replacement is a reversal of the removal sequence with the following precautions.

Care should be taken when lowering the transmission into the chassis that no damage occurs between the wet clutch housing and the heater pipes 21, cooler supply steel pipes 6 and windscreen washer bottle mounted on the engine bulkhead.

Dismantling and Assembly

C056830

The procedures for dismantling and assembling the gearbox are described in the JCB Transmissions Service Manual publication number 9803/8610.

Fig 10. 16

Fit rear engine support 19 manufactured from 40mm square section tube and bolted through into the engine flywheel housing 20, see Service Tools for dimensions. The engine may now be lowered with the jack until support 19 sits on the chassis longitudinal members C safely supporting the engine weight.

Slowly begin to lift transmission with the overhead crane whilst lowering the rear with block and tackle B causing the transmission to tilt backwards. Lower the rear of the transmission sufficiently to enable the transmission to be lifted clear.

F2-11

9803/9970-01 (F-09-00)

F2-11

Section F2 - Transmission 6 x 4 Smoothshift Gearbox Gearbox

Page left intentionally blank

F2-12

9803/9970-01 (F-09-00)

F2-12

Section F3 - Transmission

Front Axle Introduction

K Removal and Replacement - Differential Oil Seal ( T F3-2) K Removal and Replacement ( T F3-4) K Dismantling and Assembly - Hub and Drive Shaft ( T F3-7) K Removal and Replacement - Drive Head ( T F3-14) K Dismantling and Assembly - Drive Head ( T F3-16) K Dismantling and Assembly - Differential ( T F3-23)

F3-1

9803/9970-01 (F-04-00)

F3-1

Section F3 - Transmission Front Axle Removal and Replacement - Differential Oil Seal

Removal and Replacement - Differential Oil Seal This job can be done with the axle either removed or in situ on the machine.

!MWARNING 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.

not to distort it. Ensure that the seal is square and pushed fully home. 4

Install the old stake nut temporarily. Then, using a torque wrench determine the torque required to align the scribed lines (see step 1). Remove and discard the old stake nut.

Before fitting the flange, check that its bearing end is not fretted and renew if required. Clean any oil from the splines of the flange and the shaft. Run an even 2 mm diameter bead of JCB Threadlocker and sealer around the outer end of the shaft spline.

Fit the coupling flange with a new stake nut.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1

Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.

Fig 2. a

b Measure the rolling torque. The reading should be 0.5to 1 Nm (0.37 to 0.74 lbf ft, 0.05 to 0.1 kgf m) more than that recorded in Step 1 (see Note).

Fig 1. 2

Drain the oil from the rear axle casing or front axle differential casing as applicable (see Section 3 Routine Maintenence). Using Service Tool 892/ 00812, remove the coupling flange together with its stake nut. Remove the seal and fit a new one. Take care not to damage the housing when removing the old oil seal. Lubricate the lips of the new seal with JCB HP Grease. Fit the new seal into the housing, taking care

F3-2

Using Service Tool 892/00812, tighten nut to 250Nm (184 lbf ft, 25.5 kgf m).

If necessary, progressively torque tighten nut to achieve correct rolling torque.

Note: If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in Step 1 by more than 1 Nm (0.74 lbf ft, 0.1 kgf m), then the spacer mounted on the axle pinion must be renewed. d Stake the nut using a square ended staking tool.

9803/9970-01 (F-04-00)

F3-2

Section F3 - Transmission Front Axle Removal and Replacement - Differential Oil Seal 7

Fill the axle or differential casing with the specified oil, (see Section 3 - Routine Maintenence).

F3-3

9803/9970-01 (F-04-00)

F3-3

Section F3 - Transmission Front Axle Removal and Replacement

Removal and Replacement

Fig 3.

F3-4

9803/9970-01 (F-04-00)

F3-4

Section F3 - Transmission Front Axle Removal and Replacement

Removal Fig 3. (X F3-4)

Disconnect the steering drag link from the steering lug on the right side hub.

Remove the shock absorbers E.

Disconnect the 4WD shaft at F.

Remove Panhard rod G at the axle end, using a suitable ball joint splitter. Tie up the rod clear of the axle.

!MCAUTION Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure.

!MWARNING

AXL 8-2

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Completely remove anti-roll bar L assembly by disconnecting at the two axle mounting points and the two chassis mounting points.

BF-4-1_1

Remove the four nuts M on each side of the machine and remove the two fender assemblies.

Lower the jack A until springs H are fully extended.

Loosen the front road wheel retaining nuts.

Lever the springs so that they are not jammed on axle spigots J.

Position a jack A under the axle and jack the machine just far enough to install axle stands B (see Step 4).

!MCAUTION

Position axle stands B (which should be capable of taking the full weight of the machine) on either side of the chassis. Lower the jack until the chassis rests on the axle stands, but make sure it still supports the weight of the axle.

Keep your hands clear of the springs until they have been released and are no longer under load or you may trap your fingers.

Note: An alternative is to hoist the whole of the front of the machine (if suitable equipment is available) and then insert axle stands. Position a jack beneath the axle and raise it to take the axle weight. 5

SUS-1-4

14With the axle still supported by the jack, disconnect the three control arms K from the axle (see Section S Front Suspension System). Tie up the control arms to prevent them hanging on the ground. The axle is now free and can be pulled forwards with trolley jacks.

Remove the road wheels and drain oil from hubs and axle. a

ABS Machines only Disconnect the axle mounted speed sensor flying leads, one at each hub, from their chassis mounted mating connectors. Tie the cable sheathing to the axle for protection during the following procedure.

Disconnect brake pipes C and seal to prevent entry

F3-5

9803/9970-01 (F-04-00)

F3-5

Section F3 - Transmission Front Axle Removal and Replacement

Replacement Fig 3. (X F3-4) Replacement is the reverse of the removal procedure. Ensure that the chassis is correctly supported as in Removal Step 4. Do the following replacement procedures: – Shock Absorbers (see Suspension SYSTEM).

Section

Front

– Panhard Rod (see Section S - Front Suspension SYSTEM). – Control Arms (see Section S - Front Suspension SYSTEM) – Propshaft (see Section F - Propshafts). When refitting the fender assemblies tighten nuts M to a torque of 158 Nm (116 lbf ft, 16 kgf m). On completion, fill the axle with the correct oil (see Section 3 - Routine Maintenence). Bleed the brakes (see Section G).

F3-6

9803/9970-01 (F-04-00)

F3-6

Section F3 - Transmission Front Axle Dismantling and Assembly - Hub and Drive Shaft

Dismantling and Assembly - Hub and Drive Shaft

Fig 4.

F3-7

9803/9970-01 (F-04-00)

F3-7

Section F3 - Transmission Front Axle Dismantling and Assembly - Hub and Drive Shaft

Dismantling Fig 4. (X F3-7) 1

Ensure that oil has been drained from the hubs and axle. Remove screws 1.

Use a ball joint splitter to separate the steering connections from the lugs on the hub. Disconnect the flexible brake pipe.

!MCAUTION Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

Lever off the planet gear carrier 2 at the points provided. Discard the 'O' ring 3 (if fitted). Lay the planet gear carrier on a level, clean surface and examine the planet gears 4. Check planet gears for excessive side movement on the bearings. Compare with a new item if in doubt as to the correct amount of side movement. If any wear is found, the planet bearings and gears must be renewed.

Remove the planet gears 4 only if necessary. They can only be renewed as an assembly comprising the pinion 4, the bearing 5 and two circlips 6. To remove a planet gear 4 first remove the external circlip 7 then pull off the planet gear 4.

To remove driveshaft thrust pad 8, screw an M6 bolt into the hole provided.

Remove circlip 9 and slide sun gear 10 off the driveshaft.

To remove the spacer 11 revolve the spacer with a suitable drift until the holes in the spacer align with the space between bolts 12. Using two dowels and two heel bars pull out the spacer 11.

Remove the M14 Verbus Ripp bolts 12 using heavy duty tools. These bolts will be very tight and will be less difficult to slacken if first tightened slightly.

See Note below. Using three bolts 12 as jacking screws, remove the annulus carrier 13.

Note: If the hub swivel 14 and annulus carrier 13 are to be re-used, the carrier must be assembled in the same angular position as that from which it was removed; matchmark the hub swivel and carrier before removing the carrier. Fretting between the hub swivel 14 and the annulus carrier 13 mating faces might be evident; this condition is normal, do not attempt to repair. 10

Remove circlip 15 to separate the annulus ring 16 from the annulus carrier 13.

Remove the brake calipers (see Section G). On ABS machines remove the ABS sensors (see Section G).

Note: Wheel Hub Service Kit 892/01092 (see Service Tools) is required throughout steps 12 to 16, see Fig 6. (X F3-9).

Fig 5.

F3-8

9803/9970-01 (F-04-00)

F3-8

Section F3 - Transmission Front Axle Dismantling and Assembly - Hub and Drive Shaft

Fig 7.

Fig 6. 12

Assemble the puller B, screwing the legs A onto two diametrically opposite wheel studs and placing reaction tube C over the driveshaft.

Remove and discard the combination seal 21 by cutting the outer seal with a sharp chisel and carefully knocking the inner seal fully on to the stub axle, taking care not to damage the seal seat on the stub axle.

Note: Reaction tube C, must be used, otherwise damage to the driveshaft and drive shaft bearings will occur. 13

Screw in D slowly until the bearing carrier 17 together with the outer bearing cone 19 and its outer race are released from the axle. If the bearing carrier starts to turn use a suitable bar Y to prevent further rotation.

Note: If D becomes too hard to turn, tap the back of the hub with a plastic hammer to help release the bearing. Note: If necessary, the brake disc 18 and bearing carrier 17 can be separated by removing bolts 27. If disc 18 is scored, skimming is permissible but it must not reduce the thickness to less than the dimension given in Section G Brakes - Brake SYSTEM.

Fig 8. 15

Assemble the puller B, with the inner bearing plate E clamped around the inner bearing 20, attach the puller rods F and reaction tube C over the driveshaft.

Note: Reaction tube C must be used, otherwise damage to the driveshaft and drive shaft bearings will occur.

F3-9

9803/9970-01 (F-04-00)

F3-9

Section F3 - Transmission Front Axle Dismantling and Assembly - Hub and Drive Shaft 16

Slowly screw in D until the bearing 20 is released.

Remove the outer races of bearings 19 and 20 from the bearing carrier 17, using a hammer and drift.

Mark the position of the top trunnion 22 with respect to the hub swivel 14. Remove studs 23 from trunnion 22 and remove the trunnion. Retain the shim pack 24 (if fitted). Repeat for the bottom trunnion by removing capscrews 23B. Withdraw hub swivel 14.

internal chamfered end first, until it locates fully against the shaft outer shoulder. 21

Prise out the driveshaft oil seal 29 from its housing in the axle and discard.

Remove circlip 30.

Remove the bearing 31 using Service Tools 892/ 00224 and 892/00225.

Pull off the trunnion bearings 25 and seals 26.

Remove the oil seal 33 from the hub swivel 14.

Withdraw the driveshaft assembly 28.

Remove the needle bearing 34 from the hub swivel 14.

Check the wear sleeve adjacent to the shoulder at the outer end of inner drive shaft 39 for seal contact surface wear or pitting. If wear of pitting exists renew the wear sleeve as follows:

Assembly Fig 4. (X F3-7) Note: If the driveshafts have been separated, assemble them in the reverse order of dismantling. 1

Tap in the driveshaft inner bearing 31 and secure with circlip 30.

Pack JCB HP Grease between the lips of the new oil seal 29 and fit into the axle flush with the end of the housing.

Fit the driveshaft 28, taking care to locate the inner end into the splines of the differential gears.

Fit a new needle bearing 34 into swivel 14. Pack a new oil seal 33 with JCB HP Grease and fit to swivel 14 (refer to T.I. GEN 083 for installation details).

Press a new trunnion inner oil seal 26 into position followed by the bearing 25. Lightly oil bearings and seal before fitting.

Locate the hub swivel 14 in position over the driveshaft 28 and fit the bottom trunnion 22. Apply JCB Threadlocker and Sealer to the capscrews 23B and torque tighten. Table 1. Torque Settings, Zincplated (colour: golden) (X F3-13))

Refit original shim 24 (if fitted) to the top trunnion. Install trunnion 22. Align the match marks, and fit studs 23A finger tight.

Fig 9. a

Place the sleeve X horizontally on an anvil or other suitable hard surface as shown below. Protect your eyes by wearing safety glasses or goggles and then hammer the sleeve while rotating the shaft. Continue until the sleeve becomes oval and slides off the shaft.

b To fit a new sleeve it is necessary to pre-heat it to 100 - 110 Â°C (212 - 230 Â°F). To avoid personal injury from burning, wear gloves and protective overalls. After pre-heating use a suitable tube to press or tap the wear sleeve X onto the shaft,

F3-10

Note: Axles assembled from new without any shims 24 may not need shimming on re-assembly . If a new shim 24

9803/9970-01 (F-04-00)

F3-10

Section F3 - Transmission Front Axle Dismantling and Assembly - Hub and Drive Shaft has to be fitted, fit a nominal 0.25 mm and leave the top trunnion bolts finger tight.

Install outer bearing race from bearing 19 into bearing carrier 17.

Lightly oil the inner wheel bearing cone 20 and its inner race, then fit them into the bearing carrier 17.

Fig 10. 8

Fig 10. (X F3-11) Attach a spring balance to the track rod swive and measure the turning load on the hub swivel. Tighten the top trunnion bolts just enough to eliminate end float without introducing bearing preload. i.e. no increase in spring balance reading.

Measure the gap at the top trunnion and subtract 1 mm to give bearing pre-load. Add the result to nominal shim at top trunnion to give a provisional total shim thickness which must be verified as follows.

Refit top trunnion 22. Fit two diagonally opposite studs or bolts and torque tighten. Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13) Check the spring balance reading again (as at step 8). The reading should be 45 N (10 lbf) more than that recorded at Step 8. If the reading is incorrect, adjust the shim thickness as required. When correct, proceed as follows: Apply JCB Threadlocker and Sealer to all four studs 23. Fit the studs and torque tighten. Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)

Fit the brake disc 18 to the bearing carrier 17, ensuring that both surfaces are clean and lightly oiled before assembly. Torque tighten bolts 27. Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)

Fig 11. 15

Use service tool 892/00891(see Note below) to drive the seal 21 squarely into the wheel bearing carrier 17 until the oil seal is level with the wheel bearing carrier face as shown. Fig 11. (X F3-11)

Important: Do not lubricate the seal before fitting. Note: Service tool 892/00891 has been produced in two different versions. The latest version supplied with the Wheel Hub Service Kit 892/01092 has each side stamped A or B to identify which side should face the seal. All current Fastrac machines must have the seal driven in with side B towards the seal. The original service tool 892/ 00891 was supplied with a separate spacer and did not have its sides stamped A or B. The spacer must be used to prevent the seal from being driven in too far. Note: Wheel hub service kit 892/01092 (see Service Tools) is required throughout steps 16 to 23. Do not allow the wheel bearing carrier to become unsupported, otherwise the oil seal will be damaged.

Before fitting bearings and oil seal 21, ensure that all paint and dirt are removed from the nose of the carrier and the housing bore.

F3-11

9803/9970-01 (F-04-00)

F3-11

Section F3 - Transmission Front Axle Dismantling and Assembly - Hub and Drive Shaft 19

Attach the puller handle J to the bearing centre puller H, making sure that the thrust bearing is fitted between two thrust washers at L. Using the puller handle, screw in the bearing fitting tube K until the inner bearing 20 is pressed correctly into position.

Remove the puller handle J and bearing fitting tube K.

Install the outer bearing 19 into the bearing carrier 17.

Assemble the puller handle J and bearing fitting tube K onto the centre puller H, making sure that the thrust bearing is fitted between two thrust washers at L.

Using the puller handle J, screw in the bearing fitting tube K until the outer bearing 19 is pressed correctly into position so as to remove most of the free play.

Fig 12. 16

Attach the bearing centre puller H to the centre of the stub axle using the existing ‘Verbus Ripp’ bolts.

Note: Do not overtighten or the bearing will be damaged.

Note: When fitting the annulus carrier, new ‘Verbus Ripp’ bolts must be used.

Remove puller handle J, bearing fitting tube K and bearing centre puller H.

Assemble the annulus ring 16 to the annulus carrier 13 and secure with circlip 15.

Fit the annulus assembly to the hub swivel in the same angular position as it was prior to removal. Dismantling (X F3-8) Use three of the original bolts 12, draw the annulus carrier 13 and hub swivel 14 fully together. Remove and discard the three bolts and then fit a complete set of new M14 Verbus Ripp bolts 12. Do not fully tighten the bolts but allow the bearing carrier to 'rock' slightly to enable measurement of the seal drag - see step 27.

Check the seal drag rolling force as follows:

Lightly oil the inner wheel bearing 20. Position the bearing carrier (complete with inner bearing) onto the stub axle over the centre puller H.

Fig 13. 18

Slide the bearing fitting tube K over the bearing centre puller H (the wide opening towards the bearing). Make sure that the bearing and carrier are square to the shaft.

Fig 14. Temporarily refit the planet gear carrier 2.

F3-12

9803/9970-01 (F-04-00)

F3-12

Section F3 - Transmission Front Axle Dismantling and Assembly - Hub and Drive Shaft Important: Do not fit the sun gear 10 or the caliper.

Rotate the hub several turns to bed-in the seal.

Fit the planet carrier 2 onto the bearing carrier 17, ensuring that the two tapped holes are in line with those on the bearing carrier. Apply JCB Threadlocker and Sealer to screws 1 and torque tighten. Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)

Fig 14. (X F3-12) Using a spring balance and cord wrapped around the planet carrier flange as shown. Pull the spring balance so that the hub rotates; record the rolling force reading. (Ignore the extra force needed to start the rotation.)

Note: Never hit the hub in the centre with a hammer. Hammering will dislodge the thrust pad 8.

Remove the planet gear carrier after checking rolling force.

On ABS machines replace the ABS sensors (see Section G).

Torque tighten bolts 12 evenly. Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)

Check the rolling force of the bearings as follows.

Fit the brake calipers (see Section G).

Refill the hub with oil (see Section 3).

If any of the steering linkage parts have been renewed or disturbed, check and, if necessary, adjust wheel alignment (see Section 3).

Refit the planet gear carrier 2. Important: Do not fit the sun gear 10 or the caliper. Fig 14. (X F3-12) Using a spring balance and cord wrapped around the planet carrier flange as shown. Pull the spring balance so that the hub rotates; record the rolling force reading. (Ignore the extra force needed to start the rotation.). Subtract seal drag rolling force (see step 27) from this reading. The result should be 10 to 120 N (2 to 27 lbf).

Table 1. Torque Settings, Zinc-plated (colour: golden) Item Nm kgf m lbf ft 1

5.7

320

236

23B

158

166

123

Renew bearings if necessary. Remove the planet gear carrier after checking rolling force. Note: A high rolling force reading may indicate that the combination seal was damaged during fitting. 30

Press the driveshaft thrust pad 8 (chamfered side uppermost) into the recess in the planet carrier 2.

Fit new planet gears 4 in place of any that were removed. Dismantling (X F3-8) Secure with circlips 7. Check the planet gear end floats, which should be between 0.4 mm to 0.75 mm (0.016 in to 0.030 in).

Note: If planet gears 4 or sungear 10 are worn, renew the complete set. 32

Slide on the spacer 11, use a hollow tube of suitable bore and tap spacer fully home. Slide sun gear 10 onto the driveshaft 37. Secure with circlip 9.

Fit a new 'O' ring 3.

F3-13

9803/9970-01 (F-04-00)

F3-13

Section F3 - Transmission Front Axle Removal and Replacement - Drive Head

Removal and Replacement - Drive Head

Fig 15. This job can be done with the axle either removed or in situ on the machine.

Removal If the axle is in situ do steps 1 to 2a; if the axle is removed begin at step 3.

Jack up the machine and support it on axle stands.

Remove the road wheels and drain the oil from axle. Disconnect the drag link from the steer hub, using a suitable ball joint splitter.

3-3-1-1

F3-14

9803/9970-01 (F-04-00)

F3-14

Section F3 - Transmission Front Axle Removal and Replacement - Drive Head

!MCAUTION

Bleed the braking system.

Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

ABS machines only Disconnect the axle mounted speed sensor flying leads, one at each hub, from their chassis mounted mating connectors. Tie the cable sheathing to the axle for protection during the following procedure.

Remove split pins 1 and nuts 2. Use a suitable ball joint splitter and lower track rod 3 clear.

Disconnect hydraulic pipes at brake calipers B and differential lock D. Remove both sets of top and bottom trunnions 4, 5. Dismantling (X F3-8)

Pull the complete hub and swivel assemblies 6 out of the axle, complete with drive shafts.

Disconnect the propshaft.

Support the drive head 8 on a trolley jack. Remove bolts 7 and pull out the drive head 8. Remove and discard gasket 9 (if fitted).

Remove and discard axle oil seals 10.

Replacement Replacement is the reverse of the removal procedure. Use a new gasket 9, which should be greased before assembly. Alternatively, apply JCB Multigasket to the mating faces. Apply JCB Threadlocker and Sealer to bolts 7 and torque tighten to 166 Nm (122 lbf ft, 17 kgf m). Pack JCB HP Grease between the lips of new seals 10 before assembly. Ensure that the seals are fitted squarely and take care not to damage them when inserting the driveshafts. Grease the exposed parts of the trunnion pivots to prevent rusting. Set front wheel alignment (see Section 3). Torque tighten the track rod nuts 2 to 150 Nm (110 lbf ft, 15 kgf m) then tighten to next castellation and insert pin 1. Note: The damper mounting pin on the track rod should be uppermost and closest to the RH end of the axle.

F3-15

9803/9970-01 (F-04-00)

F3-15

Section F3 - Transmission Front Axle Dismantling and Assembly - Drive Head

Dismantling and Assembly - Drive Head

Fig 16.

F3-16

9803/9970-01 (F-04-00)

F3-16

Section F3 - Transmission Front Axle Dismantling and Assembly - Drive Head

Dismantling

Prise the shaft seal 29 out of the bore.

Fig 16. (X F3-16)

Remove the taper roller bearing 30 and tap out the bearing cup 31.

!MWARNING

Tap out the bearing cup 32 from the opposite bearing

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Remove the spacer 34 and bearing 35 from the pinion shaft.

Remove the hydraulic connector 36. Remove and discard the 'O' ring 37.

BF-4-1_1

Remove the drive head from the axle. Removal and Replacement - Drive Head (X F3-14)) Secure it in a vice or suitable jig for dismantling and examination.

Note: During a differential lock repair or piston replacement, inspect the housing for scores, marks or damage which could cause a leak. If necessary, polish the housing with oil-lubricated 800 grade or fine abrasive paper to remove any marks. Alternatively, renew the housing.

Remove circlip 3 from the differential lock housing.

Apply compressed air to the oil feed port (hydraulic connector 38) to force out the piston back plate 4 from the differential lock housing. Remove and discard 'O' rings 5 and 6.

Remove piston 7. Remove 'O' ring 8 and discard.

Remove compression spring 9, thrust sleeve 10, axial roller bearing 11 and end plate 12.

Remove the roll pins 13 and 14 from the castellated nuts. Remove castellated nuts 15 and 16 using a locally manufactured service tool (see drawing in Section 1).

Select shims 33 required for pinion depth setting and fit behind the bearing cup 32 in drive head housing 2. For calculating shim thickness. Pinion Depth (X F3-19)

Fit pinion bearing 35 onto pinion 28. Fit pinion into housing 2.

Fit spacer 34. Solid Spacer Installation (X F3-20)

Fit crown wheel 22 using new Verbus Ripp bolts 21. Torque tighten bolts to 166 Nm (122 lbf ft).

Fit bearings 24 and 25 to differential case spigots (if previously removed) while turning them continuously.

Locate differential case assembly 20 into the housing 2. Locate the differential lock end first by rotating the assembly about the differential lock housing.

Position split bearing carrier 2A. Apply JCB Threadlocker and Sealer to the threads of bolts 18. Fit bolts but do not fully tighten. Fit bearing cup 19 and when correctly seated, torque tighten bolts 18 to 244 Nm (180 lbf ft).

Rotate drive head through 90° so that the differential lock housing is uppermost. Tap bearing cup 17 into position over bearing 24.

Fit both castellated nuts 15 and 16 using a locally manufactured service tool (see drawing in Section 1). Tighten both nuts equally to seat all components, then slacken back. Retighten nuts to give an increase in pinion rolling torque of between 1.5 to 2 Nm (1.1 to 1.5 lbf ft) above that previously recorded. Solid Spacer Installation (X F3-20)

Assembly Lightly oil all bearings and seals before assembly.

Lay the drive head on a flat surface positioned with the split bearing carrier uppermost. The weight of the assembly 20 should be sufficient to push the bearing outer cup 17 off its seat. If not, tap the cup out gently, using the weight of the differential assembly. If the cup cannot be removed using this method, remove as detailed in step 8. Rotate the drive head through 90° to lie in the position shown in the illustration. Undo bolts 18 and remove the split bearing carrier 2A and bearing outer cup 19. Insert a three leg bearing puller into the differential lock housing and remove bearing outer cup 17.

Rotate drive head back through 90° to the vertical position and remove the differential assembly 20.

Remove bolts 21 and separate differential assembly from the crown wheel 22. Do not remove bearings 24 and 25 from differential case assembly 23 unless they are to be renewed.

Remove the pinion nut 26. Use Service Tool 892/ 00812 to prevent the drive flange 27 from rotating whilst removing the nut. Discard the nut.

Remove the drive flange 27.

Drive the pinion shaft 28 out of the drive head carrier.

F3-17

9803/9970-01 (F-04-00)

F3-17

Section F3 - Transmission Front Axle Dismantling and Assembly - Drive Head 10

Using a clock gauge with a magnetic base, check the crown wheel backlash. This should be 0.17 mm to 0.28 mm (0.006 to 0.011 in). To achieve this figure, back off one of the castellated nuts and tighten the other one by a similar amount. It is recommended that this figure is checked in four diametrically opposed places.

Apply engineersâ&#x20AC;&#x2122; marker to 3 or 4 teeth then check the crown wheel and pinion for correct meshing. Crown Wheel and Pinion Adjustment (X F3-22) If this is incorrect, adjust shim 33 accordingly.

Fit roll pin 14.

Fit a new 'O' ring 37 and fit hydraulic connector 36.

Secure the drive head with the differential lock housing uppermost.

Fit new 'O' ring 8 to piston 7. Sub-assemble piston 7, end plate 12, axial roller bearing 11, thrust sleeve 10 and compression spring 9.

Grease the differential lock housing bore and fit subassembly over differential lock actuator. Make sure that the piston is inserted squarely into the bore.

Fit new 'O' rings 5 and 6 to piston back plate 4. Fit back plate 4 over piston 7.

Gently tap the differential lock assembly with a soft faced hammer to seat all components.

Ensure that the groove A in the piston 7 lines up with the castellated nut 15. Fit anti-rotation pin 13 so that it is flush with the housing and 3 - 5 mm (0.12 - 0.2 in) clear of the base of groove A.

Compress the assembly sufficiently to fit circlip 3.

F3-18

9803/9970-01 (F-04-00)

Fig 17.

F3-18

Section F3 - Transmission Front Axle Dismantling and Assembly - Drive Head

Pinion Depth

Example (all dimensions in millimetres)

Large Pinion Bearing Note: The crown wheel and pinion are a matched pair and must be renewed as a pair if either component is damaged or excessively worn. Do not use unmatched components.

Bearing depth W

36.61

Pinion deviation (+2)

+0.02

Housing deviation (-1)

+0.01

Total

36.64

Standard value

37.27

Less total above

36.64

Shim thickness

0.63

Use shim pack size to the nearest 0.05 mm.

Fig 18. Measure direct the depth W of assembled bearing cap 32 and inner bearing 35. The depth W should be between 36.51 and 36.71 mm. If measurement is not possible, use the mean dimension of 36.61 mm. From the face of the pinion obtain the etched deviation figure (e.g. +2) which is in units of 0.01 mm. If positive add this to bearing depth; if negative, subtract from bearing depth. Obtain the deviation figure (e.g. -1) stamped on the bolt flange of housing B. If negative, add to the bearing depth; if positive, subtract from the bearing depth. Subtract the total of the above figures from the standard value of 37.27 mm. the result will be the thickness of shims 33 required behind the pinion head bearing cap

F3-19

9803/9970-01 (F-04-00)

F3-19

Section F3 - Transmission Front Axle Dismantling and Assembly - Drive Head

Solid Spacer Installation Note: Solid spacer setting tools are required for this job (see Service Tools). 1

Install pinion and bearings into the drive head casing. Install largest e.g. 13.6 mm solid spacer 34. Fig 18. (X F3-19) Fit pinion tail bearing (lightly oiled). Do not fit the oil seal at this stage.

Fig 20. 6

To select the right size spacer 34. Fig 18. (X F3-19) Subtract the end float obtained at step 5 from the solid spacer size (e.g 13.6 mm). Also subtract 0.06 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted. If there is no spacer of this size, fit the next closest size spacer.

Example Temporary spacer size Fig 19. 2

Subtract end-float

Fit special tool sleeve A and special pinion shaft adapter B and tighten to 50 Nm. If sleeve A is not available, use the drive flange instead. Fit special bracket C to the drive-head housing using two M12 x 30 nuts and bolts. Fit special tool support pillar Y so that the fork end engages in adapter B. Ensure that fork Y is centrally located on adapter B. If necessary, re-align bracket C to suit.

Fit dial test indicator (DTI) Z. Ensure that the DTI is mounted on the drive head and not on bracket C.

Set torque wrench E to 35 Nm and measure the end float while rotating the shaft.

F3-20

Total Subtract tolerance & preload Result

13.60 0.52 13.08 0.06 13.02

(No spacer available this size, use next closest size spacer i.e 13.00.) 7

Remove sleeve A and fit correct size spacer. Take care to avoid damaging the outer bearing.

Fit sleeve A. Initially tighten adapter B to no more than 50 Nm to protect against bearing damage while spacer selection is verified. Check there is no end float and pinion is free to turn smoothly by hand. Then check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft has been assembled correctly.

9803/9970-01 (F-04-00)

F3-20

Section F3 - Transmission Front Axle Dismantling and Assembly - Drive Head 9

If rolling torque measured at 8 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is assembled correctly.

Remove adapter B and sleeve A. Fit new oil seal, grease between seal lips before fitting. Before fitting the flange, check that the bearing end of the flange is not fretted and renew the flange if required. Clean any oil from the splines of the flange and the shaft. Run an even 2 mm diameter bead of JCB Threadlocker and Sealer around the outer end of the shaft spline. Fit the flange using a new stake nut.

Progressively torque tighten retaining nut to 300 Nm. Provided the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

Note: The nut tightening torque can be increased to a maximum of 390 Nm provided that the rolling torque does not exceed the maximum of 3.4 Nm. 12

Finally stake the nut into the slot.

F3-21

9803/9970-01 (F-04-00)

F3-21

Section F3 - Transmission Front Axle Dismantling and Assembly - Drive Head

Crown Wheel and Pinion Adjustment Meshing of the gears should be checked by marking three of the pinion teeth with engineers' marking compound and rotating the pinion.The marking will then be transferred to the crown wheel teeth.

Fig 23. Pinion too far out of mesh Fig 18. (X F3-19) Increase the thickness of shim 33 between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

Fig 21. Correct tooth marking.

Fig 22. Pinion too deeply in mesh Fig 18. (X F3-19) Decrease the thickness of shim 33 between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

F3-22

9803/9970-01 (F-04-00)

F3-22

Section F3 - Transmission Front Axle Dismantling and Assembly - Differential

Dismantling and Assembly - Differential

Fig 24.

F3-23

9803/9970-01 (F-04-00)

F3-23

Section F3 - Transmission Front Axle Dismantling and Assembly - Differential

Dismantling

The numerical sequence is intended as a guide to dismantling.

When satisfactory, apply JCB Threadlocker and Sealer to the threads of bolts 1 and fit. Tighten to 56 Nm, (41.3 lbf ft). Check free rotation of the gears in the horizontal position (see step 5).

For assembly the sequence should be reversed. 1

Secure the assembly in a vice or suitable jig for dismantling and examination.

Remove the bolts 1 and separate the differential lock case 2 from the rest of the assembly.

Remove actuating sleeve 3.

Remove 11 counter plates 4 and 10 friction plates 5 from the differential pinion gear 8.

Separate the differential case halves 6 and 14.

Remove the pinion gear 8, bevel gears 10, trunnion pins 9, and thrust washers 11 from the case halves. Remove the thrust washers 7 and 13 from both case halves.

Assembly Note: The bevel gears are a matched set, as are the two differential case halves also the crown wheel and pinion. These must be renewed as sets if any of their components are damaged or excessively worn. Do not use unmatched components. Note: The differential case halves are stamped for matching purposes. The stamp on the crown wheel case half can only be seen when the crown wheel is removed. 1

Assemble the trunnion pins 9, bevel gears 8, 10, 12, and their thrust washers 7, 11 and 13 into the differential case half 14.

Position the differential case half 6 aligning the match mark letters.

Fit 11 counter plates 4 and 10 friction plates 5, starting and finishing with a counter plate. Make sure the counter plate tabs are aligned.

Position the actuating sleeve 3 on top of the last counter plate. Position the differential lock case 2 over the counter and friction plates and align the bolt holes with those of the differential case half 6.

Check free rotation of the gears in the horizontal position (If held vertically the friction and counter plates would prevent rotation).

Using a hand pump test the differential lock for correct operation and leaks. Do not exceed a pressure of 35 bar (500 lbf/in2).

F3-24

9803/9970-01 (F-04-00)

F3-24

Section F4 - Transmission

Rear Axle Introduction

K Removal and Replacement - Differential Oil Seal ( T F4-2) K Dismantling and Assembly - Rear PTO Drive Shaft ( T F4-4) K Installation - Rear PTO Output Shaft ( T F4-6) K Removal and Replacement ( T F4-7) K Dismantling and Assembly - Hub and Drive Shaft ( T F4-10) K Removal and Replacement - Drive Head ( T F4-13) K Dismantling and Assembly - Drive Head ( T F4-15) K Dismantling and Assembly - Differential ( T F4-23)

F4-1

9803/9970-01 (F-11-00)

F4-1

Section F4 - Transmission Rear Axle Removal and Replacement - Differential Oil Seal

Removal and Replacement - Differential Oil Seal This job can be done with the axle either removed or in situ on the machine.

not to distort it. Ensure that the seal is square and pushed fully home. 4

Install the old stake nut temporarily. Then, using a torque wrench determine the torque required to align the scribed lines (see step 1). Remove and discard the old stake nut.

Fit the coupling flange with a new stake nut.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1

Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.

Fig 2. a

b Measure the rolling torque. The reading should be 0.5to 1 Nm (0.37 to 0.74 lbf ft, 0.05 to 0.1 kgf m) more than that recorded in Step 1 (see Note).

Fig 1. 2

F4-2

Using Service Tool 892/00812, tighten nut to 250Nm (184 lbf ft, 25.5 kgf m).

If necessary, progressively torque tighten nut to achieve correct rolling torque.

9803/9970-01 (F-11-00)

F4-2

Section F4 - Transmission Rear Axle Removal and Replacement - Differential Oil Seal 7

Fill the axle or differential casing with the specified oil, (see Section 3 - Routine Maintenence).

F4-3

9803/9970-01 (F-11-00)

F4-3

Section F4 - Transmission Rear Axle Dismantling and Assembly - Rear PTO Drive Shaft

Dismantling and Assembly - Rear PTO Drive Shaft

Fig 3.

F4-4

9803/9970-01 (F-11-00)

F4-4

Section F4 - Transmission Rear Axle Dismantling and Assembly - Rear PTO Drive Shaft K Fig 3. ( T F4-4).

to bed in the bearings. Check that the seal drag is between 0.50 - 1 Nm (0.37 - 0.75 lbf ft).

The numerical sequence is intended as a guide to dismantling.

For assembly the sequence should be reversed.

When Dismantling

Note: If the specified rolling torque is exceeded, the collapsible spacer 13 will be distorted. This spacer must be renewed and a start made again at step 2.

Undo bolts 4 and remove PTO guard 5. Disconnect prop shaft from drive flange 8 to gain access to stake nut 7. Remove and discard the stake nut and then remove drive flange 8. Drive out shaft 10 towards the rear of the machine. Make sure the shaft is withdrawn horizontally, otherwise the collapsible spacer 13 may fall into the axle casing. Catch inner bearing race 11 as it falls off the shaft. Inner bearing race 14 will remain on the shaft and must be driven off if bearings are to be renewed.

When pre-load has been set, stake nut 7.

Pack JCB HP grease between the lips of a new rear oil seal 6 and fit into the casing, with the seal lips facing inwards. Make sure the oil seal is fitted squarely and is fully seated.

Check that the final rolling torque with the rear oil seal fitted is approximately 5 Nm (3.7 lbf ft) greater than that measured in step 5.

Before fitting the PTO output shaft 3, washer 2 and circlip 1. K Installation - Rear PTO Output Shaft ( T F4-6).

The rear PTO propshaft must be fitted with the sliding joint at the axle end to prevent the possibility of fouling when the limit of suspension travel is reached.

Assembly Note: Soak oil seal 6 in mineral oil for approximately 10 minutes before fitting. 1

Use a suitable length of tube to drive new inner bearing race 14 onto drive shaft 10 until it butts up to shoulder C. Pre pack bearings with JCB HP Grease.

Fit bearing cup 12 into the drive head and bearing cup 15 into the axle casing. Fit collapsible spacer 13 to the drive shaft 10 and insert into the axle. Make sure the drive shaft is inserted horizontally otherwise the collapsible spacer may fall off into the axle casing. Fit bearing 11. Pack JCB HP Grease between the lips of a new oil seal 9 and fit into the casing, with the seal lips facing inwards. Make sure the oil seal is fitted squarely and is fully seated. Do not fit seal 6 at this stage.

Apply an even 2 mm bead of JCB Threadlocker and Sealer around the outer end of the drive shaft spline at the drive flange end. Fit drive flange 8 and a new stake nut 7.

Tighten stake nut 7 until the drive shaft end float is almost zero. Rotate the drive flange in both directions

F4-5

Continue tightening stake nut 7 to collapse the spacer 13 to give a rolling torque of 1 to 1.5 Nm (0.7 to 1.1 lbf ft) more than the previous reading given in step 4.

Note: When assembly is complete, grease both drive shaft bearings 11 and 14, see Section 3 - Greasing. It is important that these greasing instructions are followed correctly.

9803/9970-01 (F-11-00)

F4-5

Section F4 - Transmission Rear Axle Installation - Rear PTO Output Shaft

Installation - Rear PTO Output Shaft General All models have a two speed capability for PTO drive. Two rear PTO output shafts are available, as detailed below, to suit differing implement shaft sizes, speeds and power requirements. The standard 35 mm (13/8 in) output shaft A has 6 splines at one end (for 540 PTO RPM operation) and 21 splines at the other end (for 1000 PTO RPM operation). The optional 45 mm (13/4 in) shaft B is available in either 6 or 20 spline versions. As a general rule, only use the 6 spline (540 PTO RPM) end of shaft A for equipment having a power requirement of less than 49 kW (65 hp). Equipment needing a higher power output should be run at 1000 PTO RPM, using the 21 (A) or 20 (B) splined drive.

Fitting Fig 3. (X F4-4) K Fig 4. ( T F4-6) Tilt the PTO guard 5 upwards to gain access. To reverse standard shaft A, remove the circlip 1, washer 2 and withdraw the shaft. Insert the shaft facing the opposite way and refit the washer and circlip. Ensure that the washer is fitted with the chamfer towards the shaft housing.

Fig 4.

When optional shaft B is required, fit the shaft either way round and secure with circlip 1. Do not fit the washer 2.

F4-6

9803/9970-01 (F-11-00)

F4-6

Section F4 - Transmission Rear Axle Removal and Replacement

Removal and Replacement

Fig 5.

F4-7

9803/9970-01 (F-11-00)

F4-7

Section F4 - Transmission Rear Axle Removal and Replacement

Disconnect and remove the draft pins and the position sensor, (see Section B). Remove pick-up hitch lift rods E and remove pins D1 to disconnect the 3 point linkage stabilisers D. Remove the lift rod bottom pins B.

Slacken the linkage bracket bolts G (5 at each outboard end of the axle). Drive out the pick-up hitch front pivot pin H and then lower the pick-up hitch down to the ground.

Remove the circlips J from top and bottom of the lift cylinders B attachment points and remove the lift cylinder bottom pins. Slide the cylinders B off the top pins.

Remove driveshafts (i.e. main drive and PTO).

Lower the rear suspension so that the chassis sits on its bump stops

Wait for the suspension to rise and repeat step 8 to fully discharge the oil pressure in the hydraulic circuit. Disconnect both position sensor link rods L from the control arms T.

Disconnect the lower pin of the two suspension cylinders N.

Jack up the axle and chassis, place axle stands under the tube cross member. Fully support or sling the axle.

Remove the clamps/bushes P securing anti-roll bar R to the axle (see Section S - Rear Suspension SYSTEM).

Disconnect the 'V' link arm S at the top of the axle.

Disconnect the two control arms T at the axle end.

If rebound straps are fitted as shown at V, disconnect the top end of the straps from the chassis by removing bolts W.

If using an overhead gantry, lower the axle slightly and move it out to the rear. If using a jack then lower the axle and drag to the rear.

If using an overhead gantry, lower the axle slightly and move it out to the rear. If using a jack then lower the axle and drag to the rear.).

3-3-1-1

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Removal Fig 5. (X F4-7) 1

Position trolley jacks under the axle and raise the wheels off the ground.

Remove the road wheels and drain oil from the hubs/ axle. a

Disconnect brake pipes A, hydraulic hoses to pick-up hitch lift cylinders B plus the hydraulic connection to the differential lock C. Ensure that all pipes and connections are sealed to prevent loss of fluid and ingress of dirt.

F4-8

9803/9970-01 (F-11-00)

F4-8

Section F4 - Transmission Rear Axle Removal and Replacement

Replacement Fig 5. (X F4-7) Replacement is a reversal of the removal procedure. Before fitting bolts G, ensure that there is no debris between the axle and the linkage brackets that might prevent the axle and brackets from seating correctly. Treat all bolt threads with JCB Threadlocker and Sealer. Tighten bolts G to 700 Nm (516 lbf ft, 71.4 kgf m). Ensure that bushes X are fitted onto bolts W. Do the following replacement procedures: – Suspension Cylinders (see Section S - Rear Suspension SYSTEM). – Anti-Roll Bar (see Section S - Rear Suspension SYSTEM). – ‘V’ Link (see Section S - Rear Suspension SYSTEM). – Control Arms (see Section S - Rear Suspension SYSTEM). – Propshaft (see Section F - Propshafts). Ensure the axle is filled with the correct oil (see Section 3). Set the rear ride height (see Section S - Rear Suspension SYSTEM). Bleed the brakes (see Section G).

F4-9

9803/9970-01 (F-11-00)

F4-9

Section F4 - Transmission Rear Axle Dismantling and Assembly - Hub and Drive Shaft

Dismantling and Assembly - Hub and Drive Shaft

Fig 6.

F4-10

9803/9970-01 (F-11-00)

F4-10

Section F4 - Transmission Rear Axle Dismantling and Assembly - Hub and Drive Shaft

Dismantling

Fig 6. (X F4-10)

Support planet gear carrier (pin head downwards) on suitable blocks. Drive out pins 24 one at a time.

Drain the oil from the axle and hub. Remove screws 1. Use M10 screws (3 off) to jack off cover plate 2. Remove and discard 'O' ring 3.

Note: Retain pin 24, thrust washer 25, needle rollers 26 and spacer 27. Make sure that components from each position are not mixed. Make sure that all the rollers are accounted for.

Pull out the driveshaft thrust pad 4.

Remove screws 5.

Note: All three pins must be removed before the planet gears can be removed.

Suitably support planet gear carrier 6; using M10 screws (3 off), separate the carrier from bearing housing 7.

Assembly

Remove circlip 8, sun gear 9 and thrust washer 10.

Remove and discard 'O' ring 11.

Remove circlip 12 and annulus ring 13.

Suitably support bearing housing 7, remove circlip 14 and locking plates 15. Remove nut 16 using special tool 892/00864.

Remove planet gears 28 and thrust washers 29.

Fig 6. (X F4-10) Note: Stub Z is secured on early machines by bolts Y which screw into tapped holes on the axle (as shown opposite). On later machines bolts Y pass through clearance holes on the axle and are secured by nuts at the rear (not shown).

Remove bearing housing 7 and annulus carrier 17 together. Separate carrier and hub.

Remove the brake caliper (see Section G).

If required, unscrew bolts 30 to remove brake disc W. Remove bearing cone 18 using a suitable puller. On ABS machines remove the ABS sensor (see Section G).

Remove bearing cups 19 and 20.

Remove inner bearing cone 21 and seal 23.

Check bearing spacer 22 for damage and security. If necessary, it can be removed using a suitable puller. To fit a new spacer, proper heating equipment is required.

Check seal shield X for damage, security and cleanliness. Mark planet gear pins 24 and planet gear carrier 6 to make sure pins are returned to the same position when assembling.

F4-11

Secure stub Z with bolts Y (or bolts/nuts Y as appropriate), tightened to 650 Nm (480 lbf ft). Lightly oil the inner wheel bearing. Fit the inner and outer bearing cups 19 and 20 and the inner bearing cone 21 into the bearing housing 7.

Before fitting combination seal 23, ensure that all paint and dirt are removed from the nose of the carrier and the housing bore. Do not separate the components of the seal or use excessive force when fitting. Do not lubricate the seal.

Without dismantling or lubricating the new seal, drive it into the bearing carrier until the locating lip is flush as shown at B. Fig 7. (X F4-12) Use a suitable flat plate to ensure that the seal is driven in squarely

Suitably support bearing housing 7. Fit the bearing housing onto the stub Z.

Lightly oil the outer wheel bearing cone 18. Fit onto annulus carrier 17.

Fit the annulus ring 13 onto the annulus carrier 17. Secure with circlip 12.

Fit annulus assembly (items 18, 17, 13 and 12) onto stub Z. Secure with nut 16.

9803/9970-01 (F-11-00)

F4-11

Section F4 - Transmission Rear Axle Dismantling and Assembly - Hub and Drive Shaft 15

Secure brake disc W with bolts 30 tightened to 166 Nm (122 lbf ft). Suitably support planet gear carrier 6 and refit to bearing carrier 7, secure with screws 5. Tighten to 66 to 74 Nm (49 to 55 lbf ft). a

ABS machines only Replace the ABS sensor (see Section G).

Fig 7.

Insert drive shaft, Fit thrust washer 10 onto the shoulder of sun gear 9. Secure with circlip 8.

Force fit driveshaft thrust pad 4 into cover plate 2. Lubricate 'O' ring 3 with clean oil. Fit 'O' ring to cover plate.

Fit cover plate into side gear carrier.

Apply JCB Lock and Seal to screws 1. Fit screws and tighten to 33 to 37 Nm (24 to 27 lbf ft).

Note: Rotate bearing carrier backwards and forwards while carrying out torque tightening sequence. 8

Gradually tighten nut to the lower limit of tightening torque 700 to 1000 Nm (516 to 738 lbf ft). Fit locking plates 15. If locking plates will not fit, further tighten nut.

Important: Do not exceed the upper torque limit. 9

Fit lock plates 15 and secure with circlip 14.

Fit new O ring 11.

Position the three planet gears 28 and inner thrust washers 29 into the planet gear carrier 6.

Position thrust washer 25 onto pin 24. Smear the lower half (head end) of pin with grease and position first row of twenty-five needle rollers 26. Fit spacer 27, smear upper portion of pin with grease and position second row of twenty-five needle rollers.

Align planet gear 28 and thrust washer 29. Fit pin as assembled in step 11. Take great care not to dislodge any of the needle rollers.

Repeat steps 11 and 12 for other two pins.

Note: Make sure that the machined profile on the pin heads is aligned with the side gear carrier machining.

F4-12

9803/9970-01 (F-11-00)

F4-12

Section F4 - Transmission Rear Axle Removal and Replacement - Drive Head

Removal and Replacement - Drive Head

Fig 8.

F4-13

9803/9970-01 (F-11-00)

F4-13

Section F4 - Transmission Rear Axle Removal and Replacement - Drive Head

!MWARNING

Dismantling and Assembly - Rear PTO Drive Shaft (X F4-4)

Remove the two bolts 3. Lever off the planet gear carrier 4 at one end of the axle, at levering points provided. Remove and discard the â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring. Dismantling (X F4-11)

Pull the driveshafts out of the axle.

Support the drive head 6 with a trolley jack.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Remove bolts 5 and pull out the drive head 6 from the axle.

Remove two dowels 7 from the axle 8, if loose.

Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

!MWARNING

Replacement

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

K Fig 8. ( T F4-13)

BF-4-1_1

Replacement is the reversal of the removal procedure.

Note: This job can be done with the axle in situ if required.

Treat all mating surfaces with JCB Multigasket.

Removal

Fit the two bolts 3 (PD70/SD70) and tighten to a torque of 56 Nm (41 lbf ft, 5.7 kgf m).

Fig 8. (X F4-13) 1

If the axle is in situ, support the chassis. Removal and Replacement (X F4-7) Taking the full weight of the rear of the vehicle on the axle stands, plus overhead craneage if available.

Remove the road wheels and drain oil from hubs/ axle.

Disconnect hydraulic connection 1 at the differential lock. Seal the hydraulic connection to prevent loss of fluid.

Disconnect the main propshaft at flange 2.

Treat bolts 5 with JCB Threadlocker and Sealer. Tighten to a torque of 166 Nm (122 lbf ft, 17 kgf m). Before connecting the propshafts, see Section F Propshafts.

Note: Before removing the drive head, disconnect the rear PTO prop shaft and then remove the PTO driveshaft,

F4-14

9803/9970-01 (F-11-00)

F4-14

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head

Dismantling and Assembly - Drive Head

Fig 9.

F4-15

9803/9970-01 (F-11-00)

F4-15

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head

Dismantling

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Remove the taper roller bearing 30 and tap out the bearing cup 31.

Tap out the bearing cup 32 from the opposite bearing housing and remove the drive pinion shim 33.

Remove the spacer 34 and bearing 35 from the pinion shaft.

Remove the drive head from the axle. Removal and Replacement - Drive Head (X F4-13) Secure it in a vice or suitable jig for dismantling and examination.

Remove the bleed valve and dust cap 36 and 37. Keep the dust cap with the bleed valve.

Remove circlip 3 from the differential lock housing.

Remove the hydraulic connector 38. Remove and discard the 'O' ring 39.

Apply compressed air to the oil feed port (hydraulic connector 38) to force out the piston back plate 4 from the differential lock housing. Remove and discard 'O' rings 5 and 6.

Remove piston 7. Remove 'O' ring 8 and discard.

Remove compression spring 9, thrust sleeve 10, axial roller bearing 11 and end plate 12.

Remove the roll pins 13 and 14 from the castellated nuts. Remove castellated nuts 15 and 16 using a locally manufactured service tool (see drawing in Section 1).

Rotate the drivehead through 90Â° to lie in the position shown in the illustration. Undo bolts 18 and remove the split bearing carrier 2A and bearing outer cup 19. Insert a three leg bearing puller into the differential lock housing and remove bearing outer cup 17.

Rotate drivehead back through 90Â° to the vertical position and remove the differential assembly 20.

Remove bolts 21 and separate differential assembly from the crown wheel 22. Do not remove bearings 24 and 25 from differential case assembly 23 unless they are to be renewed.

Remove the pinion nut 26. Use Service Tool 892/ 00812 to prevent the drive flange 27 from rotating whilst removing the nut. Discard the nut.

Remove the drive flange 27.

Drive the pinion shaft 28 out of the drive head carrier.

Prise the shaft seal 29 out of the bore.

F4-16

9803/9970-01 (F-11-00)

F4-16

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head

Assembly

Wheel and Pinion Adjustment (X F4-22) If this is incorrect, adjust shim 33 accordingly.

Lightly oil all bearings and seals before assembly. 1

Select shims 33 required for pinion depth setting and fit behind the bearing cup 32 in drive head housing 2. Calculate the correct shim tickness. Pinion Depth (X F4-19)

Fit pinion bearing 35 onto pinion 28. Fit pinion into housing 2.

Fit spacer 34. Solid Spacer Installation (X F4-20)

Fit crown wheel 22 using new Verbus Ripp bolts 21. Torque tighten bolts to 166 Nm (122 lbf ft).

Fit bearings 24 and 25 to differential case spigots (if previously removed) while turning them continuously.

Locate differential case assembly 20 into the housing 2. Locate the differential lock end first by rotating the assembly about the differential lock housing.

Rotate drive head through 90Â° so that the differential lock housing is uppermost. Tap bearing cup 17 into position over bearing 24.

Apply engineersâ&#x20AC;&#x2122; marker to 3 or 4 teeth then check the crown wheel and pinion for correct meshing. Crown

F4-17

Fit roll pin 14.

Fit bleed valve and cap 36 and 37. Fit a new 'O' ring 40 and fit hydraulic connector 38.

Secure the drive head with the differential lock housing uppermost.

Fit new 'O' ring 8 to piston 7. Sub-assemble piston 7, end plate 12, axial roller bearing 11, thrust sleeve 10 and compression spring 9.

Grease the differential lock housing bore and fit subassembly over differential lock actuator. Make sure that the piston is inserted squarely into the bore.

Fit new 'O' rings 5 and 6 to piston back plate 4. Fit back plate 4 over piston 7.

Gently tap the differential lock assembly with a soft faced hammer to seat all components.

Compress the assembly sufficiently to fit circlip 3.

9803/9970-01 (F-11-00)

F4-17

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head

Fig 10.

F4-18

9803/9970-01 (F-11-00)

F4-18

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head

Pinion Depth

Example (all dimensions in millimetres)

Large Pinion Bearing Note: The crown wheel and pinion are a matched pair and must be renewed as a pair if either component is damaged or excessively worn. Do not use unmatched components.

Bearing depth W

36.61

Pinion deviation (+2)

+0.02

Housing deviation (-1)

+0.01

Total

36.64

Standard value

37.27

Less total above

36.64

Shim thickness

0.63

Use shim pack size to the nearest 0.05 mm.

Fig 11. Measure direct the depth W of assembled bearing cap 32 and inner bearing 35. The depth W should be between 36.51 and 36.71 mm. If measurement is not possible, use the mean dimension of 36.61 mm. From the face of the pinion obtain the etched deviation figure (e.g. +2) which is in units of 0.01 mm. If positive add this to bearing depth; if negative, subtract from bearing depth. Obtain the deviation figure (e.g. -1) stamped on the bolt flange of housing B. If negative, add to the bearing depth; if positive, subtract from the bearing depth. Subtract the total of the above figures from the standard value of 37.27 mm. the result will be the thickness of shims 33 required behind the pinion head bearing cap

F4-19

9803/9970-01 (F-11-00)

F4-19

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head

Solid Spacer Installation Note: Solid spacer setting tools are required for this job (see Service Tools). 1

Fig 11. (X F4-19) Install pinion and bearings into the drive head casing. Install largest e.g. 13.6 mm solid spacer 34 and fit pinion tail bearing (lightly oiled). Do not fit the oil seal at this stage.

Fig 13. 6

Fig 11. (X F4-19) Select the right size spacer 34. Subtract the end float obtained at step 5 from the solid spacer size (e.g 13.6 mm). Also subtract 0.06 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted. If there is no spacer of this size, fit the next closest size spacer.

Example Temporary spacer size Fig 12. 2

Subtract end-float

Fit dial test indicator (DTI) Z. Ensure that the DTI is mounted on the drive head and not on bracket C.

Set torque wrench E to 35 Nm and measure the end float while rotating the shaft.

F4-20

Total Subtract tolerance & preload Result

13.60 0.52 13.08 0.06 13.02

(No spacer available this size, use next closest size spacer i.e 13.00.) 7

Remove sleeve A and fit correct size spacer. Take care to avoid damaging the outer bearing.

9803/9970-01 (F-11-00)

F4-20

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head 9

Progressively torque tighten retaining nut to 300 Nm. Provided the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

Note: The nut tightening torque can be increased to a maximum of 390 Nm provided that the rolling torque does not exceed the maximum of 3.4 Nm. 12

Finally stake the nut into the slot.

F4-21

9803/9970-01 (F-11-00)

F4-21

Section F4 - Transmission Rear Axle Dismantling and Assembly - Drive Head

Fig 16. Pinion too far out of mesh Fig 11. (X F4-19) Increase the thickness of shim 33 between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

Fig 14. Correct tooth marking.

Fig 15. Pinion too deeply in mesh Fig 11. (X F4-19) Decrease the thickness of shim 33 between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

F4-22

9803/9970-01 (F-11-00)

F4-22

Section F4 - Transmission Rear Axle Dismantling and Assembly - Differential

Dismantling and Assembly - Differential

Fig 17.

F4-23

9803/9970-01 (F-11-00)

F4-23

Section F4 - Transmission Rear Axle Dismantling and Assembly - Differential The numerical sequence is intended as a guide to dismantling.

Check free rotation of the gears in the horizontal position (If held vertically the friction and counter plates would prevent rotation).

Using a hand pump test the differential lock for correct operation and leaks. Do not exceed a pressure of 35 bar (500 lbf/in2).

When satisfactory, apply JCB Threadlocker and Sealer to the threads of bolts 1 and fit. Tighten to 56 Nm, (41.3 lbf ft). Check free rotation of the gears in the horizontal position (see step 5).

For assembly the sequence should be reversed.

Dismantling 1

Secure the assembly in a vice or suitable jig for dismantling and examination.

Remove the bolts 1 and separate the differential lock case 2 from the rest of the assembly.

Remove actuating sleeve 3.

Remove 11 counter plates 4 and 10 friction plates 5 from the differential pinion gear 8.

Separate the differential case halves 6 and 14.

Remove the pinion gear 8, bevel gears 10, trunnion pins 9, and thrust washers 11 from the case halves. Remove the thrust washers 7 and 13 from both case halves.

Assemble the trunnion pins 9, bevel gears 8, 10, 12, and their thrust washers 7, 11 and 13 into the differential case half 14.

Position the differential case half 6 aligning the match mark letters.

Fit 11 counter plates 4 and 10 friction plates 5, starting and finishing with a counter plate. Make sure the counter plate tabs are aligned.

F4-24

9803/9970-01 (F-11-00)

F4-24

Section F5 - Transmission

Propshafts Introduction

K Removal and Replacement ( T F5-2)

F5-1

9803/9970-01 (F-06-00)

F5-1

Section F5 - Transmission Propshafts Removal and Replacement

Removal and Replacement There are three types of propshaft coupling, two of which, flange coupled types A/B/C and type D are illustrated The third, type E, is described below. Also illustrated are propshaft layouts showing the type of coupling at each location for different machines.

Coupling Type A

A302390-B1

Fig 2.

A290601-B1

Fig 1. 1

Remove nuts 1 from studs 2.

Retract flange 3 by telescoping the shaft and then lower clear of its mating flange.

Removal

Coupling Type B

3-3-1-1

Important: Disconnecting propshafts will cause the park brake to be ineffective. Block all four wheels before separating a propshaft joint. Note: Before separating any of the drive shaft couplings (flange plates, universal joints, splined shafts), mark both halves to ensure correct positioning on reassembly.

A343820-B1

Fig 3.

F5-2

9803/9970-01 (F-06-00)

F5-2

Section F5 - Transmission Propshafts Removal and Replacement 1

Remove nuts 5/bolts 6 and separate driveshaft flange 7 from the gearbox front flange (or axle flange) 8 as appropriate.

Coupling Type C

Lower the end of the shaft clear of yoke 15.

Coupling Type E Note: Not illustrated 1

This has a yoke end with sliding splines. After disconnecting the other end of the shaft, slide the splined yoke off the mating shaft.

A343810-B1

Fig 4. 1

Remove and discard Verbus Ripp bolts 9. Separate drive shaft 10 from axle flange 11.

Remove the rear driveshaft by lowering to the ground. Remove the front driveshaft by withdrawing it from the driveshaft protective bracket.

Coupling Type D

S302531-B1

Fig 5. 1

Remove bolts 12, washers 13 and straps 14.

F5-3

9803/9970-01 (F-06-00)

F5-3

Section F5 - Transmission Propshafts Removal and Replacement

Replacement Lay each propshaft on a flat surface to check that both ends are exactly on the same plane, as shown at X. The yokes must not be at right-angles (as at Y) or at an intermediate angle (as at Z). If necessary, separate the two halves of the shaft and re-align. Replacement is basically the reverse of the removal procedure but ensure match-marks are aligned (see Step 1 in Removal). Note: Verbus Ripp bolts 9, illustrated below, must never be re-used. When the propshaft has been disconnected, fit new bolts when re-connecting.

A306260-B1

Fig 7. A343780

Fig 6. – On Type D couplings, lightly grease the insides of straps 14 before assembly and use new bolts 12 and washers 13. – On Type E, grease the splines before fitting. – The rear PTO propshaft must be fitted with the sliding joint at the axle end to prevent the possibility of fouling when the limit of suspension travel is reached. – Torque tighten Settings ( T F5-4)

the

nuts.

K Torque

– Thoroughly purge all universal joints with grease. If any bearing fails to purge, move the shaft from side to side and then purge. This allows greater clearance on the thrust end of the bearing that is not purging. Wipe away any excess grease.

Item

Table 1. Torque Settings Nm kgf m

lbf ft

120

12.24

88.5

8.16

62.5

6.38

46.1

75 - 85

7.65 - 8.7

55.3 - 62.7

F5-4

9803/9970-01 (F-06-00)

F5-4

Section G Brakes Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section G - Brakes

Notes:

G-0

9803/9970-01

G-0

Section G - i Contents

Contents Page No. Brake SYSTEM (Non-ABS) Introduction ............................................................................................. G1-1 Technical Data ........................................................................................ G1-2 Service Tools .......................................................................................... G1-3 Operation Overview ................................................................................ G1-4 Air Pipes - Colour Codes .................................................................... G1-5 Air Compression ................................................................................. G1-6 Front Brake Circuit ............................................................................. G1-6 Rear Brake Circuit .............................................................................. G1-6 Trailer/Parking Brake Circuit ............................................................... G1-7 Parking Brake Circuit .......................................................................... G1-7 Tractor Services Circuit ...................................................................... G1-7 Hydraulic Trailer Brakes (if fitted) ....................................................... G1-7 Fault Finding ........................................................................................... G1-8 Introduction ......................................................................................... G1-8 Tables ................................................................................................. G1-8 Bleeding ............................................................................................... G1-12 Brake SYSTEM (ABS) Introduction ............................................................................................. G2-1 Techinical Data ....................................................................................... G2-2 Service Tools .......................................................................................... G2-3 Operation Overview ................................................................................ G2-4 Air Pipes - Colour Codes .................................................................... G2-5 Air Compression ................................................................................. G2-6 Front Brake Circuit ............................................................................. G2-6 Rear Brake Circuit .............................................................................. G2-6 Trailer/Parking Brake Circuit ............................................................... G2-6 Parking Brake Circuit .......................................................................... G2-7 Tractor Services Circuit ...................................................................... G2-7 Hydraulic Trailer Brakes (if fitted) ....................................................... G2-7 Tractor ABS ........................................................................................ G2-8 Fault Finding ......................................................................................... G2-11 Introduction ....................................................................................... G2-11 Tables ............................................................................................... G2-11 Bleeding ............................................................................................... G2-14 Service Brake Calipers Introduction ............................................................................................. G3-1 Removal and Replacement .................................................................... G3-2 Removal ............................................................................................. G3-2 Replacement ...................................................................................... G3-3 Dismantling and Assembling .............................................................. G3-4 Park Brake Caliper Introduction ............................................................................................. G4-1 Removal and Replacement .................................................................... G4-2 Dismantling and Assembly ..................................................................... G4-5 Service Brakes Air Valve Introduction ............................................................................................. G5-1 Removal and Replacement .................................................................... G5-2 Removal ............................................................................................. G5-3 Replacement ...................................................................................... G5-3 Dismantling and Assembly ..................................................................... G5-4

G-i

Section G - i Contents

Contents Page No. Air/Hydraulic Actuator Introduction ............................................................................................. G6-1 Removal and Replacement .................................................................... G6-2 Removal ............................................................................................. G6-2 Replacement ...................................................................................... G6-3 Testing .................................................................................................... G6-4 Dismantling and Assembly ..................................................................... G6-5 Bench Testing ......................................................................................... G6-6 Air Dryer/Unloader Valve Introduction ............................................................................................. G7-1 Removal and Replacement .................................................................... G7-2 Removal ............................................................................................. G7-3 Replacement ...................................................................................... G7-3 Dismantling and Assembly ..................................................................... G7-4 Non Return Air Valve Introduction ............................................................................................. G8-1 Dismantling and Assembly ..................................................................... G8-2 Failure Conscious Reducing Valve (Non ABS) Introduction ............................................................................................. G9-1 Removal and Replacement .................................................................... G9-2 Removal ............................................................................................. G9-2 Replacement ...................................................................................... G9-2 Circuit Protection Valve Introduction ........................................................................................... G10-1 Removal and Replacement .................................................................. G10-2 Removal ........................................................................................... G10-2 Replacement .................................................................................... G10-3 ABS Sensors (ABS) Introduction ........................................................................................... G11-1 Removal and Replacement .................................................................. G11-2 Removal ........................................................................................... G11-2 Replacement .................................................................................... G11-2 Pressure Modulating Valves (ABS) Introduction ........................................................................................... G12-1 Removal and Replacement .................................................................. G12-2 Removal ........................................................................................... G12-2 Replacement .................................................................................... G12-2 Trailer Brake Air Valve Introduction ........................................................................................... G13-1 Removal and Replacement .................................................................. G13-2 Removal ........................................................................................... G13-2 Replacement .................................................................................... G13-3 Testing .................................................................................................. G13-4 Dismantling and Assembly ................................................................... G13-5 When Dismantling ............................................................................ G13-5 Cleaning and Inspection ................................................................... G13-5 When Assembling ............................................................................ G13-5 Bench Tests ...................................................................................... G13-7

G-ii

Section G - i Contents

Contents Page No. Trailer Brake Hydraulic Valve Introduction ........................................................................................... G14-1 Removal and Replacement .................................................................. G14-2 When Removing ............................................................................... G14-2 When Replacing ............................................................................... G14-2 Dismantling and Assembly ............................................................... G14-3 Trailer Brake Inverse Relay Valve Introduction ........................................................................................... G15-1 Removal and Replacement .................................................................. G15-2 Removal ........................................................................................... G15-2 Replacement .................................................................................... G15-2 Dismantling and Assembly ................................................................... G15-3 When Dismantling ............................................................................ G15-3 When Assembling ............................................................................ G15-3 Trailer Brake Control Line Air Filter Introduction ........................................................................................... G16-1 Dismantling and Assembly ................................................................... G16-2 Trailer Brake Couplings (Palm Couplings) Introduction ........................................................................................... G17-1 Dismantling and Assembly ................................................................... G17-2

G-iii

Section G1 - Brakes

Brake SYSTEM (Non-ABS) 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.. Descriptions and procedures relate to the system and not the individual devices. 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. K Technical Data ( T G1-2) K Service Tools ( T G1-3) K Operation Overview ( T G1-4) K Air Pipes - Colour Codes ( T G1-5) K Air Compression ( T G1-6) K Front Brake Circuit ( T G1-6) K Rear Brake Circuit ( T G1-6) K Trailer/Parking Brake Circuit ( T G1-7) K Parking Brake Circuit ( T G1-7) K Tractor Services Circuit ( T G1-7) K Hydraulic Trailer Brakes (if fitted) ( T G1-7) K Fault Finding ( T G1-8) K Bleeding ( T G1-12)

G1-1

9803/9970-01 (G-01-00)

G1-1

Section G1 - Brakes Brake SYSTEM (Non-ABS) Technical Data

Technical Data System Operating pressure (air)

8 bar

(120 lbf/in2)

3 mm

(0.12 in)

New

9.5 mm

(0.374 in)

Minimum

8.9 mm

(0.350 in)

3 mm

(0.12 in)

Parking Brake Minimum pad thickness Disc thickness

Service Brakes Minimum pad thickness Front disc thickness New

22 mm

(0.866 in)

Minimum

19.8 mm

(0.780 in)

New

16 mm

(0.630 in)

Minimum

14.3 mm

(0.563 in)

Rear disc thickness

G1-2

9803/9970-01 (G-01-00)

G1-2

Section G1 - Brakes Brake SYSTEM (Non-ABS) Service Tools

Service Tools The following special service tools are needed for procedures detailed in this section. Part Number

Description

892/00311

Brake test kit 3 x Calibrated test gauges - 0-20 bar (0 - 290 lbf/in2) 3 x 5 metre hoses with quick release adaptors 3 x ISO test point adapters

S199470

G1-3

9803/9970-01 (G-01-00)

G1-3

Section G1 - Brakes Brake SYSTEM (Non-ABS) Operation Overview

Operation Overview

418530

Fig 1.

P V

G3 G2 G1 417790-C4

Fig 2. K Component Key ( T G1-5)

G1-4

9803/9970-01 (G-01-00)

G1-4

Section G1 - Brakes Brake SYSTEM (Non-ABS) Operation Overview Table 1. Component Key K Fig 1. ( T G1-4)

Engine air filter

Air Pipes - Colour Codes

Compressor

Air dryer/unloader/exhaust silencer

Schrader valve

Circuit protection valve

RED

Front brake circuit

Front brake circuit reservoir

YELLOW

Rear brake circuits

Rear brake circuit reservoir

GREEN

Auxiliary circuits

Trailer/parking brake circuit reservoir

BLUE

Parking brake circuit

H1-H3

Low pressure warning light switches

BLACK

Trailer brake system circuit

Parking brake ON warning light/2WD dump switch

Foot brake valve

Front brake air/hydraulic actuator

Rear brake air/hydraulic actuator

Front brake calipers

Rear brake calipers

Pressure reducing valve (failure conscious)

Trailer brake air control valve

Parking brake control valve

Parking brake actuator

TP1 TP5

Air pressure test points

Non-return valve

Inverse relay valve (single line air trailer brakes) (if fitted)

Hydraulic trailer brake valve (if fitted)

Air lines

Hydraulic brake fluid lines

Main hydraulic fluid lines

Twin line air trailer brake, supply

As an aid for service procedures the air system pipes are colour coded as follows:

ABS Electronic Components AA

Electronic Control Unit (ECU)

Wheel hub mounted sensing rings

Axle mounted wheel speed sensors

Signal lines to and from ECU

Trailer Connectors SL

Single line air trailer brake (if fitted)

Twin line air trailer brake, control

Hydraulic trailer brake (if fitted)

G1-5

9803/9970-01 (G-01-00)

G1-5

Section G1 - Brakes Brake SYSTEM (Non-ABS) Operation Overview

Air Compression

reducing valve N. Full hydraulic pressure is fed to the front brake calipers L where it applies the brakes.

K Fig 1. ( T G1-4)

Rear Brake Circuit

Filtered air is drawn via engine air filter A into the engine mounted compressor B.

K Fig 1. ( T G1-4)

Air from the compressor is directed to the air dryer/ unloader valve C which senses the air pressure stored in the braking system.

Operation of the rear brake circuit is similar to the front, utilising reservoir G2, rear brake air/hydraulic actuator K2 and rear brake calipers M.

When the braking system pressure is less than the pressure from the compressor, air is directed to the circuit reservoirs.

Additionally, the circuit incorporates a failure conscious pressure reducing valve N. The main function of the valve is to minimise the risk of the rear wheels locking under heavy braking, particularly important when the machine is heavily loaded at the front end.

When the braking system reaches its operating pressure a purge valve in valve C opens to allow the dryer internal pressure to expel accumulated condensate and solid matter. This decompression of the dryer allows dry air direct from the air system to exhaust via the dryer dessicant, taking with it the accumulated dessicant moisture, preventing it from becoming saturated. A Schrader valve E (tyre type valve) is fitted so that the system can be charged from an external source, for instance in the event of engine failure. The air flows past the Schrader valve direct to circuit protection valve F. In the event of a loss of pressure, such as a pipe failure in one or more of the four circuits, the circuit protection valve F ensures that the remaining circuits still receive sufficient air to operate normally. The four independent circuits are front brakes, rear brakes, trailer/parking brake and tractor services.

As braking pressure increases up to 43 bar valve, N has no effect and allows the pressure to the rear brake calipers to increase at the same rate as the pressure to the front brake calipers. As the pressure increases beyond 43 bar, valve N limits the rate of increase of the rear braking pressure so that the ratio of front braking pressure increase : rear braking pressure increase is 2.9 : 1. The â&#x20AC;&#x2DC;failure consciousâ&#x20AC;&#x2122; aspect of valve N is a safety feature in the event of failure of the front brake circuit. When a failure occurs the pilot feed pressure from the front circuit to valve N fails. This causes the pressure limiting function of valve N to be overridden and allows full pedal braking pressure to reach the rear calipers.

Front Brake Circuit K Fig 1. ( T G1-4) Air from the circuit protection valve is fed into the front brake circuit reservoir G1 which is fitted with a pressure test point TP1. Air from the reservoir passes low pressure warning light switch H1 before entering the dual foot brake valve J. When the foot brake is operated, air is allowed through the valve. The flow divides, some flowing to the trailer brake air control valve P to apply the trailer brakes. The rest of the air flows into the front brake air/hydraulic actuator K1. Air pressure entering the actuator is converted into hydraulic pressure. A pilot hydraulic line is teed to the pressure

G1-6

9803/9970-01 (G-01-00)

G1-6

Section G1 - Brakes Brake SYSTEM (Non-ABS) Operation Overview

Trailer/Parking Brake Circuit

Parking Brake Circuit

K Fig 1. ( T G1-4)

Air from the circuit protection valve F is fed into the trailer/ parking brake circuit reservoir G3 which is fitted with a manual drain valve and a pressure test point TP3. Air from the reservoir passes a low pressure warning light switch H3 before feeding the trailer brake air valve P. Before it enters the trailer brake air valve the line branches to feed the parking brake circuit via non-return valve V.

From non-return valve V, the air is fed to the parking brake control valve R. When this valve is put into the off position it supplies air pressure to parking brake actuator T to release the caliper parking brake. It also supplies a signal pressure to the trailer brake air valve which then cuts off the tractor control pressure.

Trailer brake air valve P provides a permanent supply to the trailer brake coupling TS. It receives control signals from the front and rear brakes when they are operated and responds by feeding the control line to the trailer brake coupling TC. On some machines, threshold valves TB are fitted to ensure that the trailer pressure reaches a pre-set level before air is allowed to flow into the air/hydraulic actuators K1 and K2 to operate the service brakes of the tractor. When a machine is fitted with single line trailer air braking, inverse relay valve W controls the feed via line SL.

When the control valve R is set to the on position, it exhausts all air downstream of non-return valve V with the following effects: â&#x20AC;&#x201C; The parking brake actuator applies the parking brake by the force of its integral spring. â&#x20AC;&#x201C; The signal pressure is exhausted from the trailer brake air valve which then supplies control pressure to apply the trailer brakes. â&#x20AC;&#x201C; Switch H4 closes to operate the park brake light and to break continuity at the 2WD dump relay.

Tractor Services Circuit K Fig 1. ( T G1-4) Air from the circuit protection valve is fed via line Q to the Selectronic system.

Hydraulic Trailer Brakes (if fitted) K Fig 1. ( T G1-4) A hydraulic trailer brake facility can be provided. A hydraulic trailer brake valve X is fed via port P at pump pressure which is output via port N to the external hydraulics valve as well as used internally. A tank return is provided via port R. The hydraulic brake output (port B) to connector TH is activated by pilot pressure into port Y from the front axle service brake circuit. The pressure of hydraulic brake output at port B is proportional to the service brake pressure.

G1-7

9803/9970-01 (G-01-00)

G1-7

Section G1 - Brakes Brake SYSTEM (Non-ABS) Fault Finding

Fault Finding Introduction

Tables

K Fig 1. ( T G1-4)

K Fault - Low Pressure Warning Lights ON ( T G1-9)

The brake system air pressure should be 8 bar (120 lbf/ in2).

K Fault - Service Brakes Performance Poor ( T G1-9)

For diagnostic purposes the air brake system is fitted with test points, on the circuit reservoirs (TP1, TP2), (TP3), on the foot brake air valve (TP4, TP5) and, on ABS machines, on the pressure modulating valves (TP6, TP7, TP8). Diagnosis of system faults requires the use of suitable gauges (three are usually sufficient). A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311.

K Fault - Front Brake Performance Good, Rear Brake Performance Poor ( T G1-10)

K Fault - Front Brake Performance Poor, Rear Brake Performance Good ( T G1-10)

K Fault - Trailer Brakes Performance Poor ( T G1-10) K Fault - Park Brake Performance Poor ( T G1-10) K Fault - Park Brake Does Not Release ( T G1-11)

General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles. As an aid to fault finding the air system pipes are colour coded as follows: Red

Front brake circuit

Yellow

Rear brake circuits

Green

Auxiliary circuit

Blue

Parking brake circuit

Black

Trailer brake system circuit

G1-8

9803/9970-01 (G-01-00)

G1-8

Section G1 - Brakes Brake SYSTEM (Non-ABS) Fault Finding CHECK 1 2 3 4 5

Table 2. Fault - Low Pressure Warning Lights ON ACTION

Are all three warning lights on?

YES:

Check 2

NO:

Check 4

Is there a leak between the compressor and the circuit YES: protection valve? NO:

Rectify leak Check 3

Is air continually pumping from air dryer/unloader valve exhaust?

YES:

Renew defective air dryer/unloader valve

NO:

Strip and examine compressor

If only one light is on, pressure test relevant tank. Is pressure OK?

YES:

Renew defective low pressure switch

NO:

Check 5

Drain air from complete system. Recharge. Does fault YES: still exist? NO:

CHECK

Renew circuit protection valve System now OK

Table 3. Fault - Service Brakes Performance Poor ACTION

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES:

Check 2

NO:

Renew pads (in complete axle sets)

Do both brake fluid reservoirs have adequate fluid?

YES:

Check 3

NO:

Top up and check for leaks

Have brakes been bled?

YES:

Check 4

NO:

Bleed brakes

Fit a gauge first to TP4 and then to TP5. Each time press the brake pedal. Does the gauge indicate that air system pressure is reaching the footbrake valve. K Fig 1. ( T G1-4)

YES:

Check 5

NO:

Check that air system pressure is reaching the circuit protection valve. If not check for a leak in the circuit from the compressor. If pressure is reaching the circuit protection valve check the valve for faults

Are air/hydraulic actuators functioning?

YES:

Check 6

NO:

Strip and inspect actuator(s)

Is there evidence of oil leakage at the failure conscious pressure relief valve?

YES:

Fit a new valve

NO:

Bleed brakes

G1-9

9803/9970-01 (G-01-00)

G1-9

Section G1 - Brakes Brake SYSTEM (Non-ABS) Fault Finding CHECK 1 2 3 4

Fit a gauge to TP1. Charge system. Does TP1 reach YES: system pressure? K Fig 1. ( T G1-4) NO:

Check for leaks or faulty circuit protection valve

Operate footbrake. Does the front air/hydraulic actuator function?

YES:

Check 3

NO:

Check footbrake valve

Is there evidence of oil leakage at the failure conscious pressure relief valve?

YES:

Fit a new valve

NO:

Check 4

Has the front hydraulic circuit been bled?

YES:

Check operation of the caliper and serviceability of the brake friction pads

NO:

Bleed front hydraulic circuit

CHECK 1 2 3 4

Table 4. Fault - Front Brake Performance Poor, Rear Brake Performance Good ACTION

Table 5. Fault - Front Brake Performance Good, Rear Brake Performance Poor ACTION

Fit a gauge to TP2. Charge system. Does TP2 reach YES: system pressure? K Fig 1. ( T G1-4) NO:

Check for leaks or faulty circuit protection valve

Operate footbrake. Does the rear air/hydraulic actuator function?

YES:

Check 3

NO:

Check footbrake valve

Is there evidence of oil leakage at the failure conscious pressure relief valve?

YES:

Fit a new valve

NO:

Check 4

Has the rear hydraulic circuit been bled?

YES:

Check operation of the calipers and serviceability of the brake friction pads

NO:

Bleed rear hydraulic circuit

CHECK 1 2 3 4

Check 2

Table 6. Fault - Trailer Brakes Performance Poor ACTION

Fit gauge to TP3. Charge system. Is tank up to system YES: pressure? K Fig 1. ( T G1-4) NO:

Check 2

Drain air from complete system. Recharge. Is tank up YES: to system pressure? NO:

Renew circuit protection valve

Fit gauges to trailer tappings TS and TC. Is TS at system pressure? K Fig 1. ( T G1-4) Operate footbrake. Is TC at system pressure?

CHECK 1

Check 2

Check 3 System now OK

YES:

Check 4

NO:

Defective trailer brake valve

YES:

Fault on trailer brakes

NO:

Defective trailer brake valve

Table 7. Fault - Park Brake Performance Poor ACTION

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES:

Check 2

NO:

Renew pads

Are pads adjusted correctly?

YES:

Check 3

NO:

Adjust

G1-10

9803/9970-01 (G-01-00)

G1-10

Section G1 - Brakes Brake SYSTEM (Non-ABS) Fault Finding CHECK

ACTION

YES:

Suspect fault in rear axle

NO:

Suspect fault in spring brake actuator

Is caliper clamping on disc?

CHECK 1 2 3

Table 8. Fault - Park Brake Does Not Release ACTION

Fit gauge to TP1 and TP3. Charge system. Is pressure OK? K Fig 1. ( T G1-4)

YES:

Check 3

NO:

Check 2

Is there a leak between the trailer brake valve and the YES: park brake actuator? NO:

Defective park brake valve

Are pads adjusted correctly?

YES:

Suspect fault in spring brake actuator

NO:

Adjust

G1-11

Rectify leak

9803/9970-01 (G-01-00)

G1-11

Section G1 - Brakes Brake SYSTEM (Non-ABS) Bleeding

Bleeding Note: The hydraulic systems for the front and rear brakes are completely separate and must be bled separately as detailed below. Note: If two calipers are fitted per wheel, they should be bled as a wheel pair via the uppermost caliper in each case.

!MWARNING Before proceeding with the bleeding procedure it is important to ensure that the park brake is engaged and that one pair of wheels is blocked on both sides. BRAK-1-2

C093010

Fig 3. 1

With the engine running, check that all three low air pressure warning lights are extinguished, indicating there is enough air pressure. Stop the engine.

Open the bleed screw and apply full pedal strokes until all air is expelled. Close the bleed screw with the pedal fully depressed.

Fill the relevant fluid reservoir with the specified fluid (see Section 3). Ensure that throughout the bleeding process the level is not allowed to fall below the lower mark on the reservoir.

Repeat the procedure for the other brake on the opposite side of the machine.

When bleeding the rear system of a vehicle fitted with a trailer brake hydraulic valve, bleed air from the bleed screw on the valve after having bled the rear calipers. (See Trailer Brake Hydraulic Valve Removal and Replacement for position of bleed screw.)

Top up the brake fluid reservoirs.

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

Attach a tube to the bleed screw to be bled (X - front, Y - rear), ensuring that the free end is immersed in fluid in a suitable container.

G1-12

9803/9970-01 (G-01-00)

G1-12

Section G2 - Brakes

Brake SYSTEM (ABS) 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.. Descriptions and procedures relate to the system and not the individual devices. 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. K Techinical Data ( T G2-2) K Service Tools ( T G2-3) K Operation Overview ( T G2-4) K Air Pipes - Colour Codes ( T G2-5) K Air Compression ( T G2-6) K Front Brake Circuit ( T G2-6) K Rear Brake Circuit ( T G2-6) K Trailer/Parking Brake Circuit ( T G2-6) K Parking Brake Circuit ( T G2-7) K Tractor Services Circuit ( T G2-7) K Hydraulic Trailer Brakes (if fitted) ( T G2-7) K Tractor ABS ( T G2-8) K Fault Finding ( T G2-11) K Bleeding ( T G2-14)

G2-1

9803/9970-01 (G-01-00)

G2-1

Section G2 - Brakes Brake SYSTEM (ABS) Techinical Data

Techinical Data System Operating pressure (air)

8 bar

(120 lbf/in2)

3 mm

(0.12 in)

New

9.5 mm

(0.374 in)

Minimum

8.9 mm

(0.350 in)

3 mm

(0.12 in)

Parking Brake Minimum pad thickness Disc thickness

Service Brakes Minimum pad thickness Front disc thickness New

22 mm

(0.866 in)

Minimum

19.8 mm

(0.780 in)

New

16 mm

(0.630 in)

Minimum

14.3 mm

(0.563 in)

Rear disc thickness

G2-2

9803/9970-01 (G-01-00)

G2-2

Section G2 - Brakes Brake SYSTEM (ABS) Service Tools

Service Tools The following special service tools are needed for procedures detailed in this section. Part Number

Description

892/00311

Brake test kit 3 x Calibrated test gauges - 0-20 bar (0 - 290 lbf/in2) 3 x 5 metre hoses with quick release adaptors 3 x ISO test point adapters

S199470

G2-3

9803/9970-01 (G-01-00)

G2-3

Section G2 - Brakes Brake SYSTEM (ABS) Operation Overview

Operation Overview

TP2 Q

TP5

TP3

TP4

G1 B

TP1

Y B

TH TS

A386022-C2

Fig 1.

C K3

K2 F

N2 N1

K1 V P G2

G1 A387692-C2

Fig 2. K Component Key ( T G2-5)

G2-4

9803/9970-01 (G-01-00)

G2-4

Section G2 - Brakes Brake SYSTEM (ABS) Operation Overview Table 1. Component Key K Fig 1. ( T G2-4) A

Engine air filter

Compressor

Air dryer/unloader/exhaust silencer

Schrader valve

Circuit protection valve

Front brake circuit reservoir

Rear brake circuit reservoir

Trailer/parking brake circuit reservoir

H1-H3

Low pressure warning light switches

Parking brake ON warning light/2WD dump switch

Electronic Control Unit (ECU)

Wheel hub mounted sensing rings

Axle mounted wheel speed sensors

Signal lines to and from ECU

Trailer Connectors SL

Single line air trailer brake (if fitted)

Twin line air trailer brake, control

Hydraulic trailer brake (if fitted)

Twin line air trailer brake, supply

Air Pipes - Colour Codes

Foot brake valve

Front brake air/hydraulic actuator

Rear right brake air/hydraulic actuator

Rear left brake air/hydraulic actuator

Front brake calipers

Rear left brake caliper

Rear right brake caliper

Pressure modulating valve (front brakes) (ABS)

Pressure modulating valve (rear right brake) (ABS)

Pressure modulating valve (rear left brake) (ABS)

Trailer brake air control valve

Cooler pipe matrix

Parking brake control valve

Parking brake actuator

TP1 TP5

Air pressure test points

Non-return valve

Inverse relay valve (single line air trailer brakes) (if fitted)

Hydraulic trailer brake valve (if fitted)

Air lines

In-line check valve (hydraulic brake fluid line)

Hydraulic brake fluid lines

Main hydraulic fluid lines

As an aid for service procedures the air system pipes are colour coded as follows: RED

Front brake circuit

YELLOW

Rear brake circuits

GREEN

Auxiliary circuits

BLUE

Parking brake circuit

BLACK

Trailer brake system circuit

ABS Electronic Components

G2-5

9803/9970-01 (G-01-00)

G2-5

Section G2 - Brakes Brake SYSTEM (ABS) Operation Overview

Air Compression

Rear Brake Circuit

K Fig 1. ( T G2-4)

Filtered air is drawn via engine air filter A into the engine mounted compressor B.

Air from circuit protector valve F is fed into rear brakes reservoir G2 which is fitted with a pressure test point TP2. Air from the reservoir passes low pressure warning light switch H2 before entering dual foot brake valve J. The air which passes through the valve when the foot brake is operated flows to the rear brake air/hydraulic actuators K2 and K3, via ABS pressure modulating valves N2† and N3† respectively, to actuate rear brake calipers MR and ML.

Air from the compressor is directed to the air dryer/ unloader valve C which senses the air pressure stored in the braking system. When the braking system pressure is less than the pressure from the compressor, air is directed to the circuit reservoirs. When the braking system reaches its operating pressure a purge valve in valve C opens to allow the dryer internal pressure to expel accumulated condensate and solid matter. This decompression of the dryer allows dry air direct from the air system to exhaust via the dryer dessicant, taking with it the accumulated dessicant moisture, preventing it from becoming saturated. A Schrader valve E (tyre type valve) is fitted so that the system can be charged from an external source, for instance in the event of engine failure. The air flows past the Schrader valve direct to circuit protection valve F. In the event of a loss of pressure, such as a pipe failure in one or more of the four circuits, the circuit protection valve F ensures that the remaining circuits still receive sufficient air to operate normally. The four independent circuits are front brakes, rear brakes, trailer/parking brake and tractor services.

†. K Tractor ABS ( T G2-8)

Trailer/Parking Brake Circuit K Fig 1. ( T G2-4) Air from the circuit protection valve F is fed into the trailer/ parking brake circuit reservoir G3 which is fitted with a manual drain valve and a pressure test point TP3. Air from the reservoir passes a low pressure warning light switch H3 before feeding the trailer brake air valve P. Before it enters the trailer brake air valve the line branches to feed the parking brake circuit via non-return valve V. Trailer brake air valve P provides a permanent supply to the trailer brake coupling TS. It receives control signals from the front and rear brakes when they are operated and responds by feeding the control line to the trailer brake coupling TC. When a machine is fitted with single line trailer air braking, inverse relay valve W controls the feed via line SL.

Front Brake Circuit K Fig 1. ( T G2-4) Air from the circuit protection valve is fed into the front brake circuit reservoir G1 which is fitted with a pressure test point TP1. Air from the reservoir passes low pressure warning light switch H1 before entering the dual foot brake valve J. When the foot brake is operated, air is allowed through the valve. The flow divides, some flowing to the trailer brake air control valve P to apply the trailer brakes. The rest of the air flows via ABS pressure modulating valve N1† into the front brake air/hydraulic actuator K1. Air pressure entering the actuator is converted into hydraulic pressure and fed to the front brake calipers L where it applies the brakes.

G2-6

9803/9970-01 (G-01-00)

G2-6

Section G2 - Brakes Brake SYSTEM (ABS) Operation Overview

Parking Brake Circuit K Fig 1. ( T G2-4) From non-return valve V, the air is fed to the parking brake control valve R. When this valve is put into the off position it supplies air pressure to parking brake actuator T to release the caliper parking brake. It also supplies a signal pressure to the trailer brake air valve which then cuts off the tractor control pressure. When the control valve R is set to the on position, it exhausts all air downstream of non-return valve V with the following effects: â&#x20AC;&#x201C; The parking brake actuator applies the parking brake by the force of its integral spring. â&#x20AC;&#x201C; The signal pressure is exhausted from the trailer brake air valve which then supplies control pressure to apply the trailer brakes. â&#x20AC;&#x201C; Switch H4 closes to operate the park brake light and to break continuity at the 2WD dump relay.

Tractor Services Circuit K Fig 1. ( T G2-4) Air from the circuit protection valve is fed via line Q to the Selectronic system.

Hydraulic Trailer Brakes (if fitted) K Fig 1. ( T G2-4) A hydraulic trailer brake facility can be provided. A hydraulic trailer brake valve X is fed via port P at pump pressure which is output via port N to the external hydraulics valve as well as used internally. A tank return is provided via port R. The hydraulic brake output (port B) to connector TH is activated by pilot pressure into port Y from the front axle service brake circuit. The pressure of hydraulic brake output at port B is proportional to the service brake pressure.

G2-7

9803/9970-01 (G-01-00)

G2-7

Section G2 - Brakes Brake SYSTEM (ABS) Operation Overview

Tractor ABS The Fastrac ABS system incorporates sensor rings attached to each of the four wheel hubs with a speed sensor mounted on the axle adjacent to each. The interaction of the speed sensors and sensor rings generates signals which are sent to the ABS Electronic Control Unit (ECU). The ECU interprets the signals and sends out appropriate control signals to pressure Braking Status

modulating valves (PMV), one controlling the pair of front brakes and one controlling each of the two rear brakes individually. The control signals from the ECU are applied to solenoid valves in the PMVâ&#x20AC;&#x2122;s. The solenoid valves and two check valves control the building-up, maintaining or releasing of brake pressure to the relevant brake cylinders according to the requirements of the braking situation.

Pressure modulating valve (PMV) Operation

Normal roading. Foot brake E released. Check valves A and B closed. Solenoid C de-energised (open). Solenoid D de-energised (closed). No air pressure from foot brake E. No air pressure at air/hydraulic brake actuator F.

Foot brake E applied. Against spring pressure, check valve A opens under air pressure from the foot brake. Check valve B remains closed due to equal air pressure on both sides. Solenoids C and D remain de-energised. Air pressure flows to actuator F to apply the brakes.

G2-8

9803/9970-01 (G-01-00)

G2-8

Section G2 - Brakes Brake SYSTEM (ABS) Operation Overview Braking Status

Pressure modulating valve (PMV) Operation

Foot brake E applied. ABS ECU senses imminent wheel lock-up and sends signal to PMV. ECU signal energises solenoid C which closes. Braking pressure is routed to both sides of check valve A which closes, due to spring pressure, to isolate the foot brake. Pressure in the actuator chamber is trapped and remains constant. Check valve B still remains closed. Solenoid D still remains de-energised.

Foot brake E applied. ECU still senses imminent wheel lock-up. also senses the need to reduce braking pressure and sends a further signal to the PMV. Solenoid C remains energised (closed). The foot brake remains isolated by check valve A. Solenoid D energises (opens). Solenoid D exhaust port opens to remove the pressure behind check valve B. Against spring pressure, check valve B is forced open by the trapped actuator pressure which decays to atmosphere via exhaust port G.

G2-9

9803/9970-01 (G-01-00)

G2-9

Section G2 - Brakes Brake SYSTEM (ABS) Operation Overview Braking Status

Pressure modulating valve (PMV) Operation

Foot brake E applied. ECU senses that wheel lock-up is no longer imminent and stops sending signals. Solenoid C de-energises (opens) and solenoid D deenergises (closes). Braking pressure overcomes the decaying pressure behind both check valve A which opens and check valve B which closes. Foot brake pressure flows directly to actuator F to re-apply the brake. The pressure behind check valves A and B continues to decay via port G until fully exhausted.

G2-10

9803/9970-01 (G-01-00)

G2-10

Section G2 - Brakes Brake SYSTEM (ABS) Fault Finding

Fault Finding Introduction

Tables

K Fig 1. ( T G2-4)

K Fault - Low Pressure Warning Lights ON ( T G2-12)

The brake system air pressure should be 8 bar (120 lbf/ in2). For diagnostic purposes the air brake system is fitted with test points, on the circuit reservoirs (TP1, TP2), (TP3), on the foot brake air valve (TP4, TP5) and, on ABS machines, on the pressure modulating valves (TP6, TP7, TP8). Diagnosis of system faults requires the use of suitable gauges (three are usually sufficient). A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311.

K Fault - Service Brakes Performance Poor ( T G2-12) K Fault - Front Brake Performance Poor, Rear Brake Performance Good ( T G2-12) K Fault - Front Brake Performance Good, Rear Brake Performance Poor ( T G2-13) K Fault - Trailer Brakes Performance Poor ( T G2-13) K Fault - Park Brake Performance Poor ( T G2-13) K Fault - Park Brake Does Not Release ( T G2-13)

Front brake circuit

Yellow

Rear brake circuits

Green

Auxiliary circuit

Blue

Parking brake circuit

Black

Trailer brake system circuit

G2-11

9803/9970-01 (G-01-00)

G2-11

Section G2 - Brakes Brake SYSTEM (ABS) Fault Finding Table 2. Fault - Low Pressure Warning Lights ON ACTION

CHECK 1 2 3 4 5

Are all three warning lights on?

YES:

Check 2

NO:

Check 4

Is there a leak between the compressor and the circuit YES: protection valve? NO:

Rectify leak Check 3

Is air continually pumping from air dryer/unloader valve exhaust?

YES:

Renew defective air dryer/unloader valve

NO:

Strip and examine compressor

If only one light is on, pressure test relevant tank. Is pressure OK?

YES:

Renew defective low pressure switch

NO:

Check 5

Drain air from complete system. Recharge. Does fault YES: still exist? NO:

Renew circuit protection valve System now OK

Table 3. Fault - Service Brakes Performance Poor ACTION

CHECK 1

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES:

Check 2

NO:

Renew pads (in complete axle sets)

Do both brake fluid reservoirs have adequate fluid?

YES:

Check 3

NO:

Top up and check for leaks

Have brakes been bled?

YES:

Check 4

NO:

Bleed brakes

Fit a gauge first to TP4 and then to TP5. Each time press the brake pedal. Does the gauge indicate that air system pressure is reaching the footbrake valve. K Fig 1. ( T G2-4)

YES:

Check 5

NO:

Are air/hydraulic actuators functioning?

YES:

Bleed brakes

NO:

Strip and inspect actuator(s)

CHECK 1 2 3 4

Table 4. Fault - Front Brake Performance Poor, Rear Brake Performance Good ACTION

Fit a gauge to TP1. Charge system. Does TP1 reach YES: system pressure? K Fig 1. ( T G2-4) NO:

Check 2 Check for leaks or faulty circuit protection valve

Operate footbrake. Does the front air/hydraulic actuator function?

YES:

Check 4

NO:

Check 3

Operate footbrake. Does TP4 or TP6 reach system pressure? K Fig 1. ( T G2-4)

YES:

Check pressure modulator valve

NO:

Check footbrake valve

Has the front hydraulic circuit been bled?

YES:

Check operation of the caliper and serviceability of the brake friction pads

NO:

Bleed front hydraulic circuit

G2-12

9803/9970-01 (G-01-00)

G2-12

Section G2 - Brakes Brake SYSTEM (ABS) Fault Finding CHECK 1 2 3 4

Table 5. Fault - Front Brake Performance Good, Rear Brake Performance Poor ACTION

Fit a gauge to TP2. Charge system. Does TP2 reach YES: system pressure? K Fig 1. ( T G2-4) NO:

Check for leaks or faulty circuit protection valve

Operate footbrake. Does the rear air/hydraulic actuator function?

YES:

Check 4

NO:

Check 3

Operate footbrake. Does TP5 or TP7 or TP8 reach system pressure? K Fig 1. ( T G2-4)

YES:

Check both pressure modulator valves

NO:

Check footbrake valve

Has the rear hydraulic circuit been bled?

YES:

Check operation of the calipers and serviceability of the brake friction pads

NO:

Bleed rear hydraulic circuit

CHECK 1 2 3 4

Table 6. Fault - Trailer Brakes Performance Poor ACTION

Fit gauge to TP3. Charge system. Is tank up to system YES: pressure? K Fig 1. ( T G2-4) NO:

Check 2

Drain air from complete system. Recharge. Is tank up YES: to system pressure? NO:

Renew circuit protection valve

Fit gauges to trailer tappings TS and TC. Is TS at system pressure? K Fig 1. ( T G2-4) Operate footbrake. Is TC at system pressure?

CHECK 1

Check 2

Check 3 System now OK

YES:

Check 4

NO:

Defective trailer brake valve

YES:

Fault on trailer brakes

NO:

Defective trailer brake valve

Table 7. Fault - Park Brake Performance Poor ACTION

Do disc pads have a minimum of 3 mm (0.12 in) friction material?

YES:

Check 2

NO:

Renew pads

Are pads adjusted correctly?

YES:

Check 3

NO:

Adjust

Is caliper clamping on disc?

YES:

Suspect fault in rear axle

NO:

Suspect fault in spring brake actuator

CHECK 1 2 3

Table 8. Fault - Park Brake Does Not Release ACTION

Fit gauge to TP1 and TP3. Charge system. Is pressure OK? K Fig 1. ( T G2-4)

YES:

Check 3

NO:

Check 2

Is there a leak between the trailer brake valve and the YES: park brake actuator? NO:

Defective park brake valve

Are pads adjusted correctly?

YES:

Suspect fault in spring brake actuator

NO:

Adjust

G2-13

Rectify leak

9803/9970-01 (G-01-00)

G2-13

Section G2 - Brakes Brake SYSTEM (ABS) Bleeding

!MWARNING Before proceeding with the bleeding procedure it is important to ensure that the park brake is engaged and that one pair of wheels is blocked on both sides. BRAK-1-2

C093010

Fig 3. 1

With the engine running, check that all three low air pressure warning lights are extinguished, indicating there is enough air pressure. Stop the engine.

Open the bleed screw and apply full pedal strokes until all air is expelled. Close the bleed screw with the pedal fully depressed.

Fill the relevant fluid reservoir with the specified fluid (see Section 3). Ensure that throughout the bleeding process the level is not allowed to fall below the lower mark on the reservoir.

Repeat the procedure for the other brake on the opposite side of the machine.

Top up the brake fluid reservoirs.

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

Attach a tube to the bleed screw to be bled (X - front, Y - rear), ensuring that the free end is immersed in fluid in a suitable container.

G2-14

9803/9970-01 (G-01-00)

G2-14

Section G3 - Brakes

Service Brake Calipers Introduction

K Removal and Replacement ( T G3-2)

G3-1

9803/9970-01 (G-02-00)

G3-1

Section G3 - Brakes Service Brake Calipers Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2. In particular refer to Brakes procedures. Note: Illustrations show typical caliper mounting positions.

Removal 1

Park the machine on firm, level ground, apply the parking brake and remove the starter key.

Chock the front wheels. Jack up the appropriate wheel, support the machine on an axle stand and remove the wheel.

Disconnect the brake pipe A (front) or B (rear) and catch the fluid in a suitable container. Take care to prevent entry of dirt or grit.

If the pistons are free, force the pads back until they clear the disc. If necessary remove the pads to provide clearance (see Section 3). Remove bolts C (front) or D (rear) and remove the caliper.

C093010

Fig 1.

G3-2

9803/9970-01 (G-02-00)

G3-2

Section G3 - Brakes Service Brake Calipers Removal and Replacement

Replacement Reverse the removal procedure, ensuring that correct spacers E and F are fitted and that JCB Threadlocker and Sealer is applied to the bolts. Bleed the brakes, see Brake SYSTEM (non ABS) or Brake SYSTEM (ABS) as applicable. Important: On ABS machines do the Servicemaster ABS diagnostic checks.

Item

Table 1. Torque Settings Nm Kgf m

lbf ft

392

289

(8.8 grade)

200

148

D(1)(10.9 grade)

300

220

(1)

(1) Torque value for Dacromet fastners, coloured mottled silver.

G3-3

9803/9970-01 (G-02-00)

G3-3

Section G3 - Brakes Service Brake Calipers Removal and Replacement

!MWARNING

Dismantling and Assembling Note: Before dismantling, the caliper must be removed from the machine and thoroughly cleaned. Take great care to prevent entry of dirt and grit. K Removal ( T G3-2)

Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work. 13-3-1-3

214310

Fig 2.

G3-4

9803/9970-01 (G-02-00)

G3-4

Section G3 - Brakes Service Brake Calipers Removal and Replacement When Dismantling Remove the pads and retaining pins (see Checking and Renewing the Foot Brake Pads, Section 3). Split the caliper by removing capscrews A. Use compressed air applied through the hydraulic fluid ports to force out the pistons B. Remove and discard dust seals C, anti-extrusion rings D and 'O' rings E and F. When Assembling Wash the piston bores with clean brake fluid and blow dry. Ensure that the pistons and their bores are free from scoring and corrosion. If in doubt, renew the pistons or the complete caliper assembly as required. Ensure that the mating faces of the caliper halves are perfectly clean. Fit new 'O' rings and anti-extrusion rings, lubricated with clean brake fluid. Fit new dust seals and reassemble the caliper halves ensuring that 'O' rings F remain in position. Fit new capscrews A, tightened evenly to the torque settings below.

Item

Table 2. Capscrew Torque Settings Nm Kgf m lbf ft

Front

235 - 255

24 - 26

173 - 188

Rear

157 - 176

16 - 18

116 - 130

G3-5

9803/9970-01 (G-02-00)

G3-5

Section G3 - Brakes Service Brake Calipers Removal and Replacement

Page left intentionally blank

G3-6

9803/9970-01 (G-02-00)

G3-6

Section G4 - Brakes

Park Brake Caliper Introduction

K Removal and Replacement ( T G4-2) K Dismantling and Assembly ( T G4-5)

G4-1

9803/9970-01 (G-06-00)

G4-1

Section G4 - Brakes Park Brake Caliper Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

!MWARNING Before checking the park brake, park on level ground. Put blocks each side of all four wheels. Ensure that all three air tank warning lights are out. Release the park brake, then stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. 13-3-1-4_1

!MWARNING Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work. 13-3-1-3

!MWARNING The actuator contains a large spring which can exert a force of up to 1134 kgf (2500 lbf) and cause injury if suddenly released. When working on or near the actuator, carefully follow all service instructions. 13-3-1_11_1

G4-2

9803/9970-01 (G-06-00)

G4-2

Section G4 - Brakes Park Brake Caliper Removal and Replacement

162442-C1

Fig 1. When Removing

become detached from the guide pins, followed by spring plate M.

Slacken locknuts X and remove pin from clevis Y. Apply brake, causing rod Z to draw back into the actuator G. Turn clevis Y through 90Â°. Disconnect the air feed by first pushing in the hose, pushing in the sleeve, then pulling out the hose F. Blank the open ports to prevent entry of dirt.

Lower the complete brake assembly clear of the brake disc and remove. Note: If the surface of the disc is badly warped, pitted or showing signs of overheating, it must be renewed. When Replacing

Remove plastic cap and insert a 1/4 in hexagon allen key at K and turn it clockwise to back the pads right away from the disc. Do not turn the screw further than necessary to free the pads. Supporting the caliper, remove split pins H and support pins J in direction of arrow. Withdraw the pads L as they

G4-3

Reverse the removal sequence. Adjust the brake using the allen key. Support the weight of the brake with one hand and turn the allen key anticlockwise until the pads are tight on the disc. From this position, turn the allen key half a turn clockwise.

9803/9970-01 (G-06-00)

G4-3

Section G4 - Brakes Park Brake Caliper Removal and Replacement Important: On ABS machines do the Servicemaster ABS diagnostic checks. Drive the machine for a short distance of 300-400m. If the brake disc is getting hot, turn the allen key clockwise slightly. The final adjustment should never be more than 3/ 4 of a turn from tight.

G4-4

9803/9970-01 (G-06-00)

G4-4

Section G4 - Brakes Park Brake Caliper Dismantling and Assembly

Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.

Note: Items 1 to 5 should be removed when the caliper is removed from the machine but are shown here for reference. K Removal and Replacement ( T G4-2)

For assembly the sequence should be reversed.

162681-B1

Fig 2.

G4-5

9803/9970-01 (G-06-00)

G4-5

Section G4 - Brakes Park Brake Caliper Dismantling and Assembly When Dismantling

Connect actuator 7 when fitting the caliper to the machine. K Removal and Replacement ( T G4-2)

Apply compressed air pressure of 4 to 7 bar (60 to 100lbf/ in2) to inlet A to extend the pushrod until there is clearance for removal of clevis pin 5. Once the pin is removed, release the compressed air slowly. Take care when removing bolts 11. The internal components are loaded by spring 19 and balls 17 can be lost easily.

Item

Table 1. Torque Settings Nm Kgf m

lbf ft

150 - 200

15 - 21

110 - 150

102 - 108

10 - 11

75 - 80

DO NOT dismantle shaft, spring and stator assembly 18 as spring B will easily be distorted. Components are not available separately. DO NOT attempt to repair or open actuator cylinder 7. The cylinder is a non serviceable item. If the cylinder is faulty it MUST be renewed. Inspection Ensure that all parts are free from excessive wear, damage or corrosion. Light scores or stains should be removed. Renew corroded or deeply scored parts. Ensure rotor 16 and stator C are free from cracks. When Assembling Position anti-rotation key 21 so that dimension E is approximately 50 mm (2 in), then ensure that its flats are in line with the keyway of stator C by screwing out as required. Lubricate the following with a molybdenum disulphide grease: Entire bore of casting 22. Keyway and all surfaces of shaft, spring and stator assembly 18. Ball pockets of rotor 16 and stator C. Shank of rotor. Thrust bearing 14 and washers 13 and 15. After fitting bracket 12, turn rotor 16 fully anti-clockwise and fit lever 9 in the position shown at F. Renew pads if lining thickness is 3 mm (0.12 in) or less.

G4-6

9803/9970-01 (G-06-00)

G4-6

Section G5 - Brakes

Service Brakes Air Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Descriptions and procedures relate to the device and not related systems. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Removal and Replacement ( T G5-2) K Dismantling and Assembly ( T G5-4)

G5-1

9803/9970-01 (G-04-01)

G5-1

Section G5 - Brakes Service Brakes Air Valve Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

!MCAUTION

!MWARNING

If this item is to be dismantled (even partially) on the machine, ensure that all pressure has been removed from the system.

Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK-8-1

BRAK-1-4

249330-C1

Fig 1.

G5-2

9803/9970-01 (G-04-01)

G5-2

Section G5 - Brakes Service Brakes Air Valve Removal and Replacement

Removal Item K Fig 1. ( T G5-2) 1

Disconnect hoses A, B, C and D by first pushing in the hose, pushing in the sleeve, then pulling out the hose. Blank the open ports to prevent entry of dirt and label the hoses to assist correct refitting. Disconnect and label the wiring from low pressure switches H1 and H2.

22.5

2.3

16.6

(1)

22.5

2.3

16.6

(1) Torque value for Dacromet fastners, coloured mottled silver.

Table 2. Hose Destinations Air/Hydraulic Actuator K1 (Front Brakes)

Air/Hydraulic Actuator K2 (Rear Brakes)

Front Brake Air Reservoir G1

Rear Brake Air Reservoir G2

TP4

Table 3. Test Point Identification Test Point, Front Circuit

TP5

Test Point, Rear Circuit

Remove bolts E and F.

Note: Bolts E are accessible from inside the cab.

lbf ft

(1)

Before disconnecting hoses, exhaust all air from the foot brake circuits by depressing the brake pedal several times.

Table 1. Torque Settings Nm Kgf m

Replacement Reverse the removal procedure. When fitting elbows and tee-pieces, clean the threads and apply Clayton System Seal SC1251.

S190091-B1

Fig 2. Adjust brake pedal return stop W to give a clearance at X between the pedal and the control valve plunger of 0.05 to 0.25 mm. Important: On ABS machines do the Servicemaster ABS diagnostic checks.

G5-3

9803/9970-01 (G-04-01)

G5-3

Section G5 - Brakes Service Brakes Air Valve Dismantling and Assembly

Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

A Service Kit should be obtained before starting this job. Note: Note that items 3 and 26 are available only as complete assemblies.

S161971

Fig 3.

G5-4

9803/9970-01 (G-04-01)

G5-4

Section G5 - Brakes Service Brakes Air Valve Dismantling and Assembly When Dismantling Mark the relative positions of the body components to ensure correct alignment on assembly. Use a screwdriver (or similar) inserted through one of the upper valve ports into a slot in valve stem 7 to retain the valve stem while unscrewing nut 4. Cleaning and Inspection Using a proprietary cleaning fluid, clean all components which are to be re-used. Inspect for wear and damage. If the pistons, bores or valve seats show signs of appreciable wear or damage a replacement valve should be obtained. When Assembling Use the new components from the Spares Kit during assembly. Ensure that the ears of circlip 25 are installed at 180Â° to the ears of the circlip at the lower end of assembly 26. Lightly grease valve stem 7 and all 'O' rings with the silicone grease supplied with the Spares Kit. DO NOT LUBRICATE RUBBER SPRING 17. After locating rubber spring 17 and spring seat 16 onto the stem of upper piston 10, secure with nut 15. Screw the nut down until its top surface is 0.254 mm (0.01 in) above the top face of piston 10. Ensure that the tabs on retaining plate 9 locate securely onto the body 27. Use the procedure described in When Dismantling to retain valve stem 7 while screwing down nut 4.

Item 18

G5-5

Table 4. Torque Settings Nm Kgf m 6.8 - 9.5

0.7 - 1.0

lbf ft 5-7

9803/9970-01 (G-04-01)

G5-5

Section G5 - Brakes Service Brakes Air Valve Dismantling and Assembly

Page left intentionally blank

G5-6

9803/9970-01 (G-04-01)

G5-6

Section G6 - Brakes

Air/Hydraulic Actuator Introduction

K Removal and Replacement ( T G6-2) K Testing ( T G6-4) K Dismantling and Assembly ( T G6-5) K Bench Testing ( T G6-6)

G6-1

9803/9970-01 (G-07-01)

G6-1

Section G6 - Brakes Air/Hydraulic Actuator Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

Park the machine on level ground, switch off the engine and remove the starter key.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK-1-4

Note: Non-ABS machines have two actuator assemblies B. ABS machines have three actuator assemblies. Some of the mounting bolts A are not visible on the illustrations but their positions relative to the actuators are the same in each case.

A386051-C1

Fig 2. ABS Machines

Removal 1

Disconnect wiring from the relevant master cylinder hydraulic reservoir level sensor.

Before disconnecting hoses, exhaust all air from the foot brake circuits by pressing the foot brake pedal several times.

Disconnect the air hose from the rear of the diaphragm by pushing in the hose, then pushing in the sleeve in the elbow or adapter and pulling out the hose. Blank the open port to prevent entry of dirt. If more than one actuator is to be removed, label the hoses to assist correct refitting.

Disconnect the hydraulic pipe from the master cylinder.

Remove two bolts A and withdraw the actuator B.

B A

417790-C1

Fig 1. Non-ABS Machines

G6-2

9803/9970-01 (G-07-01)

G6-2

Section G6 - Brakes Air/Hydraulic Actuator Removal and Replacement

Replacement Before replacing Testing ( T G6-6)

test

the

actuator.

K Bench

Reverse the removal procedure but connect the hydraulic pipe before tightening bolts A. When fitting elbows and adapters, clean the threads and apply Clayton System Seal SC1251. After replacement, bleed the front and/or rear hydraulic brake system as appropriate. See Brake SYSTEM (non ABS) or Brake SYSTEM (ABS) as applicable. Important: On ABS machines do the Servicemaster ABS diagnostic checks.

Item A

G6-3

Table 1. Torque Settings Nm Kgf m 17

1.7

lbf ft 12.5

9803/9970-01 (G-07-01)

G6-3

Section G6 - Brakes Air/Hydraulic Actuator Testing

Testing Remove the bleed screw from one of the brake calipers of the front or rear brakes as applicable to the actuator being tested. Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to the bleed screw port. Run the engine until the air pressure warning lights are off. Stop the engine. Apply the foot brakes. Check that the hydraulic pressure is at least 110 bar (1600 lbf/in2) and that there are no air or fluid leaks.

G6-4

9803/9970-01 (G-07-01)

G6-4

Section G6 - Brakes Air/Hydraulic Actuator Dismantling and Assembly

Dismantling and Assembly

A258130-B1

Fig 3. The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

Item

Table 2. Torque Settings Nm Kgf m

lbf ft

1/2

11 - 15

1.1 - 1.5

8 - 11

34 - 42

3.4 - 4.3

25 - 31

When Dismantling Take care not to drop items 6, 7, 8 when separating items 4 and 5 which will be forced apart under the pressure of spring 8. Inspection Dismantle the hydraulic master cylinder assembly 13 for inspection only. Component parts are not supplied separately. Fit a new assembly if the original is showing signs of corrosion or wear. Check all other parts for excessive wear, damage or corrosion. Renew any that are corroded or scored.

G6-5

9803/9970-01 (G-07-01)

G6-5

Section G6 - Brakes Air/Hydraulic Actuator Bench Testing

Bench Testing Before refitting a repaired actuator, do the following test. Connect a compressed air supply and a 0-20 bar (0-300 lbf/in2) pressure gauge to the air inlet port. Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to the hydraulic pipe connection. Add the correct hydraulic fluid to the reservoir (see Section 3).

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

Raise the air pressure to 6 bar (90 lbf/in2). Check that the hydraulic pressure is at least 110 bar (1600 lbf/in2) and that there are no air or fluid leaks.

G6-6

9803/9970-01 (G-07-01)

G6-6

Section G7 - Brakes

Air Dryer/Unloader Valve Introduction

K Removal and Replacement ( T G7-2) K Dismantling and Assembly ( T G7-4)

G7-1

9803/9970-01 (G-04-07)

G7-1

Section G7 - Brakes Air Dryer/Unloader Valve Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

!MCAUTION

Park the machine on level ground, switch off the engine and remove the starter key.

If this item is to be dismantled (even partially) on the machine, ensure that all pressure has been removed from the system. BRAK-8-1

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

A285850-B1

Fig 1. Non-ABS Machines

G7-2

9803/9970-01 (G-04-07)

G7-2

Section G7 - Brakes Air Dryer/Unloader Valve Removal and Replacement

A387692-B1

Fig 2. ABS Machines

Removal

Replacement

Release the system air pressure as follows:

Reverse the Removal procedure.

Grip the â&#x20AC;&#x2DC;key ringâ&#x20AC;&#x2122; fitting at the bottom of reservoir G3 and pull sideways until all air is released

When fitting elbows and adapters, clean the threads and apply Clayton System Seal SC1251.

b Repeatedly press the foot brake pedal until the stored pressure in reservoirs G1 and G2 is exhausted.

Important: On ABS machines do the Servicemaster ABS diagnostic checks.

Disconnect hoses by pushing in the hose, then pushing in the sleeve in the elbow or adapter and pulling out the hose. Blank the open ports to prevent entry of dirt and label the hoses to assist correct refitting.

Item

Remove the electrical connector from the air dryer/ unloader unit A.

Support the unit and remove the three mounting bolts B. Lift the unit clear.

G7-3

9803/9970-01 (G-04-07)

Table 1. Torque Settings Nm Kgf m 17

1.7

lbf ft 12.5

G7-3

Section G7 - Brakes Air Dryer/Unloader Valve Dismantling and Assembly

Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed. To replace the dessicant canister (see 1000 Hour Service Schedule, Section 3) unscrew item A1. Secure the replacement canister hand tight.

When Dismantling Items E1 to E9 - all are held in place by circlip E1. After releasing the circlip, take care to prevent the rest of the components flying apart.

Items F1 to F22 - F1 is a push fit into the base of the air dryer body.

When Assembling

S353970-B1

Fig 3.

G7-4

9803/9970-01 (G-04-07)

G7-4

Section G8 - Brakes

Non Return Air Valve Introduction

K Dismantling and Assembly ( T G8-2)

G8-1

9803/9970-01 (G-04-03)

G8-1

Section G8 - Brakes Non Return Air Valve Dismantling and Assembly

Dismantling and Assembly Important: Obey the Care and Safety procedures given in Section 2. The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

332550-B1

Fig 1. When Dismantling A Service Kit should be obtained before starting this job. Ensure that the kit obtained is correct for the valve fitted. Items shown grouped as K are the only parts available and are obtainable only as a complete kit. When Assembling Use the components from the Service Kit during assembly. On machines with ABS do the Servicemaster diagnostic checks.

G8-2

9803/9970-01 (G-04-03)

G8-2

Section G9 - Brakes

Failure Conscious Reducing Valve (Non ABS) Introduction

K Removal and Replacement ( T G9-2)

G9-1

9803/9970-01 (G-04-07)

G9-1

Section G9 - Brakes Failure Conscious Reducing Valve (Non ABS) Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2. Note: The valve is sealed and cannot be dismantled or repaired. If there is evidence of oil leakage and/or malfunction the valve must be renewed. Park the machine on level ground, switch off the engine and remove the starter key.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Replacement Reverse the removal procedure. When fitting elbows or adaptors, clean the threads and apply Clayton System Seal SC1251. After replacement bleed the front and rear brake circuits, see Brake SYSTEM (non ABS) or Brake SYSTEM (ABS) as applicable..

Item A

Table 1. Torque Settings Nm Kgf m 28

2.8

lbf ft 20.6

C092990

Fig 1.

Removal 1

Exhaust all air from the foot brake circuits by pressing the foot brake pedal several times.

Disconnect the hydraulic pipes from the valve. Plug the pipes and valve ports to prevent the loss of hydraulic oil and the ingress of dirt.

Remove the single mounting bolt/nut A and lift the valve clear.

G9-2

9803/9970-01 (G-04-07)

G9-2

Section G10 - Brakes

Circuit Protection Valve Introduction

K Removal and Replacement ( T G10-2)

G10-1

9803/9970-01 (G-04-00)

G10-1

Section G10 - Brakes Circuit Protection Valve Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

Note: The pressure settings of the circuit protection valve are factory-set. Adjustment and repairs are not permitted in service. If the fault finding procedure indicates a fault in this valve, a new unit must be fitted. Note: The valve mountings A and B are not shown for nonABS machines. The mountings are similar to the ABS variant.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK-1-4

G3 A387731-C1

Fig 2. ABS Machines

Removal 1

Release the system air pressure as follows: a

Grip the â&#x20AC;&#x153;keyringâ&#x20AC;? fitting at the bottom of reservoir G3 and pull sideways until all air is released.

b Repeatedly press the foot brake pedal until the stored pressure in reservoirs G1 and G2 is exhausted.

G3 G2

K Fig 2. ( T G10-2) Disconnect the hoses from the ports by first pushing in the hose, then pushing in the sleeve in the elbow or adapter, and then pulling out the hose. Remove elbow A. Blank the open ports to prevent entry of dirt and label the hoses to assist correct refitting.

K Fig 2. ( T G10-2) Remove the two mounting screws B and lift the valve F clear.

G1 417790-C2

Fig 1. Non-ABS Machines

G10-2

9803/9970-01 (G-04-00)

G10-2

Section G10 - Brakes Circuit Protection Valve Removal and Replacement

Replacement Reverse the removal procedure. When fitting elbows, clean the threads and apply Clayton System Seal SC1251. Important: On ABS machines do the Servicemaster ABS diagnostic checks.

Item B

G10-3

Table 1. Torque Settings Nm Kgf m 20

2.0

lbf ft 14.7

9803/9970-01 (G-04-00)

G10-3

Section G10 - Brakes Circuit Protection Valve Removal and Replacement

Page left intentionally blank

G10-4

9803/9970-01 (G-04-00)

G10-4

Section G11 - Brakes

ABS Sensors (ABS) Introduction

K Removal and Replacement ( T G11-2)

G11-1

9803/9970-01 (G-08-00)

G11-1

Section G11 - Brakes ABS Sensors (ABS) Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2. It is necessary to remove the brake caliper on front axles before the following can be carried out. The illustration right shows the arrangement on a nonsteering axle. The arrangement on a steering axle is very similar.

Replacement 1

Insert spring bush B as far as possible so that tabs C abut the axle.

Apply one or two drops maximum of JB Threadlocker and Sealer to the sensor at A. Press sensor fully home into the spring bush.

Note: Failure to install the sensor correctly could adversely affect the operation of the ABS system. Application of an excessive amount of Threadlocker and Sealer will make future removal of the sensor very difficult.

Make sure that the sensor cable does not touch the brake disc.

Do the Service Master ABS diagnostic checks.

C A

A386030-B1

Fig 1.

Removal 1

Remove sensor A by pulling it manually from spring bush B. The sensor is a tight fit and, should it be necessary to pry it out, care should be taken not to cause damage.

Pry out spring bush B from the axle. If damage is inflicted in the process the bush should be renewed.

G11-2

9803/9970-01 (G-08-00)

G11-2

Section G12 - Brakes

Pressure Modulating Valves (ABS) Introduction

K Removal and Replacement ( T G12-2)

G12-1

9803/9970-01 (G-04-08)

G12-1

Section G12 - Brakes Pressure Modulating Valves (ABS) Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

This procedure can only be carried out with the pannier removed from the machine.

C093000

Fig 1.

Removal

Replacement

Exhaust all air from the foot brake circuits by pressing the foot brake pedal several times.

Replacement is the reverse of Removal.

Disconnect the air hoses from the valve by pushing in the hose, then pushing in the sleeve in the elbow or adapter and pulling out the hose. If more than one valve is to be removed, label the hoses to assist correct refitting.

Remove the screws/nuts A and lift valve B clear.

Important: Do the Servicemaster ABS diagnostic checks.

Note: The M8 mounting screws/nuts A are clearly visible below for only one of the valves B in each case. The mounting screws/nuts for the remaining valves can be easily located and accessed.

G12-2

9803/9970-01 (G-04-08)

G12-2

Section G13 - Brakes

Trailer Brake Air Valve Introduction

K Removal and Replacement ( T G13-2) K Testing ( T G13-4) K Dismantling and Assembly ( T G13-5)

G13-1

9803/9970-01 (G-04-02)

G13-1

Section G13 - Brakes Trailer Brake Air Valve Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2. Park the machine on level ground, switch off the engine and remove the starter key.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK-1-4

!MCAUTION

If this item is to be dismantled (even partially) on the machine, ensure that all pressure has been removed from the system.

BRAK-8-1

G3 417790-C3

Fig 2. ABS Machines

Removal 1

Release the system air pressure as follows: a

A P

b Repeatedly press the foot brake pedal until the stored pressure in reservoirs G1 and G2 is exhausted.

V 2

Disconnect each Trailer Brake Air Valve hose by pushing in the hose, then pushing in the sleeve in the elbow or adapter and pulling out the hose. Blank the open ports to prevent entry of dirt and label the hoses to assist correct refitting.

Remove nuts A to release valve P from its mounting bracket and lift clear. Remove non-return valve V and the elbows and connectors from the ports.

G3 G2 G1 417790-C3

Fig 1. Non-ABS Machines

G13-2

Grip the â&#x20AC;&#x153;keyringâ&#x20AC;? fitting at the bottom of reservoir G3 and pull sideways until all air is released.

9803/9970-01 (G-04-02)

G13-2

Section G13 - Brakes Trailer Brake Air Valve Removal and Replacement

Replacement Reverse the removal procedure. When fitting elbows and adapters, clean the threads and apply Clayton System Seal SC1251. Important: On ABS machines do the Servicemaster ABS diagnostic checks.

Item A

Table 1. Torque Settings Nm Kgf m 28

2.8

lbf ft 20.6

1.1

Table 2. Port Connections Reservoir G3, non-return valve V

1.2

Trailer supply line

2.2

Trailer control line

4.1

Footbrake valve and air/hydraulic actuator - Front Circuit

4.2

Footbrake valve and air/hydraulic actuator - Rear Circuit

4.3

Parking Brake Valve

G13-3

9803/9970-01 (G-04-02)

G13-3

Section G13 - Brakes Trailer Brake Air Valve Testing

Testing With the valve installed on the vehicle, connect 0-20 bar (0300 lbf/in2) pressure gauges into the front service line (at port 4.1), the trailer control line (at port 2.2) and the trailer supply line (port 1.2). Note: This test should be carried out with the brakes held on at a system pressure between 2 and 6 bar (29 - 87 lbf/ in2) Charge the system and apply the service brakes to between 2 and 6 bar (29 - 87 lbf/in2). With the brakes held on, check that the gauge reading at port 2.2 is greater than the reading at port 4.1 by 0.1 bar (1.5 lbf/in2) on single caliper brakes. On twin caliper brakes this difference should be 1.4 bar (20.3 lbf/in2). Release the brakes. Disconnect the delivery line from port 2.2, to simulate a brake failure. Fully apply the brakes and check that trailer supply line pressure (at port 1.2) falls to 1.5 bar (22 lbf/in2) within two seconds. Check also that the trailer brakes are automatically applied before the pressure drops below 2 bar (30 lbf/in2).

G13-4

9803/9970-01 (G-04-02)

G13-4

Section G13 - Brakes Trailer Brake Air Valve Dismantling and Assembly

Dismantling and Assembly K Fig 3. ( T G13-6) Item The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

Table 3. Torque Settings Nm Kgf m

lbf ft

11 - 14

1.1 - 1.4

8.5 - 10.5

11 - 14

1.1 - 1.4

8.5 - 10.5

11 - 14

1.1 - 1.4

8.5 - 10.5

Note: The valve incorporates a trailer 'predominance' (or 'lead') feature which allows the trailer brake pressure to be set higher than the service brake pressure (ensuring stable braking when a trailer is connected to the machine). This is set at the factory by means of screw X which must not be disturbed in service. The predominance setting can be checked (but not adjusted) as part of the test procedure. K Testing ( T G13-4)

!MCAUTION Screw X must not be disturbed or unsafe trailer braking will result. BRAK-8-6

When Dismantling Mark the relative positions of the body components to ensure correct alignment on assembly. Link pipe 5 and nut 41 are secured with JCB Threadlocker and Sealer. Items 9 to 15 and Items 45 to 55 can be removed as complete assemblies then dismantled separately.

Cleaning and Inspection Using a proprietary cleaning fluid, clean all components which are to be re-used. Inspect for wear and damage. If the valve seat 47 or the pistons or bores show signs of wear or damage, a replacement valve should be fitted.

When Assembling Use the new components from the Spares Kit during assembly. Secure link pipe 5 and nut 41 with JCB Threadlocker and Sealer. (Ensure that both ends of the link pipe are treated with sealant.)

G13-5

9803/9970-01 (G-04-02)

G13-5

Section G13 - Brakes Trailer Brake Air Valve Dismantling and Assembly

161980-B1

Fig 3.

G13-6

9803/9970-01 (G-04-02)

G13-6

Section G13 - Brakes Trailer Brake Air Valve Dismantling and Assembly

Bench Tests Leakage Tests For the following tests, apply a soap and water solution to the valve joints and to all ports not connected to the air supply. 1

Connect a small air reservoir and a 0 - 15 bar (0 - 220 lbf/in2) pressure gauge to port C and a supply pressure of 8 bar (116 lbf/in2) at port A. Apply air at a pressure of 8 bar (116 lbf/in2) to each of the signal ports D, E and F in turn. In each case, leakage must not exceed a 25 mm (1 in) bubble in 10 seconds.

Apply air at a pressure of 8 bar (116 lbf/in2) to ports A and F. Leakage must not exceed a 25 mm (1 in) bubble in 5 seconds.

Operational Tests With air at 8 bar (116 lbf/in2) connected to ports A and F, apply a series of signal pressures to ports D and E in turn. The signal pressures should vary from 1 - 8 bar (14.5 - 116 lbf/in2) in 1 bar steps. Check that the valve responds immediately to the variations in pressure and that no leakage occurs when the valve is stabilized between variations. With air at 8 bar (116 lbf/in2) connected to port A and a 0 15 bar (0 - 220 lbf/in2) pressure gauge connected to port C, apply varying signal pressures (in the range 0 - 4 bar (0 60 lbf/in2) to port F. Check that the valve responds immediately to variations in signal pressure. (A decrease in signal pressure should cause an increase in pressure at port C, while an increasing signal pressure should produce a decreasing pressure at port C.)

Table 4. Port Identification (1.1) Main supply

(1.2) Trailer supply

(2.2) Trailer control

(4.1) Front service brake line

(4.2) Rear service brake line

(4.3) Parking brake line

(The numbers shown in brackets are cast on the body of the valve.)

G13-7

9803/9970-01 (G-04-02)

G13-7

Section G13 - Brakes Trailer Brake Air Valve Dismantling and Assembly

Page left intentionally blank

G13-8

9803/9970-01 (G-04-02)

G13-8

Section G14 - Brakes

Trailer Brake Hydraulic Valve Introduction

K Removal and Replacement ( T G14-2)

G14-1

9803/9970-01 (G-04-04)

G14-1

Section G14 - Brakes Trailer Brake Hydraulic Valve Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

When Removing

Park the machine on firm, level ground, apply the parking brake and remove the starter key.

Label and blank all hydraulic connections to assist correct replacement and to prevent entry of dirt and excessive oil loss.

The numerical sequence on the illustration is intended as a guide to removal.

When Replacing

For replacement, the sequence should be reversed.

Renew the 'O' ring seals in the hose connections (see Section 1 for torque settings). Bleed the rear hydraulic brake circuit of the Fastrac at the calipers and at screw A (see Brake SYSTEM (non ABS) or Brake SYSTEM (ABS) as applicable.

3 1

Important: On ABS machines do the Servicemaster ABS diagnostic checks.

Table 1. Port Connections Tank (via external hydraulics control valve) (port R)

High pressure carryover to external hydraulics control valve (port N)

Trailer coupling (port B)

Feed from pump (port P)

Pilot feed from rear hydraulic brake system (port Y)

Item

A C

B 5

(1)

6/7

Table 2. Torque Settings Nm Kgf m 22.5

2.3

lbf ft 16.6

(1) Torque value for Dacromet fastners, coloured mottled silver.

C093030

Fig 1.

G14-2

9803/9970-01 (G-04-04)

G14-2

Section G14 - Brakes Trailer Brake Hydraulic Valve Removal and Replacement

Dismantling and Assembly Before dismantling, the trailer brake hydraulic valve must be removed from the machine. K Removal and Replacement ( T G14-2)

A290660-B1

Fig 2. Dismantling Item The numerical sequence on the illustration is a guide to dismantling. Assembly

Table 3. Torque Settings Nm Kgf m

lbf ft

10 - 13

1 - 1.3

7 - 10

2.5 - 3.5

0.25 - 0.35

1.8 - 2.6

56 - 75

5.7 - 7.7

41 - 55

Assembly is the reverse of dismantling.

G14-3

9803/9970-01 (G-04-04)

G14-3

Section G14 - Brakes Trailer Brake Hydraulic Valve Removal and Replacement

Page left intentionally blank

G14-4

9803/9970-01 (G-04-04)

G14-4

Section G15 - Brakes

Trailer Brake Inverse Relay Valve Introduction

K Removal and Replacement ( T G15-2) K Dismantling and Assembly ( T G15-3)

G15-1

9803/9970-01 (G-04-05)

G15-1

Section G15 - Brakes Trailer Brake Inverse Relay Valve Removal and Replacement

Removal and Replacement Important: Obey the Care and Safety procedures given in Section 2.

!MWARNING

Removal 1

Drain air from the brake system.

Disconnect hoses A, B and C by pushing in the sleeve in the elbow and pulling out the hose. Blank the open ports to prevent entry of dirt and label the hoses to assist correct refitting.

Remove bolts E.

Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

!MCAUTION If this item is to be dismantled (even partially) on the machine, ensure that all pressure has been removed from the system.

Item

Table 1. Torque Settings Nm Kgf m 22.5

6/7(1)

BRAK-8-1

2.3

lbf ft 16.6

(1) Torque value for Dacromet fastners, coloured mottled silver.

Replacement Reverse the removal procedure. When fitting elbow, clean the threads and apply Clayton System Seal SC1251. Important: On ABS machines do the Servicemaster ABS diagnostic checks.

Table 2. Hose Destinantions Dual Line Trailer Brakes - Supply (red)

Dual Line Trailer Brakes - Control (yellow)

Single Line Trailer Brakes

229300-C1

Fig 1.

G15-2

9803/9970-01 (G-04-05)

G15-2

Section G15 - Brakes Trailer Brake Inverse Relay Valve Dismantling and Assembly

Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.

When Dismantling

For assembly the sequence should be reversed.

Mark the relative positions of the body components to ensure correct alignment on assembly.

Note: A Service Kit should be obtained before starting this job. Ensure that the kit obtained is correct for the valve fitted. Items shown grouped as K are the only parts available and are obtainable only as a complete kit.

When Assembling Use the new components from the Service Kit during assembly.

C093050

Fig 2.

G15-3

9803/9970-01 (G-04-05)

G15-3

Section G15 - Brakes Trailer Brake Inverse Relay Valve Dismantling and Assembly

Page left intentionally blank

G15-4

9803/9970-01 (G-04-05)

G15-4

Section G16 - Brakes

Trailer Brake Control Line Air Filter Introduction

K Dismantling and Assembly ( T G16-2)

G16-1

9803/9970-01 (G-05-00)

G16-1

Section G16 - Brakes Trailer Brake Control Line Air Filter Dismantling and Assembly

Dismantling and Assembly Important: Obey the Care and Safety procedures given in Section 2.

The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

A387680-B1

Fig 1. When Dismantling Take care when removing item 1 that the rest of the components do not spring out. When Assembling Check O-ring 3 and filter 6 for damage or wear and if necessary fit new components. If re-using, clean filter 6 by washing in clean fuel. Blow dry with compressed air. Important: On ABS machines do the Servicemaster ABS diagnostic checks.

G16-2

9803/9970-01 (G-05-00)

G16-2

Section G17 - Brakes

Trailer Brake Couplings (Palm Couplings) Introduction

K Dismantling and Assembly ( T G17-2)

G17-1

9803/9970-01 (G-04-06)

G17-1

Section G17 - Brakes Trailer Brake Couplings (Palm Couplings) Dismantling and Assembly

Dismantling and Assembly Important: Obey the Care and Safety procedures given in Section 2. Palm couplings coded black. K Fig 1. ( T G17-2) Palm couplings coded red. K Fig 2. ( T G17-2) The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed. Note: A Service Kit should be obtained before starting this job. Ensure that the kit obtained is correct for the valve fitted. Items shown grouped as K are the only parts available and are obtainable only as a complete kit.

K 332530-C1

Fig 2. Palm Coupling Coded Red When Dismantling

Mark the relative positions of the body components to ensure correct alignment on assembly. When Assembling Use the new components from the Service Kit during assembly.

5 1

Important: On ABS machines do the Servicemaster ABS diagnostic checks.

3 2

7 4

11 10

332520-C1

Fig 1. Palm Coupling Coded Black

G17-2

9803/9970-01 (G-04-06)

G17-2

Section H Steering Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section H - Steering

Notes:

H-0

9803/9970-01

H-0

Section H - i Contents

Contents Page No. Steering SYSTEM Introduction ............................................................................................. H1-1 Technical Data ........................................................................................ H1-2 Operation Overview ................................................................................ H1-3 Hydraulic Operation and Schematics ..................................................... H1-4 Fault Finding ........................................................................................... H1-5 Introduction ......................................................................................... H1-5 Fault Finding Tables ........................................................................... H1-5 Pressure Testing - Steering Pump .......................................................... H1-8 Limit Valve Setting ................................................................................ H1-10 Wheel Alignment .................................................................................. H1-12 Steering Box Introduction ............................................................................................. H2-1 Operation Overview ................................................................................ H2-2 Removal and Replacement .................................................................... H2-3 Dismantling and Assembly ..................................................................... H2-5 Fitting the Input Shaft Nut and Star Nut .............................................. H2-8 Steering Shafts Introduction ............................................................................................. H3-1 Inspection ............................................................................................... H3-2 Universal Joints and Phasing ............................................................. H3-2 Intermediate Shafts and Bearings ...................................................... H3-2 Bulkhead Shaft ................................................................................... H3-3

H-i

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.. Descriptions and procedures relate to the system and not the individual devices. 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. K Technical Data ( T H1-2) K Operation Overview ( T H1-3) K Fault Finding ( T H1-5) K Pressure Testing - Steering Pump ( T H1-8) K Limit Valve Setting ( T H1-10) K Wheel Alignment ( T H1-12)

H1-1

9803/9970-01 (H-01-00)

H1-1

Section H1 - Steering Steering SYSTEM Technical Data

Technical Data Pump Type

Rear section (P2) of gear type pump, driven by gearbox

Controlled flow at 1500 rev/min and system pressure

18 litres/min (4 UK gal/min, 4.8 US gal/min) +15% -10%

Relief valve pressure at 1500 rev/min engine speed

135 bar (1958 lb/in2) Important: DO NOT set the pressure above this value.

H1-2

9803/9970-01 (H-01-00)

H1-2

Section H1 - Steering Steering SYSTEM Operation Overview

Operation Overview

C097020

Fig 1. The front axle is steered by a recirculating ball hydraulically power assisted steering box 1. Drop arm 2 and drag link 3 transmit the steering effort to the right hand steering swivel 5. This is linked to the left hand steering swivel by track rod 6. Steering damper 7 connects between drag link 3 and the chassis. The damper reduces steering kick back on uneven ground. The steering input shafts are supported by bearings and chassis mounted brackets 8. Input shafts 9 and 10 are telescopic. Steering column assembly 12 is adjustable for angle and reach.

H1-3

9803/9970-01 (H-01-00)

H1-3

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics

Hydraulic Operation and Schematics

C097030

Fig 2. P3 is the rear section of the gearbox-driven hydraulic pump which draws fluid from tank T to supply steering box SB. An adjustable pressure and flow control valve B is built into the rear cover of the pump. Fluid exhausted from the steering box joins with the pump by-pass flow and returns to tank via cooler CS which is part of the machine cooling pack.

H1-4

9803/9970-01 (H-01-00)

H1-4

Section H1 - Steering Steering SYSTEM Fault Finding

Fault Finding Introduction

Fault Finding Tables

Before assuming that the steering box or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified.

K Fault - Heavy Steering ( T H1-6)

Before using the fault finding tables carry out the following checks: 1

Question the operator and drive the machine to establish the exact nature of the fault.

Check that the hydraulic oil is clean and to the correct and that there are no signs of oil leakage from the circuit.

Check that the steering box mountings and all steering and suspension linkages are correctly tightened.

H1-5

9803/9970-01 (H-01-00)

H1-5

Section H1 - Steering Steering SYSTEM Fault Finding CHECK 1 2 3 4 5 6 7 8 9

Is the front axle overloaded? Are the correct tyres fitted and correctly inflated? Is the 4WD clutch releasing correctly? Is the front differential operating correctly? Are the steering swivels and linkages free? Is the oil cooler free of air blockage? Is the pump relief valve pressure too low? Is the pump flow rate too low? Is the steering column turning freely?

10 11 12 13

Table 1. Fault - Heavy Steering ACTION

Is front wheel alignment correct? Are suspension and steering geometry correct? Is steering box leaking oil? Is oil temperature high?

H1-6

YES:

Reduce load

NO:

Check 2

YES:

Check 3

NO:

Replace / inflate tyres

YES:

Check 4

NO:

See Section F, Fault Finding

YES:

Check 5

NO:

See Section F, Fault Finding

YES:

Check 6

NO:

Lubricate and free off

YES:

Check 7

NO:

Clean out debris

YES:

Check for dirt at relief valve

NO:

Check 8

YES:

Check for flow control valve sticking and check 11

NO:

Check 9

YES:

Check 10

NO:

Free off / check universal joint phasing

YES:

Check 11

NO:

Adjust

YES:

Check 12

NO:

Renew parts as required

YES:

Renew seals

NO:

Check 13

YES:

Check cooler and pipework for free flow

NO:

Suspect fault in steering box

9803/9970-01 (H-01-00)

H1-6

Section H1 - Steering Steering SYSTEM Fault Finding CHECK

Table 2. Fault - Steering Wander or Free Play ACTION

If the fault is wander, start at check 1. If the fault is free play, start at check 4. 1 2 3 4 5 6

Is the rear axle overloaded? Are the correct tyres fitted and correctly inflated? Is the front wheel alignment correct? Are the column or steering linkages worn or loose? Is the pump flow correct? Is air trapped in the hydraulic oil?

H1-7

YES:

Reduce load.

NO:

Check 2.

YES:

Check 3.

NO:

Replace / inflate tyres.

YES:

Check 4.

NO:

Adjust.

YES:

Tighten or renew.

NO:

Check 5.

YES:

Check 6.

NO:

Check condition of flow control.

YES:

Bleed out air. Turn the steering wheel from lock to lock 3 times and then back to straight ahead (with engine running at idle).

NO:

Suspect fault in steering box.

9803/9970-01 (H-01-00)

H1-7

Section H1 - Steering Steering SYSTEM Pressure Testing - Steering Pump

Pressure Testing - Steering Pump 1

Park the machine on firm, level ground and apply the parking brake. Jack up the front of the machine until the wheels are clear of the ground and support it using axle stands placed under the axle. Ensure that the wheels can turn fully from lock to lock without fouling the axle stands.

Fit a 30 mm lock stop (part number 476/40702) at the left-hand side.

Run engine at 1500 rev/min, turn the steering wheel to full left lock and hold while checking the gauge reading against the pressure given in Technical Data.

If the gauge reading is not correct, the fault is likely to be in the pump relief valve which should be removed for cleaning (see Section E).

If after cleaning the pressure is still not correct it can be adjusted, but the pressure MUST NOT under any circumstances be set higher than the setting given in Technica Data. Proceed as follows: K Fig 4. ( T H1-9) The pressure setting is controlled by an adustable relief valve cartridge located in the pump end cover (shown at X).

INT-3-2-8

Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test point Y.

Make sure that the engine cannot be started. Remove the retaining cover 1. Pull out the valve cartridge 2.

b Grip the cartridge and turn the adjusting screw 3 no more than 1/4 turn, clockwise to increase the pressure setting and anticlockwise to decrease. c

Replace the cartridge and refit the retaining cap 1. tighten the cap to the correct torque. DO NOT start the engine unless the cartridge 2 and retaining cap 1 are correctly fitted.

d Start the engine and check the pressure setting. If further adjustment is required stop the engine and repeat the above from step â&#x20AC;&#x2DC;aâ&#x20AC;&#x2122;. Table 3. Torque Settings Kgf m lbf ft

Item

30 - 35

3.0 - 3.5

22 - 26

418540-C1

Fig 3.

H1-8

9803/9970-01 (H-01-00)

H1-8

Section H1 - Steering Steering SYSTEM Pressure Testing - Steering Pump

X 1

2 3

A1122-C1

Fig 4.

H1-9

9803/9970-01 (H-01-00)

H1-9

Section H1 - Steering Steering SYSTEM Limit Valve Setting

Limit Valve Setting K Fig 6. ( T H1-11) In the event of altering wheel width and lock stop sizes, fitting a new steering box or if the adjusting screws E or F have been disturbed, the limit valves must be set as follows: 1

Check that the correct lock stop D (varies in length according to track width and tyre specification) plus a 2 mm flat washer is fitted at each side of the machine. Lock stops to suit the tyres/track width of new machines are factory fitted. See Tyres and Wheels, Lock Stops in Section 3 for details for other tyres/track widths.

418540-C1

Fig 5. 4

Run the engine until the temperature of the oil in the hydraulic tank is at least 20 Â°C and then set the speed to 1500 rpm.

Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test point Y.

H1-10

9803/9970-01 (H-01-00)

H1-10

Section H1 - Steering Steering SYSTEM Limit Valve Setting once) then re-check the pressure. Adjust if necessary. Repeat this process until the pressure remains constant (four or five times is normal to achieve this). If the pressure will not remain constant, ensure that the lock stops, steering box, axle and suspension mounting points are all secure.

!MWARNING Due to the proximity of engine revolving parts and the possibility of getting trapped between the wheel and the chassis, rear limit valve screw adjustments should not be attempted until the engine has been switched off and stopped. Remove the starter key. HYD ST-5-4

Turn the steering to full right lock and repeat steps 4 and 5, reading right lock instead of left lock and viceversa. Adjust rear limit valve screw F using a flexible shaft screwdriver.

Once the pressure settings have been completed, remove the lock stops D and the 2 mm flat washers. Re-install only the lock stops.

C097060

Fig 6. 5

Turn the steering to full left lock. Set the pressure to 38- 40 bar (550-580 lbf/in2) by adjusting the front limit valve screw E. Use a long thin screwdriver through the hole in the front cross-member as shown by the arrow X. Turn clockwise to decrease the pressure and anti-clockwise to increase.

Release the steering wheel and turn it back and forth (fully onto left lock 5 times and onto right lock at least

H1-11

9803/9970-01 (H-01-00)

H1-11

Section H1 - Steering Steering SYSTEM Wheel Alignment

Wheel Alignment For the wheel alignment procedure refer to Section 3, Routine Maintenance.

H1-12

9803/9970-01 (H-01-00)

H1-12

Section H2 - Steering

Steering Box Introduction

K Operation Overview ( T H2-2) K Removal and Replacement ( T H2-3) K Dismantling and Assembly ( T H2-5)

H2-1

9803/9970-01 (H-02-00)

H2-1

Section H2 - Steering Steering Box Operation Overview

Operation Overview

A161504-B1

Fig 1. The steering box incorporates pressure limit valves E and F (see schematic diagram below). The valves operate just before the steering rack reaches full lock to vent the power assist pressure to the exhaust side of the rack.

H2-2

9803/9970-01 (H-02-00)

H2-2

Section H2 - Steering Steering Box Removal and Replacement

Removal and Replacement K Fig 3. ( T H2-7) Note: Before assuming that the steering box is the cause of a steering problem, ensure that all other steering system faults have been rectified (see Steering SYSTEM). Remove the cooling pack to gain access to the top of the steering box.

Use puller adapters A with a 20 tonne general purpose hydraulic ram B to remove the drop arm 6. (See Service Tools for details of the tools.) Before disconnecting pipes, label them to assist correct refitting. Blank the open ports to prevent loss of oil and entry of dirt. When Replacing

The numerical sequence shown on the illustration is intended as a guide to removal. For replacement the sequence should be reversed.

It is absolutely critical that the steering box mounting bolts are tightened to the torque setting specified below. Failure to do this may result in erratic steering. Before fitting pinch bolt 9, ensure that the steering shaft universal joints are correctly aligned (see Steering Shafts) and that the steering shaft is not exerting any end load on the input shaft of the steering box. After fitting pipework and before fitting drop arm, purge air from the hydraulic system by turning the steering wheel from lock to lock 3 times and then back to straight ahead (with engine running at idle).

!MWARNING

When fitting drop arm, align marks X and Y on shaft and drop arm.

Do not weld, hammer or apply heat to the drop arm or its shaft. These actions will cause weakness and may result in steering failure.

Tighten drag link nut 4 to specified torque setting and then on to next split pin hole before fitting split pin.

HYD ST-5-1

After fitting the steering box, ensure that lock limit valves are correctly set, see Steering SYSTEM.

When Removing

!MWARNING

Item

Table 1. Torque Settings Nm Kgf m lbf ft

The drop arm will be very tight on the splines. Take great care when pulling off the arm as it is likely to be released suddenly with considerable force.

16 - 18

1.7 - 2.0

12 - 15

915

675

HYD ST-5-2

135

13.7

100

7.6

10(1)

500

370

Note the positions of index marks X and Y on shaft and drop arm. Use a suitable ball joint splitter when removing drag link 5.

(1) Torque value for Dacromet fastners, coloured mottled silver

Do not disturb the length adjustment of drag link 5 which is preset to 930 mm (36.6 in) between centres of ball pins.

H2-3

9803/9970-01 (H-02-00)

H2-3

Section H2 - Steering Steering Box Removal and Replacement

S301830-C1

Fig 2.

H2-4

9803/9970-01 (H-02-00)

H2-4

Section H2 - Steering Steering Box Dismantling and Assembly

Dismantling and Assembly K Fig 3. ( T H2-7)

When Assembling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

Remove any burrs from the piston using a fine hand stone. Apply a light coat of grease to the seals, thrust bearings and thrust washers.

For assembly the sequence should be reversed. Note: Input seals 43 and 44 may be replaced by unscrewing bolts 40 and removing cover plate 42. When Dismantling Remove screws 10 and 11 to prevent them being damaged. They must be re-set after fitting the steering box. See Steering SYSTEM. When cover 2 has been removed ensure that there are timing marks on adjacent teeth of the sector shaft 5 and piston rack. With the steering box positioned so that ball retainer cap 17 is pointing upwards, carefully withdraw bearing cap and shaft assembly X and the piston 20 from the main housing as one unit. If this is not done carefully, balls 19 may fall out. When the piston is out of the housing, remove cap 17 and split race 18, rotate the input shaft 31 to release the balls (24 off) and separate the piston from the bearing cap assembly. This will allow seal 21 to be removed.

When fitting shaft seal 36 ensure that the lip faces towards the inside of the steering box and that the seal bottoms in the bearing cap bore. Fit the salt seal 35 until it is flush with the face of the bearing cap. When renewing seals 25, ensure that the piston grooves are free of nicks and burrs. Install energising rings 26 into the grooves first with the seals 25 over the top as shown at W. Before inserting the input shaft into the bearing cap, compress the seals into their grooves using a piece of thin sheet steel rolled into a tubular form. Do not rotate the input shaft when fitting it into the bearing cap as this is likely to damage the seals. Fit the shaft nut, star nut and check bearing preload as detailed on the next page. When fitting new seals to the piston, position back-up 'O' ring 23 in the groove and position new seal ring 22 over the 'O' ring. Due to the nature of the seal material, it will stretch as it is fitted but will contract over a period of time to allow entry into the bore of the housing. If shortage of time does not allow sufficient contraction of the seal, use a suitable piston ring clamp to compress the seal.

Do not remove plugs C and D from the piston. Renewal of rotary valve seals 25 and their energising rings 26 is not necessary unless they are cut or damaged. To renew input shaft seals 35 and 36 the bearing cap and shaft assembly (items 27 to 37) must be dismantled. Note: Special spanners will be required to tighten star nut 27 and shaft nut 28 to their correct torque settings. To allow star nut 27 to be removed it may be necessary to split it with a chisel. Take appropriate safety precautions when using the chisel.

Enter the piston 20 into the housing bore with the ball cavity Y uppermost and just exposed at the end of the bore. Enter the input shaft into the piston so that the bearing cap 37 is within 75 mm (3 in) of the end of the piston 20. Slowly turn the bearing cap assembly inwards whilst inserting balls at Y until balls start to appear at Z. Insert split race 18 and press home. Insert final balls and fit cap 17.

Note: The gear is secured to the sector shaft 5 by means of dowel 39 and roll pin 38. These should not normally be removed as the gear and shaft would be renewed as an assembly.

H2-5

9803/9970-01 (H-02-00)

H2-5

Section H2 - Steering Steering Box Dismantling and Assembly

!MCAUTION Do not turn the steering wheel to the left with a 0 - 40 bar pressure gauge connected. Doing this would damage the gauge due to the high pressure at the test point during a left turn. HYD ST-5-3

When sliding the piston through the housing bore, take care to avoid damaging seals as they pass the edges of the housing bore for sector shaft 5. Position the timing mark on the piston rack on the centre-line of the sector shaft bore. Install the sector shaft so that the timing mark on the sector shaft gear tooth aligns with the timing mark on the piston rack. Tap the end of the sector shaft with a soft hammer to ensure full tooth engagement.

Item

Table 2. Torque Settings Nm Kgf m lbf ft

249 - 263

24.8 - 26.8

184 - 19

72 - 85

7.3 - 8.6

53 - 63

249 - 263

125.4 - 26.8

184 - 190

H2-6

9803/9970-01 (H-02-00)

H2-6

Section H2 - Steering Steering Box Dismantling and Assembly

S222451A-C1

Fig 3.

H2-7

9803/9970-01 (H-02-00)

H2-7

Section H2 - Steering Steering Box Dismantling and Assembly

Fitting the Input Shaft Nut and Star Nut 1

Ensure that the input shaft, thrust bearings and thrust washers are correctly installed in the positons shown on the assembly illustration. Using spanner A, part no. 892/00883, tighten the shaft nut 28 to 2.8-4.7 Nm (2-3 lbf ft).

222470-B1

Fig 5. 3

Bend two tangs of the star nut into the two plain holes in the bearing cap as at C. Stake the star nut into the shaft nut at the two notches D.

222460-B1

Fig 4. 2

Fit a new star nut 27. While preventing the shaft nut from turning using spanner A, tighten the star nut to 14-16 Nm (10-12 lbf ft) using spanner B (part no. 892/ 00884). Continue tightening the star nut until two of the tangs align with the two plain holes in the bearing cap.

Note: Do not use the threaded hole in the bearing cap. This is for the lock limit screw. Turn the bearing cap over in the vice. Rotate the splined end of the shaft using a torque meter and a suitable socket. The reading should be less than 2.8 Nm (2 lbf ft). If this figure is exceeded, re-check the torque on the shaft nut.

H2-8

9803/9970-01 (H-02-00)

222480-B1

Fig 6.

H2-8

Section H3 - Steering

Steering Shafts Introduction

K Inspection ( T H3-2) K Universal Joints and Phasing ( T H3-2) K Intermediate Shafts and Bearings ( T H3-2) K Bulkhead Shaft ( T H3-3)

H3-1

9803/9970-01 (H-03-00)

H3-1

Section H3 - Steering Steering Shafts Inspection

Inspection 4 1

2 5

3 4 7 6 5

1 6

6 6 7

C097110

Fig 1.

Universal Joints and Phasing Check for stiff (seized) or worn universal joints (UJ) 1 on the steering shafts. Make sure that the shafts are not rubbing against any other components, (for example hoses or pipework). Note: It is important that high pressure water jets are not pointed at universal joints during cleaning. The universal joints have grease nipples which should be greased if steering becomes stiff or if a new shaft is fitted.

When installing shafts make sure bearing grub screws 5 are loose. Install and tighten the shaft universal clamp bolts 4 and bearing bracket support bolts 6. Tighten the bearing grub screws 5 last.

Intermediate Shafts and Bearings If the steering wheel does not turn smoothly inspect the bearings 7. Check that the bearing has not seized. If necessary remove the shafts together their bearings to help determine which bearing is defective.

Shafts with worn or seized unversal joints must be replaced. Item The phasing of the shaft universal joints is fixed by means of location slots 2. Align the shaft splines so that the universal joint clamp bolts holes 3 align with the slot in the shafts. The clamp bolts can not be installed if the phasing is not correct.

H3-2

Table 1. Torque Settings Nm Kgf m

lbf ft

3.8

7.6

9803/9970-01 (H-03-00)

H3-2

Section H3 - Steering Steering Shafts Inspection

Bulkhead Shaft Item Replace the bulkhead shaft 1 if it is defective. The shaft bearings can not be replaced. Replace the sliding shaft 6 if the universal joints are defective. 1

Remove the dash board shroud.

Remove clamp bolt 5 and uncouple the sliding shaft 6

Uncouple the sliding shaft at the opposite end of shaft assembly 1.

Remove four bolts 2 and pull out the shaft assembly 1 from outside the cab.

Table 2. Torque Settings Nm Kgf m

lbf ft

22.5

2.3

3.8

C097140

Fig 2. When replacing: â&#x20AC;&#x201C; Seal the shaft plate 1 to the cab bulkhead with sealant DP2205. â&#x20AC;&#x201C; Align the shaft splines so that the universal joint clamp bolt hole aligns with the slot 3 in the shaft. The clamp bolt 5 can not be installed if the phasing is not correct.

H3-3

9803/9970-01 (H-03-00)

H3-3

Section H3 - Steering Steering Shafts Inspection

Page left intentionally blank

H3-4

9803/9970-01 (H-03-00)

H3-4

Section S Suspension Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section S - Suspension

Notes:

S-0

9803/9970-01

S-0

Section S - i Contents Page No. Front Suspension SYSTEM Introduction ............................................................................................. S1-1 Operation Overview ................................................................................ S1-2 Removal and Replacement - Shock Absorber (D) ................................. S1-3 Removal and Replacement - Control Arm (A) ........................................ S1-4 Outer Control Arms ............................................................................ S1-4 Centre Control Arm ............................................................................ S1-5 Control Arm Bosses (View Y) ............................................................. S1-5 Removal and Replacement - Panhard Rod (B) ...................................... S1-7 Removal and Replacement - Anti Roll Bar (E) ....................................... S1-9 Removal and Replacement - Coil Spring and Microcellular Spring ....... S1-11 Rear Suspension SYSTEM Introduction ............................................................................................. S2-1 Technical Data ........................................................................................ S2-2 Operation Overview ................................................................................ S2-3 Primary System .................................................................................. S2-3 Ride Height Control ............................................................................ S2-4 Ride Height Calibration ........................................................................... S2-6 Testing .................................................................................................... S2-8 Pressure Maintenance Valve .............................................................. S2-8 Accumulator and Gas Spring .............................................................. S2-9 Discharging the Hydraulic Pressure ..................................................... S2-10 Removal and Replacement - Potentiometer ......................................... S2-12 Removal ........................................................................................... S2-12 Replacement .................................................................................... S2-12 After Replacement ............................................................................ S2-12 Removal and Replacement - Accumulator (A), Gas Spring (G) ........... S2-13 Removal and Replacement - Anti-roll Bar ............................................ S2-15 Removal and Replacement - Control Arm (J) ....................................... S2-16 Removal and Replacement - â&#x20AC;&#x2DC;Vâ&#x20AC;&#x2122; Link ................................................... S2-18 Dismantling and Assembly - Ball Joint ............................................. S2-20 Removal and Replacement - Suspension Cylinder (S) ........................ S2-21 Dismantling and Assembly - Suspension Cylinder ............................... S2-23 Testing .............................................................................................. S2-25 Gland Fitting Procedure ................................................................... S2-25

S-i

Section S1 - Suspension

Front Suspension 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.. Descriptions and procedures relate to the system and not the individual devices. 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.

K Operation Overview ( T S1-2) K Removal and Replacement - Shock Absorber (D) ( T S1-3) K Removal and Replacement - Control Arm (A) ( T S1-4) K Removal and Replacement - Panhard Rod (B) ( T S1-7) K Removal and Replacement - Anti Roll Bar (E) ( T S1-9) K Removal and Replacement - Coil Spring and Microcellular Spring ( T S1-11)

S1-1

9803/9970-01 (S-01-00)

S1-1

Section S1 - Suspension Front Suspension SYSTEM Operation Overview

Operation Overview The front axle is located by a four link system consisting of three control arms A and Panhard rod B.

which offer progressively increasing suspension stiffness over bumps.

Primary suspension stiffness is provided by coil springs C, supplemented by microcellular polyurethane springs

Suspension movement is controlled by two telescopic shock absorbers D. Anti-roll bar E controls vehicle roll when cornering.

B E C

714751-C1

Fig 1.

S1-2

9803/9970-01 (S-01-00)

S1-2

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Shock Absorber (D)

Removal and Replacement - Shock Absorber (D)

!MWARNING

Note: Note: This job can be done with the machine standing on its wheels.

When Replacing When fitting the mounting pin D12 into the axle, apply JCB Threadlocker and Sealer to the threads.

3-3-1-1

Item Nm

Table 1. Torque Settings Kgf m lbf ft

The numerical sequence shown on the illustration (items D1 to D12) is intended as a guide to removing.

180

18.4

133

180

18.4

133

For Replacement the sequence should be reversed.

D12

300

220

714740-C1

Fig 2.

S1-3

9803/9970-01 (S-01-00)

S1-3

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Control Arm (A)

Removal and Replacement - Control Arm (A)

!MWARNING

Outer Control Arms

K Fig 3. ( T S1-6) Removal

3-3-1-1

Support the control arm and remove nut A6 (V) at the front end and nut A3 (Y) at the rear end. Separate the tapers and lift the control arm clear.

K Fig 3. ( T S1-6)

Replacement

Note: View V opposite shows the front end of the two outer control arms. View W shows the front end of the centre control arm. View X shows the rear end of the centre control arm. View Y shows the rear end of the two outer control arms.

Replacement is the reverse of Removal.

When Removing Just support the weight of the chassis by means of axle stands beneath the lower control arm chassis mount cross member. Note: If more than one arm is to be removed it is also necessary to support the axle on stands, so as to maintain its location relative to the chassis. When Replacing Tighten all bolts and nuts to the specified torque with the machine standing on its wheels.

S1-4

9803/9970-01 (S-01-00)

S1-4

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Control Arm (A)

Centre Control Arm

Control Arm Bosses (View Y)

K Fig 3. ( T S1-6)

Removal

Removal and Replacement

Support the control arm. At the front end, loosen nut A4 (W) and then remove socket head screws A5 (W). At the rear end remove bolts A1/nuts A2 (X). Lift the control arm clear.

Check the torque of the four bolts U, securing each front control arm boss T is 115 Nm (85 lbf ft). If any bolt is loose, broken or missing, separate the boss from the chassis while still connected to the control arm.

Clean the mating surfaces of the chassis and the control arm boss down to bare metal using a medium grade emery cloth to produce the final surface finish.

Refit the boss to the chassis using bolts U, spacers V and nuts W tightened to a torque of 115 Nm (85 lbf ft).

Separate the control arm from mounting block E by removing nut A4 and using a 20 tonnes press to force the tapered stud out of the mounting block. Replacement Install the control arm taper in mounting block E and loosely fit nut A4. Apply JCB Threadlocker and Sealer to mounting block socket head screws A5 and tighten to the specified torque. Use a torque multiplier (993/45400) to tighten nut A4 to the specified minimum torque. Further tighten nut A4 to the next castle nut slot and install split pin. Finally tighten bolts A1/nuts A2 (X) as specified. Table 2. Torque Settings Nm Kgf m lbf ft

Item

Centre arm - front 1400

A4 (W)(1)

143

1033

647

482

250

184

Center arm - rear 559

412

Side arms - rear

184

A5 Side Arms - front

(1)

A6 (V)

A1/A2 (X) (1)

A3 (Y)

(1)

250

(1) Torque value for Dacromet fastners, coloured mottled silver

S1-5

9803/9970-01 (S-01-00)

S1-5

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Control Arm (A)

714720-C1

Fig 3.

S1-6

9803/9970-01 (S-01-00)

S1-6

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Panhard Rod (B)

Removal and Replacement - Panhard Rod (B) K Fig 4. ( T S1-8)

100 hours after fitting the Panhard rod, check the torque tightness of nuts B2 and B4.

Table 3. Torque Settings Kgf m lbf ft

Item

B2/B4

244

180

70 - 80

7.1 - 8.2

52 - 59

3-3-1-1

The numerical sequence shown on the illustration (items B1 to B6) is intended as a guide to dismantling. For assembly the sequence should be reversed. Note: This job can be done with the machine standing on its wheels. When Removing Separate the taper ball pins from their brackets using a ball joint splitter.

!MCAUTION Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

When Replacing Before fitting, check dimension X which should be 660 to 690 mm (26.5 to 26.7 in). If necessary, adjust by slackening nut Y and screwing ball joint B5 in or out as required. Retighten nut Y to the specified torque. Tighten nuts B2 and B4 to the specified torque and then tighten further until the next slot in the castellation is in line with the split pin hole. Fit the split pins. After fitting the Panhard rod, recheck adjustment by measuring the distance between the top of each front wheel rim and the chassis side member when the wheels are in the straight ahead position. The two measurements should be within 5 mm (0.4 in) of each other. If required, readjust the length of the rod.

S1-7

9803/9970-01 (S-01-00)

S1-7

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Panhard Rod (B)

714710-C2

Fig 4.

S1-8

9803/9970-01 (S-01-00)

S1-8

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Anti Roll Bar (E)

Removal and Replacement - Anti Roll Bar (E) K Fig 5. ( T S1-10)

The numerical sequence shown on the illustration (items E1 to E8) is intended as a guide to dismantling. For assembly the sequence should be reversed. Note: This job can be done with the machine standing on its wheels. When Removing Remove nuts E1 and bolts E2 from both ends of the antiroll bar and then remove the two nuts E3/bolts E4 from each of the central mounting brackets. Remove the bar forwards out of the central mounting brackets, complete with plastic insulators E6, bushes E7 and sleeves E8. When Replacing Renew sleeves E8 if they are not a good fit between the axle lugs. Do not overtighten nuts E1 and bolts E2. Table 4. Torque Settings Kgf m lbf ft

Item

E1/E2(1)

200

148

E3/E4

47.5

4.8

(1) Torque value for Dacromet fastners, coloured mottled silver

S1-9

9803/9970-01 (S-01-00)

S1-9

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Anti Roll Bar (E)

714710-C1

Fig 5.

S1-10

9803/9970-01 (S-01-00)

S1-10

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Coil Spring and Microcellular Spring

Removal and Replacement - Coil Spring and Microcellular Spring K Fig 6. ( T S1-12)

Note: Tighten the microcellular spring onto the spacer using hand pressure only.

Removal The coil spring C and the microcellular spring G2 must be removed together.

Table 5. Torque Settings Kgf m lbf ft

Item

392

289

Raise both sides of the machine equally by one of the following methods:

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Use an overhead hoist to raise front of chassis (minimum lift capacity for basic machine is 3.5 tonnes or 5 tonnes with optional equipment). Lift until front wheels are about to clear the ground.

Insert a piece of timber 50 x 50 mm ( 2 x 2 in) between the axle and each bump stop as at X to prevent the springs from compressing and to achieve maximum lift on the jack. Use a jack under the axle to raise the machine and insert stands under the chassis. Lower the jack so that the load is off the springs.

Remove bolt G1 which holds the springs to the chassis. Allow the microcellular spring G2 and spacer G3 to rest on top of the axle. Pry out coil spring C from the top and lift it clear of the locating boss on the axle along with microcellular spring G2 and spacer G3.

!MCAUTION Keep your hands clear of the springs until they have been released and are no longer under load or you may trap your fingers. SUS-1-4

Unscrew the microcellular spring from the spacer. Replacement Reverse the dismantling sequence.

S1-11

9803/9970-01 (S-01-00)

S1-11

Section S1 - Suspension Front Suspension SYSTEM Removal and Replacement - Coil Spring and Microcellular Spring

714700-C1

Fig 6.

S1-12

9803/9970-01 (S-01-00)

S1-12

Section S2 - Suspension

Rear Suspension 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. Descriptions and procedures relate to the system and not the individual devices. 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.

K Technical Data ( T S2-2) K Operation Overview ( T S2-3) K Primary System ( T S2-3) K Ride Height Control ( T S2-4) K Ride Height Calibration ( T S2-6) K Testing ( T S2-8) K Pressure Maintenance Valve ( T S2-8) K Accumulator and Gas Spring ( T S2-9) K Discharging the Hydraulic Pressure ( T S2-10) K Removal and Replacement - Potentiometer ( T S2-12) K Removal and Replacement - Accumulator (A), Gas Spring (G) ( T S2-13) K Removal and Replacement - Anti-roll Bar ( T S2-15) K Removal and Replacement - Control Arm (J) ( T S2-16) K Removal and Replacement - â&#x20AC;&#x2DC;Vâ&#x20AC;&#x2122; Link ( T S2-18) K Removal and Replacement - Suspension Cylinder (S) ( T S2-21) K Dismantling and Assembly - Suspension Cylinder ( T S2-23)

S2-1

9803/9970-01 (S-02-00)

S2-1

Section S2 - Suspension Rear Suspension SYSTEM Technical Data

Technical Data Pump Type

Front section (P1) of gear type pump, driven by engine.

Maximum flow

36.5 litres/min (8.0 UK gal/min, 9.6 US gal/min)

Pressures

bar

kgf/cm3

lbf/in2

Cut-out pressure

200

204

2900

Cut-in pressure

180

184

2610

Accumulator charge pressure

76.5

1087

Gas spring charge pressure

508

Pressure maintaining valve

S2-2

9803/9970-01 (S-02-00)

S2-2

Section S2 - Suspension Rear Suspension SYSTEM Operation Overview

Operation Overview Primary System

C095690

Fig 1. The variable rate hydropneumatic rear suspension minimises fore and aft vehicle pitch whilst maintaining 'low rate' characteristics for ride quality and tractive performance. Axle location is by control rods J and 'V' link L. An anti-roll bar K is also fitted. Primary suspension comprises two nitrogen-charged gas springs F and one hydraulic cylinder G on each side of the machine. Movement of the axle varies the pressure in the cylinders which in turn works against the pressure in the gas springs to give a variable rate suspension.

S2-3

9803/9970-01 (S-02-00)

S2-3

Section S2 - Suspension Rear Suspension SYSTEM Operation Overview

Ride Height Control The rear axle has an automatic ride height control system. The system is controlled by the central control ECU (ECU1). The ECU controls the ride height by energising or de-energising hydraulic solenoid valves CT8, 9, 10 and 11 in response to inputs from ride height potentiometers C. Hydraulic pressure is provided by section P2 of the engine driven hydraulic pump. The solenoid control valve block V has a pressure maintenance valve CT1 and accumulator A to ensure reliable operation. When increasing loads cause the chassis to lower in relation to the rear axle. When the axle control rods J move, potentiometers C are displaced by operating links D. The electrical signal from the potentiometers is read by the central control ECU (ECU1). The ECU responds by energising solenoid valves CT8 and CT10 which allow oil flow into the system, pressurising the gas springs F and restoring the pre-set ride height by means of cylinders G. At this point the ECU de-energises the solenoid valves, trapping oil within the system. The extra pressure in the gas springs increases suspension stiffness, thereby maintaining vehicle pitching control. As the load is taken off the chassis, it is lifted by the pressure retained in the system. This action once again displaces the potentiometers, but in the opposite direction, and the ECU energises solenoid valves CT9 and CT11 which allow oil from the gas springs to flow back to tank.

C095700

Fig 2. The reducing pressure allows the chassis to settle until the potentiometers reach the pre-set ride height position. The ECU then de-energises the solenoid valves retaining the new volume of oil in the system. The height control system is not affected by normal suspension movements which are too rapid for the in-built response delay time.

Table 1. Solenoid Valve Function Suspension Raise Solenoid Lower Solenoid Cylinder Valve Valve Left Hand

CT8

CT9

Right Hand

CT10

CT11

K Hydraulic Schematic ( T S2-5)

S2-4

9803/9970-01 (S-02-00)

S2-4

Section S2 - Suspension Rear Suspension SYSTEM Operation Overview

A P

CT2 CT5

CT1

CT8

TP1 C1 (LH)

CT9

CT10

C2 (RH)

M G

CT11

C095740

Fig 3. Hydraulic Schematic

S2-5

9803/9970-01 (S-02-00)

S2-5

Section S2 - Suspension Rear Suspension SYSTEM Ride Height Calibration

Ride Height Calibration Calibration is necessary after replacement of any of the following:

Start the engine when the instrument panel displays `START'.

!MWARNING

– Suspension potentiometer (angle sensor). – Suspension potentiometer operating link

The procedure below must be carried out with the engine running. Apply the park brake, block the wheels and ensure that no-one enters the cab.

– Lower suspension link (control arm) – ECU1 (Fastrac Central Controller) Important: Be aware that this process is time critical read the following steps before you start.

SUS-1-1

Note: If at any point during calibration, the instrument panel displays `FAILED', note which stage it was at, exit from calibration and use the Service Master Datalog tool to retrieve the error codes from the error log.

MIRRORS L

0 403731-C1

Fig 5. C090110-C1

Fig 4. 1

Apply the park brake.

Make sure the transport switch T is not engaged.

Switch the Ignition `ON'.

As the first instrument panel buzzer has finished sounding and within 10 seconds after you have switched on the ignition, cycle the transport switch on and off twice.

When `RS RAISE' is displayed, press and hold in button C and the rear suspension will raise. Keep button C depressed until dimension X is just over 65mm (2.6 in).

Note: If the suspension is fully down on the bump stops, there may be a delay before the suspension starts to raise. 7

Place blocks, 65mm (2.6 in) thick btween the rear axle and bump stops at X. This should give an axle ride height of 50mm (2 in) with a 15mm (0.6 in) allowance for bump stop compression during calibration.

The instrument panel will display `SUSP CAL' for a short time.

S2-6

9803/9970-01 (S-02-00)

S2-6

Section S2 - Suspension Rear Suspension SYSTEM Ride Height Calibration

!MCAUTION

The instrument panel will display the position of the rear suspension in the following format:

Keep clear of the chassis members as they are lowering otherwise you could be trapped between them and the axle casing.

`LxxxRyyy'

SUS-1-6

The actual figures `xxx' indicate the left hand suspension height signal. The actual figures `yyy' indicate the right hand suspension height signal. These can also be monitored in JCB Service Master. 11

Let the rear suspension settle fully onto the bump stops. When the suspension appears to have stopped moving, leave it 30 seconds more to make sure it has fully settled.

Press button C once to store the values. (These should be between 350 and 575 each.)

The instrument panel will display `OK' if the calibration values are acceptable.

D Z

If the instrument panel displays `FAILED', a fault code will appear on the touch screen.

C039350-B6

Fig 6. 8

Use down arrow D to scroll down to `RS LOWER'.

Use arrow D to scroll down to `RS REL'.

Press and hold in button C and the rear suspension will raise.

Remove the blocks from between the rear axle and the bump stops.

Scroll down to `SAVE'.

Press button C once to save the calibration.

The system will now exit calibration mode.

C096040

Fig 7. 9

Press button C once and release. The suspension will lower on to the calibration tools.

Note: Button C is located at one of two positions.

S2-7

9803/9970-01 (S-02-00)

S2-7

Section S2 - Suspension Rear Suspension SYSTEM Testing

Testing Pressure Maintenance Valve

!MWARNING The procedure below must be carried out with the engine running. Apply the park brake, block the wheels and ensure that no-one enters the cab. SUS-1-1

Connect a 0-400 bar (0 - 6000 lbf/in2) gauge to test point TP1. With engine running, push up one of the potentiometer operating links and check the gauge reading which should be between the cut-in and cut-out pressures. K Technical Data ( T S2-2) If the reading is incorrect, adjust the valve at CT1. Note: If this is the first time the valve has been adjusted, the adjusting screw will be covered by a plastic cap which should be removed and discarded.

CT1 TP1

C096910

Fig 8.

S2-8

9803/9970-01 (S-02-00)

S2-8

Section S2 - Suspension Rear Suspension SYSTEM Testing

Accumulator and Gas Spring

Connect a hand pump and a 0 to 400 bar (0 to 6000 lbf/in2) pressure gauge.

Note: Gas spring and accumulator are similar in appearance but can be positively identified by the nominal pressure (bar) stamped on the body near boss B: 26 or 35

Indicates gas spring. K Technical Data ( T S2-2)

Indicates accumulator

Operate the hand pump and watch the reading on the gauge. If the gas spring or accumulator is in good condition, the pressure should rise steadily to the charge pressure, see Technical Data) and then rise much more slowly for a period before climbing again.

Remove the gas spring G or accumulator A from the machine and screw it into adapter block X, part number 892/00314.

If the pressure continues to rise steadily to well past the charge pressure, the diaphragm is ruptured and the unit must be renewed.

162220-B1

Fig 9.

S2-9

9803/9970-01 (S-02-00)

S2-9

Section S2 - Suspension Rear Suspension SYSTEM Discharging the Hydraulic Pressure

Discharging the Hydraulic Pressure The chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve.

Press down arrow D. When `RS RAISE' is displayed, hold in button C and the suspension may raise slightly.

Use down arrow D to scroll down to `RS LOWER'.

Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure. Important: Be aware that this process is time critical read the following steps before you start. 1

Make sure the transport switch T is not engaged.

T D Z

C039350-B6

Fig 11. MIRRORS L

C090110-C1

Fig 10. 2

Apply the park brake.

Switch the Ignition `On'.

C096040

Fig 12. 4

As the first instrument panel buzzer has finished sounding and within 10 seconds after you have switched on the ignition, cycle the transport switch on and off twice. The instrument panel will display `SUSP CAL' for a short time.

When the instrument panel displays `START', DO NOT START THE ENGINE.

!MCAUTION Keep clear of the chassis members as they are lowering otherwise you could be trapped between them and the axle casing. SUS-1-6

Press button C and the suspension will lower.

Note: Button C is located at one of two positions.

S2-10

9803/9970-01 (S-02-00)

S2-10

Section S2 - Suspension Rear Suspension SYSTEM Discharging the Hydraulic Pressure 9

When the suspension has lowered fully, press button U to scroll back until `RS RAISE' is displayed.

Hold in button C and the suspension may raise slightly.

Use down arrow D to scroll down to `RS LOWER'.

Press button C and the suspension will lower.

When the suspension has lowered fully, press button U to scroll back until `RS RAISE' is displayed.

Hold in button C and the suspension may raise slightly.

Use down arrow D to scroll down to `RS LOWER'.

Press button C and the suspension will lower.

When the suspension has lowered fully, switch off the ignition.

S2-11

9803/9970-01 (S-02-00)

S2-11

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Potentiometer

Removal and Replacement - Potentiometer

!MWARNING

Removal

Disconnect the electrical connector at A.

Remove nut B and disconnect the potentiometer operating link E.

Remove bolts C.

Remove the potentiometer D.

3-3-1-1

Note: This job can be done with the machine standing on its wheels but wooden blocks should be placed between chassis and rear axle to prevent the possibility of the ride height dropping while the potentiometer is removed.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Be sure to put the operating link in the correct location on the potentiometer actuator arm G.

â&#x20AC;&#x201C; Be sure that the length of operating link is correct. If necessary loosen lock nuts F then rotate the link. When the length dimension is correct tighten the lock nuts F.

G A

After Replacement

Calibrate the suspension. Calibration ( T S2-6)

K Ride

Height

370 C095760

Fig 13.

S2-12

9803/9970-01 (S-02-00)

S2-12

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Accumulator (A), Gas Spring (G)

Removal and Replacement - Accumulator (A), Gas Spring (G) Note: This job can be done with the machine standing on its wheels but heed the WARNINGS below.

!MWARNING

Table 2. Torque Settings Kgf m lbf ft

Item

23 - 30

2.4 - 3.0

17 - 22

23 - 30

2.4 - 3.0

17 - 22

!MWARNING The rear of the chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve. Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure. See Discharging Hydraulic Pressure (Section S) for correct procedure. SUS-1-2_2

The numerical sequence shown on the illustration is intended as a guide to removal. For replacement the sequence should be reversed. When Removing Gas Spring or Accumulator Simply unscrew the unit from its mounting (complete with square section seal ring). Renew the seal when refitting the unit. Note: Gas spring and accumulator are similar in appearance but can be positively identified by the nominal pressure (bar) stamped on the face of the threaded mounting boss: 26 or 35 indicates gas spring (see Technical Data). 75 indicates accumulator. After Replacing Check the suspension ride height. K Ride Height Calibration ( T S2-6)

S2-13

9803/9970-01 (S-02-00)

S2-13

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Accumulator (A), Gas Spring (G)

403710-C2

Fig 14.

S2-14

9803/9970-01 (S-02-00)

S2-14

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Anti-roll Bar

Removal and Replacement - Anti-roll Bar Note: This job can be done with the machine standing on its wheels.

The numerical sequence shown on the illustration is intended as a guide to removal. The illustrations depict only the left end of the anti-roll bar, but the appropriate steps should be repeated immediately afterwards on the right end of the bar. Replacement is the reverse of Removal. S293360-C1

Fig 15.

When Replacing Assemble all the component parts of the assembly before tightening up the nuts and bolts which actually support the anti-roll bar. Note: Install clamps K10 with the chamferred sides of the anti-roll bar cut-out facing outwards. Finally, before tightening nuts K8/bolts K9, slide clamps K10 outwards towards clamps K5 to leave a 5 mm gap between the two.

Item

Table 3. Torque Settings Nm Kgf m lbf ft

K1/K2(1)

278

205

8.2

22.5

2.3

16.6

100

392

289

(1)

K8/K9 (1)

K12

(1)

K15/K16

(1) Torque value for Dacromet fastners, coloured mottled silver

S2-15

9803/9970-01 (S-02-00)

S2-15

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Control Arm (J)

Removal and Replacement - Control Arm (J) Note: This job can be done with the machine standing on its wheels but the rear wheels must be chocked to maintaing axle location..

Remove the anti-roll bar first. The numerical sequence J1 to J8 shown on the illustration is intended as a guide to removal. For replacement the sequence should be reversed. When Removing Unscrew nuts J1 and disconnect spring box from control arm. Remove nuts J2/bolts J3/spacers J4 and nuts J6/ bolts J7 holding the control arm to the axle and chassis respectively. Table 4. Torque Settings Nm Kgf m lbf ft

Item J1

1.2

(1)

J2/J3

278

205

J6/J7(1)

278

205

(1) Torque value for Dacromet fastners, coloured mottled silver.

S2-16

9803/9970-01 (S-02-00)

S2-16

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Control Arm (J)

J5 J3

J2 J4

J4 J

J1 J8 J7

J J6

403700-C1

Fig 16.

S2-17

9803/9970-01 (S-02-00)

S2-17

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - ‘V’ Link

Removal and Replacement - ‘V’ Link Note: This job can be done with the machine standing on its wheels but the rear axle must be supported by means of an overhead hoist to prevent it from rotating out of position.

Item

Table 5. Torque Settings Nm Kgf m lbf ft

1(1)

395

See text

291

(1) Torque value for Dacromet fastners, coloured mottled silver.

3-3-1-1

The numerical sequence shown on the illustration is intended as a guide to removal. For replacement the sequence should be reversed. When Removing Support axle and 'V' link L. Remove bolts 1 and block nuts 2 from front end of 'V' link. Remove flange nuts 3, spacers 4, special bolts 5 and hardened washers 6 holding rear of 'V' link to axle and lift the 'V' link clear. When Replacing Always replace damaged fasteners by the specified JCB supplied parts which will be to the correct grade. Ensure that special bolts 5, hardened washers 6, spacers 4, and flange nuts 3 are assembled as shown. Before assembly, grease the threads and underside of the heads of bolts 5, both sides of hardened washers 6 and threads of flange nuts 3. Torque bolts 5 to 300 Nm (30.6 kgf m, 221 lbf ft) then tighten by a further 180o, ensuring that the nuts do not rotate.

S2-18

9803/9970-01 (S-02-00)

S2-18

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - ‘V’ Link

418450-C1

Fig 17.

S2-19

9803/9970-01 (S-02-00)

S2-19

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - ‘V’ Link

Dismantling and Assembly - Ball Joint 1 The ‘V’ link ball joint should not be dismantled unless wear is detected. Items 1 to 9, 11 and 12 plus a tube of special grease constitute a repair kit which should be obtained before commencing work. Note: Item 9 which is identical to item 5 will not be required and can be discarded if the lower end of the bore in item 10 is chamfered.

2 3 4

The numerical sequence shown on illustration X is intended as a guide to dismantling.

For assembly the sequence should be reversed.

When Dismantling Cover 1 is spot welded to ‘V’ link 10. Remove by grinding off or otherwise breaking the weld.

To separate the taper which connects items 8 and 13 use an M16 x 1.5 bolt of suitable length screwed down through the threaded hole in 8 to jack the two apart (see illustration Y).

9 10

When Assembling When assembling items 1 to 8 (9 if appropriate) and 10 to 12, pack the joint with the special grease supplied.

To secure item 1 in position, spot weld at three points, or alternatively peen at six points.

Item

Table 6. Torque Settings Nm Kgf m lbf ft

135

13.7

A243370-C1

Fig 18.

S2-20

9803/9970-01 (S-02-00)

S2-20

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Suspension Cylinder (S)

Removal and Replacement - Suspension Cylinder (S) Note: This job can be done with the machine standing on its wheels but heed the WARNINGS below.

S268400-C1

Fig 19. Check the suspension ride height. K Ride Height Calibration ( T S2-6)

5.0

800

592

SUS-1-2_2

The numerical sequence shown on the illustration is intended as a guide to removal.

Table 7. Torque Settings Kgf m lbf ft

Item (1)

(1) Torque setting is for use when fitting the pin to the axle.

For replacement the sequence should be reversed. When Removing Disconnect hose at S1. remove nut S2. Remove circlips S3 and S4 to gether with pin S5 After Replacing Lugs Z at the lower end of the cylinder should fave the rear of the machine.

S2-21

9803/9970-01 (S-02-00)

S2-21

Section S2 - Suspension Rear Suspension SYSTEM Removal and Replacement - Suspension Cylinder (S)

403710-C1

Fig 20.

S2-22

9803/9970-01 (S-02-00)

S2-22

Section S2 - Suspension Rear Suspension SYSTEM Dismantling and Assembly - Suspension Cylinder

Dismantling and Assembly - Suspension Cylinder Note: Machines can be fitted with either damped or undamped suspension cylinders. The external parts shown at A are the same for both types but the part number stamped on the cylinder will identify which type is fitted. The internal parts are shown at B (undamped) and at C (damped). The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Take extreme care not to damage the cylinder bore. When Dismantling Remove grease nipple 1 and prise off the dust cover 2 in the direction of the arrow. Heat the threaded area of gland bearing 3 to a minimum of 300Â° to release the locking sealant and unscrew the gland bearing from the cylinder 4. Withdraw the piston rod 18 complete with the internal parts shown at either B or C. On undamped cylinders, remove circlip 5B to allow gland bearing 3 to slide off the piston rod. On damped cylinders, heat the threaded area of seal carrier 5C to a minimum of 300Â° to release the locking sealant and unscrew the seal carrier using a suitable peg spanner to fit holes W. The holes are 5 mm dia. positioned at a pitch circle diameter of 35 mm. Removal of the seal carrier will allow gland bearing 3 to slide off the piston rod. Remove and discard the sealing components 6 to 9 and also 10 to 12 where applicable. When Assembling Before assembling, check the components for damage and wear, especially the cylinder bore. Renew the complete assembly if necessary. Lightly oil all seals. Use the procedure right for fitting gland seals 6 to 8. Apply JCB Retainer (High Strength) to the threads of gland bearing 3 (undamped and damped) and seal carrier (undamped only). Tighten both to a torque of 200 Nm (148 lbf ft).

S2-23

9803/9970-01 (S-02-00)

S2-23

Section S2 - Suspension Rear Suspension SYSTEM Dismantling and Assembly - Suspension Cylinder

A234821-C1

Fig 21.

S2-24

9803/9970-01 (S-02-00)

S2-24

Section S2 - Suspension Rear Suspension SYSTEM Dismantling and Assembly - Suspension Cylinder

Testing Using a hydraulic hand pump (see Service Tools, Section 1), check for smooth operation of the ram.

With the ram extended, pressurise to 250 bar (3625 lbf/in2) and check for leakage. No leakage is permitted.

Gland Fitting Procedure

The size (diameter) and position of pins D is determined by the diameter and radial width of the gland seal being fitted. The pins are screwed into threaded holes in the tool body. The spacing of the holes is designed to suit small or large diameter gland seals.

To fit new gland seals 6 to 8: 1

Open the tool as shown at X and insert the new gland seal. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

Close the tool as shown at Y. The seal must form a kidney shape.

Locate area E of the seal in the appropriate groove of the gland bearing, as shown at Z. When the seal is in position, open the tool to release the seal. Remove the tool and expand the seal so that it is correctly installed in its groove.

E Z

S161750-C2

Fig 22.

S2-25

9803/9970-01 (S-02-00)

S2-25

Section S2 - Suspension Rear Suspension SYSTEM Dismantling and Assembly - Suspension Cylinder

Page left intentionally blank

S2-26

9803/9970-01 (S-02-00)

S2-26

Section T Engine Service Manual - 3000 XTRA Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Hitches and Attachments Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/9970-01

Section T - Engine

Notes:

T-0

9803/9970-01

T-0

Section T - i Contents Page No. Cummins QSB 6.7 Introduction .............................................................................................. T1-1 Technical Data ......................................................................................... T1-2 Removal and Replacement - Flywheel Damper ...................................... T1-3 Removal ..............................................................................................T1-3 Replacement .......................................................................................T1-3 Dismantling and Assembly ...................................................................... T1-4

T-i

Section T1 - Engine

Cummins QSB 6.7 Introduction

K Technical Data ( T T1-2) K Removal and Replacement - Flywheel Damper ( T T1-3) K Dismantling and Assembly ( T T1-4)

T1-1

9803/9970-01 (T-01-00)

T1-1

Section T1 - Engine Cummins QSB 6.7 Technical Data

Technical Data Engine Model

QSB 6.7, 6-cylinder

Turbocharged, charge air cooled.

Swept Volume

6702 cm3

(409 in3)

Bore

107 mm

(4.21 in)

Stroke

124 mm

(4.88 in)

Dry Weight

485 kg

(1069 lb)

Firing Order

1, 5, 3, 6, 2, 4

Compression Ratio

17.2 : 1

Valve Clearance - Inlet

0.31 mm

(0.012 in)

- Exhaust

0.56 mm

(0.022 in)

(minimum allowable)

0.52 bar

(7.5 lbf/in2)

Oil Pressure, regulated

3.8 bar

(55 lbf/in2)

Rated Speed

2200 rev/min

Idling Speed

750 rev/min

Maximum No Load Speed

2520 rev/min

Oil Pressure at idle

T1-2

9803/9970-01 (T-01-00)

T1-2

Section T1 - Engine Cummins QSB 6.7 Removal and Replacement - Flywheel Damper

Removal and Replacement - Flywheel Damper Note: The flywheel damper is a sealed unit. If the damper is faulty it must be renewed. The drive shaft X is an integral

part of the damper. If the shaft is damaged then the complete damper/shaft assembly must be renewed.

1 A353530-C1

Fig 1.

Removal

Replacement

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Support the damper assembly 1. Progressively undo the 6 fixing bolts 2. If necessary engage a bar in the starter teeth on the flywheel Y to prevent the engine rotating, do not put the shaft X under any strain.

â&#x20AC;&#x201C; Clean the damper assembly. Make sure that the mating faces of the damper and engine flywheel are perfectly clean and dry.

Retrieve the hardened spacer washers 3 and lift the damper assembly from the engine flywheel Y. Store the damper on its rear face. Do not let the damper rest on the drive shaft X. Make sure that the drive shaft is not damaged during storage, it is not designed to withstand any side loads.

T1-3

â&#x20AC;&#x201C; Progressively tighten the bolts 2 to the correct torque. Tighten opposite bolts in order to minimise the risk of distorting the damper. Do not overtighten the bolts.

Item

Table 1. Torque Settings Nm kgf m

9803/9970-01 (T-01-00)

7.3

lbf ft 53

T1-3

Section T1 - Engine Cummins QSB 6.7 Dismantling and Assembly

Dismantling and Assembly For engine dismantling and assembly procedures refer to the correct Cummins technical documentation.

T1-4

9803/9970-01 (T-01-00)

T1-4

Section T1 - Engine Cummins QSB 6.7 Dismantling and Assembly

Page left intentionally blank

T1-5

9803/9970-01 (T-01-00)

T1-5