JCB 434S/435S Wheeled Loading Shovel Service Repair Manual – PDF Download by www.heydownloads.com

Service Manual Wheeled Loading Shovel - 434S/435S Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

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 Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section 1 General Information Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

Section 1 - General Information

Notes:

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Section 1 - General Information Contents Page No. Introduction About this Publication .............................................................................. 1 - 1 Identifying your Machine 434S ........................................................................................................ 1 - 5 435S ........................................................................................................ 1 - 8 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1 - 9 Hydraulic Connections ........................................................................... 1 - 13 Service Tools Numerical List ........................................................................................ 1 - 17 Tool Detail Reference ............................................................................ 1 - 18 Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 37 Terms and Definitions Colour Coding ........................................................................................ 1 - 39

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Section 1 - General Information Contents

1 - ii

Page No.

1 - ii

Section 1 - General Information

Introduction About this Publication Machine Model and Serial Number

Finally, please remember above all else safety must come first!

This manual provides information for the following model(s) in the JCB machine range:

Section Numbering T11-005

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

434S From machine 1244000 435S: From 2063353 to 2063382.

Using the Service Manual T11-004

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. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them.

General Information - includes torque settings and service tools.

Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

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.

Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.

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. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.

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Section 1 - General Information Introduction About this Publication

Left Side, Right Side

9A Tool box (434S)

In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine.

Fig 1.

T033800-1

Cab/Canopy T1-003_2

This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines.

9B Tool box (435S) 10

Battery isolator switch

Rear grille

Coolant filler cap

Air filter assembly

Hydraulic fluid filter

Fuel filter - suction side

Hydraulic fluid filler cap

Fuel filter - pressure side

Engine oil dipstick

Engine oil filler cap

Exhaust

Radiator

Diesel filler point

Engine oil filter

Transmission oil dipstick/filler point

Coolant header tank

Cross References T1-004_2

In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-2).

Component Location Note: The illustration(s) show a typical machine model; your machine may look different from the model shown. For example, the 435S has a diesel particulate filter. 1

Shovel

Loader arms

Beacon

ROPS/FOPS cab

Engine cover

Articulation lock

Heater door

Hydraulic fluid level - sight glass

1-2

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Section 1 - General Information Introduction About this Publication

1 12 7

6 8 11

15 16 20

24 Fig 2.

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21 T066060-10A

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Section 1 - General Information Introduction About this Publication Page left intentionally blank

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Section 1 - General Information

Identifying your Machine 434S Identification Plate

The machine and engine serial numbers can help identify exactly the type of equipment you have.

Your machine has an identification plate 3X mounted on the left hand side of the machine. The serial numbers of the machine and its major units are stamped on the plate.

Unit Identification The engine serial number is stamped on a plate 4Y which is fastened to the right side of the cylinder block, near the fuel filter.

Fig 3.

Explanation of Vehicle Identification Number (VIN) 1

SLP

43400

1244000 Fig 4.

World Manufacturer Identification, SLP = JCB

Machine Model, 43400 = 434

Year of Manufacture 6, ( W = 1998, X = 1999, Y = 2000, 1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7 = 2007, etc.)

Manufacturing Location (E = England)

Machine Serial Number (1244000)

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.

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Section 1 - General Information Identifying your Machine 434S

Typical Engine Identification Number 1

50457

576887

Engine Type, YB = 6 cylinder turbo

Build Number

Country of Origin

Engine Sequence Number

Year of Manufacture

The Transmission serial number is stamped on plate 5Z as shown.

Fig 5.

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Section 1 - General Information Identifying your Machine 434S

Component Identification Plates

ROPS Data Plate

!MWARNING

FOPS Data Plate

!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

Seat Belts The ROPS/FOPS is designed to give you protection in an accident. If you do not wear your seat belt, you could be thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 0153

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

Machines built to the ROPS/FOPS standard have a data plate attached to the inside of the cab.

The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides.

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

JCB WHEELED LOADER

427, 437,

MAXIMUM UNLADEN MASS 26000Kg

– Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services.

FOPS: COMPLIES TO EN 13627: 2000 LEVEL2

YEAR:

There are two levels of FOPS: 332/A5586

ROPS: COMPLIES TO EN 13510: 2000 ISO 3471:1994

CAB PART No: 335/06840, 335/09298

SERIAL No:

Fig 6. Example

332-A5586-1

– Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry.

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Section 1 - General Information Identifying your Machine 435S

435S Machine Identification Plate

Typical Product Identification Number

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

435S

2063353

Note: The machine model and build specification is indicated by the PIN. Refer to Typical Product Identification Number (PIN).

World Manufacturer Identification (3 Digits)

Model Number (3 Digits)

Loader End Type (1 Digit) O = HT Loader End Z = ZX Loader End

The machine and engine serial numbers can help identify exactly the type of equipment you have.

Designation (1 Digit) S = Farmmaster O = Non Farmmaster I = India

Year of Manufacture (1 Digit) 7 = 2007

A = 2010

8 = 2008

B = 2011

9 = 2009

C = 2012

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

Fig 7.

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T033550-2

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

Torque Settings 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 1-9).

Torque settings are given for the following conditions:

Fastener Type

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

Condition 1

Table 1. Fastener Types Colour Part No. Suffix

– 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 – Lubricated zinc and yellow plated 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.

– 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.

1-9

Fig 8. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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Section 1 - 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

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Section 1 - 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

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Section 1 - 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 - 12

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

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Section 1 - 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 - 13

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

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

Fig 9. Hoses 9-B screwed into adaptors 9-A seal onto an `O' ring 9-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1 - 14

Note: Dimension 9-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

9803/9420

kgf m

lbf ft

1 - 14

Section 1 - 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 - 15

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

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Section 1 - General Information Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 10. `Torque Stop' Hoses 10-B screwed into adaptors 10-A seal onto an 'O' ring 10-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 10-D, which acts as a physical stop. Note: Minimum dimension 10-E fixed by shoulder 10-D.

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

1 - 16

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

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Section 1 - General Information

Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. 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.

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Section 1 - General Information Service Tools Tool Detail Reference

Tool Detail Reference Section B - Body and Framework

Fig 11. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

993/68107

Bar - M20 x M20 X 800 mm

2 3

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 12. Rivet Nut Tool

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 13. 892/00842 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.

Fig 16. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K Fig 19. ( T 1-20).

Fig 17. 892/00847 Nylon Spatula

Fig 14. 892/00843 Folding Stand

General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

Essential for preparing new glass prior to installation.

Fig 18. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. K Fig 19. ( T 1-20).

Fig 15. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

1 - 19

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 19. 892/00849 Braided Cutting Wire

Fig 22. 992/12400 Static Oven 240V

Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 16. ( T 1-19). Approx 25 m length.

Required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.

Fig 20. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 23. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 21. 992/12300 Mobile Oven 12V 1 cartridge capacity. Required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

1 - 20

Fig 24. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K Fig 23. ( T 1-20). Unit quantity = 5 off.

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 25. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). Fig 27. 892/00844 Note: - used to give extended reach for normally inaccessible areas.

Fig 26. 892/00848 Note: - used to access braided cutting wire (below) through original polyurethane seal.

1 - 21

Fig 28. 825/99849 Note: - used with bearing locator to set up Upper Centre Pivot.

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Section 1 - General Information Service Tools Tool Detail Reference

Section C - Electrics

Fig 29. 825/99851 Note: - used with dummy bush to set up Upper Centre Pivot.

Fig 30. 892/00298 Fluke Meter

Fig 31. 892/00285 Hydraulic Temperature Probe

Fig 32. 892/00284 Venture Microtach Digital Tachometer

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 34. 993/85700

Fig 33. 1

892/00283 Tool Kit Case

892/00298 Fluke Meter

892/00286 Surface Temperature Probe

892/00284 Venture Microtach Digital Tachometer

892/00282 100 amp Shunt - open type

892/00285 Hydraulic Temperature Probe

1 - 23

Fig 35. 892/01066

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Section 1 - General Information Service Tools Tool Detail Reference

Section E- Hydraulics MACHINE

ELECTRONIC SERVICE TOOL

CANBUS J1700

POWER COMPUTER

Fig 38. Spool Clamps 892/00039 Spool Clamp 992/10100 Spool Clamp Fig 36. 892/01174

Fig 39. Accumulator Charge Equipment 892/00239 Charging Tool (Diaphragm Accumulators) 892/01042 Charging Tool (Diaphragm Accumulators) C031270

Fig 37. 718/20237

1 - 24

892/01043 Adaptor (use with 892/01042) 892/00948 Charging Tool (Piston Accumulators)

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Section 1 - General Information Service Tools Tool Detail Reference 892/00309 A.R.V. Pressure Test Kit 1 892/00340 Test Block Body 2 892/00341 Setting Body 3 993/68300 Adjusting Pin 4 892/00343 Spanner 5 892/00345 Anti-cavitation Lock Out Bung 6 892/00335 A.R.V. Cartridge Removal Tool

Fig 40. Components for Valve Block A.R.V. Testing

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. Fig 41. Male Adaptors

1604/0004A 1/2 in. x 1/2 in. 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

1/2 in. x 3/8 in.

Fig 42. Pressure Test Adapters

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Section 1 - General Information Service Tools Tool Detail Reference 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

Fig 43. Pressure Test 'T' Adapters

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 44. '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 45. 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 46. 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 47. Female Connectors

Fig 48. Bonded Washers

1 - 27

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 49. Ram Protection Sleeves

892/01016

For 25 mm Rod Diameter

892/01017

For 30 mm Rod Diameter

892/01018

For 40 mm Rod Diameter

892/01019

For 50 mm Rod Diameter

892/01020

For 50 mm Rod Diameter (slew ram)

892/01021

For 60 mm Rod Diameter

892/01022

For 60 mm Rod Diameter (slew ram)

892/01023

For 65 mm Rod Diameter

892/01024

For 70 mm Rod Diameter

892/01025

For 75 mm Rod Diameter

892/01026

For 80 mm Rod Diameter

892/00167

For 90 mm Rod Diameter

7mm 11o 20mm

10mm

Fig 50. 892/00334 Ram Seal Fitting Tool 5mm

m 3m

110mm 175mm 3o

Fig 51. Hexagon Spanners for Ram Pistons and End Caps 992/09300

55mm A/F

992/09400

65mm A/F

992/09500

75mm A/F

992/09600

85mm A/F

992/09700

95mm A/F

992/09900

115mm A/F

992/10000

125mm A/F

1 - 28

1.4

Fig 52. 892/01027 Piston Seal Assembly Tool

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Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 54. ( T 1-29).

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 53. 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 54. 998/11046 JCB ServiceMaster Flow Test Kit

1 - 29

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Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 56. ( T 1-30).

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

Fig 55. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 56. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

1 - 30

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Section 1 - General Information 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)

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 57. Hand Pump Equipment

Fig 58. 892/00881 Valve Spool Seal Fitting Tool

Fig 59. Hydraulic Circuit Test Gauges and Connections

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Section 1 - General Information Service Tools Tool Detail Reference

Section F - Transmission

Fig 60. 992/07603 Fig 63.

Fig 61. Heavy Duty Socket for Durlock Bolts 892/00817 17 mm A/F x 3/4 in. Square Drive 892/00818 22 mm A/F x 3/4 in. Square Drive 892/00819 15 mm A/F x 1/2 in. Square Drive

Fig 62. 992/04000 Note: Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.

892/00865 Computer test harness 892/00866 Computer test indicator box 892/00867 Computer test interrogator box

1 - 32

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 64. 892/00859 Fig 67. 1 892/00860 Bearing Remover Shim 2 892/00861 Bearing Remover Base Tool

Fig 65. 892/00862

Fig 68. 892/00863

Fig 69.

Fig 66. 892/00909

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 73. 892/01007 Pipe Swaging Tool Fig 70.

892/01008 Pipe Swaging Tool

892/01001 Bearing Tool

892/01009 Pipe Swaging Tool

892/01004 Bearing Tool

892/01010 Pipe Swaging Tool

892/01005 Bearing Tool

Fig 74.

Fig 71. 892/01002 892/01013 Lifting Eye 892/01015 Lifting Eye

Fig 72. 892/01006

Fig 75. 892/01014

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Section 1 - General Information Service Tools Tool Detail Reference

Section H - Steering

Fig 76. 892/00180 - Seal Fitting Tool Seal Fitting Tool for fitting 'O' ring and back-up ring to Danfoss Orbitrol Unit. 892/00181 - Replacement Plastic Boss

Section K - Engine

Fig 77. 892/00041 Note: De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings) For details of other engine service tools refer to Perkins Service Manual Publication No. 9806/0100

1 - 35

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Section 1 - General Information Service Tools Tool Detail Reference Page left intentionally blank

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Section 1 - General Information 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 - 37

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Section 1 - General Information Service Consumables Sealing and Retaining Compounds Page left intentionally blank

1 - 38

9803/9420

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Section 1 - General Information

Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes T11-006

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 MRV 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 - 39

Servo: Oil pressure used in controlling a device (servo).

Neutral: 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).

9803/8420

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Section 1 - General Information Terms and Definitions Colour Coding Page left intentionally blank

1 - 40

9803/8420

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Section 2 Care and Safety Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

Section 2 - Care and Safety

Notes:

2-0

9803/9420-3

2-0

Section 2 - Care and Safety Contents Page No. Safety Notices Safety Check List ..................................................................................... 2 - 1 Safety - Yours and Others .................................................................. 2 - 1 General Safety ................................................................................... 2 - 1 Operating Safety ................................................................................ 2 - 3 Maintenance Safety ............................................................................ 2 - 6 Safety Labels ......................................................................................... 2 - 11 Introduction ....................................................................................... 2 - 11 Safety Label Identification ................................................................ 2 - 12 Part Numbers and Descriptions ....................................................... 2 - 13

2-i

Section 2 - Care and Safety Contents

2 - ii

Page No.

2 - ii

Section 2 - Care and Safety

Safety Notices Safety Check List P4-1004_3

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. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. 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

T1-043

To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The Operator Manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others. INT-1-4-1

!MWARNING 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. INT-1-3-5

!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. Remove rings, watches and personal jewellery. INT-1-3-6_2

2-1

9803/9420

2-1

Section 2 - Care and Safety Safety Notices Safety Check List

!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.

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-1-3-9_2

INT-3-3-7_1

!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. Switch off and do not use your mobile phone when refuelling the machine.

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

INT-3-3-9

!MWARNING Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. INT-1-3-7_2

!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). Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

2-2

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2-2

Section 2 - Care and Safety Safety Notices 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

!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 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.

Work Sites Work sites can be hazardous. Inspect the site before working on it. You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs, ironwork etc. Any of these could cause you to lose control of your machine. 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_2

!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

!MWARNING

INT-2-1-5

!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

!MWARNING Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice. Remove oil, grease and ice from the machine tyres. Make sure the machine will not foul on the ramp angle. See Static Dimensions in SPECIFICATION section for the minimum ground clearance of your machine. 2-2-7-5_1

2-3

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2-3

Section 2 - Care and Safety Safety Notices Safety Check List

!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.

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-2-2-8

!MDANGER

5-3-1-12_3

!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.

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.

INT-2-2-10

2-2-3-6

!MWARNING

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.

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

INT-2-1-14

!MWARNING

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

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 Practise 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-2-1-1

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

Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier. 2-2-5-4

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Section 2 - Care and Safety Safety Notices Safety Check List

!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.

Travelling at High Speeds Travelling at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always travel at a safe speed to suit working conditions. INT-5-3-3

5-5-1-1_2

!MWARNING

!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.

High Loads A high load can block your view and reduce the machine's stability. Travel with the load low to the ground. Travel slowly and with caution over rough, muddy or loose surfaces. 5-1-3-2

!MWARNING

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

Slopes When transporting a load on a slope, drive slowly and keep the load uphill of the machine. This will increase stability.

2-4-5-2_1

!MDANGER Working Platform Using the machine as a working platform is hazardous; you can fall off and be killed or injured. Never use the machine as a working platform.

5-1-4-1

5-1-5-9

Hillsides Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. Operate in first gear on hillsides, when applicable, keep all attachments low to the ground. Never coast down a hill with the engine off or the transmission in neutral.

!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

!MWARNING

INT-2-2-7

!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.

!MWARNING 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. 0179_2

!MCAUTION

INT-2-1-9_6

Passengers Passengers in or on the machine can cause accidents. Do not carry passengers. INT-2-2-2_1

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

Maintenance Safety

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

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 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. INT-2-1-12

!MWARNING 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

!MWARNING

!MWARNING 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

Safe Working Loads Overloading the machine can damage it and make it unstable. Study the specifications in the Operator Manual before using the machine. 7-1-1-8_2

!MWARNING

!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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

!MCAUTION

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.

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-3-1-10_3

!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

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

!MWARNING 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

!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.

!MCAUTION 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

INT-3-2-2_3

!MCAUTION

!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

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MCAUTION

!MWARNING

'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.

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

INT-3-2-12

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

!MWARNING 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

!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. 5-3-1-9

!MWARNING 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. INT-3-3-8_2

Used fluoroelastomeric components whose temperatures have not exceeded 300°C (572°F) 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. Used fluoroelastomeric components subjected to temperatures greater than 300°C (572°F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1

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

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.

area

with

DO NOT BURN FLUOROELASTOMERIC MATERIALS. INT-3-3-5_4

!MWARNING 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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

To avoid burning wear personal protective equipment (PPE) when handling hot components. To protect your eyes, wear personal protective equipment (PPE) when using a brush to clean components.

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.

HYD-1-3_3

!MWARNING

INT-3-1-17

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. 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. 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. 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.

!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

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

!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. 0125

INT-3-1-15_2

!MWARNING

!MWARNING Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them. INT-3-2-5

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

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 an approved battery tester. INT-3-1-8_2

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Section 2 - Care and Safety Safety Notices Safety Check List

!MDANGER

!MWARNING

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 personal protective equipment (PPE).

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

INT-3-2-1_4

13-3-1-7_1

Store with care to ensure that they cannot fall and cause injury.

!MWARNING

!MCAUTION

Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth.

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.

When connecting the battery, connect the earth (-) lead last.

8-3-4-8

When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

!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.

!MWARNING Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual. 5-1-6-1

!MCAUTION

2-3-2-7_2

!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.

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

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. INT-3-1-16

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Section 2 - Care and Safety Safety Notices Safety Labels

Safety Labels Introduction

!MWARNING

T1-014_2

Safety Labels Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown. INT-1-3-11

Safety labels are strategically placed around the machine to remind you of possible hazards. If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-stretch or place yourself in dangerous positions to read the safety labels. If you do not understand the hazard shown on the safety label, then refer to Safety Label Identification. Note: The illustration(s) show a typical machine model. Your machine may look different from the model shown. Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB distributor.

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Section 2 - Care and Safety Safety Notices Safety Labels

Safety Label Identification ISO-13A (x2)

ISO-05C

ISO-04A (x2)

ISO-02C

ISO-07D (x2)

ISO-07C (x2)

ISO-01A

ISO-06B

ISO-10A

ISO-12B

ISO-06C

ISO-09F

Fig 1.

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T010560-8

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Section 2 - Care and Safety Safety Notices Safety Labels

Part Numbers and Descriptions

ISO-06B Part Number: 332/P7131

ISO-01A

Description: Pressure hazard. Refer to Cooling System (Routine Maintenance Section).

Part Number: 817/70014 Description: Warning. Read the operator manual before you operate the machine.

332-P7131-1 817-70014-3

ISO-06C ISO-02C

Part Number: 817/70002

Part Number: 332/P7181

Description: Pressure hazard. Stop the engine, remove the starter key and refer to Releasing the Hydraulic Pressure (Routine Maintenance Section) before you start maintenance work.

Description: Crushing of whole body. Install the articulation lock before you start maintenance work. Refer to Articulation Lock (Operation Section).

817-70002-2 332-P7181-1

ISO-07C ISO-04A

Part Number: 817/70008

Part Number: 332/P7128

Description: Crushing of whole body. Keep a safe distance from the machine.

Description: Burns to fingers and hands. Stay a safe distance away.

817/70008

817-70008-2

332-P7128-1

ISO-07D Part Number: 817/70027

ISO-05C

Description: Crush hazard. Keep a safe distance from the moving parts.

Part Number: 332/P7129 Description: Runover. Start the engine from the operator seat only. Do not short across the terminals.

817-70027-2

332-P7129-1

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Section 2 - Care and Safety Safety Notices Safety Labels ISO-09F Part Number: 332/P7132 Description: Severing of hands or fingers. Keep clear of/ do not reach into the moving parts. Stop the engine and remove the starter key before you start maintenance work. Refer to Making the Machine Safe (Routine Maintenance Section).

332-P7132-1

ISO-010A Part Number: 817/70029 Description: Crush hazard. Wear the seat belt when you operate the machine.

817-70029-3

ISO-12B Part Number: 332/W6368 Description: Strike. Keep clear of a reversing machine.

332-W6368

ISO-13A Part Number: 332/P7134 Description: Entanglement hazard. Do not touch.

332-P7134-1

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Section A Attachments Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

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Section A - Attachments

Notes:

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Section A - Attachments Contents Page No. Optional Attachments Connecting/Disconnecting Hydraulic Hoses ........................................... A - 1

A-i

Section A - Attachments Contents

A - ii

Page No.

A - ii

Section A - Attachments

Optional Attachments Connecting/Disconnecting Hydraulic Hoses T4-004_2

Introduction

Connecting the Hydraulic Hoses

!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.

Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.

Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.

If necessary, remove the blanking caps.

Check the hoses and adaptors for damage. Refer to Routine Maintenance, Checking for Damage.

Connect the hoses.

INT-3-1-10_3

If the hoses have quick releases couplings, refer to Quick Release Couplings. a

Make sure that the hose is not twisted. Pressure applied to a twisted hose can cause the hose to fail or the connections to loosen.

INT-3-1-11_2

Some attachments are hydraulically powered. The following procedures show how to connect and disconnect the hydraulic hoses safely.

Fig 1.

T037400

b Make sure that the hose does not touch hot parts. High ambient temperatures can cause the hose to fail. c

Make sure that the hose does not touch parts which can rub or cause abrasion.

d Use the hose clamps (where possible) to support long hose runs and keep the hoses away from moving parts, etc.

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Section A - Attachments Optional Attachments Connecting/Disconnecting Hydraulic Hoses

Disconnecting the Hydraulic Hoses

Fig 2.

Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.

Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.

Disconnect the hoses.

T037420

To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change.

If the hoses have quick releases couplings, then refer to Quick Release Couplings. 4

Check the hoses and adaptors for damage. Refer to Routine Maintenance, Checking for Damage.

If necessary, install the blanking caps

Check for leaks. a

Start the engine.

b Operate the related control to increase the pressure in the hydraulic system. c

Fig 3. 6

T037410

Stop the engine then remove the starter key.

d Check for indications of leakage at the hose connections. Correct, as necessary.

Check for leaks. a

Start the engine.

b Operate the related control to increase the pressure in the hydraulic system. c

Stop the engine then remove the starter key.

d Check for indications of leakage at the hose connections. Correct, as necessary.

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Section A - Attachments Optional Attachments Connecting/Disconnecting Hydraulic Hoses

Quick Release Couplings

by dirt in the coupling or physical damage due to abuse.

!MWARNING

– Connect and disconnect new couplings two or three times to work the PTFE seals. Sometimes a new coupling will stick if the seal has not been worked.

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.

– When fitting couplings, only apply the spanner or grips to the hexagon and nowhere else. – Avoid damage to the coupling faces. Burrs and scratches cause damage to the seals and cause leaks. They can also impede connection and disconnection of the couplings.

2-4-1-15

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 4. ( T A-4).

– Periodically lubricate the internal locking balls on the female half of the coupling with silicone grease.

Essential Don'ts

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 you install or remove any optional attachment fitted with quick release couplings.

Essential Do's – 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. – Always wipe the two mating faces clean before connecting. – Use caps and plugs when the couplings are disconnected. – Always align the external locking ball (if used) with the notch in the locking sleeve and then pull the locking sleeve back fully to disconnect. – If a coupling sticks, first check that pressure has been released. Ensure the locking ball and notch in the locking sleeve are aligned, pull back the sleeve and twist the couplings apart. Sticking is normally caused

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– Never attempt to reconnect using a damaged half coupling as this will destroy the seals in the mating half and necessitate replacement of both halves. – Do not leave the coupling where it may be run over by a vehicle or otherwise crushed - this will distort the sleeve and prevent connection and disconnection. – Never try to turn the sleeve when the coupling is disconnected since this will cause the locking ball to jam under the locking sleeve and damage the coupling. – Never try to strip the coupling down, there are no user serviceable parts. If the coupling is damaged it should be replaced with a new one. See coupling guides for a reference. – Never hit the centre poppet of the coupling to try and release locked in pressure. This can cause irreparable damage to the coupling and serious injury. – When fitting couplings, never clamp on the sleeve of the female or nose of the male - this will cause distortion and/or damage. – Never subject the couplings to external forces, especially side load. This can reduce the life of the coupling or cause failure. – Never allow the torsional forces transmitted from hoses to unscrew/screw together couplings. – Never use a coupling as a plug. – Do not connect and disconnect with pressure in the line unless the coupling type is specifically designed to do so.

A-3

Section A - Attachments Optional Attachments Connecting/Disconnecting Hydraulic Hoses 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 C in the female coupling is located in one of its slots.

Fit the male coupling into the female coupling.

Where applicable, rotate sleeve E half a turn and make sure that the locking ball C does not align with the slot D.

Disconnecting Quick Release Couplings 1

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

Where applicable, align the slot D with ball C.

Pull back sleeve E to release the coupling.

Fig 4.

A-4

C007100-1

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Section B Body and Framework Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

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World Class Customer Support Copyright Â© 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 Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section B - Body and Framework

Notes:

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Section B - Body and Framework Contents Page No. Technical Data Air Conditioning Option ........................................................................... B - 1 Fault Finding Air Conditioning ...................................................................................... B - 3 Service Procedures Rivet Nuts ............................................................................................. B - 17 Air Conditioning .................................................................................... B - 19 Air Conditioning Air Conditioning Components ............................................................... B - 29 Cab Glazing ................................................................................................. B - 43 ROP/FOPS Structure ........................................................................... B - 49 Bodywork Removal and Replacement of the Rear Bodywork ............................... B - 51 Cooling Pack System ................................................................................................. B - 57 Centre Pivot Removal and Installation ...................................................................... B - 61

B-i

Section B - Body and Framework Contents

B - ii

Page No.

B - ii

Section B - Body & Framework

Technical Data Air Conditioning Option Binary Switch Settings Low pressure

2.05 bar (29.8 lbf/ in. 2.1Kg/cm)

High pressure

23.5 bar (341 lbf/ in, 24Kg/cm)

Thermostatic Switch Settings Cut out

32.0°F to 34.0°F (0°C to 1.1°C)

Cut in

44.0°F to 46.0°F (6.6°C to 7.7°C)

Refrigerant 1.3 Kg of R134a Gas Oil Type

Pag oil

Quantities: - Recharge the system

1.5 fluid oz. (42.6 millilitres)

- Condenser replacement

2.0 fluid oz (56.8 millilitres)

- Evaporator replacement

3.0 fluid oz. (85.2 millilitres)

- Hoses replacement

2 to 4 fluid oz. (56.8 to 113.6 millilitres)

- Receiver Drier replacement

2.0 fluid oz. (56.8 millilitres)

- Compressor replacement

None - pre charged

Fig 1. Typical Condenser

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Section B - Body & Framework Technical Data Air Conditioning Option Page left intentionally blank

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Section B - Body & Framework

Fault Finding Air Conditioning

!MWARNING

Make the machine safe before working underneath it. Park the machine on level ground and lower the attachments, (If it is necessary to work with the loader arms raised, then the loader arm safety strut must be fitted). See Loader Arm Safety Strut in MAINTENANCE section. Engage the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. If you are working near the articulation danger zone, fit the articulation safety lock. See Articulation Lock in MAINTENANCE section.

While inspecting the condenser, check the hose connections. Condenser failure can be caused by loose hoses. Hose movement can cause a fatigue failure of the condenser tubing adjacent to the fittings. Make sure the hoses are securely clamped.

Receiver Drier The receiver drier is located under the engine cover attached to the radiator cowl 1

Clean the sight glass on the top housing of the receiver drier.

Visual Inspection

The following checks are visual inspection items that can be carried out without the need for specialist equipment or the need to open the air conditioning circuit.

Check the sight glass, in a normal operating system the sight glass should be clear. (See K Sight Glass Indications ( T B-5).)

Check the hose connections to the receiver drier for signs of cracks or wear due to being insecurely clamped. Any suspect hoses should be noted and rectified only as detailed in K Service Procedures ( T B-17). Do not attempt to remove any hoses from a charged air conditioning system.

4-3-2-4_1

!MWARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1_2

The visual checks are to be carried out without the engine running unless specifically stated.

Condenser

4-3-4-1_2

The condenser is located at the rear of the machine.

Compressor and Drive Belt

Raise the rear grille and engine covers.

The compressor is mounted to a bracket secured to the engine.

Check that the condenser is free of leaves, debris, mud or built up dirt deposits. The condenser needs to be relatively clean in order to function efficiently as a heat exchanger. If the condenser obviously needs cleaning refer to K Condenser ( T B-28).

B-3

Check that the compressor is securely mounted to the its bracket and that the bracket is securely mounted to the engine.

Check that the compressor clutch assembly and drive pulley are secure.

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Section B - Body & Framework Fault Finding Air Conditioning 3

Check that the drive belt is in good condition. The belt should not show signs of excessive wear or be frayed and should be correctly tensioned. Frayed or badly worn belts should be replaced. Belts that are obviously incorrectly tensioned should be adjusted. (See Section 3 - Routine Maintenance - Belt Adjustment.)

General Fault Indications There are several indications that may help to determine the fault area on a system not working efficiently:

Check the belt run between the compressor clutch pulley and the belts engine drive pulley. The belt run should form a straight line parallel to the engine timing cover.

Hoses and Fittings 1

Check all visible hoses and fitting. Look for places where the hoses flex or are fastened, clamped, connected, bent or pass through panels. All these places are potential wear and damage points. Any suspect hoses should be noted and rectified only as detailed in K Service Procedures ( T B-17). Do not attempt to remove any hoses from a charged air conditioning system.

For any hoses that may appear to require tightening See K Tightening Leaking Hoses ( T B-20). (see above Warning.)

The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant pressure gauge should be used. However, leaks can be detected on the system by using soapy water applied to the suspected leak area and system pressure can be assessed by the state of refrigerant passing through the receiver drier sight glass. Following sections of the manual deal with the major components of the air conditioning systems and give further fault finding and maintenance information.

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Section B - Body & Framework Fault Finding Air Conditioning a)

Poor performance.

Low system pressure -

Evacuate and recharge system.

Condenser matrix air flow restricted -

Remove debris from around matrix using compressed air or low pressure water.

Air filter blocked -

Remove and replace.

Compressor drive belt too slack -

Adjust to correct tension.

Warm or slightly cool air emitted from unit.

Expansion valve stuck open or closed -

Renew expansion valve.

Blower operates on fan speed 3 only.

Blower resistor failed -

Renew resistor.

Blower motor failed -

Renew complete blower unit.

Blower does not operate.

Fuse blown -

Replace fuse and retest.

Compressor clutch continually cuts out.

Condenser matrix blockage -

Remove debris from around matrix/renew condenser.

Overcharging of refrigerant system -

Evacuate and recharge system.

Blocked expansion valve/condenser -

Clear blocked component.

Sight Glass Indications

glass when the compressor is running. Refer also to K Checking Refrigerant Charge Level ( T B-19).

An approximate indication of the condition of the refrigerant can be seen through the receiver/drier sight Clear - No fault indicated unless the system is unable to provide cool air. The indication then is that the system is completely discharged of refrigerant.

Foam or bubbles - Refrigerant low and in need of charging. (Some slight bubbling is to be expected when R134a refrigerant is used.)

Clouded - Desiccant breakdown in the receiver-drier.

Note: Sight glass indications cannot always give a positive identification of a problem. Further diagnosis, preferably by a refrigeration engineer using pressure gauges, is advisable before reaching a definite conclusion.

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Section B - Body & Framework Fault Finding Air Conditioning No Air Conditioning

CHECK 1

2 3

ACTION

Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on?

YES:

Check 2

NO:

Reset controls and retest.

Is the air conditioning (evaporator) blower working? YES: Is the compressor running (visual check of pulley/ clutch)?

Check 3.

NO:

Check 4.

YES:

Check 9.

NO:

Check 5.

YES:

Renew fuse(s) and retest.

Is the air conditioning fuse(s) blown?

NO:

Check 8.

Is there a 12V supply to the pressure switch harness?

YES:

Check 6.

Refer to K Pressure Switch Assembly (Two Switch System) ( T B-26)

NO:

Check 7.

Does the compressor clutch engage with pressure switch assembly bypassed?

YES:

Replace pressure switch assembly.

Refer to K Pressure Switch Assembly (Two Switch System) ( T B-26)

NO:

Renew the compressor clutch and retest.

Does the clutch engage with thermostat switch bypassed?

YES:

Renew thermostat switch and retest.

NO:

Check all electrical connections.

8 9

10 11

Are blower switch and wiring OK? Is sight glass indication OK?

Is condenser air flow blocked? Is evaporator air flow blocked?

B-6

YES:

Renew blower unit complete.

NO:

Renew switch or wiring.

YES:

Check 10.

NO:

Charge check required by refrigeration engineer or suitably trained person.

YES:

Clean condenser and radiator.

NO:

Check 11.

YES:

Clean filter and, if necessary the evaporator.

NO:

Call in refrigeration engineer or suitably trained person.

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Section B - Body & Framework Fault Finding Air Conditioning

System Diagnosis Normally Functioning A/C System Gauge Readings: Low Side Gauge - Normal. High Side Gauge - Normal. Other symptoms: Sight Glass - Clear. Discharge Air - Cold. Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are closed and the readings are stable and that the system has a full charge. The pressures on the manifold at 25 Â°C with the engine at 1500 RPM, the blower on maximum and the thermostat set to maximum, should be approximately: Typically, the high pressure is 6 - 8 times the low pressure. LOW SIDE - 2.0 bar (2.0 kgf/cm2)(29 lbf/in2) HIGH SIDE - 14.8 bar (15.1 kgf/cm2)(215 lbf/in2)

B-7

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Section B - Body & Framework Fault Finding Air Conditioning

Fig 2.

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B-8

Section B - Body & Framework Fault Finding Air Conditioning Low R-134a Charge Gauge Readings: Low Side Gauge - Low. High Side Gauge - Low. Other symptoms: Sight Glass - Bubbles continuously visible. Diagnosis: System slightly low on R-134a, due to leak or incorrect charge. Correction: 1

Leak test system.

Evacuate A/C system.

Repair system leaks.

Charge system with R-134a.

Operate system and check performance.

B-9

Fig 3.

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Section B - Body & Framework Fault Finding Air Conditioning Poor Refrigerant Circulation Gauge Readings: Low Side Gauge - Zero to negative. High Side Gauge - Low. Other symptoms: Receiver-Drier - Frost on tubes from receiver-drier to evaporator unit. Diagnosis: Refrigerant flow obstructed by dirt, receiver-drier clogged. Correction: 1

Evacuate A/C system.

Replace receiver-drier.

Charge system with R-134a.

Operate system and check performance. Fig 4.

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Section B - Body & Framework Fault Finding Air Conditioning No Refrigerant Circulation Gauge Readings: Low Side Gauge - Zero to negative. High Side Gauge - Low. Other symptoms: Receiver-Drier - Frost or moisture on tubes before and after receiver-drier. Diagnosis: Refrigerant flow obstructed by dirt, moisture or gas leakage from expansion valve heat sensing tube. Correction: 1

Evacuate A/C system.

Check heat sensing tube at expansion valve. Replace expansion valve if necessary.

Remove expansion valve and attempt removal of dirt. If dirt cannot be removed, replace expansion valve.

Replace receiver-drier.

Charge system with R-134a.

Operate system and check performance.

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Fig 5.

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B - 11

Section B - Body & Framework Fault Finding Air Conditioning Insufficient Cooling of Condenser or Refrigerant Overcharge Gauge Readings: Low Side Gauge - High. High Side Gauge - High. Other symptoms: Sight Glass - No bubbles visible even at lower engine RPM. Diagnosis: Refrigerant overcharge, condenser cooling fins clogged with dirt or cooling fans malfunctioning. Correction: 1

Clean condenser cooling fins.

Check cooling fan operation.

Evacuate A/C system.

Charge system with R-134a.

Operate system and check performance.

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Fig 6.

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B - 12

Section B - Body & Framework Fault Finding Air Conditioning Air in System Gauge Readings: Low Side Gauge - High. High Side Gauge - High. Other symptoms: Sight Glass - Bubbles visible during system operation. Pipes - Low pressure pipes are hot to the touch. Diagnosis: Air is present in the system, possibly from inadequate evacuation procedure. Correction: 1

Evacuate A/C system.

Check compressor oil for contamination. Check compressor for proper oil amount. Correct if necessary.

Charge system with R-134a.

Operate system and check performance.

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Fig 7.

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B - 13

Section B - Body & Framework Fault Finding Air Conditioning Expansion Valve Improperly Mounted or Heat Sensing Tube Defective (Opening Too Wide) Gauge Readings: Low Side Gauge - High. High Side Gauge - High. Other symptoms: Pipes - Large amount of frost or moisture on low side pipes. Diagnosis: Excessive refrigerant in low side pipes possibly from expansion valve being opened too wide. Correction: 1

Leak test system.

Evacuate A/C system.

Repair system leaks.

Charge system with R-134a.

Operate system and check performance.

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Fig 8.

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B - 14

Section B - Body & Framework Fault Finding Air Conditioning Compressor Malfunction Gauge Readings: Low Side Gauge - High. High Side Gauge - Low. Diagnosis: Internal compressor leak or compressor mechanically broken. Correction: 1

Evacuate A/C system.

Repair or replace compressor.

Charge system with R-134a.

Operate system and check performance.

Fig 9.

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Section B - Body & Framework Fault Finding Air Conditioning Some Moisture in the System Gauge Readings: Low Side Gauge - Normal, then sometimes drops to below zero. High Side Gauge - Normal, then sometimes goes high. Diagnosis: Moisture in system freezes, temporarily stopping cycle, normal system operation returns when ice melts. Correction: 1

Evacuate A/C system.

Replace receiver-drier.

Remove moisture by repeatedly evacuating system.

Charge system with R-134a.

Operate system and check performance.

Fig 10.

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Section B - Body & Framework

Service Procedures Rivet Nuts TB-001_2

A 'Rivet Nut' is a one piece fastener installed 'blind' from one side of the machine body/framework. The rivet nut 11A is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread 11-B.

Table 1. Specifications Rivet Nut Rivet Nut Material Rivet Thread Outside Thickness Length Diameter Diameter (Total)

Drill Hole Dia.

7.10

M10

0.25 - 3.00

14.00

3.00 - 5.50

17.00

0.50 - 3.00

16.00

3.00 - 5.50

19.00

0.50 - 3.00

18.00

3.00 - 5.50

21.00

1.00 - 3.50

23.00

3.50 - 6.00

26.00

9.10 11.10 13.10

Note: All dimensions in mm Fig 11. Rivet nuts are fitted to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and hydraulic valve retention etc. Various sized rivet nuts are available. K Table 1. Specifications ( T B-17) to determine the size of rivet nut to be used for particular applications. If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed. K Fitting Procedure ( T B-18). Note: In an emergency, and if no installation tool is available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.

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Section B - Body & Framework Service Procedures Rivet Nuts

Fitting Procedure

(smooth bulge) seating itself against the body/ framework 14-E.

Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.

Screw the rivet nut onto the mandrel of the installation tool. The bottom of the mandrel should be in line with the bottom of the rivet nut 12-A.

Note: The thread of the rivet nut must not be stripped, take care when 'upsetting' the rivet nut.

Fig 14. Fig 12. 3

Remove the installation tool.

Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut 13-B.

Fig 13. 4

Insert the rivet nut (assembled to the tool) into the hole drilled in step 1.

Hold handle 14-C and at the same time draw the mandrel into the installation tool by turning nut 14-D. The rivet nut will contract in length and form an 'upset'

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Section B - Body & Framework Service Procedures Air Conditioning

Air Conditioning Checking Refrigerant Charge Level The pressure in the system, i.e. the refrigerant charge level can be determined by checking the state of refrigerant at the receiver drier sight glass. The receiver drier is mounted beneath the right-side engine cover on a vertical bulkhead at the rear of the engine. If the level of charge is correct the sight glass will be clear. If the charge is low bubbles will be seen. Bubbles may also be an indication of inadequate cooling, due to a restriction of air flow around the condenser coil. Recharging of the system should be carried out by an air conditioning engineer. Check refrigerant charge level as follows: Note: When R143a refrigerant is used slight bubbling will be seen at the system sight glass. This is normal for this type of refrigerant. If the system is not providing adequate cooling refer to K Fault Finding ( T B-3). 1

Park the machine on firm, level ground. Lower the loader arms to the ground. Engage the parking brake.

Chock the wheels, to prevent movement.

Raise the right-side engine cover.

Start the engine and run at idle. Switch air conditioning ON to circulate refrigerant.

Fig 15.

Leak Testing

!MWARNING

Check refrigerant charge level at sight glass 15A.

TB-004

Leak testing in Air Conditioning systems should be carried out only in a well ventilated area. BF-1-2

Note: The refrigerant is heavier than air and will leak downwards from the defective component. Check in still conditions but in a well ventilated area. Hose or pipe connections are likely leakage points of any refrigerant circuit. It is essential that an electronic leak detector is used to locate leaks accurately. However, if a leak detector is not available, an approximate source can be found by applying soap solution to the suspect area. To test for leaks in the high pressure side of the system i.e. from the compressor output to the expansion valve, run the

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Section B - Body & Framework Service Procedures Air Conditioning air conditioning for a few minutes then switch off the engine and test for leakage using an electronic leak detector or soapy water. To test for leakage in the low pressure side of the system, switch off the air conditioning and leave for a few minutes before testing.

Tightening Leaking Hoses

The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an 'O' ring seal which compresses when the connection is tight, creating an air tight seal. Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion valve (the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes). If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector up and repeat the leakage test. If leakage is still evident, it will be necessary to discharge the system and renew the connector 'O' ring seal.

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Section B - Body & Framework Service Procedures Air Conditioning

Refrigerant Charging and Discharging TB-005

Note: The procedures for refrigerant charging and discharging must only be carried out by qualified service personnel who have received specialist training on the air conditioning system.

Note: If the high pressure warning light on the `Javac' unit comes on, throttle back the manifold low pressure valve to provide a restriction. 7

The 'Javac' unit 16-E will automatically switch off when a pressure balance exists between the system and the receiver bottle. Switch off 'Javac' at main switch, but leave the system connected. Switch on after 10 minutes, the 'Javac' will restart if residual pressure remains.

Close valves and remove equipment.

Refrigerant Recovery The recovery process clears the system refrigerant prior to servicing or for refrigerant renewal. Note: Do not re-use refrigerant unless you are aware of its purity. Note: The JCB recommended 'Javac' unit only recovers refrigerant as a gas. Other units can recover refrigerant as a liquid and/or gas. Always check manufacturers instructions before using. 1

Ensure that the engine is OFF and the starter key removed.

Connect the manifold to the system as shown, with the blue hose 16-A connected to the system low pressure port. Do Not connect the red hose 16-B. Make sure that both valves are closed.

Connect the yellow hose 16-C to the 'Javac' unit filter 16-D.

Connect the filter 16-D to the 'Javac' unit 16-E.

Connect the 'Javac' unit 16-E to an empty receiver bottle 16-F. Weigh the bottle before and after filling to assess system capacity.

Fig 16. Refrigerant Recovery

Note: Do not fill the receiver bottle to more than 80% by weight. 6

Switch on 'Javac' unit 16-E and open the low pressure manifold valve.

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Section B - Body & Framework Service Procedures Air Conditioning Evacuating (Vacuuming) This procedure follows on from the 'Recovery' process and is necessary to ensure proper refilling of the system with refrigerant. To avoid leakage in the vacuum system itself, Do not use extensions to the yellow hose (use standard 2 metre length). 1

Recover all refrigerant from K Refrigerant Recovery ( T B-21).

the

system.

Close all valves and connect the manifold as shown. Connect the blue hose 17-A to the system low pressure port and the red hose 17-B to the high pressure port.

Connect the yellow hose 17-C to the vacuum pump 17-D.

Fig 17. Evacuating

Note: If the Electronic Vacuum Gauge 17-E is used Vacuum connected as shown. K Electronic Gauge ( T B-23), for further information. 4

Open manifold valves.

Switch on the vacuum pump 17-D until 740mm (29 in) mercury vacuum reads on both gauges.

Note: Achievable vacuum will vary with altitude. Maximum gauge reading will be 25mm (1 in) less for every 305 metres (1000 feet) above sea level. 6

Maintain suction for approximately 30 minutes.

Note: If the vacuum falls rapidly the system is leaking. Check all connections and reseal. If the point of leakage is not obvious, recharge the system and test again. 7

Close valves and remove equipment.

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Section B - Body & Framework Service Procedures Air Conditioning Electronic Vacuum Gauge

ATM/BAT

Normal atmospheric pressure reading. Battery condition.

15"/510mbar

381mm (15 in)Hg. Partial vacuum Vacuum system is operating.

29"/980mbar

736mm (29 in)Hg. No vacuum drawn Possible system leakage.

8000

8.0mm (0.31 in)Hg. Partial vacuum - If the reading does not progress the system may have a slow leak.

1000

1.0mm (0.039 in)Hg. Deeper vacuum.

600

0.6mm (0.023 in)Hg. Deep vacuum.

400

0.4mm (0.015 in)Hg. Deep vacuum.

200

0.2mm (0.0078 in)Hg. Deep vacuum.

0.025mm (0.00098 in)Hg. Pump Test. Maximum sustainable vacuum.

A396790

Fig 18. The CPS VG100 vacuum gauge is an electronic type using LED's to indicate various states of vacuum. It is used in place of or to supplement the gauge on the vacuum pump. Before connecting into the system switch on to check that the first LED lights to show that the battery is in good condition. Note: The indicator lights show pressure in inches of mercury (Hg) and vacuum in microns (0.001mm Hg).

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Section B - Body & Framework Service Procedures Air Conditioning Relubricating Pre-lubrication is essential after recovering system refrigerant, vacuuming and component flushing. The system should be evacuated to a vacuum of 740mm (29 in) of mercury before re-lubricating. 1

Ensure that the engine is OFF and the starter key is removed.

Close all valves and connect the manifold as shown, with the blue hose 19-A connected to the oil injector 19-E and the red hose 19-B to the system high pressure port.

Connect the yellow hose 19-C to the vacuum pump 19-D.

Connect the other end of the oil injector 19-E to the system low pressure point 19-F.

Switch on the vacuum pump 19-D and open the high pressure side valve.

Unscrew the oil injector cap and add the specified quantity of refrigerant oil.

When 740mm (29 in) mercury shows on the vacuum gauge, open the oil injector valve to allow the oil into the system.

If more oil is needed repeat the above procedure. The quantity of oil should be the same as that taken out during the 'Recovery' procedure.

F Fig 19. Relubricating

Note: Use only PAG oil in R-134a systems.

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Section B - Body & Framework Service Procedures Air Conditioning Charging This procedure is industry recommended practice for refilling air conditioning systems with refrigerant. Evacuate the system beforehand to 740mm (29 in) of mercury. 1

Close all valves and connect the manifold as shown. Connect the blue hose 20-A to system low pressure and the red hose 20-B to system high pressure. Connect the yellow hose 20-C to the refrigerant cylinder 20-D.

Invert single valve cylinder on the scales 20-E and zero the scale reading

Note: Some refrigerant cylinders have separate valves for gas and liquid. Be sure to connect to the liquid port when following the above procedure. Note: Refrigerant can be used either in gas or liquid form. If recharging with gas follow the manufacturers instructions and recharge only via the low pressure port. Do not use liquid refrigerant at the low pressure port. 3

Fig 20. Charging

Slowly open the high pressure valve and allow the vacuum to draw-in refrigerant to the specified weight for the system. Refer to Technical Data. Add refrigerant until the scales 20-E indicate the specified weight for the system or the weight obtained when the system refrigerant was previously recovered.

Note: To speed up the process a thermostatically controlled thermal blanket 20-F can be used around the replenishing cylinder. 4

Close all valves and remove the equipment.

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Section B - Body & Framework Service Procedures Air Conditioning

Pressure Switch Assembly (Two Switch System) The pressure switch assembly comprises a low pressure switch designed to open at approximately 2 bar (30 lbf/in2) and a high pressure switch designed to open at 24 bar (342 lbf/in2) When the refrigerant pressure is within the 2 and 24 bar limits the switches will be closed and providing the thermostat and on/off switches are closed, a current will be supplied to the field coil of the clutch. Through electromagnetic action the field coil clutch will be pulled towards the compressor's clutch and the refrigeration cycle will commence. If the fault finding table indicates that the pressure switch assembly is defective the fault may be electrical or due to incorrect system pressure. Follow the procedure for checking the refrigerant charge level (K Checking Refrigerant Charge Level ( T B-19)) to isolate the fault area. If the refrigerant charge level is OK use the following electrical test procedures.

Pressure Switch Testing 1

Switch the engine off so that the air conditioning system cannot operate.

Disconnect the pressure switch harness, FS, from the side console harness and connect an external 24V power supply between the pressure switch harness connector and chassis. If both pressure switches are working correctly, and the system is at the correct charge level, the compressor clutch will operate. If the compressor clutch does not operate with the external power supply, one of the pressure switches in the assembly is faulty or the level of refrigerant charge is insufficient to close the low pressure switch.

Replace the pressure switch assembly. If the clutch still fails to operate check all electrical connections.

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Section B - Body & Framework Service Procedures Air Conditioning

Binary Pressure Switch Testing (Single Switch System) If the fault finding table indicates that the binary pressure switch assembly is defective the fault may be electrical or due to incorrect system pressure. Before testing the binary pressure switch 21-A it is important to check the refrigerant charge level. If the refrigerant charge level is satisfactory, test the switch as described below: 1

Switch OFF the engine and remove the harness connectors 21-B from the pressure switch 21-A.

B A

C023830

Fig 21. 2

Connect a link wire between the two harness connectors (effectively bypassing the pressure switch).

Switch on the engine and air conditioning system. If the system operates, one of the switches inside the binary pressure switch assembly is faulty.

Renew the pressure switch assembly. If the clutch still fails to operate, check the harness electrical wiring for damage and open or short circuits. For details of the electrical circuits and connections, see Electrical Connections.

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Section B - Body & Framework Service Procedures Air Conditioning

Condenser It is likely that over a period of time, because of the machines working environment, the airflow around the condenser coil will become restricted due to a build up of airborne particles If the build up of particles is severe, heat dissipation from the refrigerant to the air will be significantly reduced, resulting in poor air conditioning performance. In extreme cases, over pressurisation of the system occurs, causing the high pressure cut-out switch to operate and switch off the system. High pressure cut-out can also be caused by an internal blockage of the condenser coil.

Condenser Coil Cleaning Take care not to damage the condenser fins or tubes. Damaged fins must be straightened out to ensure a good air flow through the coil. The condenser is located at the rear of the machine. 1

Park the machine on firm level ground. Lower the loader arms to the ground.

Remove the stater key.

Chock both front and rear wheels

Swing out and raise the grille at the rear of the machine.

Use compressed air or low pressure water to backflow through the coil fins. Take care not to damage the fins.

Run the air performance.

B - 28

conditioning

and

check

cooling

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Section B - Body & Framework

Air Conditioning Air Conditioning Components The Air Conditioning Unit

The air conditioning unit (a/c) contains a blower unit; evaporator; heater radiator; filters and thermostat. It is located on the right side of the cab behind a hinged panel.

Reach under the side of the cab and remove the two air conditioning unit drain hoses from the unit by pulling them from the units welded drain tubes. (Not shown.)

Note: Unlike the earlier models supplied by this manufacturer, the binary pressure switch is now located on the receiver drier.

Note: There are no clips fitted to these hoses during production. If the hoses are stretched to a point where they are not a snug push fit they should be replaced when refitting the unit.

!MWARNING

The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant.

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

Allow the engine to cool down. Slowly release the filler cap to release any residual pressure. Refit the cap once the pressure has been released.

K Fig 23. ( T B-31)

Loosen the coolant hose clips 3 and 5. Remove and plug the hoses to prevent the loss of coolant.

The removal of the unit will require the assistance of a refrigeration engineer or suitably qualified person since the refrigerant will need to be discharged from the system

Release the clips securing the control cables 4 and 9 to the heater coolant valve and the ventilation flap at the control levers. Remove the cables.

4-3-4-1_2

Removal

Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine. Open the access panel on the right hand side of the machine. Remove the electrical harnesses 1 and 2 from the heater blower motor and the air conditioning at the their connections on the air conditioning cabinet.

Note: When facing the cabinet, the upper left hand wiring harness connector is for the heater motor, the right hand connector is for the air conducting.

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!MWARNING When working on the Air Conditioning System, gloves, eye protection and protective clothing must be worn. Do not smoke or expose refrigerant to naked flames or hot surfaces. BF-1-3

Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person. Charging and K Refrigerant Discharging ( T B-21).

With the system fully discharged, disconnect the high and low pressure hoses 6 and 7 from their connection at the expansion valve 8.

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Section B - Body & Framework Air Conditioning Air Conditioning Components 10

Remove the seven bolts 22A securing the air conditioning unit to the cab and with the aid of an assistant withdraw the unit.

A A A

A A Fig 22.

Replacement K Fig 23. ( T B-31). Replacement is the reverse of the removal procedure, however, note of the following: 1

When refitting the unit care must be taken to ensure the condensation drain hoses are correctly routed. There must be no kinks in the hoses and no â&#x20AC;&#x2DC;uphill runsâ&#x20AC;&#x2122; that would allow drained condensation to pool which may result in a build up of stagnant water.

Important: If the cooling system has been drained, when refilling, do not exceed the maximum fill rate of 10 litres per minute. 2

When refilling the cooling system use the correct water/antifreeze mixture. A 50% mixture should be maintained even if frost protection is not required. Refer to Section 3 - Routine Maintenance - Coolant Mixtures.

The air conditioning system will need to be recharged with refrigerant by a refrigeration engineer or suitably trained and qualified person. K Refrigerant Charging and Discharging ( T B-21).

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Section B - Body & Framework Air Conditioning Air Conditioning Components

2 3

4 8

6 Fig 23.

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Section B - Body & Framework Air Conditioning Air Conditioning Components

Filters Alongside the paper element filter fitted as standard, an additional filter can be fitted should operating conditions dictate.

K Fig 26. ( T B-34).

Removal 1

Open the access panel on the right hand side of the machine.

Release the two â&#x20AC;&#x2DC;1/4 turn fastenersâ&#x20AC;&#x2122; 24A securing the filter cover to the main air conditioning cabinet.

Note: There is no need to remove the ventilation flap control cable as there is sufficient flexibility in the cable to allow the removal of the cover.

A Fig 24.

!MWARNING Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others. 0147_1

Remove the standard filter element 24B. Shake out the loose dust and clean using low pressure compressed air. Renew the filter if required.

If fitted, remove the secondary filter 24C by grasping the removal tag at the top edge of the filter and pulling.

Replacement Replacement is the reverse of the removal procedure, however, note the following: â&#x20AC;&#x201C; The secondary filter, regardless of its type, is secured in position by two magnets. These magnets are a part of the filter element, therefore care must be taken to ensure the filter is installed the correct way round.

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Section B - Body & Framework Air Conditioning Air Conditioning Components

Blower Motor

Withdraw the blower motor assembly 26-5 slowly from the air conditioning cabinet until the wiring connections at the motor are accessible. Label and disconnect the wiring.

Remove the thermostat from the heater blower support tray 26-4, K Thermostat ( T B-35).

Fully withdraw the blower motor assembly.

For component layout see, K Fig 26. ( T B-34). The blower motor is located inside the air conditioning unit. The only user serviceable component being the resistor which governs the fan speed. other faults, with the exception of wiring defects, necessitate the replacement of the blower motor as a unit. Note: The blower motor can be removed from the air conditioning cabinet with the air conditioning assembly in position.

Replacement Replacement is the reverse of the removal procedure.

Removal 1

Open the access panel on the right hand side of the machine.

Remove the filter K Filters ( T B-32).

Remove the eight screws 25A securing the cover to the air conditioning cabinet, and remove the cover.

housing

and

filter(s),

A A

A Fig 25.

B - 33

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Section B - Body & Framework Air Conditioning Air Conditioning Components

6 5 3

2 1

9 8 7 Fig 26. Component Key: 1

Filter Cover

Standard Air Filter Element

Secondary Filter Element (HEPA/ Carbon)

Blower Motor Support Tray

Blower Motor Assembly

Air Conditioning Cabinet

Heater Matrix

Expansion valve

Evaporator

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Section B - Body & Framework Air Conditioning Air Conditioning Components

Thermostat

Disconnect the harness connection 28B to the thermostat.

The thermostat monitors the external temperature of the evaporator and is located within the air conditioning cabinet alongside of the blower motor.

Remove the securing bolts 28C Lift the thermostat from the heater motor mounting plate and slowly remove, withdrawing the probe from its hole through the mounting plate.

Removal 1

Open the access panel on the right hand side of the machine.

Remove the filter K Filters ( T B-32).

Remove the eight screws 27A securing the cover to the air conditioning cabinet, and remove the cover.

housing

and

Replacement Replacement is the reverse of the removal procedure. Important: Care must be taken when inserting the thermostat probe into the evaporator coil to ensure the evaporator is not damaged.

filter(s).

Fig 28.

A Fig 27. 5

Withdrawn the temperature probe 28A carefully from the evaporator core.

Withdraw the heater motor sufficiently to secure access to the thermostat securing bolts. K Fig 26. ( T B-34).

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Section B - Body & Framework Air Conditioning Air Conditioning Components

!MWARNING

Evaporator The evaporator is located in the air conditioning cabinet. Its removal will require the assistance of a refrigeration engineer or suitably qualified person since the refrigerant will need to be discharged from the system

When working on the Air Conditioning System, gloves, eye protection and protective clothing must be worn. Do not smoke or expose refrigerant to naked flames or hot surfaces. BF-1-3

Refer to K Fig 23. ( T B-31) and K Fig 26. ( T B-34).

!MWARNING

Removal 1

Open the access panel on the right hand side of the machine.

Remove the filter K Filters ( T B-32).

housing

Remove the eight screws 29A securing the cover to the air conditioning cabinet, and remove the cover.

and

With the system fully discharged, disconnect the high (23-7) and low (23-6) pressure hoses from their connection at the expansion valve 23-8.

Remove the bolt 30A securing the expansion valve 30B to the cabinet.

filter(s).

A A

A Fig 29.

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Section B - Body & Framework Air Conditioning Air Conditioning Components

B A

Fig 30. 8

Carefully withdraw the evaporator unit 26-9, complete with the expansion valve 26-8 from the air conditioning cabinet.

Replacement Replacement is the reverse of the removal procedure, however note the following: 1

The air conditioning system will need to be recharged with refrigerant by a refrigeration engineer or suitably trained and qualified person. K Refrigerant Charging and Discharging ( T B-21).

B - 37

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Section B - Body & Framework Air Conditioning Air Conditioning Components

Expansion Valve The expansion valve is located on the air conditioning cabinet. Refer to K Fig 23. ( T B-31) and K Fig 26. ( T B-34).

Removal 1

E D

B 2

Open the access panel on the right hand side of the machine.

!MWARNING When working on the Air Conditioning System, gloves, eye protection and protective clothing must be worn. Do not smoke or expose refrigerant to naked flames or hot surfaces.

Fig 31. 7

Remove the bolt 31A securing the expansion valve to the air conditioning cabinet and remove the valve assembly.

Remove and discard the O-rings from the pipes 31C and D

BF-1-3

Replacement. Replacement is the reverse of the removal procedure, however, note the following:

4-3-4-1_2

With the system fully discharged, disconnect the high (23-7) and low (23-6) pressure hoses from their connection at the expansion valve 23-8.

Peel back the insulation 31E from the pipes.

Disconnect the pipes 31C and D at the expansion valve 31B.

B - 38

Always replace the pipe fittings O-rings with new.

The air conditioning system will need to be recharged with refrigerant by a refrigeration engineer or suitably trained and qualified person. K Refrigerant Charging and Discharging ( T B-21).

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B - 38

Section B - Body & Framework Air Conditioning Air Conditioning Components

Heater Radiator The heater radiator is located in the air conditioning cabinet. Refer to K Fig 23. ( T B-31) and K Fig 26. ( T B-34).

A Removal 1

Open the access panel on the right hand side of the machine.

!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

Allow the engine to cool down. Slowly release the filler cap to release any residual pressure. Refit the cap once the pressure has been released.

Loosen the coolant hose clips 23-3 and 23-5. Remove and plug the hoses to prevent the loss of coolant.

Release the clips securing the control cable 23-4 to the heater coolant valve. Remove the cable.

Remove the upper hose clip 32A securing the heater control valve 32B to the heater matrix and remove the valve.

Fig 32. 7

Remove the four screws 33A securing the right hand access panel to the air conditioning cabinet and remove the panel

Fig 33. 8

B - 39

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Withdraw the heater radiator 26-7 from the air conditioning cabinet.

B - 39

Section B - Body & Framework Air Conditioning Air Conditioning Components Replacement. Replacement is the reverse of the removal procedure, however, note the following: Important: If the cooling system has been drained, when refilling, do not exceed the maximum fill rate of 10 litres per minute. 1

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Section B - Body & Framework Air Conditioning Air Conditioning Components

Binary Pressure Switch The binary pressure switch assembly is located in the engine compartment, screwed into the receiver drier unit.

Removal

!MWARNING Goggles and rubber gloves must be worn when pressure switches are removed or fitted. A small amount of refrigerant is released which can be harmful to the skin or eyes.

BF-1-10

Disconnect the battery.

Remove the harness connectors 34A, then unscrew the pressure switch assembly 34B.

Replacement 1

Screw the pressure switch 34B into the threaded port and tighten sufficiently to form a gas-tight seal.

Reconnect the harness connectors 34A.

If the system is in an un-charged condition, charge the air conditioning system. K Refrigerant Charging and Discharging ( T B-21).

Fig 34.

!MWARNING Leak testing in Air Conditioning systems should be carried out only in a well ventilated area. BF-1-2

Operate the air conditioning system and check around the pressure switch for leaks. If any leaks are found, tighten the pressure switch further until the leaking stops.

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Section B - Body & Framework Air Conditioning Air Conditioning Components Page left intentionally blank

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Section B - Body & Framework

Cab Glazing

!MWARNING

Direct Glazing TB-002_6

The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken.

Laminated glass must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the glass in a horizontal attitude it must be supported over its whole area, not just at the edges.

Always wear safety glasses during both removal and replacement.

BF-1-8_1

Use protective gloves - heavy duty leather gauntlet type gloves when cutting out the broken glass; 'nonslip' type gloves when handling/moving panes of glass; surgical type gloves when using the polyurethane adhesives.

Removing the Broken Glass and Old Sealant

Wear protective overalls.

Do not smoke - the activators and primers used in the procedures are highly flammable.

Do not attempt to handle or move panes of glass unless you are using glass lifters.

Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see Service Tools).

!MWARNING Always wear safety glasses when removing or installing screen glass. Never use a power operated knife when removing the sealant around a toughened glass screen. The action of the knife could cause particles of glass to be thrown with sufficient force to cause serious injury, even when safety glasses are being worn. Use only hand operated tools when working with toughened glass. BF-2-3_1

Position the machine on level ground and apply the park brake. Stop the engine. Put protective covers over the cab seat and control pedestals.

If a laminated pane breaks it will stay in one piece even though the glass is cracked. A toughened pane will shatter and fall apart. The method of removal of the glass depends upon which type it is.

The work must only be carried out in a dry, frost free environment. A protective canopy may be required or the machine/frame must be moved to a sheltered area. In damp or wet conditions, hinged doors and window frames can be removed from the machine and taken to a more suitable (dry) environment.

b Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant.

Glass should not be replaced at temperatures below 5Â°C (41Â°F).

B - 43

Laminated glass - leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.

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Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this:

B - 43

Section B - Body & Framework Cab Glazing a

Pneumatic Knife. K Fig 35. ( T B-44). This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.

Fig 35. Pneumatic Knife i

Press the handle to start the knife blade oscillating.

Important: This tool must not be used on toughened glass. ii

Fig 36. Braided Cutting Wire and Handles

Insert the knife blade into the sealant.

iii Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. Do not allow the knife blade to overheat or the sealant will melt.

iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass.

b Braided Cutting Wire and Handles. K Fig 36. ( T B-44). This method uses a 3-core wire, a wire starter tube and two handles. i

Insert the braided cutting wire B down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire.

iv Secure the end of the braided cutting wire (found on the outer side of the glass) in the special handle C.

Insert the steel tube A into the old sealant on the inside of the glass.

Slowly remove the steel tube A.

vi Secure the second end of the braided cutting wire in the special handle D. vii Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant. c

B - 44

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Cut-out Knife. K Fig 37. ( T B-45). The cut-out knife can be used as a left handed or right handed tool.

B - 44

Section B - Body & Framework Cab Glazing 5

If necessary, trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab frame aperture. K Fig 39. ( T B-45).

1-2 mm

Fig 37. Cut-out Knife

Fig 39.

Insert the knife blade into the sealant.

Make sure that the blade of the knife is against the glass A. K Fig 37. ( T B-45).

iii Use the 'pull-handle' to pull the knife along and cut out the old sealant. d Craft Knife. K Fig 38. ( T B-45). The blades A are replaceable. i

Insert the knife blade into the sealant.

Pull the knife along and cut out the old sealant.

Apply a coat of 'Black Primer 206J' to the paintwork if: Paintwork was damaged or scratched during the glass/sealant removal procedures.

b The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures.

Preparing the Cab Frame Aperture 1

If damp or wet, dry the aperture area using a hot air gun (sourced locally).

Use 'Active Wipe 205' to thoroughly clean and 'prime' the trimmed sealant. Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.

Note: Do not use any other type of cleaning fluids, otherwise they may be absorbed into the old sealant and ultimately prevent the new glass from bonding.

Preparing the New Glass

!MWARNING

Fig 38. Craft Knife 4

Laminated glass - lift out the broken pane using glass lifters. Toughened glass - remove the cut off sealant and all remaining particles of shattered glass.

B - 45

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B - 45

Section B - Body & Framework Cab Glazing 1

Make sure that the new glass correctly fits the frame aperture A. K Fig 40. ( T B-46). a

Put two spacer blocks B onto the bottom part of the frame aperture.

b Install the new glass on the spacer blocks Always use glass lifters C. Check that there is an equal sized gap all round the edge of the glass. Note: The spacer blocks are rectangular in section to give two common gap widths. If necessary they can be trimmed to a smaller size to give an equal sized gap around the glass.

Fig 41. Glass Stand

Important: The glass edges must not touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass.

Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board, sourced locally to fit the glass stand. K Fig 42. ( T B-46). It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an antiscratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

Fig 40. 2

Fig 42.

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 41. ( T B-46).

Make sure the glass is positioned on the stand the correct way up (i.e. with the black ceramic ink band upwards) ready for application of primer etc.

Clean the glass a

B - 46

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Use 'Active Wipe 205' to thoroughly clean and 'prime' the black ceramic ink band printed on the glass (see Note). Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time.

B - 46

Section B - Body & Framework Cab Glazing Note: Do not touch the glass after cleaning with the 'Active Wipe 205'. b If the glass does not have a black ceramic ink band, paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line. K Fig 43. ( T B-47).

Fig 44. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 45. ( T B-47)

Fig 43. 5

Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note) into a suitable applicator gun: a

Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.

b Make sure that the rolled edge of the cartridge is not damaged - if necessary, the edges should be pressed flat, otherwise it will be difficult to remove the cartridge from the applicator gun. c

Pierce the front 'nozzle' end of the cartridge to its maximum diameter.

Fig 45. Note: Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. After approximately 10 minutes the sealant will form a 'skin', this will prevent the glass from bonding. 7

d Fit the pre-cut nozzle. K Fig 44. ( T B-47). e

Install the cartridge in the applicator gun.

After applying the adhesive, leave a small amount of sealant protruding from the nozzle. This will prevent any adhesive left in the cartridge from 'curing'.

Installing the New Glass

Note: Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven for 1 hour to a temperature of 80Â°C (176Â°F). Pre-heating the cartridges makes the adhesive more workable and also brings the 'curing' time down to 30 minutes.

If the internal trim strip is damaged, renew it (cut to length as required) before fitting the new glass. Make sure the two spacer blocks are in position. K Preparing the New Glass ( T B-45) - step 1.

Install the glass in the frame aperture: a

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Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 46. ( T B-48).

B - 47

Section B - Body & Framework Cab Glazing 4

All exposed edges must be sealed using Black Polyurethane Sealant (see Sealing and Retaining Compounds, Section 1).

Important: Use extreme caution when wiping the inside of the new glass - pushing too hard on the inside of the glass will affect the integrity of the bonded seal. 5

Clean the glass after installation: a

Fig 46. Typical M/c. Installation

Small amounts of sealant can be cleaned from the glass using the 'Active Wipe 205'.

b Large amounts of excess sealant should be left to 'cure' and then cut off with a sharp knife.

b Sit the bottom edge of the glass on the spacer blocks. K Fig 47. ( T B-48)

Note: On completion of the glass replacement procedures, the sealant 'curing' time is 30 minutes. This means that the machine can be driven and used after 30 minutes, but it must not be used during the curing period of 30 minutes. c

Clean the glass using a purpose made glass cleaner

On completion of the glass installation procedures tidy the work area: a

Remove all broken glass from the cab area.

b Remove the protective covers from the cab seat and control pedestals. c

Renew all safety and instructional labels so that the new installation conforms with the original cab installation.

Fig 47. c

Make sure that the glass is correctly positioned, then gently press around the edges of the glass and ensure full adhesive contact is achieved. Do not press too hard or too much adhesive will squeeze out.

Make the inside seal smooth: a

Wearing surgical gloves, dip your finger in a soapy water solution.

b Use your finger to make the inside seal smooth.

B - 48

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Section B - Body & Framework Cab ROP/FOPS Structure

ROP/FOPS Structure Checking the Structure

Check the structure for damage.

Make sure that all the ROPS/FOPS mounting bolts A are in place and undamaged.

Make sure that the ROPS/FOPS mounting bolts A are tightened to the correct torque setting. This should be 270 Nm (199 lbf ft).

W A

W A Fig 48.

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Section B - Body & Framework Cab ROP/FOPS Structure Page left intentionally blank

B - 50

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Section B - Body & Framework

Bodywork Removal and Replacement of the Rear Bodywork It will be necessary to remove the rear bodywork section covering the engine and cooling pack to carry out certain essential maintenance tasks.

Remove the six bolts securing the fan grille to the fan housing. (The lower three are fitted on the under side of the grille.)

!MWARNING

To remove the bodywork proceed as follows:

Removal 1

Park the machine on firm level ground, lower the attachments to the ground, apply the park brake and set the transmission to neutral. Stop the engine. Block both sides of all four wheels.

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5

Important: The procedure detailed below must be followed to correctly vent the residual hydraulic pressure. 2

Vent the hydraulic pressure as detailed in Section E - Hydraulics - Service Procedures - Venting the System Pressure.

Disconnect the batteries to prevent the engine being started whilst carrying out this procedure.

Open the left and right-hand side engine covers. From inside the right-hand side cover pull the release cable 49A to unlatch the rear fan housing assembly.

Label and disconnect the hoses to the cooling fan motor 50A, 50B and 50C. Plug the hoses and cap the open motor ports to prevent the ingress of dirt or debris. Section E - Hydraulics - Service Procedures - Connecting and Disconnecting Hydraulic Hoses.

A C B C021330

Fig 50. 7

Remove the plastic body panel fitted above the fan housing covering the upper rear bodywork support panel.

Feed the released fan hydraulic hoses up through the top of the fan housing, through the upper bodywork

A Fig 49.

B - 51

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B - 51

Section B - Body & Framework Bodywork Removal and Replacement of the Rear Bodywork support panel and rest over the right-hand side chassis. 9

Raise the fan housing fully on its gas struts, attach a suitable sling to the motor and connect the sling to a overhead crane.K Fig 51. ( T B-52).

Disconnect the coolant top hose from its connections at the cooling pack and the engine and remove the hose from the bulkhead. Plug the open ports to prevent dirt ingress.

Disconnect the two small bore coolant hoses 52A and 52B from the header tank where they are connected to the steel pipes just on the engine side of the rear bulkhead on the right-hand side of the machine. The hose to the engine can be left connected at the engine end. The hose passing through the bulkhead to the cooling pack should be pulled through the bulkhead but can be left secured at the cooling pack connection.

Fig 51.

With the weight of the fan motor and housing assembly held by the overhead crane, release the two gas struts from the fan housing.

Working from inside the fan housing aperture, remove the four bolts securing the fan housing top hinges to the upper rear bodywork support panel and slide the assembly away from the rear of the machine until the hinges are free of the panel. Lower the fan housing assembly to the ground and stow safely.

Disconnect the charge air cooler steel pipe at the hose connections each side of the rear engine bulkhead. Plug the open ports and hoses and remove the steel pipe from the rear bulkhead.

Note: Access to the cooling pack sections drain plugs is via holes machined into the rear panel beneath the batteries accessed from the rear. 13

Drain the coolant from the cooling pack radiator section into a suitable container. (Cover the container to prevent dirt ingress if the coolant is to be reused. If the coolant is to be discarded, dispose of in an environmentally friendly manner in line with local legislation.)

B - 52

C021250

Fig 52. 16

Disconnect the exhaust flexi-pipe at the silencer and the engine and remove. Plug the open ports to prevent any ingress of dirt or debris. The silencer should be left secured to the bodywork.

Disconnect the air cleaner hose between the filter housing and the engine. Plug the open ports to prevent any ingress of dirt or debris. The air cleaner assembly can be left secured to the bodywork.

Label and disconnect the harness from the air filter restriction switch. Release the harness from its securing at the bulkhead

Disconnect the large bore coolant hose from the header tank. Plug the open hose to prevent the ingress of dirt or debris. The header tank can be left secured to the bodywork.

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B - 52

Section B - Body & Framework Bodywork Removal and Replacement of the Rear Bodywork 20

Label and disconnect the grid heater harness cable 53A from the solenoid attached to the front bulkhead. Label and disconnect the grid heater solenoid activation cables 53B and 53C from the solenoid and, release the harness from its bulkhead securing fasteners.

Fig 54.

label and disconnect the emergency steer motor feed cable 55A at its connection at the solenoid. Also label and disconnect the solenoid operating harness cables 55B and C. Release the operating harness from its bulkhead securing fasteners. The solenoid can be left attached to the bulkhead.

A Fig 53. 21

Label and disconnect the emergency steer positive feed cable 54A from its connection at the fusible link on the bulkhead.

Fig 55.

B - 53

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Section B - Body & Framework Bodywork Removal and Replacement of the Rear Bodywork 23

Remove the bolts securing the emergency steering motor/pump and electrical units to the front bulkhead. Secure the components to the engine so that the weight of the assembly is not hanging on the electrical harness or the hydraulic hoses.

Label and disconnect the rear and engine harness connections at their connections through the front bulkhead on the right-hand side of the machine. K Fig 56. ( T B-54).

Securely fit the lifting eyes to the threaded holes provided in the rear bodywork and attach suitable lifting slings. Securely attach the slings to an overhead crane.

Remove the four bolts 57A (two each side) securing the rear bodywork securing panel to the cast rear corner uprights.

A C021240

Fig 57. 29

Remove the four bolts 58A (two each side) securing the rear bulkhead to the chassis.

C021220

Fig 56. 25

Remove the two bolts securing the fuel sedimenter bowl to the rear bulkhead and temporarily secure the sedimenter to the engine. There is no need to disconnect the fuel pipes to the sedimenter.

Note: It will be necessary to simultaneously feed the main transmission hydraulic hose and the two smaller engine fan hydraulic hoses 58B and 58C through the apertures in the lower left hand and right-hand corners of the rear bulkhead as the bodywork is lifted.

Remove the two bolts securing the air conditioning receiver drier to the rear bulkhead and secure the receiver drier to the chassis or engine. DO NOT release the air conditioning hoses at the receiver drier.

B - 54

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B - 54

Section B - Body & Framework Bodywork Removal and Replacement of the Rear Bodywork

Replacement Replacement is the reverse of the removal procedure, however note the following:

Remember to feed the two fan hydraulic hoses and the transmission hose up through the apertures in the lower corners of the rear bulkhead as the bodywork is lowered into place.

A C021260

Fig 58. 30

Remove the four bolts 59A (two each side) securing the bodywork to the front bulkhead supports. (The upper bolt each side is adjacent to the cab mounting.)

INT-3-1-10_3

All hydraulic hose sealing O-rings must be replaced. Do not over tighten the Allen bolts 60A securing the hose flanges to the cooling pack. See K Table 2. Torque Settings ( T B-56).

Top up all fluids as necessary using the correct grade of fluid for each system. Refer to Section 3 - Routine Maintenance.

!MWARNING

Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze. 7-3-4-4_1

The correct concentration of coolant antifreeze is to be added to the cooling system. A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolants boiling point.

To provide sufficient corrosion protection, Supplemental Coolant Additive (SCA) must be added to the coolant mixture. The coolant filter provides the required amount of SCA, provided it is replaced at regular intervals. If the drained coolant is to be reused then no action need be taken other than renewing the coolant filter at its scheduled time. If however the coolant is to be replaced with a fresh coolant mixture, it is advisable to renew the coolant filter

C021310

Fig 59. 31

Using the overhead crane and, whilst checking for unreleased connections, slowly lift the complete rear bodywork section from the machine. Once clear of the machine lower the bodywork section to the ground and secure.

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Section B - Body & Framework Bodywork Removal and Replacement of the Rear Bodywork Note: It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate is any higher than this there is a possibility of air becoming trapped in the system. 6

When refitting the batteries, make sure they are connected in the correct manner by connecting the earth lead last.

Item

Table 2. Torque Settings Nm kgf m

lbf ft

2.5

Coolant drain plug

5.6

(1)

(1) Allen Bolt

Fig 60.

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Section B - Body & Framework

Cooling Pack System Introduction The 434S cooling pack has individual sections for Charge Air Cooling, Engine Coolant, Transmission Fluid and Hydraulic Oil Cooling, though only the engine cooling fan is piped into the hydraulic oil cooler.

The pack sections are positioned vertically. When viewed from the rear of the machine the sections from left to right are, Charge Air Cooling, Transmission Fluid Cooling, Engine Coolant Radiator and Hydraulic oil cooler. The sections can be replaced individually by unbolting them from their top and bottom mounting plates although, in order for a section to be replaced, the whole cooling pack will need to be removed from the machine.

Removal 1

Remove the rear bodywork as detailed in K Removal and Replacement of the Rear Bodywork ( T B-51).

!MWARNING

C C021340

4-3-4-1_2

Fig 61.

Important: Do not undo the hoses to the air conditioning condenser. If the hoses are of insufficient length to allow the condenser to be safely stowed and must therefore be undone, then the system will need to be discharged by a suitably qualified technician/refrigeration engineer. 2

Lift the condenser forwards away from the cooling pack and place securely inside the chassis.

Release the catch on the left-hand side of the cooling pack holding the air conditioning condenser in the closed position.

Disconnect the lower charge air cooler hose, plug the open port and cap the hose to prevent the ingress of dirt or debris.

Remove the two bolts 61A on the right-hand side of the cooling pack holding the air conditioning condenser 61B to the cooling pack 61C.

Disconnect the hoses to the transmission cooler. Plug the open ports and cap the hoses to prevent fluid loss and the ingress of dirt or debris.

Remove the lower coolant hose being careful to collect any coolant still in the hoses.

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Section B - Body & Framework Cooling Pack System 8

flanges to the cooling pack. See K Table 3. Torque Settings ( T B-58).

Disconnect the hoses to the hydraulic cooler. Plug the open ports and cap the hoses to prevent fluid loss and the ingress of dirt or debris. 2

Note: Do not lift the cooling pack by any points other than the designated lifting eyes, to do so could cause damage to the cooling pack. 9

Attach a suitable sling to the lifting eyes incorporated into the top of the cooling pack and attach to a overhead crane.

Remove the lower cooing pack to chassis mounting bolts.

Take the weight of the cooling pack on the crane. Remove the upper mounting bolts 62A and rubber mountings.

Note: It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate is any higher than this there is a possibility of air becoming trapped in the system.

!MWARNING Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze. 7-3-4-4_1

When refitting the batteries, make sure they are connected in the correct manner by connecting the earth lead last.

Item

Table 3. Torque Settings Nm kgf m

lbf ft

2.5

Coolant drain plug

5.6

(1)

Fig 62. 12

Using the crane slowly lift the cooling pack from the machine and stow safely on the ground.

(1) Allen Bolt

Replacement Replacement is the reverse of removal but note the following: 1

All hydraulic hose sealing O-rings must be replaced. Do not over-tighten the Allen bolts securing the hose

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Section B - Body & Framework Cooling Pack System

Cleaning the Cooling Pack 1

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Open the left rear side engine cover.

Turn the fastener A on the left-hand side of the cooling pack to release the condenser B.

Note: The type of fastener A can vary depending on the machine serial number. 4

Swing the condenser away from the cooling pack.

B Fig 63. 5

Use a soft brush to remove debris from both sides of the cooling pack.

!MWARNING If using compressed air for cleaning down equipment, do so with extreme caution. Take care not to blow debris at yourself or other persons or into machinery. Use eye protection. 2-2-7-24

Use a low-pressure air line (maximum 1 bar/15 psi) to clear debris from the cooling pack fins. Make sure that the air nozzle is at a minimum distance of 300 mm (11.8 in.) away from the cooling pack.

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Section B - Body & Framework Cooling Pack System

Condenser

Removal 1

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

C A

B 2

You must de-gas the AC system before any hoses are removed.

Open both of the rear engine covers.

Important: Always hold the condenser port with one spanner and use another spanner to remove the hose to prevent damage to the condenser. 4

On the right side of the machine, remove the two hoses A. Keep the O-rings.

With help, do the work from both sides of the machine. Support the condenser B.

Remove the four nuts, bolts and washers (x4) C. There are two sets of fixings either side of the condenser B.

Carefully remove the condenser B from its frame D.

A Fig 64.

Installation The installation procedure is the reverse of the removal procedure. â&#x20AC;&#x201C; Replace damaged O-rings. â&#x20AC;&#x201C; Re-charge the AC system. â&#x20AC;&#x201C; Test the system and check for leaks. Important: Always hold the condenser port with one spanner and use another spanner to remove the hose to prevent damage to the condenser.

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Section B - Body & Framework

Centre Pivot Removal and Installation Removal

Fig 65. Note: Make the machine safe. Refer to Prepare the

B - 61

Machine for Maintenance, Routine Maintenance.

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Section B - Body & Framework Centre Pivot Removal and Installation

Installation

Securely block all of the wheels on both sides.

Remove the cab. Installation ( T B-61).

Remove the pin from each steering ram rod end. Move the steering rams away from the front chassis.

Disconnect the driveshaft at the brake disc flange. Mark all four flanges to make sure they are assembled correctly.

Separate the two halves of the hydraulic pipe clamp to release the hydraulic pipe work.

K Removal

and

Note: There must be sufficient slack in the hydraulic pipework to separate the front and rear chassis without disconnecting the pipework. Be careful when you separate the chassis, do not put too much strain on the hydraulic pipework. 6

Use suitable blocks to support the rear chassis at front and rear.

Put a piece of timber between the contact points, then put a trolley jack under the lower pivot flange of the front chassis.

Remove the lower pivot-pin: a

Fig 66. Install new bearings 18 during the assembly procedure. To get the correct clearance, set up the shims 9 to 14 with a dummy boss and a bearing locator, see K Numerical List ( T 1-15):

Remove the screw 3, washer 4 and spacer 31. 1

Grease the face of the bottom end cap 5. Attach the bottom bearing cup to the housing and secure with the bolts 23 and washer 24. Torque tighten the bolt.

Pack the bottom bearing with grease and install into the new bearing cup.

b Remove the pivot-pin 2. Keep the shims 30 and bearing 20. Discard the seals 6. 9

Remove the upper pivot: a

Remove the split pin 22 and castellated nut 21 then remove the bolt 17 and washers 28.

Note: Make sure that the bearing is completely filled with grease.

b Remove the bolts 23 and washers 24, then remove the end caps 5.

Put the dummy boss A into the bottom bearing.

Put the top bearing on top of the dummy boss A. Hold the top bearing, then turn the dummy boss three or four times to seat the rollers.

d Remove and discard the bearings 18. Remove and discard the lip seals 7.

Put the bearing locator B into the top bearing.

Remove the blocks from under the front wheels.

Measure the gap d between the top of the bearing locator B and the face X.

Release the park brake and manually separate the front and rear chassis sufficiently to do work to on the centre pivot.

Add the dimension d to the dimension t which is stamped on the front module. This dimension (d + t) is equal to the shims required to give the correct clearance.

Remove the pivot-pin 1. Keep the shims 9 to 14 and washers 26.

Note: If there is no dimension t stamped on the front module, use zero as the dimension t.

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Section B - Body & Framework Centre Pivot Removal and Installation 8

Select the shims from the table which correspond to the dimension (d + t), then insert below the bearing locator B.

The bearing locator should be above the face X equivalent to the dimension t +/-0.025mm.

Remove the bearing locator B, shim pack, top bearing and dummy boss A.

Install the new lip seals 7 over the large diameter portion of the rear module pivot boss, or rolled inside out to protect the seal lips during chassis mating.

Put the top bearing cone on the pivot-pin 1 to the dimension Y (178 mm) as shown.

Smear locking fluid onto the top portion of the pivotpin 1 and assemble through the housing and boss.

Pack the top bearing with grease and install the bearing cup.

Note: Make sure that the bearing is completely filled with grease. 19

Install the shim pack and washer 26.

Grease the face of the top end cap 5, then secure with the washers 24 and bolt 23. Torque tighten the bolt.

Install the bolt 17, washers 28 and castellated nut 21. Torque tighten the nut, then install a new split pin 22.

Note: If necessary, the castellated nut can be further tightened until the next castellation aligns with the split pin drilling in the bolt. 22

Put the lip seals 7 into position.

Insert grease through each of the nipples until it comes through the lip seals.

The remainder of the procedure is a reversal of the removal procedure. Table 4. Torque Settings

kgf m

lbf ft

244

24.9

180

6.9

244

24.9

180

Shim

Table 5. Shim Information Part No. Nominal Thickness mm (in)

819/00106

1.0

(0.039)

Smear the bottom portion of the rear module pivot bore with locking fluid.

819/00107

0.25

(0.010)

819/00108

0.15

(0.006)

Remove the bottom end cap 5, install the washer 26 and replace the bottom end cap. Torque tighten the screw 23.

819/00109

0.6

(0.024)

819/00110

0.9

(0.035)

819/00111

0.7

(0.028)

Fig 67. 13

Item

Carefully connect the front and rear chassis.

Assemble the lower pivot-pin 2 with the shims 30, bearing 20 and new seals 6. Secure with the spacer 31, washer 4 and screw 3. Torque tighten the screw.

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Section B - Body & Framework Centre Pivot Removal and Installation Table 6. Shim Requirements Dimension (d + t) Shims mm (in) 0.83 - 0.87 (0.033 - 0.034)

D+B

0.88 - 0.92 (0.035 - 0.036)

0.93 - 0.97 (0.037 - 0.038)

F+B

0.98 - 1.02 (0.039 - 0.040)

1.03 - 1.07 (0.040 - 0.042)

E+C

1.08 - 1.12 (0.042 - 0.044)

D+2xB

1.13 - 1.17 (0.044 - 0.046)

A+C

1.18 - 1.22 (0.046 - 0.048)

2xD

1.23 - 1.27 (0.048 - 0.050)

A+B

1.28 - 1.32 (0.050 - 0.052)

D+F

1.33 - 1.37 (0.052 - 0.054)

2xD+C

1.38 - 1.42 (0.054 - 0.056)

2xF

1.43 - 1.47 (0.056 - 0.058)

F+D+C

1.48 - 1.52 (0.058 - 0.060)

D+E

1.53 - 1.57 (0.060 - 0.062)

2xF+C

1.58 - 1.62 (0.062 - 0.064)

A+D

1.63 - 1.67 (0.064 - 0.066)

D+E+C

1.68 - 1.72 (0.066 - 0.068)

A+F

1.73 - 1.77 (0.068 - 0.070)

E+F+C

1.78 - 1.82 (0.070 - 0.072)

2xE

1.83 - 1.87 (0.072 - 0.074)

B+E+F

1.88 - 1.92 (0.074 - 0.076)

A+E

1.93 - 1.97 (0.076 - 0.078)

A+B+F

1.98 - 2.02 (0.078 - 0.079)

2xA

2.03 - 2.07 (0.080 - 0.081)

A+C+E

2.08 - 2.12 (0.082 - 0.083)

2xD+E

2.13 - 2.17 (0.084 - 0.085)

2xA+C

2.18 - 2.22 (0.086 - 0.087)

D+E+F

2.23 - 2.27 (0.088 - 0.089)

2xA+B

2.28 - 2.32 (0.090 - 0.091)

2xF+E

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Section C Electrics Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

Section C - Electrics

Notes:

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C-0

Section C - Electrics Contents Page No. Technical Data General Electrical Data ........................................................................... C - 1 Service Procedures Using a Multimeter .................................................................................. C - 3 Battery .................................................................................................... C - 7 Alternator .............................................................................................. C - 10 Starter Motor ......................................................................................... C - 13 Wire and Harness Number Identification .............................................. C - 15 Wiring Harness Repair ......................................................................... C - 17 Fault Finding Introduction to Fault - Finding Techniques ............................................ C - 21 Circuit Diagrams 434S ..................................................................................................... C - 25 435S Tier 4 ........................................................................................... C - 50 Harness Data 434S ..................................................................................................... C - 73 435S Tier 4 ......................................................................................... C - 108 Electronic Monitoring System (EMS) - 434S 434S .................................................................................................. C - 113 Electronic Monitoring System (EMS) - 435S 435S ................................................................................................... C - 123

C-i

Section C - Electrics Contents

C - ii

Page No.

C - ii

Section C - Electrics

Technical Data General Electrical Data System Type

24 Volts, negative earth

Battery Cold Crank Amps for 1 minute to 1.4VPCat -18 Â°C (0 Â°F) 410 Amps Reserve Capacity (minutes) for 25 Amp load

180

Alternator

434S - (0120-488-206), 435S - (24V 70A Delco-24SI)

Starter Motor

434S - (42-MT/400), 435S - (24V 4.8kW Denso-PA90S)

Bulbs Bulb

Rating (Watts)

Headlights - main

75 W

Headlights - dip

70 W

Indicators

21 W

Indicator repeater

Instruments

1.2 W

Work lights

70 W Halogen

Number plate light

Tail lights

Front sidelights

Interior lights

10 W

Stop lights

21 W

Beacon

70 W Halogen

Rear fog

21 W

Warning lights

1.2 W

Master Warning Light

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Section C - Electrics Technical Data General Electrical Data Page left intentionally blank

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Section C - Electrics

Service Procedures Using a Multimeter TC-002

In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter. The approach is based on a fault finding check list. In tracing the fault from the symptoms displayed you will be directed to make measurements using a multimeter. These instructions are intended to cover the use of the recommended multimeters.

Fig 2. AVO 2003

Fig 1. FLUKE 85

Fig 3. A Typical Analogue Meter

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Section C - Electrics Service Procedures Using a Multimeter 1

Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a "-", or "E" or marked as "COMMON" or "COM"). The red test lead should be plugged into the red socket marked with "+", "V" or "立". When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease, dirt, and corrosion as these can cause a false reading.

Measuring Resistance 1

Make sure there is no power to the part of the circuit you are about to measure.

Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not matter which way round the two probes are placed.

Select the correct range on the multimeter. a

When measuring voltage: Make sure that the correct range is selected, that is set the selector to a value equal to or greater than that you are about to measure. e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the next range higher, 20V for instance. If the meter is set to a range that is too low, it may be damaged. e.g. setting to the 2V range to measure 12V.

On the FLUKE 85. i

b On the AV0 2003.

Measuring DC Voltage

i 1

Select the correct range on the multimeter. a

Turn the switch to position 1-C and check that the W sign at the right hand side of the display window is on. If the F sign is on instead, press the blue button 1-G to change the reading to 立. Touch the meter lead probes together and press the REL3 key on the meter to eliminate the lead resistance from the meter reading.

On the FLUKE 85. c

Turn the switch to position 1-B.

On an analogue meter. i

b On the AV0 2003.

Move the right hand slider switch to position 2B, and the left hand slider switch to the appropriate Ohms (立) range.

Move the dial to the appropriate Ohms (立) range.

Move the right slider switch to position 2-A, and the left hand slider switch to the appropriate range. c

On an analogue meter. Turn the dial to the appropriate DC Volts range.

Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery negative, or the chassis. Connect the red probe to the wire or contact from which you are measuring the voltage.

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Section C - Electrics Service Procedures Using a Multimeter

Measuring Continuity

Measuring Frequency

Make sure there is no power to the part of the circuit you are checking for continuity.

The AVO 2003 and the analogue meter are not capable of measuring frequency, therefore a Fluke 85 digital multimeter must be used.

Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not matter which way round the two probes are placed.

Insert the black plug into the COM socket on the meter and attach the probe to the nearest suitable earth point on the chassis, for example, the battery negative terminal.

Insert the red probe into socket 1-J.

Turn the selector switch to position 1-A and depress 1-G repeatedly until 1-F is highlighted on the top row of the display.

Press button 1-H once.

Touch or connect the red probe to the frequency source to be measured. Press and hold button if an average reading is required.

Select the correct range on the multimeter. a

On the FLUKE 85. Turn the switch to position 1-C and check that the beeper symbol appears at the left hand side of the display window. If the F sign is on instead, press the button labelled 1-F in the meter drawing. If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.

b On the AV0 2003. Move the right hand slider switch to position 2-B, and the left hand slider switch to position 2-C. If there is continuity (i.e. very low resistance) between two points the buzzer will sound. c

On an analogue meter. Turn the dial to the lowest Ohms (ÎŠ) range. If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.

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Section C - Electrics Service Procedures Using a Multimeter

Testing a Diode or a Diode Wire

A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving. 1

On an analogue meter. i

Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. The meter should read 20-400 kÎŠ, if it reads more than this the diode is faulty.

To test a Diode or a Diode Wire a

On the FLUKE 85. i

Turn the switch to position 1-D.

Press the HOLD button and check that the H sign appears at the top right hand side of the display window.

iii Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty.

Select the Ohms 1000s (1k) range.

Select the Ohms 100s range. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. The meter should read 300-400ÎŠ, if it reads less than this the diode is faulty.

iv Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read O.L., the diode or diode wire is faulty. v

Press the HOLD button and check that the H sign disappears from the right hand side of the display window.

b On the AV0 2003. i

Move the right hand slider to position 2-A, and the left hand slider switch to position 2-C.

iii Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the Avometer does not read "1" the diode is faulty.

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Section C - Electrics Service Procedures Battery

Battery TC-001_5

!MWARNING

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.

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: – Never boost-charge a maintenance free battery (if fitted). – Never charge a battery at a voltage in excess of 15.8 Volts. – Never continue to charge a battery after it begins to gas.

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 personal protective equipment (PPE). 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_2

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 27°C). Ensure that the battery is completely disconnected from the vehicle. Connect up the battery tester as follows:

C-7

Set the CHECK/LOAD switch 4-A to OFF.

Set rocker switch 4-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.

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Section C - Electrics Service Procedures Battery 4

Set the CHECK/LOAD switch 4-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts.

Set the CHECK/LOAD switch 4-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 C-8), if the foregoing tests are unsatisfactory.

Battery Tester Readings 1

Fig 4. 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

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Section C - Electrics Service Procedures Battery

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

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Section C - Electrics Service Procedures Alternator

Alternator TC-006_2

General Description

Charging Circuit Test

The alternator is a three phase generator having a rotating field winding and static power windings.

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.

Adjust the alternator drive belt tension if necessary and make sure that the battery is well charged.

Turn the start switch to the ON position.

When the start switch is turned on, current from the battery flows by way of the 'No Charge' warning light to the field winding. This creates a magnetic field which supplements the residual magnetism in the rotor poles. As the engine is started, the fan belt drives the rotor and alternating current is generated in the power windings as they are cut by the rotating magnetic field. Output is controlled by a solid state regulator which varies the field current in accordance with electrical demand. Servicing is restricted to periodic inspection of slip ring brushes. Bearings are 'sealed for life'.

'Oil pressure' and 'No charge' warning lights should glow. If any light fails, K Check 1 ( T C-10). 4

If the 'No charge' warning light remains ON, K Check 2 ( T C-11).

Service Precautions 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. During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables). If jump starting starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The second battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.

C - 10

Start the engine; all warning lights should extinguish rapidly.

If the oil pressure warning remains on stop engine Immediately and investigate the engine lubrication system.

Check 1 With start switch 'ON' try the heater motor and screen wiper. If they operate normally, check the warning light bulb/LED is not defective. Simultaneous failure of all items indicates a fault at the start switch. Check for cable disconnection before condemning the switch itself. If the 'No charge' warning bulb/LED is in good order, withdraw the triple plug from the back of the alternator. Make a temporary connection between the SMALL terminal in the plug and earth as shown below. If the 'No charge' warning bulb/LED still fails to light, check the cable for continuity. If the bulb/LED now lights, check the alternator for a defective regulator. K Alternator Charging Test ( T C-11).

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Section C - Electrics Service Procedures Alternator

Alternator Charging Test

Fig 5.

Check 2 Note: The following checks should be made using an analogue (moving pointer) type meter. 1

Stop the engine and turn the starter switch to OFF.

Withdraw the alternator plug and connect the test meter between the large terminals and 'earth'. With the meter set to measure 12V DC, the meter should show battery voltage. If the reading is zero, check the cables for continuity, particularly at the starter terminals.

Fig 7. 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 correctly adjusted.

If the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test. Alternatively, operate the starter for a few moments with the engine stop fuse removed (See Fuse Identification).

Install a 100 amp open - type shunt between the battery positive lead and the battery positive terminal.

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.

Fig 6. If the voltage is correct, check the alternator. K Alternator Charging Test ( T C-11).

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Section C - Electrics Service Procedures Alternator AVO 2002

Faults d, e, and f may be checked only by removing and dismantling the alternator for further testing.

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– Red lead to volts (middle) socket on meter. – Black lead to negative on meter. – RH slider to DC voltage. – LH slider. K Fig 7. ( T C-11).

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 Technical Data). Meter should show maximum alternator output in Amps (see Technical Data).

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.

C - 12

Section C - Electrics Service Procedures Starter Motor

Starter Motor TC-005_2

Starting Circuit Test

than 0.5V below the reading obtained in Step 1. Minimum permissible reading in 'start' position 9.0V.

Before carrying out the voltmeter tests, check the battery condition and ensure that all connections are clean and tight.

If the reading is within this limit, continue to Step 3. If the reading is outside the limit, proceed to Step 4 and Step 5.

To prevent the engine starting during the tests ensure that the engine stop fuse is removed, (refer to Fuse Identification page). Check the readings in the following sequence using a voltmeter. Unless otherwise stated, the readings must be taken with the starter switch held in the 'start' position and the transmission forward/reverse selector in neutral. Note: Do not operate the starter motor for more than 20 seconds at one time. Let the starter motor cool for at least two minutes between starts. 1

Connect the voltmeter across the battery terminals. K Fig 8. ( T C-13). Reading in 'start' position: 10.0V approximately. Minimum permissible reading in 'start' position 9.5V.

Fig 9. 3

A low reading probably indicates a fault in the starter motor.

Connect the voltmeter between the solenoid terminal 10-C and a good earth. Minimum permissible reading in 'start' position: 8.0V.

Fig 10.

Fig 8. 2

Connect the voltmeter between the starter main terminal 9-A and the commutator end bracket 9-B. In the 'start' position, the reading should not be more

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9803/9420

If the reading is less than specified, connect the voltmeter between the neutral start relay terminal 11-D and earth. An increase in reading to 8.0V indicates a fault in the wiring from the start relay to the solenoid.

C - 13

Section C - Electrics Service Procedures Starter Motor b If the reading between terminal 11-D and earth is below 8.0V, connect the voltmeter between terminal 11-E and earth. An increase in the reading to 8.0V indicates either a faulty start relay or a fault in the feed from the transmission selector switch to the relay solenoid. Check also the solenoid earth connection.

Connect the voltmeter between battery positive and the starter main terminal 13-A. With the starter switch 'off', the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to the 'on' position, maximum permissible reading 0.25V.

If the reading between 11-E and earth is less than 8.0V, the fault must be in either the starter switch or in the wiring between the solenoid, starter switch, and the start relay.

Fig 13. If the reading is above 0.25V, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive and solenoid connection 14-H. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.

Fig 11. 4

Connect the voltmeter between battery negative and starter earth connection 12-B. The reading in the 'start' position should be practically zero, maximum permissible reading 0.25V. If the reading is above 0.25V, a high resistance in the earth lead or connections is indicated.

Fig 14. 6

Finally refit the engine stop fuse.

Fig 12.

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C - 14

Section C - Electrics Service Procedures Wire and Harness Number Identification

Wire and Harness Number Identification TC-003_2

Introduction This section details the allocation of wire numbers and the identification of wires in the wiring harness.

Fig 15. Typical Wire and Harness Number K Fig 15. ( T C-15). The illustration shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it's length.

The number stamped on the wire identifies the following:

Table 3. Wire and Harness Number Identification Ident. No.

Description

The # indicates the start of the identification number. It is always printed to the left of the identification number.

If applicable - The colour of the flying lead that the harness wire should mate with. For instance, if wire 819 from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed on the wire would be B-819 9/371.

819

The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. K Wire Numbers and Functions ( T C-16).

9/371

If applicable - The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).

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Section C - Electrics Service Procedures Wire and Harness Number Identification

Wire Numbers and Functions

Wires 800-999

Wires 000-199

These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc.

These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:

Wires In Splices

– Wires 000 - 099 are allocated to unfused ignition feeds. – Wires 100 - 199 are allocated to fused ignition feeds. Note: Feeds via ignition relays are classed as ignition feeds.

The main input wire is allocated with a wire number and a suitable description, i.e. Wire 640 earth splice to earth. The additional wires in the splice are allocated the same wire number and a postfix, i.e. 640A, 640B, etc. K Fig 17. ( T C-16). Note: The letters I, O, Q and S are not used.

Wires 200-399 These numbers are reserved for battery feeds, They can be further categorised by: – Wires 200 - 299 are allocated to unfused battery feeds. – Wires 300 - 399 are allocated to fused battery feeds.

Wires 400-599 These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems. Fig 17.

Wires 600-799 General Points These numbers are used for earth wires. When the number is printed onto a wire A it is prefixed by the Earth symbol B. K Fig 16. ( T C-16). This symbol is printed onto the wire, it may however be omitted from harness drawings.

Wires continue to have the same number even after passing through a connector block to another harness.

If all the numbers in a category have been allocated, then the category is re-used with an additional prefix '1', i.e. 1832.

Fig 16. Where a load is switched negative, the wire number from the load to the switch shall be different to that of the wire from the switch to the earth.

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Section C - Electrics Service Procedures Wiring Harness Repair

Wiring Harness Repair TC-004

!MCAUTION

Introduction Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness. This will also apply to other machines in addition to those of manufacture.

When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not touch the reflector until it has had time to cool down after switching off. If flame reappears at the reflector when the heater is in use, the catalytic element is damaged or used up. Stop work immediately and replace the heater.

To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used. Note that JCB harnesses have an International Protection rating of 67 (I.P.67).

ELEC-2-3

The sheath covering of the recommended splice is heat shrunk onto the original wire insulation. This results in a seal and corresponding joint to IP 67 specifications.

!MCAUTION When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular circuit. It is unacceptable to simply increase the fuse rating as this can cause overloading and consequential failure of wiring, along with failure of integral circuit components, which the fuse is protecting.

Repair Procedure Part No.

Table 4. Tools Required Description

892/00350

Butane Heater assembly

892/00349

Crimp tool

892/00351

Splice 0.5-1.5 mm (Red)

892/00352

Splice 1.5-2.5 mm (Blue)

892/00353

Splice 3.0-6.0 mm (Yellow)

Qty

Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in K Table 4. ( T C-17), the dimension is 7mm.

ELEC-2-1

!MWARNING In addition to the warnings incorporated into this procedure, extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair, i.e. other wires, floor panels, floor mats, sound proofing, paintwork, etc. This tool should not be used in any restricted location prohibiting the use of "Naked Flames" or where risk of explosive gas or similar safety parameters apply. No other heat source should be used to attempt a sealed joint.

Fig 18.

ELEC-2-2

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Using the correct sized splice, attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool. K Fig 18. ( T C-17). Note that each of the splices detailed is colour-coded to make size and range

C - 17

Section C - Electrics Service Procedures Wiring Harness Repair readily visible. They are secured using the corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size. 3

With the Butane heater assembly, connection. K Fig 19. ( T C-18). a

seal

the

Remove the cap 20-A from the end of the disposable gas cartridge 20-B.

Fig 21. d Turn the small ring 22-E so that the air holes at 22F are completely closed. Fig 19. b Before assembling the gas cartridge to the reflector element 21-C, turn the red ring 21-D to the left, (in the direction of the minus sign marked on the ring).

Fig 22. e Fig 20. c

C - 18

Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together. K Fig 21. ( T C-18). A click will be heard.

Turn the red ring 23-D to the right (in the direction of the plus sign) in order to turn on the gas.

Important: Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartridge is held in the hand for a long time. The temperature difference between the cartridge and the reflector element may cause long yellow flames to appear on ignition.

9803/9420

C - 18

Section C - Electrics Service Procedures Wiring Harness Repair i

Side wings 25-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).

Fig 23. f

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Fig 25. Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red. Then turn the small ring 24-E until the air holes at 24-F are completely open. The tool is ready for use.

Side wings 26-G up, reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices).

Note: The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty. No sound will be heard even when the cartridge is full.

Fig 26. h To switch off the heater, turn the red ring 26-D to the left (in the direction of the minus sign). Fig 24. g The heater can be used in two modes:

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Section C - Electrics Service Procedures Wiring Harness Repair Page left intentionally blank

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Section C - Electrics

Fault Finding Introduction to Fault - Finding Techniques The fault-finding procedures detailed in this manual rely on the correct use of a Fluke 85 digital multimeter for measuring voltage, current, continuity and frequency. Instructions on the use of this meter are provided on K Using a Multimeter ( T C-3) to K Measuring Frequency ( T C-5) to enable the technician to use the fault-finding tables to maximum effect. Fault diagnosis could involve the measurement of continuity between certain points in a circuit. Whilst the location of these points may look straightforward on the schematic diagram, the reality is somewhat different. The wiring in your machine is not laid out as shown in the schematic diagram. For a variety of reasons associated with safety, reliability, ease of manufacturing and servicing, the wires are shielded for most of their length, by a woven sleeve from which groups of wires (splices) protrude in no apparent order. The sleeve or harness is tucked into inaccessible parts of the machine and generally speaking, tracing a wire from source to destination can prove rather difficult.

Harness Routing As a major aid to fault-finding we have detailed the point to point wiring throughout the machine. The machines have individual harnesses as follows: 1

front chassis harness

rear chassis harness

side console harness

rear cab harness

cab roof harness

controller harness

rear grille harness

hydraulic mode harness

under bonnet light

Their approximate locations are shown in K Harnesses: ( T C-73). Each harness has a number of associated connectors which connect to specific machine functions within the harness area, such as brake light, rear wipe etc. on the rear cab harness. Some signals may need to be routed to functions in other parts of the machine, for instance the side light switch wire (803) in the cab must be routed to the sidelights via the rear chassis harness and the front chassis harness. This necessitates inter-harness connections and these are identified in the diagram as TE/ RK, FF/RA etc. Fig 27. Schematic Diagram

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Section C - Electrics Fault Finding Introduction to Fault - Finding Techniques

Fig 28. Wiring Harness

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Section C - Electrics Fault Finding

Fig 29.

Introduction to Fault - Finding Techniques

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Section C - Electrics Fault Finding Introduction to Fault - Finding Techniques

Example of Wire Tracing This section contains information for each harness in the form of a diagram showing the actual wire harness and tables detailing the harness connections and wire identification. The diagram shows how wiring can be traced from point to point using the harness information. With the knowledge gained from this worked example it should be straightforward to trace any wire through the machine. Two way connector FE is connected to the front washer motor. Wire 819 is the live wire and 600 AG, the chassis connection. (All 600 series wires are chassis wires). The FE table states that the destination of FE 1 is FH 4. FH 4 is the interface connector between the rear cab harness and the rear chassis harness (K Fig 78. ( T C-107)). Wire 819 is routed from RF 4 to RK 10, which is a 31-way interface connector. It links the rear chassis harness to the side console harness via connector TE 10 to column switch connector SD 2. In this way the column switch in the cab is able to control the washer motor. Using the wiring information for the five harnesses all wires can be traced from source to destination. It should be noted, however, that, unlike in the example, some wires undergo a number change particularly when switched through a relay. Connectors are identified by a two letter code, eg. FE. Splices are also identified by a two letter code of which the first letter is always S, eg SA. On the Side Console Harness, (K Fig 58. ( T C-84) to K Fig 59. ( T C-86)), there are also connectors whose codes start with S. Splices are identified on the page by showing them in a dotted line box.

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C - 24

Section C - Electrics Circuit Diagrams 434S

Circuit Diagrams 434S The basic circuit shows a `standard' machine. Connection: Table 5. Main Components K Fig 30. ( T C-27) 1

Battery isolator

Battery

Start relay

Starter motor

Ignition switch

Alternator

Grid heater relay

HVAC(1) relay

Ignition relay 1

Front work lights relay

Lighting relay

Ignition relay 2

Ignition relay 3

(1) Heating Ventilation Air Conditioning Table 6. Primary Fuses K Fig 30. ( T C-27) PF1

Ignition relay 1/front work light circuits

PF2

Hazard indicators, beacon, Interior light, radio (24v), head light flash

PF3

Ignition/starter circuits

PF4

Grid heater relay

PF5

Lighting

PF6

HVAC circuit

PF7

Right and left hand sidelights, heated rear screen, Battery feed for EMS and ZF computer.

Table 7. Refer to:

K Fig 31. ( T C-29)

K Fig 38. ( T C-43)

K Fig 31. ( T C-29)

K Fig 30. ( T C-27)

K Fig 31. ( T C-29)

K Fig 38. ( T C-43)

K Fig 36. ( T C-39)

K Fig 39. ( T C-45)

K Fig 42. ( T C-49)

C10

K Fig 33. ( T C-33)

C11

K Fig 41. ( T C-48)

C12

K Fig 34. ( T C-35)

C13

K Fig 34. ( T C-35)

C14

K Fig 36. ( T C-39)

C15

K Fig 36. ( T C-39)

C16

K Fig 31. ( T C-29)

C17

K Fig 32. ( T C-31)

C18

K Fig 37. ( T C-41)

C19

K Fig 38. ( T C-43)

C20

K Fig 38. ( T C-43)

C21

K Fig 36. ( T C-39)

C22

K Fig 41. ( T C-48)

C23

K Fig 35. ( T C-37)

C24

K Fig 35. ( T C-37)

C25

K Fig 38. ( T C-43)

C26

K Fig 41. ( T C-48)

C27

K Fig 35. ( T C-37)

C28

K Fig 35. ( T C-37)

PF8

Engine ECU

C29

K Fig 36. ( T C-39)

PF9

Emergency steering circuit

C30

K Fig 41. ( T C-48)

C31

K Fig 37. ( T C-41)

C32

K Fig 40. ( T C-47)

PF10 Engine grid heater circuit

C - 25

9803/9420-3

C - 25

Section C - Electrics Circuit Diagrams 434S Connection:

Refer to:

C33

K Fig 34. ( T C-35)

C34

K Fig 34. ( T C-35)

C35

K Fig 41. ( T C-48)

C36

K Fig 36. ( T C-39)

C37

K Fig 35. ( T C-37)

C38

K Fig 37. ( T C-41)

C39

K Fig 36. ( T C-39)

C40

K Fig 37. ( T C-41)

C41

K Fig 38. ( T C-43)

C42

K Fig 36. ( T C-39)

C43

K Fig 39. ( T C-45)

C44

K Fig 41. ( T C-48)

C45

K Fig 36. ( T C-39)

C46

K Fig 34. ( T C-35)

C47

K Fig 31. ( T C-29)

C48

K Fig 32. ( T C-31)

C49

K Fig 33. ( T C-33)

C - 26

9803/9420-3

C - 26

C - 27

9803/9420-3 C47

C45

C39

C37

C25

C48

C46

C38

C36

C15

C14

C78

C49

C35

C26

Fig 30. Primary Fuses, Ignition Switch and Relays: Sheet 1 of 13

For key to connecting circuits K Table 7. ( T C-25)

For component key K Table 5. ( T C-25).

C31 C33

C11

C24

C23

C34

C32

C44

C30

C22

C13

C12

C10

6 C5

C43

C41

C29

C28

C27

C21

C20

C19

C18

C17

C16

C42

C40

Section C - Electrics Circuit Diagrams 434S

C - 27

C - 28

9803/9420-3

K Fig 41. ( T C-48)

K Fig 38. ( T C-43)

K Fig 42. ( T C-49)

C53

C54

C55

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

C52

C57

K Fig 39. ( T C-45)

C51

K Fig 41. ( T C-48)

C50

C56

Table 9. Refer to:

Connection:

Note: All the items listed here are not necessarily fitted to all machines in the range.

b Water temperature sender (Tier II Engine only)

a Fuel level sensor

EMS Connector B

CAN Terminating resistor

Vari-flow fan solenoid

CAN J1939 Connector

EMS Diagnostic port

j Charge air cooler temperature switch

h Hydraulic oil temperature switch

g Air filter blocked switch

f Engine oil pressure switch

e Steer pressure switch

d Brake pressure switch (engine mounted)

c Brake pressure switch

b Emergency steer switch

a Buzzer

EMS Connector A

Table 8. Main Components K Fig 31. ( T C-29)

CB3

CB2

CB1

C68

C67

C66

C65

C64

C63

C62

C61

C60

K Fig 32. ( T C-31)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

K Fig 38. ( T C-43)

K Fig 42. ( T C-49)

C58 C59

Refer to:

Connection:

Section C - Electrics Circuit Diagrams 434S

C - 28

C - 29

9803/9420-3

CB2 CB3

CB1

For key to connecting circuits K Table 9. ( T C-28).

For component key K Table 8. ( T C-28).

C16

C47

C66

C65

C118

C144

C146

C128

C90

C127

C131

C62

C61

C60

C54

C170

C74

C72

C88

Fig 31. Instrumentation - EMS display, Sheet 2 of 13

C51

14 C50

C68

C67

C64

C63

C59

C58

C57

C56

C55

C53

C52

Section C - Electrics Circuit Diagrams 434S

C - 29

C - 30

Left hand column switch

Joystick

SRS(1) Solenoid

SRS Switch

Auto/manual ON/OFF switch

Dump switch

E-stop type switch (456 only)

ZF Computer

9803/9420-3

Table 11. Refer to:

K Fig 42. ( T C-49)

K Fig 36. ( T C-39)

K Fig 31. ( T C-29)

K Fig 41. ( T C-48)

K Fig 31. ( T C-29)

K Fig 41. ( T C-48)

Connection:

C69

C70

C71

C72

C73

C74

C75

C76

(1) Smooth Ride System

g Torque converter out temperature sensor

f Gearbox controller

e Hand brake solenoid

d Engine speed sensor

c Turbine speed sensor

b Internal gear chain speed sensor

a Diagnostic port

Handbrake lever switch

a Transmission disconnect pressure switches

Speed sensor

Table 10. Main Components K Fig 32. ( T C-31)

CB3a

CB2a K Fig 33. ( T C-33)

K Fig 33. ( T C-33)

K Fig 41. ( T C-48)

C77 CB1a

Refer to:

Connection:

Section C - Electrics Circuit Diagrams 434S

C - 30

C - 31

9803/9420-3

CB1a CB2b CB3c

CB3

C77

CB2

C74

C72

C70

C69

CB1

Fig 32. ZF Computer and Gearbox Controller, Sheet 3 of 13

C76

C75

C73

C140

For key to connecting circuits K Table 11. ( T C-30).

C71

For component key K Table 10. ( T C-30).

C119

C121

C120

C17

C48

Section C - Electrics Circuit Diagrams 434S

C - 31

C - 32

9803/9420-3

K Fig 42. ( T C-49)

K Fig 30. ( T C-27)

C78

C79

Table 13. Refer to:

CAN Terminating resistor

Connection:

Engine ECU power connector

t Injector 6

s Injector 5

r Injector 4

q Injector 3

p Injector 2

n Injector 1

m CAN bus data link

l Fuel pump actuator

k Engine oil pressure switch

j Fuel lift pump

h Engine coolant temperature sensor

g Barometric

f Engine oil pressure sensor

e Intake manifold pressure/air temperature sensor

d Water in fuel sensor (WIF)

c Fuel rail pressure sensor

b Camshaft position sensor

a Crankshaft speed sensor

Engine ECU J1 connector

Engine ECU connector (Engine harness)

a Coolant level sense resistor

Electronic foot throttle

Table 12. Main Components K Fig 33. ( T C-33)

Section C - Electrics Circuit Diagrams 434S

C - 32

C - 33

9803/9420-3

C159

For key to connecting circuits K Table 13. ( T C-32).

For component key K Table 12. ( T C-32).

CB2a CB3a

CB1a

C79

C49

C10

C78

Fig 33. Tier 3 Engine ECU, Sheet 4 of 13

31 32

Section C - Electrics Circuit Diagrams 434S

C - 33

C - 34

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

K Fig 31. ( T C-29)

C82

C83

C84

C85

C86

C87

C88

Compressor clutch

C81

Hi/low binary switch

K Fig 41. ( T C-48)

Air conditioning switch

C80

Air conditioning relay

Table 15. Refer to:

HVAC Unit

Connection:

Heater motor switch

Wash/wipe switch

Rear wiper motor

Horn

Rear washer motor

Front washer motor

Wiper motor

Right hand column switch

Table 14. Main Components K Fig 34. ( T C-35)

Section C - Electrics Circuit Diagrams 434S

9803/9420-3

C - 34

C - 35

9803/9420-3

C112

C84

Fig 34. Front Wiper, Rear Wiper and Heater/AC, Sheet 5 of 13

For key to connecting circuits K Table 15. ( T C-34).

For component key K Table 14. ( T C-34).

C46

C13

C12

C33

C34

C87

C86

C85

C83

C82

C81

C80

C88

Section C - Electrics Circuit Diagrams 434S

C - 35

C - 36

Left hand rear work light

Right hand rear work light

Left hand rear auxiliary work light

Right hand rear auxiliary work light

Left hand rear auxiliary work light (bonnet)

Right hand rear auxiliary work light (bonnet)

Beacon switch

9803/9420-3

K Fig 41. ( T C-48)

K Fig 38. ( T C-43)

K Fig 41. ( T C-48)

C92

C93

C94

C95

C96

C97

C98

K Fig 41. ( T C-48)

K Fig 36. ( T C-39)

C91

K Fig 41. ( T C-48)

K Fig 31. ( T C-29)

C90

C100

K Fig 41. ( T C-48)

C89

C99

Table 17. Refer to:

Connection:

Interior light left hand

Rear work light switch

Right hand front auxiliary work light

Interior light right hand

Left hand front auxiliary work light

Beacon

Right hand front work light

Left hand front work light

Front work light switch

Table 16. Main Components K Fig 35. ( T C-37)

C108

C107

C106

C105

C104

C103

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

C101 C102

Refer to:

Connection:

Section C - Electrics Circuit Diagrams 434S

C - 36

C - 37

9803/9420-3

C95

C94

Fig 35. Front and Rear Beacons, Auxiliary Work Lights, Sheet 6 of 13

For key to connecting circuits K Table 17. ( T C-36).

For component key K Table 16. ( T C-36).

C37

C25

C27

C117

C24

C23

C91

C90

C108

C107

C106

C105

C104

C103

C102

C101

C100

C99

C98

C97

C96

C93

C92

C89

Section C - Electrics Circuit Diagrams 434S

C - 37

C - 38

hazard switch

Flasher unit

Right hand column switch

9803/9420-3

C150

C146 C147

K Fig 37. ( T C-41)

K Fig 40. ( T C-47)

K Fig 38. ( T C-43)

C114

C115

C116 C149

C145

K Fig 37. ( T C-41)

C113

K Fig 31. ( T C-29)

C144

K Fig 34. ( T C-35)

C112

C118

C143

K Fig 37. ( T C-41)

C111

K Fig 35. ( T C-37)

K Fig 31. ( T C-29)

C142

K Fig 39. ( T C-45)

C110

C117

K Fig 42. ( T C-49)

C141

K Fig 41. ( T C-48)

C109

C148

K Fig 32. ( T C-31)

C140

K Fig 41. ( T C-48)

K Fig 37. ( T C-41)

K Fig 39. ( T C-45)

K Fig 31. ( T C-29)

K Fig 41. ( T C-48)

K Fig 39. ( T C-45)

K Fig 41. ( T C-48)

K Fig 39. ( T C-45)

C139

K Fig 39. ( T C-45)

C138

Connection:

K Fig 42. ( T C-49)

K Fig 37. ( T C-41)

K Fig 39. ( T C-45)

K Fig 42. ( T C-49)

K Fig 39. ( T C-45)

K Fig 31. ( T C-29)

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 31. ( T C-29)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

K Fig 40. ( T C-47)

K Fig 39. ( T C-45)

K Fig 32. ( T C-31)

C137

C136

C135

C134

C133

C132

C131

C130

C129

C128

C127

C126

C125

C124

C123

C122

C121

K Fig 32. ( T C-31)

C119 C120

Connection:

Refer to:

Connection:

Table 19. Refer to:

Left hand number plate light (rear grille)

Left hand rear combination lamp

Reverse alarm

Brake light switch (mainframe)

Reverse relay

Rear fog light switch

Brake light switch

Right hand front headlight

Left hand front headlight

Brake light relay

Right hand column switch

Right hand number plate light (roof)

Right hand combination lamp

Left hand number plate light (roof)

Roadlight switch

Table 18. Main Components K Fig 36. ( T C-39) K Fig 42. ( T C-49)

Refer to:

Section C - Electrics Circuit Diagrams 434S

C - 38

C - 39

9803/9420-3

C42

C21

C39

C71

C148

For key to connecting circuits K Table 19. ( T C-38).

For component key K Table 18. ( T C-38).

C36

C15

C29

C45

C14

C91

C141

C109

C140

C136

C145

C137

C146

C149

C131

C144

C123

C116

C130

C122

C115

C128

C127

C121

C114

Fig 36. Road Lighting, Sheet 7 of 13

C120

C113

C117

C119

C118 C112

C111

C110

C147

C142

C139

C138

C133

C132

C150

C135

C129

C126

C125

C124

C143

C134

Section C - Electrics Circuit Diagrams 434S

C - 39

C - 40

24/12v Dropper

Cigar lighter 12v

radio power 12v

Table 21. Refer to:

K Fig 41. ( T C-48)

K Fig 38. ( T C-43)

K Fig 41. ( T C-48)

Connection:

C151

C152

C153

C154

C155

C156

CCTV Camera

Right hand radio speaker

Left hand radio speaker

Cigar lighter 24v

Radio power 24v

CCTV system

Tow hitch solenoid 2

Tow hitch solenoid 1

Tow hitch switch

Table 20. Main Components K Fig 37. ( T C-41)

Section C - Electrics Circuit Diagrams 434S

9803/9420-3

C - 40

C - 41

9803/9420-3 C114

C136

C152

C111

C154

C156

Fig 37. Radio, Cigar Lighter, CCTV and Tow Hitch, Sheet 8 of 13

For key to connecting circuits K Table 21. ( T C-40).

For component key K Table 20. ( T C-40).

C18

C31

C40

C38

C148

C113

C155

C153

C151

Section C - Electrics Circuit Diagrams 434S

C - 41

C - 42

Heated mirror switch

Left hand heated mirror

Right hand heated mirror

Seat

Heated seat switch

Reverse fan relay

Reverse fan solenoid

Emergency steer test switch

Emergency steer relay 1

100

101

102

103

104

105

106

9803/9420-3

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

C160

C161

C162

K Fig 41. ( T C-48)

K Fig 33. ( T C-33)

C159

K Fig 41. ( T C-48)

C158

C164

K Fig 41. ( T C-48)

C157

C163

Table 23. Refer to:

Connection:

Emergency steer relay 2

ESOS (Tier 2 only)

Emergency steer motor

Shutdown relay

108

Dallas key pad

107

Immobiliser control unit

Table 22. Main Components K Fig 38. ( T C-43)

C172

C171

C170

C169

C168

C167

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 31. ( T C-29)

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

C165 C166

Refer to:

Connection:

Section C - Electrics Circuit Diagrams 434S

C - 42

C - 43

9803/9420-3 C116

C95

C94

C61

C60

C62

105

102

103

106

C170

C166

C163

C168

101

C161

C25

C159

C172

C169

104

107

C158

C157

100

108

C167

C171

C165

C164

C162

C160

For key to connecting circuits K Table 23. ( T C-42).

For component key K Table 22. ( T C-42).

Fig 38. ESOS, Heated Mirrors Heated Seat, Seat Suspension, Reverse Fan and Emergency Steering, Sheet 9 of 13

C19

C41

C20

C152

Section C - Electrics Circuit Diagrams 434S

C - 43

C - 44

Detent (loader valve)

Shovel reset

Reset switch (456 HT only)

119

120

121

9803/9420-3

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

C174

C175

C176

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

C173

K Fig 42. ( T C-49)

K Fig 36. ( T C-39)

C135

C178

K Fig 41. ( T C-48)

C99

C177

Table 25. Refer to:

Connection:

Changeover solenoid

Lift reset

118

126

Weighload/Autolube plug

117

4th Spool change over switch

12v trailer socket plug

116

125

Fog light relay

115

Float detent (loader valve)

Brake light relay

114

124

Right hand tail light relay

113

Detent (loader valve)

Left hand tail light relay

112

Fork reset

Right hand indicator relay

111

123

Left hand indicator relay

110

122

24/12V Dropper

109

Table 24. Main Components K Fig 39. ( T C-45)

C182

C181 K Fig 40. ( T C-47)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

C179 C180

Refer to:

Connection:

Section C - Electrics Circuit Diagrams 434S

C - 44

C - 45

9803/9420-3 125

123

120

118

C51

C139

C133

C142

C132

C147

C138

C182

121

117

114

112

110

115

113

111

Fig 39. 12v Trailer Electrics and Loader Functions, Sheet 10 of 13

C187

C122

C110

For key to connecting circuits K Table 25. ( T C-44).

For component key K Table 24. ( T C-44).

109

126

124

122

119

C135

C181

C180

C179

C178

C177

C176

C99

C175

C174

C173

116

Section C - Electrics Circuit Diagrams 434S

C - 45

C - 46

9803/9420-3

Proportional joystick

ECU4 Indicator

Changeover relay

Resistor

136

137

138

139

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 41. ( T C-48)

K Fig 42. ( T C-49)

K Fig 39. ( T C-45)

K Fig 41. ( T C-48)

C183

C184

C185

C186

C187

C188

Table 27. Refer to:

UCU4 Auxiliary controller

135

Connection:

Diode pack

134

Neutral relay

131

Joystick connection

Servo isolator solenoid

130

3rd Spool recovery switch

Servo isolator switch

129

133

Quick hitch locking solenoid

128

132

Quick hitch isolator switch

127

Table 26. Main Components K Fig 40. ( T C-47)

Section C - Electrics Circuit Diagrams 434S

C - 46

C - 47

9803/9420-3

C188

For key to connecting circuits K Table 27. ( T C-46).

For component key K Table 26. ( T C-46).

C182

C32

C115

C123

135

133

139

130

C185

128

C183

138

134

C186

C184

Fig 40. Loader Auxiliaries (Proportional), Sheet 11 of 13

137

136

129

127

131

132

Section C - Electrics Circuit Diagrams 434S

C - 47

C - 48 C124

Refer to:

9803/9420-3

C158

C164

C106

C162

C96

C92

C97

C93

C108

C179

C176

C99

C174

C173

C169

Table 28. Refer to: K Fig 41. ( T C-48) K Fig 41. ( T C-48)

Connection: X Y

Connection:

Fig 41. Earthing - Cab Roof and 12v Trailer Electrics, Sheet 12 of 13

C153

C102

C100

C163

C105

C98

C89

C166

C107

C101

C99

C125

C77

C165

C141

C130

K Fig 41. ( T C-48)

C66

C44

C109

C65

C35

C145

C188

C172

C26 C30

C168

C22

C84

C183

C161

C156 C11

C151 C154

C149

C63

C83 C67

C157

C81

C85

C87

C50

C53

C52

C80

C185

C76

C75

C73

C180

Section C - Electrics Circuit Diagrams 434S

C - 48

For connections K Table 28. ( T C-48).

C137

C103

C104

C - 49

9803/9420-3

Fig 42. Earthing - Front Chassis, Rear Chassis and Engine, Sheet 13 of 13

C57

C64

C79

C55

C58

C59

C68

C160

C70

C69

C82

C177

C175

C129

C126

C181

C178

C186

C184

C171

C167

C134

C143

C150

Section C - Electrics Circuit Diagrams 434S

C - 49

C - 50

Mega Fuse 1

Batteries

Battery Isolator

Interposing Start Relay

Starter Lockout Relay

BAT

9803/9420-3

Primary Fuse 1

Primary Fuse 2

Primary Fuse 3

Primary Fuse 4

Primary Fuse 5

Primary Fuse 6

Primary Fuse 7

Alternator

Ignition Relay 3

Starter Motor

Ignition Relay 2

In-Line Fuse

Main Start Relay

Lights Relay

Ignition Relay 1

HVAC Relay

DA,DB Ignition Switch (DA, DB)

Mega Fuse 2

Table 29.

Main Components:

Primary Fuses, Ignition Switch and Ignition Relays

435S Tier 4

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 50

Section C - Electrics Circuit Diagrams

Fig 43. Primary Fuses, Ignition Switch and Ignition Relays

333-R7512-3-1

435S Tier 4

C - 51

9803/9420-3

C - 51

C - 52

Instrument Cluster Connector 2

CAN Connector

Air Filter Blocked Switch

MC Hydraulic Oil Temperature Sender

MD Fuel Level Sender

Instrument Cluster Connector 1

Table 30.

Main Components:

Instrumentation

Section C - Electrics Circuit Diagrams 435S Tier 4

9803/9420-3

C - 52

Section C - Electrics Circuit Diagrams

Fig 44. Instrumentation

333-R7512-3-2

435S Tier 4

C - 53

9803/9420-3

C - 53

C - 54

Left Hand Column Switch FNR, Kickdown, Gearchange

ICCO Switch (On-Off)

ZF Diagnostic Port

Ergo Traction Solenoid

Park Brake Status Pressure Switch

9803/9420-3

Prop Auxiliary - Option

Filter Bypass Pressure Switch

Lockup Clutch Solenoid

Torque Converter Out Temperature Sensor

Gearbox

Internal Gear Chain Speed Sensor

Speed Sensor

Engine Speed Sensor

Multi Lever Switch - Option

Turbine Speed Sensor

F-N-R Switch - Option

Standard Fit

Auxiliary Detent - Option

NM Electrical Detents - Option

NG Arm Position Switch

MG Park Brake Release Solenoid

GR Ergo Traction Relay

Ergo Traction Switch

EW ICCO Diode

Auto/Manual Switch (On-Off)

DW ZF Computer

DM Park Brake Switch

ICCO and Brake Pressure Sensor

Table 31.

Main Components:

ZF Transmission Controller

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 54

Section C - Electrics Circuit Diagrams

Fig 45. ZF Transmission Controller

333-R7512-3-4

435S Tier 4

C - 55

9803/9420-3

C - 55

C - 56

Table 32.

Climate Control Unit

Rear Wiper Motor

Air Conditioning Switch (On-Off)

Horn Relay

9803/9420-3

Rear Washer Motor

Compressor Clutch

NE Horn

Front Washer Motor

FW Climate Control Panel

High/Low Switch (Binary)

Air Conditioning Relay

ED Rear Wash/Wipe Switch

DS Thermostsat

DP HVAC Unit

DN Fan Control Pressure Switch

DG Front Wiper Motor

DE Right Hand Column Switch Wiper/Wash, Horn

DC Heater Motor Switch

Main Components:

Front Wipe, Rear Wipe, Heater Air Conditioning or Climate Control

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 56

Fig 46. Front Wipe, Rear Wipe, Heater/AC or Climate Control

333-R7512-3-6

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 57

9803/9420-3

C - 57

C - 58

Right Hand Auxiliary Work Light (Bonnet)

Left Hand Aux Work Light (Bonnet)

Front and Rear Work Light Switch

Beacon Switch (On-Off)

Left Hand Front Work Light

Right Hand Front Work Light

Left Hand Front Auxiliary Work Light

Right Hand Front Auxiliary Work Light

Left Hand Rear Work Light

Right Hand Rear Work Light

Right Hand Auxiliary Work Light (Roof)

Beacon

Interior Light

RM Left Hand Auxiliary Work Light (Roof)

RWL Relay

FWL Relay

Table 33.

Main Components:

Front and Rear Work Lights and Beacon

Section C - Electrics Circuit Diagrams 435S Tier 4

9803/9420-3

C - 58

Section C - Electrics Circuit Diagrams

Fig 47. Front and Rear Work Lights and Beacon

333-R7512-3-7

435S Tier 4

C - 59

9803/9420-3

C - 59

C - 60

Right Hand Column Switch Main/Dip Only

Brake Light Relay

Fog Light Relay

Right Hand Rear Combination

Left Hand Rear Combination

Right Hand Front Headlamp

Left Hand Front Headlamp

Roadlight Switch (Off-On-On)

Fog Light Switch (On-OFF)

Right Hand Number Plate Light (Roof)

Left Hand Number Plate Light (Roof)

GPA Reverse Relay

Reverse Alarm

Left Hand Number Plate Light

Flasher Unit

Fog Light Relay Diode

Work Light Diode

DEA Right Hand Column Switch Indicators Only

Hazard Switch

Table 34.

Main Components:

Roadlights

Section C - Electrics Circuit Diagrams 435S Tier 4

9803/9420-3

C - 60

Section C - Electrics Circuit Diagrams

Fig 48. Roadlights

333-R7512-3-8

435S Tier 4

C - 61

9803/9420-3

C - 61

C - 62

TRB Monitor

TRA CCTV Camera

Control Box CCTV Option

Radio Speaker

Radio 12V

Radio 24V

Engine Bay Lamp

Left Hand Speaker

12V Auxiliary Feed

Right Hand Speaker

Power Socket 12V

24/12V Dropper

24V Auxiliary Feed

Power Socket 24V

Table 35.

Main Components:

Radio, Power Socket, Auxiliary Socket, LiveLink and CCTV

Section C - Electrics Circuit Diagrams 435S Tier 4

9803/9420-3

C - 62

Fig 49. Radio, Power Socket, Auxiliary Socket and CCTV

(TR)

C - 63

9803/9420-3

(TRA)

(TRB)

333-R7512-3-9

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 63

C - 64

Bucket/Fork/Changeover Switch

Immobiliser Link Connector

Weighload/Autolube Plug

Bucket Reset

Fork Reset

Secondary Steer Pump

Heated Mirror Switch (On-Off)

Left Hand Heated Mirror

Right Hand Heated Mirror

Heated Seat Switch (On-Off)

MU Secondary Steer Pump Relay

GM Seat

EM Immobiliser Control Unit

Relay Fork

Table 36.

Main Components:

Immobiliser, Heated Mirrors And Seat, Emergency Steer, Autolube, Bucket/Fork

Section C - Electrics Circuit Diagrams 435S Tier 4

9803/9420-3

C - 64

Fig 50. Immobiliser, Heated Mirrors And Seat, Emergency Steer, Autolube, Bucket/Fork

333-R7512-3-10

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 65

9803/9420-3

C - 65

C - 66

Table 37.

Right Hand Indicator Relay

Brake Light Relay

LM Left Hand Tail Light Relay

LK Right Hand Tail Light Relay

LH Fog Light Relay

LG Left Hand Indicator Relay

LF 24/12V Voltage Dropper

LC 12V Trailer Socket Plug

CN CAN Terminating Resistor

Main Components:

Trailer Electrics and CANBUS

Section C - Electrics Circuit Diagrams 435S Tier 4

9803/9420-3

C - 66

Section C - Electrics Circuit Diagrams

Fig 51. Trailer Electrics and CANBUS

333-R7512-3-11

435S Tier 4

C - 67

9803/9420-3

C - 67

C - 68

Table 38.

Temperature/Barometric Sensor Cummins Engine Connector

Engine ECU J2 Connector Engine Harness

Water In Fuel Sensor

Electronic Foot Throttle

Cummins Engine Connector - Water in Fuel

Coolant Level Sensor

DP Filter Temperature

DP Filter Pressure

Engine OEM 24W Connector

9803/9420-3

MR Grid Heater Relay

KR 3-Position After-treatment Switch: UPMomentary, Down-manual Regeneration, Latched-disable Regeneration, Centre- Auto Mode

CAN Terminating Resistor

GX Grid Heater

GF Coolant Level Sensor

Main Components:

Engine ECU

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 68

Section C - Electrics Circuit Diagrams

Fig 52. Engine ECU

333-R7512-3-5

435S Tier 4

C - 69

9803/9420-3

C - 69

Section C - Electrics Circuit Diagrams

Earthing

Fig 53. Earthing

333-R7512-3-12

435S Tier 4

C - 70

9803/9420-3

C - 70

C - 71

Main Pressure Sensor

9803/9420-3

ECU Connector 1

Seat Link

Auxiliary Changeover Solenoid

Servo Isolator Solenoid

ECU Connector 2

4th Spool Solenoid B

Seat Switch

4th Spool Solenoid A

3rd Spool Solenoid B

Quickhitch Unlock Solenoid

3rd Spool Solenoid A

Lift Reset

4th Spool Changeover Switch

Servo Isolator Switch

Brake accumulator Peressure Sensor

Quickhitch Solenoid Switch

Secondary Steer System Valve Pressure Sensor

Secondary Steer System Test Switch

Reverse Fan Solenoid

SRS Switch

Proportional Fan

Lever Detents Enable Switch

ECO Mode Switch

Table 39.

Main Components:

Cummins QSB and QSL T4i

Section C - Electrics Circuit Diagrams 435S Tier 4

C - 71

Section C - Electrics Circuit Diagrams

Fig 54.

333-R7512-3-3

435S Tier 4

C - 72

9803/9420-3

C - 72

Section C - Electrics

Harness Data 434S Harnesses: The harness number refers to and corresponds with the annotations in the schematic drawing. Harness No. 1

Issue Remarks

Drawing

Cab Roof Harness 721/11818

K ( T C-79)

Main components connected to this harness:

Cab harness Front work light switch Rear work light switch Beacon switch Front work lights Front auxiliary work lights Rear work lights Rear auxiliary work lights Beacon socket Interior light Number plate lights Radio power and speakers Heated mirror switch Heated mirrors Earth point

Transmission Harness 721/11826

K ( T C-107)

Main components connected to this harness:

Output speed sensor Turbine speed senor Gear chain speed sensor Engine speed Control unit Cab connector

Engine Harness 721/12214

C - 73

K ( T C-82)

9803/9420-3

C - 73

Section C - Electrics Harness Data 434S Main components connected to this harness:

Torque converter Engine ECU CAN Bus system Steer pressure switch Air conditioning compressor Brake pressure switch Foot throttle

Quickhitch Locking Harness 721/11922

K ( T C-99)

Main components connected to this harness

Front chassis connector Quickhitch solenoid

Front Chassis Harness HT 721/11928

K ( T C-85)

Main components connected to this harness

Front lights Horn Fork reset Lift reset Shovel reset Quickhitch locking Servo isolator Change over Load suspension Main harness connector

Rear Cab Harness 721/11941

K ( T C-103)

Main components connected to this harness

Park brake switch Cab connector Front wash pump Rear wash pump

Proportional Auxiliary Harness 721/11943

K ( T C-101)

Main components connected to this harness

Proportional auxiliary options plug ECU 4

C - 74

9803/9420-3

C - 74

Section C - Electrics Harness Data 434S Recovery switch Joystick ECU 4 indicator Change over/Neutral relay Side console connection Diode pack ECU 4 Diode pack 3rd/4th spool connection 8

3rd/4th Spool Harness 721/11944

K ( T C-105)

Main components connected to this harness

Cab connector 3rd Spool solenoid C1 4th Spool solenoid C2 4th Spool solenoid C3 3rd Spool solenoid C4

3rd Spool Harness 721/11945

K ( T C-104)

Main components connected to this harness

Cab connector 3rd Spool solenoid C1 3rd Spool connector

10 Multi-Lever Harness 721/11967

K ( T C-106)

Main components connected to this harness

Cab harness joystick plug FNR paddle switch Dump/Kickdown switch

11 Rear Chassis Harness 721/12215

K ( T C-87)

Main components connected to this harness

Primary fuses Rear lights Park brake solenoid Cab connectors 1 and 2 Emergency steering relay Grid heater relays

C - 75

9803/9420-3

C - 75

Section C - Electrics Harness Data 434S

12 Rear Grille Harness 721/12218

K ( T C-90)

Main components connected to this harness

Rear chassis connector Auxiliary lighting Reverse alarm Number plate light

13 Cab Harness 721/12117

K ( T C-91)

Main components connected to this harness

Ignition switch Column switch Wiper motor Chassis connector EMS Cab switches Loader control lever Transmission computer Fuse boxes Air conditioning Diagnostic port Heated screen Roadlighting Hazard switch Park brake switch ZF Computer Dallas key pad CCTV Ignition relays

14 CAN Backbone Harness 727/00004

K ( T C-97)

Main components connected to this harness

15 Throttle Link Harness (T3 Only) 721/12119

C - 76

K ( T C-98)

9803/9420-3

C - 76

Section C - Electrics Harness Data 434S Main components connected to this harness

Foot throttle Engine harness

16 Grid Heater Link 718/20291

K ( T C-100)

Main components connected to this harness

Rear Chassis Harness Grid Heater Relay 1 Grid Heater Relay 2

C - 77

9803/9420-3

C - 77

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. To identify the correct harness drawing for a particular machine refer to the relevant Harness Interconnection page for the machine serial number range.

Drawings

Section C - Electrics Harness Data 434S

C - 78

9803/9420-3

C - 78

Heated Seat Switch Earth Point Radio Power 12v Interior Light 2 Interior Light 2

TD TE2 TE3

Key to Connectors:

Cab Connector 1

Cab Connector 2

Front Work Light Switch

Rear Work Light Switch

Beacon Switch

LH Front Work Light

RH Front Work Light

LH Front Auxiliary Work Light

RH Front Auxiliary Work Light

LH Rear Work Light

RH Rear Work Light

C - 79

9803/9420-3

Beacon Socket

Interior Light

RH Number Plate Light

LH Number Plate Light

Radio Power 24v

Radio Speakers

RQ2

RQ3

Heated Mirror Switch

LH Heated Mirror

RH Heated Mirror

RH Speaker

RX2

RH Speaker

RX1

RW2 LH Speaker

RW1 LH Speaker

LH Rear Auxiliary Work Light

RH Rear Auxiliary Work Light

K Fig 55. ( T C-80) and K Fig 56. ( T C-81). TC

Key to Connectors: TB

Cab Roof Harness - 721/11818 Issue 3

Section C - Electrics Harness Data 434S

C - 79

Section C - Electrics Harness Data

Fig 55.

434S

C - 80

9803/9420-3

C - 80

C - 81

9803/9420-3 RG RH Front Worklight (Twin Power)

RF LH Front Worklight (Twin Power)

RE Beacon Switch

RD Rear Worklight Switch

RC Front Worklight switch

RB Cab Harness Conn 2

RA Cab Connector 1

RV Radio Speakers

RU Radio Power 24V

RT LH No Plate Light

RS RH No Plate Light

RQ 3 Interior Light

RQ 2 Interior Light

RP Beacon Socket

RN RH Rear Aux Worklight

RM LH Rear Aux Worklight

RL RH Rear Worklight

RK LH Rear Worklight

RJ RH Front Aux Worklight

RH LH Front Aux Worklight

Fig 56.

TD Radio Power 12V

TC Earth Point

TB Heated Seat Switch

TA RH Heated Mirror

RZ LH Heated Mirror

RY Heated Mirror Switch

RX 2 RH Speaker

RX 1 RH Speaker

RW 2 LH Speaker

RW 1 LH Speaker

S64 Earth Splice 1

S38 Front Worklight

S40 Rear Worklight

S39 Aux Front Worklight

S25 Illumination

S18 Heated Mirrors

S17 Fuse C6

S11 Aux Rear Worklights

TE 3 Interior Light 2

TE 2 Interior Light 2

S86 Fuse B7

S84 No Plate

S65 Earth Splice 2

Section C - Electrics Harness Data 434S

C - 81

C - 82

Earth

Starter Solenoid

Brake Pressure Switch

Foot Throttle

Earth Splice

S69

Alternator

Air Conditioning Compressor

Grid Heater Relay

Air Filter

JU-2

ECM CAN Connector

Steer Pressure Switch

Engine ECM

Grid Heater Relay 1

ECM Power Converter

JU-1

Torque Converter Temperature Sender

Cab Connector

Key to Connectors:

K Fig 57. ( T C-83) and K Fig 58. ( T C-84)

Engine Harness - 721/12214 Issue 1

Section C - Electrics Harness Data 434S

9803/9420-3

C - 82

Section C - Electrics Harness Data

Fig 57.

434S

C - 83

9803/9420-3

C - 83

Section C - Electrics Harness Data

Fig 58.

434S

C - 84

9803/9420-3

C - 84

C - 85

Right Hand Front Lights

Left Hand Front Lights

Shovel Reset

Lift Reset

Horn

Main Harness Connector

Change Over

Quickhitch locking

Load Suspension

Fork reset

Servo Isolator

Key to Connectors:

K Fig 59. ( T C-86)

Front Chassis Harness - 721/11928 Issue 1

Section C - Electrics Harness Data 434S

9803/9420-3

C - 85

Section C - Electrics Harness Data

Fig 59.

434S

C - 86

9803/9420-3

C - 86

C - 87

9803/9420-3

Hydraulic Oil Temperature Switch

Fuel Sender

Right Hand Side Rear Lights

Left Hand Side Rear Lights

Park brake Solenoid

Cab Connector 2

Cab Connector 1

12V Trailer Feed

Emergency Steering Switch

Emergency Steer Relay 1

Emergency Steer Relay 2

Primary Fuses 5 and 7

Primary Fuses 6 and 8

Rear Grille Connector

Grid Heater Relay 1

Binary Switch

Earth

RT-1

RT-2

LH Sidelights

Primary Fuses 2 and 4

Primary Fuses 1 and 3

Key to Connectors:

K Fig 60. ( T C-88) and K Fig 61. ( T C-89)

Rear Chassis Harness - 721/12100 Issue 1

Section C - Electrics Harness Data 434S

C - 87

Section C - Electrics Harness Data

Fig 60. Sheet 1 of 2

434S

C - 88

9803/9420-3

C - 88

Section C - Electrics Harness Data

Fig 61. Sheet 2 of 2

434S

C - 89

9803/9420-3

C - 89

C - 90

Rear Chassis Connector

Right Hand Auxiliary Light

Key to Connectors:

Rear Grille Harness - 721/12218 Issue 1

RE Prop Fan

Fig 62.

Number Plate Light S51

S12 Earth Splice

Aux Light

Reverse Fan

Reverse Alarm

Left hand Auxiliary Light

RC RD

Key to Connectors:

Section C - Electrics Harness Data 434S

9803/9420-3

C - 90

C - 91

EMS

9803/9420-3

Earth Point Front Console

Earth Point Side Console 1

Loader Lever

Air Conditioning Unit

Earth Point Side Console 2

Heater Blower

ZF Computer

Heater Switch

Cab Connection 1

Cab Connection 2

CAN J1939 Connection

Auto/Manual Switch

Dump Switch

Loader Lever

EMS

Front Chassis Connector

Park Brake switch (456 only)

Front Wiper Motor

Left Hand Column Switch

Buzzer 2

Right Hand Column Switch

DL-2

Hazard Switch

Buzzer

Ignition Switch 2

DL-1

Ignition Switch

K Fig 64. ( T C-93), K Fig 66. ( T C-95) and

Key to Connectors:

K Fig 63. ( T C-92), K Fig 65. ( T C-94), K Fig 67. ( T C-96)

Cab Harness - 721/12104 Issue 1

Immobiliser Control Switch

FS-2

FS-1

FP-1

Engine Connector

Rear Cab Connector

SRS Switch

Air Conditioning Shut-Down Relay

4th Spool Switch

Air Conditioning Switch

Rear Wiper Motor

Flasher Unit

Cigar Lighter Illumination

Cigar lighter 24v

Ignition Relay 3

Ignition Relay 2

Start Relay

Diagnostic Port

Lights Relay

FWL relay

Ignition Relay 1

Dump Relay

Fuse Box D

Fuse Box C

Fuse Box B

Fuse Box A

Work Light Diode

CCTV System

Dallas Keypad Earth

Dallas Keypad

Rear Fog Light Switch

EJ EN

Roadlight Switch

EH ZF Diagnostic Plug

ZF CAN Connector

Diagnostic Connector CAN Connector

EMS CAN Connection

Rear Chassis Connector 2

Heated Rear Screen switch

Servo Isolator Switch

Quickhitch Switch

Emergency Steer Test Switch

Heated Screen Relay

Heated Screen Timer

Weigh-Load/Autolube Plug

Shovel Reset Switch

Reset C/O Switch

Reverse Fan and E/Steer Relay

Brake/Reverse Relay

Tow-Hitch Connector

Seat Connector

12v Auxiliary Feed

Cigar Lighter 12v

24/12v Converter

Proportional Auxiliary Connector

GD-2 Heated Rear Screen 2

GD-1 Heated Rear Screen 1

transmission Connector

Rear Chassis Connector 1

Rear Wiper Switch

ED GA

Key to Connectors:

Section C - Electrics Harness Data 434S

C - 91

Section C - Electrics Harness Data

Fig 63. Sheet 1 of 5

434S

C - 92

9803/9420-3

C - 92

Section C - Electrics Harness Data

Fig 64. Sheet 2 of 5

434S

C - 93

9803/9420-3

C - 93

C - 94

9803/9420-3

DG Front Wiper Motor

DF LH Column Switch

DE RH Column Switch

DD Hazard Switch

DB Ignition Switch 2

DA Ignition Switch

DJ EMS

DL 1 Buzzer

DH Front Chassis Connector

DT AC Unit

DS Loader Lever

DR Earth Point Side Console 1

DQ Earth Point Front Console

DP Loader Lever

DM Parkbrake Switch (456)

DL 2 Buzzer 2

DK EMS

Fig 65. Sheet 3 of 5

EA CAN J1939 conn

DZ Cab Conn 2

DY Cab Conn 1

DX Heater Switch

DV Heater Blower

DU Earth Point Side Console 2 DW ZF Computer

EJ Rear Fog Switch

EH Roadlight Switch

ED Rear Wiper Switch

EC Dump Switch

EB Auto Manual Switch

FA Fusebox A

ES Worklight Diode

ER CCTV System

EP Dallas Keypad Earth

EN Dallas Keypad

EM Immobiliser Control Unit

Section C - Electrics Harness Data 434S

C - 94

C - 95

FD Fusebox D

FC Fusebox C

FB Fusebox B

9803/9420-3

FK Start Relay

FJ Diagnostic Port

FH Lights Relay

FG FWL Relay

FF Ignition Relay 1

FE Dump Relay

FS 2 AC Switch

FS 1 AC Switch

FR Rear Wiper Motor

FQ Flasher Unit

FP - 1 Cigar Lighter Illumination

FP Cigar Lighter 24V

FM Ignition Relay 3

FL Ignition Relay 1

Fig 66. Sheet 4 of 5

FX Rear Cab Connector

FV SRS Switch

FU Shutdown AC Relay

FT 4th Spool Switch

FZ Rear Chassis Connector 1

FY Engine Connector

GF Prop Aux Conn

GD - 2 Heated Rear Screen 2

GD - 1 Heated Rear Screen 1

GB ZF Diagnostic Plug

GA Transmission Connector

GR Rev Fan & E/Steer Relay

GP Brake/Reverse Relay

GN Tow Hitch Connector

GM Seat Connector

GK 12V Aux Feed

GJ Cigar Lighter 12V

GG 24/12V Converter

Section C - Electrics Harness Data 434S

C - 95

C - 96

9803/9420-3

HA Emerg Steer Test Switch

GY Heated Screen Relay

GW Heated Screen Timer

GV WeighLoad/Autolube Plug

GT Shovel Reset Link

GS Reset C/O Switch

HE Rear Chassis Connector 2

HD Heated Rear Screen Switch

HC Servo Isolator Switch

HB Quickhitch Switch

S6 Can L

S5 Temp Sensor

S4 ZF (9904)

S3 Trans Disc

S2 LH Column Switch

S1 Fuse D2 (ZF)

S41 Fuse D9

S36 Fuse C4

S35 Front Wash Splice

S34 Fuse C5

S32 Fuse D5

S27 Grid Heater

S26 RH Sidelights

S23 Fuse D4

S21 Primary Fuse 3

Fig 67. Sheet 5 of 5

S20 Lift Reset

S19 Fuse D10

S16 12V Earth

S15 12V Feed

S14 Dip Beam

S10 Parkbrake

S9 ZF Earth

S8 ZF Sen Earth

HG Diagnostic Conn CAN Conn

HH ZF CAN Conn

S7 Parkbrake Solenoid

HF EMS CAN Conn

S59 Fuse C3

S56 B/Press Switch

S55 Emergency Steer

S47 RH Sidelights

S46 LH Sidelights

S43 LH Indicators

S42 RH Indicators

S68 Earth Side Console 1

S67 Earth Side Console 2

S66 Earth Front Console

S62 Fuse B10

S88 Earth

S87 Fuse C7

S85 Worklight

S83 Primary Fuse Splice

S81 Fuse D1

S73 Fuse D8

Section C - Electrics Harness Data 434S

C - 96

C - 97

C001 CAN Backbone End A

Key to Connectors:

CAN Backbone Harness - 727/00004 Issue 1

Fig 68.

C002 CAN Backbone End B

Key to Connectors:

C002 CAN Backbone End B

Section C - Electrics Harness Data 434S

9803/9420-3

C - 97

C - 98

Engine Harness

Key to Connectors:

Throttle Link Harness - 721/12119 - Issue 1 LB

Foot Throttle

Key to Connectors:

Fig 69.

Section C - Electrics Harness Data 434S

9803/9420-3

C - 98

C - 99

AA Front Chassis Connector

Front Chassis Connector

Key to Connectors:

Quickhitch Locking Harness - 721/11922 Issue 1 AB

Fig 70.

Quickhitch Solenoid

Key to Connectors:

AB Quickhitch Solenoid

Section C - Electrics Harness Data 434S

9803/9420-3

C - 99

C - 100

C001

Rear Chassis Harness

Key to Connectors:

Grid Heater Link Harness - 708/20291 Issue 1 C002-2

C002-1

Fig 71.

Grid Heater Relay 2

Grid Heater Relay 1

Key to Connectors:

Section C - Electrics Harness Data 434S

9803/9420-3

C - 100

C - 101

Proportional Auxiliary Options Plug

ECU 4

Recovery Switch

Key to Connectors:

Proportional Auxiliary Harness - 721/11943 Issue 2

Joystick Diode Pack

AF AG AH

Fig 72.

Change Over/Neutral Relay

AE AM

AJ 3rd/4th Spool Connection

Diode Pack ECU 4

Side Console Connection

Resistor

Joystick ECU 4 Indicator

Key to Connectors:

Section C - Electrics Harness Data 434S

9803/9420-3

C - 101

C - 102

9803/9420-3

S92 3rd Spool Earth

AC Recovery Switch

AB ECU4

AA Prop Aux Option Plug

AL Diode Pack ECU4

AJ Side Console Conn

AC Joystick

Fig 73.

AD Joystick

S94 Earth Splice

S91 Changeover

S89 Resistor

S95 Fuse C3

AK Resistor

AF Changeover/Neutral Relay

S52 Neutral Relay

S49 Joystick 3

S31 Joystick 2

S28 Joystick 1

S93 4th Spool Splice

AE ECU4 Indicator

AM 3rd/4th Spool Conn

AH Diode Pack

Section C - Electrics Harness Data 434S

C - 102

C - 103

KA Cab Connector

Cab Connector

Key to Connectors:

Rear Cab Harness - 721/11941 Issue 1

KF Handbrake Switch

9803/9420-3

Fig 74.

S82 Earth splice

Park Brake Switch

Rear Washer Pump

Front Washer Pump

Key to Connectors:

KC Rear Washer Pump

KB Front Washer Pump

Section C - Electrics Harness Data 434S

C - 103

C - 104

BA Cab Connector

Cab Connector

Key to Connectors:

3rd Spool Harness - 721/11945 Issue 1 BC

Fig 75.

3rd Spool Solenoid C4

3rd Spool Solenoid C1

Key to Connectors:

BB 3rd Spool Solenoid C1

BC 3rd Spool Connector C4

Section C - Electrics Harness Data 434S

9803/9420-3

C - 104

C - 105

BA Cab Connector

Cab Connector

Key to Connectors:

3rd/4th Spool Harness - 721/11944 Issue 1

Fig 76.

BB 3rd Spool Solenoid C1

BD 4th Spool Solenoid C2

4th Spool Solenoid C3

4th Spool Solenoid C2

BE 4th Spool Solenoid C3

3rd Spool Solenoid C4

3rd Spool Solenoid C1

BB BC

Key to Connectors:

BC 3rd Spool Solenoid C4

Section C - Electrics Harness Data 434S

9803/9420-3

C - 105

C - 106

C001 Cab Harness Joystick Plug

Key to Connectors:

Multi-Lever Harness - 721/11967 Issue 1

Fig 77.

C003 Dump/Kickdown Switch

C002 FNR Paddle Switch

Key to Connectors:

C003 Dump/Kickdown Switch

C002 FNR Paddle Switch

Section C - Electrics Harness Data 434S

9803/9420-3

C - 106

C - 107

TA Output Speed Sensor

Key to Connectors:

Transmission Harness - 721/11826 - Issue 3

Fig 78.

TD Int. Gear Chain Speed

TF Cab Connector

TE Control Unit

TB Engine Speed TC Turbine Speed

Key to Connectors:

Section C - Electrics Harness Data 434S

9803/9420-3

C - 107

C - 108

Engine ECU

Key to Connectors:

Diesel Particulate Filter Harness 333/S2922 Issue 1 ??? DPF Temperature

Fig 79.

DP Filter Pressure

Key to Connectors:

435S Tier 4

333-S2922-1-1

Section C - Electrics Harness Data 435S Tier 4

9803/9420-3

C - 108

Section C - Electrics Harness Data

Cab Floor Harness 333/V5112 Issue 1

Fig 80.

333-V5112-1-1

435S Tier 4

C - 109

9803/9420-3

C - 109

Section C - Electrics Harness Data

Transmission Harness 332/S5092 Issue 2

Fig 81.

332-S5092-2-1

435S Tier 4

C - 110

9803/9420-3

C - 110

Section C - Electrics Harness Data

Rear Chassis Harness 333/T9751-1 Issue 1

Fig 82.

333-T9751-1-1

435S Tier 4

C - 111

9803/9420-3

C - 111

Section C - Electrics Harness Data

Fig 83.

333-T9751-1-2

435S Tier 4

C - 112

9803/9420-3

C - 112

Section C - Electrics

Electronic Monitoring System (EMS) - 434S 434S General C164 (EMS 728/80077) is the EMS system first introduced in January 2006.

Note: For these diagnostic tools to work correctly, the Data Link Adaptor (892/01174) must be connected (in conjuction with the interrogation lead 71820237) between the Diagnostic Connector and the PC, and the machine's ignition must be turned ON.

EMS Tools Following is an outline of the available software tools and how they are to be used. Service Tools 1

Flash Loader program - to download the latest software files to the EMS (these are called Application files). This can be used by double clicking the icon as shown.

Set-up program - to enter the machine Serial Number, Rolling Radius etc. and Languages. This program can be used by double clicking the icon as shown

Diagnostics program - to help fault find on the machine. This includes information about the Electronic Engine, Transmission and the EMS. This program can be used by double clicking the icon as shown.

Service History program - for checking when the machine was last maintained by a JCB Dealer. This program can be used by double clicking on the icon as shown.

Fig 84. With the introduction of this new type EMS there is a requirement for advanced Standard Software Tools. These tools are available within JCB Servicemaster 2. They will come under the Large Wheeled Loader screen shown: K Fig 85. ( T C-113).

Fig 85.

C - 113

9803/9420

C - 113

Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S Service Tools 5

Data Logger program - this program logs various conditions of the machine before a failure, which will help in the diagnosis of certain problems. This program can be selected by double clicking on the icon as shown.

A B C D

Flash Loader Program

In order to download the latest software, the following has to be done: 1

Connect the DLA (Data Link Adapter), to the 9 Pin Deutsch diagnostic connector in the cab and to the the Interrogation PC. K Connecting Lead ( T C-121).

Turn the ignition to the first position so that the EMS is powered up.

Fig 86.

Double click on the "Flash Loader" icon. K EMS Tools ( T C-113).

The icon 1 will appear as shown as confirmation that the EMS system is communicating with the machine's CAN-Bus network. If the icon is not present, check the power to the DLA and the connections to the PC and cab harness.

This icon is used to download the latest Software to the EMS. This Software is referred to as the "Application code". The icon launches a windows application called the "Flash Downloader". 4

With the mouse, click this icon once. Doing this will fill the boxes A to E with information, providing the information is already stored in the EMS.

The following "Flash Downloader" screen will appear: 5

With the icon now selected, the software can be downloaded. Click on the button indicated by 2 and browse for a file which should be in the following or similar directory: a

D:\Machine\Software\Updates/Earthmovers\ Large\Wheeled Loading Shovels\LWLS C164 EMS\ 728-90269.vsf

Note: Ensure you are entering the correct and most up to date software. b Once the correct software has been selected, click "OK" in the window. The Software and its directory path (see example above) will then be shown in the box labelled 3. 6

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9803/9420

To start downloading the Software into the EMS, click the "Start" button labelled 4 and then click "OK" to

C - 114

Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S confirm. A blue bar will then continue to fill box 5 to show how complete the downloading is. When this is full it will prompt you that the operation is complete. Finally, click "OK" to complete. The EMS will then reset itself and restart its normal operation. 7

Once this has done, close the "Flash Loader" window by clicking the cross (x) in the top right hand corner.

The EMS will now have the new software installed.

Note: If you are just loading the latest software, you do not need to re enter all the settings for the EMS (which can be done using the following Set-up Program) as these will be retained in memory from the last download.

Set-up Program When a machine is being set-up for the first time, or a new EMS unit has been fitted, the machine's details and the required language must be entered into the EMS. This is achieved using the following procedure: 1

Double click on the Set-up icon on the desktop. K EMS Tools ( T C-113). The following screen K Fig 87. ( T C-115).

should

then

Fig 87. Set-up Screen 1

appear. a

Select the 'Vehicle Set-up' tab 6, if it does not start with this automatically.

b Select the `Model Number' 8 as you require, if this has not appeared automatically. Note: Once the serial Number has been entered into the EMS it will locked and cannot be changed again. c

Enter the `Serial Number' in box 9.

d With the mouse, click the `Next' button 11 to proceed to the `Options' selection screen. Note: If you just want to use this tool to read what settings are in the EMS for the particular machine you are looking at, just click this button. Once clicked, all the previously entered data will be shown within this software tool. (That is, assuming the EMS has been set up previously.) e

C - 115

9803/9420

Once the `Next' button identified by 11 has been clicked, the following screen will then appear. This screen can also have been selected by clicking on the `Options' tab 7. K Fig 87. ( T C-115).

C - 115

Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S value entered in box 14 has elapsed, entering a time in box 14 activates the feature. The value to be entered can be any value required by the operator, however, the entered value must be expressed in minutes.

12 13

After the machine has been working/running for specific periods of time, the EMS will display a warning to the operator that a service by a JCB Dealer is due. The specific time for the service request is entered into box 15, expressed as hours.

In certain circumstances, machines can be set-up to be tracked by a satellite system and certain parameters can be made visible via the Internet. This feature can be turned On by checking box 16.

14 15 17 19

16 18 20 21 22 23

Note: This feature will not yet be available to the early machines. 7

In order to track how many miles/kilometers the machine has covered throughout its life, the EMS contains an optional feature to record this data. To turn the feature ON, check box 17 `Odometer'. To turn the feature OFF, toggle box 17 so the check mark is removed and the box is left empty.

Certain machines have the option of having an Electric Emergency Steering Pump fitted to the machine. If this is required then this option is toggled and a check mark will be displayed in box 18.

On 456 Large Wheeled Loading Shovels, a different type of Park Brake system is fitted. The option (box 19) will only be selectable when `456' was selected from the Set-up tab. In all other cases the option will be `ghosted out' and cannot be selected.

Once the user has selected a tyre type from box 12, the rolling radius for that tyre will automatically appear in box 13.

The engine cooling fan is proportionally controlled by the EMS. Box 20 should be checked to turn the feature ON.

Note: If the tyre type fitted to the machine does not appear on the drop-down listing from box 12, the user can select `Other' from the list and manually input the required details. However if this option is taken, the rolling radius for the tyre will need to be manually input to box 13.

The heated rear screen option can, once selected by checking the box, have a custom operating time value entered by the user into box 21.

The Anti-stall feature:

24 26

25 27

Fig 88. Set-up Screen 2 3

Depending on which particular machine was selected at the start of the `Set-up procedure', a list of tyre options will appear in box 12, that relate only to this particular machine range.

If the machine requires an idle shutdown feature, which means that the EMS will shut down the machine if the machine is in `neutral' and the `time'

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9803/9420

To reduce the loading on the engine during cold cranking, the anti-stall feature can be selected by

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Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S checking the box. When selected this feature enables the EMS to isolate the hydraulic load from the engine. When selected the user can enter a custom value of RPM (Revolutions Per Minute) into box 22. This will be the Active Output Cut-off value. 13

The Reverse Fan option: This option once selected can have custom time values entered by the user for both the forward and reverse running time of the fan. These values can be entered at boxes 23.

Hydraulic Flow and Pressure Monitoring:

This option once selected can have custom values of flow measure in PPL (Pulse Per Litre) and Bar entered by the user into boxes 24. 15

30 31 32

Engine Specification: The Large Wheeled Loading Shovels are gradually changing over from Mechanically Controlled Engines to higher specification Electronically Controlled Engines. The EMS incorporates a `Toggle Facility', boxes 25, by which it can monitor and control the same features regardless of whether they are interpreted as mechanical or electronic.

Note: It is important that you select the correct 'Engine Specification' toggle for the machine. The way the EMS translates the engine information depends on which option, 'Electronic Engine' or 'Manual Engine', has been selected. See Box 25. 16

All the unit settings displayed within the Set-up tool have `Metric' and `Imperial' interpretations. The toggle, boxes 26, allow the user to switch between them.

Fig 89. Set-up Screen 3 17

Once the user clicks on the `Next', box 28 the following Language screen will appear:

C - 117

To select the country of operation the user has to select box 29 and scroll down the list to the relevant country. Once the country of operation has been selected from the list, first, second and third language options will automatically appear in the areas 30, 31 and 32.

To advance to the next screen to complete the `Set-up', the user now needs to click on the `Next', box 28. In order to review the previous page (the first `Set-up' screen) the user needs to click on the `Prev', box 27.

If all the settings have been entered for all the domains of each tab, the user should now click on the button identified as 34, `Transfer of Settings', to save the information to the EMS. Note: Until the user clicks on Transfer of Setting button 34, the collated information will remain on the laptop. No transfer of data to the EMS will take place

9803/9420

C - 117

Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S If the user has made a mistake or needs to change a setting they have already entered onto this or either of the two preceding screens, they can, by clicking on the `Prev' buttons 33 and 27, navigate back to the item they wish to change.

Important: If the user returns to change any input information or setting after the settings have been transferred to the EMS, the changes must be written to the EMS by clicking on button 34 again. If the user fails to do this the changes will not be written to the EMS.

Each diagnostic aspect of the machine can be viewed by making a selection from the menu toolbar 36 as shown. K Diagnostic Screen 2 ( T C-118).

36 37

Diagnostic Program As an aid to fault diagnosis, the EMS contains a tool that can diagnose the electrical circuits of the EMS, Electronic Engine faults and parameters and also the fault codes and parameters of the Smoothshift transmission.

In order to activate the diagnostic program proceed as follows: 1

Double click on the `Diagnostic' icon. K EMS Tools ( T C-113).

Fig 91. Diagnostic Screen 2 5

The following systems diagnostic screen will appear.

This will then allow you to make a further selection from the dropdown menu 37 that will appear on the left hand side of the screen. To select an item from this menu, click the `tick box' alongside the required item. This will open up a window with the required information.

Various information appertaining to the displayed circuits, Voltages, pressures, states etc. will be displayed in the window, and a key (38) to this information will appear in the bottom left hand corner of the screen.

Note: The information will be displayed in `real time', which means the information is accurately displayed and instantly updated from the relevant source.

Fig 90. Diagnostic Screen 1 3

Before you can see any information, the `Green' light 35 must be clicked on to enable the software to start the diagnosis. The software will start the process of communicating on the CAN-Bus network with all the electronic controllers.

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Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S Engine Diagnosis

Service History Program

Under the `Engine' menu and `Fault codes' selection, the following screen appears. This screen is split into `Active Fault Codes' and any historic ones, `Previously Active Fault Codes'. K Diagnostic Screen 3 ( T C-119).

A comprehensive history of the machines maintenance is contained in the EMS. To view this history proceed as follows: 1

Double click on the `Service History' icon. K EMS Tools ( T C-113).

This will open up the following screen:

A B

Fig 92. Diagnostic Screen 3 The `Active Fault Codes' box A, shows all the current faults that are on the machine with the ignition turned ON. These errors will also be displayed on the EMS Liquid Crystal Display, for example, E156. The `Previously Active Fault Codes' box B, are all the faults that were logged into the engine ECM, on all the previous occasions while the machine was running Note: Previously active fault codes will not be displayed on the EMS LCD. These faults can only be seen through use of this service software tool. The operator can, if required, erase all the previously active fault codes by clicking on the button identified as item 39.

Fig 93. Service History Screen With this tool the Dealer can add and retrieve service records created for an individual machine. To Start a Service Record, the dealer has to Àdd a Service Record' from the windows file menu as identified by A. With this selection, the user can add all the known and required information. The file Ìmport' and Èxport' selections will enable the service records to be seen and saved to the Dealer's PC only.

To exit the program, click on the small cross (X) in the top right hand corner of the window.

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Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S

Data Logger Program The Data Logger program enables the dealers to see various statistics appertaining to a particular machine. This information can be details of minimum and maximum values of the machine recorded throughout the life of its current EMS unit. To enable this program proceed as follows:

Note: Other information, for example, `Engine Coolant' and `Error Logs' can be seen by clicking on the relevant tabs. An additional feature of this tool enables the user to produce a report for the machine. To activate this facility proceed as follows: 1

Select `File' on the windows menu toolbar.

Double click on the `Data Logger' icon. K EMS Tools ( T C-113).

Select `Report' from the File dropdown menu.

The following screen will appear.

This will produce a Report file as shown below.

Fig 95. Report File 4

This report can be saved or printed as required. To achieve either of these select the required option from the menu toolbar as illustrated at A above.

Fig 94. Data Logger Screen 3

To read the Data Logger information for the machine: a

Select `File' from the windows menu toolbar.

b Select `Read Data' from the File dropdown menu. c

The software will take a few seconds to gather the required information.

d Once the required data has been retrieved, it will be displayed as shown above. K Data Logger Screen ( T C-120).

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Section C - Electrics Electronic Monitoring System (EMS) - 434S 434S

Connecting the Interrogation Lead

the single fastener on the panel cover and remove the cover.

To install the laptop computer to the EMS: 1

Connect plug C on the USB Lead (718/20235) to the USB port on the laptop. Connect the other end to the Data link Adapter A (728/26500)

Note: It is possible to use a serial port lead (718/20236), supplied with the diagnostic kit (892/01174), in place of the USB port Lead.

Fig 97.

C M C A HNI E

O IC E L ETCR N E S E VR IC TO O L

C A BNU S J 1 07 0 P O EWR R C O PMUET

Fig 96. 2

Connect plug B on the interrogation lead (718/20237) to the connector on the fuse/relay panel.

Note: The fuse/relay panel is located behind the operator's seat. To access the interrogation lead connector, release

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Section C - Electrics

Electronic Monitoring System (EMS) - 435S 435S General This document details the full range of Servicemaster tools that provide the off-board diagnostic capability for machine faults.

Instrument Cluster Setup The following sequence is used to configure the instrument cluster for a particular machine, model and serial number. The options available are restricted by the selected model, therefore it is not possible for example, to select a JCB 427 axle ratio for a JCB 467 machine.

20 10

10 0

30 20

40 30

mph km/h

60 ++

C109360a

T05930-C1

Fig 99. Example screen

Fig 98.

If a new instrument cluster is fitted to an old machine, the setup tool page may be used to increase the recorded machine hours to the correct value.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

C109360-1

Fig 100. If during setup, the choice is made to increase the recorded hours, you must accept a warning message before the value is changed.

C109360-2

Fig 101. If there is a need to reduce the stored hours value, the third page of the tool can be used which is locked until an unlock code from JCB Service is entered.

JCB will then respond with an unlock code which allows that particular computer to reduce the stored hours value for a limited time.

To unlock the page, the challenge code must be emailed to JCB Service.

Once this time limit has expired the tool is locked again and the procedure has to be repeated.

C109360-3

Fig 102. Select ‘Unlock Fields’ A from the ‘Utilities’ menu.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

C109360-4

Fig 103. Email the challenge value B to JCB Service to unlock the stored data.

Paste the ‘unlock code’ in box C. Click ‘Apply’ D.

C109360-5

Fig 104. With machine’s ignition OFF and main beam flash ON, click the ‘Reset Hours’ button E to set current hours to 0.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

Management ECU Setup

All other parameters are stored within the software and are not service tool adjustable.

The following tool is used to configure the Management ECU for a particular machine model.

C109360-6

Fig 105.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

Machine Data Logger

The data log records each fault code that has occurred with a date, time and hours stamp.

The following tool is used to read and reset the data log in the instrument cluster.

It also records the total machine hours, the number of ignition switch cycles, maximum values recorded for a range of machine parameters and engine torque data.

C109360-7

Fig 106. Total machine hours and key cycle count shown at F. Machine serial number, date of log and model shown at G. Maximum temperatures and values listed at H. Read log, erase log and display report buttons at J. All faults listed in data log K. Detailed description of selected fault shown at L.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

C109360-8

Fig 107. Engine torque data showing hours spent at each section of the torque curve M. The following illustrates a report generated using the data logger tool. The report may be printed for archiving or saved and sent to JCB to help with fault finding.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

C109360-9

Fig 108. Machine information logged at N. Engine torque data at P. Error log listed at Q.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

Machine Diagnostics The following tool is used to help diagnose faults with the many systems on the machine.

Data can be viewed in real time with the option of exporting data to Microsoft Excel to analyse later or send to JCB to help with fault finding.

C109370

Fig 109. Data capture button R to enable data to be recorded in Microsoft Excel for analysis. Example diagnostics screen showing inputs to and outputs from S the instrument cluster.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

C109370-1

Fig 110. Sample data log T exported and viewed in Excel.

C109370-2

Fig 111. Fault code screen showing ant current active fault codes on the machine, with a description and occurrence count at U.

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Section C - Electrics Electronic Monitoring System (EMS) - 435S 435S

C109370-3

Fig 112. CAN bus statistics screen showing diagnostic information V about the machine CAN bus.

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Section E Hydraulics Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

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Section E - Hydraulics

Notes:

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Section E - Hydraulics Contents Page No. Technical Data Rexroth Valve Machines ......................................................................... E - 1 Parker Valve Machines ........................................................................... E - 4 Basic Operation General Description ................................................................................ E - 8 Introduction to Hydraulic Schematic Symbols ........................................ E - 9 Schematic Circuits 434S Rexroth Valves (Before June 2009) ............................................ E - 16 Schematic Circuits 434S/435S - Parker Valves (After June 2009) ...................................... E - 24 Circuit Descriptions (Rexroth Valves) Pump Operation .................................................................................... F - 32 Pump Pressure/Flow Regulator Valves ................................................. F - 33 Loader Valve .......................................................................................... F - 34 Loader Valve - Arms Raise/Lower ......................................................... F - 36 Loader Valve - Shovel Float .................................................................. F - 37 Loader Valve - Shovel Tip ...................................................................... F - 38 Loader Valve - Shovel Crowd ................................................................ F - 39 Compensator Spool - Operation 1 ......................................................... F - 40 Compensator Spool - Operation 2 ......................................................... F - 41 Auxiliary Services .................................................................................. F - 42 Servo Pressure Regulating Valve .......................................................... F - 43 Smooth Ride System (SRS) .................................................................. F - 44 Electronic Emergency Steering ............................................................. F - 50 Circuit Descriptions (Parker Valves) Pump Operation ................................................................................... Pump Pressure/Flow Regulator Valves ................................................ Loader Valve - Operation ...................................................................... Smooth Ride System ............................................................................ Loader Valves .......................................................................................

E - 52 E - 53 E - 54 E - 55 E - 64

Fault Finding Hydraulic Fault Finding ......................................................................... E - 76 Service Procedures Hydraulic Contamination ...................................................................... Releasing the Hydraulic Pressure ........................................................ Connecting and Disconnecting Hydraulic Hoses .................................. `Positional Type' Hydraulic Adaptors .................................................... Flow and Pressure Tests ...................................................................... Hydraulic Cooling Fan Setting .............................................................. Emergency Steering (Electronic) .........................................................

E - 78 E - 80 E - 81 E - 82 E - 83 E - 89 E - 91

Engine Driven Gear Pump Disassembly, Inspection and Assembly ............................................... E - 93 Pumps Removal and Replacement ................................................................... F - 99 Tandem Pumps .................................................................................... F - 100 Replacing the Pressure/Flow Regulator .............................................. F - 102

E-i

Section E - Hydraulics Contents Page No. Renewing Drive Shaft Seal .................................................................. F - 103 Dismantling, Inspecting and Assembly ................................................ F - 104 Cooling Fan Motor Removal and Replacement ................................................................ G - 107 Rams Precautions During Use ...................................................................... H - 115 Typical Ram ........................................................................................ H - 117 SRS Isolating Valve Removal and Installation .................................................................... E - 123 SRS Control Valve Removal and Installation .................................................................... E - 125 SRS Accumulators Removal and Installation .................................................................... E - 127 Servo Control Lever Removal and Installation .................................................................... E - 129 Servo Valve Removal and Installation .................................................................... E - 131 Loader Valve Removal and Installation .................................................................... E - 135 Stall Speed Tests Hot Test Settings ................................................................................ E - 137

E - ii

Section E - Hydraulics

Technical Data Rexroth Valve Machines Pump Type

Rexroth. Tandem variable displacement axial piston

Ref

A20VO60

Pump 1

litres/min

UK gal/min

US gal/min

Standby flow

1.1

1.3

Full flow at 2200 rev/min

132

29.0

34.8

Flow at max. pressure (220 bar)

1.1

1.3

Standby flow

1.1

1.3

Full flow at 2200 rev/min

132

29.0

34.8

Flow at max. pressure (160 bar)

1.1

1.3

Pump 2

Engine Driven Charge Pump Type

Parker. Single, Fixed Displacement with Charge Valve

Ref Displacement

20 cc/rev

Direction of Rotation

Clockwise

Engine Driven Charge Pump

litres/min

UK gal/min

US gal/min

Full flow at 2200 rev/min

9.24

11.1

Loader Valve Type

Rexroth, stacked directional control, model MP-22. Closed centre, load sensing parallel circuit

Services Operated Section 1 (SV)

Priority Steer

Section 2 (LV1)

Loader arms

Section 3 (LV2)

Shovel

Section 4 (LV3)

Auxiliary (Quickhitch)

Section 5 (LV4)

Auxiliary (Clam) (optional)

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Section E - Hydraulics Technical Data Rexroth Valve Machines Relief Valve Operating Pressures

bar

kgf/cm2

lbf/in2

Standby pressure

27 +3 -0

27.5 +3.06 -0

391.5 +43.5 -0

System control pressure

245 - 255

250 - 260

3552 - 3697

Standby pressure

25 +3 -0

25.5 +3.06 -0

362.5 +43.5 -0

System control pressure

155 - 165

158 - 168

2247 - 2394

Charge Valve Settings (Engine Driven Gear Pump)

bar

kgf/cm2

lbf/in2

Cut In Pressure

160

163.2

2320

Cut Out Pressure

200

204

2900

Max Pressure @ Port EF

220

224.4

3190

litres/min

UK gal/min

US gal/min

1.1

1.32

Operating Pressures

bar

kgf/cm2

lbf/in2

Inlet section Clipper relief valve

272

277.4

3944

Pump 1

Pump 2

Total Flow to Accumulators

Auxiliary Relief Valve (ARV) Settings

Lift ram, head side

345

352

4985

Shovel ram, head side

260

265

3770

Shovel ram, rod side

260

265

3770

Servo

27-35

27.5-35.6

391.5-508

Brake (non-adjustable)

81.6

1160

Steer relief pressure (at ram)

175

178.5

3262

Steer relief pressure (at pump)

190

193.8

2755

Pilot control pressure

27-33

27.5-33.6

391.5-478.6

Engine Cooling Fan

rev/min

Fan Speed (tested @ engine speed of 2200 rev/min) 1800 By-pass Pressures

bar

kgf/cm2

lbf/in2

Filter

1.5

1.53

Capacities

Litres

UKgal

US gal

Hydraulic tank

181

39.8

47.9

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Section E - Hydraulics Technical Data Rexroth Valve Machines Emergency Steer Operating Pressure

40 bar

Rams

Bore

Rod Dia.

Stroke

Shovel Ram

130

5.1

2.8

575

22.6

Lift Ram

130

5.1

2.8

814

32.0

Steer Ram

3.1

2.0

312

12.3

Filter Filtration Size

10 Micron

By pass Setting

1.5 bar

Suction Strainer Size

140 Micron

Accumulators Gas Type - Nitrogen Gas Pre-Charge Pressures @ 20Â° C

Bar

PSI

Accumulator Function - Brakes

57 +/- 1

825 + 30 - 15

- Smooth Ride System

24 +/- 1.0

350 +/-15

Gas Volume (each)

Litre

Cubic inch

Brakes

0.75

45.8

Smooth Ride System

0.95

Accumulator Function

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Section E - Hydraulics Technical Data Parker Valve Machines

Parker Valve Machines Pump Type

Tandem variable displacement axial piston.

Ref

A20VO60

Pump 1

litres/min

UK gal/min

US gal/min

Standby flow

1.1

1.3

Full flow at 2100 rev/min

126

27.7

33.2

Flow at maximum pressure (220 bar)

1.1

1.3

Standby flow

1.1

1.3

Full flow at 2100 rev/min

126

27.7

33.2

Flow at maximum pressure (160 bar)

1.1

1.3

Pump 2

Engine Driven Charge Pump Type

Parker. Single, Fixed Displacement with Charge Valve

Ref Displacement

23 cc/rev

Direction of rotation

Clockwise

Engine Driven Charge Pump

litres/min

UK gal/min

US gal/min

Full flow at 2200 rev/minute

9.24

11.1

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Section E - Hydraulics Technical Data Parker Valve Machines

Loader Valve l/minute

US gal/min

Maximum pump connection flow

400

105

Maximum service port flow

325

Pilot supply flow

2.64

bar

lbf/in2

Maximum pump connection pressure

340

4930

Maximum service port pressure

340

4930

Maximum tank pressure

290

Crowd ARV

280

4060

Dump ARV

280

4060

Lift ARV

350

5076

Pilot supply pressure

500

Temperature

Oil temperature, working range -20 to +90 0C(68 to 194 0F)

Relief Valve Operating Pressures

bar

lbf/in2

Standby pressure

27 +3 -0

391.5 +43.5 -0

System control pressure

245 - 255

3552 - 3697

Pump 1

Pump 2 Standby pressure

25 +3 -0

362.5 +43.5 -0

System control pressure

155 - 165

2247 - 2394

Charge Valve Settings (Engine Driven Gear Pump)

bar

lbf/in2

Cut-in pressure

160

2320

Cut-out pressure

200

2900

Max pressure @ Port EF

220

3190

litres/min

US gal/min

1.32

Total flow to accumulators

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Section E - Hydraulics Technical Data Parker Valve Machines

Auxiliary Relief Valve Settings Operating Pressures

bar

kgf/cm2

lbf/in2

Inlet section clipper relief valve

272

277.4

3944

Lift ram, head side

345

352

4985

HT shovel ram, head side

125

127

1812

ZX shovel ram, head side

260

265

3770

Shovel ram, rod side

260

265.2

3770

Servo

27-35

27.5-35.6

391.5-508

Brake (non-adjustable)

81.6

1160

Steer relief pressure (at ram)

175

178.5

3262

Steer relief pressure (at pump)

190

193.8

2755

Pilot control pressure

27-33

27.5-33.6

391.5-478.6

Engine Cooling Fan

rev/min

Fan speed (tested @ engine speed of 2200 rev/min)

1800

By-pass Pressures

bar

kgf/cm2

lbf/in2

Filter

1.5

1.53

Capacities

Litres

UK gal

US gal

Hydraulic tank

170

37.4

Emergency Steer Operating pressure

40 bar (+3 -0)

Rams

Bore

Rod Diameter

Stroke

Shovel ram (HT 427)

100

3.9

2.4

1056

41.6

Shovel ram (HT 437)

110

4.3

2.6

1056

41.6

Shovel ram (ZX 427)

130

5.1

2.8

575

22.6

Shovel ram (ZX 437)

160

6.3

3.1

530

20.9

Lift ram (427)

130

5.1

2.8

814

32.0

Lift ram (437)

130

5.1

2.8

814

32.0

Steer ram

3.1

2.0

312

12.3

Filter Filtration size

10 Micron

Bypass setting

1.5 bar

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Section E - Hydraulics Technical Data Parker Valve Machines Filter Suction strainer size

140 Micron

Accumulators Gas Type Nitrogen Gas Pre-Charge Pressures @ 20Â° C

Bar

PSI

Brakes

57 +/- 1

825 + 30 - 15

Smooth ride system

24 +/- 1.0 bar

350 +/-15

Gas Volume (each)

Litre

Cubic inch

Brakes

1.75

106.7

Smooth ride system

0.95

Accumulator Function

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E-7

Section E - Hydraulics

Basic Operation General Description Introduction The main components of the Wheeled Loader hydraulic system are the pump, priority valve, loader valve block, servo control valve, steering valve, brake valve, tank, rams and filters. For descriptions of the steering and brake valves, refer to the relevant Sections. The pump is driven by the engine and delivers pressurised oil to the system. A priority valve ensures that the steering circuit has first demand on pump pressure. A pressure regulated outlet from the end section of the loader valve is routed to the servo control valve which in turn is redirected to the loader valve service spools as control inputs. When the servo control valve is operated, it causes the selected service valve spool in the loader valve block to direct pressurised oil from the pump to the selected service ram. Pressurised oil forces the piston along the bore to cause a service movement. As the piston moves, oil is pushed from the opposite end of the ram and returns to tank by way of a filter. Relief valves in the system prevent undue pressure rises through internal and external sources.

Valve Block Tie-Rods When assembling MP22 valve blocks, the tie-rods should be torque tightened to 55 - 60 lbf ft (74.6 - 81.4 Nm, 7.6 8.3 kgf m).

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Section E - Hydraulics Basic Operation 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

Variable capacity motor one direction of flow

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

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Section E - Hydraulics Basic Operation 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 Relief valve

3-Position, 4-port spring centered solenoid & pilot pressure operated valve 3-Position, 4-port spring centered detent hand operated 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)

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Section E - Hydraulics Basic Operation 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 Cooler - with no indication of coolant flow

Line plugged, also pressure test point Line plugged with take off line

Cooler - indicating direction of coolant flow

Quick release couplings connected Heater Quick release couplings disconnected

Reservoir - return line above fluid level

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Section E - Hydraulics Basic Operation 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)

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Section E - Hydraulics Basic Operation Introduction to Hydraulic Schematic Symbols

Control Valves Control valves are usually represented by one or more square boxes. K Fig 1. ( T E-13) 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 E-13) - 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 E-13) shows a 'D' type spool.

Fig 2. K Fig 4. ( T E-13) 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 E-13) - '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 E-13) - '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 E-13). 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 E-13).

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Fig 6.

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Section E - Hydraulics Basic Operation 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 E-14). 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.

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Section E - Hydraulics Basic Operation Introduction to Hydraulic Schematic Symbols Page left intentionally blank

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E - 16

K Reverse Fan (Option) Circuit ( T E-23)

K Smooth Ride System (SRS) Circuit ( T E-22)

K Twin Spool Proportional Auxiliary Circuit ( T E-21)

K Single Spool Proportional Auxiliary Circuit ( T E-20)

K 4-Spool Standard HT ( T E-19)

K 3 Spool HT Circuit ( T E-18)

434S Rexroth Valves (Before June 2009)

Schematic Circuits

Section E - Hydraulics Schematic Circuits

434S Rexroth Valves (Before June 2009)

9803/9420

E - 16

Section E - Hydraulics Schematic Circuits

K Component Key ( T E-17)

Component Key

434S Rexroth Valves (Before June 2009)

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E - 17

E - 18

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4 d

10 19

Fig 8. 3 Spool HT Circuit

30 A1

K Component Key ( T E-17)

45 x

49 49

Section E - Hydraulics Schematic Circuits

434S Rexroth Valves (Before June 2009)

E - 18

Section E - Hydraulics Schematic Circuits

Fig 9. 4-Spool Standard HT

K Component Key ( T E-17)

434S Rexroth Valves (Before June 2009)

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E - 19

K Component Key ( T E-17)

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Fig 10. Single Spool Proportional Auxiliary Circuit

C1 C4

Section E - Hydraulics Schematic Circuits

434S Rexroth Valves (Before June 2009)

E - 20

K Component Key ( T E-17)

E - 21

9803/9420 54

11 13

Fig 11. Twin Spool Proportional Auxiliary Circuit

C1 C2 C3 C4

Section E - Hydraulics Schematic Circuits

434S Rexroth Valves (Before June 2009)

E - 21

E - 22

K Component Key ( T E-17)

21 11

22 13

21 20

Fig 12. Smooth Ride System (SRS) Circuit

Section E - Hydraulics Schematic Circuits

434S Rexroth Valves (Before June 2009)

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Section E - Hydraulics Schematic Circuits

E - 23

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K Component Key ( T E-17)

Fig 13. Reverse Fan (Option) Circuit

434S Rexroth Valves (Before June 2009)

E - 23

E - 24

Load Hold Check - Lower

Sequence Valve

Load Hold Check - Lift

Sequence Valve

Float Sequence Valve

Lift / Lower Spool

ARV - Crowd 280 Bar

ARV - Dump 125 Bar

Load Hold Check - Crowd

Sequence Valve

Load Hold Check - Dump

Sequence Valve

Crowd/Dump Spool

Auxiliary Ram (Optional)

Quickhitch Ram (Optional)

ARV - Lift 350 Bar

Quickhitch Locking Valve (Optional)

Quickhitch Locking Solenoid (Aux Circuit)

3rd Section Spool

Shuttle Valve - LS

Loader Valve

3rd Section ARV - 280 Bar (Optional)

Check Valve

Test Point - Fan

Accumulator - Servo Control

Isolator Valve - Servo Control

Pressure Sensor Oil Cooler Park Brake Park Brake Valve Park Brake Accumulator Brake Modulation Valve Rear Brake Actuators Front Brake Actuators Accumulator Brake Pump and Charge Valve Pressure Sensor - Brakes Cooling Fan Motor Hydraulic Oil Tank Suction Strainer Main Return Filter Breather

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Pump 1 (P1)

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76 Auxiliary Circuit - Spool (Optional 4th Spool)

Auxiliary Circuit - ARV1 (Optional 4th Spool)

Test Point - Pump 2

Test Point - Pump 1

74 75

Test Point - Pilot Pressure

Relief Valve

Electric Motor

Relief Valve

Pump - - Emergency Steer

Pressure Reducing Valve

Cross Line Reliefs

SCU Gerator

SCU Spool and Sleeve

P1 Control Piston

Pump 2 (P2)

SCU LS Relief

P1 System Pressure Relief Valve

SCU Shock Valves

P1 Standby Pressure Relief Valve

Pressure Sensor - Emergency Steer Priority Valve

P2 Stroking Piston

Emergency Steering Pump

P2 Control Piston

P1 Stroking Piston

P2 System Pressure Relief Valve

P2 Standby Pressure Relief Valve

Rams - Steer

Rams - Lift Arm

Filter

Rams - Shovel

Test Point - Brakes

Restrictor Check Valve - LS

Pilot Control Valve

Counter Pressure Valve

434S/435S - Parker Valves (After June 2009)

Schematic Circuits

Section E - Hydraulics Schematic Circuits

434S/435S - Parker Valves (After June 2009)

E - 24

Proportional Control Valve

SRS Valve 2

SRS Accumulators

SRS Shut-off Valve

Cooling Fan Motor Reversing Valve (Optional)

Changeover Valve - 4 Spool only

Supply from P2

Front Brakes

Rear Brakes

BR1

BR2

Section E - Hydraulics Schematic Circuits

434S/435S - Parker Valves (After June 2009)

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Section E - Hydraulics Schematic Circuits

Fig 14. Reverse Fan Circuit

333/T9152-1

434S/435S - Parker Valves (After June 2009)

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Section E - Hydraulics Schematic Circuits

Fig 15. 3 Spool HT Circuit

333/U4845-1

434S/435S - Parker Valves (After June 2009)

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Section E - Hydraulics Schematic Circuits

Fig 16. 4 Spool Standard HT Circuit

333/W7003-1

434S/435S - Parker Valves (After June 2009)

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Section E - Hydraulics Schematic Circuits

Fig 17. 4 Spool Proportional HT Circuit

333/W7040-1

434S/435S - Parker Valves (After June 2009)

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Section E - Hydraulics Schematic Circuits

Fig 18. 3 Spool Proportional HT Circuit

333/W7105-1

434S/435S - Parker Valves (After June 2009)

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Section E - Hydraulics Schematic Circuits

Fig 19. Smooth Ride System

333/W7156-1

434S/435S - Parker Valves (After June 2009)

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Pump Operation

Circuit Descriptions (Rexroth Valves) Pump Operation The hydraulic system of the machine is powered by one pump with a rated flow of 100 cc/rev. The pumps are of the variable displacement axial piston type. Displacement of oil is achieved by the continuous operation of nine pistons. Pump fluid output is controlled by a tilting cam (swashplate), the angle of which is regulated to ensure that only the amount of fluid necessary to satisfy load conditions is delivered. If a load condition is such that no flow is required, only sufficient fluid for cooling and lubrication is provided. Main components of pump 20P are a cylinder barrel 20P1 splined to a drive shaft 20P2 which is held against a kidney plate 20P3. Contained in the cylinder barrel are the axial pistons 20P4, each having an articulated shoe that is in held contact with the swashplate 20P5 by an attachment plate 20P6. The tilting action of the swashplate is exercised by a stroking piston 20P8 and a control piston

20P9, the latter fed by servo pressure. Fitted to the pump exterior is the valve block 20P10 housing the pressure/flow regulators that provide servo control. Rotation of the cylinder barrel causes linear movement of the axial pistons and fluid from the suction port is drawn into the pump through the kidney plate to fill a developing vacuum behind the piston. As the cylinder barrel rotates the fluid is carried from an elongated suction kidney to an elongated pressure kidney where linear movement starts to return the piston into the cylinder barrel. Fluid is forced from the pump through the pressure port. The stroke length of the pistons and consequently the output of fluid is directly related to the swashplate angle. The swashplate is normally held in its maximum displacement angle (17Â°) by the stroking piston spring and system pressure inside the stroking piston.

Fig 20.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Pump Pressure/Flow Regulator Valves

Pump Pressure/Flow Regulator Valves Start Up The Start Up Valve 21SUV is energised, opening chamber setting spring 21P14, to exhaust. This allows spool 21P15 to move up against spring 21P14. Oil from pump signal port is able to flow across the spool and into the pump control piston 21P9. The control piston moves the pump swashplate to the minimum flow position.

A signal from loader valve moves spool 21P15 down onto its stop. Oil in control piston 21P9 is open to exhaust through restrictor 21P13 allowing the swash plate to be moved by control spring to maximum flow position.

Minimum Flow/Maximum Pressure The Start Up Valve 21SUV is de-energised, opening chamber setting spring 21P14, to loader valve signal circuit.

Hydraulic Service Operated The Start Up Valve 21SUV is de-energised, opening chamber setting spring 21P14, to loader valve signal circuit.

System pressure acts on spool 21P12 moving it against spring 21P11. Oil is then diverted to control piston 21P9 moving the swashplate to the minimum flow position. Minimal flow is allowed across restrictor 21P13 to stabilize pump.

Fig 21.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Loader Valve

Loader Valve The loader valve 22LV is a stack type, directional control valve that is configured for closed centre operation. The basic valve block comprises two service valve sections 23LV1 and 23LV2 and a section containing a pressure regulating valve 23LV4. 23LV4 regulates the pressure of the servo valve supply to 30 bar. Additionally, one or two optional valve sections may be fitted. The illustration shows a typical valve block with one optional section, 23LV3. When operated, the designated valve section controls the volume and direction of oil by way of service ports 23A or 23B. A constant flow is maintained regardless of changing load pressures. The three position valve spool in each service has a centre (neutral) position that is maintained by spring loading. In neutral, pump delivery to the service is blocked and vented to exhaust. The valve sections spools are of the following type and service: LV1 Loader Arms. Double acting A to B, double acting B to A, float A to B to tank. LV2 Shovel.

Fig 22.

4-ram machines - Regenerative B to A, double acting A to B. Z-bar machines - Double acting A to B, double acting B to A. LV3 (if fitted) Auxiliary. Double acting A to B, double acting B to A.

F - 34

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Loader Valve

Fig 23.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Loader Valve - Arms Raise/Lower

Loader Valve - Arms Raise/Lower With the raise service selected, servo pressure is applied to the loader valve section 24LV1. The spool 24A is moved from the neutral position, both pressure and return lines are blocked, pressure oil entering gallery 24P from the pump is routed over the waisted section at 24B to port B. From port B oil is directed to the piston heads of the raise/ lower rams. Simultaneously the line from the rod side of

the piston entering the loader valve at port A, is connected to exhaust at 24C. The rams extend and raise the arms. When the lower service is selected, servo pressure moves the spool so that the pressure and return line galleries are interchanged. Pressure oil is directed from port A, port B is connected to exhaust. The rams retract causing a controlled lowering of the arms.

Fig 24.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Loader Valve - Shovel Float

Loader Valve - Shovel Float Operation of the servo control valve from arms lower to arms float selection increases the servo pressure acting on the loading valve section 25LV1. The spool 25A is moved further to shut off pressure oil previously directed to port B and open the galleries to exhaust by way of the waisted portion at 25B. Port Ais also shut off from pressurised oil at 25C and remains connected to exhaust.

Lifting ram oil can now be freely displaced to and from rod and piston faces allowing the rams to extend and retract as required. This condition allows the arms and bucket attachment to follow ground contours with no demand on pump pressure.

Fig 25.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Loader Valve - Shovel Tip

Loader Valve - Shovel Tip The loader valve section 26LV2 controls the shovel tip and return operation when selected. The spool 26A is moved by servo pressure, pressure oil is routed around its waisted section to the shovel rams. Because the A and B ports remain interconnected, pressure on both sides of the ram pistons is equal. However, the operating area is less in the cylinder portion occupied by the piston rod and this causes the ram to extend. Oil returning from the bucket rams is used in a regenerative action to supplement pressure oil from the pumps and speed shovel tipping. Because movement of the spool 26A has also blocked off the outlet line at 26B

returning oil is directed to port A. The rate of ram operation in the tip mode is increased. During shovel tip selection, servo pressure is also fed to the 2 stage (80/225 bar) Auxiliary Relief Valve 2 26ARV. This increases relief valve setting to cater for system pressure. Stage 1 (80 bar) controls pressure on the total head side of the ram. Stage 2 (225 bar) controls pressure in the rod side of the ram only. Stage 2 must be set higher than pump control pressure so that the engine will not stall when the shovel is fully tipped.

Fig 26.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Loader Valve - Shovel Crowd

Loader Valve - Shovel Crowd With shovel crowd servo pressure applied to the loader valve section 27LV2, the spool 27A is moved to separate the ram pressure and return lines at 27B. Pressure oil is routed to port B and the exhaust line to port A. Higher

pressure is now on the rod side of the piston and this causes the ram to retract. Service lines are protected by the 27ARV and by the 272-ARV acting at the lower setting.

Fig 27.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Compensator Spool - Operation 1

Compensator Spool - Operation 1 When the loader valve section 28LV1 raise service is selected the weight of the load being lifted produces a higher pressure than is being generated by the pump. This pressure difference causes the Compensator Spool 28A to operate and stop any reverse fluid flow from the rams.

Pressure from port B assisted by spring action moves the Compensator Spool A to close the pump pressure inlet at 28B. Consequently ram pressure is 'locked up' and the loaded arms prevented from dropping. This condition is maintained until pump pressure exceeds load pressure (Operation 2).

Fig 28.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Compensator Spool - Operation 2

Compensator Spool - Operation 2 If pump pressure continues to be delivered to the loader valve block section 29LV1, pressure will increase until it is greater than the pressure acting on the Compensator Spool 29A. This pressure difference is fed to spool 29A which will move back against spring force and uncover galleries across the waisted portion of the spool 29B.

Pressure oil is directed from port B to operate the raise arms. Compensator Spools are fitted to all loader valve block sections.

Fig 29.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Auxiliary Services

Auxiliary Services With the B port power selected for the Auxiliary Services (Quick hitch or Clam circuits), servo pressure is applied to the loader valve section 30LV3 or 30LV4 respectively. Spool 30A is moved from the neutral position, where both pressure and return lines are blocked, to a position where pressure oil is routed over the waisted section at 30B to port B. From port B, oil is directed to one side of the service. Simultaneously, oil returning from the service

enters the valve at port A which is connected to exhaust at 30C. When A port power is selected, servo pressure moves the spool so that the pressure and return line galleries are reversed. Pressure oil is then directed from port A, whilst port B is connected to exhaust.

Fig 30.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Servo Pressure Regulating Valve

Servo Pressure Regulating Valve A pressure regulating valve (PRV) is incorporated in the loader valve end cover section 31LV5. This valve is used to reduce system pressure (variable between 50-220 bar), down to 30 bar required for servo control.

Neutral Standby Pressure

Service Operating Pressure at 30 bar lifts spool 31A against a controlling spring, preventing high pressure feeding through the servo circuit. Spool 31A is held in balance allowing a small bleed to exhaust to control servo pressure.

Initial servo pressure is generated by pump 'stand by' pressure set at 27 bar.

Fig 31.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Smooth Ride System (SRS)

Smooth Ride System (SRS) General

Circuit Descriptions

SRS is a hydraulic suspension system that is designed to enable a â&#x20AC;&#x153;cushionâ&#x20AC;? effect for the loader lift rams, giving the benefit of a smoother ride when travelling over undulating terrain. The system is fully effective under all load conditions, from full payload to empty shovel.

System Charging

The system utilises a valve block, the main operations of which are given below. Note: The circuits that follow are for description purposes only. When fault finding the system always refer to the main hydraulic schematic circuits.

With the engine running and the SRS isolator valve 59 closed, regardless of whether the cab system activation switch is set to ON or OFF, whenever loader operations are carried out, the SRS circuit will be charged as follows. When the lift service is operated, pressurised oil flows from the loader valve spool 19 out of Port B to the head end of the loader lift rams 17 causing them to rise. Simultaneously, oil flows from a connection in this feed line to the SRS valve 57. The pressurised oil enter the SRS valve at Port A, and flows on through the one way valve to the accumulators where it acts upon one side of the accumulator pistons, against the accumulators stored gas charge pressure, causing the hydraulic pressure to rise. This hydraulic pressure rise will be in correlation to the pressure generated by the lift circuit, i.e. the heavier the load lifted, the greater the pressure generated.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 32. System Charging

F - 44

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Smooth Ride System (SRS) System Fully Charged With the engine running, the system isolator valve 59 closed, and regardless of the status of the systemâ&#x20AC;&#x2122;s cab activation switch, should the loading operations being carried out cause the hydraulic pressure stored in the SRS valve to rise to high the following will happen.

the left. The internal pilot supply to the left side of the spool is, via the double check valve and the solenoid spool, supplied with a pathway to tank, so cannot impair the operation of the spool. With the spool in this position, flow between the loader rams and the accumulators is dead ended by the operating spool preventing the loader operations charging the system further.

When the charge pressure of the hydraulic oil rises above a predetermined level, this level being set by the pressure relief valve, the relief valve will be forced off its seat by the generated internal pilot pressure, allowing the excess pressure to bled to tank.

As the internal pressure is lowered by the relief valve, the pilot pressure on the right side of the operating spool is also reduced, allowing the spring pressures to center the spool to the charging position, ready for the cycle to begin again.

Simultaneously, a second internal pilot pressure acts upon the right side of the operating spool causing it to move to

At this stage the stem is charged but not active.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 33. System Fully Charged

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Smooth Ride System (SRS) System Operating

pressure to the right of the operating spool causing the spool to move to the right.

With the engine running, the system isolator valve 59 closed, the cab system activation switch in the ON position and the machines road speed above the speed required to activate the SRS system, the status of the SRS opening valve will be as follows. With the system activation switch turned ON, and the road speed above the required activation speed, the solenoid in the SRS valve is switched, closing the path to tank of the oil in the pilot line to the left of the operating spool, and opening a pilot line from the accumulator charged internal pressure to the left hand side of the spool via the double check valve. This pilot pressure in conjunction with the spring pressure over comes the combined spring and pilot

With the spool in this position, oil from the head end of the lift rams is connected to the accumulators, thereby allowing the fluctuations in the oil pressure caused by the machine traversing uneven ground to be dampened by the action of the stored gas pressure acting on the opposing side of the accumulator pistons. With the loader valve lift spool 19 in the closed position, the oil from the rod end of the lift rams path to tank has been dead ended by spool 19. However, a connection has been opened by the SRS operating spool to tank allowing the rod end of the lift rams to induce or dissipate oil as required.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 34. System Operating

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Smooth Ride System (SRS) System Pressure Equalisation

pressure differential between the stored accumulator oil pressure and the pressure in the loader arms.

With the system activating cab switch turn ON and the machine carrying out loading operations, there is a sequence of events that could potentially allow the stored accumulator pressure to be greater than the pressure in the loader arm circuit. This when the system activates, would cause a sudden and possibly violent rise of the loader arms. To stop this from happening, the SRS valve operating spool has an additional position that operates as follows. The machine travelling with a loaded shovel, and with the SRS system operating, stops and empties the load from the shovel. On resumption of road travel, when the predetermined speed at which the SRS valveâ&#x20AC;&#x2122;s solenoid is activated to switch the stem on, the valve senses the

The effect of this pressure differential causes the combined spring and pilot pressure acting on the right side of the SRS operating spool to move it fully to the left. With the spool in this position, the high pressure oil from the accumulators is allowed to bleed to tank, thereby reducing the internal pressures, while dead ending the connections from the loader rams. Once the pressure differential equalises, the combined spring and pilot pressure acting on the left side of the operating spool overcome those forces applied to the right side, moving the spool to the right, thereby providing the required dampening effect to the loader rams.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 35. Pressure Equalisation

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Smooth Ride System (SRS) System Isolation

An isolation valve 59 is fitted to the system to allow safe working on the hydraulic circuit.

!MWARNING When the isolator valve is opened, lift ram head side pressure is vented to tank. Before opening the isolator valve, the loader end must be either lowered to the ground or be suitably supported to prevent unexpected movement of the loader end. 7-3-7-13

When the valve is opened, the stored hydraulic pressure in the SRS valve and accumulators is vented to tank. Note: Only the stored hydraulic pressure is vented. The accumulators gas charge pressure will still be stored inside the accumulators. For more information on the accumulators refer to Accumulators. Note: Should the loader arms be raised with the isolator valve open, the arms will slowly lower to the ground.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 36. System Isolation

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Smooth Ride System (SRS)

Maintenance Safety Before attempting any maintenance work on the load suspension hydraulic system, the isolating ball valve must be OPEN. The isolating ball valve is normally CLOSED for SRS to be operative.

Fig 37.

!MWARNING The loader arms will fall to the ground if they are not on the ground or securely supported before the isolating ball valve is opened. Ensure isolating ball valve is open before attempting any maintenance work on the load suspension hydraulic circuit. The isolating ball valve is closed for normal system operation. 0106

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Electronic Emergency Steering

Electronic Emergency Steering General The emergency steering is provided by an electronicallydriven pump controlled by the EMS system. The EMS system monitors the main hydraulic system pressure. If the pressure falls below a preset limit the emergency steering system will be activated automatically.

The system self tests every time the ignition is turned on and will disable the machines starting system if a fault is detected. A switch is provided in the cab for the manual testing of the system.

The pump and motor are located mounted to the front bulkhead beneath the engine cover.

The system basically consists of a cab switch, low pressure switch, pump 38A, motor 38B, in-line 100 Amp fusible link 38C, solenoid 38D, system at pressure switch 38E and pressure adjusting screw 38F.

G F

C004460

Fig 38.

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Section F - Hydraulics Circuit Descriptions (Rexroth Valves) Electronic Emergency Steering Page left intentionally blank

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Section E - Hydraulics

Circuit Descriptions (Parker Valves) Pump Operation The hydraulic system is powered by two pumps, a primary pump with a rated flow of 100 cc/rev and a secondary pump rated at 45 cc/rev. The illustration shows a typical pump, however, apart from the difference in size, the pumps are of the same type and basically similar in construction and operation. The pumps are of the variable displacement axial piston type. Displacement of oil is achieved by the continuous operation of nine pistons. Pump fluid output is controlled by a tilting cam (swashplate), the angle of which is regulated to ensure that only the amount of fluid necessary to satisfy load conditions is delivered. If a load condition is such that no flow is required, only sufficient fluid for cooling and lubrication is provided. Main components of pump P are a cylinder barrel P1 splined to a drive shaft P2 which is held against a kidney plate P3. Contained in the cylinder barrel are the axial pistons P4, each having an articulated shoe that is in held contact with the swashplate P5 by an attachment plate P6. The tilting action of the swashplate is exercised by a stroking piston P8 and a control piston P9, the latter fed by servo pressure. Fitted to the pump exterior is the valve block P10 housing the pressure/flow regulators that provide servo control. Rotation of the cylinder barrel causes linear movement of the axial pistons and fluid from the suction port is drawn into the pump through the kidney plate to fill a developing vacuum behind the piston. As the cylinder barrel rotates the fluid is carried from an elongated suction kidney to an elongated pressure kidney where linear movement starts to return the piston into the cylinder barrel. Fluid is forced from the pump through the pressure port. The stroke length of the pistons and consequently the output of fluid is directly related to the swashplate angle. The swashplate is normally held in its maximum displacement angle (17Â°) by the stroking piston spring and system pressure inside the stroking piston.

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Section E - Hydraulics Circuit Descriptions (Parker Valves) Pump Pressure/Flow Regulator Valves

Pump Pressure/Flow Regulator Valves Start Up The Start Up Valve SUV is energised, opening chamber setting spring P14, to exhaust. K Fig 39. ( T E-53). This allows spool P15 to move up against spring P14. Oil from pump signal port is able to flow across the spool and into the pump control piston P9. The control piston moves the pump swashplate to the minimum flow position.

Hydraulic Service Operated The Start Up Valve SUV is de-energised, opening chamber setting spring P14, to loader valve signal circuit.

A signal from loader valve moves spool P15 down onto its stop. Oil in control piston P9 is open to exhaust through restrictor P13 allowing the swash plate to be moved by control spring to maximum flow position.

Minimum Flow/Maximum Pressure The Start Up Valve SUV is de-energised, opening chamber setting spring P14, to loader valve signal circuit. System pressure acts on spool P12 moving it against spring P11. Oil is then diverted to control piston P9 moving the swashplate to the minimum flow position. Minimal flow is allowed across restrictor P13 to stabilize pump.

Fig 39.

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Section E - Hydraulics Circuit Descriptions (Parker Valves) Loader Valve - Operation

Loader Valve - Operation Loader Valve A schematic diagram showing the loader valve internal components and fluid flow for both the HT and ZX loader configurations are shown on the following pages. For the full hydraulic schematics please refer to the correct circuit as shown elsewhere in this section.

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Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System

Smooth Ride System Introduction The Smooth Ride System (SRS) is a hydraulic suspension system that is designed to enable a â&#x20AC;&#x153;cushionâ&#x20AC;? effect for the loader lift rams, giving the benefit of a smoother ride when travelling over undulating terrain. The system is fully effective under all load conditions, from full payload to empty shovel. Nitrogen accumulators act via a stabilisation module valve to balance the oil displacement across the lift rams as the machine travels across rough terrain. The accumulators use hydraulic pressure on one side of a diaphragm,

working against nitrogen gas pressure on the other, to damp out the forces felt in the loader arms, so keeping the machine steady at all times. The stabilisation valve is solenoid activated through a speed sensing switch, and operates automatically at speeds in excess of 7 km/hr. A manual override allows the system to be switched off if not required and because the accumulators retain their charge at all times, there is no possibility of loader arm hydraulic collapse when the system is reactivated.

Fig 40.

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Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System

Hydraulic Circuit A

Stabilisation Module

2 Way Cartridge Valve

Solenoid Valve

Pressure Relief Valve

Accumulator

Loader Control Valve

Sequencing Valve

Lift Rams

Shut off Valve

Tank

2 Way Cartridge Valve

Fig 41.

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Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System

Operation When driving at speeds in excess of 7 km/hr the solenoid 1 inside the stabilisation module A is switched on. This connects the head side of the lift rams 9 to the hydraulic accumulators 2. K Fig 41. ( T E-56). During the working process, the solenoid 1 is switched off so that the accumulators can be loaded up to a maximum value of the set pressure during the lifting operation. If the pressure on the head side of the lifting rams is lower than the peak pressure in the accumulator, the 2 way cartridge valve 5 closes. The accumulators are not subjected to continuous pressure fluctuations. The sequencing valve 3 and the pressure relief valve 7 in the stabilisation module limit the maximum accumulator pressure. As the pressure in the accumulator is always equal to or greater than the pressure in the lifting rams, the bucket will be slightly raised when the stabilisation system cuts in. The piston side of the lifting rams is connected via a second 2 way cartridge valve 6 to the tank. When the system is activated both cartridge valves 5 and 6 are operated simultaneously via the solenoid valve 1 this ensures cavitation free oscillation of the lifting ram pistons.

Maintenance Safety

Fig 42.

Before attempting any maintenance work on the load suspension hydraulic system, the isolating ball valve must be OPEN.

0106

The isolating ball valve is normally CLOSED for SRS to be operative.

Note: The circuits that follow are for description purposes only. When fault finding the system always refer to the main hydraulic schematic circuits.

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General

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Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System

Circuit Descriptions System Charging With the engine running and the SRS isolator valve 59 closed, regardless of whether the cab system activation switch is set to ON or OFF, whenever loader operations are carried out, the SRS circuit will be charged as follows. When the lift service is operated, pressurised oil flows from the loader valve spool 19 out of Port B to the head end of

the loader lift rams 17 causing them to rise. Simultaneously, oil flows from a connection in this feed line to the SRS valve 57. The pressurised oil enter the SRS valve at Port A, and flows on through the one way valve to the accumulators where it acts upon one side of the accumulator pistons, against the accumulators stored gas charge pressure, causing the hydraulic pressure to rise. This hydraulic pressure rise will be in correlation to the pressure generated by the lift circuit, i.e. the heavier the load lifted, the greater the pressure generated.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 43. System Charging

E - 58

9803-9420-3

E - 58

Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System System Fully Charged With the engine running, the system isolator valve 59 closed, and regardless of the status of the systemâ&#x20AC;&#x2122;s cab activation switch, should the loading operations being carried out cause the hydraulic pressure stored in the SRS valve to rise to high the following will happen.

Simultaneously, a second internal pilot pressure acts upon the right side of the operating spool causing it to move to

At this stage the stem is charged but not active.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 44. System Fully Charged

E - 59

9803-9420-3

E - 59

Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System System Operating

pressure to the right of the operating spool causing the spool to move to the right.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 45. System Operating

E - 60

9803-9420-3

E - 60

Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System System Pressure Equalisation

pressure differential between the stored accumulator oil pressure and the pressure in the loader arms.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 46. Pressure Equalisation

E - 61

9803-9420-3

E - 61

Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System System Isolation

An isolation valve 59 is fitted to the system to allow safe working on the hydraulic circuit.

When the valve is opened, the stored hydraulic pressure in the SRS valve and accumulators is vented to tank. Note: Only the stored hydraulic pressure is vented. The accumulators gas charge pressure will still be stored inside the accumulators. Note: Should the loader arms be raised with the isolator valve open, the arms will slowly lower to the ground.

58 5 9 9

22 21 11

14 13

22 21 15

21 16

12 17

Fig 47. System Isolation

E - 62

9803-9420-3

E - 62

Section E - Hydraulics Circuit Descriptions (Parker Valves) Smooth Ride System

Maintenance Safety Before you do any maintenance work on the load suspension hydraulic system, the isolating valve must be OPEN.

Note: Only the stored hydraulic pressure is vented. The accumulators gas charge pressure will still be stored inside the accumulators.

The isolating valve is normally CLOSED for the SRS to be operative. When the valve is opened, the stored hydraulic pressure in the SRS valve and accumulators is vented to tank.

A327750-1

Fig 48.

E - 63

9803-9420-3

E - 63

E - 64

9803-9420-3

Fig 49.

332-W1149-2

332/W1149

Port for priority function Pump

8 9

PS Connection Measuring port A2

13 14

Additional connection pump

Motor port B1

Measuring port B1

Measuring port B2

Motor port B2

Spool actuation P-A1-B1-T

Motor port A1

Spool actuation P-A2-B2-T

Spool actuation P-B2-A2-T

Proportional valve

C4 Changeover valve Table 8. Spool actuation P-B1-A1-T

Proportional valve

C2 Changeover valve C3 Changeover valve

Proportional valve

C1 Changeover valve

Joystick & bulkhead connection plate

4-Spool ZX Valve

Joystick & bulkhead connection plate

3 Joystick & bulkhead connection plate

Joystick & bulkhead connection plate

Standard or Multi-Lever Proportional

Table 7. The matching port on the component the hose connects to Control Type

The double pump connections, enable the connection of a second pump.

The valve has double work ports at 1800, which give the shortest and simplest path to the cylinders. The dimensions are also kept small, because only half the flow passes through each work port.

The M250LS is a directional valve, designed for use in closed-centre (Load Sense (LS)) hydraulic systems with variable pumps.

Introduction

Loader Valves

PS connection

28 29

Motor port A1

Pump

Motor port A2

C4 Spool actuation P-B-A-T

C3 Spool actuation P-B-A-T

C2 Spool actuation P-A-B-T

C1 Spool actuation P-A-B-T

Additional connection A2

Motor port B section 1

Tank connection Motor port B section 2

Load-hold check valve

Motor port A section 2

Motor port B2

Drain

Pilot connection counter-pressure

Additional connection B2

Sequence valve

Motor port A section 1

LS connection

Motor port A2

Measuring port A1

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 64

E - 65

9803-9420-3

C4 C3

C1 C2

6 15

23 24

4 26

Fig 50.

27 28 29 30 31 1 32 2 33 18

21 22

11 3

332-V1134

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 65

E - 66

332-W2099

9803-9420-3

Joystick & bulkhead connection plate

Changeover valve

Proportional valve

Joystick & bulkhead connection plate

Standard or Multi-Lever Proportional

Table 9. The matching port on the component the hose connects to Control Type

Fig 51.

332/W2099

4-Spool HT Valve

LS connection Sequence valve

17 18

Motor port B2

Additional connection A2 Motor port A2

PS connection

Motor port B section 1

Motor port B section 2

Tank connection

Additional connection B2

Motor port A section 1

Load-hold check valve

Motor port A section 2

Drain

Pilot connection counter-pressure

Motor port A2

Measuring port A1

Measuring port A2

14 16

PS Connection

13 15

Additional connection pump

Port for priority function

Measuring port B2

Motor port B1

Measuring port B1

Motor port B2

Motor port A1

Spool actuation P-A1-B1-T

Spool actuation P-A2-B2-T

Pump

Spool actuation P-B2-A2-T

Table 10. Spool actuation P-B1-A1-T

Spool actuation P-B-A-T

Spool actuation P-A-B-T

Motor port A1

Pump

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 66

E - 67

9803-9420-3

C4 C3

C1 C2

6 15

23 24

2 26

Fig 52.

27 28 29 30 31 1 32 4 33 18

21 22

332-V1134-1

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 67

E - 68 332/W2095

9803-9420-3

Joystick & bulkhead connection plate

N/A

Joystick & bulkhead connection plate

2.1 Joystick & bulkhead connection plate

Joystick & bulkhead connection plate

N/A

Joystick & bulkhead connection plate

1.1 Joystick & bulkhead connection plate

Joystick & bulkhead connection plate

Standard or Multi-Lever Proportional

Table 11. The matching port on the component the hose connects to Control Type

Fig 53.

332/W2095

2.1

1.1

3-Spool ZX Valve

Pump Motor port A1 Measuring port B2 Additional connection pump PS Connection Measuring port A2

9 10 11 12 13 14

Motor port B section 2 Motor port B section 1 PS connection Additional connection A2 Motor port A2

27 28 29 30 31

Tank connection

Additional connection B2 Motor port B2

Motor port A section 1

Load-hold check valve

Motor port A section 2

Drain

Pilot connection counter-pressure

Sequence valve

Port for priority function

Motor port B1

LS connection

Measuring port B1

Motor port B2

Measuring port A1

Spool actuation P-A1-B1-T

Motor port A2

Spool actuation P-A2-B2-T

Spool actuation P-B2-A2-T

Table 12. Spool actuation P-B1-A1-T

1 Motor port A1

Pump

1.1 Spool actuation P-B-A-T

2.1 Spool actuation P-A-B-T

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 68

Section E - Hydraulics Circuit Descriptions (Parker Valves)

Fig 54.

E - 69

9803-9420-3

1.1

14 13

2.1

23 24

11 3

27 29 30 31 1 32 2 33 18

332-V1128-1

Loader Valves

E - 69

E - 70 332/W2096

9803-9420-3

Joystick & bulkhead connection plate

N/A

Proportional valve

Joystick & bulkhead connection plate

Standard or Multi-Lever Proportional

Table 13. The matching port on the component the hose connects to Control Type

Fig 55.

332/W2096

3-Spool Proportional ZX Valve Spool actuation P-B2-A2-T Spool actuation P-A2-B2-T Spool actuation P-A1-B1-T Motor port B2 Measuring port B1 Motor port B1 Port for priority function Pump

2 3 4 5 6 7 8 9 Measuring port B2

31 Motor port A2

30 Additional connection A2

29 PS connection

28 Motor port B section 1

27 Motor port B section 2

26 Tank connection

25 Load-hold check valve

24 Motor port B2

23 Additional connection B2

22 Motor port A section 1

21 Motor port A section 2

20 Drain

19 Pilot connection counter-pressure

18 Sequence valve

17 LS connection

16 Motor port A2

15 Measuring port A1

14 Measuring port A2

13 PS Connection

12 Additional connection pump

10 Motor port A1

Table 14. Spool actuation P-B1-A1-T

1 Motor port A1

Pump

C4 Spool actuation P-B-A-T

C1 Spool actuation P-A-B-T

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 70

Section E - Hydraulics Circuit Descriptions (Parker Valves)

Fig 56.

E - 71

9803-9420-3

14 13

23 24

11 3

27 29 30 31 1 32 2 33 18

332-V1128-2

Loader Valves

E - 71

E - 72

Fig 57.

332/W2098

9803-9420-3

Joystick & bulkhead connection plate

Proportional valve

Joystick & bulkhead connection plate

C4 N/A

Joystick & bulkhead connection plate

Proportional valve

Joystick & bulkhead connection plate

C1 N/A

Joystick & bulkhead connection plate

Standard or Multi-Lever Proportional

Table 15. The matching port on the component the hose connects to Control Type

3-Spool Proportional HT Valve

Spool actuation P-A2-B2-T Spool actuation P-A1-B1-T Motor port B2 Measuring port B1 Motor port B1 Port for priority function

3 4 5 6 7 8

Measuring port B2

31 Motor port A2

30 Additional connection A2

29 PS connection

28 Motor port B section 1

27 Motor port B section 2

26 Tank connection

25 Load-hold check valve

24 Motor port B2

23 Additional connection B2

22 Motor port A section 1

21 Motor port A section 2

20 Drain

19 Pilot connection counter-pressure

18 Sequence valve

17 LS connection

16 Motor port A2

15 Measuring port A1

14 Measuring port A2

13 PS Connection

12 Additional connection pump

10 Motor port A1

Pump

Spool actuation P-B2-A2-T

Table 16. Spool actuation P-B1-A1-T

1 Motor port A1

Pump

C4 Spool actuation P-B-A-T

C1 Spool actuation P-A-B-T

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 72

Section E - Hydraulics Circuit Descriptions (Parker Valves)

Fig 58.

E - 73

9803-9420-3

14 13

23 24

11 3

27 29 30 31 1 32 4 33 18

332-V1128-3

Loader Valves

E - 73

E - 74

9803-9420-3

Joystick & bulkhead connection plate

N/A

Joystick & bulkhead connection plate

2.1 Joystick & bulkhead connection plate

Joystick & bulkhead connection plate

N/A

Joystick & bulkhead connection plate

1.1 Joystick & bulkhead connection plate

Joystick & bulkhead connection plate

Standard or Multi-Lever Proportional

Table 17. The matching port on the component the hose connects to Control Type Sequence valve

Motor port B2

Motor port B section 2 Motor port B section 1 PS connection Additional connection A2 Motor port A2

27 28 29 30 31

Tank connection

Additional connection B2

Motor port A section 1

Load-hold check valve

Motor port A section 2

Drain

Pilot connection counter-pressure

LS connection

17 19

Motor port A2

Measuring port A2

332/W2097

Measuring port A1

PS Connection

Additional connection pump

Measuring port B2

Fig 59.

Motor port A1

332/W2097

Pump

Port for priority function

8 3

Motor port B1

Measuring port B1

Motor port B2

Spool actuation P-A1-B1-T

Spool actuation P-A2-B2-T

Spool actuation P-B2-A2-T

2.1

Table 18. Spool actuation P-B1-A1-T

1.1

3-Spool HT Valve Motor port A1

Pump

1.1 Spool actuation P-B-A-T

2.1 Spool actuation P-A-B-T

Section E - Hydraulics

Circuit Descriptions (Parker Valves) Loader Valves

E - 74

Section E - Hydraulics Circuit Descriptions (Parker Valves)

E - 75

9803-9420-3

Fig 60.

1.1

14 13

2.1

23 24

11 3

27 29 30 31 1 32 4 33 18

332-V1128-4

Loader Valves

E - 75

Section E - Hydraulics

Fault Finding Hydraulic Fault Finding To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault.

Remember safety must always be the first priority, refer to Section 2 - Care and safety for a reminder on safety practices.

Fault

Possible Cause

Action

Insufficient hydraulic fluid.

Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance.

Pump control setting incorrect.

Check and adjust as required.

Low pump flow.

Check for external leaks, replace seals.

Priority valve sticking.

Check priority valve.

Lack of power in all hydraulic functions.

All hydraulic rams slow to operate. Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Check pipe lines and replace as required.

Pump control setting incorrect.

Check and adjust as required.

Low pump flow

Check pump flow. Check for external leaks, replace seals. Check for priority valve sticking.

One hydraulic service fails to operate or is slow to operate.

Associated service pipe lines leaking, damaged, trapped or kinked.

Check hoses, replace as required.

Associated ram leaking.

Replace seals.

A.R.V. setting incorrect.

Check and adjust as required.

Associated valve block section leaking Check for leaks, rectify as required. or not operating. Check that the control lever is operating the spool, rectify as required. Associated check valve not opening to Check and rectify as required. allow return of oil to tank.

The engine tends to stall when hydraulics are under load. Ram creep.

Diverter not opening.

Check electrical power supply and valve operation, rectify as required.

Pump control setting incorrect.

Check and adjust as required.

Engine performance.

Check engine performance.

Ram seals.

Check and rectify as required.

A.R.V.

E - 76

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E - 76

Section E - Hydraulics Fault Finding Hydraulic Fault Finding Page left intentionally blank

E - 77

9803/9420

E - 77

Section E - Hydraulics

Service Procedures Hydraulic Contamination TE-002_3

cleaning unit. K Fig 61. ( T E-78). General Bulletin 011 also refers.

Hydraulic Fluid Quality 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.

Procedure Connect the cleaning unit in place of the hydraulic filter. K Fig 61. ( T E-78). 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.

S168050-1

Fig 61. Cleaning Unit 2

Liquid - usually water and incompatible oils and greases.

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

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

E - 78

9803/9420

E - 78

Section E - Hydraulics Service 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.

E - 79

9803/9420

E - 79

Section E - Hydraulics Service Procedures Releasing the Hydraulic Pressure

Releasing the Hydraulic Pressure Procedure

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and carry out the full venting procedure. Make sure the engine cannot be started while the hoses are open.

Turn OFF the ignition and disconnect the batteries to ensure the machine cannot be started while the hydraulic system is open.

Smooth Ride System Venting Before attempting any maintenance work on the load suspension hydraulic system, the isolating ball valve must be OPEN. The isolating ball valve is normally CLOSED for SRS to be operative.

INT-3-1-18

Machines are now fitted with a new generation loader control valve. A feature of this new valve is that when the ignition is turned off, the servo control is disconnected from its pressure accumulator. This can falsely give the impression should the control lever be operated, that there is no residual pressure in the system. To prevent the hydraulic system being opened whilst there is still residual pressure present, the following venting procedure MUST be carried out: 1

Park the machine on firm level ground. Lower the attachments to the ground, apply the park brake and set the transmission to neutral.

Switch the engine OFF.

Turn the ignition ON, but DO NOT start the engine.

Ensured the loader isolation switch in the right hand side cab switch bank is turned ON. (The switch will be illuminated when ON.) K Fig 62. ( T E-80) Fig 63.

Fig 62. 5

0106

Operate the loader control lever repeatedly to vent any residual pressure.

E - 80

9803/9420

E - 80

Section E - Hydraulics Service Procedures Connecting and Disconnecting Hydraulic Hoses

Connecting and Disconnecting Hydraulic Hoses The following paragraphs describe how to connect and disconnect hydraulic hoses safely.

Connecting the Hoses 1

Disconnect the hoses. Where the connection is of the quick release type, see Section A, contents. For all other hose connections, plug both sides of the connection to prevent loss of fluid.

Connect the hoses. Where the connection is of the quick release type, see section A, contents. For all other hose connections, use correct tools and ensure that connections are not cross-threaded. Support the weight of the hose until the connection is made. Do not exceed the recommended torque loading.

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

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD-1-5

Vent the hydraulic pressure as described K Releasing the Hydraulic Pressure ( T E-80).

E - 81

9803/9420

E - 81

Section E - Hydraulics Service Procedures `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 64A can occur resulting in oil leaks. 1

Ensure the locknut 64B is screwed back onto the body of the adaptor as far as possible as shown.

Check the `O' ring backing washer 64C 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 64A is fitted and that it is free from damage or nicks. Before fitting the adaptor, smear the `O' ring with clean hydraulic fluid.

Fig 64.

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 64B.

Note: When fitted correctly no more than one thread should be visible at 65Z as shown. 6

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

Fig 65.

E - 82

9803/9420

E - 82

Section E - Hydraulics Service Procedures Flow and Pressure Tests

Flow and Pressure Tests

!MCAUTION

Main Pump

After checking the standby pressure, turn the starter key to HS to allow the engine rotation to stop. Do not turn the key to OFF while the engine is turning; otherwise the test gauge may be damaged. HYD-3-3

Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

Remove the ESOS connector 66B from the fuel injection pump, crank the engine with the starter key and check that the standby pressure is as stated in K Technical Data ( T E-1). If necessary, adjust at 68C.

Note: System control pressure will only show with the ESOS disconnected. When the ESOS is reconnected, the pressure shown will be approximately 50 bar.

!MWARNING Make sure the articulation lock is in the transport position before you transport the machine. The articulation lock must also be in the transport position if you are carrying out daily checks or doing any maintenance work in the articulation danger zone. If the articulation lock is not in the transport position you could be crushed between the two parts of the chassis. 4-3-5-7

Standby Pressure 1

Connect Pressure Test Gauge Kit 892/00253 (see Note) to test point 67A on the emergency steer valve assembly.

Fig 66.

System Control Pressure 1

E - 83

9803/9420

If you are using individual gauges, rather than Gauge Kit 892/00253, remove the existing gauge from test

E - 83

Section E - Hydraulics Service Procedures Flow and Pressure Tests point 67A and connect a higher pressure gauge (see Note). 2

Ensure that the engine rotation has stopped. Reconnect the ESOS connector 66B.

Run the engine at idle and select ‘arms lower’ with the shovel on the ground. Do not select ‘Float’

This will cause the hydraulic pressure to rise to the idle control pressure setting, which should be as stated in K Technical Data ( T E-1). If necessary, adjust the pressure at E

If the pressure is correct, Slowly increase engine speed to Maximum. Pressure should rise to system control pressure stated in K Technical Data ( T E-1). Note the engine speed at which the gauge indicates the pressure rise and check against the figures in K Technical Data ( T E-1). Note: If Pressure Test Gauge Kit 892/00253 is not available, use a suitable gauge which incorporates protection against over pressurisation. See K Technical Data ( T E-1) for pressures.

Fig 67.

E - 84

9803/9420

E - 84

Section E - Hydraulics Service Procedures Flow and Pressure Tests

Fig 68.

Pressure Testing the Loader Valve A.R.V.’s Using a Hand Pump

!MWARNING

892/00223

Hand Pump

892/00279

Pressure Gauge 0 - 400 bar

Other associated equipment as detailed in Section 1 Service Tools.

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).

Remove the loader valve A.R.V.’s from the loader valve block. Note their positions for correct reassembly.

Install the first A.R.V. assembly in the test block at the port marked ‘RV’ (relief valve).

Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

To pressure test and re-set the loader auxiliary relief valves (A.R.V.), the following equipment must be used: 892/00340

E - 85

Test Block Body

9803/9420

E - 85

Section E - Hydraulics Service Procedures Flow and Pressure Tests

Fig 69. 3

Connect a hydraulic hand pump to port ‘P’ (pump) of the test block. Make sure that the hand pump is filled with JCB Hydraulic Fluid.

Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure test gauge to port ‘G’ (gauge) of the test block.

Port ‘T’ (tank) can be left open when using a hydraulic hand pump.

Raise the pressure at the valve inlet using the hydraulic hand pump, when the A.R.V. ‘cracks’ and oil escapes from the port marked ‘T’ the pressure gauge will indicate the A.R.V. setting.

If the A.R.V. setting is correct as stated in K Technical Data ( T E-1), release the pressure in the test block and remove the A.R.V. assembly. Refit the A.R.V. in the loader valve block.

If the A.R.V. setting needs to be adjusted release locknut 70W and adjust 70V, using a 5 mm Allen Key and repeat the test until the correct pressure is obtained. Tighten the locking nut to preserve the setting. If the specified pressure is higher than the maximum achievable by adjustment, additional shims will need to be fitted.

When the correct A.R.V. setting has been attained, release the pressure in the test block. Remove the A.R.V. assembly and refit it to its correct position in the loader valve block.

Repeat the procedure for the other A.R.V.’s.

E - 86

9803/9420

E - 86

Section E - Hydraulics Service Procedures Flow and Pressure Tests

Fig 70.

E - 87

9803/9420

E - 87

Section E - Hydraulics Service Procedures Flow and Pressure Tests

Steering Relief Valve

Connect Pressure Test Gauge Kit 892/00253 to test point A (see Note).

Turn the steering wheel and check that the indicated pressure is as stated in K Technical Data ( T E-1) â&#x20AC;&#x2DC;At Pumpâ&#x20AC;&#x2122; pressure.

If the indicated pressure does not meet the specified pressure, do the following: a

Separate the hydraulic steering unit from the steering column, leaving the hoses connected.

b Remove the steer relief valve (see Section H Steering). Dismantle, clean and refit the relief valve. Reassemble the steer valve to the steer column. Repeat steps 1 and 2. If the pressure is still incorrect, the steering unit will need to be renewed. Note: If Pressure Test Gauge Kit 892/00253 is not available, use a suitable gauge which incorporates protection against over pressurisation. See K Technical Data ( T E-1) for pressures.

E - 88

9803/9420

E - 88

Section E - Hydraulics Service Procedures Hydraulic Cooling Fan Setting

Hydraulic Cooling Fan Setting Procedure

Note: Make adjustments to the adjusting screw in small increments only. Recheck the fan speed after each adjustment. Screw the adjuster in to increase the fan speed and pressure, out to decrease.

If the articulation lock is not in the transport position you could be crushed between the two parts of the chassis. 4-3-5-7

Slacken the locknut A on the fan motor relief valve cartridge using a 13 mm spanner and slow turn the adjusting screw using a 4 mm Allen key to obtain the recommended speed. If the fan exceeds the recommended speed, reduce the speed by at least 100 rpm below the requirement then slowly increase until the correct speed is obtained.

!MWARNING

!MWARNING When working close to the machine with the engine running, protective clothing must be worn, ie. Safety glasses, ear protection, gloves etc. GEN-4-3

Checking the Fan Speed 1

Attach tacho-reflective tape to the fan hub rather than to the fan blades.

Warm up the hydraulic system until 4 or 5 segments show on the hydraulic oil temperature gauge.

Hold the engine at Max specified revs as detailed in K Technical Data ( T E-1).

Check the fan reaches its recommended speed as detailed in K Technical Data ( T E-1).

Fig 71. Uni-Directional Fan Motor

Adjusting the Fan Speed K Fig 71. ( T E-89) and K Fig 72. ( T E-90).

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Section E - Hydraulics Service Procedures Hydraulic Cooling Fan Setting

Fig 72. Bi-Directional Fan Motor 2

Tighten the locknut A and recheck the fan speed.

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Section E - Hydraulics Service Procedures Emergency Steering (Electronic)

Emergency Steering (Electronic) Checking/Adjusting the System Pressure

C004340

Fig 73.

Adjusting the Pressure

HYD-1-5

Checking the pressure 1

Connect a 400 bar test gauge to the test point 73T.

Note: The emergency steering system test point (73T) is located beneath the front panel, on the right hand side of the loader valve when viewed from the front of the machine. 2

With the engine switched OFF, turn on the ignition. Wait for the EMS System to carry out its self diagnostic test (approximately 4 seconds). Depress and hold the Emergency Steer Test Switch in the cab. Read and record the pressure generated on the test gauge. Release the switch once the pressure reading has been obtained. Check the pressure reading against the system max pressure as detailed in K Technical Data ( T E-1).

Important: If the pressure needs to be adjusted, providing the pressure is not greater than 50 bar, replace the 400 bar test gauge with a 50 bar one. The pressure setting is quite critical and an analogue 400 bar gauge may not be sensitive enough to fine tune the output pressure. (A 400 bar calibrated â&#x20AC;&#x153;Digitalâ&#x20AC;? gauge may be used as an alternative.) Note: the adjuster is very sensitive, make only very small adjustments at the adjusting screw. 1

Connect a 50 bar test gauge to the test point 73T, (the maximum pressure having already been confirmed as being below 50 bar).

Turn on the ignition but do not start the engine. Depress and hold the emergency steering test switch and check the pressure.

Release the switch (there is no need to run the pump whilst adjusting).

Remove the 400 bar test gauge.

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Section E - Hydraulics Service Procedures Emergency Steering (Electronic) 4

Hold the nut 74H and release the locknut 74G. Using an Allen key inserted into the threaded adjuster 74F, adjust as required.

After each small alteration to the adjuster 74F, nip the locknut 74G. With the ignition on, depress and hold the emergency steer test switch and record the reading.

Release the switch before making any adjustment to the pressure.

Continue making small alterations to the adjuster until the correct pressure as detailed in K Technical Data ( T E-1) has been achieved.

Tighten the locknut and recheck the pressure.

Remove the test gauge.

G F

C004460

Fig 74.

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Section E - Hydraulics Engine Driven Gear Pump Disassembly, Inspection and Assembly

Engine Driven Gear Pump Disassembly, Inspection and Assembly Introduction

Remove the bolts 1 and spring washers 2.

The unit comprises an end cover, a body, housing a matched gear pair, bushes and a mounting flange bolted together with through bolts. The gear journals are supported in plain bearings within pressure balanced bushes to give high volumetric and mechanical efficiencies.

Remove the end cover 3, body O-ring 4, bush seal 6 and back-up seal 5.

Turn the unit over and lightly tap the mounting flange 15 to disengage it from the locating dowels and slide the flange squarely off the shaft.

Routine Maintenance

Remove the clip 17 and push the shaft seal 16 squarely out of the mounting flange taking care not to damage any sealing surfaces.

Remove the body O-ring 4, bush seal 6 and back-up seal 5.

Before removing the internal components, mark the bushes to denote the location in the body. On a plain area away from the seal location and adjacent to the driveshaft mark:

No maintenance is necessary other than periodic checks for tightness of the mounting bolts and the port fittings plus visual examination for oil leaks. The unit should be kept externally clean, especially in the area of the shaft seal as dirt can accelerate seal wear and cause leakage. Only the JCB recommended fluid should be used in the pump. See Section 3 - Lubricants and Capacities. Servicing is limited to seal replacement.

F = Bush Flange End

Direction of Rotation

C = Bush Cover End

The direction of rotation is indicated by an arrow on the body adjacent to the driveshaft.

With the unit lying on its side, hold the driveshaft 11 and pull it squarely out of the body bringing the bushes 7 with it.

Remove the driven gear and the remaining bushes.

Disassembly For component details K Fig 75. ( T E-96).

Inspection Before starting work on the pump, ensure that the work area and all the tools are thoroughly clean to prevent contamination entering the unit. Mark the body, flange and end cover to assist reassembly. 1

Withdraw the drive coupling from the driveshaft using as suitable puller.

Note: The coupling must not be levered or hammered off the driveshaft as this will result in internal damage. 2

Remove the key 12 from the driveshaft (if fitted).

Note: Some units are intentionally built without a key being installed in the shaft. Do not install a key when rebuilding.

E - 93

Assessment Each component should be thoroughly cleaned, carefully examined and assessed for re-use. Following is a guide for inspecting the various components. Should any component not be suitable for further use, the pump should be replaced.

Body Inspect the body bore cut-in on the inlet side where the gears wipe the body.

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Section E - Hydraulics Engine Driven Gear Pump Disassembly, Inspection and Assembly The body can only be re-used if the cut-in is bright and polished in appearance and the depth does not exceed 0.08 mm. The body should not be scored, have a ‘matt’ appearance or show signs that the tip of the gears have dug in and torn away the surface material. The body should be inspected to ensure that there is no superficial damage, which may adversely affect performance or sealing. Pay particular attention to the port threads and body O-ring seal recesses.

Mounting Flange and End Cover The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the regions where the body O-rings and bush seals contact, which could result in external leakage. Check the shaft seal recess for scoring or damage that could result in oil leakage around the outer diameter of the shaft seal. replacement shaft seals can be refitted with Loctite hydraulic sealant to overcome slight damage in this area.

The gear teeth should then be carefully examined to ensure that there are no signs of scuffing or pitting on the involute face. The Journal bearing surfaces should be completely free from scoring or bruising. The surface should appear highly polished and smooth to the touch. Examine the area where the shaft seal lips run on the driveshaft, this shows up as a polished ring or rings. If a noticeable groove can be felt or there is scoring the shaft is unserviceable. Provided the driveshaft is not damaged from the drive coupling and the gears have not been harmed as described above, then the gears can be re-used. As a matter of good practice, when pumps are dismantled, all the seals should be replaced. it is most important that genuine JCB parts are used.

Assembly For component details K Fig 75. ( T E-96).

Bushes The side faces, which abut the gears, should be perfectly flat, showing no signs of scoring. Characteristically there are bright polished areas on this surface caused by loading against the gear side faces and is often more pronounced on the low pressure side. Often there is a witness mark where the tips of the opposing gears have wiped an overlap resembling a halfmoon shape. There must be no noticeable wear step as it is critical that the bush side face is completely flat on the gear side face.

Ensure all parts are perfectly clean and lubricate the bushes and gears with clean hydraulic fluid (ensure O-ring recesses and end faces of the body remain dry). This will assist assembly of the components into the body bores. A light smear of petroleum jelly may be applied to the body seals 4 to help keep them in place during assembly. 1

Refit the cover end bush (marked ‘C’) into the undowelled end body from where it was removed. The ‘T’ shaped cut-out in the bushes must face towards the pump outlet and against the gear side-face.

Place the end cover 3 against the un-dowelled end of the body 9 and stand the assembly on the cover so that the dowels are uppermost.

Fit the driveshaft 11 and driven gear 10 into their original positions in the body.

Re-fit the flange end bush (marked ‘F’) into the bores with the ‘T’ cut-out towards the outlet side of the body and against the gear side-face.

Fit a new body O-ring 4 bush seal 6 and back-up seal 5 ensuring that the seals locate correctly in the seal grooves.

The bush bearing liners are acceptable for use providing that they are not scored, have bronze appearing through the grey surface or show any prominent signs of wear.

Gears The gear side faces should be examined for bruising or scoring. Often operation on contaminated fluid shows scoring between the root of the gear and the journal, which leaves a wear step. If a wear step can be felt coincident with the root diameter by drawing a fingernail across the surface from the journal outwards to the tip of the gear, then the gear is unserviceable.

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Section E - Hydraulics Engine Driven Gear Pump Disassembly, Inspection and Assembly 6

Fit a new shaft seal into the recess in the mounting flange with the ‘garter’ spring facing into the pump. Refit the circlip 17 in its groove.

Note: In some applications there may be two shaft seals fitted back tot back. In this case the outer seal is fitted with the ‘garter’ spring facing outwards. If the seal recess is scored, Loctite hydraulic sealant must be applied to the outer diameter of the seal. Apply a light coat of high melting point grease to the seal lips. 7

Fit the shaft seal assembly sleeve 20, supplied in the seal kit, over the driveshaft and carefully refit the mounting flange 15 ensuring it locates squarely onto the dowels in the body. Remove the assembly sleeve.

Holding the unit securely together, carefully turn the unit over ensuring it is supported on the mounting flange and not the driveshaft.

Component Identification K Fig 75. ( T E-96), 1

Securing Bolt

Spring Washer

End Cover

Body O-ring

Back-up Seal

Seal Element

Thrust Block

Dowel Pin

Body

Driven Gear

Driveshaft

Woodruff Key (if fitted)

Square Key (not used)

Snap-ring (not used)

Remove the end cover 3 and fit a new body O-ring 4, bush seals 6 and back-up seals 5.

Mounting Flange

Shaft Seal

Replace the end cover and refit the securing bolts and washers. Evenly torque tighten the bolts to the correct torque. K Table 19. Torque Settings ( T E-95).

Circlip

Tab Washer

Nut

Pour a small amount of clean filtered hydraulic fluid into a port and check that the driveshaft can be rotated without undue force using a suitable tool.

Sleeve (assembly tool)

Item

Table 19. Torque Settings Nm lbf-ft

42 - 47

31 - 35

85.5

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Section E - Hydraulics Engine Driven Gear Pump

Fig 75. Engine Driven Gear Pump Components

Disassembly, Inspection and Assembly

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Excess Port (EF)

Accumulator Port A2

Gauge Port

Accumulator Port A1

Fig 76. 21 cc Pump

Pump Circuit Diagram

Torque tighten to 80 Nm

C 333-T1003

Section E - Hydraulics

Engine Driven Gear Pump

Disassembly, Inspection and Assembly

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Section F - Hydraulics

Pumps Removal and Replacement

!MWARNING

approximately one minute, a pipe connection leakage is indicated.

This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

When Removing Release the hydraulic tank cap to vent system pressure before removing the pump. Disconnect all hoses and blank off to prevent ingress of dirt. With the pump adequately supported and the two mounting bolts removed, manoeuvre the pump so that the splined drive shaft is clear of the engine gearbox housing. Once the pump is clear carefully lower it to the ground. If it is intended to replace the pressure/flow regulator or the drive shaft seal, follow the procedures given on K Replacing the Pressure/Flow Regulator ( T F-102) or K Renewing Drive Shaft Seal ( T F-103) respectively. See K Fig 80. ( T F-105) for pump dismantling and assembling procedures.

When Replacing Before refitting ensure that the pump casing has been filled with the specified quantity of hydraulic oil. Renew all 'O' rings. Apply JCB Lock & Seal to the threads of mounting bolts (two off). With the pump adequately supported engage the pump and the splined drive shaft with the engine gearbox housing. Fit and torque tighten mounting bolts. Ensure an exact alignment between the pump and gearbox drive. When all hose connections have been made run the pump without load and allow it to deliver without pressure for a few seconds to ensure adequate lubrication. Run the pump to check for fluid leakage at connections. If the pump is not delivering without air bubbles after

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Section F - Hydraulics Pumps Tandem Pumps

Tandem Pumps General

The ‘Tandem Pump Set’ is driven from the rear of the transmission Access to the pumps is via the gap between the rear chassis and the cab floor, or from in front of the rear chassis. When working from the front of the rear chassis you will be working in the machines ‘Articulation Zone’. Never work in this area without the Articulation Lock being installed.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

The pumps share a common suction hose.

Removal and Replacement K Fig 77. ( T F-101). The following procedure describes replacement of the tandem pumps.

Label and disconnect the pumps outlet hoses from the pumps. Blank off all exposed connections to prevent the ingress of dirt.

Support the pump assembly and remove the four bolts B securing the pump to the transmission casing. Carefully withdraw the pump assembly from the transmission drive and remove from the machine.

Replacement removal

and

Removal

Replacement is the reverse of the removal procedure, however, please note the following: 1

!MWARNING Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

Clean off all traces of sealant compound from the pump and transmission housing faces. Apply a thin bead of Loctite 5910 sealant to the transmission mounting face.

Note: The pump set must be assembled onto the transmission within 15 minutes of applying the sealant.

INT-3-2-4

Park the machine on firm level ground, lower the attachments to the ground. Apply the park brake, set the transmission to neutral, stop the engine and remove the starter key to prevent the machine being started while you are working on it.

Install the articulation lock. Refer to Section 3 Routine Maintenance.

Block both sides of all four wheel.

Carry out the hydraulic pressure venting procedure the Hydraulic as detailed. K Releasing Pressure ( T E-80)

Drain the hydraulic fluid from the hydraulic tank.

Remove the four flange bolts A securing the suction hose flange to the pump body. Blank off the exposed connections to prevent the ingress of dirt.

F - 100

Pour a small amount of clean hydraulic fluid into the pumps inlet and outlet ports prior to installation to assist with initial lubrication.

Locate the splined shaft of the pump into the transmission drive. Apply JCB Threadlocker and sealer to the bolts B and secure the pump set to the transmission.

Torque tighten the bolts B to the values given in K Torque Settings ( T F-101).

Reconnect the pumps outlet hoses as detailed in K Connecting and Disconnecting Hydraulic Hoses ( T E-81).

Note: All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal sealant applied to the threads of the adaptor.

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Section F - Hydraulics Pumps Tandem Pumps 6

Fit a new sealing O-ring to the suction hose flange. Reconnect the pumps suction hose flange to the pumps body with bolts A.

Fill the hydraulic tank with the correct grade of hydraulic fluid. Section 3 - Routine Maintenance.

When all hose connections have been made run the pump without load and allow it to deliver without pressure for a few seconds to ensure adequate lubrication.

Check the main and stand-by pressures as detailed in K Flow and Pressure Tests ( T E-83).

Note: Replace the suction strainer and return line filter if fitting a new or serviced pump set. Item

Table 20. Torque Settings Nm kgf m

lbf ft

130

95.8

13.26

Fig 77.

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Section F - Hydraulics Pumps Replacing the Pressure/Flow Regulator

Replacing the Pressure/Flow Regulator Remove the capscrews 78-1 (four off) and detach the regulator 78-2 from the pump housing. An unserviceable regulator must be replaced with a new item. Ensure new

'O' rings 78-3 are fitted in the regulator body before assembly to the pump.

Fig 78.

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Section F - Hydraulics Pumps Renewing Drive Shaft Seal

Renewing Drive Shaft Seal Remove the retaining ring 79-1. Remove the shaft seal 792, (note positioning of seal grooved face as an aid to refitting). Remove the 'O' ring 79-3 from pump housing. Examine the seal running area (drive shaft and housing) for wear or damage. Damage in these areas will require the pump to be further dismantled as shown on K Fig 80. ( T F-105). Lubricate a new seal with Mobilplex or equivalent grease containing Molybdenum Disulphide. Fit new seal ensuring it enters the housing evenly and with the grooved face correctly positioned. Position a new 'O' ring on the pump housing.

Fig 79.

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Section F - Hydraulics Pumps Dismantling, Inspecting and Assembly

Dismantling, Inspecting and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling and assembly. Before dismantling the pump make sure the exterior of the pump and the working area is thoroughly clean and free from possible sources of contamination.

Dismantling During dismantling note the following: Mark covers and housing to ensure correct replacement. Use a soft-faced hammer to separate components. Do not use levers or other tools that may damage machined surfaces. The port plate 80-2 is removed complete with the control plate 80-6 and control pistons 80-8 and 80-9. The rotary group 80-3 is removed complete with shaft 8011, taper bearing races 80-10, 80-13 and cradle 80-12. Remove the outer bearing races from the port plate and pump casing only if unserviceable and need to be renewed.

Inspecting Generally check all pump parts for damage and/or wear. The shaft 'O' ring grooves and all sealing faces must be free of burrs and scores. Carry out a check for free running of the rotary group and control pistons during assembly.

Assembly For assembly the sequence should be reversed but note the following: Renew all 'O' rings. Apply JCB Lock & Seal to the securing threads of the control pistons 80-8 and 80-9. The cradle 80-12 is correctly positioned with its lubrication bore on the high pressure side.

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Section F - Hydraulics Pumps Dismantling, Inspecting and Assembly

Fig 80.

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Section G - Hydraulics

Cooling Fan Motor Removal and Replacement Removal

Note: The following procedureâ&#x20AC;&#x2122;s illustrations depict a UniDirectional Motor; the Bi-Directional motor has an additional hose. In all other aspects the procedures are the same. 1

Park the machine on firm level ground, lower the attachments to the ground, apply the park brake and set the transmission to neutral. Stop the engine. Block both sides of all four wheels.

Important: The procedure detailed below must be followed to correctly vent the residual hydraulic pressure.

6 2

Vent the hydraulic pressure as detailed in K Releasing the Hydraulic Pressure ( T E-80).

Disconnect the batteries to prevent the engine being started whilst carrying out this procedure.

Open the left and right-hand side engine covers. From inside the right-hand side cover pull the release cable 81A to unlatch the rear fan housing assembly.

Remove the six bolts securing the fan grille to the fan housing. (The lower three are fitted on the under side of the grille.)

Label and disconnect the hoses 82A and 82B to the cooling fan motor. plug the hoses and cap the open motor ports to prevent the ingress of dirt or debris. K Connecting and Disconnecting Hydraulic Hoses ( T E-81).

A B

Fig 82. Uni-Directional Motor 7

Open the fan housing and remove the four bolts 83A securing the inner guard to the housing and remove the guard.

Fig 81.

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Section G - Hydraulics Cooling Fan Motor Removal and Replacement

Replacement Replacement is the reverse of the removal procedure, however note the following:

B B

INT-3-1-10_3

A C021490

Take care to secure the hydraulic hoses inside the fan housing to prevent possible contact with the fan.

Top up the hydraulic fluid as necessary with the correct grade of fluid. Refer to Section 3 - Routine Maintenance.

Fig 83. 8

Remove the four bolts 83B securing the fan blades to the motor hub and remove the fan. Store the fan carefully so as not to damage the blades. (Do not refit a fan with damaged blades.)

Lower the fan housing to the closed position and remove the two Allen bolts 84A securing the fan motor to the spider and remove the motor.

Fig 84.

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Section G - Hydraulics Cooling Fan Motor Removal and Replacement

Uni-Directional Motor

Inspection

General

Clean and dry all parts thoroughly prior to inspection. (It is not necessary to check the seals as all seals need to be replaced). Inspect all O-ring grooves and shaft seal recesses, make sure there are no burrs.

Check the driveshaft for damage. Check for marks or grooves on the driveshaft in the area of the seal. Slight discolouration of the shaft is allowable.

Inspect the faces of the gears for scoring or excessive wear. If the face of the gear is sharp, it could mill into the bearing block. If wear is evident then the parts must be replaced.

Inspect the bearing blocks for excessive wear or scoring on the surfaces that are in contact with the gears. Also inspect the bearing for excessive wear or damage.

Inspect the area inside the gear housings. It is normal for the surface inside the gear housing to show a clean “wipe” on the surface of the intake side. There should however be no excessive wear or scoring.

Note: Before removing or dismantling the motor, check that its performance is as specified in Technical Data. If the performance is below that specified, the motor should be renewed. Renewal of components such as gears, bearings and housing will not effect a permanent cure. if a motor’s output is satisfactory but there is evidence of external leakage, it should be dismantled for re-sealing only. Before dismantling make sure the motor’s external body and the work area are thoroughly cleaned and are free from possible causes of contamination.

Dismantling, Inspection and Assembly For motor components, K Fig 85. ( T G-111). Dismantling Note: It is very important to work in a clean environment when repairing hydraulic motors. Plug all ports and wash the exterior of the motor with a proper cleaning solvent before stripping the motors. 1

Remove the port plugs and ensure all oil is drained from the motor.

Prior to dismantling the motor, mark the motor body 9 and flanges 3 and 16 with a permanent marker pen to ensure correct alignment when assembling.

Mount the motor vertically in a vice (use vice soft-jaws to protect the motor mounting flange) by the mounting flange, with the driveshaft pointing downwards and slacken the bolts 23.

Remove the bolts 23, washers 22 and the rear housing 16.

Carefully remove the gear housing 9 and place on a clean work bench. Ensure the rear bearing block 13 stays in place on the driveshaft gear 12 and idler gear 11.

Remove the rear bearing block 13, remove the idler shaft 11 and the driveshaft gear 12.

Remove the front bearing block 6.

Turn the mounting flange over, with the shaft seal uppermost, and remove the retaining circlip 1 and the seal 2.

Clean all sealant from mating surfaces, discard the seal and O-rings

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The motor must be renewed if any of the following defects are found: i

The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.

The PTFE coated bearings in the body or flanges are worn through so that the bronze base is visible.

iii The gear side faces or bearing blocks are scarred. iv The driveshaft has a wear groove where the shaft seal lips run.

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Section G - Hydraulics Cooling Fan Motor Removal and Replacement Assembly

petroleum jelly to the O-rings (7 and 10) and install them in their grooves.

Wash all components in a suitable aromatic solvent. When dry apply hydraulic fluid immediately to prevent moisture collecting. 1

Install a new shaft seal 2 into the mounting flange 3, with the part number of the seal facing outwards. Press the new seal into its bore until fully seated. Install the circlip 1 into its groove in the mounting flange 3.

Place the front 6 and rear 13 bearing blocks on a clean work bench with the E-seal grooves facing upwards. Apply a coating of petroleum jelly to the grooves. Apply a coating of petroleum jelly to the Eseals and back-up seals. (This will help keep the seals in place during assembly.)

Place the E-seals 5 and 14, flat side outwards, into the bearing blocks 6 and 13. Carefully place the backup seals 4 and 15, with the flat side outwards, in the respective groove made by the E-seal and the groove in the bearing block.

Note: In the centre of the back-up seal and the E-seal there is a â&#x20AC;&#x153;notchâ&#x20AC;?. Make sure these notches line up, so that the back-up seal sits flush with the E-seal. 4

Place the mounting flange 3, with the seal side facing downwards on a clean flat surface.

Apply a light coating of petroleum jelly to the exposed face of the front bearing block 6.

Insert the drive end of the driveshaft 12 through the bearing block 6 with the seal side down, and the open side of the E-seal pointing to the intake side of the motor.

Install a sleeve over the driveshaft threads to protect the seal 2 and carefully slide the driveshaft through the seal 2. Remove the sleeve from the driveshaft.

Gently slide the gear housing 9 over the rear bearing block 14. Slide the housing down until the housing dowel pins come into contact with their respective bores in the mounting flange 3. Press the housing home firmly with your hands, do not force or use any kind of tool. Make sure that the intake port in the housing is on the same side as the open end of the Eseal 14 and that the marks made on the casings prior to dismantling are in alignment.

The surface of the rear bearing block 13 should be slightly below the face of the gear housing 9. If the bearing block sits higher than the rear face of the housing then the E-seal or O-ring may have become detached from its seat and be trapped. Remove the housing and check the seals for correct installation.

Install the rear housing 16 onto the dowels in the housing 9, taking care to align the marks made on the casings prior to dismantling and press home using hand pressure only.

Install the four bolts 23 with their respective washers 22 and hand tighten.

Place the assembled motors into a vice (using soft jaws to protect the mounting flange) and alternately tighten the bolts 23 to the torque specified in K Table 21. ( T G-110).

Remove the motor assembly from the vice.

Place a small amount of clean hydraulic oil in the inlet of the motors and rotate the driveshaft away from the inlet by one revolution. If the driveshaft binds, disassemble the motor and check for assembly problems. Rectify the problems and reassemble the motor.

Item 8

Install the idler gear shaft 11 into the remaining position in the bearing block. Apply a light coat of clean hydraulic oil to the face of the driveshaft and idler gears.

Pick up the rear bearing block 13, with the seals facing upwards and the open ends of the E-seals facing the intake side of the motor, and place over the driveshaft and idler gear shafts.

Ensure the dowel pins 8 are in place in the housing 9.

Table 21. Kgf m

lbf ft

4.08

29.5

5.71

41.3

Note: On later housings there are two long dowels through the housing that locate in the front mounting flange and the rear cover. These replace the four short dowels item 8. 11

Apply a coating of petroleum jelly to the seal grooves in both sides of the housing 9. Apply a light coating of

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Locating dowels

Front bearing block

E-seal

O-ring

Back-up seal

Front housing

Seal

Table 22. Uni-Directional Motor Circlip

10 11

Gear housing

Fig 85. Uni-Directional Motor Components

17 Proportional relief valve cartridge

16 Rear housing

15 Back-up seal

14 E-seal

13 Rear bearing block

12 Driveshaft gear

11 Idler gear

10 O-ring

13 16

23 Bolt

22 Washer

21 Valve seat

20 Ball

19 Spring

18 Measuring coupling

Section G - Hydraulics Cooling Fan Motor

Removal and Replacement

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Section G - Hydraulics Cooling Fan Motor Removal and Replacement

Bi-Directional Motor

Turn the mounting flange over, with the shaft seal uppermost, and remove the retaining circlip 1 and the seal 2.

Clean all sealant from mating surfaces, discard all seals and “O” rings.

General Note: Before removing or dismantling the pump, check that its performance is as specified in Technical Data. If the performance is below that specified, the motor should be renewed. Renewal of components such as gears, bearings and housing will not effect a permanent cure. If a motor’s output is satisfactory but there is evidence of external leakage, it should be dismantled for re-sealing only. Before dismantling make sure the motor’s external body and the work area are thoroughly cleaned and are free from possible causes of contamination.

Inspection 1

Clean and dry all parts thoroughly prior to inspection. (It is not necessary to check the seals as all seals need to be replaced). Inspect all “O” ring grooves and shaft seal recesses, make sure there are no burrs.

Check the driveshaft for damage. Check for marks or grooves on the driveshaft in the area of the seal. Slight discolouration of the shaft is allowable.

Inspect the faces of the gears for scoring or excessive wear. If the face of the gear is sharp, it could mill into the bearing block. If wear is evident then the parts must be replaced.

Inspect the bearing blocks for excessive wear or scoring on the surfaces that are in contact with the gears. Also inspect the bearing for excessive wear or damage.

Dismantling, Inspection and Assembly For motor components, K Fig 86. ( T G-114). Dismantling Note: It is very important to work in a clean environment when repairing hydraulic motors. Plug all ports and wash the exterior of the motor with a proper cleaning solvent before stripping the motors. 1

Remove the port plugs and ensure all oil is drained from the pump. Prior to dismantling the motor, mark the motor body 7, flange 3 and the solenoid operated control valve 14 with a permanent marker pen to ensure correct alignment when assembling. Mount the motor vertically in a vice (use vice soft-jaws to protect the motor mounting flange) by the mounting flange 3 with the driveshaft pointing downwards and slacken the bolts 16.

Remove the bolts 16, washers 17 and the solenoid operated control valve 14.

Carefully remove the gear housing 7 and place on a clean work bench. Ensure the rear bearing block 12 stays in place on the driveshaft and idler gears, items 11 and 10.

Remove the rear bearing block 12, remove the driveshaft 11 and the idler gear 10.

Remove the front bearing block 5.

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The motor must be renewed if any of the following defects are found: v

The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.

vi The PTFE coated bearings in the body or flanges are worn through so that the bronze base is visible. vii The gear side faces or bearing blocks are scarred. viii The driveshaft has a wear groove where the shaft seal lips run.

G - 112

Section G - Hydraulics Cooling Fan Motor Removal and Replacement Assembly

Apply a coating of petroleum jelly to the seal grooves in both sides of the housing 7. Apply a light coating of petroleum jelly to the O-rings (6 and 9) and install them in their grooves.

Gently slide the gear housing 7 over the rear bearing block 12. Slide the housing down until the housing dowel pins come into contact with their respective bores in the mounting flange 3. Press the housing home firmly with your hands, do not force or use any kind of tool. Make sure that the marks made on the casings prior to dismantling are in alignment.

The surface of the rear bearing block 12 should be slightly below the face of the gear housing 7. If the bearing block sits higher than the rear face of the housing then the seal or O-ring may have become detached from its seat and be trapped. Remove the housing and check the seals for correct installation.

Install the solenoid operated control valve 14 onto the dowels in the housing 7, taking care to align the marks made on the casings prior to dismantling and press home using hand pressure only.

For motor components, K Fig 86. ( T G-114) Wash all components in a suitable aromatic solvent. When dry apply hydraulic fluid immediately to prevent moisture collecting. 1

Place the front 5 and rear 12 bearing blocks on a clean work bench with the seal grooves facing upwards. Apply a coating of petroleum jelly to the grooves. Apply a coating of petroleum jelly to the seals 4 and 13 (This will help keep the seals in place during assembly.)

Place the seals 4 and 13, flat side outwards, into the bearing blocks 5 and 12.

Place the mounting flange 3, with the seal side facing downwards, on a clean flat surface.

Install the four bolts 16 with their respective washers 17 and hand tighten.

Apply a light coating of petroleum jelly to the exposed face of the front bearing block 5.

Place the assembled motor into a vice (using soft jaws to protect the mounting flange) and alternately tighten the bolts 16 to the torque specified in K Table 23. Torque Settings ( T G-113).

Remove the motor assembly from the vice.

Insert the drive end of the driveshaft 11 through the bearing block 5 with the seal side down.

Install a protective sleeve over the driveshaft to protect the seal 2 and carefully slide the driveshaft through the seal 2. Remove the protective sleeve from the driveshaft.

Install the idler gear shaft 10 into the remaining position in the bearing block. Apply a light coat of clean hydraulic oil to the face of the driveshaft and idler gears.

Pick up the rear bearing block 12, with the seals facing upwards and place over the driveshaft and idler gear shafts.

Item

Table 23. Torque Settings Nm Kgf m lbf ft

4.08

29.5

5.71

41.3

Ensure the dowel pins 8 are in place in the housing 7.

Note: On later housings there are two long dowels through the housing that locate in the front mounting flange and the rear cover. These replace the four short dowels item 8.

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Seal

Front housing

Seal

Front bearing block

O-ring

Gear housing

Locating dowels

Table 24. Bi-Directional Motor Circlip

1 4

9 10

Bolt

Proportional relief valve cartridge

Solenoid operated control valve

Seal

Rear bearing block

Driveshaft gear

Idler gear

O-ring

Fig 86. Bi-Directional Motor Components

Washer

Section G - Hydraulics Cooling Fan Motor

Removal and Replacement

G - 114

Section H - Hydraulics

Rams Precautions During Use TE-006

Installation 1

Special seal materials are necessary so check to see if the ram that you are using is suitable or not.

Precautions when installing the ram on the machine. a

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

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

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.

When painting the machine, mask 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

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.

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

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.

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

Install the ram only when it is clean.

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.

Caution During Use

Maintenance, Inspection Points

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.

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Carry out daily maintenance and inspection. a

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

H - 115

Section H - Hydraulics Rams Precautions During Use 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. 2

Use genuine JCB parts when replacing parts. 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.

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H - 116

Section H - Hydraulics Rams Typical Ram

Typical Ram Dismantle and Assembly K Fig 88. ( T H-118). The numerical sequence shown on the illustration is intended as a guide to dismantling.

Dismantle 1

Place ram assembly on a locally manufactured strip/ rebuild bench. K Fig 87. ( T H-117).

Fig 87. 2

Use the correct size spanner to release end cap 88-1 and remove the piston rod assembly 88-9 from the cylinder.

!MWARNING If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod. HYD-1-2

Position piston rod assembly on bench in place of ram cylinder. Remove seals 88-5, 88-6 and wear ring 884, 88-7 from piston head 88-3.

Extract dowel 88-2 from the piston head using the appropriate sized screw threaded into the extractor hole.

Use the correct size spanner, remove piston head 883 from rod 88-9 and remove ‘O’ ring 88-8.

Remove gland bearing and end cap 88-1 from piston rod and remove the ‘O’ ring 88-10, wiper seal 88-12 and rod seal 88-11. Check end cap bearing for damage, scores or nicks. If damaged, the bearing must be replaced as part of the end cap assembly.

Ensure that metal components are free from scoring, nicks and burrs. A damaged piston rod will impair the life of the gland seals. Check the bore of the ram cylinder for damage.

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H - 117

Section H - Hydraulics Rams Typical Ram

Fig 88. Typical Ram

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H - 118

Section H - Hydraulics Rams Typical Ram Assemble Ram size 1

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and old sealing/retaining compounds. Allow 15 minutes for solvent to dry before applying JCB Threadlocker and Sealer (High Strength).

Important: Ensure that seals or ‘O’ rings do not come into contact with JCB Activator or anaerobic sealing and retaining compounds such as JCB Threadlocker and Sealer. 2

Table 25. Torque Settings Item Nm kgf m

lbf ft

All except 60 x 30 & 50 x 25

678

500

All except 60 x 30 & 50 x 25

405

300

60 x 30 only

450

332

60 x 30 only

300

221

50 x 25 only

400

295

50 x 25 only

250

184

Fit new seals, ‘O’ rings and wear rings. For the correct method of fitting seals to the end cap Ram Sealing and piston head, K JCB Procedure ( T H-120).

Important: Ensure that lubricants used during assembly do not come into contact with degreased components or sealing/retaining compounds. 3

Fit locking dowel 88-2 to piston 88-3. K Piston Head Retention ( T H-122).

Position cylinder 88-19 on the bench and install the piston rod assembly into the cylinder.

Apply JCB Activator to threads of end cap and cylinder. Allow JCB Activator to dry for 15 minutes before bringing into contact with JCB Threadlocker.

Apply JCB Threadlocker to threads of cylinder and torque tighten end cap 88-1. K Table 25. Torque Settings ( T H-119).

Note: If hydraulic oil contacts uncured JCB Threadlocker a weakening of the bond will result. Cure times vary according to the ambient temperature. The following approximate cure time applies at 20 °C and is the minimum period between assembly and filling the ram with oil. JCB Threadlocker & Sealer (High Strength) or JCB Threadlocker with JCB Activator - 1 hour. Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.

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H - 119

Section H - Hydraulics Rams Typical Ram

JCB Ram Sealing Procedure TE-005_2

Fit new rod seals. Use seal fitting tool 89-A to fit rod seals, the size (diameter) and position of pins 89-B is determined by the diameter and radial width of the rod seal being fitted.

153212-1

Fig 91. b Close the tool. K Fig 92. ( T H-120). The seal must form a reniform (kidney shape). S216250-1

Fig 89. Seal Fitting Tool The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals. a

Open the tool and insert the new rod seal 90-A. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

S161750 Y-1

Fig 92. c

Before fitting the rod seals check the seal grooves are free of contamination and sharp edges.

d Locate the seal in the end cap groove. K Fig 93. ( T H-120). When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its grooved and remove the tool.

S161750 X-1

Fig 90. Note: Later ram end caps and piston heads are metric threads. The seals are also different, make sure the correct seals are fitted. On metric threaded rams make sure the seals are fitted the correct way round, as shown at 91-A and 91-B. S161750 Z-1

Fig 93. e

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Fit rod wiper seal 91-A into seal groove. Make sure the seal is correctly installed as shown.

H - 120

Section H - Hydraulics Rams Typical Ram Note: Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to ensure the seal is square before it is pressed in.

b Fit outer seal 95-C using the same procedure as stated for seal 95-B. Check the external grooves are visible. c

Sleeve 94-A must be used to protect the rod seals from damage when fitting end cap onto the piston rod. There are various sizes of sleeve, see Service Tools, Section 1. Make sure the hexagon on the end cap is towards the eye end of the rod.

Ensure the O-ring is fitted into the internal seal groove on the piston head. Screw the piston head onto the thread of the piston rod, refer to the relevant section for torque figure and completion of ram assembly.

d Fit the piston head retaining dowel, refer to the relevant section for torque figure and completion of ram assembly. e

Fit wear rings 96-A and 96-B. Rotate the wear rings so that the piston retention dowel is covered by the wear ring, Not as shown at 96-C.

187361-1

Fig 94. 2

Fit new head piston seals. a

Use a blunt instrument 95-A (Part no. 892/01027) to lever the inner seal 95-B into the piston head seal groove. Do not let the seal twist. There are identification marks on the outer diameter of the seal, make sure the marks are visible and the seal is free to rotate, if not remove the seal and refit. 338490-1

Fig 96. 3

Fit the piston rod and head assembly into the cylinder. a

Insert the piston/rod assembly into the cylinder. Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.

b Fit the end cap, refer to the relevant section for torque figure and completion of ram assembly.

338480-1

Fig 95.

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Section H - Hydraulics Rams Typical Ram

Piston Head Retention

Drilling Dimensions

Fit locking dowel to piston as follows:

Existing piston head and rod Align holes so that dowel can be fitted with tapped extractor hole showing.

New piston head and rod Drill and ream piston head and rod to the diameter and depth indicated. K Drilling Dimensions ( T H-122). Remove all swarf and contamination and insert dowel with tapped extractor hole showing. Note: Ensure that the top of the dowel is below the level of the bearing ring groove and use an undersized pilot drill before drilling to the final size shown in the table. Fig 97.

Existing piston head and new rod Table 26. Drill Depth Chart Diameter X Depth Y

Drill through existing hole in piston head to the diameter and depth indicated. K Drilling Dimensions ( T H-122). Remove all swarf and contamination and insert dowel with tapped extractor hole showing.

Ram size

Note: Ensure that the top of the dowel is below the level of the bearing ring groove and use an undersized pilot drill before drilling to the final size shown in the table.

70 x 40

6.02mm - 6.10mm

22.0mm - 23.0mm

80 x 50

6.02mm - 6.10mm

22.0mm - 23.0mm

50 x 25

6.02mm - 6.10mm

22.0mm - 23.0mm

New piston head and existing rod Same as Existing piston head and new rod but at 90 degrees to existing hole in rod.

H - 122

90 x 50

8.02mm - 8.10mm

27.0mm - 28.0mm

60 x 30

6.02mm - 6.10mm

22.0mm - 23.0mm

100 x 60 8.02mm - 8.10mm

27.0mm - 28.0mm

130 x 70 12.02mm -12.10mm

37.0mm - 38.0mm

110 x 60 12.02mm -12.10mm

32.0mm - 33.0mm

110 x 65 12.02mm -12.10mm

32.0mm - 33.0mm

140 x 75 12.02mm -12.10mm

47.0mm - 48.0mm

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H - 122

Section E - Hydraulics

SRS Isolating Valve Removal and Installation Removal

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Install the articulation strut A. K Fig 1. ( T E-123).

The SRS isolating valve is located at the front of the machine. K Fig 2. ( T E-123).

A327750-1

Fig 2. 8

Put a container below the control valve D to collect the hydraulic fluid.

Disconnect the hose B. K Fig 3. ( T E-124).

Install blanking caps to prevent contamination and excess fluid loss.

Disconnect the isolating valve C from the control valve D.

If you install a new valve:

P002110

Fig 1. 3

Release the hydraulic pressure. Refer to Venting the Hydraulic Pressure, Service Procedures.

Release the Smooth Ride System (SRS) pressure. Refer to Venting the Smooth Ride System, Service Procedures.

b Remove the original adapters E, F, G and transfer them to the new valve.

Remove the starter key from the cab.

Isolate the battery.

E-123

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Working at a bench, use soft grips to clamp the isolating valve C in a vice.

E-123

Section E - Hydraulics SRS Isolating Valve Removal and Installation

G F C E B

P006110

Fig 3.

Installation

Check the level of the hydraulic oil. Add as necessary.

The installation procedure is the reverse of the removal procedure.

Check the system for leaks.

Check the operation of the isolating valve.

During the installation procedure: 1

If you install a new valve: a

Working at a bench, use soft grips to clamp the isolating valve C in a vice.

b Remove the original adapters E, F, G and transfer them to the new valve.

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E-124

Section E - Hydraulics

SRS Control Valve Removal and Installation Removal

Put a container below the SRS control valve K to collect the hydraulic fluid.

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Install blanking caps onto the hoses B, C, D and E to prevent contamination and excessive fluid loss.

Install the articulation strut A.

Disconnect the electrical connector.

Support the SRS control valve K and remove the securing bolts F (x2).

If you install a new control valve, remove the adapters G, H, I and J, and transfer them to the new valve.

Installation The installation procedure is the opposite of the removal procedure. 1

Check the hydraulic oil level, top-up as necessary.

Check the valve operation.

Check the valve for leaks.

P002110

Fig 1. 3

Release the Hydraulic pressure. Refer to Releasing the Hydraulic Pressure, Maintenance Section.

Remove the SRS Isolating Valve. Refer to SRS Isolating Valve, Removal and Installation.

Label the SRS control valve hoses to aid installation.

Disconnect the hoses B, C, D and E from the SRS control valve K.

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E-125

Section E - Hydraulics SRS Control Valve Removal and Installation

G B

H C

K D

P003360

Fig 2. SRS Control Valve Assembly P003350

Fig 3. SRS Control Valve With Adapters

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E-126

Section E - Hydraulics

SRS Accumulators Removal and Installation Removal 1

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Install the articulation strut A.

Install blanking caps onto the hoses B to prevent contamination and excessive fluid loss.

Working below the front right fender loosen the nuts (x4) C at the top accumulator E and the nuts (x4) D at the lower accumulator F.

Remove the accumulators E and F from the machine.

Installation The installation procedure is the opposite of the removal procedure. 1

Make sure to install the pre-charged accumulators.

Check the hydraulic level, top up as necessary.

Check the accumulator for leaks.

P002110

Fig 1. 3

Release the SRS pressure. Refer to De-Pressuring the Smooth Ride System, Maintenance Section.

Label the accumulator hoses B to aid installation.

Disconnect the hoses B.

Put a container below the accumulators E and F to collect the hydraulic fluid.

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E-127

Section E - Hydraulics SRS Accumulators Removal and Installation

B D

P003820

Fig 2. SRS Accumulators

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E-128

Section E - Hydraulics

Servo Control Lever Removal and Installation Removal 1

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Install the articulation strut A.

B P002440

Fig 2. 4

Remove the gaiter retaining plate C.

C P002110

Fig 1. 3

Remove the securing screws B from the gaiter.

P002450

Fig 3.

E-129

Remove the securing screws D from the trim panel E.

Remove the trim panel E.

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E-129

Section E - Hydraulics Servo Control Lever Removal and Installation

E P002480

Fig 6.

P002460

Fig 4. 9 7

Remove the cable clamp screw F.

Loosen the securing nut H, then unscrew the lever I from the servo valve.

I F

H P002470

Fig 5. 8

P002490

Disconnect the electrical connectors G.

Fig 7.

Installation The installation procedure is the opposite of the removal procedure.

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E-130

Section E - Hydraulics

Servo Valve Removal and Installation Removal 1

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Important: Make sure all of the pilot pressure is released, refer to Releasing the Hydraulic Pressure. 2

Install the articulation start A.

B P002440

Fig 2. 4

Remove the gaiter retaining plate and gaiter C.

P002110

Fig 1. 3

Remove the securing screws B (x4) from the gaiter. P002450

Fig 3. 5

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Remove the securing screws D (x3) from the trim panel.

E-131

Section E - Hydraulics Servo Valve Removal and Installation 6

Remove the trim panel E.

E P002480

Fig 6. P002460

Fig 4. 7

Loosen the lever securing nut H and unscrew the lever I from the servo valve.

Remove the cable clamp screw F.

P002470

P002490

Fig 5. 8

Disconnect the electrical connectors G.

E-132

Fig 7. 10

Remove the securing screws J (x4) from the lower access panel.

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E-132

Section E - Hydraulics Servo Valve Removal and Installation

P002500

P002520

Fig 8.

Fig 10. 12

Remove the securing bolts from the servo valve, then remove the servo valve.

Installation The installation procedure is the opposite of the removal procedure.

P002510

Fig 9. 11

Put a label on the servo hoses and disconnect.

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Section E - Hydraulics Servo Valve Removal and Installation

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E-134

Section E - Hydraulics

Loader Valve Removal and Installation Removal 1

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Important: Make sure all of the pilot pressure is released, refer to Releasing the Hydraulic Pressure. 2

Install the articulation strut A.

B P011020

Fig 2. 5

Label the hoses D to help the installation.

Remove all the hose connections D from the loader valve F. Blank the hoses and fittings to prevent contamination and excessive oil loss.

P002110

Fig 1. 3

Remove the bolts B (x4) that secure the loader valve cover plate C.

Remove the cover plate C.

D D D P011030

Fig 3.

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Section E - Hydraulics Loader Valve Removal and Installation 7

Attach suitable lifting equipment to the lift-eye E on the top of the valve F.

Apply a little tension to the lift-eye to support the valve F while the retaining bolts G are removed.

Installation The installation procedure is the opposite of the removal procedure. 1

Top-up with hydraulic fluid if necessary.

Operate the machine and check for leaks.

E F

P011040

Fig 4. 9

Working on the underside of the valve F remove the bolts G (x3) and washers H (x3) that secure the valve F to the chassis.

H G

P011050

Fig 5. 10

Remove the valve F from the machine.

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Section E - Hydraulics

Stall Speed Tests Hot Test Settings Introduction

For the stall speed tests the hydraulic temperature gauge, the coolant gauge and the transmission gauge must show at least 4 bars.

You must warm the machine before checking that: - The coolant is above 800C 0

- The hydraulic oil is between 45-55 C. For a stall speed test with the transmission engaged, take a reading just before it enters the red band.

For the fan rpm, the hydraulic temperature gauge must show at least 4-5 bars. At flight, loosen the adjuster to slow the fan below the required value, then increase the fan to the required value. All of the electrics must be OFF.

To show the actual temperatures for the transmission, coolant and the hydraulic fluids (instead of using a gauge):

Make sure the A/M switch is OFF and the transmission disconnect function is OFF. Select 3rd gear.

- With the ignition ON, push SETUP, then the UP ARROW until TRANS OIL or WATER or HYD OIL TEMP is shown.

For a stall speed test with the transmission engaged, take a reading just before it enters the red band.

- Push SETUP again to show the temperature related to the selected fluid. Start the engine.

Report excessive or continual adjustments to the Engineering Department, who will contact the Supplier.

- To select another fluids push SETUP, then the ARROW to select the fluid, then SETUP again to show its temperature.

Complete all of the entries. If the specifications are not met, contact the Engineering Department.

Before you check the stall speed, all of the electrics must be OFF (air conditioning, lights, heater blower, etc). Make sure the A/M switch and the transmission disconnect functions are OFF. Select 3rd gear.

Keep the completed test sheets for a minimum of 12 months. The test sheet is subject to a continuous update by the Engineering Department.

Report excessive or continual adjustments to the Engineering Department, who will contact the Supplier. Complete all of the entries. If the specifications are not met, contact the Engineering Department. Keep the completed test sheets for a minimum of 12 months. The test sheet is subject to a continuous update by the Engineering Department. For Tier 2 engines: For pumps, steering, auxiliary relief valves, brakes and lift time the hydraulic temperature gauge must show at least 4 bars.

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Section E - Hydraulics Stall Speed Tests Hot Test Settings

434S T3 ZF Axles Serial No:..................................

Destination:..........................................

Inspector:...........................

Build No:.................................

Fuel Colour:.........................................

Date:.....................................

Pressures are in bars

Requirements

Pumps

434S

Standby - P1

27-29

Standby - P2

25-27

Control pilot

27-33

System pressure - P1

250-255

System pressure - P2

160-165

Initial

Final

Reading

Steering (where a ‘full lock’ test is required, steer slowly into full lock to make sure the relief valve opens fully) P1 at idle, LS is connected, after standby is set

40-43 typical

Steer pressure at P1 on full lock

215-225

Check steering does not ‘stick’, especially on full lock

Ok/Sticks

Emergency Steer Pump

55-56

Auxiliary Relief Valves Lift headside ARV @ minimum engine speed at P1

340-350(1)

Bucket rodside ARV @ minimum engine speed at P1

260 typical, must exceed P1

Bucket headside ARV @ minimum engine speed at P1

125-140

Brakes Brake charge cut-in

155-165

Brake charge cut-out

195-205

Brake line pressure

95-105

Brake, dead engine:...Line pressure on 1st pedal press

95-105

...Line pressure on 5th full pedal press

Must equal 1st press

Fan RPM at flight (Disconnect plug next to adjuster)

1800-1810

Fan RPM at flight (after plug is re-connected)(2)

1260-1810

Engine Stall Speed (RPM) Idle

850+/-5

Flight

2370 +/-5

Transmission stall in 3rd gear

2240-2260

Hydraulic RV stall (arms fully lowered)

+0/-10 of flight

Combined transmission and hydraulic

+0/-50 of transmission stall

Steer RV stall Combined transmission and steer RV

+0/-10 of flight +0/-50 of transmission stall

Lift Time (Seconds) Full lift cycle, maximum revolutions

(1) Can not be set by production, make sure the reading = P1 record. If less than P1 contact Engineering. (2) The fan speed is software controlled. After reconnecting if it still reaches maximum setting, check for a fault.

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E-138

Section E - Hydraulics Stall Speed Tests Hot Test Settings

434S T3 Graziano Axles Serial No:..................................

Destination:..........................................

Inspector:...........................

Build No:.................................

Fuel Colour:.........................................

Date:.....................................

Pressures are in bars

Requirements

Pumps

434S

Standby - P1

27-29

Standby - P2

25-27

Control pilot

27-33

System pressure - P1

250-255

System pressure - P2

160-165

Initial

Final

Reading

Steering (where a ‘full lock’ test is required, steer slowly into full lock to make sure the relief valve opens fully) P1 at idle, LS is connected, after standby is set

40-43 typical

Steer pressure at P1 on full lock

215-225

Check steering does not ‘stick’, especially on full lock

Ok/Sticks

Emergency Steer Pump

55-56

Auxiliary Relief Valves Lift headside ARV @ minimum engine speed at P1

340-350(1)

Bucket rodside ARV @ minimum engine speed at P1

260 typical, must exceed P1

Bucket headside ARV @ minimum engine speed at P1

125-140

Brakes Brake charge cut-in

155-165

Brake charge cut-out

195-205

Brake line pressure

75-85

Brake, dead engine:...Line pressure on 1st pedal press

75-85

...Line pressure on 5th full pedal press

Must equal 1st press

Fan RPM at flight (Disconnect plug next to adjuster)

1800-1810

Fan RPM at flight (after plug is re-connected)(2)

1260-1810

Engine Stall Speed (RPM) Idle

850+/-5

Flight

2370 +/-5

Transmission stall in 3rd gear

2240-2260

Hydraulic RV stall (arms fully lowered)

+0/-10 of flight

Combined transmission and hydraulic

+0/-50 of transmission stall

Steer RV stall Combined transmission and steer RV

+0/-10 of flight +0/-50 of transmission stall

Lift Time (Seconds) Full lift cycle, maximum revolutions

E-139

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E-139

Section E - Hydraulics Stall Speed Tests Hot Test Settings

435S T4i Axles Serial No:..................................

Destination:..........................................

Inspector:...........................

Build No:.................................

Fuel Colour:.........................................

Date:.....................................

Pressures are in bars

Requirements

Pumps

434S

Standby - P1

27-29

Standby - P2

25-27

Control pilot

27-33

System pressure - P1

250-255

System pressure - P2

160-165

Initial

Final

Reading

Steering (where a ‘full lock’ test is required, steer slowly into full lock to make sure the relief valve opens fully) P1 at idle, LS is connected, after standby is set

40-43 typical

Steer pressure at P1 on full lock

215-225

Check steering does not ‘stick’, especially on full lock

Ok/Sticks

Emergency Steer Pump

55-56

Auxiliary Relief Valves Lift headside ARV @ minimum engine speed at P1

340-350(1)

Bucket rodside ARV @ minimum engine speed at P1

260 typical, must exceed P1

Bucket headside ARV @ minimum engine speed at P1

125-140

Brakes Brake charge cut-in

155-165

Brake charge cut-out

195-205

Brake line pressure

60-65

Brake, dead engine:...Line pressure on 1st pedal press

60-65

...Line pressure on 5th full pedal press

Must equal 1st press

Fan RPM at flight (Disconnect plug next to adjuster)

1800-1810

Fan RPM at flight (after plug is re-connected)(2)

1260-1810

Engine Stall Speed (RPM) Idle

950/700 +/-5

Flight

2360 +/-5

Transmission stall in 3rd gear

2160 +/-5

Hydraulic RV stall (arms fully lowered)

+0/-10 of flight

Combined transmission and hydraulic

+0/-50 of transmission stall

Steer RV stall Combined transmission and steer RV

+0/-10 of flight +0/-50 of transmission stall

Lift Time (Seconds) Full lift cycle, maximum revolutions

E-140

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E-140

Section F Transmission Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

Section F - Transmission

Notes:

F-0

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F-0

Section F - Transmission Contents Page No. Technical Data Transmission ........................................................................................... F - 1 Axles ........................................................................................................ F - 2 Tyres ........................................................................................................ F - 5 Axles Front Axle ................................................................................................ F - 7 Rear Axle ................................................................................................. F - 8 Hub and Driveshaft ................................................................................ F - 12 Drive Head ............................................................................................. F - 17 Crown Wheel and Pinion ....................................................................... F - 24 Limited Slip Differential Unit .................................................................. F - 26 ZF Axles ................................................................................................ F - 29 Removal and Replacement General ................................................................................................ F - 121 Propshafts Basic Operation ................................................................................... F - 123 Powershift Transmission WG 210 ............................................................................................... F - 125 Functional Testing General Information ............................................................................. F - 187 Transmission Fault Finding ................................................................. F - 193 Removal and Replacement ................................................................. F - 250 Electronic Monitoring System Display Panel ....................................... F - 252

F-i

Section F - Transmission Contents

F - ii

Page No.

F - ii

Section F - Transmission Technical Data Transmission

Technical Data Transmission Important: Before attempting to tow the machine read the instructions, see Section 1 - Basic Operation. Type

Powershift Type WG-210

Torque Converter Dia.

300mm (11 in)

Torque Multiplication at Stall

3.01:1 (434S) 2.95:1 (435S)

Gear Ratios

Forward

Reverse

1st

5.562

1st

5.274

2nd

3.615

2nd

2.138

3rd

2.555

3rd

0.894

4th

1.466

Not Applicable

5th

0.942

Not Applicable

6th

0.613

Not Applicable

Charge pump flow

105 l/min (23.1 gal/min) @ 2000 rev/min

Oil Temperature

80 to 95Â°C (176 to 203Â°F)

Stall Testing

Note: Switch off transmission dump (transmission disconnect); the switch on the cab roof panel should not be illuminated. Engage the parking brake and apply the footbrake. Select Forward Drive, keep brake pedal pushed down, push the accelerator pedal down fully and record the engine speed. Maximum engine speed (rev/min) at:

434S-Graziano 434S-ZF

435S-ZF

- Converter stall only

2270 - 2280

2240 - 2260

2150 - 2160

2070 - 2080

1925 - 1935

-1st Gear

F-1

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F-1

Section F - Transmission Technical Data Axles

Axles Unit Identification

The axle serial number is stamped on the unit identification plate A as shown. When ordering replacement parts, always quote the details on the unit identification plate. In the case of gear replacemets, always check the part number stamped on the gear and verify the number of teeth.

Fig 1.

434S - Graziano (With Standard or Limited Slip Differential) Front

Rear

Crownwheel & Pinion Ratio

4.083:1

Crownwheel & Pinion Ratio

4.083:1

Hub Ratio

5.16:1

Hub Ratio

5.16:1

Overall Axle Ratio

21.098:1

Overall Axle Ratio

21.098:1

Note: Front and rear axles can have Standard Differential (S) or Limited Slip Differential (LSD).

F-2

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F-2

Section F - Transmission Technical Data Axles

ZF Axles (With Standard or Limited Slip Differential or Auto Differential lock) Table 1. Rear

Front Multi-Disk Differential Lock Axle Weight

Rear

Multi-Disk Differential Lock 1080 kg

Axle Weight

780 kg

Axle Ratio

20.184:1

Axle Ratio

21.53:1

Bias Ratio

0% / 30% / 100%

Bias Ratio

0% / 30% / 100%

Torque Information 1

Front Axle Torque all of the bolts to 874Nm.

333-R7272-3-1

Fig 2.

Front Trunnion - Rear Axle Torque all of the bolts 1 to 259Nm.

333-R3711-4-1

Fig 3.

F-3

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F-3

Section F - Transmission Technical Data Axles Rear Trunnion - Rear Axle

5 4

3 333-R3459-4-1

Fig 4. 1

22Nm

311Nm

259Nm

311Nm

360Nm

F-4

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F-4

Section F - Transmission Technical Data Tyres

Tyres Table 2. Tyre Sizes and Pressures Size

Bar (front)

lbf/in2 (front)

Bar (rear)

lbf/in2 (rear)

750/65R26

2.7

1.8

620/75R26

3.8

2.4

F-5

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F-5

Section F - Transmission Technical Data Tyres Page left intentionally blank

F-6

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F-6

Section F - Transmission

Axles Front Axle Replacement

Raise the loader arms and fit the safety strut.

!MWARNING

For assembly the removal sequence should be reversed.

A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine.

Refit the road wheels and carry out wheelnut tightness check. Bleed the brake system. Check the axle and hubs are filled to the correct level with the appropriate oil, see Section 3 - Routine Maintenance for recommended oil.

Item

Table 3. Torque Settings Nm kgf m

lbf ft

785

579

GEN-1-1

Removal

Raise and support the front end of the machine. Remove the front road wheels. Disconnect the brake hose at the axle. Blank exposed connections. Disconnect front propshaft at axle yoke. Support the axle on a trolley jack at the point of balance. Remove nuts and bolts securing axle. Remove the axle. If dismantling of the axle is to be carried out, drain the axle as detailed in Section 3 - Routine Maintenance.

F-7

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F-7

Section F - Transmission Axles Rear Axle

Rear Axle

!MWARNING

Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

INT-1-3-7_2

GEN-1-1

Raise and support the rear of the machine.

Important: The lifting equipment required to carry out this procedure, MUST be capable of lifting and holding the weight of the rear of the machine, approximately 8 tonnes. Likewise any stands or axle blocks intended for use as a part of this procedure MUST also be capable of holding this weight.

Disconnect the remote grease hoses from the front and rear trunnions.

Disconnect the brake hose from the axle to the chassis. Blank off the exposed connections.

Remove the bolts 13 complete with washers 11 from the end cover 14, and remove the end cover.

Remove the thrust washer 6 from the rear face of the trunnion 4.

Disconnect the propshaft from the axle pinion yoke.

Remove the six bolts 9 from the front trunnion seal housing 3 and remove the housing.

Using suitable equipment, support the weight of the rear axle beam.

Screw three bolts into the tapped extraction holes in the front trunnion bearing housing assembly 2, and extract the assembly from the front chassis beam.

Remove the rear trunnion securing bolts 10. Screw a M24 into the tapped hole in the centre of the rear trunnion 4 and withdraw the trunnion.

Lift the rear of the machine, tipping the front of the axle upwards to clear the front chassis beam while simultaneously manoeuvring the axle rearwards. Support the front of the axle as it disengages from the front chassis beam.

If dismantling of the axle is to be carried out, remove the axle from beneath the chassis and secure the chassis as required. Drain the axle oil as detailed in

Removal K Fig 5. ( T F-11). 1

Park the machine on firm level ground. Apply the park brake and set the transmission to neutral. Chock both side of both front wheels. Raise the loader arms and install the safety strut as described in Section 3 Routine Maintenance Stop the engine and remove the starter key to prevent the machine being started whilst you are working on it.

!MCAUTION Lifting the Machine When lifting the machine using the mainframe lifting points it is necessary to use a lifting frame to prevent the chains causing damage to the ROPS/FOPS structure GEN-9-1

F-8

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F-8

Section F - Transmission Axles Rear Axle Section 3 - Routine Maintenance and mark or label the axle casing to that effect. 15

If no other procedures (other than the replacement of the trunnion bushes and seals) are to be carried out on the axle, secure the positions of the axle and the rear chassis.

Replacement K Fig 5. ( T F-11). 1

Ensure the threaded holes in the axleâ&#x20AC;&#x2122;s chassis beams (front and rear) are clear of any dirt or debris

Using a suitable installation tool, press the trunnion bearing 1a into the rear bearing housing 5, until fully home.

Remove the rear bearing housing assembly 5 from the rear chassis beam.

Remove the seal 7a and using a suitable extraction tool remove the brass trunnion bearing 1b from the front bearing housing 2. Inspect the bearing contact face and the seal recess for damage.

Using a suitable installer, press seal 8 into the recess the rear bearing housing 5, until the seal body is flush with the outer face. Ensure the seal lip is facing outwards.

Remove the seal 7b from the front trunnion seal housing 3. Ensure that the seal recess is clean and undamaged.

Remove the seal 8 and using a suitable extraction tool remove the brass trunnion bearing 1a from the rear bearing housing 5. Inspect the bearing contact face and the seal recess for damage.

Apply a light coating of general purpose grease to the outer diameter of the sub assembly 5 and press the sub assembly into the rear chassis beam until the outer face of the assembly is sitting approximately 2 mm below the face of the beam. Temporarily secure with two diagonally opposed bolts.

Apply a generous coating of chassis grease to the inner diameter and thrust face of the trunnion bearing 1a.

Inspect the contact faces between the front bearing housing 2 and the front chassis beam for signs of excessive wear or damage.

Inspect the rear trunnion's mounting recess in the rear of the axle beam for signs of excess wear or damage.

Inspect the contact faces between the rear bearing housing 5 and the rear chassis beam for signs of excessive wear or damage.

F-9

9803/9420

Using suitable lifting equipment, and with the pinion nose of the axle tilted upwards, raise the axle (or lower the chassis) until the nose of the axleâ&#x20AC;&#x2122;s differential pinion is engaged through the front trunnion aperture in the chassis beam. Once the

F-9

Section F - Transmission Axles Rear Axle pinion nose is engaged, adjust the axles position so that the rear trunnion face is perpendicular. 7

Align the axles rear trunnion mounting face centrally with the previously installed rear bearing housing 5.

Temporarily install two alignment guides to the threaded holes in the axle.

Place the rear trunnion 4 onto the installed alignment guides and tap home using a soft faced mallet.

Fit the securing bolts 10 (8 off), removing the guides once the trunnion is secured. At this stage, tighten the bolts just sufficiently to secure the trunnion into its recess in the axle case.

Remove the two temporary bolts securing the rear bearing housing 5 to the rear chassis beam. Fit hardened washers 11 onto bolts 13, then apply JCB threadlocker to the threads of the bolts.

Place the end cover 14 over the rear bearing housing 5 and align the bolt holes. Fit the bolts 13 with washers 11 through the end cover and the rear bearing housing, and screw into the rear chassis beam.

Torque tighten the bolts 13 to the specified value. K Table 4. ( T F-10).

Re-connect the propshaft to the rear axle yoke. K Removing and Replacing ( T F-123).

Using a suitable installation tool, press the trunnion bearing 1b into the front trunnion bearing housing 2, until fully home.

Reconnect the remote grease pipes to the front and rear trunnions, then grease as described in Section 3 - Routine Maintenance.

Using a suitable installer, press seal 7a into the recess the front bearing housing 2, until the seal body is flush with the outer face. Ensure the seal lip is facing outwards.

Reconnect the brake hose to the rear axle, then bleed the brake system, as described in Section G Brakes.

Using a suitable installer, press seal 7b into the recess the front seal housing 3, until the seal body is flush with the outer face. Ensure the seal lip is facing outwards.

Align the front axle trunnion centrally in the front beam aperture. Apply a generous coating of chassis grease to the inner diameter a of the trunnion bearing 1b, then place the pre-assembled front bearing housing 2 over the trunnion and pull fully home using dummy bolts 9. Once home remove the dummy bolts.

Place the pre-assembled front seal housing 3 over the front trunnion, ensuring the seal lip is facing outwards, align the bolt holes with the holes in the previously installed bearing housing 2.

Apply JCB Threadlocker to the threads of the bolts 9, then fit the bolts through items 2 and 3 and screw into the chassis beam. Torque tighten to the specified value. K Table 4. ( T F-10).

Tighten the rear trunnion securing bolts 10 to the specified value. K Table 4. ( T F-10).

Apply grease to both sides of the thrust washer 6 and position onto the rear trunnion 4.

F - 10

Item

Table 4. Torque Settings Nm Kgf m

lbf ft

360

36.72

265

311

31.72

229

259

26.42

191

9803/9420

F - 10

Section F - Transmission Axles Rear Axle

Fig 5. Heavy Duty Axle Components

F - 11

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F - 11

Section F - Transmission Axles Hub and Driveshaft

Hub and Driveshaft

Fig 6.

F - 12

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F - 12

Section F - Transmission Axles Hub and Driveshaft

Dismantling 1

If not already done, drain the oil from the axle and hub.

Remove six screws 6-8 and, using the three tapped holes provided, use screws to pull off cover 6-1. Remove and discard O ring 6-2.

Pull out axle shaft backing plate 6-3 using puller screw.

Remove screws 6-4 and, suitably supporting side gear carrier 6-5, pry carrier from wheel hub 6-31.

Remove lockring 6-15 retaining sun gear 6-14 on driveshaft and pull out sun gear.

Remove disk carrier hub 6-16 together with thrust washer 6-27 resting against wheel hub sleeve.

Remove solid and lined brake disks 6-17, 6-18.

Remove driveshaft.

Pull out lockring 6-26 securing ring nut lock plates 624. Remove lock plates.

A 25

A219340-V1

Fig 7.

Install the spring retainer 7-A (Part No. TBA) secured through the three tapped holes in the disk pressure plate 7-21 to compress brake return spring 7-22 (3 in each hub) and allow ring nut 7-25 to be removed.

F - 13

Remove ring nut 6-25 from sleeve 6-38.

Remove pressure plate 6-21 with brake return springs 6-22 together with their retainers 6-23, spring clips 6-47 and pins 6-46.

Suitably support wheel hub 6-31 and pull out ring gear unit 6-30 and support 6-29.

Pick up the six rods 6-19 located in corresponding seats on ring gear support 6-29.

Pry off lockring 6-20 from ring gear 6-30 by using a suitable screwdriver.

Disassemble ring gear support 6-29 from ring gear 630.

Should replacement of outer wheel bearing 6-28 inner race be necessary, the bearing may be removed by a suitable puller or by a remover that can be inserted in the holes of ring gear support 6-29.

Remove brake unit spring retainer 7-A, disassemble spring 7-22, retaining cup 6-23 and pressure plate 721.

9803/9420

F - 13

Section F - Transmission Axles Hub and Driveshaft

!MWARNING

Assembly

If it is necessary to force out the piston, use only gentle pressure, ensuring that adequate safety precautions are taken. Severe injury can be caused by a piston being released suddenly.

Fit outer races of wheel inner and outer bearings 6-36 and 6-28 into wheel hub 6-31, ensuring that they are correctly seated. Position inner race with roller cage of wheel inner side bearing 6-36 before fitting lip seal 6-37.

Lubricate and fit a new O-ring 6-13.

Suitably support wheel hub 6-31 to prevent damage to seals and fit inner race of wheel inner bearing 6-36 onto sleeve 6-38.

Lubricate and fit new O-rings 6-33 and 6-35 on piston 6-34, insert the piston onto wheel hub sleeve 6-38.

Press inner race of wheel outer bearing 6-28 on to ring gear support 6-29, applying gentle heating if necessary; then mount support 6-29 in ring gear 6-30 and secure by lockring 6-20.

BRAK-8-4

Remove brake actuating piston 6-34 from wheel hub sleeve 6-38 by using compressed air through brake oil ducting.

Remove and discard the two O rings 6-33 and 6-35 in corresponding seats on brake actuating piston.

Pull out the complete wheel hub 6-31. Remove and discard O-ring 6-13.

Pry off seal 6-37 from wheel hub and remove inner race with roller cage of inner wheel bearing 6-36.

Using a suitable press, press out outer races of outer and inner wheel bearings 6-28 and 6-36 from hub 631.

Should sleeve 6-38 be damaged, it can be removed by undoing fixing screws 6-41. At reassembly, smear recommended sealing compound (see Section 1 Service Consumables) on axle case joining flange and tighten screws with torque of 60 da Nm (61.2 kgf m, 444 lbf ft).

Note: When heating bearings, use heating plates, oven or an oil bath. Never heat parts by using a torch. 6

Mount ring gear and support unit 6-30 and 29 on sleeve 6-38.

Fit the six rods 6-19 in their seats on ring gear support 6-29.

Install the spring retainer (see K Fig 7. ( T F-13) in K Dismantling ( T F-13)) and compress springs 622 (3 off) with relevant cup 6-23, spring clips and pins with the pressure plate 6-21.

Mark side gear pins 6-6, accompanying components and seats for identification of original position at reassembly.

Arrange side gear carrier 6-5 on wooden blocks and, using a suitable press, push out pins 6-6.

Mount the pressure plate-spring assembly on ring gear support 6-29.

Pick up all needle rollers 6-10, 6-11.

Screw ring nut 6-25 on wheel hub sleeve 6-38 by hand. Tighten ring nut 6-25 using an accurately fitting wrench so as to reach the prescribed pre-load for wheel bearings, corresponding to a revolving torque of 2.5 to 3.5 da Nm, checking alignment for the lock plates 6-24.

Note: It is important to keep matched needle rollers and thrust washers 6-9 with corresponding pin 6-6, because of predetermined assembly tolerance limits. 28

Remove side gears 6-12 and corresponding thrust washers.

Note: To prevent wrong recording of torque values, it is advisable to seat bearing properly before checks by revolving the wheel hub repeatedly. 11

F - 14

9803/9420

Remove the spring retainer.

F - 14

Section F - Transmission Axles Hub and Driveshaft 12

Insert lock plates 6-24 securing ring nut and fit lockring 6-26.

Calculate the space available 10-X to form the disk pack as follows: a

Record depth 8-A from seating surface of side gear carrier on wheel hub to outer edge of ring gear.

b Record depth 8-B from ring gear outer edge to brake pressure plate. Subtract the value recorded from value 8-A recorded on previous step, identify it as D. i.e. A - B = D A219370-V1

Fig 9.

Fig 8. c

Fig 10.

Record depth 9-C from disk reaction face to outer edge of side gear carrier.

d Subtract 9-C from value D previously calculated. i.e. D - C = X

Form the disk pack. Compute the thickness required as follows: a

Add total thickness of all disks, solid + lined ones. Call this E.

b Add 1mm for each disk. Call the total F. i.e. Required disk pack thickness = E + F E + F should be within Âą 0.25 mm of dimension 10-X calculated in Step 13d.

F - 15

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F - 15

Section F - Transmission Axles Hub and Driveshaft 15

Arrange the three side gears 6-12 in their seats in side gear carrier 6-5.

Note: Two rows of needle rollers of the same selection class should be used for replacement in each single side gear pin. 16

Insert outer thrust washers 6-9, smear pin lower portion (head end) with grease and position the first row of needle rollers 6-10, fit spacers 6-11, smear pin upper portion with grease and position the second row of needle rollers 6-10.

Position inner thrust washers 6-40 of side gear on side gear carrier and align holes.

Insert and force fit complete pins 6-6, avoiding any bump or knock that could cause roller fall.

Insert driveshaft.

Insert thrust washer 6-50.

Mount disk carrier hub 6-16 on driveshaft.

Mount alternately solid disks 6-18 and lined disks 617.

Note: Insert a solid disk (outer teeth) facing the pressure plate 6-21. 23

Insert sun gear 6-14 and secure with lockring 6-15.

Mount the side gear carrier assembly 6-5 on side gear unit and secure on wheel hub 6-31, tightening fixing screws to a torque of 7 da Nm (7.1 kgf m, 51.8 lbf ft).

Force fit wheel shaft backing plate 6-3.

Lubricate and fit O-ring 6-2.

Rotate and align pins 6-6 to allow mounting of cover 6-1. Fit side final drive cover 6-1. The cover locks the pins, preventing them rotating.

Smear fixing screws 6-8 with sealing compound, then tighten with a torque of 3.5 da Nm (3.6 kgf m, 25.9 lbf ft).

F - 16

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F - 16

Section F - Transmission Axles Drive Head

Drive Head

Fig 11.

F - 17

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F - 17

Section F - Transmission Axles Drive Head

Dismantling 1

Unlock and undo retaining screws 11-1, then remove differential unit from axle case. Drive out spring pins 11-2 to release slotted rings 113. Match mark caps 11-4, release fixing screws 11-5 and remove caps 11-4 and slotted rings 11-3.

Release and remove screws 11-6 securing support 11-7 of bearing 11-8 of bevel pinion shank.

Remove support 11-7 of bevel pinion bearing by means of puller screws.

Carry out a visual and dimensional check for wear on sun and side gears 11-25 and 11-26 together with thrust washers 11-27 and 11-28 and spider 11-29.

Using a suitable puller, remove bearings 11-30 from case halves 11-22 and 11-23.

Clamp crown wheel 11-31 in a vice fitted with soft caps and remove screws 11-32 securing crown wheel 11-31 to half-case 11-22.

Overhauling Pinion Bearing Support 1

Remove split pin 11-33, washer 11-34 and pin 11-35.

Remove bearing outer race from support 11-7 of pinion 11-16. Check wear conditions of components, renew as required.

Press fit outer race of bearing 11-8 on support 11-7.

Insert a screw in the seat of plunger 11-10 to react against unscrewing torque of pinion ring nut 11-12.

Reassemble retaining washer 11-34, pin 11-35 and split pin 11-33 on support 11-7.

Note: This screw should have a threaded length of 100 mm, its tip should be shaped so as not to cause damage when contacting pinion teeth. Make sure that the screw is correctly engaged in pinion teeth.

Mount crown wheel 11-31 on half-case 11-22, tighten fixing screws 11-32 with a torque of 33 da Nm (33.7 kgf m, 244 lbf ft).

Position differential components in relevant seats, then join case halves 11-22 and 11-23. matching reference marks made prior to disassembly.

Refit fixing screws 11-24, tightening with a torque of 12 da Nm (12.2 kgf m, 88.9 lbf ft).

Fit differential bearings 11-30 on case halves.

Lift up differential unit from differential support 11-9, together with bearing support 11-7.

Remove ring gear deflection plunger 11-10 and locknut 11-11.

Straighten notches on pinion ring nut 11-12. Unlock and remove ring nut.

Remove drive flange 11-13 and washer 11-14, then remove reaction screw. Pry off oil seal 11-15 from drive flange and discard.

Drive out bevel pinion 11-16 from differential support 11-9, taking care not to damage threads. Pick up inner race of pinion shank bearing 11-17.

Remove from differential support outer races of outer and inner pinion bearings 11-17 and 11-18. Pick up shims 11-19 for pinion axial position adjustment, spacer 11-20 and shim 11-21.

Flatten notches retaining bearing race 11-8 on shank of pinion 11-16. Press off bearing race 11-8 from pinion shank. Press off pinion underhead bearing 1118.

Match mark differential case halves 11-22 and 11-23, remove fixing screws 11-24 and separate case halves.

F - 18

Note: When heating bearings, use heating plates, oven or an oil bath. Never heat parts by using a torch.

9803/9420

F - 18

Section F - Transmission Axles Drive Head

Pinion Depth

Fig 12. Note: See K Crown Wheel and Pinion ( T F-24) for general guidance on crown wheel and pinion adjustment. Some dimensions should be recorded before starting reassembly of the bevel pinion to determine the thickness of the spacer to be fitted between the inner (underhead) pinion bearing and the backing of relevant seat in differential support. Record the dimension 12A from the crown wheel axis to the seat of the inner (underhead) pinion bearing.

b A

The simplest way to achieve this is by positioning a reference tube 13T across the differential bearing seats as shown K Fig 13. ( T F-19), then measure and record dimension 13a. Add to this the radius of the differential bearing 13b to produce the required overall dimension A. e.g.: K Table 5. Examples - Dimension â&#x20AC;&#x2DC;Aâ&#x20AC;&#x2122; ( T F-20).

F - 19

Fig 13.

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F - 19

Section F - Transmission Axles Drive Head Table 5. Examples - Dimension ‘A’ PR 12 Axle

Therefore using our case:

A = Measured distance (a) + Bearing Radius (b)

PR 12 Axle

A = 162.6 + 62.5 = 225.1 mm

S=A-B-D S = 225.1 - 183.9 - 37.00 = 4.2 mm

PR 10 Axle

A = Measured distance (a) + Bearing Radius (b)

S=A-B-D

A = 144.1 + 62.5 = 206.6 mm

S = 206.6 - 168.4 - 34.1 = 4.1 mm

Each bevel pinion head face is marked with a number 12X suffixed by a + or - symbol. This value, expressed in units of 0.1 mm, indicates the deviation from the theoretical pinion underhead to crown wheel axis dimension B.

Increase the calculated value of S by 0.05 mm, to provide the required bearing pre-load. Then round the value up or down to the nearest tenth of a millimetre to give the required shim value. e.g.:

i.e.: - 1 = - 0.1 mm.

4.02 rounded down to= 4 mm.

Consequently, the true distance 12B will be:

3.88 rounded up to = 3.9 mm.

B = Theoretical distance ± deviation.

Example: using the theoretical figures for PR 10: (all dimensions in millimetres)

e.g.: PR 12 Axle

Crown wheel axis to bearing seat distance 12A

206.6

Theoretical distance gear axis/pinion underhead

168.5

B = Theoretical pinion dimension ± deviation

Value 12X, given as -1

B = 184.00 - 0.10 = 183.90 mm

True distance 12B = 168.5 - 0.1 =

168.4

Thickness of pinion head bearing 12D

34.10

-0.1

PR 10 Axle Thickness of shim 12S = A - B - D

B = Theoretical pinion dimension ± deviation B = 168.50 - 0.10 = 168.40 mm

12S = 206.6 - 168.4 - 34.10 =

Measure the total width 12D of pinion underhead bearing. e.g.:

Increase by 0.05 =

4.1 4.15

Thickness of shim required = 4.2 mm.

PR 12 Axle D = 37.00 mm PR 10 Axle D = 34.10 mm Determine the thickness of shim 12S required to give the correct axial position of the bevel pinion: S = A - B - D.

F - 20

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F - 20

Section F - Transmission Axles Drive Head Reference Measurement A final measurement needs to be taken before the pinion nose support bearing 11-8 is fitted. This measurement will enable the verification of the pinionâ&#x20AC;&#x2122;s position prior to the fitment of the crown wheel. Note: Failure to carry out the verification check, may result in the differential assembly having to be completely disassembled to correct the pinionâ&#x20AC;&#x2122;s position. Place the pinion nose down on a measuring block. Measure and record the pinion head height (H) as shown, K Fig 14. ( T F-21).

Fig 14. Examples of Pinion Height PR 12 Axle H = 82.00 mm PR 10 Axle H = 78.50 mm

F - 21

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F - 21

Section F - Transmission Axles Drive Head

Assembly 1

Press fit inner race of inner (underhead) pinion bearing 11-18 on pinion, using heat if required.

Note: When heating bearings, use heating plates, oven or an oil bath. Never heat parts by using a torch. 2

Position shim 11-19, computed as in K Pinion Depth ( T F-19), in its seat and press fit outer races of inner pinion bearing 11-18 and outer pinion bearing 11-17.

Position the pinion on its seat in the differential housing. Position a reference tube T across the differential bearing seats as shown K Fig 15. ( T F-22), and, measure and record dimension E.

Important: The dimension measured as H has to result in a figure 0.05mm less than the theoretical computation (E) because there is no bearing pre-load. Important: If the recorded dimension H, allowing for the pre-load deviation, does not result in the theoretical computation E then the Pinion Depth procedure needs to be re-applied as the calculated shim thickness is incorrect. 4

Note: To facilitate proper pre-load computation, it is advisable to mount as many shims as required to warrant a pinion end play and not pre-load (which could be excessive) on bearings. 5

Fit drive flange 11-13 on pinion 11-16, clamp drive flange 11-13 to prevent pinion turning and tighten nut 11-12 with a torque of 57 to 63 da Nm (58.2 to 64.3 kgf m, 422 to 467 lbf ft). Back up reaction screw from pinion.

Check pinion end play by mean of a dial gauge; then disassemble parts and change shims so as to eliminate all end play and reach the intended preload.

Reassemble components, noting that proper pre-load of bearing corresponds to a revolving torque (no seal installed) of 0.20 to 0.40 da Nm (0.2 to 0.4 kgf m, 1.5 to 3 lbf ft).

When the prescribed pre-load of bearings has been reached, remove drive flange 11-13 and fit lip seal 1115 in its seat. Remount drive flange again and tighten as specified above.

Position differential assembly with crown wheel on support 11-9.

Insert support 11-7 of bearing 11-8 whilst differential is lowered and tighten fixing screw 11-6 with a torque of 33 da Nm (33.7 kgf m, 244 lbf ft).

Fit ring nuts 11-3 and adjust backlash temporarily.

Mount caps 11-4, taking care not to invert position, fit and tighten screws 11-5 to a torque of 33 Nm (33.7 kgf m, 244 lbf ft). Check differential end play using a dial gauge.

Fig 15. Calculate pinionâ&#x20AC;&#x2122;s axial position as follows:

Fit spacer 11-20 on pinion together with shims 11-21 for bearing pre-load adjustment, then mount inner race of pinion outer bearing 11-17.

E = B - 62.50 - H Examples of Pinion Axial Position Calculation Using our case figures PR 12 Axle E = 183.9 - 62.5 - 82.00 = 39.4 mm PR 10 Axle E = 168.4 - 62.5 - 78.5 = 27.4 mm

F - 22

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F - 22

Section F - Transmission Axles Drive Head 13

Screw in one of the ring nuts 11-3 so that a notch aligns against the slot of lock plate and screw up the opposite ring nut to eliminate end play.

When this condition has been reached, apply bearing pre-load by screwing in ring nut one more notch.

Position a dial gauge perpendicular to the ring gear 11-31 tooth as shown at 16A and check that, with pinion steady, backlash is 0.17 mm to 0.28 mm (0.006 - 0.010 in), otherwise rotate both ring nuts 11-3, displacing them the same number of notches and moving the ring gear nearer to the pinion if backlash is excessive or moving it away if the backlash is less than specified.

PR10

PR12

(22.4 kgf m, 163 lbf ft)

(11.8 kgf m, 85 lbf ft)

Note: Check the axle plate to identify which axle type is fitted.

Fig 16. 16

Check gears for correct K Adjustment ( T F-24)).

Fit spring pins 11-2 to lock differential ring nuts. Make two lock notches on collar of pinion ring nut 11-12.

Apply sealing compound to bevel ring gear deflection plunger 11-10, then screw in up to contact; turn back by about 90Â° to leave the required clearance and tighten locknut.

Thoroughly clean matching surfaces, apply sealing compound and mount differential unit on axle case. Insert and tighten screws 11-1 with a torque from the table below:

PR10

PR12

22 da Nm

11.5 da Nm

F - 23

meshing

(see

9803/9420

F - 23

Section F - Transmission Axles Crown Wheel and Pinion

Crown Wheel and Pinion Adjustment

Incorrect Pattern - High Contact

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. After every repair, check the markings to verify settings.

Correct Pattern

Fig 19. Concave Side

Fig 17. Concave Side

Fig 20. Convex Side High Contact Increase the shim thickness. Repeat the procedure on K Pinion Depth ( T F-19) to determine the correct shim thickness. Fig 18. Convex Side

F - 24

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F - 24

Section F - Transmission Axles Crown Wheel and Pinion Decrease the shim thickness. Repeat the procedure on K Pinion Depth ( T F-19) to determine the correct shim thickness.

Fig 21.

Incorrect Pattern - Low Contact Fig 24.

Fig 22. Concave Side

Fig 23. Convex Side Low Contact

F - 25

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F - 25

Section F - Transmission Axles Limited Slip Differential Unit

Limited Slip Differential Unit

Fig 25.

F - 26

9803/9420

F - 26

Section F - Transmission Axles Limited Slip Differential Unit

Dismantling

disc 4

Match mark differential case halves 25-2 and 25-3.

disc 6 (Fitted with lined face DOWN)

Place differential unit with the crown wheel at the bottom.

Note: Disc 4 has outer lugs. Disc 5 is thin, has internal splines and is lined on both faces. Disc 6 is thick, has internal splines and is lined on one face.

Remove bolts 25-1 and separate differential case halves 25-2 and 25-3.

Fit sun gear 25-7, take care to mesh splines with discs 25-5 and 25-6.

Remove discs 25-4, 25-5 and 25-6 and sun gear 257.

Fit spider assembly 25-10 complete with side gears 25-9 and thrust washers 25-8.

Remove spider assembly 25-10 complete with side gears 25-9 and thrust washers 25-8.

Fit sun gear 25-7.

Remove discs 25-4, 25-5 and 25-6 and sun gear 257.

Place disc pack on to sun gear 25-7. The disc pack is made up as follows:

Using a suitable puller, remove bearings 25-13.

b disc 4

Note: Bearings 25-13 should only be removed if damaged or worn. 8

Clamp crown wheel 25-12 in a vice fitted with soft caps and remove screws 25-11 securing crown wheel 25-12 to half-case 25-2.

If necessary, fit new bearings 25-13.

Secure crown wheel 25-12 onto half-case 25-2 using screws 25-11.

Place differential unit with the crown wheel at the bottom.

disc 4

Fit case-half 25-3, take care to mesh outer lugs of discs 25-4.

Fit and torque tighten screws 25-1.

Check the free play of each disc pack. There must be a clearance of between 0.05 to 0.1 mm (0.002 to 0.004 in.) for correct operation of the limited slip differential.

disc 4

Check the clearance at two points, 120ยบ apart, as shown.

b disc 5 c

disc 5

Note: Make sure match marks are aligned.

Place disc pack into half-case 25-2. The disc pack is made up as follows: a

Note: Align outer lugs of discs 25-4.

Note: When heating bearings, use heating plates, oven or an oil bath. Never heat parts by using a torch.

disc 5

d disc 4

Assembly 1

disc 6 (Fitted with lined face UP)

Turn the differential unit over and check the clearance on the second disc pack.

disc 4

d disc 5

F - 27

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F - 27

Section F - Transmission Axles Limited Slip Differential Unit Note: If the clearance is out of limits, dismantle and select discs 25-4 of different thickness, reassemble and carry out step 11 again.

Fig 26. 12

Refit differential unit to drive head. Table 6. Torque Settings Nm kgf m

Item

11.5 to 12.5

lbf ft

113.8 to 122.6

11(1)

308.9 to 338.3 31.5 to 34.5

7.7 to 8.4 21.1 to 23.2

(2)

308.9 to 338.3 31.5 to 34.5

21.1 to 23.2

(3)

451.1 to 490.3 46 to 50

30.9 to 33.6

(1) PR10 (2) PR12 (3) PR15 Note: Details of axle type (PR10, 12 or 15) is shown on axle data plate.

F - 28

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F - 28

Section F - Transmission Axles ZF Axles

ZF Axles Introduction

Contact Patterns

Identification Plate

Application The examples of contact patterns apply to all of the bevelgear sets in the MT and MS axles, which have a ratio between 1.5 < i < 6. The examples only apply to the ground bevel-gear sets. (The examples do not completely apply to the lapped contact patterns).

P028400-4

Fig 27. 1

Axle type

Axle number

ZF â&#x20AC;&#x201C; parts list number

Overall axle ratio/ version with or without ZF â&#x20AC;&#x201C; multidisk differential lock

Oil grade

Oil quality

Note: On item 6 ZF List of Lubricants for ZF axles TE - ML 05.

T060960-1

Fig 28. Ideal Contact Pattern A

Pinion shimming

Middle of the tooth

C Convex D Concave E

Root of the tooth

Top of the tooth

G Toe H Heel

F - 29

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F - 29

Section F - Transmission Axles ZF Axles Contact Pattern Setting

Dedendum Tooth Position

The contact patterns are shown on the flanks of the crownwheel. The contact pattern must be at a tangent to the centre of the tooth flank B (middle of the tooth). If not, the contact pattern will be too close to the top of the tooth F or to the root of the tooth E sections. The contact pattern size should be a minimum 50% of the flank in the h direction. – Convex flank = Drive side – Concave flank = Coast side – Toe = Crown-wheel: inner side

T060960-2

Fig 29. Poor Contact Pattern

– Heel = Crown-wheel: outer side.

C Convex

General

D Concave When the pinion distance is changed, the position of the contact pattern is changed: – Shimming in ‘+’ = decrease the thickness of the pinion shim (the contact pattern moves to the top) – Shimming in ‘-’ = increase the thickness of the pinion shim (the contact pattern moves to the root).

The contact pattern on the convex and concave flanks is too far in the root section, although more than 50% of the flank in the h direction is covered. On the convex flank, the contact pattern has an impression at the toe / root and on the concave flank on the heel/root. Adjustment: Add a smaller shim to the pinion.

T060960-3

Fig 30. Contact Pattern Okay The contact pattern is in the flank and a minimum 50% of the flank in the h direction is covered. The contact pattern in the example is relatively small. But, the contact pattern has an impression on the middle of the tooth and would cover the flank optimally with a greater load.

F - 30

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F - 30

Section F - Transmission Axles ZF Axles Addendum Tooth Position

Line Contact Pattern

T060960-6

T060960-4

Fig 33. Poor Contact Pattern

Fig 31. Poor Contact Pattern C Convex

C Convex

D Concave

The contact pattern on the convex and concave flanks is too far in the top section. The contact pattern is too small and is not at a tangent to the flank middle line.

The contact pattern on the convex and concave flanks is too far up on the crown-wheel. The contact pattern is also too small and is not at a tangent to the middle line of the flank. Adjustment: Add a thicker shim to the pinion.

Adjustment: Add a thicker shim to the pinion.

T060960-7

Fig 34. Contact Pattern Okay T060960-5

Fig 32. Contact Pattern Okay The convex contact pattern must be visible in the direction of the tooth centre depth. A minimum 50% of the flank in the direction of the tooth depth is covered.

The convex contact pattern must have an impression at the tooth middle line. A minimum of 50% of the tooth depth (flank) is covered. Note: An edge X on the root of the tooth is allowed, this is caused by the shot-peening process.

T060960-8

Fig 35.

F - 31

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F - 31

Section F - Transmission Axles ZF Axles

Disassembly: 3065-3075

Note: For machines with internal brake tubes, this step is not necessary.

Output and Brake 1

Disassemble the brake tube C.

Put the axle A on a suitable work-platform and make sure that its secure.

P028400

P028400-3

Fig 36. 2

Fig 39.

Loosen the three plugs B, then let the oil drain from the axle. K Fig 37. ( T F-32).K Fig 38. ( T F-32).

Attach a suitable lifting-device to the output-assembly E. Use a wheel-nut to secure the lifting-device in position. Loosen the hexagon-screws D. Separate the output-assembly E from the axle housing.

Note: Be careful when you release the end-plate and the multi-disks.

P028400-1

Fig 37.

P028400-5

Fig 40.

P028400-2

Fig 38.

F - 32

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F - 32

Section F - Transmission Axles ZF Axles Note: Be careful, this step can release the shims. 5

Remove the stub-shaft F and the sun gear-shaft G.

P028400-8

Fig 43. 9

Loosen the locking-screws L, then remove the cover M.

P028400-6

Fig 41. 6

Attach the output-assembly to the work-platform.

Remove the end-plate H, brake breather-valve I and the screw-neck J.

P028400-9

Fig 44. 10

Use the lifting-device to remove the planetary-carrier from the brake-housing. 3065: with 3 planetary-gears

P028400-7

Fig 42. 8

3075: with 4 planetary-gears.

Use a lever to remove the cover K from the outputshaft.

P028400-10

Fig 45.

F - 33

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F - 33

Section F - Transmission Axles ZF Axles 11

Disengage the retaining-ring N.

P028400-14

Fig 49. P028400-11

Fig 46. 12

Remove the planetary-gear O.

Loosen the hexagon-screws.

Remove the releasing-cover Q, cup-spring R and the washer S.

P028400-12

Fig 47.

P028400-15

Fig 50. 13

Remove the tapered planetary-carrier.

roller-bearing

from

the 17

P028400-13

Fig 48. 14

Use a lever to remove the piston.

P028400-154

Fig 51.

Remove the disk-package P from the brake-housing.

F - 34

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F - 34

Section F - Transmission Axles ZF Axles 18

If necessary, remove the guide-ring T, backup-rings U and the grooved-rings V from the annular-grooves in the brake-housing W.

T Guide-ring U Backup-ring U Backup-ring

Note: For the installation positions of these components refer to K Fig 53. ( T F-35).

V Grooved-ring V Grooved-ring W Brake-housing 19

Use the lifting-device to remove the brake-housing W from the output-shaft.

P028400-145

Fig 52.

P028400-17

Fig 54. 20

Use a lever to remove the shaft seal X from the brakehousing Y. If necessary, remove both of the bearing outer-rings.

P028400-16

Fig 53. P028400-18

Fig 55.

F - 35

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F - 35

Section F - Transmission Axles ZF Axles 21

Pull the tapered roller-bearing from the output-shaft.

P028400-19

Fig 56. 22

Examine the screening-plate for wear-marks. If necessary, separate it from the output-shaft.

P028400-20

Fig 57.

F - 36

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F - 36

Section F - Transmission Axles ZF Axles Axle Housing 1

Attach the lifting-device to the axle housing A.

Loosen the hexagon screws B.

Carefully separate the axle housing A from the axle drive-housing.

Note: Use a stand i to support the axle.

P028400-22

Fig 59. 7

Loosen the threaded connections E and F.

Remove the releasing brake tube G.

Loosen the screw-neck H.

P028400-21

Fig 58. 4

Remove the bearing outer-ring C from the bearinghole, then remove the shim from behind it.

Remove the O-ring D.

Note: This step 6, is only necessary for a machine with the DHL option. 6

Remove the piston from the axle housing A.

P028400-24

Fig 60.

F - 37

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F - 37

Section F - Transmission Axles ZF Axles Bearing Bushing

Bearing Flange

An axle model with an above centre-pivot bearing.

Loosen the bolts, then remove the bearing flange A.

P028400-25

Fig 61. If necessary, make a groove A. Force the bearing bushing from the hole, this can destroy the bearing bushing. P028400-27

Fig 63.

P028400-26

Fig 62.

F - 38

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F - 38

Section F - Transmission Axles ZF Axles Input 1

Use the lifting-device to lift the differential A from the axle drive-housing B.

Note: For information on the disassembly differentials, refer to.K Differentials ( T F-41).

of the

P028400-30

Fig 66. 4

Loosen the hexagon-nut D, then remove the shim from behind it.

P028400-28

Fig 64. 2

Remove the bearing outer-ring C from the housinghole, then remove the shim from behind it.

P028400-31

Fig 67. 5

Pull the input-flange E from the input-pinion.

Use a lever to remove the shaft seal from behind the axle drive-housing.

P028400-29

Fig 65. 3

Use a hot air blower to heat the hexagon-nut D.

Note: The hexagon-nut is secured with Loctite.

P028400-32

Fig 68.

F - 39

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F - 39

Section F - Transmission Axles ZF Axles 7

Remove the input-pinion F from the axle drivehousing.

Remove the tapered roller-bearing.

P028400-35

Fig 71.

P028400-33

Fig 69. 9

Remove the spacer-ring.

Remove the tapered roller-bearing from the inputpinion.

P028400-34

Fig 70. 11

If necessary, remove both of the bearing outer-rings G from the axle drive-housing.

F - 40

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F - 40

Section F - Transmission Axles ZF Axles Differentials Multi-Disk Differential Lock DHL-1200 1

Remove both of the tapered roller-bearings from the differential.

P028400-38

Fig 74.

P028400-36

Use a press to preload the housing-cover/ compression-spring, then disengage the retainingring.

Remove the sliding-sleeve and compression-spring from the housing-cover.

Fig 72. 2

Use a press to preload the differential, then loosen the hexagon-screws.

P028500

Fig 75. P028400-37

Remove the disk-package F and the disk-carrier.

Fig 73. 3

Remove the lid A and the:

B Cylindrical-pins C Cage D Pressure-piece E Lever

P028510

Fig 76.

F - 41

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F - 41

Section F - Transmission Axles ZF Axles 7

Remove the crown-wheel H, axle bevel-gear K, thrust-washer J and the spacer I.

Disassemble the differential housing:

P028400-40

Fig 79.

P028520

Fig 77. G

Differential housing

Slotted-pin (x2)

Spider-shaft (split model)

Spider-shaft (one-piece)

Spider-gear (x4)

Thrust-washer (x4)

Remove the slotted-pins L from each half of the spider-shaft.

Axle bevel-gear

Spacer

Separate both halves of the spider-shaft in the direction of the arrows.

Outer-disk

Thrust-washer

G Differential housing H Crown-wheel I

Spacer

Thrust-washer

K Axle bevel-gear

P028400-39

Fig 78.

F - 42

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F - 42

Section F - Transmission Axles ZF Axles Differential D-1200 1

Crown-wheel components:

Remove both of the tapered roller-bearings from the differential.

P028520

Fig 83. P028400-41

Fig 80. 2

G Differential housing

Use a press to preload the differential, loosen the locking-screws A and remove the housing-cover.

H Crown-wheel I

Spacer

Thrust-washer

K Axle bevel-gear 5

Remove the slotted-pins L from each half of the spider-shaft (split model).

Separate the spider-shaft halves in the direction of the arrows.

P028400-42

Fig 81. 3

Put some of the locking-screws and the pressureplate in position, then press the differential housing G from the crown-wheel H.

P028400-39

Fig 84. 7

Remove the components from the differential housing.

P028400-43

Fig 82.

F - 43

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F - 43

Section F - Transmission Axles ZF Axles

P028400-40

Fig 85. G

Differential housing

Slotted-pin (x2)

Spider-shaft: split model (short)

Spider-shaft: one-piece (long)

Spider-gear (x4)

Thrust-washer (x4)

Axle bevel-gear

Spacer

Outer-disk

Thrust-washer

F - 44

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F - 44

Section F - Transmission Axles ZF Axles Multi-Disk Differential Lock DZ-1200 1

Remove both of the tapered roller-bearings from the differential.

P028400-43

Fig 88. 4

Remove the disk-package F, thrust-washer J and the axle bevel-gear K.

P028400-41

Fig 86. 2

Use a press to preload the differential, loosen the locking-screws A and remove the housing-cover.

P028400-44

Fig 89. 5

Remove the slotted-pins L from each half of the spider-shaft (split model).

Separate the spider-shaft halves in the direction of the arrows.

P028400-42

Fig 87. 3

Put some of the locking-screws and the pressureplate in position, then press the differential housing G from the crown-wheel H.

F - 45

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F - 45

Section F - Transmission Axles ZF Axles

P028400-39 P028400-46

Fig 90. 7

Fig 92.

Remove the components from the differential housing.

Assembly: 3065-3075 Differentials Multi-Disk Differential Lock DHL-1200 1

Put the spacer A into the differential housing.

P028400-45

Fig 91. O

Spider-shaft: one-piece (long)

Spider-gear (x4)

Thrust-washer (x4)

Spider-shaft: split model (short)

Slotted-pin (x2)

P028400-47

Fig 93. 2

Put the outer-disk B and the thrust-washer C in the differential housing.

Note: Make sure they are installed correctly. 8

Remove the axle bevel-gear K, thrust-washer J and the disk-package F.

F - 46

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F - 46

Section F - Transmission Axles ZF Axles

P028400-50

Fig 96.

P028400-48

Fig 94. 3

Install the axle bevel-gear D in the differential housing.

Spider-shaft: one-piece (long)

Spider-gear (x4)

Thrust-washer (x4)

Spider-shaft: split model (short)

Slotted-pin (x2)

Put the spider-gears F and the thrust-washers G into the differential housing. Secure them in position with either: Spider-shaft E (long) K Fig 97. ( T F-48) Spider-shafts H (short). K Fig 98. ( T F-48).

P028400-49

Fig 95. 4

Differential-spider components:

F - 47

Note: Put the tabs of the thrust-washers G into the recesses in the differential housing.

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F - 47

Section F - Transmission Axles ZF Axles 7

Install the second axle bevel-gear K.

P028400-51

Fig 97. P028400-54

Fig 100.

Note: The securing-holes in the spider-shafts H. 8

Put the thrust-washer L and the spacer M into the differential housing.

Note: Make sure they are installed correctly.

P028400-52

Fig 98. 6

Secure the spider-shafts H in position with the slottedpins I. P028400-55

Fig 101.

Note: Make sure that the slotted-pins are installed flush. Important: Make sure that the slotted-pins are installed with their openings 180Â° offset to each other.

Put the two locating-pins P in position, then press the crown-wheel N into position on the differential housing.

P028400-53

Fig 99.

F - 48

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F - 48

Section F - Transmission Axles ZF Axles

P028400-58

P028400-56

Fig 104.

Fig 102. 10

Put the compression-spring O onto the sliding-sleeve.

Assemble the components, K Fig 105. ( T F-49).

refer

Note: Make sure that lid P is only supported on the pressure-piece Q, never on the sliding-sleeve.

P028400-57

Fig 103. 11

Put the assembled sliding-sleeve into the housingcover.

Use a press to preload the compression-spring O, then engage the retaining-ring into the annulargroove in the sliding-sleeve.

F - 49

P028400-59

Fig 105.

Lid

Pressure-piece

Cage

Lever (x12)

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F - 49

Section F - Transmission Axles ZF Axles Setting the Disk-Package 1

Grease, then put the cylindrical-pins A into the housing-cover B.

P028400-62

Fig 108. 5

Preload the disk-package: Use an axial force of F = 50 +30 KN.

P028400-60

Fig 106. 6 2

Measure the setting dimension E.

Put the disk-package C into the housing-cover B. E = From the collar of the housing-cover G to the plane-face of the outer-disk. K Fig 110. ( T F-51)

Important: The locating-grooves (see arrow) of the outerdisk must be positioned over the cylindrical-pins (see arrow).

P028400-61

P028400-63

Fig 107.

Fig 109.

Put the snap-ring D into the annular-groove in the disk-carrier.

Install the assembled disk-carrier, so that all of the inner-disks are in their correct positions.

F - 50

Note: Use the outer-disks to correct any measured deviation from the specified setting dimension E.

9803/9420

F - 50

Section F - Transmission Axles ZF Axles E

Setting dimension = 0.8 +/- 0.1mm

50 +30 KN

Housing-cover

Sliding-sleeve

Disk-package

Disk-carrier

Pressure-piece

Load-cell

P028400-65

Fig 111. 9

Use a press and a pressure-piece to preload the differential.

Secure the housing-cover G in position with the new locking-screws. Torque to 400Nm.

P028400-66

P028400-64

Fig 112.

Fig 110. Important: Make sure that the housing-cover G is only supported on the pressure-piece 1, never on the slidingsleeve H.

Heat both of the tapered roller-bearings K, then move them into position.

Note: Make sure that pressure-piece 2 is seated on the disk-package I, never on the disk-carrier J. 7

Use the lifting-device to put the differential onto the housing-cover G.

Use new locking-screws to temporarily secure the housing-cover G in position.

P028400-156

Fig 113. Note: If necessary, when the tapered roller-bearings have cooled, adjust their position.

F - 51

9803/9420

F - 51

Section F - Transmission Axles ZF Axles Differential D-1200 1

Put the spacer A into differential housing.

P028400-49

Fig 116.

P028400-47

Fig 114. 4 2

Differential-spider components:

Put the outer-disk B and the thrust-washer C in the differential housing.

Note: Make sure they are installed correctly.

P028400-50

Fig 117.

P028400-48

Fig 115. 3

Install the axle bevel-gear D.

F - 52

Spider-shaft: one-piece (long)

Spider-gear (x4)

Thrust-washer (x4)

Spider-shaft: split model (short)

Slotted-pin (x2)

9803/9420

F - 52

Section F - Transmission Axles ZF Axles 5

Put the spider-gears F and the thrust-washers G into the differential housing. Secure them in position with either: Spider-shaft E (long) K Fig 118. ( T F-53) Spider-shafts H (short) K Fig 119. ( T F-53).

Note: Put the tabs of the thrust-washers G into the recesses in the differential housing.

P028400-53

Fig 120. 7

Install the second axle bevel-gear K.

P028400-51

Fig 118. Note: The securing-holes in the spider-shafts H.

P028400-54

Fig 121. 8

Put the thrust-washer L and the spacer M into the differential housing.

Note: Make sure they are installed correctly.

P028400-52

Fig 119. 6

Secure the spider-shafts H in position with the slottedpins I.

Important: Make sure that the slotted-pins are installed flush. Important: Make sure that the slotted-pins are installed with their openings 180Â° offset to each other. P028400-55

Fig 122. 9

F - 53

9803/9420

Put the two locating-pins P in position.

F - 53

Section F - Transmission Axles ZF Axles 10

Press the crown-wheel N into position on the differential housing.

P028400-67

Fig 125. P028400-56

Fig 123. 11

Put the housing-cover in position on the crown-wheel.

Use a press to preload the differential.

Secure the housing-cover in position with new locking-screws. Torque to 400Nm.

P028400-66

Fig 124. 14

Heat both of the tapered roller-bearings O, then move them into position.

Note: If necessary, when the tapered roller-bearings have cooled down, adjust their position.

F - 54

9803/9420

F - 54

Section F - Transmission Axles ZF Axles Multi-Disk Differential Lock DZ-1200

P028400-69

Fig 127. 2

Install the axle bevel-gear F into the differential housing.

P028400-68

Fig 126. A

Housing-cover

Crown-wheel

Spider-shaft: split model (short)

Slotted-pins

Spider-gear

Axle bevel-gear

Differential housing

Disk-package

Installation dimension = 18.6mm

Installation dimension =16.7mm

P028400-70

Fig 128.

Note: Use outer-disks with different thicknesses, to get a disk-package with the installation dimension J. Note the installation position. 1

Put the disk-package J and a thrust-washer M into the differential housing G.

Note: Make sure they are installed correctly.

F - 55

9803/9420

F - 55

Section F - Transmission Axles ZF Axles Note: Put the tabs of the thrust-washers M into the recesses in the differential housing. Note: The securing-holes in the spider-shafts C.

P028400-71

Fig 129. Differential-spider components N

Spider-shaft: one-piece (long)

Spider-gear (x4)

Thrust-washer (x4)

Spider-shaft: split model (short)

Slotted-pin (x2)

P028400-73

Fig 131. 4

Secure the spider-shafts C in position with the slottedpins D.

Note: Make sure that the two slotted-pins are installed flush.

Put the spider-gears E and the thrust-washers M into the differential housing. Secure them in position with either:

Important: Make sure that the slotted-pins are installed with their openings 180Â° offset to each other.

Spider-shaft N (long) K Fig 130. ( T F-56) Spider-shafts C (short) K Fig 131. ( T F-56).

P028400-74

Fig 132. 5

Install the second axle bevel-gear F.

P028400-72

Fig 130.

F - 56

9803/9420

F - 56

Section F - Transmission Axles ZF Axles 8

Put the housing-cover in position on the crown-wheel.

Use a press to preload the differential.

Secure the housing-cover with new locking-screws. Torque to 400Nm.

P028400-75

Fig 133. 6

Put the thrust-washer L and the disk-package K into the differential housing. P028400-77a

Note: Use outer-disks with different thicknesses, to get a disk-package of the installation dimension K.

Fig 136. 11

Heat both of the tapered roller-bearings Q, then move them into position.

Note: If necessary, when the tapered roller-bearings have cooled, adjust their position.

P028400-76

Fig 134. 7

Put the two locating-pins into position, then press the crown-wheel P into position on the differential housing.

P028400-78

Fig 137.

P028400-77

Fig 135.

F - 57

9803/9420

F - 57

Section F - Transmission Axles ZF Axles Input If the crown-wheel or the input-pinion are damaged, you must replace both components. When there is a new installation of a complete set of bevel-gears, make a record of the mating numbers of the input-pinion and the crownwheel. The following procedure must be done accurately. An inaccurate measurement can cause an incorrect contact pattern, which will require an additional disassemble and reassemble of the input-pinion and differential. Refer to K Contact Patterns ( T F-29). P028400-158

Fig 139.

Read the dimension I in the axle drive-housing. 3

For example, the dimension = 182.80mm.

Calculate the dimension III (bearing width). For example, the dimension = 33.60mm.

Calculate the shim dimension:

Dimension I

182.80mm

Dimension II

-148.00mm

Dimension III

-33.60mm

Difference = shim (S)

S = 1.20mm

P028400-79

Fig 138. 2

Read the dimension II on the pinion. For example, the dimension = 148.00mm.

The pinion dimension without a ‘+’ or ‘–’ deviation value

148.0mm

The pinion dimension with a + 0.1 deviation value

148.1mm

The pinion dimension with a 0.1 deviation value

147.9mm

P028400-159

Fig 140.

F - 58

9803/9420

F - 58

Section F - Transmission Axles ZF Axles 5

Put the calculated shim A into the hole in the housing.

P028400-82

Fig 143.

P028400-80

Fig 141. 10

Let the internal-bearing outer-ring cool.

Put the internal-bearing outer-ring into its position in the hole in the housing.

Heat the tapered roller-bearing B, then put it into position in the input-pinion.

P028400-83

Fig 144. P028400-81

Fig 142. 8

Let the external-bearing outer-ring cool.

Put the external-bearing outer-ring into its position in the hole in the housing.

F - 59

9803/9420

F - 59

Section F - Transmission Axles ZF Axles Note: Do not install the shaft seal until the contact pattern has been checked, refer to K Contact Patterns ( T F-29).

Setting the Rolling Torque of the Input Pinion Note: 1.0 to 5.0Nm without the shaft seal. 1

Install the spacer C.

Note: To get the correct rolling torque, use the spacer which was removed during disassembly. (For example S=8.70mm). The rolling torque, must be checked again later in this procedure.

P028400-86

Fig 147. Note: Temporarily install the hexagon-nut without Loctite. 5

P028400-84

Fig 145. 2

Put the assembled input-pinion into the axle drivehousing.

Put the heated tapered roller-bearing D into position.

Use a disk and the hexagon-nut F to install the inputflange E. Torque to 700Nm.

Important: During the tightening procedure, turn the inputpinion several times in both directions.

P028400-87

Fig 148.

P028400-85

Fig 146. 4

Press the protection-plate into position on the inputflange E.

F - 60

9803/9420

F - 60

Section F - Transmission Axles ZF Axles Note: When new bearings are installed, try to get the upper value of the rolling torque. 6

Check the rolling torque. (1.0 to 5.0Nm without the shaft seal).

P028400-88

Fig 149. 7

If there is a deviation from the correct rolling torque, use a spacer. a

Insufficient rolling torque: Install a thinner spacer

b Excessive rolling torque: Install a thicker spacer

F - 61

9803/9420

F - 61

Section F - Transmission Axles ZF Axles Setting the Bearing Rolling Torque and the Backlash

For example:

Shim Calculation

The test dimension ‘77’ A is stamped into the rear crown-wheel side.

How to calculate the necessary shims to set the bearing rolling torque (differential housing) and the backlash (bevel gear set).

If there is no ‘+’ or ‘–’ deviation B shown, the deviation corresponds to the value ‘0’ in the table. For this deviation, the required shim thickness is ‘1.1’.

If there is a ‘+’ or ‘–’ deviation B (which is caused during production), the deviation can correspond to one of the values - 20, - 10 or 10 shown in the table. If ‘-10’ is shown the required shim thickness is ‘1.2’.

To calculate the required shims, refer to the test dimension and the value in the table. K Table 7. ( T F-62).

P028400-89

Fig 150.

P028400-90

Fig 151. C

Axle housing

Shim (crown-wheel side)

Shim (differential-carrier side)

Axle housing

Table 7. Shims for the Differential D/DZ and DHL-1200 in ZF axles MT-L 3065/3075 Crown-wheel marking

- 20

- 10

Deviation

- 0.2

- 0.1

0.1

Shim thickness: Differential-carrier side

0.7

0.8

0.9

1.0

Shim thickness: Crown-wheel side

1.3

1.2

1.1

1.0

F - 62

9803/9420

F - 62

Section F - Transmission Axles ZF Axles Procedure 1

Put the calculated shim G (for example S = 0.9mm) into the hole in the axle-housing, then adjust the bearing outer-ring until there is contact.

P028400-93

Fig 154. 5

Put the piston in position in the bearing-housing.

P028400-91

Fig 152. 2

Put a thin layer of marking-ink on the drive and coastflanks of the crown-wheel.

Put the assembled differential H into the axle drivehousing I.

P028400-94

Fig 155. 6

Put the calculated shim X, (for example S = 1.1mm) into the hole in the axle-housing.

Adjust the position of the bearing outer-ring until there is contact.

P028400-92

Fig 153. Note: Steps 4 and 5 are only necessary for machines with the DHL option. P028400-95

Grease the O-rings J, then put them into the annulargrooves in the piston.

F - 63

9803/9420

Fig 156.

F - 63

Section F - Transmission Axles ZF Axles 8

Use the lifting-device to move the axle housing into position with the axle drive-housing I.

Turn the input-flange to roll the crown-wheel over the input-pinion in both directions several times.

Use the hexagon-screws K to secure the axle housing. Torque to 390Nm.

Remove the axle housing again.

Remove the differential from the axle drive-housing.

Check the contact pattern, refer to K Contact Patterns ( T F-29).

Note: Temporarily attach the axle housing without the Oring.

Important: If there is a deviation from the correct contact pattern, a measuring error was made when the shim thickness was calculated. Do the calculation again.

P028400-155

Fig 157. Important: This step is only necessary for machines with the DHL option. P028400-98

Fig 159.

Pressurise the lock, close the shut-off valve and remove the air line. 15

Important: No noticeable pressure loss is allowed to occur within 10 seconds.

Loosen the hexagon-nut L, then remove the inputflange M from the input-pinion.

P028400-97

Fig 158.

F - 64

P028400-99

Fig 160.

9803/9420

F - 64

Section F - Transmission Axles ZF Axles Important: Before installation, wet the outer diameter of the shaft seal with spirit and fill the space between the seal and the dust lip with grease. 16

Install the shaft seal with the seal-lip facing the oil chamber.

P028400-92

Fig 163. Note: This step is only necessary for machines with the DHL option. 19 P028400-100

Grease, then install axial roller-cage N in the slidingsleeve.

Fig 161. Important: Put a layer of Loctite on the thread of the hexagon-nut. 17

Put the input-flange M in position, then secure with a disk and hexagon-nut L. Torque to 700Nm.

P028400-103

Fig 164.

P028400-101

Fig 162. 18

After a good contact pattern check, put the differential H again into the axle drive-housing I.

F - 65

9803/9420

F - 65

Section F - Transmission Axles ZF Axles Axle Housing 1

Grease the O-ring A, then put it into the annulargroove of the brake tube C.

P028400-104

Fig 165. P028400-106

Fig 167.

Attach the fitting B. Torque to 36Nm.

Install the brake tube C with the threaded connection D and hexagon-nut E. Torque to 100Nm.

Use the lifting-device to move the axle housing F into position with the axle drive-housing G.

Use the hexagon-screws H to secure the axle housing in position. Torque to 390Nm.

P028400-105

Fig 166. 4

Grease the O-ring A, then put it into the axle-housing F. P028400-96

Fig 168.

F - 66

9803/9420

F - 66

Section F - Transmission Axles ZF Axles Bearing Bushing

Bearing Flange (Pivot-Bearing)

Located above the centre-pivot bearing.

Put the bearing flange I in position and secure with the hexagon-screws J. Torque to 185Nm.

Use a hot air blower to heat the hole in the axle drivehousing.

P028400-107

Fig 169.

P028400-109

Fig 171. Put the bearing-bushing in the axle drive-housing. Make sure the groove in the front-face (see arrow), is in the 6 oâ&#x20AC;&#x2122;clock position.

P028400-108

Fig 170.

F - 67

9803/9420

F - 67

Section F - Transmission Axles ZF Axles Output and Brake 1

Important: Before the installation, wet the outer diameter of the shaft seal with spirit.

Heat the slide-bushing, then put it in the collar of the output-shaft.

Install the shaft seal X into the brake-housing, also refer to K Fig 175. ( T F-68).

Important: Make sure the components are installed in the correct position. Put a layer of Loctite on the contact faces of the slide-bushing/output-shaft. 2

Use a pressure-ring to position the slide-bushing.

P028400-112

Fig 174. 5

Installation positions:

P028400-110

Fig 172. 3

Heat the tapered roller-bearing A, then put it into position on the output-shaft.

P028400-113

Fig 175. 1

Output-shaft

Brake-housing

Combination seal consists of: X

Shaft seal

Screening-plate

P028400-111

Fig 173. Important: Make sure the components are installed in the correct position.

F - 68

9803/9420

F - 68

Section F - Transmission Axles ZF Axles 6

Press the outside-bearing outer-ring into position in the brake-housing.

P028400-116

Fig 178. P028400-114

Fig 176. 7

Press the inside bearing outer-ring into position in the brake-housing.

Important: Clean the annular-groove in the brake-housing with spirit. 9

Put the sealing-elements into the annular-grooves in the brake-housing. For the installation positions, refer to K Fig 180. ( T F-70).

Put the guide-ring into the annular-groove.

Note: The orifice in the guide-ring must face-up (12 oâ&#x20AC;&#x2122;clock). 11

Make sure the whole of the circumference of the guide-ring is installed correctly. Secure the end-points of the guide-ring with Loctite.

P028400-115

Fig 177. 8

Use the lifting-device to move the assembled brakehousing into position on the output-shaft.

P028400-118

Fig 179.

F - 69

9803/9420

F - 69

Section F - Transmission Axles ZF Axles

P028400-122

Fig 182. 15

Put the disk H, cup-spring I and cover J into the piston.

P028400-117

Fig 180. A Brake-housing B Guide-ring C Support-ring D Grooved-ring F Grooved-ring E Support-ring 12

Install the slotted-pins G flush into the holes in the piston.

P028400-120

Fig 183.

P028400-119

Fig 181. 13

Put the piston into the brake-housing and carefully install with the fixing device until there is contact.

Use W-10 oils to seal the surface of the piston/ support-rings, grooved-rings and guide-ring.

F - 70

9803/9420

F - 70

Section F - Transmission Axles ZF Axles

P028400-124

P028400-121

Fig 186.

Fig 184. Component installation positions 19

H Disk I

Cup-spring

Cover

Press the stop-bolt N into position in the planetarycarrier.

K Piston L Hexagon-screw A Brake-housing 16

Secure the cover J with the hexagon-screws L. Torque to 34Nm.

P028400-125

Fig 187. 20

Use the lifting-device to manoeuvre the planetarycarrier into its position with the teeth of the outputshaft.

P028400-123

Fig 185. 17

Heat the tapered roller-bearing M, then put it in position in the planetary-carrier.

Note: If necessary, when cool adjust the position of the tapered roller-bearing. 18

Wet the profile and the front-face, with an anticorrosive agent. P028400-126

Fig 188.

F - 71

9803/9420

F - 71

Section F - Transmission Axles ZF Axles 21

With the old locking-screws (removed during the disassembly procedure) move the planetary-carrier into the contact position with the cover.

Attach the O-ring O to the cover.

Wet the contact-face of the cover with Terostat. The curing period for Terostat is > 24 hours.

Remove the locking-screws again.

P028400-129

Fig 191. 27

Put the cover in position in the output-shaft.

P028400-127

Fig 189. 23

Pivot the output 90O.

Install the disk, then secure planetary-carrier with new locking-screws.

Important: Tighten the locking-screws crosswise to a torque of 200Nm. Important: Tighten the locking-screws crosswise again, to a torque of 500Nm.

P028400-130

Fig 192. 28

Install the outer and inner-disks.

P028400-128

Fig 190.

P028400-131

Fig 193. Note: Use a new cover and O-ring O.

F - 72

9803/9420

F - 72

Section F - Transmission Axles ZF Axles Note: Make sure that the end-plate P is installed in the radial position. The driving-tabs of the end-plate must be installed in the grooves of the brake-housing. 29

Install the end-plate P.

P028400-134

Fig 196. 34

Use a straight edge to calculate the dimension I, from the mounting-face of the brake-housing to the frontface of the stop-bolt.

P028400-132

Fig 194.

For example the dimension I = 21.25mm.

Put the cylindrical roller-bearing Q into the planetarygear T.

Press the cylindrical roller-bearing Q through the packaging-sleeve R until the snap-ring S engages into the annular-groove of the planetary-gear T.

P028400-135

Fig 197. 35

P028400-133

Fig 195. Q

Cylindrical roller-bearing

Packaging-sleeve

Snap-ring

Planetary-gear

Put the stub-shaft with the sun-gear into the teeth of the axle bevel-gear until there is contact.

Important: Make sure that the stub-shaft is installed with the long teeth facing the differential.

Heat the bearing inner-rings, then put the assembled planetary-gears T (with the large radius facing the planetary-carrier (downwards)) in position.

Note: If necessary, when cool adjust the position of the bearing inner-rings. 33

Use the retaining-rings to secure the planetary-gears T.

F - 73

9803/9420

P028400-136

Fig 198.

F - 73

Section F - Transmission Axles ZF Axles 36

Use a straight edge to measure the dimension II from the front-face of the sun gear-shaft to the mounting surface of the axle-housing. For example the dimension II = 19mm.

P028400-139

Fig 201. 40

Use the lifting-device to lift the output.

Use the locating-screw to install the disk-package.

P028400-137

Fig 199. Table 8. Calculation example Dimension I

21.25mm

Dimension II

-19.00mm

Difference

2.25mm

Required axial play

-1.25mm

Difference = shim

= 1.00mm

Remove the stub-shaft C with the sun gear-shaft A from the axle-housing.

Put the calculated shim B into the sun gear-shaft A, then install the stub-shaft C.

P028400-140

Fig 202. 42

Install the assembled stub-shaft into the teeth of the planetary-gears.

P028400-138

Fig 200. 39

Grease the O-ring D, then install it in the axlehousing.

P028400-141

Fig 203.

F - 74

9803/9420

F - 74

Section F - Transmission Axles ZF Axles 43

Install the stub-shaft into the gearing of the axle bevel-gear to move the output-assembly into the contact position with the axle-housing.

Note: Be aware of the end-plate.

P028400-142

Fig 206. 48 P028400-160

Install the brake tube H, with the: Screw-nut I: Torque to 100Nm

Fig 204. Cylindrical-screw J: Torque to 23Nm. 44

Use the hexagon-screws to secure the outputassembly. Torque to 390Nm.

P028400-143

Fig 207. P028400-161

Fig 205. 45

Install the screw-neck E with a new O-ring. Torque to 36Nm.

Install the breather-valve F. Torque to 6Nm.

Install the plug G with a new O-ring. Torque to 50Nm.

F - 75

9803/9420

F - 75

Section F - Transmission Axles ZF Axles Test Procedures Check the Brake Hydraulics for Leakage Before you start the test, completely release the hydraulic pressure from the brake. Temporarily pressurise the brakes (5x) with p = 100 bar maximum. High-Pressure Test Increase the test pressure to p = 100 bar maximum, then use the shut-off valve to close the connection to the HP pump.

P028460-48

Fig 209. A decrease in the pressure of a maximum 2% (2 bar) is permitted during a 5-minute test time.

Loosen the three plugs B, then let the oil drain from the axle.

Low Pressure Test Decrease the test pressure to p = 5 bar then close the shutoff valve. No decrease in pressure is allowed during a 5minute test time.

P028460-70

Fig 210.

P028400-144

Fig 208.

Disassembly: 3085-3095 Output Shaft and Brake 1

Put the axle A on an suitable work-platform and make sure its secure.

P028460-69

Fig 211. 3

F - 76

9803/9420

Remove the breather-valve C.

F - 76

Section F - Transmission Axles ZF Axles

P028460-74

P028460-71

Fig 215.

Fig 212. 4

Attach a suitable lifting-device to the output-assembly D. Use a wheel-nut to secure the lifting-device in position.

Use a lever to remove the cover I from the outputshaft.

Loosen the hexagon-screws E. Separate the output-assembly D from the axlehousing.

P028460-75

Fig 216. 8

Loosen the locking-screws J, then remove the-cover K.

P028460-72

Fig 213. 5

Remove the stub-shaft F and the sun gear-shaft G. Be careful, this can release the shims.

P028460-76

Fig 217. 9

Use a two-armed puller to remove the planetarycarrier from the profile of the output-shaft.

P028460-73

Fig 214. 6

Attach the output-assembly H to the work-platform.

F - 77

9803/9420

F - 77

Section F - Transmission Axles ZF Axles 12

Remove the retaining-ring M.

P028460-77

Fig 218. P028460-80

Fig 221.

Use the lifting-device to remove the planetary-carrier L from the brake-housing. 13

Remove the planetary-gear N.

3085: 3 planetary-gears 3095: 4 planetary-gears.

P028460-81

Fig 222. P028460-78

Fig 219. 11

Remove the tapered planetary-carrier.

roller-bearing

14 from

Remove the end-plate O from the brake-housing.

the

P028460-82

Fig 223. P028460-79

Fig 220.

F - 78

9803/9420

Remove the disk-package P from the brake-housing.

F - 78

Section F - Transmission Axles ZF Axles

P028460-85

P028460-83

Fig 226.

Fig 224. 16

Loosen the hexagon-screws Q.

Remove the cover R and the cup-spring.

If necessary, remove the guide-ring, the backup-rings T and the grooved-rings U from the annular-grooves in the brake-housing.

P028460-86 P028460-84

Fig 227.

Fig 225. 18

Connect the breather-valve S. Use compressed air to push the piston from the brake-housing.

F - 79

9803/9420

F - 79

Section F - Transmission Axles ZF Axles 1

Brake-housing

Guide-ring

Backup-ring

Grooved-ring

Backup-ring

Slide-ring seal

Output-shaft

Use the lifting-device to remove the brake-housing V from the output-shaft.

P028460-87

Fig 228. Component locations

P028460-88

Fig 229. 21

Axles with slide-ring seals: Use a lever to remove the slide-ring seal W from the brake-housing.

Axles with combination-seals: Use a lever to remove the shaft seal from the brakehousing. If necessary, remove both of the bearing outer-rings.

F - 80

9803/9420

F - 80

Section F - Transmission Axles ZF Axles

P028460-89 P028460-91

Fig 230. 23

Fig 232.

Axles with slide-ring seals Use a lever to remove the slide-ring seal X from the output-shaft.

Axles with combination-seals: Examine the screening-plate for wear marks. If necessary separate it from the output-shaft.

P028460-90

Fig 231. 25

Remove the tapered roller-bearing from the outputshaft.

F - 81

9803/9420

F - 81

Section F - Transmission Axles ZF Axles Axle Housing 1

Attach the lifting-device to the axle-housing A.

Loosen the hexagon-screws B.

Carefully separate the axle-housing A from the axle drive-housing.

P028460-94

Fig 235. 6

Remove the bearing outer-ring E, then remove the shim from behind it.

Remove the O-ring F.

P028460-92

Fig 233. 4

Loosen the threaded connections, then remove the brake tube C.

P028460-95

Fig 236.

P028460-93

Fig 234. 5

Loosen the screw-neck D.

F - 82

9803/9420

F - 82

Section F - Transmission Axles ZF Axles Input Pinion 1

Use the lifting-device to lift the differential A from the axle drive-housing.

P028460-237

Fig 239.

P028460-96

Use a hot air blower to heat the slotted-nut D.

Loosen the slotted-nut D, then remove the shim from behind it.

Fig 237. Note: For the disassembly of the differentials, refer to. K Differential ( T F-85). 2

Remove the bearing outer-ring B, then remove the shim from behind it.

P028460-98

Fig 240. 6

Remove the input-flange E from the input-pinion. Use a lever to remove the shaft seal from behind the axle drive-housing.

P028460-97

Fig 238. Note: This operation is only necessary for the version with DHL. 3

Use compressed air to push the piston C out of the axle-housing.

P028460-99

Fig 241.

F - 83

9803/9420

F - 83

Section F - Transmission Axles ZF Axles 7

Remove the input-pinion F from the axle drivehousing.

Remove the tapered roller-bearing.

P028460-102

Fig 244.

P028460-100

Fig 242. 9

Remove the spacer-ring.

Remove the tapered roller-bearing from the inputpinion.

P028460-101

Fig 243. 11

If necessary, remove both of the bearing outer-rings G from the axle drive-housing.

F - 84

9803/9420

F - 84

Section F - Transmission Axles ZF Axles Differential Multi-Disk Differential Lock DHL-2400 1

Remove the axial roller-cage A.

P028460-105

Fig 247. 5

Use a press to preload the housing-cover/ compression-spring, then remove the retaining-ring E.

Remove the sliding-sleeve and compression-spring from the housing-cover.

P028460-103

Fig 245. 2

Remove both of the tapered roller-bearings from the differential.

P028460-106

Fig 248. P028460-104

Fig 246. 3

Use a press to preload the differential.

Loosen the hexagon-screws B and remove the housing-cover C.

Remove the pressure-piece F, cage G, lever H, diskcarrier I and disk-package J.

P028460-107

Fig 249.

F - 85

9803/9420

F - 85

Section F - Transmission Axles ZF Axles 8

Use a press to preload the differential.

Loosen the locking-screws K and remove the housing-cover L.

P028460-110

Fig 252.

P028460-108

Remove both of the spider-shafts P (short).

Remove the spider-gears Q and the thrust-washers from the differential housing.

Fig 250. 10

Remove the axle bevel-gear M and thrust-washers N from the differential housing.

P028460-111

Fig 253. P028460-108

Fig 251. 11

Remove the spider-shaft R (long), then remove the spider-gears S and thrust-washers from the differential housing.

Remove both of the slotted-pins O.

P028460-112

Fig 254.

F - 86

9803/9420

F - 86

Section F - Transmission Axles ZF Axles 15

Remove the axle bevel-gear T and the shim from behind it.

P028460-113

Fig 255. 16

Remove the crown-wheel U from the differential housing V.

P028460-114

Fig 256.

F - 87

9803/9420

F - 87

Section F - Transmission Axles ZF Axles Differential D-2400 1

Remove both of the tapered roller-bearings from the differential.

P028460-116

Fig 259. 6

Remove the axle bevel-gear G from the differential housing.

Remove the thrust-washers H from the differential housing.

P028460-115

Fig 257. 2

Use a press to preload the differential.

Loosen the hexagon-screws C, then remove the housing-cover D.

P028460-117

Fig 260. 8

Remove both of the slotted-pins I.

P028460-105

Fig 258. 4

Use a press to preload the differential.

Loosen the locking-screws E, then remove the housing-cover F.

P028460-118

Fig 261.

F - 88

9803/9420

F - 88

Section F - Transmission Axles ZF Axles 9

Remove both of the spider-shafts J (short), then remove the spider-gears K and the thrust-washers from the differential housing.

P028460-121

Fig 264. 12 P028460-119

Remove the crown-wheel O from the differential housing.

Fig 262. 10

Remove the spider-shaft axle L (long) and remove the spider-gears M and the thrust-washers from the differential housing.

P028460-122

Fig 265.

P028460-120

Fig 263. 11

Remove the axle bevel-gear N and the shim from behind it.

F - 89

9803/9420

F - 89

Section F - Transmission Axles ZF Axles Multi-Disk Differential Lock DL-2400 1

Remove both of the tapered roller-bearings from the differential.

P028460-125

Fig 268. 5

Remove the spider-shafts F from the differential housing.

Remove the axle bevel-gears G from the differential housing.

P028460-123

Fig 266. 2

Use a press to preload the differential.

Loosen the locking-screws B and the housing-cover C.

P028460-126

Fig 269. 7

Remove the second axle bevel-gear H.

P028460-124

Fig 267. 4

Remove the axle bevel-gear D with pressure-ring, the disk-package E and the thrust-washers from the differential housing.

P028460-127

Fig 270.

F - 90

9803/9420

F - 90

Section F - Transmission Axles ZF Axles 8

Lift the pressure-ring I from the differential housing, then remove the disk-package and the thrustwashers from behind it.

P028460-130

Fig 273. 2

Put the thrust-washer B into the differential housing.

P028460-128

Fig 271. 9

Remove the crown-wheel J from the differential housing.

P028460-131

Fig 274. 3

Install the axle bevel-gear C.

P028460-129

Fig 272.

Assembly: 3085-3095 Differential Multi-Disk Differential Lock DHL-2400 1

Put the two locating-pins a in position, then push the heated crown-wheel A onto the differential housing until there is contact.

F - 91

9803/9420

F - 91

Section F - Transmission Axles ZF Axles Note: Make sure the tabs of the thrust-washers H go into the recesses i of the differential housing. 5

Put the spider-gears G and the thrust-washers H into the differential housing, then secure them in position with the two spider-shafts (short).

Note: The holes ii are used for the radial installation of the spider-shafts.

P028460-132

Fig 275. 4

Put the spider-gears D and the thrust-washers E into the differential housing. Secure them in position with the spider-shaft F (long).

Note: Make sure the tabs of the thrust-washers E go into the recesses i in the differential housing. P028460-134

Fig 277. 6

Install the spider-shafts (short) with the slotted-pins.

Note: Make sure that the slotted-pins are installed flush.

P028460-133

Fig 276.

P028460-135

Fig 278. 7

F - 92

9803/9420

Install the second axle bevel-gear J.

F - 92

Section F - Transmission Axles ZF Axles 12

Put a compression-spring N on the sliding-sleeve O.

P028460-139

Fig 282. 13

Put the sliding-sleeve O into the housing-cover.

Use a press to preload the compression-spring, then engage the retaining-ring into the annular-groove of the sliding-sleeve.

P028460-136

Fig 279. 8

Grease, then put the thrust-washers K into the housing-cover.

P028460-140

P028460-137

Fig 283.

Fig 280. 15

Install the two adjusting-screws.

Put the housing-cover L in position on the differential housing.

Setting the Disk-Package: c

Assemble the:

Use a press to preload the differential. Secure the housing-cover L position with new locking-screws M. Torque to 400Nm.

Housing-cover

Pressure-piece

Cage

Lever

Disk-carrier

Pressure-ring

Inner-disks

Outer-disks (optional)

Snap-ring

P028460-138

Fig 281.

F - 93

9803/9420

F - 93

Section F - Transmission Axles ZF Axles 17

Put the housing-cover R in position on a pressurepiece S.

Put the two hexagon-screws into the housing-cover R to radially set the disk-package.

P028460-141

Fig 284. d Preload the disk-package with an axial force of F=50+30KN.

P028460-144

Fig 287. 19

Use the lifting-device T to hold the differential U.

Put the housing-cover R in position, then loosely install the hexagon-screws V.

P028460-142

Fig 285. e

Check the setting dimension P: P = 1.05+/-0.1mm from the collar of the differential-cover to the plane-face of the outerdisk.

P028460-145

To make sure that the measurement is correct, support the housing-cover on the contact-face Q. Only support the assembly on the disk-package and not on the disk-carrier.

g Use the outer-disks to correct any deviation from the specified setting-dimension P.

Fig 288. 21

Use the press and the pressure-piece to preload the differential U.

Secure the housing-cover R in position with the hexagon-screws V. Torque to 185Nm.

P028460-143

Fig 286.

F - 94

9803/9420

F - 94

Section F - Transmission Axles ZF Axles

P028460-148

Fig 291. P028460-146

Fig 289. 23

Heat both of the tapered roller-bearings W, then put them into position.

Note: When the tapered roller-bearing have cooled, if necessary adjust their position.

P028460-147

Fig 290. 24

Grease the axial roller-cage X, then attach it to the sliding-sleeve.

F - 95

9803/9420

F - 95

Section F - Transmission Axles ZF Axles Differential D-2400 1

Put the two locating-pins a in position, then push the heated crown-wheel A onto the differential housing until there is contact.

P028460-132

Fig 294. 4

Put the spider-gears D and the thrust-washers E into the differential housing. Secure them in position with the spider-shaft F (long).

P028460-130

Note: Put the tabs of the thrust-washers E into the recesses i of the differential housing.

Fig 292. 2

Put the thrust-washer B into the differential housing.

P028460-133 P028460-131

Fig 295.

Fig 293. 3

Install the axle bevel-gear C.

F - 96

9803/9420

F - 96

Section F - Transmission Axles ZF Axles Note: Put the tabs of the thrust-washers H into the recesses i of the differential housing. 5

Put the spider-gears G and the thrust-washers H into the differential housing. Secure them in position and with the two spider-shafts I (short).

Note: The holes ii are used for the radial installation of the spider-shafts.

P028460-136

Fig 298. 8

Grease, then put the thrust-washers K into the housing-cover.

P028460-134

Fig 296. 6

Install the spider-shafts (short) with the slotted-pins.

Note: Make sure that the slotted-pins are installed flush.

P028460-137

Fig 299.

P028460-135

Fig 297. 7

Install the second axle bevel-gear J.

F - 97

9803/9420

F - 97

Section F - Transmission Axles ZF Axles Note: Make sure the two adjusting-screws are in position. 9

Move the housing-cover L into position with the differential housing.

Use a press to preload the differential, then secure the housing-cover L with new locking-screws M. Torque to 400Nm.

Heat both of the tapered roller-bearings P, then put them into position.

When the tapered roller-bearings P have cooled, if necessary adjust their position.

P028460-150

Fig 302.

P028460-138

Fig 300. 11

Put the housing-cover N in position.

Use a press to preload the differential.

Secure the housing-cover N with the hexagon-screws O. Torque of 185Nm.

P028460-149

Fig 301.

F - 98

9803/9420

F - 98

Section F - Transmission Axles ZF Axles Multi-Disk Differential Lock DL-2400 1

Put the two locating-pins i in position, then push the heated crown-wheel A onto the differential housing until there is contact.

Important: The difference in thickness between the left and the right disk-packages must be a maximum of 0.1mm. 4

Put the pressure-ring D in position.

P028460-151

P028460-154

Fig 303. 2

Fig 306.

Put the thrust-washer B into the differential housing.

Install the axle bevel-gear E.

Install the inner-disks with teeth.

P028460-152

Fig 304. 3

Install the outer and inner-disks C in alternating order, start with an outer-disk. Use the outer-disks to set the installation clearance. Refer to Calculate the Installation Clearance, Step 11.

P028460-155

Fig 307. 7

Assemble the differential-spider F.

Put the differential-spider F into position.

P028460-153

Fig 305.

P028460-156

Fig 308.

F - 99

9803/9420

F - 99

Section F - Transmission Axles ZF Axles 9

Install the second axle bevel-gear G.

P028460-159

Fig 311. P028460-157

Fig 309. 10

b Measure the dimension II from the contact-face of the outer-disk to the mounting-face on the housing-cover.

Install the outer and inner-disks H in alternating order, start with an inner-disk. For more information refer to Calculate the Installation Clearance, Step 11.

For example, dimension II = 43.95mm

P028460-160

Fig 312. P028460-158

Fig 310. 11

Calculate the Installation Clearance (0.2-0.7mm): a

Measure the dimension I from the mounting-face of the differential housing to the plane-face of the outer-disk. For example, dimension I = 44.30mm

F - 100

Calculation example:

Dimension I

44.30mm

Dimension II

43.95mm

Difference = disk clearance

0.35mm

Note: Use the outer-disks (which have different thicknesses) to set the installation clearance to the correct dimension. (S=2.7, S=2.9, S=3.0, S=3.1, S=3.2, S=3.3 or S=3.5mm). Make sure that the difference in thickness between the left and the right disk-packages is a maximum of 0.1mm.

9803/9420

F - 100

Section F - Transmission Axles ZF Axles 13

Grease the thrust-washers J, then put them in position in the housing-cover.

P028460-163

Fig 315. P028460-161

Fig 313. 14

Put the two adjusting-screws in position in the housing-cover K.

Put the housing-cover K in position with the differential housing.

Use the press to preload the differential.

Secure the housing-cover K with new locking-screws L. Torque to 400Nm.

When the tapered roller-bearings have cooled, if necessary adjust their position.

P028460-162

Fig 314. 18

Heat both of the tapered roller-bearings M, then move them into position.

F - 101

9803/9420

F - 101

Section F - Transmission Axles ZF Axles Input Introduction If the crown-wheel or the input-pinion are damaged, you must replace both components. When there is a new installation of a complete set of bevel-gears, make a record of the mating numbers of the input-pinion and the crownwheel. The following procedure must be done accurately. An inaccurate measurement can cause an incorrect contact pattern, which will require an additional disassemble and reassemble of the input-pinion and differential. Refer to K Contact Patterns ( T F-29).

P028460-165

Fig 317. 3

Calculate the dimension III (the bearing width).

Calculate the Thickness of the Shims For example, the dimension = 39.10mm. 1

Read the dimension I in the axle drive-housing. For example, the dimension = 221.10mm.

P028460-166

Fig 318. P028460-164

Calculate the shim dimension:

Fig 316. 2

Read the dimension II on the pinion. For example, the dimension = 181.00mm.

F - 102

Dimension I

221.10mm

Dimension II

181.00mm

Dimension III

39.10mm

Difference = shim (S)

S = 1.00mm

9803/9420

F - 102

Section F - Transmission Axles ZF Axles Assemble the Input Pinion 1

Let the external-bearing outer-ring A cool, then put it in position in the axle drive-housing B.

P028460-169

Fig 321. 4

Heat the tapered roller-bearing E, then put it in position in the input-pinion F.

P028460-167

Fig 319. 2

Put the â&#x20AC;&#x2DC;calculatedâ&#x20AC;&#x2122; shim C (for example S = 1.0mm) into the hole in the housing. Refer to K Calculate the Thickness of the Shims ( T F-102).

P028460-170

Fig 322.

P028460-168

Fig 320. 3

Let the internal-bearing outer-ring D cool, then put it in position in the hole in the housing.

F - 103

9803/9420

F - 103

Section F - Transmission Axles ZF Axles Setting the Rolling Torque of the Input Pinion-Bearing

Note: Do not install the shaft seal until the contact pattern has been checked, refer to K Contact Patterns ( T F-29).

Note: Without the shaft seal. 1

Install the spacer G.

Note: To get the correct rolling torque, use the spacer which was removed during disassembly. (for example S=8.18mm). The rolling torque, must be checked again later in this procedure.

P028460-173

Fig 325. 5

Put the input-flange J in position.

Use the disk and the slotted-nut K to secure the inputflange J in position. Torque the slotted-nut K to 1200Nm.

P028460-171

Fig 323. Note: Do not use Loctite on the slotted-nut. 2

Put the input-pinion F into the axle drive-housing.

Put the heated tapered roller-bearing H into position.

Important: During the tightening procedure, make sure that the input-pinion is turned several times in both directions.

P028460-172

Fig 324. P028460-174

Fig 326.

Push the protection-plate I into position on the inputflange J. 7

F - 104

9803/9420

Check the rolling torque (1.5 to 4.0Nm without the shaft seal).

F - 104

Section F - Transmission Axles ZF Axles Note: When new bearings are installed, try to get the upper value of the rolling torque. 8

To get the correct rolling torque, install a spacer: If there is not enough rolling torque, install a thinner spacer. If there is too much rolling torque, install a thicker spacer.

P028460-177

Fig 329.

P028460-175

Fig 327. 9

For models with the DHL option: a

Grease the O-rings L, then put them into the annular-grooves of the piston M.

P028460-176

Fig 328. b Put the piston M into position in the bearinghousing.

F - 105

9803/9420

F - 105

Section F - Transmission Axles ZF Axles Setting the Bearing Rolling Torque and Backlash

The test dimension ‘101’ A is stamped into the rear crown-wheel side.

Shim Calculation How to calculate the necessary shims to set the bearing rolling torque (differential housing) and the backlash (bevel gear set). 1

For example:

If there is no ‘+’ or ‘–’ deviation B shown, the deviation corresponds to the value ‘0’ in the table. For this deviation, the required shim thickness is ‘1.1’.

To calculate the required shims, refer to the test dimension and the value in the table. K Table 9. ( T F-106).

P028460-178 P028460-179

Fig 330.

Fig 331. C

Axle housing

Shim (crown-wheel side)

Shim (differential-carrier side)

Axle housing

Table 9. Shims for the Differential D/DL and DHL-2400 in ZF axles MT-L 3085/3095 Crown-wheel marking

-20

-10

Deviation

-0.2

-0.1

0.1

Shim thickness: Differential-carrier side

0.7

0.8

0.9

1.0

Shim thickness: Crown-wheel side

1.3

1.2

1.1

1.0

F - 106

9803/9420

F - 106

Section F - Transmission Axles ZF Axles Procedure 1

Put the calculated shim G (for example S = 0.9mm) into position in the axle-housing. Adjust the bearing outer-ring until there is contact. K Setting the Bearing Rolling Torque and Backlash ( T F-106).

P028460-182

Fig 334. 5

Put the two locating-pins in position.

Use the lifting-device to move the axle housing K into position with the axle drive-housing I.

Note: Temporarily attach the axle housing without the Oring. P028460-180

Fig 332.

Put a layer of marking-ink on the drive and coastflanks of the crown-wheel.

Put the differential H into the axle drive-housing I.

Put the four hexagon-screws L into the axle housing K. Torque to 560Nm.

P028460-183

Fig 335. 8

DHL model only: Pressurize the lock (P=1 bar), close the shut-off valve and remove the air-line.

P028460-181

Fig 333. 4

Put the calculated shim J (for example J = 1.1mm) into position in the axle housing. Adjust the bearing outer-ring until there is contact.

There must be no noticeable pressure loss within 10 seconds.

P028460-184

Fig 336.

F - 107

9803/9420

F - 107

Section F - Transmission Axles ZF Axles 9

Turn the input-flange to move the crown-wheel over the input-pinion in both directions several times.

Remove the axle housing again, then lift the differential out of the axle drive-housing.

Compare the obtained contact pattern with the contact patterns. Refer to K Contact Patterns ( T F-29).

Loosen the slotted-nut M and pull the input-flange N from the input-pinion.

Important: If there is a deviation from the contact pattern, there was a shim measurement error, refer to Step 2, K Assemble the Input Pinion ( T F-103).

P028460-187

Fig 339. Important: Wet the outer diameter of the shaft seal with spirit and fill the space between the seal and the dust lip with grease before installation. 14

Install the shaft seal with the seal-lip facing the oil chamber.

P028460-185

Fig 337. 12

After the contact pattern check, insert the differential into the axle drive-housing.

P028460-188

Fig 340.

P028460-186

Fig 338.

F - 108

9803/9420

F - 108

Section F - Transmission Axles ZF Axles Note: Cover the thread of the slotted-nut with Loctite. 15

Install the input-flange M, then tighten with the disk and slotted-nut N. Torque to 1200Nm.

P028460-189

Fig 341.

F - 109

9803/9420

F - 109

Section F - Transmission Axles ZF Axles Axle Housing 1

Grease the O-ring A, then put it into the axle-housing B.

P028460-192

Fig 344. 6

Grease the O-ring F, then put it into the annulargroove of the brake-tube G.

P028460-190

Fig 342. 2

Put the two locating-pins in position.

Use the lifting-device to move the axle housing B into position with the axle drive-housing C.

Use the hexagon-screws D to secure the axle housing B. Torque to 560Nm.

P028460-193

Fig 345. 7

Install the brake-tube G and the hexagon-nut H. Torque to 100Nm.

Note: When the axle housing B is assembled, secure the axle with clamping-brackets.

P028460-194

Fig 346. 8

Install the screw-plug I with a new O-ring. Torque to 50Nm.

P028460-191

Fig 343. 5

Install the fitting E and torque to 36Nm.

P028460-195

Fig 347.

F - 110

9803/9420

F - 110

Section F - Transmission Axles ZF Axles Output and Brake 1

Use the wheel-stud puller i to pull the wheel-stud A into the output-shaft.

Note: Only use a wheel-stud puller i when individual wheel-studs are exchanged on an installed output-shaft. When a new output-shaft is used, use a press to install the wheel-studs.

P028460-198

Fig 350. Important: The surface area of the slide-ring seal may not have any grooves, scratches or other types of damage. d Make sure that the sealing surface is parallel to the housing-face. Important: Be careful, the metal rings have very sharp edges, you must wear protective gloves. P028460-196

Fig 348. 2

Install the O-rings evenly into the locating-holes, they must not protrude out of the locating-hole

Heat the tapered roller-bearing B, the put it into the output-shaft until there is contact.

P028460-199

Fig 351. f P028460-197

Fig 349. 3

Install the two bearing outer-rings E into position into the brake-housing.

Models with a Slide-Ring Seal: a

Wet the O-ring of the slide-ring seal and the locating-hole with spirit.

b Install a new slide-ring seal C into the outputshaft. c

Install a new slide-ring seal D into the brakehousing.

Note: For the installation position of the seal also refer to K Fig 359. ( T F-113). P028460-200

Fig 352.

F - 111

9803/9420

F - 111

Section F - Transmission Axles ZF Axles 4

Models with a Combination Seal: a

d Wet the outer diameter of the shaft seal with spirit before assembly.

The figure shows the installation position of the combination seal.

Put the shaft seal into the brake-housing.

Important: Make sure that all of the components have been assembled correctly, refer to the K Fig 353. ( T F-112).

3 X Y P028460-238

Fig 353. 5

Output-shaft

Brake-housing

Combination seal consists of:

P028460-202

Fig 355.

Shaft seal

Screening-plate

b Heat the slide-bushing F, then position it on the collar of the output-shaft. c

Use a pressure-ring to move the slide-bushing to its correct position.

Use the lifting-device to move the brake-housing G over to its installation position over the output-shaft.

Note: Before the slide-seal rings are clamped, clean the sliding surfaces and apply a layer of oil. For example, use a leather cloth soaked with oil.

P028460-203

Fig 356.

P028460-201

Fig 354. 7

F - 112

9803/9420

Put the backup-rings H and grooved-rings I into the annular-grooves of the brake-housing G.

F - 112

Section F - Transmission Axles ZF Axles 8

Make sure the components are installed correctly, refer to K Fig 359. ( T F-113).

1 2 3 4 5 6 7

P028460-204

Fig 357. 9

Clean the annular-groove of the brake-housing with spirit.

Put the guide-ring J into the annular-groove and secure it with Loctite at its extremities. Also refer to K Fig 359. ( T F-113)

8 P028460-239

Fig 359. Installation Positions 1

Brake-housing

Note: The full circumference of the guide-ring must be in the correct contact position.

Guide-ring

Backup-ring

Important: When installed, the orifice in the guide-ring must face up (12 o'clock).

Grooved-ring

Backup-ring

Slide-ring seal

Output-shaft

Install the slotted-pins K (x6) into the holes in the piston L. Make sure the slotted-pins are installed flush.

P028460-205

Fig 358.

P028460-206

Fig 360.

F - 113

9803/9420

F - 113

Section F - Transmission Axles ZF Axles 12

Put the piston L into the brake-housing G, then use a a fixing device i to carefully install it in its correct position.

Note: Use enough oil to seal she surfaces of the piston/ backup-rings, grooved-rings and guide-ring (use W-10 oils).

P028460-209

Fig 363. 15

Install the outer and inner-disks Q.

P028460-207

Fig 361. 13

Put the disk M and the cup-spring N (with the convex side at the top) into the piston L.

P028460-210

Fig 364. 16

Install the end-plate R.

P028460-208

Fig 362. 14

Put the cover O into position and secure with the hexagon-screws P. Torque to 34Nm.

P028460-211

Fig 365. 17

F - 114

9803/9420

Push the stop-bolt A into the planetary-carrier B until there is contact.

F - 114

Section F - Transmission Axles ZF Axles

P028460-212

Fig 366. P028460-214

Push the cylindrical roller-bearing C through the packaging-sleeve D until the snap-ring E engages into the annular-groove of the planetary-gear F.

Fig 368. 22

Heat the tapered roller-bearing H, then put it in position on the planetary-carrier I.

P028460-213

Fig 367.

P028460-215

Fig 369. 19

Heat the bearing inner-rings, then put the planetarygears F (with large radius facing the planetary-carrier (downwards)) in position.

If necessary, adjust the bearing inner-rings when they have cooled.

Use the retaining-rings G to secure the planetarygears.

Use an anti-corrosive agent to wet the front-face (contact-face of the bearing inner-ring J) and the profile (teeth K) in the output-shaft.

P028460-216

Fig 370.

F - 115

9803/9420

F - 115

Section F - Transmission Axles ZF Axles 24

Align the disk-package centrally and radially. Use the lifting-device to move the planetary-carrier onto the teeth of the output-shaft.

Remove the locking-screws and the measuring-disk.

3085: planetary-carrier with 3-planetary gears 3095: planetary-carrier with 4-planetary gears.

P028460-219

Fig 373.

P028460-217

Fig 371.

Setting the Gap Width with the Output-Shaft / Planetary-Carrier 1

Move the planetary-carrier with the measuring-disk and the three locking-screws, (removed during disassembly), into position. Torque to 200Nm. P028460-240

Fig 374. 1

Planetary-carrier

Output-shaft

Width of the gap

P028460-218

Fig 372. 2

Pivot the output 180Â° and measure the width of the gap from the output-shaft to the planetary-carrier. (For example the width of the gap = 0.21mm).

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Section F - Transmission Axles ZF Axles Table 10. Determined Gap Width Offset to be Used on the (Delta) Cover 0.30...0.24mm

0.13+/-0.01mm

0.239...0.18mm

0.07+/-0.01mm

0.179...0.10mm

0.0mm

Select the cover L (optional) based on the table. K Table 10. ( T F-117)

Note: The cover L has an offset of 0.07mm on one side and an offset of 0.13mm on the other side. Note: The offset i 0.13mm is visually marked with an annular-groove.

P028460-221

Fig 376. 8

Attach the O-ring N to the cover O. Wet the contact face with Terostat MS 9360. Use a new cover and Oring.

Note: The Terostat curing period is more than 24 hours.

P028460-220

Fig 375.

P028460-222

Fig 377. 5

Put the cover L with the offset (for example 0.07mm) showing to the planetary-carrier, then tighten with new locking-screws M.

When the cover with an offset of 0.07mm is used, the groove must be visible when the cover L is installed.

Tighten the locking-screws M in sequence to a torque of 200Nm. Tighten the locking-screws M again in sequence to a torque of 500Nm.

Put the cover O into position on the output-shaft.

P028460-223

Fig 378.

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Section F - Transmission Axles ZF Axles Set the Axial-Play of the Sun Gear-Shaft 0.5....2.0mm 1

Use gauge blocks and a straight edge to calculate the dimension I, from the mounting-face of the brakehousing to the front-face of the stop-bolt. (For example the dimension = 19.75mm).

P028460-226

Fig 381. 4

Use a straight edge to measure the dimension II from the front-face of the sun gear-shaft to the mountingsurface of the axle-housing.

P028460-224

Fig 379. 2

Put the stub-shaft P into the teeth of the axle bevelgear until there is contact.

Note: Make sure to position the stub-shaft with the long teeth facing the differential.

P028460-227

Fig 382. Calculated Shim Example: Dimension I

19.75mm

Dimension II

-17.15mm

Difference

2.60mm

Required axial play, for example

1.00mm

Difference = shim, for example

1.60mm

P028460-225

Fig 380. 3

Put the sun gear-shaft Q into position.

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Section F - Transmission Axles ZF Axles 5

Put the sun gear-shaft R into the planetary-carrier.

P028460-231

Fig 386. P028460-228

Fig 383. 6

Put the two adjusting-screws in position, then use the lifting-device to move the output into position with the axle-housing.

Use the hexagon-screws V to secure the output.

Grease, then install the â&#x20AC;&#x2DC;calculatedâ&#x20AC;&#x2122; shim S (for example S= 1.60mm) into the sun gear-shaft.

Note: Use a wheel-stud to secure the lifting-device.

P028460-229

Fig 384. 7

Grease, then install the O-ring T into the countersink of the brake-housing.

P028460-232

Fig 387. 11

Install the breather W.

P028460-230

Fig 385. 8

Grease, then install the O-ring U into the axle housing.

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P028460-233

Fig 388.

F - 119

Section F - Transmission Axles ZF Axles Test Procedures

Check the Operability of DHL

Check the Brake Hydraulics for Leakage

Increase the pressure to p = 20 bar maximum then use the shut-off valve to close the connection to the HP pump.

Before you start the test, completely release the brake hydraulic pressure. Temporarily pressurise the brakes (5x) with p = 100 bar maximum.

Lock On: When you turn the input-flange, both outputs must have the same direction of rotation.

High-Pressure Test Increase the test pressure to p = 100-10 bar maximum then use the shut-off valve to close the connection to the HP pump.

Lock Off: When you turn the input-flange, one side has no movement or has the opposite direction of rotation.

A decrease in the pressure of a maximum 2% (2 bar) is permitted during a 5-minute test time. Low Pressure Test Decrease the test pressure to p = 5 bar then close the shutoff valve. No decrease in pressure is allowed during a 5minute test time.

P028460-235

Fig 390. Note: Fill the axle with oil before it is used.

P028460-234

Fig 389.

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Section F - Transmission

Removal and Replacement General Replacement of Loader Arm Control Transmission Dump and Kickdown Switches 1

Prise the top off the Loader Arm Control lever using a fine bladed screwdriver or knife.

Disconnect connector from the rear of the switch.

Depress tabs 391-A on the switch and press switch out through the Control Lever.

Note: It is advisable to check the suspect switch at this stage to rule out the possibility of a defective harness before reassembling the Control Lever. 4

Assembly is the reverse of the dismantling procedure.

Replacement of Wiring to Kick down and Transmission Dump Switches 1

Remove switch as detailed in steps 1 - 3 above.

Remove the instrument panel to access connector.

Remove the connector, making a note of the respective positions. Cut the wires close to the connector.

Draw the wires through the top of the control lever.

Feed new wire through aperture for switch 391-B and out through aperture 391-C.

Strip sleeving from last 10 mm of wire. Use special tool to fit connector to end of wires.

Mate connector to instrument cluster connector.

Refit cap on Loader Arm Control Lever.

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Fig 391.

F - 121

Section F - Transmission Removal and Replacement General

Removal and Replacement of Control Lever 1

Prise out centre of steering wheel 392-D using a fine bladed screwdriver.

Remove steering wheel securing nut 392-E and withdraw steering wheel.

Release the two column cover securing bolts, 392-F and remove column cover 392-G.

Disconnect connector 392-SE and gently pull the control lever sideways to clear the locating spigot, 392-H from the steering column.

Assembly is reverse of removal procedure.

Fig 392.

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Section F - Transmission

Propshafts Basic Operation Removing and Replacing When Removing Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal.

When Replacing Upon reassembly, after lubricating sliding joints with JCB HP Grease, align the shafts against identification marks previously made or, in the case of a shaft being renewed, use the manufacturers alignment markings. Apply JCB Lock and Seal to threads of all flange bolts. Retaining straps 393B stretch with use, therefore these straps must always be replaced with new ones.

Fig 394.

Item A

Table 11. Torque Settings Nm kgf m 75 - 85

7.7 - 8.7

lbf ft 55 - 63

Note: The rear propshaft is secured at the gearbox end by flange bolts and nuts. These should be tightened to a torque of 118 Nm (12 kgf m, 87 lbf ft). Fig 393. The propshafts must have both ends exactly on the same plane as shown at 394X. The yokes must not be at right angles as at 394Y or at an intermediate angle as at 394Z.

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Section F - Transmission Propshafts Basic Operation Page left intentionally blank

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Section F - Transmission Powershift Transmission WG 210

Powershift Transmission WG 210 Main Components

Fig 395. Key 1

Input drive plate

Torque converter

Converter bell housing

Breather

Cover - transmission case

Filter head

Filter

Parking brake caliper

Output drive flange/brake disc to front axle

Magnetic oil drain plug

Output drive flange to rear axle

Transmission case

Lifting lugs

Hydraulic pump mounting

Electro-hydraulic control unit

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F - 126

Note: This schematic shows the oil flow for forward 1st speed, as selected by the energising of the solenoids of proportional valves 395-11 and 395-13 and the subsequent pressurisation of clutches 396-

Oil Circulation Schematic

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KV and 396-K1. The principle is identical for the remaining forward speeds and the reverse speeds Flow Forward (refer to K Power Speeds ( T F-128) or K Power Flow - Reverse

Fig 396. Speeds ( T F-130) for the combinations of clutches which give the other speeds).

Section F - Transmission Powershift Transmission WG 210

F - 126

F - 127

Oscillation damper

Restrictor

Proportional valve - clutch K4

Proportional valve - clutch KV

Proportional valve - clutch K2

Pressure regulators

Torque converter relief valve

Torque converter

Torque converter back pressure valve

Oil cooler

Lubrication

Temperature sensors

Valve block control schematic

Main oil schematic

Test points, see K Test Points and connections ( T F-131)

Clutch forward

Clutch reverse

Clutch 1st speed

15 - 20

29 - 40

Proportional valve - clutch K3

Metering valve

Pressure reducing valve

Proportional valve - clutch KR

System pressure valve

Proportional valve - clutch K1

Filter

Transmission pump

Oil sump

Component Key Clutch 3rd speed Clutch 4th speed

K3 K4

(Clutches K1 and KV shown)

Pilot pressure --------------------------------------

Controlled clutch pressure _ _ _ _ _ _ _ _ _

System pressure/return ______________

Clutch 2nd speed

Section F - Transmission Powershift Transmission WG 210

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Section F - Transmission Powershift Transmission WG 210

Power Flow - Forward Speeds

KR IN

Fig 397.

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Section F - Transmission Powershift Transmission WG 210 Clutches Actuated K Fig 397. ( T F-128) Speed

Clutches

1st Forward

KV/K1

2nd Forward

K4/K1

3rd Forward

KV/K2

4th Forward

K4/K2

5th Forward

KV/K3

6th Forward

K4/K3

Key KV

Clutch forward

Clutch reverse

Clutch 1st speed

Clutch 2nd speed

Clutch 3rd speed

Clutch 4th speed

Input

Output

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Section F - Transmission Powershift Transmission WG 210

Power Flow - Reverse Speeds

Fig 398.

Clutches Actuated K Fig 398. ( T F-130) Speed

Clutches

1st Reverse

KR/K1

2nd Reverse

KR/K2

3rd Reverse

KR/K3

Key KV

Clutch forward

Clutch reverse

Clutch 1st speed

Clutch 2nd speed

Clutch 3rd speed

Clutch 4th speed

Input

Output

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Section F - Transmission Powershift Transmission WG 210

Test Points and connections

Fig 399.

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Section F - Transmission Powershift Transmission WG 210 Item

Description

Control Unit Valve Block Port Identification

Test Points 29

Torque Converter, Inlet Pressure

Torque Converter, Outlet Pressure

Clutch - Forward (KV) Pressure

Clutch - Reverse (KR) Pressure

Clutch - 1st Speed (K1) Pressure

Clutch - 2nd Speed (K2) Pressure

Clutch - 3rd Speed (K3) Pressure

Clutch - 4th Speed (K4) Pressure

Torque Converter, Outlet Temperature

System Pressure

Cooler Input Flow

Cooler Output Flow

Inductive Transmitter - turbine rpm

Speed Sensor Output

Inductive Transmitter - central Geartrain rpm

Inductive Transmitter - engine rpm

Measuring Devices 41

Connections 45

Electrical Connection to Control Unit

Pilot Pressure (optional)

System Pressure (optional)

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Section F - Transmission Powershift Transmission WG 210

Electro-Hydraulic Shift Control

9 19

A-A

B-B

Note: View B-B shows proportional valve 13. Proportional valves 9-12 and 14 are functionally identical.

Key V Valve block W Housing X Cover Y Duct plate Z Gasket

A344060-V1

Fig 400.

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Section F - Transmission Powershift Transmission WG 210 Table 12. Key to Electro-Hydraulic Shift Control Note: View B-B shows proportional valve 13. Proportional valves 9 - 12 and 14 are functionally identical Key V

Valve block

Housing

Cover

Duct plate

Gasket

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Section F - Transmission Powershift Transmission WG 210

Dismantling

Mark radial installation position of the housing cover 404-11 and bell housing 404-26. Remove the screws 404-16/nuts 404-17.

Separate converter along with cover 404-11 from the bell housing using lifting device.

Press drive shaft torque converter out of the cover 404-11.

Remove two socket head screws 403-1 (one top and one bottom). Install threaded alignment dowels (M6) in their place to prevent hidden components falling out during dismantling.

Remove circlip 404-19 and extract bearing 404-20 from cover 404-11.

Remove the four screws 404-21 and separate diaphragm 404-22, complete with drive shaft 404-18, from torque converter 404-23.

Remove the remaining socket head screws 403-1 and separate control unit 403-2 from duct plate 403-3.

Remove screws 404-24 and separate drive shaft 40418 from diaphragm 404-22.

Returning to the transmission assembly, remove the engine inductive transmitter arrowed in K Fig 402. ( T F-135).

K Fig 403. ( T F-136) and K Fig 404. ( T F-136). To facilitate the following procedures it is advisable to support the transmission assembly in a suitable adjustable jig which allows the unit to be rotated as necessary.

Separate Hydraulic Control Unit (HSG-90) and Duct Plate from Gearbox 1

Note: For dismantling and assembly of control unit 403-2, Control Unit ( T F-179), refer to K Hydraulic K Dismantling ( T F-179) and K Assembly ( T F-181). 2

Remove gaskets 403-4 and 403-6 and intermediate plate 403-5. Remove socket head screws 403-7 and nuts 403-8/washers 403-9. Separate duct plate 403-3 from gearbox housing. Remove gasket 403-10.

Pull the torque converter safety valve out of the gearbox housing bore as shown in K Fig 401. ( T F-135).

Fig 402. 12

Remove screws 404-25 and separate the converter bell housing 404-26 from the transmission assembly.

Note: Mark radial installation position of converter bell housing 404-26 and the transmission housing. Fig 401. 4

Remove lock plate 404-12 and the two screws 40413. Remove disc 404-14 and pry drive flange 404-15 off the shaft.

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Section F - Transmission Powershift Transmission WG 210

Fig 403.

Fig 404.

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Section F - Transmission Powershift Transmission WG 210 Hydraulic Pump K Fig 408. ( T F-138). 13

Remove screws 408-1 securing the hydraulic pump assembly, 408-2 to 408-4, to the transmission housing.

Using a suitable separating device clamped to the exposed portion of pump stator shaft 408-4 as shown in K Fig 405. ( T F-137), pull pump carefully out of the housing bore by means of two-leg puller.

Fig 406. 16

Remove socket head screws 408-5, 408-6, 408-7 as well as the two hexagonal screws 408-8. Remove oil feed housing 408-9 and gasket 408-10 from housing 408-11.

Converter Back Pressure Valve K Fig 408. ( T F-138). 17 Fig 405. 15

Preload compression spring and remove lock plate 407B. Remove released components 407C, 407D, 407E in K Fig 407. ( T F-137).

Separate the pump 406-2 and 406-3 from stator shaft 406-4. Separate control disc 406-3 from pump rotor 406-2. If the original pump is to be refitted position control disc 406-3 on top of rotor 406-2 and secure together using two grooved pins 406-A via the holes arrowed in K Fig 406. ( T F-137).

Fig 407. 18

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Remove screws 408-12 and take off cover 408-13 and gasket 408-14.

F - 137

Section F - Transmission Powershift Transmission WG 210

Fig 408.

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F - 138

Section F - Transmission Powershift Transmission WG 210 Remove Output Shaft, Input Shaft and Clutches K Fig 414. ( T F-142). 19

Remove lock plate 414-1, screws 414-2 and retainer disc 414-3. Remove seal 414-4 and pry torque converter-side drive flange 414-5 off the shaft. Pry shaft seal 414-6 out of the housing bore. Repeat for the opposite drive flange assembly 414-7 to 414-12.

Remove speed sensor 409F as well as both inductive transmitters 409G.

Fig 410. 24

To facilitate separation of the housing cover from the transmission gearbox housing proceed as follows: a

Attach two M20 eyebolts 411H and one M16 eyebolt 411J to the housing cover. Lifting Eye (M20) 892/01015 Lifting Eye (M16) 892/01013

b Attach retainers 411K to the threaded studs protruding through the housing cover from the six clutches. As an alternative to the retainers, fit washers and M10 nuts over each stud and tighten firmly. Retainer 892/01014

Fig 409. 21

Remove nuts 414-13 and washers 414-14. Remove cover 414-15 and seal 414-16. Repeat for the second cover assembly 414-18 to 41421.

Remove screw 414-23 connection (housing/housing cover).

Drive out both cylindrical pins (see arrows in K Fig 410. ( T F-139)). Fig 411. 25

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Separate housing cover along with clutches from the gearbox housing, using lifting device. Fasten housing cover on the assembly jig.

F - 139

Section F - Transmission Powershift Transmission WG 210 26

Remove socket head screws 414-24 and remove output shaft assembly 414-25 to 414-27 as well as the two oil collecting plates 414-28 and 414-29. Pull off tapered roller bearing 414-26. Remove opposite tapered roller bearing 414-27 accordingly. Separate oil collecting plates 414-28 and 414-29 from output shaft 414-25.

Remove clutches K2 and K3 in turn.

Lift clutch KV and KR by means of pry bars and remove clutch K4.

Lift clutch KV and clutch KR as well as input shaft AN together out of the housing cover.

Remove the bearing outer races left behind in the housing after clutch/shaft removal but only those for individual bearings, if any, which are being renewed.

Tilt housing cover 90Â°.

Remove screws 413-1, retaining plate 413-2 and gasket 413-3.

Extract circlip 413-4 and separate pump shaft 413-5/ ring 413-6/ bearing 413-7 from housing cover.

Extract ring 413-6 and press bearing 413-7 from shaft 413-5.

Bearing Tool 892/01004 Bearing Puller 892/01003 28

Rotate the torque converter half of the transmission gearbox in the support jig so that the clutch assemblies are uppermost. The clutches are identified below. K Fig 412. ( T F-140). AN = Input (drive) Shaft KV = Clutch - Forward KR = Clutch - Reverse K1 = Clutch - 1st Speed K2 = Clutch - 2nd Speed K3 = Clutch - 3rd Speed K4 = Clutch - 4th Speed

Fig 412. 29

Remove the six clutch retainers fitted at step 6b.

Note: The following procedures to remove the clutch packs require the participation of two people. 30

Lever clutch K4 upwards from its bearing seat and lift out clutch K1. Relocate clutch K4 to its bearing seat.

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Section F - Transmission Powershift Transmission WG 210

Fig 413.

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Section F - Transmission Powershift Transmission WG 210

Fig 414. Output Shaft, Input Shaft and Clutches

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Section F - Transmission Powershift Transmission WG 210 Clutches KV and KR K Fig 415. ( T F-144). Note: The following steps 39 to 46 describe the disassembly of clutch KV. The disassembly of clutch KR is similar. 39

Extract rectangular ring 415-1. Pull tapered roller bearing 415-2 from the shaft 415-3.

Remove opposite tapered roller bearing accordingly. Bearing Puller 892/01000 Bearing Tool 892/01001 Bearing Tool 892/01005

Remove circlip 415-6 and separate plate carrier 4157 from shaft 415-3.

Remove snap ring 415-8 and remove plate pack 4159 to 415-11.

Preload compression spring 415-13, remove snap ring 415-15 and remove components 415-12, 415-13, 415-14. Spring Compressor 892/01002

Force out piston 415-16 from its bore by applying compressed air to the oil port on the innermost bore of plate carrier 415-7. Remove O-rings 415-17 and 415-18 from the piston.

Lift idler gear 415-19 a bit by means of pry bars. Apply puller and separate idler gear from clutch shaft 415-3.

Remove circlip 415-20 and remove ball bearing 41521.

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Section F - Transmission Powershift Transmission WG 210

Fig 415. Clutches KV and KR

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F - 144

Section F - Transmission Powershift Transmission WG 210 Clutches K1, K2, K3 K Fig 416. ( T F-146). Note: The following steps 1 to 54 describe the disassembly of clutch K3. The disassembly of the clutches K1 and K2 is similar. 47

Remove rectangular ring 416-1. Pull tapered roller bearing 416-2 from shaft 416-3.

Remove the opposite rectangular ring 416-4/tapered roller bearing 416-5 accordingly. Bearing Puller 892/01000 Bearing Puller 892/01003 Bearing Tool 892/01004 Bearing Tool 892/01005

Remove running disc 416-6, axial needle cage 416-7 and axial washer 416-8 followed by idler gear 416-9.

Remove needle bearings 416-10 as well as the disc 416-11/axial needle cage 416-12/axial bearing 41613.

Remove snap ring 416-14 and remove plate pack 416-15 to 416-17.

Preload cup spring pack 416-18, 416-19 and remove snap ring 20. Remove released components. Spring Compressor 892/01002

Fit special tool circlip into the inner groove of plate carrier 416-21. Use a suitable puller to remove the plate carrier from clutch shaft 416-3.

Force out piston 416-22 from its bore by applying compressed air to the oil port on the innermost bore of plate carrier 416-21. Remove O-rings 416-23 and 416-24 from the piston.

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Section F - Transmission Powershift Transmission WG 210

Fig 416. Clutches K1, K2, K3

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Section F - Transmission Powershift Transmission WG 210 Clutch K4 K Fig 417. ( T F-148). 1

Remove rectangular ring 417-1. Pull tapered roller bearing 417-2 from the shaft 417-3.

Remove opposite tapered roller bearing 417-5 accordingly. Bearing Puller 892/01000 Bearing Tool 892/01001 Bearing Tool 892/01005

Remove circlip 417-6 and, using a three-leg puller, separate plate carrier 417-7 from shaft 417-3.

Remove snap ring 417-8 and remove the plate pack 417-9 to 417-11.

Preload cup spring pack 417-12, 417-13 and remove snap ring 417-14. Remove released components 417-12, 417-13. Spring Compressor 892/01002

Force out piston 417-15 from its box by applying compressed air to the oil port on the innermost bore of plate carrier 417-7. Remove O-rings 417-16 and 417-17 from the piston.

Remove idler gear 417-18 and remove released components 417-19 to 417-21.

Remove needle bearings 417-22, axial washers 41723, 417-25 and needle cage 417-24.

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Section F - Transmission Powershift Transmission WG 210

Fig 417. Clutch K4

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Section F - Transmission Powershift Transmission WG 210 Drive Shaft K Fig 418. ( T F-150). 1

Remove rectangular ring 418-1. Pull off tapered roller bearing 418-2 from shaft 418-3. Bearing Puller 892/01003

Remove opposite tapered roller bearing 418-4 accordingly.

Remove circlip 418-5 and slide off gear 418-6.

If necessary, press turbine shaft 418-7 off drive shaft 418-3.

Note: The turbine shaft is axially fixed with snap ring 4188 which will be destroyed at the pressing out.

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Section F - Transmission Powershift Transmission WG 210

Fig 418. Driveshaft

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Section F - Transmission Powershift Transmission WG 210

Assembly Install Oil Tubes Note: To ensure the correct installation of the oil tubes, the use of one of the Special Tools is imperative. 1

Insert suction pipe 419-1, pressure pipes 419-2, 4193 and pressure lubrication pipe 419-4 into the housing bores. Fasten suction and pressure pipes by means of socket head screws (arrowed in K Fig 420. ( T F-151)). Torque limit (M8/8)................ 23 Nm (17 lbf ft).

Fig 420. Pipe Swaging Tool 892/01008 Pipe Swaging Tool 892/01007 Pipe Swaging Tool 892/01009 3

Fig 421.

Fig 419. 2

Insert O-rings (arrowed in K Fig 421. ( T F-151)) into the annular grooves of the two oil tubes and oil them.

Tilt housing 180Â°.

Note: The rolled pipe ends must not protrude beyond the level of the mating flange of the housing. If necessary adjust individual pipes to suit.

Assemble both oil tubes 422A until contact is obtained. Equip screw plug 422B with new O-ring and install it. Torque limit...................................140 Nm (103 lbf ft).

Roll the suction and pressure pipes into the housing apertures arrowed in K Fig 421. ( T F-151), using special tool.

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Section F - Transmission Powershift Transmission WG 210 Install Studs, Plugs and Sealing Cover 6

Mount studs 424D (M8 x 25). Torque limit (studs)......................9.0 Nm (6.6 lbf ft)

Note: Wet screw-in thread with JCB Threadlocker and Sealer (High Strength) 7

Equip plugs 424E with new O-rings and install them. Torque limit (M16 x 1.5) .................... 40 Nm (30 lbf ft) Torque limit (M18 x 1.5) .................... 50 Nm (37 lbf ft)

Fig 422. 5

Torque limit (M26 x 1.5) .................... 80 Nm (59 lbf ft)

Insert both oil tubes 423C into the housing cover. Tilt housing cover 180Â° and roll oil tubes into the housing bores.

Note: The rolled pipe ends must not protrude beyond the level of the mating flange of the housing. If necessary adjust individual pipes to suit. If necessary equalise projection of the tube.

Fig 424. 8

Insert sealing cover 425D with the recess showing upward.

Note: Wet contact face with JCB Threadlocker and Sealer (High Strength).

Fig 423.

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Section F - Transmission Powershift Transmission WG 210

Fig 425.

F - 153

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F - 153

Section F - Transmission Powershift Transmission WG 210 Clutches KV and KR K Fig 431. ( T F-156). Note: The following steps 9 and 27 of Gearbox WG - 210 describe the assembly of clutch KV. The assembly of clutch KR is similar. 9

Check function of the purge valve in clutch piston 431-16 (see K Fig 426. ( T F-154)).

Note: Ball must not stick, if necessary, clean with compressed air.

Fig 427. Key

Fig 426. 10

Plate carrier

Snap ring (optional 2.1 - 4.2 mm)

Shim plate

Friction plates (coated both sides)

10A

Friction plate (coated one side)

Counter plates

Piston

Fit O-rings 431-17, 431-18 scroll free into the grooves of piston 431-16 and oil. Introduce piston into the plate carrier 431-7 until contact is obtained.

Feed the assembled plate pack, free of oil, into plate carrier 431-7. Fit shim plate 431-9 and a nominal thickness snap ring 431-8.

Note: Pay attention to the installation position, i.e. purge valve side first.

Set up a dial indicator as shown below. Apply pressure of approximately 10 kg (22 lb) to the shim plates and, while maintaining this pressure, set the dial to zero.

Install disc 431-12, spring 431-13 and guide ring 43114.

Preload spring 431-13 and fix it by means of snap ring 431-15. Spring Compressor 892/01002

Assemble the friction plate 431-10, 431-10A and counter plate 431-11 pack, as shown following, according to gearbox model:

Note: Install friction plate 431-10A with the uncoated side facing piston 431-16. Gearbox WG - 210 Fig 428.

Effective friction surfaces - 20

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Section F - Transmission Powershift Transmission WG 210 16

Using a screwdriver, raise shim plate 431-9 until it contacts snap ring 431-8 (K Fig 429. ( T F-155)). Note the clearance reading on the dial indicator. The reading should be within the limits for the relevant gearbox, as indicated on the illustrations at step 18. If the clearance is not as indicated, this can be corrected by fitment of a suitable alternative thickness snap ring 431-8.

Heat inner diameter of plate carrier 431-7 to about 120Â°C using a hot air blower. Heater 110 Volt 892/01006

Fit pre-assembled plate carrier 431-7 over idler gear 431-19 until contact is obtained. Secure with circlip 431-6.

Check function of the clutch by means of compressed air.

Note: With correctly installed components, the closing/ opening of the clutch is clearly audible.

Fig 429. 17

Withdraw the original plate pack. Immerse the plates in oil and re-assemble into the plate carrier. Secure with the correct thickness snap ring 431-8 as determined at step 16.

Introduce idler gear 431-19 until all counter plates 431-11 are located.

Fig 430. 26

Press tapered roller bearing 431-2 against shoulder. Repeat for roller bearing 431-5.

Fit rings 431-1 and 431-4, letting them snap in.

Note: This step makes the later assembly of the idler gear easier. Remove the idler gear. 19

Mount stud 431-3A.

Note: Wet screw-in thread with JCB Threadlocker and Sealer (High Strength). Torque limit (M10).........................17 Nm (13 lbf ft). 20

Insert bearing 431-21 until contact is obtained and fix by means of circlip 431-20.

Install needle bearing 431-22.

Press idler gear 431-19 onto clutch shaft 431-3.

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Section F - Transmission Powershift Transmission WG 210

Fig 431. Clutches KV/KR

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F - 156

Section F - Transmission Powershift Transmission WG 210 Clutches K1, K2 and K3

Preload cup spring pack and fix it by means of snap ring 438-20.

K Fig 438. ( T F-159). Spring Compressor 892/01002 Note: The following describes the assembly of Clutch K3. The assembly of Clutches K1 and K2 is similar. 28

Install stud 438-3A.

Note: Wet screw-in thread with JCB Threadlocker and Sealer (High Strength).

Assemble the friction plate 438-16, 438-16A and counter plate 438-17 pack, as shown following, according to gearbox model and clutch identity.

Note: Install friction plate 438-16A with the uncoated side facing piston 438-22.

Torque limit (M10) ......................... 17 Nm (13 lbf ft).

Gearbox WG - 210

Heat inner diameter of plate carrier 438-21 using a hot air blower. Install onto clutch shaft 438-3 until contact is obtained.

Clutch K1 Effective friction surfaces - 18

Heater 110 Volt 892/01006 30

Check function of the purge valve in clutch piston 438-22.

Note: Ball must not stick, if necessary, clean with compressed air.

Fig 433.

Fig 432. 31

Insert O-rings 438-23, 438-24 scrollfree into the grooves of piston 438-22 and oil. Introduce the piston into plate carrier 438-21 until contact is obtained.

Note: Pay attention to the installation position i.e. purge valve side first. 32

Install cup-spring pack 438-19 and guide ring 438-18.

Note: Pay attention to the stacking of the cup springs 43819 (see step 34).

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F - 157

Section F - Transmission Powershift Transmission WG 210 Clutches K2, K3

Effective friction surfaces - 14

Using a screwdriver, raise shim plate 438-15 until it contacts snap ring 438-14 (see K Fig 436. ( T F-158)). Note the clearance reading on the dial indicator. The reading should be within the limits for the relevant gearbox, as indicated on the illustrations at step 41. If the clearance is not as indicated, this can be corrected by fitment of a suitable alternative thickness snap ring 438-14.

Fig 434. 35

Feed the assembled plate pack, free of oil, into plate carrier 438-21. Fit shim plate 438-15 and a nominal thickness snap ring 438-14.

Set up a dial indicator as shown below. Apply pressure of approximately 10 kg (22 lb) to the shim plates and, while maintaining this pressure, set the dial to zero.

Fig 436. 38

Withdraw the original plate pack. Immerse the plates in oil and reassemble into the plate carrier. Secure with the correct thickness snap ring 438-14 as determined at step 37.

Install running disc 438-13, axial needle cage 438-12 and axial washer 438-11 onto clutch shaft 438-3.

Install needle bearings 438-10.

Install idler gear 438-9 until all counter plates 438-17 are located.

Install axial washer 438-8, axial needle cage 438-7 and running disc 438-6 onto clutch shaft 438-3.

Note: Install running disc 438-6 with the chamfer facing the axial needle cage. Note: If running disc 438-6 does not fit over the collar of clutch shaft 438-3, idler gear 438-9 is not fully engaged with all the counter plates 438-17. Repeat step 41. Fig 435.

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Section F - Transmission Powershift Transmission WG 210 43

Press tapered roller bearing 438-2 against shoulder of clutch shaft 438-3. Press opposite tapered roller bearing 438-5 against shoulder.

Check function of the clutch by means of compressed air.

Note: With correctly installed components, the closing/ opening of the clutch is clearly audible.

Fig 437. 45

Fit rings 438-1 and 438-4, letting them snap in.

Fig 438. Clutches K1, K2, K3

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Section F - Transmission Powershift Transmission WG 210 Clutch K4

Preload cup-spring pack and fix it by means of snap ring 444-14.

Assemble the friction plate 444-10 and 444-10Aand counter plate 444-11 pack, as shown following, according to gearbox model.

K Fig 444. ( T F-162). 46

If previously separated, re-assemble clutch shaft 3 as follows. Cool the shaft to - 80Â°C and heat the gear to +120Â°C. Fit the gear onto the shaft against the shoulder and secure with a circlip.

!MCAUTION

Note: Install friction plate 444-10A with the uncoated side facing piston 444-15.

Gearbox WG-210

Protective gloves must be worn when handling extremely hot or cold components.

Effective friction surfaces - 10

GEN-1-15_1

Install stud 444-3A.

Note: Wet screw-in thread with JCB Threadlocker and Sealer (High Strength 48

Check function of the purge valve in clutch piston 444-15.

Note: Ball must not stick, if necessary, clean with compressed air.

Fig 440. Key

Fig 439.

Plate carrier

Snap ring (2.1 - 4.2 mm)

Shim plate

Friction plates (coated both sides)

10A

Friction plate (coated one side)

Counter plates

Piston

Insert O-rings 444-16 and 444-17 scrollfree into the grooves of piston 444-15 and oil them. Introduce the piston into plate carrier 444-7 until contact is made.

Feed the assembled plate pack, free of oil, in plate carrier 444-7. Fit shim plate 444-9 and a nominal thickness snap ring 444-8.

Note: Pay attention to the installation position i.e. purge valve side first.

Set up a dial indicator as shown below. Apply pressure of approximately 10 kg (22 lb) to the shim plates and, while maintaining this pressure, set the dial to zero.

Install cup-spring pack 444-13 and guide ring 444-12.

Note: Pay attention to the stacking of the cup springs 44413 (see step 7).

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Section F - Transmission Powershift Transmission WG 210 58

Install axial washer 444-25, needle cage 444-24 and axial washer 444-23.

Note: Axial washers 444-23 and 444-25 have the same thickness (1 mm). 59

Install needle bearings 444-22 and idler gear 444-18.

Install axial washer 444-21 (1 mm thick), needle cage 444-20 and running disk 444-19 (5 mm thick).

Note: Install running disk 444-19 with chamfer facing needle cage 444-20. 61

Fig 441. 55

Using a screwdriver, raise shim plate 444-9 until it contacts snap ring 444-8 (K Fig 442. ( T F-161)). Note the clearance reading on the dial indicator. The reading should be within the limits for the relevant gearbox, as indicated on the illustrations at step 59. If the clearance is not as indicated, this can be corrected by fitment of a suitable alternative thickness snap ring 444-8.

Heat the inner diameter of plate carrier 444-7 to about 120Â°C using a hot air blower. Install the preassembled plate carrier until all counter plates 444-11 locate with idler gear 444-18.

!MCAUTION Protective gloves must be worn when handling extremely hot or cold components. GEN-1-15_1

Secure plate carrier 444-7 by means of circlip 444-6.

Check function of the clutch by means of compressed air.

Note: With correctly installed components, the closing/ opening of the clutch is clearly audible.

Fig 442. 56

Withdraw the original plate pack. Immerse the plates in oil and re-assemble into the plate carrier. Secure with the correct thickness snap ring 444-8 as determined at step 55.

Introduce idler gear 444-18 until all counter plates 444-11 are located.

Note: This step makes the later assembly of the idler gear easier.

Fig 443. 64

Remove the idler gear.

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Press tapered roller bearing 444-2 and 444-5 against the shoulders of clutch shaft 444-3. Retain with snapin rectangular rings 444-6 and 444-4 respectively.

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Section F - Transmission Powershift Transmission WG 210

Fig 444. Clutch K4

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Section F - Transmission Powershift Transmission WG 210 Drive Shaft K Fig 445. ( T F-164). 65

Cool drive shaft 445-3 to - 80 Â°C and heat gear 445-6 to about +120Â°C. Fit the gear onto the shaft until contact is obtained. Secure gear axially by means of circlip 445-5.

!MCAUTION Protective gloves must be worn when handling extremely hot or cold components. GEN-1-15_1

If previously removed, fit a new snap ring 445-8 into the groove of turbine shaft 445-7.

Install turbine shaft 445-7 until snap ring 445-8 locates in the groove of drive shaft 445-3. This axially secures the turbine shaft.

Press tapered roller bearing 445-2 against the shoulder of drive shaft 445-3. Squeeze rectangular ring 445-1 into the groove of the drive shaft and let it snap in.

Press tapered roller bearing 445-4 against the shoulder of drive shaft 445-3.

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Section F - Transmission Powershift Transmission WG 210

Fig 445. Driveshaft

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Section F - Transmission Powershift Transmission WG 210 Pre-assembly and Installation - Output Shaft

oil collecting plates by means of socket head screws 447-24.

K Fig 447. ( T F-166). Torque limit (M8/8.8) .................. 23 Nm (17 lbf ft). 70

Fit oil collecting plate 447-29 over shaft 447-25.

Heat tapered roller bearings 447-27 and 447-26 and assemble until contact is obtained.

Insert outer races for bearing being renewed into the relevant bearing bores of the housing. Install a new O-ring in every bore.

Fig 446. Key AN = Input (drive) shaft KV = Clutch - Forward KR = Clutch - Reverse K1 = Clutch - 1st Speed K2 = Clutch - 2nd Speed K3 = Clutch - 3rd Speed K4 = Clutch - 4th Speed AB = Output shaft 73

Position oil collecting plate 447-28 over bore AB. Install the pre-assembled output shaft and secure the

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Section F - Transmission Powershift Transmission WG 210

Fig 447. Output Shaft

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Section F - Transmission Powershift Transmission WG 210 Install Pre-assembled Drive Shaft and Clutches 74

Insert outer races for bearings being renewed into the relevant bearing bores of the housing cover.

Fig 449. 75

Insert clutch 449KR, drive shaft 449AN and clutch 449KV together into the housing cover.

Raise drive shaft 449AN and install clutch 449K4.

Install clutch 449K3 followed by clutch 449K2.

Raise clutch 449K4 and install clutch 449K1.

Grease rectangular rings (arrowed K Fig 448. ( T F-167)) and align them centrally.

Attach retainers 450A to the threaded studs protruding through the housing cover from the six clutches. As an alternative to the retainers, fit washers and M10 nuts over each stud and tighten firmly.

Fig 448. Key AN = Input (drive) shaft KV = Clutch - Forward Retainer 892/01014 KR = Clutch - Reverse K1 = Clutch - 1st Speed K2 = Clutch - 2nd Speed K3 = Clutch - 3rd Speed K4 = Clutch - 4th Speed AB = Output shaft Note: Prior to the installation of the clutches and the drive shaft, grease the rectangular rings retaining the taper bearings and align them centrally. When installing refer to K Fig 449. ( T F-167) for the shaft position and orientation.

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Fig 450.

F - 167

Section F - Transmission Powershift Transmission WG 210 81

Rotate housing cover 180Â°. Attach two M20 eyebolts 450B and one M16 eyebolt 450C to the torque converter case half. Lifting Eye (M20) 892/01015 Lifting Eye (M16) 892/01013

Grease O-rings of the two oil tubes 451D installed at step 4. Wet mounting face with JCB Multigasket sealing compound.

Fig 452. Fasten housing cover by means of hexagonal head screws 452E. Torque limit (M10/8.8) ............... 46 Nm (34 lbf ft). Note: Pay attention to the position of the lifting ring 452F.

Fig 451. 83

Position pre-assembled housing cover by means of lifting device carefully on the gearbox housing until contact is obtained.

Note: Pay attention to the alignment of the oil tubes 451D with the bores in the housing cover. 84

Remove the six clutch retainers fitted at step 80.

Install both cylindrical pins (arrowed in K Fig 452. ( T F-168)) centrally to the housing face.

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F - 168

Section F - Transmission Powershift Transmission WG 210 Install Pump Shaft K Fig 453. ( T F-170) Item A. 86

Install ball bearing 453-7. Fit rectangular ring 453-6 and let it snap in.

Grease rectangular ring 453-6, align it centrally and introduce pump shaft 453-5 into the housing cover until contact is obtained.

Fix pump shaft 453-5 by means of circlip 453-4. Fit gasket 453-3 and retaining plate 453-2 and secure with screws 453-1.

Install Oil Seal Covers K Fig 453. ( T F-170) Item B. 89

Insert O-rings 453-16 and 453-21 into the annular groove of the oil feed covers 453-15 and 453-20 respectively.

Fasten covers 15 and 20 by means of nuts/plain washers 453-13/453-14and 453-18/45319respectively. Torque limit ...................... 23 Nm (17 lbf ft).

Install Output Flanges K Fig 453. ( T F-170) Item B. 91

Install shaft seal 453-12 with the sealing lip facing the oil chamber. Wet rubber coated outer diameter with spirit. Grease sealing lip.

Fit output flange 453-11. Insert O-ring 453-10 into the gap between drive flange and shaft.

Secure output flange 453-11 by means of disc 453-9 and screws 453-8. Torque limit ........................ 46 Nm (34 lbf ft).

Secure screws by means of lock plate 453-7.

Repeat steps 91 - 94 for the opposite drive flange assembly 453-1/453-2/453-3/453-4/453-5/453-6.

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Section F - Transmission Powershift Transmission WG 210

Fig 453. Pump Shaft and Output Flanges

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Section F - Transmission Powershift Transmission WG 210 Installation - Converter Back Pressure Valve K Fig 457. ( T F-173). 96

Introduce piston 454C, compression spring 454D and pressure plate 454E into oil feed housing 457-9. Preload and secure by means of lock plate 454F.

Note: Install pressure plate 454E with the spigot facing lock plate 454F. 97

Fit plug 454G with new O-ring and install it. Torque limit (M14 x 1.5) ............25 Nm (19 lbf ft)

Fig 455. 99

Install oil feed housing 457-9 and fix it provisionally by means of socket head screws 457-5, 457-6 and 4577.

Note: Screw in socket head screws only until contact is obtained. DO NOT TIGHTEN. 100 Fit alignment dowels (M10) into the gearbox housing via the centre hole of feed housing 457-9. Introduce stator shaft 457-4 until contact is obtained. Note: Pay attention to the overlapping of the bores. 101 Insert O-ring into the annular groove of oil pump 4572/457-3 and oil it. 102 Insert pump 457-2/457-3 over the pump drive shaft and position it evenly against shoulder by means of socket head screws 457-1 (without O-rings).

Fig 454.

Installation - Oil Feed Housing/Transmission Pump

103 Remove socket head screws 457-1 and equip them with new greased O-rings.

K Fig 457. ( T F-173). 98

Install two alignment dowels (M8) (arrowed in K Fig 455. ( T F-171)) and fit gasket 457-10.

104 Fasten transmission pump by means of socket head screws 457-1. Torque limit ............................. 46 Nm (34 lbf ft) 105 Secure oil feed housing 457-9 by means of socket head screws 457-5, 457-6, 457-7 and two hexagonal head screws 457-8. Torque limit 457-5, 457-6, 457-7 ..23 Nm (17 lbf ft) Torque limit (457-8) ......................... 46 Nm (34 lbf ft)

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Section F - Transmission Powershift Transmission WG 210 Note: Pay attention to the position of the lifting ring (arrowed in K Fig 456. ( T F-172)).

Fig 456.

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Section F - Transmission Powershift Transmission WG 210

Fig 457. Converter Back Pressure valve Installation

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Section F - Transmission Powershift Transmission WG 210 Installation - Torque Converter

means of screws 460-13, pull the flange evenly against shoulder.

Refer to View A K Fig 460. ( T F-175). Torque limit (M8/10.9) ............... 34 Nm (25 lbf ft) 106 Install converter bell housing 460-26 by means of screws 460-25 after aligning the match marks made during dismantling.

112 Secure screws 460-13 by means of lock plate 460-12. 113 Fasten cover 460-11 by means of screws 460-16/nuts 460-17.

Torque limit (M10/10.9) ............. 68 Nm (50 lbf ft)

Torque limit (M10/8.8) ........... 46 Nm (34 lbf ft)

107 Assemble drive shaft 460-18 and diaphragm 460-22 and secure with screws 460-21.

114 Refer to view B K Fig 460. ( T F-175). Torque limit (M10/10.9) ............. 115 Nm (85 lbf ft) Mount gasket 14 and fasten cover 13 by means of screws 12.

108 Fasten diaphragm 460-22 to torque converter 460-23 by means of screws 460-25.

Torque limit (M8/8.8) ................. 23 Nm (17 lbf ft) Torque limit (M10/10.9) ............. 115 Nm (85 lbf ft) Note: Apply JCB Threadlocker and Sealer (High strength) to the threads of screws 460-25.

115 Insert converter safety valve into the housing bore as shown in K Fig 459. ( T F-174).

109 Insert converter assembly until contact is obtained. Note: Pulse disc of the converter must be positioned axially to the bore (arrowed in K Fig 458. ( T F-174)) of the inductive transmitter.

Fig 459.

Fig 458. 110 Insert ball bearing 460-20 until contact is obtained and fix it by means of circlip 460-19. 111 Fit cover 460-11 loose over bell housing 460-26, aligning the match marks made during dismantling. Install drive flange 460-15, fit disk 460-14 and, by

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Section F - Transmission Powershift Transmission WG 210

Fig 460. Torque Converter Installation

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Section F - Transmission Powershift Transmission WG 210 Installation - Duct Plate and Hydraulic Control Unit See K Fig 467. ( T F-178) 116 Install components 467-3, 467-4, 467-5, and 467-10. Note: Pay attention to the orientation and relative positions of gaskets 467-4/467-6 and intermediate plate 467-5, Secure duct plate467-3 with screws 467-7 and nuts 467-8/washers 467-9. 117 Fit screw plug (arrowed in K Fig 461. ( T F-176)) with new O-ring and install it.

Fig 462. 120 Install oil level tube 463C using a new gasket.

Torque limit (M16 x 1.5) ............ 30 Nm (22 lbf ft) Torque limit (M8/10.9) ............ 34 Nm (25 lbf ft)

Fig 461. 118 Fasten hydraulic control unit 467-2 by means of screws 467-1. Torque limit (M6) ......... 9.5 Nm (7 lbf ft)

Fig 463.

Install Plugs and Oil Level Tube

121 Install cover plate 464D using a new gasket.

119 Fit plugs 462A and 462B with new O-rings and install. Torque limit (M18 x 1.5) (plug 462A) ..... 50 Nm (37 lbf ft) Torque limit (M26 x 1.5) (plug 462B) ..... 80 Nm (59 lbf ft)

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Torque limit (M8/8.8) .............. 23 Nm (17 lbf ft) Equip screw plug 464E with new O-ring and install. Torque limit (M38 x 1.5) ......... 140 Nm (103 lbf ft)

F - 176

Section F - Transmission Powershift Transmission WG 210

Fig 464. Fig 466.

Install Speed Sensor and Inductive Transmitters 122 Grease O-rings and install speed sensor 465F. Torque limit ................. 23 Nm (17 lbf ft)

Fig 465. 123 Grease O-rings and install inductive transmitters 466G, 466H and 466J. Torque limit ................... 30 Nm (22 lbf ft) Install breather 466K. Torque limit ................... 12 Nm (9 lbf ft)

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Section F - Transmission Powershift Transmission WG 210

Fig 467. Duct Plate and Hydraulic Control

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Section F - Transmission Powershift Transmission WG 210

Hydraulic Control Unit Dismantling K Fig 468. ( T F-180) 1

Match-mark relative to each other the relevant positions of valve housing 468-1, housing covers 468-12 and 468-15, and end covers 468-2 and 468-3.

Remove socket head screws 468-5. Separate duct plate 468-6, gasket 468-7, intermediate plate 468-8 and gasket 468-9 from the valve housing.

Remove retaining clip 468-10.

Remove socket head screws 468-11 and 468-14. Separate cover 468-2/gasket 468-2A from housing 468-12 and cable harness 468-4. Separate cover 468-3/gasket 468-3A from housing 468-15.

Disconnect cable harness 468-4 from the pressure regulators 468-17 (3 off)/468-29 (3 off) and remove.

Remove the three socket head screws 468-18, fixing plates 468-19 and pressure regulators 468-17.

Remove the two outermost socket head screws 46820 and replace provisionally with adjusting screws. Remove the remaining socket head screws 468-20.

Separate housing 468-12/gasket 468-13 from valve housing 468-1 by loosening the compression tools uniformly to release the spring loading.

Remove components 468-21/468-22 (1 off), 468-23/ 468-24 (3 off) and 468-25/468-26(3 off).

Remove the three socket head screws 468-27, fixing plates 468-28 and pressure regulators 468-29.

Remove the two outermost socket head screws 46830 and replace provisionally with adjusting screws (M5). Remove the remaining socket head screws 468-30.

Separate housing 468-15 and gasket 468-16 from valve housing 468-1 by loosening the adjusting screws uniformly to release the spring loading.

Remove components 468-31/468-32(1 off), 468-33/ 468-34(3 off) and 468-35/468-36 (3 off).

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Section F - Transmission Powershift Transmission WG 210

Fig 468. Hydraulic Control Unit

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Section F - Transmission Powershift Transmission WG 210 Assembly K Fig 468. ( T F-180) 1

Check all components for damage and renew if necessary. Prior to installation, check free travel of all moving parts in the housing. Oil the components prior to assembly.

Note: Spools can be changed individually. 2

Insert diaphragms 468-37 (arrowed in K Fig 469. ( T F-181)) with the concave side showing upward until contact is obtained.

Fig 470. 4

Assemble gasket 468-13 and housing cover 468-12. Position the housing cover 468-12 uniformly and secure using adjusting screws (M5) in the two outermost positions of screws 468-20, until contact is obtained. Remove cylindrical pins fitted at step 3.

Note: Pay attention to the different housing covers. Install recess 15 mm Ă&#x2DC; (arrowed in K Fig 471. ( T F-181)) facing the spring 468-21 of the pressure reducing valve.

Fig 469. 3

Install components 468-21/468-22 (1 off), 468-23/ 468-24, (3 off) and 468-25/468-26 (3 off). Preload compression spring of the follow-on slides 468-25/ 468-26 and locate spool provisionally by means of cylindrical pins 5,0 mm Ă&#x2DC; (arrowed in K Fig 470. ( T F-181)).

Fig 471. 5

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Secure housing cover 468-12 by means of socket head screws 468-20 in the remaining positions.

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Section F - Transmission Powershift Transmission WG 210 Remove the two adjusting screws and fit the further screws 468-20. Torque limit .......................... 5.5 Nm (4 lbf ft). 6

Fit pressure regulators 468-17 and fix by means of fixing plates 468-19 and socket head screws 468-18.

Note: Install fixing plates with the claw showing downward. Pay attention to the radial installation position of the pressure regulators, see K Fig 472. ( T F-182). Torque limit ........................ 5.5 Nm (4 lbf ft).

Fig 473. 8

Assemble gasket 468-16 and housing cover 468-15. Position the housing cover 468-15 uniformly against shoulder, using adjusting screws (M5) in the two outermost locations for screws 468-30. Remove the cylindrical pins fitted at step 7.

Note: Pay attention to the different housing covers. Install the recess 473-A (19 mm Ă&#x2DC;) facing the main pressure valve 468-31/468-32. 9 Fig 472. 7

Install components 468-31/468-32 (1 off), 468-33/ 468-34 (3 off) and 468-35/468-36 (3 off). Preload compression springs of the follow-on slides 468-35/468-36 and locate spool provisionally by means of cylindrical pins 5 mm Ă&#x2DC; (arrowed in K Fig 473. ( T F-182)).

Fasten housing cover 468-15 by means of socket head screws 468-30 in the remaining positions. Remove the two adjusting screws and fit the further screws 468-30. Torque limit ............................... 5.5 Nm (4 lbf ft)

Fit pressure regulators 468-29 and fix by means of fixing plates 468-28 and socket head screws 468-27.

Note: Install fixing plates with the claw showing downward. Pay attention to the radial installation position of the pressure regulators, see K Fig 474. ( T F-183). Torque limit ............................... 5.5 Nm (4 lbf ft)

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Section F - Transmission Powershift Transmission WG 210

Fig 474. 11

Connect cable harness 468-4 to pressure regulators 468-17 (3 off) and 468-29 (3 off).

Note: Pay attention to the installation position of the cable harness. 12

Install gasket 468-2A on housing 468-12. Fit the harness connector into cover 468-2 against shoulder, with the groove facing the guide nose of the cover. Fasten cover by means of socket head screws 46811.

A334950-V1

Fig 475. Note: Pay attention to the difference between gaskets 7 and 9, see exploded view. b Insert screens (arrowed in K Fig 476. ( T F-184)) flush mounted into the bore of intermediate plate 8. Note: Install screens visible on the side facing duct plate 6.

Torque limit ............................... 5.5 Nm (4 lbf ft) 13

Secure harness connector by means of retaining clamp 468-10.

Fit cover 468-3/gasket 468-3A by means of socket head screws 468-14. Torque limit ............................... 5.5 Nm (4 lbf ft)

Fitting the intermediate K Fig 468. ( T F-180). a

plate

with

gaskets.

Fit two alignment dowels (M6) 468-B and install gasket 468-9.

Note: For procedure to install Coated Intermediate Sheet (no gaskets) see Step 16.

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Section F - Transmission Powershift Transmission WG 210

Fig 477. 16

Note: If the later type Coated Intermediate Sheet is being installed as a replacement for the earlier Gasket Type, it is MOST important that it is fitted with the correct Shorter Torx Screws 5. (See K Table 13. Bolt Fitting Chart ( T F-185)) The installation procedure for the Gasket Type intermediate Sheet can be found on the preceeding pages.

Fig 476. c

Fitting the intermediate plate Coated Sheet (without gaskets). K Fig 481. ( T F-186)

Install intermediate plate 8, screens uppermost, followed by gasket 7.

d Install duct plate 6 and fasten it uniformly by means of socket head screws 5. Remove the alignment dowels fitted at step 15a. Torque limit .............................. 9.5 Nm (7 lbf ft) e

Equip screw plugs (arrowed in K Fig 477. ( T F-184)) with new O-rings and install them. Torque limit .............................. 6 Nm (4.4 lbf ft)

Fig 478. 1

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Fit two alignment dowels (M6) 475-B.

F - 184

Section F - Transmission Powershift Transmission WG 210 2

Insert screens (arrowed in K Fig 479. ( T F-185)) flush mounted into the bore of intermediate plate 4688.

Note: Install screens visible on the side facing duct plate 468-6.

Fig 480.

Type

Table 13. Bolt Fitting Chart Length Application Torque Setting

Torx Screw M6 X 80

Paper gaskets 12 Nm (9 lbf ft)

Torx Screw M6 X 76

Coated sheet

Torx Screw M6 X 25

Paper gaskets 12 Nm (9 lbf ft)

Torx Screw M6 X 23

Coated sheet

9.5 Nm (7 lbf ft) 9.5 Nm (7 lbf ft)

Fig 479. 3

Install intermediate plate 468-8 screens uppermost. Take care not to damage the coating.

Install duct plate 468-6 and fasten it uniformly by means of socket head screws 468-5. Remove the alignment dowels fitted at step 1 Torque limit .............................. 9.5 Nm (7 lbf ft)

Equip screw plugs (arrowed in K Fig 480. ( T F-185)) with new O-rings and install them. Torque limit .............................. 6 Nm (4.4 lbf ft)

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Section F - Transmission Powershift Transmission WG 210

Fig 481.

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F - 186

Section F - Transmission

Functional Testing General Information Introduction

Remove the 35-way connector 482-C from the computer and connect it to the test box.

The transmission system is controlled by an on-board computer which measures the transmission output speed and monitors the driver's actions.

Connect the 35-way female connector from the test box to the computer.

Connect PR78 A (light indicator unit) to the 25-way female connector.

Connect PR78 B (interrogator unit) to the remaining 25-way female connector.

The computer makes basic decisions on gear shifts, it also monitors the driver actions via the accelerator, gear and direction of travel controls and the kick-down selector. These inputs enable the computer to override and smoothly control any actions made by the driver which could have potentially dangerous consequences for the driver or machine. For example, if a driver switches from forward 4th gear to reverse drive the computer will shift down the gears to 2nd gear before it engages reverse drive.

PR78 A detects the various inputs and outputs to and from the machine's computer and illuminates the lights which correspond to the selections the driver has made. This system allows the probable fault area of a defective transmission unit to be identified immediately.

Because the computer is 'aware' of all the transmission functions it is an ideal tool for fault diagnosis on the transmission system.

The Drive/Gear Selection Status Lights table shows the possible transmission selections that a driver can make and also shows the correct status of the lights when each selection is made.

Most of the tests on the semi-automatic option can be done with the machine stationary. (With the automatic transmission option some tests must be done with the wheels turning.)

For example, if the driver selected forward direction gear 2 with the machine stationary the following lamps would illuminate:

The following transmission.

equipment

needed

A computer test harness (892/00865)

A test indicator box PR78 A (892/00866)

A test interrogator box PR78 B (892/00867)

A Fluke 85 digital multimeter

A frequency meter.

test

the

V, B3, M3 and M4.

The transmission computer is located near the fuse box in the cab, to get access: 1

Turn the starter key to off, then remove the key.

Remove the arm rest.

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Fig 482.

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Section F - Transmission Functional Testing General Information

Automatic To do the diagnostic tests on the automatic transmission the wheels must be turning, i.e. a computer input from the roadspeed transducer (nAb) is required. Raise the machine so that the road wheels are off the ground. Support the machine securely on axle stands or suitable blocks.

Reverse Gear

Lamps Lit

R + B2 + B3

R + B1 + B2 + B3

Note: When kickdown is selected, the WK lamp should light. 6

Put barriers around the machine and make sure that no one goes near the machine while it is running.

!MCAUTION

If any of the above indications are incorrect, the gear selector control should be connected directly to the test harness as described below and the test repeated. a

b Remove the top fascia of the steering column.

On startup, before selecting drive, allow 5 seconds for the transmission computer to carry out its selfdiagnosis checks. Failure to do so will result in a delay of up to 10 seconds before drive is engaged.

4-2-2-4

Connect the test K Fig 482. ( T F-187).

equipment,

Check that the transmission fluid level is correct, see Transmission - Section 3 - Routine Maintenance.

Check that the transmission pressure agrees with the figure quoted on the transmission date plate (e.g. 16 + 2 = 18 bar).

Start the engine.

Check the inputs to the transmission computer by turning the gear selector control and observing the middle row of lights on the test indicator box as follows:

Forward Gear

Lamps Lit

2 - 1 + kickdown

V + B1 + B3 + WK

2-1

V + B1 + B3

V + B3

V + B2 + B3

V + B1 + B2 + B3

Reverse Gear

Lamps Lit

2-1

R + B1 + B3

R + B3

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Remove the steering wheel.

For ease of access, remove the plug from the hazard warning light and remove the hazard warning switch.

d Remove the plug from the gear control lever and reconnect to the test harness.

see 7

Repeat the checks in step 5. a

If the indications are now correct, the fault lies in the cab harness (SE). Do t a continuity check on harness SE, refer to Section C - Electrics. Repair any open-circuits as necessary then repeat the checks in step 5.

b If the indications are still incorrect, the gear selector control must be replaced. c

If the indications are correct but B3 fails to light, check the proximity switch on the throttle pedal. Adjust or replace as necessary.

d If B3 stays lit when the throttle pedal is pushed then no up-shifts are permitted. 8

Check the output from the transmission computer to the transmission solenoids by turning the gear selector control and observing the top row of lights on the test indicator box as follows:

Forward Gear

Lamps Lit

2 - 1 + kickdown

M2 + M3 + M4

2-1

M2 + M4 + M5

M3 + M4

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Section F - Transmission Functional Testing General Information Forward Gear

Lamps Lit

M4 + M5

M2 + M4 + M5 (1)

If the indications are correct and the machine drives in all gears then the transmission computer is faulty.

d If the indications are incorrect, do the following checks:

(1) With A selected and machine stationary, computer will select 2nd gear Forward. 12

Reverse Gear

Lamps Lit

2 - 1 + kickdown

M1 + M2 + M4

2-1

M1 + M4

M1 + M4 (1)

Faults

Check

No reverse gears

No forward gears (1, 3)

No forward gears (2, 4)

No forward 2, reverse 2

No forward 1, reverse 1

M2 (1)

(1) Only if forward 2, reverse 2 are correct. (1) With A selected, if the machine is driven: when F3 is engaged, M3 will light. when F4 is engaged, M5 will light.

The frequency output can be measured in each gear during the tests in step 9 by connecting a frequency meter between the nAb and -ve sockets on the test indicator box.

The electrical resistance of the output gear speed sensor and turbine speed sensor can be measured by removing the 35-way connector from the transmission computer and connecting the digital multimeter between the nAb and -ve sockets on the test indicator box. With the toggle switch on the righthand side of the test indicator box in the ‘down’ position, the output gear speed sensor is selected, and when the switch is in the ‘up’ position the turbine speed sensor is selected. The resistance of both sensors should be between 1400 and 1600 ohms.

Note: Energising the solenoids causes the transmission to drive the machine in the gear selected. 9

If any of the indications in step 8 are incorrect, operation of the transmission solenoids can be checked directly as described below. a

Remove the connecting links on the test interrogator box. Energise the solenoids by connecting to the red (+) terminal as follows:

Forward Gear

Connect To

M2 + M3 + M4

M2 + M4 + M5

M3 + M4

M4 + M5

Note: 1. The Output gear Frequency or Turbine Frequency; depends on which transducer is selected on the test box. Note: 2 Illuminates when 1st gear is selected and held. If it flashes, the selected transducer or associated wiring is faulty.

Reverse Gear

Connect To

M1 + M2 + M4

M1 + M4

M1 b Correct selection of the solenoids can be checked by observing the lights on the test indicator box.

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Note: 3.B3 Illuminates when the throttle pedal is at rest. B3 should go out after 5° of pedal movement; if not, adjust proximity switch on pedal linkage. B3 prevents upshifts on a trailing throttle, i.e. going downhill. Note: 4.Only this lamp will be illuminated when the transmission has auto-shifted from 2 to 3 by driving the machine.

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Section F - Transmission Functional Testing General Information Note: 5. Only this lamp will be illuminated when the transmission has auto-shifted from 2 to 4 by driving the machine.

Fig 483. Drive/Gear Selection Status Lights (Automatic Transmissions)

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Section F - Transmission Functional Testing General Information

Semi-Automatic 1

Connect the test equipment, then insert the starter key and turn it to the ON position. Do not start the engine.

Select neutral drive gear 1 and check that the lights illuminate where indicated by the dots in the table.

Select neutral drive gear 2 and compare the dots in the table with the lights illuminated on the indicator unit (PR78 A).

Work through the gear/drive selection in the table. If a light should illuminate but doesn't, make a note of the drive and gear selection made and the reference of the light which failed to illuminate.

Note: Because this is a static test, light nAb will not illuminate.

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Section F - Transmission Functional Testing General Information

OUTPUTS FROM COMPUTER A

AUXILIARY INPUTS

R B1 B2 B3 M1 M2 M3 M4 M5 SKD SDA nAb

AUXILIARY OUTPUT AS

1 2 3 4

1 2 3

ON Fig 484. Drive/Gear Selection Status Lights (Semi-automatic Transmissions)

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Section F - Transmission Functional Testing Transmission Fault Finding

Transmission Fault Finding Drive/Gear Selection Status Lights When all of the tests in the Drive/Gear Selection Status Lights table are completed, if some or all of the lights failed.

Check 1

Table 14. All the lights on PR78 A failed Action

Turn starter switch off. Observe lights M1 to M5 YES: on top row of PR78 A. Turn starter switch on. Did M1 to M5 flash? NO:

Press the Transmission Dump and Kickdown YES: buttons on the loader control lever. Did SDA and SKD illuminate?

Are fuses 100 and 101 in locations A4 and C3 intact?

Do all the lights on PR78 A still fail?

YES:

Check 4.

NO:

Replace fuse(s) and repeat check 1.

YES:

Check 5.

NO:

Check FF table relevant to lights which do fail.

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat tests. Do all lights still fail?

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Check 6.

Check 4.

Is there battery voltage between sockets 1 and YES: 13 on PR78 A?

Is there continuity along wire 9504?

Check 3.

NO:

NO: 6

Check 2.

Replace PR78 A. Check 6. Check 7.

NO:

Replace control lever.

YES:

Replace computer.

NO:

Replace wire 9504 or appropriate harness.

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Section F - Transmission Functional Testing Transmission Fault Finding Check

Table 15. Some or all of the 'B' lights failed when gear selector switch rotated Action

Is the battery voltage present at the appropriate YES: socket on PR78 B?

Is the battery voltage present between sockets 1 and 13 on PR78 A?

NO:

Check 2.

YES:

Replace PR78 A.

NO:

Replace test harness.

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat test.Do any 'B' lights fail? Rotate the gear selector switch. Does B1 illuminate?

Check 3.

Check 4.

NO:

Replace the machine connector SE.

YES:

Check 6.

NO:

Check 5.

Is there continuity on wire 9524?

YES:

Replace the Control Lever.

NO:

Replace or repair the appropriate harness.

Rotate the gear selector switch. Does B2 illuminate?

YES:

Check 8.

NO:

Check 7.

YES:

Replace the Control Lever.

NO:

Replace or repair the appropriate harness.

YES:

Check FF table relevant to lights which do fail.

Is there continuity on wire 9528?

Rotate the gear selector switch. Does B3 illuminate?

Is there continuity on wire 9508?

Is there continuity on wire 9508A?

Check 1 2

NO:

Check 9.

YES:

Check 10.

NO:

Replace or repair the appropriate harness.

YES:

Check the wire link between wires 9508 and 9508A.

NO:

Replace or repair the appropriate harness.

Table 16. `V' light failed when forward selected Action

Is there continuity on wire 9512?

YES:

Check 2.

NO:

Replace or repair the appropriate harness.

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat test. Does V light still fail when forward selected? NO:

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Replace the Control Lever.

Replace or repair the appropriate harness.

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Section F - Transmission Functional Testing Transmission Fault Finding Check 1 2

Table 17. `As' light failed when neutral selected Action

Is there continuity on wire 9674?

YES:

Check 2.

NO:

Replace or repair the appropriate harness.

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat test. Does As light still fail when neutral selected? NO:

Replace Control Lever.

Replace the machine connector SE.

Note: If machine still refuses to start, suspect wire 9584 and neutral start relay.

Check

Table 18. `R' light failed when reverse selected Action

Is there continuity on wire 9658?

YES:

Check 2.

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat test. Does R light still fail when reverse selected?

NO:

Replace or repair the appropriate harness.

NO:

Check 1

Did all 'M' lights fail regardless of gear and drive YES: selection?

Follow appropriate procedure below, for light which has failed. ensure that appropriate gear is selected to drive light.

Is there battery voltage at appropriate socket on YES: PR78 B? NO:

Is there battery voltage between sockets 1 and YES: 13 on PR78 A?

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat tests. Do all lights still fail?

Is there continuity along wire 9504?

NO:

Select Reverse drive. Does M1 fail?

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Replace the machine connector SE.

Table 19. Some or all of the `M' lights failed during gear and drive selection Action

NO:

Replace Control Lever.

Check 3. Check 2.

Check 5. Check 4. Replace PR78 A. Check 5. Check 6.

NO:

Replace Control Lever.

YES:

Replace computer.

NO:

Replace wire 9504 or appropriate harness.

YES:

Check 8.

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Section F - Transmission Functional Testing Transmission Fault Finding Check

Action NO:

Select Forward drive. Measure voltage between YES: coil end of wire 9434 and a good earth. Is it within range 150-180mV?

Select Reverse drive. Measure voltage between YES: coil end of wire 9434 and a good earth. Is it equal to the battery voltage?

Is there continuity on wire 9434?

NO:

15 16

Replace the computer.

NO:

Replace or repair the appropriate harness.

Replace the control lever.

YES:

Check 13.

NO:

Check fault-finding procedure appropriate to failed light.

Select Reverse drive. Measure voltage between YES: coil end of wire 9438 and a good earth.Is it equal to the battery voltage?

Replace the coil.

YES:

Check 16.

NO:

Replace or repair the appropriate harness. Replace the harness connector.

Replace the control lever.

YES:

Check 18.

NO:

Check fault-finding procedure appropriate to failed light.

Select Forward drive. Measure voltage between YES: coil end of wire 9442 and a good earth.Is it within range 150-180mV? Select Reverse drive. Measure voltage between YES: coil end of wire 9442 and a good earth.Is it equal to the battery voltage?

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Check 15.

Replace the computer.

NO: 19

Check 14.

NO:

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat tests.Does M2 still fail? Select Reverse drive. Does M3 fail?

Replace the harness connector.

NO:

NO: 17

Replace the coil.

Check 11.

Select Forward drive. Measure voltage between YES: coil end of wire 9438 and a good earth.Is it within range 150-180mV?

Is there continuity on wire 9434?

Check 10.

YES:

NO: 14

Check 9.

NO:

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat tests. Does M1 still fail? Select Reverse drive. Does M2 fail?

Check fault-finding procedure appropriate to failed light.

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Check 19.

Check 20. Replace the coil.

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Section F - Transmission Functional Testing Transmission Fault Finding Check 20 21

Is there continuity on wire 9442?

Action NO:

Replace the computer.

YES:

Check 21.

NO:

Replace or repair the appropriate harness.

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat tests. Does M3 still fail? Select Reverse drive. Does M4 fail?

NO:

Replace the control lever.

YES:

Check 23.

NO:

Check fault-finding procedure appropriate to failed light.

Select Forward drive. Measure voltage between YES: coil end of wire 9446 and a good earth. Is it within range 150-180mV?

Select Reverse drive. Measure voltage between YES: coil end of wire 9446 and a good earth. Is it equal to the battery voltage?

Is there continuity on wire 9446?

NO:

30 31

Replace the computer.

NO:

Replace or repair the appropriate harness. Replace the harness connector.

NO:

Replace the control lever.

YES:

Check 28.

NO:

Check fault-finding procedure appropriate to failed light.

Select Reverse drive. Measure voltage between YES: coil end of wire 9430 and a good earth. Is it equal to the battery voltage?

Check 29.

Check 30. Replace the coil.

NO:

Replace the computer.

YES:

Check 31.

NO:

Replace or repair the appropriate harness.

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat tests. Does M5 still fail? NO:

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Replace the coil.

Check 26.

Select Forward drive. Measure voltage between YES: coil end of wire 9430 and a good earth. Is it within range 150-180mV?

Is there continuity on wire 9430?

Check 25.

YES:

NO: 29

Check 24.

NO:

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Repeat tests. Does M4 still fail? Select Reverse drive. Does M5 fail?

Replace the harness connector.

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Replace the harness connector.

Replace the control lever.

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Section F - Transmission Functional Testing Transmission Fault Finding Check

Table 20. `SKD' light failed on selection Action

Select SKD on the control lever. Does SKD on PR78 A illuminate?

YES:

Check 5.

Measure the voltage on pin 1 of harness YES: connector SE. Is it equal to the battery voltage?

NO:

Check 2.

NO: 3

Remove 8-way connector from control lever and YES: fit 8-way connector from test harness. Is battery voltage now on SE pin 1? Is there continuity on wire 9536?

YES:

Replace the harness connector.

NO:

Replace or repair the appropriate harness.

YES:

No faults in SKD circuit.

Measure the voltage on pin 1 of harness YES: connector SE. Is it equal to the battery voltage?

NO:

Is there continuity along wire 9536A between computer and loader control lever switch?

Check 1 2

3 4

Check 6. Check 9536/9536A splice.

NO:

Check 7.

YES:

Check 8.

NO:

Replace or repair the appropriate harness.

YES:

Replace switch.

NO:

Replace or repair the appropriate harness.

Table 21. `SDA' Light failed on selection Action

Is Dump Inhibit switch in cab roof selected? Press Dump switch on Loader Control. Does SDA illuminate? Has 10 Amp. fuse at location 4A blown? Check continuity of wire between fuse holder and splice SS. Is it O.K.? Check continuity of wire 101M between splice SS and Dump Button terminal 1. Is it O.K.?

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Check 4.

Replace the control lever.

Select SKD on loader control lever. Does SKD on PR78 A illuminate?

Is there continuity along wire 9612A between fuse 3C and loader control lever switch?

Check 3.

NO:

Replace the computer.

YES:

Deselect and check 2.

NO:

Check 2.

YES:

Check 8.

NO:

Check 3.

YES:

Replace fuse with one of correct value.

NO:

Check 4.

YES:

Check 5.

NO:

Repair or replace the harness.

YES:

Check 6.

NO:

Repair or replace the harness.

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Section F - Transmission Functional Testing Transmission Fault Finding Check

Action

Check 7.

Select voltage range on the meter. Connect YES: between terminal 2 of Dump Button TJ and a good earth. Does battery voltage register when Dump Button is pressed? NO:

11 12

Does the battery voltage appear at the computer YES: end of wire 9600 when the Dump Button is pressed? Select Neutral and start the engine. Apply footbrake. Does the SDA lamp illuminate?

Check continuity of wire 840. Is it O.K.?

Repair wire 9600 or replace the harness.

YES:

SDA function O. K.

NO:

Check 9.

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Check 10.

NO:

Repair or replace the harness.

YES:

Check 11.

NO:

Replace the Dump Inhibit switch.

YES:

Check 12.

NO:

Repair or replace the harness.

Connect meter across pins 1 and 2 of the dump YES: switch at connector FD1. Does resistance reading change dramatically when switch is operated? Check continuity of wire 9600. Is it O.K.?

Replace the computer.

NO:

Check continuity of wire 101A between splice YES: SS and Dump Pressure Switch (Dump Inhibit) in the cab roof.Is continuity O.K.? Check continuity between wire 101A and wire 840. Does reading change from an infinite reading to almost zero Ohms when the Dump Inhibit switch is depressed?

Replace dump switch.

Check 13.

NO:

Replace the switch.

YES:

Replace computer.

NO:

Repair or replace the harness.

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Section F - Transmission Functional Testing Transmission Fault Finding

Definition of Operating Modes

The operator has to slow down the vehicle. The transmission will stay in neutral.

Normal

TCU-Shutdown

There are no failures detected in the transmission system or the failure has no or a slight effects on the transmission control. The TCU will work without or in special cases with little limitations.

Substitute Clutch Control The TCU can not change the gears or the direction under the control of the normal clutch modulation. The TCU uses the substitute strategy for clutch control. All modulations are only time controlled.

The TCU has detected a severe failure that disables control of system. The TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will engage, also all functions are disabled which use ADM 1 to ADM 8. The transmission will stay in neutral.

Limp Home The detected failure in the system has strong limitations to transmission control. The TCU can engage only one gear in each direction. In some cases only one direction will be possible. The TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift the gear selector into neutral position. If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or reverse, the TCU will select the limp-home gear. If output speed is less than a threshold for reversal speed and the TCU has changed into the limp-home gear and the operator selects a shuttle shift, The TCU will shift immediately into the limp-home gear of the selected direction. If output speed is greater than the threshold, Tthe CU will shift the transmission into neutral. The operator has to slow down the vehicle and must shift the gear selector into neutral position.

Transmission-Shutdown: The TCU has detected a severe failure that disables control of the transmission. The TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8.

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F - 200

F - 201

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5010

5020

5000

FMI

EMS

TCU

SPN

FMI CS

The TCU does not sense a reaction from the engine when the derating device is active

A Logical Error at the Engine Derating Device

-The shift lever is defective

-A cable is defective, it has a SC to the battery or earth

-A cable from the shift lever to the TCU is broken

Failure Mode Indicator

Check the cables from the TCU to the shift lever

Repair Procedures

Customer Specific

Short Circuit

OP-Mode: limp home

After neutral is selected the TCU changes to

Note: The fault is reset after the power-up of the TCU

Check the engine derating device

Note: The fault is reset if the TCU senses a valid signal for that direction at the shift lever

Check the signal combinations at the shift lever OP-Mode: transmission shutdown positions F-N-R

Check the cables from the TCU to the shift lever

Note: The fault is reset if the TCU senses a valid signal for that shift lever position

Note: A failure can not be detected in a system with a DW2/DW3 shift lever

Check the signal combinations at the shift lever OP-Mode: transmission shutdown positions for the gear range

The TCU senses an incorrect signal combination for the TCU shifts the transmission to selected direction: neutral

A Logical Error for the Selected Direction

-The shift lever is defective

-A cable is defective, it has a SC to the battery or earth

-A cable from the shift lever to the TCU is broken

The TCU senses an incorrect signal combination for the TCU shifts the transmission to selected gear range: neutral

A Logical Error for the Selected Gear Range

Table 22. ZF Error Codes Reaction of the TCU

Electronic Monitoring System

Transmission Control Unit

Serial Parameter Number

Further details of the EMS system can be found in Section C - Electrics.

The code will be displayed on the top line of the EMS display panel in the format: ZFCB ERROR?

Description of the Fault Code

Open Circuit

SPN

Internal Code (Dec)

Fault Code (Hex.)

The Electronic Monitoring System (EMS) will display an error code in the event of a fault developing in the transmission system.

ZF Error Codes (4WG-160/190/210)

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 201

F - 202

5060

5040

5050

5030

SPN

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FMI

148

178

176

169

OP-Mode: normal

-A connector pin has a SC to earth

-A CS function-1 device has an internal defect

-A cable is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin that could be a SC to earth:

A Short Circuit to Earth, Customer Specific Function-1 CS

Check the resistance of the CS function-1 device

Check the cables and the connectors between the TCU and the CS function-1 device

Check the signals at the feedback axle connection switch

-The axle can not be connected or disconnected due to a mechanical problem

-A cable from the feedback axle connection switch to the TCU is broken

Check the cables from the TCU to the feedback axle connection switch

Note: The fault is reset if the TCU senses a valid neutral signal for the direction at the shift lever

The feedback axle connection measured by the TCU and OP-Mode: normal the output signal axle connection do not correspond:

A Logical Error at the Axle Connection

-The shift lever is defective

-A cable is defective, it has a SC to the battery or earth

Check all the cables from the TCU to the shift lever-2

Check the signals at the status switches

OP-Mode: transmission shutdown Check the signal combinations at the shift lever if the selector is active positions, F-N-R

The TCU senses an incorrect signal combination for the TCU shifts the transmission to selected direction: neutral if the selector is active

-A cable from the shift lever-2 to the TCU is broken

Repair Procedures

TCU shifts the transmission to the Check the cables from the electronic boxes to DCO state the status switches

Reaction of the TCU

A Logical Error at the Direction Select Signal-2 Shift Lever

-A status switch is defective

-A cable from the status switch to the electronic box is broken

The park brake status signal measured by the TCU and the park brake status signal sent by the CAN do not correspond:

A Logical Error at the Park Brake Status Signal

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 202

F - 203

5070

5060

5070

5060

SPN

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FMI

153

151

149

150

Reaction of the TCU

-A connector pin has a SC to the battery

-A CS function-2 device has an internal defect

-A cable is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin that could be a SC to the battery:

A Short Circuit to the Battery, Customer Specific Function-2

-A connector pin has a SC to earth

-A CS function-2 device has an internal defect

-A cable is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin that could be a SC to earth:

A Short Circuit to Earth, Customer Specific Function-2

-A connector is not connected to the TCU

-A CS function-1 device has an internal defect

-A cable is defective, it is not connected to the TCU

The TCU senses an incorrect voltage at the output pin that could be an OC:

An Open Circuit, Customer Specific Function-1

-A connector pin has a SC to the battery

-A CS function-1 device has an internal defect

-A cable is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin that could be a SC to the battery:

A Short Circuit to the Battery, Customer Specific Function-1

Description of the Fault Code

Check the resistance of the CS function-2 device

Check the cables and the connectors between the TCU and the CS function-2 device

Check the resistance of the CS function-2 device

Check the cables and the connectors between the TCU and the CS function-2 device

Check the resistance of the CS function-1 device

Check the cables and the connectors between the TCU and the CS function-1 device

Check the resistance of the CS function-1 device

Check the cables and the connectors between the TCU and the CS function-1 device

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 203

F - 204

5080

5070

SPN

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FMI

155

156

154

152

Reaction of the TCU

-A connector is not connected to the TCU

-A CS function-3 device has an internal defect

-A cable is defective, it is not connected to the TCU

The TCU senses an incorrect voltage at the output pin:

An Open Circuit, Customer Specific Function-3

-A connector pin has a SC to the battery

-A CS function-3 device has an internal defect

-A cable is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin that could be a SC to the battery:

A Short Circuit to the Battery, Customer Specific Function-3

-A connector pin has a SC to earth

-A CS function-3 device has an internal defect

-A cable is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin that could be a SC to earth:

A Short Circuit to Earth, Customer Specific Function-3

-A connector is not connected to the TCU

-A CS function-2 device has an internal defect

-A cable is defective, it is not connected to the TCU

The TCU senses an incorrect voltage at the output pin that could be an OC:

An Open Circuit, Customer Specific Function-2

Description of the Fault Code

Check the resistance of the CS function-3 device

Check the cables and the connectors between the TCU and the CS function-3 device

Check the resistance of the CS function-3 device

Check the cables and the connectors between the TCU and the CS function-3 device

Check the resistance of the CS function-3 device

Check the cables and the connectors between the TCU and the CS function-3 device

Check the resistance of the CS function-2 device

Check the cables and the connectors between the TCU and the CS function-2 device

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 204

F - 205

5090

5100

5090

SPN

FMI

Reaction of the TCU

OP-Mode: normal

-A cable is defective, it has a SC to the battery

OP-Mode: normal

-A cable is defective, it has a SC to earth:

9803/9420

TCU uses the default load OP-Mode: normal

-A cable is defective, it has a SC to the battery

-The load sensor has an internal defect

-A cable is not connected to the TCU

Retarder function is affected

The measured voltage is too high:

A Short Circuit to the Battery at the Input to the Load Sensor

-A cable is not connected to the TCU

-A connector pin has a SC to earth or is broken

-The clutch cutoff sensor has an internal defect

Clutch cutoff function is disabled

The measured voltage is too low:

A Short Circuit to Earth or an Open Circuit at the Input to the Clutch Cutoff

-A connector pin has a SC to the battery

-The clutch cutoff sensor has an internal defect

Clutch cutoff function is disabled

The measured voltage is too high:

A Short Circuit to the Battery at the Input to the Clutch Cutoff

Description of the Fault Code

Note: The availability of the retarder depends on the default load

Check the assembly tolerances of the load sensor

Check the load sensor

Check the cable and the connectors from the TCU to the sensor

Check the clutch cutoff sensor

Check the cable and the connectors from the TCU to the sensor

Check the clutch cutoff sensor

Check the cable and the connectors from the TCU to the sensor

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 205

F - 206

5110

5100

SPN

FMI

Reaction of the TCU

TCU uses the default load OP-Mode: normal

-A cable is defective, it has a SC to earth

-A cable is not connected to the TCU

Note: The availability of the retarder depends on the default load

Check the assembly tolerances of the load sensor

Check the load sensor

Check the cable and the connectors from the TCU to the sensor

Repair Procedures

9803/9420

TCU uses the default temperature OP-Mode: normal

-A cable is defective, it has a SC to earth

-The temperature sensor has an internal defect

-A connector pin has a SC to earth

No reaction

The measured voltage is too low:

A Short Circuit to Earth at the Input to the Transmission Sump Temperature Sensor

-A connector pin has a SC to the battery or is broken

-The temperature sensor has an internal defect

-A cable is not connected to the TCU

Check the temperature sensor

Check the cable and the connectors from the TCU to the sensor

TCU uses the default temperature OP-Mode: normal Check the temperature sensor

-A cable is defective, it has a SC to the battery

Check the cable and the connectors from the TCU to the sensor

No reaction

The measured voltage is too high:

A Short Circuit to the Battery or an Open Circuit at the Input to the Transmission Sump Temperature Sensor

-A connector pin has a SC to earth or is broken

-The load sensor has an internal defect

Retarder function is affected

The measured voltage is too low:

A Short Circuit to Earth or an Open Circuit at the Input to the Load Sensor

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 206

F - 207

5130

5120

5130

5120

SPN

9803/9420

FMI

Reaction of the TCU

Repair Procedures

TCU uses the default temperature OP-Mode: normal

-A cable is defective, it has a SC to the battery

-A cable is not connected to the TCU

TCU uses the default temperature OP-Mode: normal

-A cable is defective, it has a SC to earth

-The temperature sensor has an internal defect

OP-Mode: normal

-A cable is defective, it has a SC to the battery

OP-Mode: normal

-A cable is defective, it has a SC to earth

-A connector pin has a SC to earth

-The sensor has an internal defect

TCU uses the default value

The measured voltage is too low:

A Short Circuit to Earth at the Input to the Park Brake Sensor

-A connector pin has a SC to the battery or is broken

-The sensor has an internal defect

-A cable is not connected to the TCU

TCU uses the default value

The measured voltage is too high:

A Short Circuit to the Battery or an Open Circuit at the Input to the Park Brake Sensor

-A connector pin has a SC to earth

No reaction

The measured voltage is too low:

A Short Circuit to Earth at the Input to the Retarder Temperature Sensor

-A connector pin has a SC to the battery or is broken

-The temperature sensor has an internal defect

No reaction

The measured voltage is too high:

Check the park brake sensor

Check the cable and the connectors from the TCU to the sensor

Check the park brake sensor

Check the cable and the connectors from the TCU to the sensor

Check the temperature sensor

Check the cable and the connectors from the TCU to the sensor

Check the temperature sensor

Check the cable and the connectors from the TCU to the sensor

A Short Circuit to the Battery or an Open Circuit at the Input to the Retarder Temperature Sensor

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 207

F - 208

5140

5313

SPN

9803/9420

FMI

135

OP-Mode: normal

Check the speed sensor

OP-Mode: substitute clutch control Check the cable and the connectors from the TCU to the sensor

Check the speed sensor

Check the sensor gap Note: The fault is reset after a power-up of the TCU

-The speed sensor has an internal defect

-A sensor gap is incorrect

The TCU measures an engine speed over the threshold OP-Mode: substitute clutch control Check the speed sensor and immediately the measured speed becomes zero: Check the cable and the connectors from the -A cable/connector is defective, it has bad contacts TCU to the sensor

A Logical Error at the Engine Speed Input

-The speed sensor has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU measures a voltage less than 0.45V at the speed input pin:

A Short Circuit to Earth at the Engine Speed Input

-A connector pin has a SC to the battery or has an OC

-The speed sensor has an internal defect

-A cable is not connected to the TCU

-A cable is defective, it has a SC to the battery

The TCU measures a voltage higher than 7V at the speed OP-Mode: substitute clutch control Check the cable and the connectors from the input pin: TCU to the sensor

A Short Circuit to the Battery or an Open Circuit at the Engine Speed Input

-The sensor has an internal defect

Check the sensor

When not inching there is no change

-A cable is defective

Repair Procedures Check the cable and the connectors from the TCU to the sensor

Reaction of the TCU

The measured voltages from the CCO and CCO2 signals During inching mode the TCU do not correspond: shifts to neutral

A Mismatch of the Inch Sensor Signals

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 208

F - 209

5150

SPN

FMI

Reaction of the TCU

Repair Procedures

OP-Mode: limp home

-The speed sensor has an internal defect

9803/9420

-The sensor gap is incorrect

Note: The fault is reset after a power-up of the TCU

Check the sensor gap

OP-Mode: limp home

-The speed sensor has an internal defect

-A cable/connector is defective, it has bad contacts

OP-Mode: substitute clutch control Check the cable from the TCU to the sensor, check the connectors If a failure exists at the output speed, the TCU shifts to neutral Check the speed sensor

The TCU measures a turbine speed over the threshold and immediately the measured speed becomes zero:

Logical Error at the Turbine Speed Input

-A cable/connector is defective, it has a SC to earth

OP-Mode: substitute clutch control Check the cable and the connectors from the TCU to the sensor If a failure exists at the output speed, the TCU shifts to neutral Check the speed sensor

OP-Mode: limp home

The TCU measures a voltage less than 0.45V at the speed input pin:

A Short Circuit to Earth at the Turbine Speed Input

-A connector pin has a SC to the battery or has an OC

-The speed sensor has an internal defect

-A cable is not connected to the TCU

The TCU measures a voltage higher than 7V at the speed OP-Mode: substitute clutch control Check the cable and the connectors from the input pin: TCU to the sensor If a failure exists at the output -A cable is defective, it has a SC to the battery speed, the TCU shifts to neutral Check the speed sensor

A Short Circuit to the Battery or an Open Circuit at the Turbine Speed Input

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 209

F - 210

5160

SPN

FMI

Reaction of the TCU

Repair Procedures

9803/9420

Check the speed sensor Check the sensor gap Note: The fault is reset after the power-up of the TCU

-The speed sensor has an internal defect

-The sensor gap is incorrect

OP-Mode: substitute clutch control Check the cable and the connectors from the TCU to the sensor

Check the speed sensor

OP-Mode: substitute clutch control Check the cable and the connectors from the TCU to the sensor

Check the speed sensor

-A cable/connector is defective, it has bad contacts

The TCU measures a internal speed over the threshold and immediately the measured speed becomes zero:

A Logical Error at the Internal Speed Input

-The speed sensor has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU measures a voltage less than 0.45V at the speed input pin:

A Short Circuit to Earth at the Internal Speed Input

-A connector pin has a SC to the battery or has an OC

-The speed sensor has an internal defect

-A cable is not connected to the TCU

-A cable is defective, it has a SC to the battery

The TCU measures a voltage higher than 7V at the speed OP-Mode: substitute clutch control Check the cable and the connectors from the input pin: TCU to the sensor

A Short Circuit to the Battery or an Open Circuit at the Internal Speed Input

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 210

F - 211

5170

9803/9420

5170

SPN

FMI

Reaction of the TCU

OP-Mode: limp home

TCU shifts to neutral

If a failure exists at turbine speed

OP-Mode: substitute clutch control

Special mode for gear selection

OP-Mode: limp home

TCU shifts to neutral

If a failure exists at turbine speed

OP-Mode: substitute clutch control

The Turbine Speed of Zero Does Not Correspond to the Other Speed Signals

-The sensor gap is incorrect

-The speed sensor has an internal defect

-A cable/connector is defective, it has bad contacts

The TCU measures an output speed over the threshold and immediate the measured speed becomes zero:

A Logical Error at the Output Speed Input

-The speed sensor has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU measures a voltage less than 1V at the speed input pin:

A Short Circuit to Earth at the Output Speed Input Special mode for gear selection

-The speed sensor has an internal defect

-A connector pin has a SC to the battery or has an OC

OP-Mode: limp home

-A cable is not connected to the TCU

OP-Mode: substitute clutch control

Special mode for gear selection

If a failure exists at turbine speed TCU shifts to neutral

-A cable is defective, it has a SC to the battery

The TCU measures a voltage higher than 12.5V at the speed input pin:

A Short Circuit to the Battery or an Open Circuit at the Output Speed Input

Description of the Fault Code

Not used

Note: The fault is reset after a power-up of the TCU

Check the sensor gap

Check the speed sensor

Check the cable and the connectors from the TCU to the sensor

Check the speed sensor

Check the cable and the connectors from the TCU to the sensor

Check the speed sensor

Check the cable and the connectors from the TCU to the sensor

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 211

F - 212

5210

5190

5200

5180

SPN

9803/9420

FMI

147

146

Reaction of the TCU

Repair Procedures

Gear range set from 1st to 5th

Not used

Check the CAN bus wiring

Check the FWD controller

Check the cable to the cluster controller

Check the CAN bus wiring

Check the cluster controller

Note: The fault is reset after a power-up of the TCU

OP-Mode: limp home

No gear range restriction

Check the cable from the TCU to the sensor

TCU shifts to neutral

The configuration states that the FWD controller is not installed

Ignore the FWD commands

Reconfigure with the TCU configuration command (ID PC)

The TCU Receives the Messages: Gear Range Select (ZF3IDENT) and Front Wheel Drive Status (VIDENTFWD)

A Declutch Modulation Selection Signal

Contains invalid data

An FCAN Message: Gear Range Select (ZF_3_IDENT)

-Interference on the CAN bus

-The cluster controller is defective

The CAN Signal for a Gear Range Restriction is Defective:

A Gear Range Restriction Signal

-The sensor gap is incorrect

If the transmission is not in neutral and the shifts have Special mode for gear selection Check the sensor signal of the output speed finished, the TCU measured output speed is zero and the sensor turbine speed or internal speed is not equal to zero: OP-Mode: substitute clutch control Check the sensor gap of the output speed -The speed sensor has an internal defect If a failure exists at turbine speed sensor

The Output Speed of Zero Does Not Correspond to the Other Speed Signals

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 212

F - 213

5230

5240

5220

SPN

FMI

101

100

9803/9420

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message EAM1 from the I/O controller:

An EAMODUL1 Timeout

-The engine controller is defective

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message FMR2 from the engine controller:

A FMR2 Timeout

-The engine controller is defective

-A CAN wire/connector is defective, it has a SC to earth or the battery

-A CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN-message FMR1 from the engine controller:

A FMR1 Timeout

Description of the Fault Code

Repair Procedures

Check the cable to the I/O controller

Check the CAN bus wiring

Uses a substitute gear selector OP-Mode: normal

Check the I/O controller

TCU shifts to neutral

Check the cable to the engine controller

Check the CAN bus wiring

OP-Mode: substitute clutch control Check the engine controller

TCU operates as if the park brake Check the engine controller is off and the exhaust brake is off Check the CAN bus wiring OP-Mode: normal Check the cable to the engine controller

Reaction of the TCU

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 213

F - 214

5260

5250

SPN

FMI

103

102

9803/9420

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message DCT1 from the display computer:

A DCT1 Timeout

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message MDU1 from the cluster controller:

A MDU1 Timeout

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message ABS from the ABS controller:

An ABS Timeout

Description of the Fault Code

OP-Mode: normal

Check the cable to the display computer

Check the CAN bus wiring

Check the display computer

Check the cable to the cluster controller

Check the CAN bus wiring

-Old auto downshift data -Old manual downshift data

Check the cluster controller

Check the cable to the ABS controller

Check the CAN bus wiring

Check the ABS controller

Repair Procedures

TCU keeps the:

No reaction

Reaction of the TCU

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 214

F - 215

5270

5260

SPN

FMI

177

103

IC Gear range set from 1st to 5th

Reaction of the TCU

9803/9420

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message SCT 1 from the steering computer:

A SCT1 Timeout

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

OP-Mode: normal

A timeout of the CAN-message DNS1 from the OMRON- TCU shifts to neutral master: OP-Mode: normal -Interference on the CAN bus

A DNS1 Timeout

-The FWD controller is defective

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message gear range select (ZF_3_IDENT):

A Gear Range Select Timeout

Description of the Fault Code

Check the cable to the steering computer

Check the CAN bus wiring

Check the steering computer

Check the cable to the OMRON-master

Check the CAN bus wiring

Check the OMRON-master

Check the FWD controller

Check the CAN bus wiring

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 215

F - 216

5270

5280

5270

SPN

FMI

105

177

9803/9420

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message engine conf from the engine controller:

An Engine Conf Timeout

-The FWD controller is defective

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message front wheel drive status (V_IDENT_FWD):

A Front Wheel Drive Status Timeout

Check the FWD controller

Check the CAN bus wiring

Check the cable to the engine controller

Check the CAN bus wiring

OP-Mode: substitute clutch control Check the engine controller

TCU shifts to neutral

Check the cable to the cluster controller

Check the CAN bus wiring

- Old auto/man selection -Old clutch cutoff selection

Check the cluster controller

Repair Procedures

TCU keeps the:

Reaction of the TCU

-Old clutch cutoff setting -The CAN wire/connector is defective, it has a SC to earth or the battery OP-Mode: normal

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN-message FCL1 from the cluster controller:

A FLC1 Timeout

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 216

F - 217

5320

5300

5310

5290

SPN

9803/9420

FMI

109

108

107

106

Repair Procedures

Check the cable to the cluster controller

-Interference on the CAN bus

Check the cluster controller Check the CAN bus wiring

No reaction

-The cluster controller is defective

The CAN signal for the park brake status is incorrect:

A Park Brake Status Signal

Check the cable to the cluster controller

-Interference on the CAN bus

Check the cluster controller Check the CAN bus wiring

If active, the test mode is aborted

Check the cable to the EEC controller

Check the CAN bus wiring

OP-Mode: substitute clutch control Check the EEC controller

Check the cable to the EEC controller

Check the CAN bus wiring

OP-Mode: substitute clutch control Check the EEC controller

Reaction of the TCU

-The cluster controller is defective

The CAN signal for the test mode status is incorrect:

A Test Mode Signal

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message EEC3 from the EEC controller:

An EEC3 Timeout

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message EEC1 from the EEC controller:

An EEC1 Timeout

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 217

F - 218

5370

5350

5340

5360

5330

SPN

9803/9420

FMI

179

114

113

112

111

110

The CAN Message Front Wheel Drive Status (V_IDENT_FWD) Contains Invalid Data

-Interference on the CAN bus

-The I/O controller is defective

The CAN signal for the shift lever is incorrect:

Shift Lever Signal

TCU shifts to neutral

Check the FWD controller

TCU shifts to neutral and uses Check the I/O controller data from the substitute shift lever Check the CAN bus wiring OP-Mode: normal Check the cable to the I/O controller

Check the cable to the cluster controller

-Interference on the CAN bus

Check the cluster controller Check the CAN bus wiring

Last selection is kept

Check the cable to the cluster controller

Check the CAN bus wiring

Check the cluster controller

-The cluster controller is defective

The CAN signal for a CCO request is incorrect:

A CCO Request Signal

-Interference on the CAN bus

-The cluster controller is defective

The CAN signal for a manual downshift is incorrect:

Last selection is kept

Check the cable to the cluster controller

-Interference on the CAN bus

A Manual Downshift Signal

Check the CAN bus wiring

-The cluster controller is defective

The CAN signal for an automatic downshift is incorrect: Check the cluster controller

Check the cable to the cluster controller

-Interference on the CAN bus

An Automatic Downshift Signal

Check the CAN bus wiring

-The cluster controller is defective

Repair Procedures Check the cluster controller

Last selection is kept

Reaction of the TCU

The CAN signal for the shift quality selection is incorrect:

A Shift Quality Selection Signal

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 218

F - 219

9803/9420

5410

5390

5380

5400

5370

SPN

FMI

118

117

116

115

179

Last selection is kept

-Interference on the CAN bus

OP-Mode: normal

TCU uses a default driving mode signal

-The I/O controller is defective

-Interference on the CAN bus

No reaction

OP-Mode: normal

TCU uses a default PTO torque signal

The CAN signal for the driving mode is incorrect:

A Driving Mode Signal

-Interference on the CAN bus

-The I/O controller is defective

The CAN signal for the power take off torque is incorrect: No reaction

A PTO Torque Signal

OP-Mode: normal

No reaction

Check the CAN bus wiring

OP-Mode: normal

Check the cable to the I/O controller

Check the CAN bus wiring

Check the I/O controller

Check the cable to the I/O controller

Check the CAN bus wiring

Check the I/O controller

Check the cable to the I/O controller

Check the CAN bus wiring

Check the I/O controller

Check the cable to the I/O controller

Check the I/O controller

Check the cable to the steering computer

Check the CAN bus wiring

Check the steering computer

Repair Procedures

No reaction

OP-Mode: normal

Reaction of the TCU

-The I/O controller is defective

The CAN signal for an AEB request is incorrect:

An AEB Request Signal

-Interference on the CAN bus

-The I/O controller is defective

The CAN signal for the additional park brake status is incorrect:

An Additional Brake Status Signal

-Interference on the CAN bus

-The steering computer is defective

The CAN signal for a transmission neutral request is incorrect:

A Transmission Neutral Request Signal

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 219

F - 220

5460

5440

5430

5450

5420

SPN

9803/9420

FMI

126

125

124

120

119

Check the cable to the engine controller

-Interference on the CAN bus

-The engine controller is defective

The CAN signal for the nominal friction torque is incorrect:

Check the cable to the engine controller

Check the CAN bus wiring

OP-Mode: substitute clutch control Check the engine controller

Check the cable to the engine controller

-Interference on the CAN bus

A Nominal Friction Torque Signal

Check the CAN bus wiring

-The engine controller is defective

The CAN signal for the actual engine torque is incorrect: OP-Mode: substitute clutch control Check the engine controller

An Actual Engine Torque Signal

The CAN signal for the reference of the engine torque is OP-Mode: substitute clutch control Check the engine controller incorrect: Check the CAN bus wiring -The engine controller is defective Check the cable to the engine controller -Interference on the CAN bus

A Reference Engine Torque Signal

Check the CAN bus wiring

Check the engine controller

-The engine controller is defective

The CAN signal for the engine torque is incorrect: OP-Mode: substitute clutch

OP-Mode: normal

-Interference on the CAN bus

An Engine Torque Signal

Check the CAN bus wiring

TCU uses a default starting gear

-The I/O controller is defective (illegal starting gear) Check the cable to the I/O controller

Check the I/O controller

Repair Procedures

No reaction

Reaction of the TCU

The CAN signal for the starting gear is incorrect:

A Starting Gear Signal

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 220

F - 221

5480

5470

SPN

9803/9420

FMI

144

-The regulator has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The measured resistance value of the valve is out of range:

An Open Circuit at the Clutch K1

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to another regulator TCU output

-A cable/connector is defective, it has a SC to earth

The measured resistance value of the valve is out of range, the voltage at the K1 valve is too low:

A Short Circuit to Earth at the Clutch K1

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The measured resistance value of the valve is out of range, the voltage at the K1 valve is too high:

A Short Circuit to the Battery at the Clutch K1

OP-Mode: TCU shutdown

If failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cable and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cable and the connectors between the TCU and the gearbox

Check the internal wire harness of the gearbox

Check the regulator resistance

Check the cable and the connectors between the TCU and the gearbox

Check the cable to the EEC controller

Check the CAN bus wiring

TCU uses a default signal Accelerator pedal is in the idle position

Check the EEC controller

Repair Procedures

No reaction

Reaction of the TCU

-The CAN wire/connector is defective, it has a SC to earth OP-Mode: normal or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message EEC2 from the EEC controller:

An EEC2 Timeout

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 221

F - 222

5500

5490

SPN

9803/9420

FMI

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The measured resistance value of the valve is out of range, the voltage at the K3 valve is too high:

A Short Circuit to the Battery at the Clutch K3

-The regulator has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The measured resistance value of the valve is out of range:

An Open Circuit at the Clutch K2

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to another regulator TCU output

-A cable/connector is defective, it has a SC to earth

The measured resistance value of the valve is out of range, the voltage at the K2 valve is too low:

A Short Circuit to Earth at the Clutch K2

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The measured resistance value of the valve is out of range, the voltage at the K2 valve is too high:

A Short Circuit to the Battery at the Clutch K2

Description of the Fault Code

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

Reaction of the TCU

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cable and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cable and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cable and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cable and the connectors between the TCU and the gearbox

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 222

F - 223

5500

5540

5550

5540

5500

SPN

9803/9420

FMI

168

166

OP-Mode: normal

-A connector pin has a SC to earth

-The engine derating device has an internal defect

OP-Mode: normal

-A cable/connector is defective, it has a SC to the battery No reaction

A Short Circuit to the Battery at the Engine Derating Device

-The engine derating device has an internal defect

Engine derating will operate until the TCU power-down, even if the fault vanishes (loose connection)

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

Reaction of the TCU

-A cable/connector is defective, it has a SC to earth

A Short Circuit to Earth at the Engine Derating Device

An Open Circuit at the Converter Clutch

A Short Circuit to Earth at the Converter Clutch

A Short Circuit to the Battery at the Converter Clutch

-The regulator has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The measured resistance value of the valve is out of range:

An Open Circuit at the Clutch K3

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to another regulator TCU output

-A cable/connector is defective, it has a SC to earth

The measured resistance value of the valve is out of range, the voltage at the K3 valve is too low:

A Short Circuit to Earth at the Clutch K3

Description of the Fault Code

Check the resistance of the backup alarm device

Check the connectors from the backup alarm device to the TCU

Check the cables and the connectors between the engine derating device and the TCU

Check the resistance of the engine derating device

Check the cables and the connectors between the engine derating device and the TCU

Not used

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cables and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cables and the connectors between the TCU and the gearbox

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 223

F - 224

5510

5550

SPN

FMI

167

9803/9420

-The regulator has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The measured resistance value of the valve is out of range:

An Open Circuit at the Clutch K4

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to another regulator output of TCU

-A cable/connector is defective, it has a SC to earth

The measured resistance value of the valve is out of range, the voltage at the K4 valve is too low:

A Short Circuit to Earth at the Clutch K4

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The measured resistance value of the valve is out of range, the voltage at the K4 valve is too high:

A Short Circuit to the Battery at the Clutch K4

-The engine derating device has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit at the Engine Derating Device

Description of the Fault Code

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: normal

No reaction

Reaction of the TCU

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cables and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cables and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cables and the connectors between the TCU and the gearbox

Check the resistance of the engine derating device

Check the cables and the connectors between the engine derating device and the TCU

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 224

F - 225

5530

5520

SPN

9803/9420

FMI

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The measured resistance value of the valve is out of range, the voltage at the KR valve is too high:

A Short Circuit to the Battery at the Clutch KR

-The regulator has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The measured resistance value of the valve is out of range:

An Open Circuit at the Clutch KV

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to another regulator TCU output

-A cable/connector is defective, it has a SC to earth

The measured resistance value of the valve is out of range, the voltage at the KV valve is too low:

A Short Circuit to Earth at the Clutch KV

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The measured resistance value of the valve is out of range, the voltage at the K4 valve is too high:

A Short Circuit to the Battery at the Clutch K4

Description of the Fault Code

OP-Mode: TCU shutdown

Check the internal wiring harness of the gearbox

Check the cables and the connectors between the TCU and the gearbox

OP-Mode: limp home If a failure at another clutch is pending, TCU shifts to neutral

Check the regulator resistance

TCU shifts to neutral

OP-Mode: TCU shutdown

Check the cables and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

OP-Mode: limp home If a failure at another clutch is pending, TCU shifts to neutral

Check the regulator resistance

TCU shifts to neutral

OP-Mode: TCU shutdown

Check the internal wiring harness of the gearbox

Check the cables and the connectors between the TCU and the gearbox

OP-Mode: limp home If a failure at another clutch is pending, TCU shifts to neutral

Check the regulator resistance

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cables and the connectors between the TCU and the gearbox

Repair Procedures

TCU shifts to neutral

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

Reaction of the TCU

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 225

F - 226

5560

5530

5560

5530

SPN

9803/9420

FMI

OP-Mode: TCU shutdown

If a failure at another clutch is pending, TCU shifts to neutral

OP-Mode: limp home

TCU shifts to neutral

OP-Mode: TCU shutdown

-A connector pin has a SC to the battery

-The backup alarm device has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

OP-Mode: normal

No reaction

Check the resistance of the backup alarm device

Check the cables and the connectors between the TCU and the backup alarm device

Backup alarm will be on until the Check the cables and the connectors between TCU power-down even if the fault the TCU and the backup alarm device clears (loose connection) Check the resistance of the backup alarm device OP-Mode: normal

A Short Circuit to the Battery at the Relay Reverse Warning Alarm

-A connector pin has a SC to earth

-The backup alarm device has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

Check the internal wiring harness of the gearbox

Check the regulator resistance

Check the cables and the connectors between the TCU and the gearbox

Check the internal wiring harness of the gearbox

Check the cables and the connectors between the TCU and the gearbox

OP-Mode: limp home If a failure at another clutch is pending, TCU shifts to neutral

Check the regulator resistance

Repair Procedures

TCU shifts to neutral

Reaction of the TCU

A Short Circuit to Earth at the Relay Reverse Warning Alarm

-The regulator has an internal defect

-A cable/connector is defective, It has an OC to the TCU

The measured resistance value of the valve is out of range:

An Open Circuit at the Clutch KR

-The regulator has an internal defect

-A cable/connector is defective, it has a SC to another regulator TCU output

-A cable/connector is defective, it has a SC to earth

The measured resistance value of the valve is out of range, the voltage at the KR valve is too low:

A Short Circuit to Earth at the Clutch KR

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 226

F - 227

5570

5560

SPN

FMI

9803/9420

-The starter interlock relay has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be a OC:

An Open Circuit at the Relay Starter Interlock

-A connector pin has a SC to the battery

-The starter interlock relay has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

A Short Circuit to the Battery at the Relay Starter Interlock

-A connector pin has a SC to earth

-The starter interlock relay has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

A Short Circuit to Earth at the Relay Starter Interlock

-The backup alarm device has an internal defect

- A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit at the Relay Reverse Warning Alarm

Description of the Fault Code

OP-Mode: normal

No reaction

OP-Mode: normal

No reaction

OP-Mode: normal

No reaction

OP-Mode: normal

No reaction

Reaction of the TCU

Check the resistance of the starter interlock relay

Check the cables and the connectors between the TCU and the starter interlock relay

Check the resistance of the starter interlock relay

Check the cables and the connectors between the TCU and the starter interlock relay

Check the resistance of the starter interlock relay

Check the cable and the connectors between the TCU and the starter interlock relay

Check the resistance of the backup alarm device

Check the cables and the connectors between the TCU and the backup alarm device

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 227

F - 228

5590

5580

SPN

9803/9420

FMI

No reaction

OP-Mode: normal

No reaction

Reaction of the TCU

Check the cables and the connectors between the TCU and the park brake solenoid

Check the resistance of park brake solenoid

Check the cable and the connectors between the TCU and the park brake solenoid

Repair Procedures

No reaction

Check the cables and the connectors between the TCU and the park brake solenoid

-A connector pin has a SC to earth

-The converter clutch solenoid has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

OP-mode: normal

No reaction

A Short Circuit to Earth at the Converter Lock Up Clutch Solenoid

Check the resistance of the converter clutch solenoid

Check the cables and the connectors between the TCU and the converter clutch solenoid

Optional: Feedback from the park -A cable/connector is defective, it has an OC to the TCU brake causes the TCU to shift to Check the resistance of the park brake solenoid neutral -The park brake solenoid has an internal defect OP-Mode: normal

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit at the Park Brake Solenoid

Optional: Feedback from the park -A cable/connector is defective, it has a SC to the battery brake causes the TCU to shift to Check the resistance of the park brake solenoid neutral -The park brake solenoid has an internal defect OP-Mode: normal -A connector pin has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

A Short Circuit to the Battery at the Park Brake Solenoid

-A connector pin has a SC to earth

-The park brake solenoid has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

A Short Circuit to Earth at the Park Brake Solenoid

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 228

F - 229

5590

5600

5590

SPN

FMI

Reaction of the TCU Converter clutch is always open, the retarder is not available

9803/9420

-The retarder solenoid has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be a OC:

An Open Circuit at the Retarder Solenoid

-A connector pin has a SC to earth

-The retarder solenoid has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

A Short Circuit to Earth at the Retarder Solenoid

-A connector pin has a SC to the battery

-The converter clutch solenoid has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

OP-mode: normal

No reaction

OP-mode: normal

No reaction

OP-mode: normal

No reaction

A Short Circuit to the Battery at the Converter Lock Up Clutch Solenoid

-The converter clutch solenoid has an internal defect

-A cable/connector is defective, it has an OC to the TCU OP-mode: normal

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit at the Converter Lock Up Clutch Solenoid

Description of the Fault Code

Check the resistance of the retarder solenoid

Check the cables and the connectors between the TCU and the retarder solenoid

Check the resistance of the retarder solenoid

Check the cables and the connectors between the TCU and the retarder solenoid

Check the resistance of the converter clutch solenoid

Check the cables and the connectors between the TCU and the converter clutch solenoid

Check the resistance of the converter clutch solenoid

Check the cables and the connectors between the TCU and the converter clutch solenoid

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 229

F - 230

5610

5600

SPN

9803/9420

FMI

OP-mode: normal

No reaction

Reaction of the TCU

OP-mode: normal

No reaction

-The difflock solenoid has an internal defect

-A cable/connector is defective, has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be an OC:

OP-mode: normal

No reaction

An Open Circuit at the Difflock or the Axle Connection Solenoid

-A connector pin has a SC to the battery

-The difflock solenoid has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

A Short Circuit to the Battery at the Difflock or the Axle Connection Solenoid

-A connector pin has a SC to earth

-The difflock solenoid has an internal defect

The TCU senses a incorrect voltage at the output pin, that No reaction could be a SC to earth: OP-mode: normal -A cable/connector is defective, it has a SC to earth

A Short Circuit to Earth at the Difflock or the Axle Connection Solenoid

-A connector pin has a SC to the battery

-The retarder solenoid has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

A Short Circuit to the Battery at the Retarder Solenoid

Description of the Fault Code

Check the resistance of the difflock solenoid

Check the cable and the connectors between the TCU and the difflock solenoid

Check the resistance of the difflock solenoid

Check the cable and the connectors between the TCU and the difflock solenoid

Check the resistance of the difflock solenoid

Check the cable and the connectors between the TCU and the difflock solenoid

Check the resistance of the retarder solenoid

Check the cables and the connectors between the TCU and the retarder solenoid

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 230

F - 231

5620

5630

5620

SPN

FMI

157

OP-mode: normal

No reaction

OP-mode: normal

No reaction

Reaction of the TCU

9803/9420

-A connector pin has a SC to earth

-The CS function-4 device has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

A Short Circuit to Earth, Customer Specific Function-4

-A connector pin has a SC to the battery

-The warning device has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

OP-mode: normal

No reaction

A Short Circuit to the Battery at the Warning Signal Output

-The warning device has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit at the Warning Signal Output

-A connector pin has a SC to earth

-The warning device has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

A Short Circuit to Earth at the Warning Signal Output

Description of the Fault Code

Check the resistance of the CS function-4 device

Check the cables and the connectors between the TCU and the CS function-4 device

Check the resistance of the warning device

Check the cable and the connectors between the TCU and the warning device

Check the resistance of the warning device

Check the cable and the connectors between the TCU and the warning device

Check the resistance of the warning device

Check the cable and the connectors between the TCU and the warning device

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 231

F - 232

5630

5640

5630

SPN

FMI

162

160

158

159

Reaction of the TCU

9803/9420

-A connector pin has a SC to the battery

-The CS function-5 device has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery: CS

A Short Circuit to the Battery, Customer Specific Function-5

-A connector pin has a SC to earth

-The CS function-5 device has an internal defect

Check the resistance of the CS function-5 device

Check the cables and the connectors between the TCU and the CS function-5 device

Check the resistance of the CS function-5 device

-A cable/connector is defective, it has a SC to earth

Check the resistance of the CS function-4 device

Check the cables and the connectors between the TCU and the CS function-4 device

Check the resistance of the CS function-4 device

Check the cables and the connectors between the TCU and the CS function-4 device

Check the cables and the connectors between the TCU and the CS function-5 device

Repair Procedures

The TCU senses a incorrect voltage at the output pin, that CS could be a SC to earth:

A Short Circuit to Earth, Customer Specific Function-5

-The CS function-4 device has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit, Customer Specific Function-4

-A connector pin has a SC to the battery

-The CS function-4 device has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

A Short Circuit to the Battery, Customer Specific Function-4

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 232

F - 233

5650

5640

SPN

FMI

164

165

163

161

Reaction of the TCU

9803/9420

-The CS function-6 device has an internal defect

-A cable/connector is defective. it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit, Customer Specific Function-6

-A connector pin has a SC to the battery

-The CS function-6 device has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that could be a SC to the battery:

A Short Circuit to the Battery, Customer Specific Function-6

-A connector pin has a SC to earth

-The CS function-6 device has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that could be a SC to earth:

A Short Circuit to Earth, Customer Specific Function-6

-The CS function-5 device has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that could be an OC:

An Open Circuit, Customer Specific Function-5

Description of the Fault Code

Check the resistance of the CS function-6 device

Check the cables and the connectors between the TCU and the CS function-6 device

Check the resistance of the CS function-6 device

Check the cables and the connectors between the TCU and the CS function-6 device

Check the resistance of the CS function-6 device

Check the cables and the connectors between the TCU and the CS function-6 device

Check the resistance of the CS function-5 device

Check the cables and the connectors between the TCU and the CS function-5 device

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 233

SPN

5660

5665

F - 234

FMI

9803/9420

Check the signal at the output speed sensor Replace the clutch

-Incorrect size of the sensor gap

-Clutch is defective

Check the gap at the output speed sensor

Check the gap at the internal speed sensor

Check the main pressure in the system

OP-Mode: TCU shutdown

-Incorrect signal at the output speed sensor

-Incorrect signal at the internal speed sensor

-Low main pressure

Check the signal at the internal speed sensor

-Low pressure at the clutch K2

If failure at another clutch is pending,

Check the signal at the internal speed sensor

Check the pressure at the clutch K2

The TCU calculates a differential speed at the closed TCU shifts to neutral clutch K2. If this value is out of range, the TCU interprets this as a slipping clutch: OP-Mode: limp home

A Slippage at the Clutch K2

-Clutch is defective

Replace the clutch

-Incorrect size of the sensor gap

Check the main pressure in the system

Check the gap at the output speed sensor

Check the signal at the output speed sensor

OP-Mode: TCU shutdown

-Incorrect signal at the output speed sensor

-Incorrect signal at the internal speed sensor

-Low main pressure

Check the gap at the internal speed sensor

If failure at another clutch is pending,

-Low pressure at the clutch K1

Check the pressure at the clutch K1

Repair Procedures

Check the signal at the internal speed sensor

Reaction of the TCU

The TCU calculates a differential speed at the closed TCU shifts to neutral clutch K1. If this value is out of range, the TCU interprets this as a slipping clutch: OP-Mode: limp home

A Slippage at the Clutch K1

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 234

SPN

5670

5675

F - 235

FMI

9803/9420

-Clutch is defective

Replace the clutch

-Incorrect signal at the output speed sensor

Check the gap at the internal speed sensor

Check the gap at the turbine speed sensor

Check the signal at the turbine speed sensor

OP-Mode: TCU shutdown

-Incorrect size of the sensor gap

-Incorrect signal at the internal speed sensor

-Low main pressure

Check the main pressure in the system

If failure at another clutch is pending,

-Low pressure at the clutch K4

Check the pressure at the clutch K4

Replace the clutch

Check the signal at the output speed sensor

Check the gap at the output speed sensor

Check the signal at the internal speed sensor

OP-Mode: TCU shutdown

The TCU calculates a differential speed at the closed TCU shifts to neutral clutch K4. If this value is out of range, the TCU interprets this as slipping clutch: OP-Mode: limp home

A Slippage at the Clutch K4

-Clutch is defective

-Incorrect size of the sensor gap

-Incorrect signal at the output speed sensor

-Incorrect signal at the internal speed sensor

-Low main pressure

Check the signal at the internal speed sensor

If failure at another clutch is pending,

-Low pressure at the clutch K3

Check the gap at the internal speed sensor

Repair Procedures

Check the main pressure in the system

Reaction of the TCU

The TCU calculates a differential speed at the closed TCU shifts to neutral clutch K3. If this value is out of range, the TCU interprets this as a slipping clutch: OP-Mode: limp home

A Slippage at the Clutch K3

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 235

SPN

5680

5685

F - 236

FMI

Reaction of the TCU

9803/9420

-Clutch is defective

Replace the clutch

-Incorrect size of the sensor gap

Check the gap at the internal speed sensor

Check the main pressure in the system

Check the signal at the turbine speed sensor

OP-Mode: TCU shutdown

-Incorrect signal at the turbine speed sensor

-Incorrect signal at the internal speed sensor

-Low main pressure

Check the gap at the turbine speed sensor

-Low pressure at the clutch KR

If failure at another clutch is pending,

Check the signal at the internal speed sensor

The TCU calculates a differential speed at the closed TCU shifts to neutral clutch KR. If this value is out of range, the TCU interprets this as a slipping clutch: OP-Mode: limp home

Check the pressure at the clutch KR

Replace the clutch

-Clutch is defective

A Slippage at the Clutch KR

Check the signal at the turbine speed sensor

-Incorrect size of the sensor gap

Check the sensor gap at the turbine speed sensor

Check the main pressure in the system

Check the signal at the internal speed sensor

OP-Mode: TCU shutdown

If failure at another clutch is pending,

Check the sensor gap at the internal speed sensor

Check the pressure at the clutch KV

Repair Procedures

-Incorrect signal at the turbine speed sensor

-Incorrect signal at the internal speed sensor

-Low main pressure

-Low pressure at the clutch KV

The TCU calculates a differential speed at the closed TCU shifts to neutral clutch KV. If this value is out of range, TCU interprets this as a slipping clutch: OP-Mode: limp home

A Slippage at the Clutch KV

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 236

SPN

5700

5710

5720

5730

F - 237

FMI

Reaction of the TCU

OP-Mode: normal

If configured, the retarder is applied

9803/9420

-The differential pressure switch is defective

-The oil filter is polluted

The TCU measures a voltage at the differential pressure No reaction switch which is out of the allowed range: OP-Mode: normal -A cable/connector is defective, it has a SC to the battery or earth

The Differential Pressure Oil Filter

An Over-Speeding Engine

The TCU measures a temperature in the retarder oil that is over the allowed threshold.

A High Temperature at the Retarder

The TCU measures a temperature in the oil sump that is No reaction over the allowed threshold. OP-Mode: normal

A High Temperature at the Sump

Description of the Fault Code

Check the differential pressure switch (measure the resistance)

Check the wiring from the TCU to the differential pressure switch

Check the oil filter

Check the temperature sensor

Check the oil level

Check the temperature sensor

Check the oil level

Cool down the machine

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 237

F - 238

5750

5740

SPN

FMI

171

169

172

Replace the clutch

-Clutch is defective

9803/9420

-A connector pin has a SC to the battery

-The engine brake solenoid has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that looks like a SC to the battery:

A Short Circuit to the Battery at the Engine Brake

-A connector pin has a SC to earth

-The engine brake solenoid has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that looks like a SC to earth:

OP-mode: normal

No reaction

OP-mode: normal

Check the signal at the turbine speed sensor

-Incorrect size of the sensor gap

Check the resistance of the engine brake solenoid

Check the cables and the connectors between the TCU and engine brake solenoid

Check the resistance of the engine brake solenoid

Check the cables and the connectors between the TCU and the engine brake solenoid

Check the main pressure in the system

-Incorrect signal at the turbine speed sensor

A Short Circuit to Earth at the Engine Brake Solenoid

Check the signal at the engine speed sensor

-Incorrect signal at the engine speed sensor

Check the pressure at the converter lockup clutch

Check the gap at the engine speed sensor

Repair Procedures

Check the sensor gap at the turbine speed sensor

No reaction

Reaction of the TCU

-Low main pressure

-Low pressure at converter lockup clutch

The TCU calculates a differential speed at the closed converter lockup clutch. If this calculated value is out of range, the TCU interprets this as slipping clutch:

A Slippage at the Converter Lockup Clutch

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 238

F - 239

5760

5770

5750

SPN

FMI

131

129

170

9803/9420

OP-mode: normal

No reaction

Check the oil level

OP-mode: normal

-A connector pin has a SC to the battery

-The joystick status indicator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that looks like a SC to the battery:

OP-mode: normal

No reaction

Check the resistance of the joystick status indicator

Check the cables and the connectors between the TCU and the joystick status indicator

Check the resistance of the joystick status indicator

Check the cables and the connectors between the TCU and the joystick status indicator

Check the temperature sensor

Cool down the machine

Check the resistance of the engine brake solenoid

Check the cables and the connectors between the TCU and the engine brake solenoid

Repair Procedures

No reaction

OP-mode: normal

No reaction

Reaction of the TCU

A Short Circuit to the Battery at the Joystick Status Indicator

-A connector pin has a SC to earth

-The joystick status indicator has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that looks like a SC to earth:

A Short Circuit to Earth at the Joystick Status Indicator

The TCU measures the oil temperature at the converter output that is over the allowed threshold

A High Temperature at the Converter Output

-The engine brake solenoid has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that looks like an OC:

An Open Circuit at the Engine Brake

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 239

SPN

5770

5780

F - 240

9803/9420

FMI

133

134

132

130

OP-mode: normal

No reaction

Reaction of the TCU

OP-mode: normal

No reaction

OP-mode: normal

No reaction

-The over-temperature status indicator has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that looks like an OC:

OP-mode: normal

No reaction

An Open Circuit at the Over-Temperature Neutral Indicator

-A connector pin has a SC to the battery

-The over-temperature status indicator has an internal defect

-A cable/connector is defective, it has a SC to the battery

The TCU senses an incorrect voltage at the output pin, that looks like a SC to the battery:

A Short Circuit to the Battery at the Over-Temperature Neutral Indicator

-A connector pin has a SC to earth

-The over-temperature status indicator has an internal defect

-A cable/connector is defective, it has a SC to earth

The TCU senses an incorrect voltage at the output pin, that looks like a SC to earth:

A Short Circuit to Earth at the Over-Temperature Neutral Indicator

-The joystick status indicator has an internal defect

-A cable/connector is defective, it has an OC to the TCU

The TCU senses an incorrect voltage at the output pin, that looks like an OC:

An Open Circuit at the Joystick Status Indicator

Description of the Fault Code

Check the resistance of the over-temperature neutral indicator

Check the cables and the connectors between the TCU and the over-temperature neutral indicator

Check the resistance of the over-temperature neutral indicator

Check the cables and the connectors between the TCU and the over-temperature neutral indicator

Check the resistance of the over-temperature neutral indicator

Check the cables and the connectors between the TCU and the over-temperature neutral indicator

Check the resistance of the joystick status indicator

Check the cables and the connectors between the TCU and the joystick status indicator

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 240

F - 241

9803/9420

5810

5800

5810

5790

SPN

FMI

122

121

Repair Procedures

See fault codes no. 21 to 2C

The TCU measures less than 4V at the pin AU1 (5V sensor supply)

See fault codes no. 21 to 2C

A Short Circuit to Earth at the Power Supply for the Sensors

The TCU measures more than 6V at the pin AU1 (5V sensor supply)

A Short Circuit to the Battery at the Power Supply for the Sensors

-The CAN wire/connector is defective, it has a SC to earth or the battery

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message ERC1 from the EEC controller:

An ERC1 Timeout

-The CAN wire/connector is defective, it has a SC to earth or the battery

Check the power supply at the pin AU1 (should be approx. 5V)

Check the cables and connectors to the sensors, which are supplied from AU1

Check the power supply at the pin AU1 (should be approx. 5V)

Check the cables and connectors to the sensors, which are supplied from AU1

Check the cable to the EEC controller

Check the wiring of the CAN bus

OP-Mode: substitute clutch control Check the EEC controller

Check the cable to the EEC controller

-Interference on the CAN bus

-The CAN wire/connector is broken,

Check the wiring of the CAN bus

OP-Mode: substitute clutch control Check the EEC controller

Reaction of the TCU

-The engine retarder config from the EEC controller

A timeout of the CAN message:

An Engine Retarder Config Timeout

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 241

F - 242

5820

5830

5840

5820

SPN

FMI

Reaction of the TCU

9803/9420

-The permanent power supply KL30 is missing

-The TCU has an internal defect

-A cable/connector is defective, it has a SC to the battery or earth

The TCU switches on VPS2 but the measured VPS2 is off Shift to neutral or the TCU switches off VPS2 and the measured VPS2 is on: OP-Mode: TCU shutdown

An Error at the Valve Power Supply VPS2

-The permanent power supply KL30 is missing

-The TCU has an internal defect

-A cable/connector is defective, it has a SC to the battery or earth

The TCU switches on VPS1 but the measured VPS1 is off Shift to neutral or the TCU switches off VPS1 and the measured VPS1 is on: OP-Mode: TCU shutdown

An Error at the Valve Power Supply VPS1

The measured voltage at the power supply is higher than Shift to neutral 18V (a 12V device) or higher than 32.5V (a 24V device) OP-Mode: TCU shutdown

A High Voltage at the Battery

The measured voltage at the power supply is lower than Shift to neutral 10V (a 12V device) or lower than 18V (a 24V device) OP-Mode: TCU shutdown

A Low Voltage at the Battery

Description of the Fault Code

Replace the TCU

Check the cables and the connectors between the gearbox and the TCU

Check the fuse

Replace the TCU

Check the cables and the connectors between the gearbox and the TCU

Check the fuse

Check the cables and the connectors between the batteries and the TCU

Check the power supply battery

Check the cables and the connectors between the batteries and the TCU

Check the power supply battery

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 242

F - 243

5860

5270

5860

SPN

FMI

104

Reaction of the TCU

Change the display

Check the cables and the connectors between the TCU and the display,

Change the display

Check the cables and the connectors between the TCU and the display

Repair Procedures

9803/9420

-OP-Mode: normal

Check the cable to the cluster controller

Check the wiring of the CAN bus

-Status test mode -Status lock

Check the cluster controller

TCU keeps old information for:

-Shift quality selection -The CAN wire/connector is defective, it has a SC to earth or the battery -Gear range restriction

-The CAN wire/connector is broken

-Interference on the CAN bus

A timeout of the CAN message CL1 from the cluster controller:

A CL1 Timeout

-The CAN wire/connector is defective, it has a SC to earth or the battery

A timeout of the CAN message DISPID1 from the display TCU select parameter set with the Check the display controller controller: ID0 Check the wiring of the CAN bus -Interference on the CAN bus OP-Mode: Limp Home Check the cable to the display controller -The CAN wire/connector is broken

A DISPID1 Timeout

-The display has an internal defect

The TCU sends data to the display and measures a high No reaction voltage level on the connector: OP-Mode: normal -A cable/connector is defective, it has a SC to earth,

A Short Circuit to Earth at the Display Output

-The display has an internal defect

The TCU sends data to the display and measures a high No reaction voltage level on the connector: OP-Mode: normal -A cable/connector is defective, it has a SC to the battery,

A Short Circuit to the Battery at the Display Output

Description of the Fault Code

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 243

SPN

5880

5890

5900

F - 244

FMI

9803/9420

-The TCU is new or from another machine

-Interference when data is saved on the non-volatile memory

The TCU has lost the FWD configuration:

A Lost FWD Configuration

-The TCU is new or from another machine

-Interference when data is saved on the non-volatile memory

The TCU has lost the correct configuration and can not control the transmission:

Gear range set from 1st to 4th

OP-Mode: TCU shutdown

Transmission stays neutral

OP-Mode: normal

-The TCU is defective

A Lost Configuration

No reaction

OP-Mode: TCU shutdown

Transmission stays neutral

Reaction of the TCU

The TCU can not read the non-volatile memory:

A General EEPROM Fault

An Illegal ID Request Via the CAN

Description of the Fault Code

Reconfigure with the CU Configuration Command (ID PC)

Reprogram the correct configuration for the machine (for example with a cluster controller)

Replace the TCU

Repair Procedures

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 244

F - 245

ZF ref.

Destination

Table 23. ZF Controller Plug Fault Wire From Fault code code Res/ No. pin No. OC Earth To pin Test value No.

CAN Bus to EMS

Auxiliaries

CANF-H

CANF-L

Handbrake data to EMS

CAN bus communication

848

439

438

9803/9420

Auxiliaries

Frequency

Auxiliaries

Frequency

Control

EF3

EF2

EF1

ED3

ED13

ED8

Mid range speed sensor

Turbine speed sensor

Engine speed sensor

Filter bypass warning

Load suspension (SRS) solenoid

Load suspension (SRS) input

Handbrake pressure switch state 456

Handbrake output 456

Neutral select loader lever

Reverse select loader lever

Forward select loader lever

9420

9410

9400

RPM error

9580

897

896

9821

893A

882

881

880

All of the following checks are to be made with the 68-way plug removed from the transmission computer

CAN Bus

B15

Ignition On

Ignition Off

Ignition On

Ignition Off

Ignition status

1050 Ohm

Ignition Off

1050 Ohms Ignition Off

500 Ohms

Battery voltage

Ohms at solenoid

Battery voltage

0 Ohms

The checks are to be made with the 68-way plug removed from the transmission computer and both plugs removed from the EMS

Pin No.

ZF Controller Plug

OC with a blocked filter

Confirms the continuity of the solenoid coil

Load suspension switch is in the On position

Comfirms the handbrake is on

Confirms the continuity of the solenoid coil

Select Neutral on the loader lever

Select Reverse on the loader lever

Select Forward on the loader lever

Remarks

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 245

F - 246

Control

Temperature

Gearbox inputs

Frequency

Gearbox inputs

Frequency

Gearbox inputs

Temperature

Gearbox inputs

Pin No.

9803/9420

ED6

ED5

ED2

ED4

ED13

EF4

VMG 2

VMGA2

ER1

AIP6

AIP5

AIP4

AIP3

AIP2

AIP1

ZF ref.

Fault code OC

Convertor out temperature sender

Neutral select.

Reverse select

B2 range select

Forward select

B1 range select

Output sensor (Hall 3C type)

Hall sensor (output Speed)

Temperature sender earth

Control valve temperature probe

Proportional valve Y6 (K2)

Proportional valve Y5 (KV)

Proportional valve Y4 (K3)

Proportional valve Y3 (K1)

Proportional valve Y2 (KR)

Proportional valve Y1 (K4)

Destination

9570

9548

9544

9542

9540

9528

9504

9500

9462

9458

9450

9446

9442

9438

9434

9430

Fault Wire code Res/ No. Earth

From pin No.

See pin 39

Ignition Off

Ignition status

Battery voltage

No value available

Ignition On

1000 - 1500 Ignition Ohms Off

19 Ohm

To pin Test value No.

Select neutral on the direction control lever

Select reverse on the direction control lever

Select 4th gear

Select forward on the direction control lever

Select 2nd gear

Remove the sensor, 35 Mega-Ohms on pins 2-3 of the sensor

Range 17.1 - 20.9 Ohms @ 20OC

Range 17.1 - 20.9 Ohms @20OC

Range 17.1 - 20.9 Ohms @ 20OC

Range 17.1 - 20.9 Ohms @20OC

Remarks

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 246

F - 247

Supply input

Frequency

Gearbox inputs

Supply input

Auxiliaries

Supply input

Auxiliaries

Test

Auxiliaries

Test

Pin No.

9803/9420

VP1

VPS1

VMG1

VM2

VPE2

VPE1

ED11

VM1

ED9

ADM2

ZF ref.

Ignition feed +

Proportional valve earth

Inductive earth

Earth

Battery +

Auto/Manual switch input +

Earth

Transmission disconnect inputs+

Reverse relay earth

Transmission diagnostic port

Destination

CAN light on

Fault code OC

9916

9908

9904

9900

9856

9836

9832

9824

9920

9816

9808

9652

9644

Fault Wire code Res/ No. Earth

From pin No.

See pins 45, 23 & 68

Battery voltage

0 Ohms

See 0 Ohms remark

To pin Test value No.

Ignition On

Ignition Off

Ignition On

Ignition Off

Ignition status

With the A/M switch in the On position

1. Check by pushing the disconnect button on the loader lever. 2.Select the On position on the Transmission switch and apply the foot brake.

Confirms the continuity of the relay coil

Connect to pin 2 on the ZF diagnostic plug. Open circuit.

Connect to pin 2 on the ZF diagnostic plug

Remarks

Section F - Transmission Functional Testing

Transmission Fault Finding

F - 247

F - 248

Control

Auxiliaries

Pin No.

ED10

ED7

ZF ref.

Hand brake switch input +

KD input from the controls

Destination

Fault code OC

9820A

9532A

Fault Wire code Res/ No. Earth

From pin No.

Battery voltage

To pin Test value No.

Ignition On

Ignition status

Hand brake lever/switch is in the On position

1. Check by pushing the end in on the direction control lever. 2. Or check by pushing the KD button on the loader lever.

Remarks

Section F - Transmission Functional Testing

Transmission Fault Finding

9803/9420

F - 248

Section F - Transmission Functional Testing Transmission Fault Finding Page left intentionally blank

F - 249

9803/9420

F - 249

Section F - Transmission Functional Testing Removal and Replacement

Removal and Replacement Loader Arm Control Transmission Dump and Kickdown Switches 1

Prise the top off the Loader Arm Control lever using a fine bladed screwdriver or knife.

Disconnect connector from the rear of the switch.

Depress tabs 485-A on the switch and press switch out through the Control Lever.

Note: It is advisable to check the suspect switch at this stage to rule out the possibility of a defective harness before reassembling the Control Lever. 4

Assembly is the reverse of the dismantling procedure.

Wiring to Kickdown and Transmission Dump Switches 1

Remove switch as detailed in steps 1 - 3 above.

Remove the instrument panel to access connector.

Remove the connector, making a note of the respective positions. Cut the wires close to the connector.

Draw the wires through the top of the control lever.

Feed new wire through aperture for switch 485-B and out through aperture 485-C.

Strip sleeving from last 10 mm of wire. Use special tool to fit connector to end of wires.

Mate connector to instrument cluster connector.

Refit cap on Loader Arm Control Lever.

F - 250

Fig 485.

9803/9420

F - 250

Section F - Transmission Functional Testing Removal and Replacement

Removal and Replacement of Control Lever 1

Prise out centre of steering wheel 486-D using a fine bladed screwdriver.

Remove steering wheel securing nut 486-E and withdraw steering wheel.

Release the two column cover securing bolts, 486-F and remove column cover 486-G.

Disconnect connector 486-SE and gently pull the control lever sideways to clear the locating spigot, 486-H from the steering column.

Assembly is reverse of removal procedure.

Fig 486.

F - 251

9803/9420

F - 251

Section F - Transmission Functional Testing Electronic Monitoring System Display Panel

Electronic Monitoring System Display Panel Details of the EMS Display Panel and the set-up procedures can be found in Section C - Electrics.

F - 252

9803/9420

F - 252

Section G Brakes Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

Section G - Brakes

Notes:

G-0

9803/9420-3

G-0

Section G - Brakes Contents Page No. Technical Data Brakes .................................................................................................... G - 1 Brake Circuits 434S Machines ....................................................................................... G - 3 435S Machines ....................................................................................... G - 4 Service Procedures Service Brakes ....................................................................................... G - 5 System Accumulators ........................................................................... G - 10 Park Brake ............................................................................................ G - 11 Park Brake Testing ............................................................................... G - 15 Brake Valves Foot Valve ............................................................................................. G - 17 Park Brake Dismantling and Assembly ................................................................... G - 21

G-i

Section G - Brakes Contents

G - ii

Page No.

G - ii

Section G - Brakes Technical Data Brakes

Technical Data Brakes

Service Brake Type

Oil-Immersed Multi-Plate Disc Actuation

Actuation

Dual Circuit, Full Hydraulic with compact valve and pressure accumulators

Location

Front and Rear Axle (4 plates per hub)

Control Valve Type

Compact

Pressure Regulator Setting Cut-in Pressure

64 bar

2378 lbf/in2

Cut-out Pressure

200 bar

2900 lbf/in2

Maximum Pressure Differential

36 bar

522 lbf/in2

Charge Valve Setting Cut-in Pressure

145 bar

2103 lbf/in2

Cut-out Pressure

180 bar

2611 lbf/in2

Maximum Pressure Differential

35 bar

508 lbf/in2

434S (Graziano Axle)

80 bar

1160 lbf/in2

434S (ZF Axle)

100 bar

1450 lbf/in2

435S (Tier4i)

70 bar

1015 lbf/in2

105 bar

1523 lbf/in2

Service Brake Operating Pressure

Pressure Switch Operating Pressure Low Pressure Warning on Accumulator Capacity per circuit - 434S

0.75 litre

1.3 pint

Capacity per circuit - 435S

1.75 litre

3 pint

Number (fitted)

Accumulator Gas

Nitrogen

Pre-charge

57 bar

826 lbf/in2

Parking Brake Type

Manually Adjusted Disc, cable operated

Location

Front face of transmission

G-1

9803/9420-3

G-1

Section G - Brakes Technical Data Brakes Page left intentionally blank

G-2

9803/9420-3

G-2

Section G - Brakes

Brake Circuits 434S Machines

Fig 1. Component Key 1

Suction Strainer

Engine Driven Gear Pump and Charge Valve

Accumulators

Brake Valve

Front Axle Brakes

Rear Axle Brakes

Oil Cooler

Return Filter/Diffuser

Filler Breather

Engine Cooling Fan Hydraulic Motor

Tank

G-3

9803/9420-3

G-3

Section G - Brakes Brake Circuits 435S Machines

435S Machines 10 3

2 S

BR2

SP2

BR1

SP1

1 A439550-V2

Fig 2. Component key: 1

Suction strainer

Engine driven gear pump

Accumulators (piston type)

Modulation brake valve

Rear axle brakes

Front axle brakes

Charge valve

Tank

EF To engine hydraulic cooling fan motor

G-4

9803/9420-3

G-4

Section G - Brakes

Service Procedures Service Brakes System Testing

Testing the System Pressure

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Fig 3.

!MWARNING

Key:

Before disconnecting any part of the brake hydraulic system, make sure that engine is switched off and hydraulic pressure is fully discharged.

Brake Test Point

Hydraulic Engine Fan Test Point

Low Pressure Switch

BRAK-3-1

G-5

Switch off the engine and operate the brake pedal repeatedly to make sure that all the hydraulic pressure stored in the accumulators is discharged.

Connect a 400 bar test gauge to the test point A on the combined engine driven gear pump and charge valve.

Switch on the engine and check that the gauge reading rises to the Charge Valve Cut-out Pressure. (See K Technical Data ( T G-1))

With the engine running and the maximum charge pressure obtained, repeatedly operate the brake pedal. Check that the pressure is recharged to its maximum pressure as each stoke of the brake pedal is applied.

9803/9420

G-5

Section G - Brakes Service Procedures Service Brakes Note: There is no noticeable successive reduction in the system pressure (with each stoke of the brake pedal) until the Cut-in pressure is reached. The system will start to recharge after the first full stroke of the pedal. 5

Fully charge the system.

Switch off the engine. Switch the ignition ON. Slowly and repeatedly operate the brake pedal (apply full pedal stokes) until the low brake pressure warning lamp illuminates. Check the pressure reading on the gauge. (See K Technical Data ( T G-1) for Low Pressure Switch operating Pressure)

Continue to operate the brake pedal until the pressure drop-off point is reached. There must be a Minimum of 5 Full Pressure Strokes Before the pressure drop off point is reached.

Note: As the brake pedal is repeatedly applied (engine switched OFF) the stored accumulator pressure is gradually depleted At a pressure normally below 80 bar, the stored pressure will be exhausted. At this point the pressure gauge reading will fall to zero. Note: The system charge pressures (cut-in, cut-out pressures) are pre-set and non-adjustable. If the pressures are found to be outside the given parameters, the charge valve will need to be replaced. Note: If you suspect the pressure depletion per full stoke of the brake pedal is excessive, or the minimum number of strokes before drop-off are not obtained, check the accumulator charge pressures and where necessary correct, (See K Charging the Accumulators ( T G-10)) before retesting the brake system.

G-6

9803/9420

G-6

Section G - Brakes Service Procedures Service Brakes

Brake Pressure Setting

Note: Use the following procedure to test and set the brake pressure if the heat shrink sleeving A, B has been removed.

Without changing the adjustment, disconnect the push rod from the pedal. Apply heat shrink sleeving as shown at B.

Re-check the pressure. Remove the test point and gauge.

!MDANGER Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone. If the articulation lock is not fitted you could be crushed between the two parts of the chassis. GEN-3-1_1

!MWARNING Before disconnecting any part of the brake hydraulic system, make sure that engine is switched off and hydraulic pressure is fully discharged. BRAK-3-1

!MWARNING A minimum of 10 applications of the service brake is possible from the stored accumulator pressure. Disconnect service brake accumulator hoses with extreme caution. BRAK-3-2

With the brake pedal fully up, check that there is a little free play between the brake push rod and the pedal assembly.

With the engine stopped and brake pressure released, connect a â&#x20AC;&#x153;Tâ&#x20AC;? adaptor at point C then connect a suitable pressure gauge (capable of reading 300 bar).

With the brake system operational, depress the brake pedal until the gauge shows the correct Operating Pressure. (See K Technical Data ( T G-1)). With the pedal held in this position, adjust pedal stop D to contact the pedal. Release and re-operate the pedal a few times, checking each time that the gauge reading does not exceed the stated operating pressure. Tighten the stop locking nut.

Apply heat shrink sleeving as shown at A.

G-7

9803/9420

G-7

Section G - Brakes Service Procedures Service Brakes

Fig 4.

G-8

9803/9420

G-8

Section G - Brakes Service Procedures Service Brakes

Bleeding the System

!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

Note: The braking systems are fed from the main hydraulic system and incorporate brake accumulators. These allow approximately nine applications of the brakes with the engine stopped. Bleed each axle separately as follows: – Attach a tube to the brake bleed screw, located near the axle centre. Ensure that the free end of the tube is immersed in fluid contained in a suitable container. – Open the brake bleed screw and fully depress the brake pedal. Hold the pedal fully depressed until air free fluid flow from the bleed screw. – Close the brake bleed screw with the pedal fully depressed. Repeat the procedure for the rear axle. Check the hydraulic fluid level.

G-9

9803/9420

G-9

Section G - Brakes Service Procedures System Accumulators

System Accumulators Charging the Accumulators For details on the identification of and charging procedures for the accumulators, please refer to Section E Hydraulics - ACCS - Accumulators.

G - 10

9803/9420

G - 10

Section G - Brakes Service Procedures Park Brake

Park Brake Adjusting the Park Brake 1

Disengage the park brake (lever horizontal).

Turn adjuster X clockwise, half a turn.

Test the park brake. Testing ( T G-15).

If the brake fails the test, repeat steps 1 to 3.

See

K Park

Brake

Note: If after completing the above steps, the park brake does not pass the testing procedure. K Adjusting the Cable Slack ( T G-12).

Fig 5.

G - 11

9803/9420

G - 11

Section G - Brakes Service Procedures Park Brake

Adjusting the Cable Slack 1

Parking brake lever with safety catch (K Fig 6. ( T G-12)). Turn adjuster X anti-clockwise to return pin Y to the bottom of the slot. Make sure that the lever is fully down against its stop at Z.

Loosen locknut A and remove pin B (at either end of the cable).

Screw in the clevis C only enough to remove the cable slack.

Refit pin B and tighten locknut A to 27 Nm (19.9 lbf ft).

Test the parking Testing ( T G-15).

If the brake fails the test, repeat steps 1 to 5.

brake,

see

K Park

Brake

Note: If the brake cannot be adjusted by adjusting the cable slack, replace the brake pads and/or the brake cable. Note: Operating arm D has three machined holed to accommodate pin B. It is MOST IMPORTANT that pin B is fitted ONLY to the CENTRE HOLE. Note: If the operating arm securing bolt E has to be removed it is MOST IMPORTANT that prior to removing the operating arm D its position on its splined shaft is carefully marked. The arm MUST be refitted in its ORIGINAL POSITION. Under NO CIRCUMSTANCES must the arms position in relation to its shaft be altered in an attempt to gain additional movement, as this could cause damage to or failure of the parking brake.

Fig 7.

Fig 6.

G - 12

9803/9420

G - 12

Section G - Brakes Service Procedures Park Brake

Renewing the Brake Pads Renew pads when thickness of friction material is 1mm (0.039 in). 1

Release brake and disconnect actuator from brake lever.

Slacken one and remove the other brake mounting bolt 1, washer 2 and nut 3 position brake to expose brake pads.

Use flat bladed screw driver to remove pads 4 and 5.

Note: Take care when removing pad from the plastic actuator cover. 4

Place pads in position.

Note: Centre hole in lever side pad snaps over tabs on actuator cover. Align pad with flat on rotor cover B. If tabs are broken dab pad adhesive on the back edge of the pad and press firmly into correct position. 5

Remove pad adhesive from pad compartment in pad carrier plate A.

Apply adhesive along back edge of pad carrier plate and press into place.

Push lever side pad as far as possible into the brake.

Position brake over disc, fit mounting bolt 1, washer 2 and nut 3 and torque both bolts to 119Nm (140 lb ft).

Attach cable to lever.

Adjust pad gap.

G - 13

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G - 13

Section G - Brakes Service Procedures Park Brake

Fig 8.

G - 14

9803/9420

G - 14

Section G - Brakes Service Procedures Park Brake Testing

Park Brake Testing Testing The Parking Brake

b Reduce the engine speed to idle and set the forward/ reverse lever (or switch) to neutral.

!MWARNING

Do not do this test for longer than 20 seconds.

Before testing the park brake make sure the area around the machine is clear of people.

Return the parking brake lever to the fully on position from its partially applied position.

Press SETUP key again to select park brake test off.

Lower attachment and stop the engine.

2-2-4-5

Test the brake on a level, dry surface. Make sure your seat belt is securely fastened. 1

The attachment should be in the travelling position.

Make sure the parking brake is fully engaged.

Switch off transmission dump.

Switch off Auto/Manual switch. a

If you have any queries concerning this test procedure or parking brake adjustment, consult your local JCB dealer.

On the EMS press the two arrow keys and the SETUP key at the same time, to select the AEB setup menu.

b Use the UP or DOWN arrows to select the park brake test menu. c 5

Note: If the machine moved during the test, see K Adjusting the Park Brake ( T G-11). Do not use the machine with faulty brakes.

!MWARNING Do not use a machine with a faulty park brake. 3-2-3-10_2

!MWARNING

Press SETUP key to select park brake test on.

Select third gear/range (3).

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

Push down hard on the brake pedal and select forward drive.

Parking Brake Transmission Disconnect Note: An audible alarm will sound and a warning light will show when the parking brake is engaged with the machine in forward (F) drive. The alarm will stop when neutral (N) drive is selected.

When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parking brake on.

!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

Release the brake pedal. a

G - 15

If the machine has not moved, use the accelerator pedal to gradually increase the engine speed to 1500rpm. The machine should not move.

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G - 15

Section G - Brakes Service Procedures Park Brake Testing Page left intentionally blank

G - 16

9803/9420

G - 16

Section G - Brakes

Brake Valves Foot Valve Removal and Replacement

!MDANGER

Replacement

Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone. If the articulation lock is not fitted you could be crushed between the two parts of the chassis. GEN-3-1_1

Refit the valve by reversing the removal sequence.

When connecting the foot pedal linkage, adjust clevis 3 to take up any slack in the valve push rod.

Note: If there are two holes in the brake pedal lever, connect the valve push rod to the upper hole. 3

Removal 1

Remove cap screws 2 and remove the valve from the bracket.

Park the machine on firm, level ground. Apply the parking brake and stop the engine. Securely chock all four wheels. Repeatedly apply and release the service brakes and parking brake until all the pressure in the accumulators is exhausted.

After refitting the valve, start the engine and wait for a few minutes until the accumulators are charged. Bleed the service brakes as described in K Bleeding the System ( T G-9).

!MWARNING Before disconnecting any part of the brake hydraulic system, make sure that engine is switched off and hydraulic pressure is fully discharged. BRAK-3-1

!MWARNING A minimum of 10 applications of the service brake is possible from the stored accumulator pressure. Disconnect service brake accumulator hoses with extreme caution. BRAK-3-2

Disconnect and blank all hydraulic hoses having first identified them to ensure correct replacement.

Identify then unplug the electrical connections from the three pressure switches.

Remove the clip 1 from the foot brake push rod assembly.

G - 17

9803/9420

Fig 9.

G - 17

Section G - Brakes Brake Valves Foot Valve

Dismantling and Assembly The valve may only be dismantled to renew seals. If any other part fails the complete valve must be renewed. Remove only sufficient components to gain access to the seals. Do not dismantle further. Two repair kits are available: one consists of all the seals and the other is a repair kit for the brake linkages and includes the necessary rubber gaiters. Key 1

Brake valve

Foot brake push rod assembly

Brake light switch

Transmission dump switch

Accumulator inlet adaptors (2 off)

Low pressure warning switch

Pilot valve adjuster

90Â° Adaptor (return to tank)

Tee adaptors (brake supply)

Adaptor (Pressure from pump)

Adaptor (Return to tank via loader valve)

Straight adaptors (2 off)

Seal washer (4 off)

Seal washer (M18)

Seal washer (5 off)

Adaptor (Return to tank)

G - 18

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G - 18

Section G - Brakes Brake Valves Foot Valve

Fig 10.

G - 19

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G - 19

Section G - Brakes Brake Valves Foot Valve Page left intentionally blank

G - 20

9803/9420

G - 20

Section G - Brakes

Park Brake Dismantling and Assembly Dismantling 1

Disconnect actuator cable and remove brake.

Remove friction pads 4 and 5.

Note: Before dismantling, mark the relative position of the lever 11-10 to the shaft. The lever MUST be refitted in the same position.

Install lever 10 making sure the small diameter of the spring 14 is piloted on the outside of the four pins in the lever.

Set the lever 10 in the 4 oâ&#x20AC;&#x2122;clock position.

Install washer 11 and anti rotation clip 12, with its tab inserted into the lower hole in the lever.

Insert screw 13 into rotor assembly shaft 6 and tighten to 12.4-15.8Nm (110-140 in.lbs.), while guiding lever 10 over rotor assembly spine.

Unbend anti-rotation clip 12, remove screw 13, clip 12, washer 11, lever 10 and spring 14.

Push out rotor assembly 6 from casting 9.

Bend up tab on the ant-rotation clip 12.

Remove 3 ball bearings 8.

Install the friction pads 4 and 5.

Only if shaft seal 15 requires replacement. Press out plastic shaft seal from casting using steel spacer block 27.38mm [1.078in} diameter by 63.5mm [2.5in] long and an arbor press.

Stroke lever 10 in the correct direction. The lever must rotate through 60 degrees of rotation. Return lever to 4 oâ&#x20AC;&#x2122;clock position and make sure the lever side friction pad 5, is fully returned.

Remove any plastic left in casting.

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G - 21

Note: Before assembly insure all parts are clean and serviceable

Assembly 1

Insert seal 15 into casting with extended smooth surface first. Using an arbor press with protective spacer block, gently press seal until it snaps into groove.

Grease ball pockets in casting 9, shaft and ball pockets of the rotor assembly 6.

Insert 3 ball bearings 8 and ball spacer 7 into the pockets in the casting 9.

From the inside of the casting 9, slide the shaft of the rotor assembly 6 through the shaft seal 15 and seat ball pockets against the ball bearings 8.

Place the spring 14 over the large diameter pilot on the outside of the casting 9.

G - 21

Section G - Brakes Park Brake Dismantling and Assembly

Fig 11.

G - 22

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G - 22

Section H Hydraulic Steering Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

Section H - Hydraulic Steering

Notes:

H-0

9803/9420-3

H-0

Section H - Hydraulic Steering Contents Page No. Technical Data General Data .......................................................................................... H - 1 Circuit Descriptions Steering Operations ................................................................................ H - 3 Emergency Steering System Description ................................................................................. H - 5 Hydraulic Steering Unit Dismantling and Assembly ..................................................................... H - 7 Steering Column Removal and Installation ...................................................................... H - 13 Steering Ram Removal and Installation ...................................................................... H - 17

H-i

Section H - Hydraulic Steering Contents

H - ii

Page No.

H - ii

Section H - Hydraulic Steering

Technical Data General Data Pump Supply from hydraulic K Pumps ( T F-99)

system.

Refer

Steering Valve Type

Eaton Steering Control Unit ABV.

Relief Valve Operating Pressure

bar

kgf/cm2

lbf/in2

Shock valve

176

180

2550

Ram Dimensions

Bore

3.1

Rod Diameter

2.0

Stroke

312

12.3

H-1

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H-1

Section H - Hydraulic Steering Technical Data General Data Page left intentionally blank

H-2

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H-2

Section H - Hydraulic Steering Circuit Descriptions Steering Operations

Circuit Descriptions Steering Operations General Description

Steering Valve - Operation

Steering is hydraulically controlled. Two rams, one either side of a centre pivot articulate the front chassis in the required direction.

Fitted as an extension of the steering column, the steering valve SV comprises a housing SV1 incorporating a sleeve SV2 that contains a spool SV3. Attached beneath the housing is a metering unit SV4. Within the metering unit is a lobed rotor SV5 that is attached to the spool and driven by it inside a stator SV6 formed by the unit casing.

Hydraulic oil is delivered from the pump via a steering priority valve to the steering valve. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority valve spool. The spool moves and directs pressurised oil from the pump to the steering valve and then the steering rams. Pressurised oil enters the ram cylinders (rod side first ram and head side second ram) and causes the rams to extend or retract to turn the machine in the required direction. A pressure relief valve is fitted to guard against shock steering loads. A gearbox driven emergency steer pump may be fitted which provides pressure for steering in the event of hydraulic pump or engine failure. Instructions for removal and refitting of this pump are given in Section F Transmission.

Pressure oil is supplied to the steering valve by way of the steering priority valve PV. With the wheel stationary the spool is held in a closed centre position within the sleeve by spring action. Output from the pump is 'dead ended' and the load sensing port to the priority valve is connected to exhaust. When actuated by the steering column, the spool turns within the sleeve, oil galleries are aligned and a demand pressure signal is sent to the priority valve. Pressure oil directed to the steering valve is routed through the sleeve and spool to the metering unit. The rotor is also being turned by the steering column and interaction between rotor and stator lobes pumps oil out to the steering rams to achieve steering action. With the main pump inoperative, or the engine stopped but the machine still moving, hydraulic steering supply is maintained by a gearbox driven emergency pump, see K Steering Operations ( T H-3). In the unlikely event of failure of both the main and emergency pumps, the supply line is closed by a spring assisted non-return valve. Turning the steering wheel rotates the spool further until the sleeve is mechanically engaged. The sleeve is turned and routes oil to the meter unit which is also being turned, this pumps oil to the rams under manual pressure. Manual operation is supplemented by oil exhausted from the opposite side of the rams which now has sufficient pressure to lift the nonreturn valve and cross connect the pressure and exhaust systems.

H-3

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H-3

H-4

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H-4

Steering Operations

Circuit Descriptions

Section H - Hydraulic Steering

Fig 1.

Section H - Steering

Emergency Steering System Description General

A switch is provided in the cab for the manual testing of the system.

The emergency steering is an electronically driven pump controlled by the EMS system. If the EMS system detects a drop in the hydraulic pressure, at a preset level the EMS will switch on the emergency steering pump. The system self tests every time the ignition is turned on and will disable the machines starting system if a fault is detected.

The pump and motor are mounted on a bracket attached to the rear chassis flange. The system consists of a cab switch, low pressure sensor, pump A, motor B, in-line 100A fuse link C, solenoid D, system pressure test point E, pressure adjusting screw F and system at pressure switch J.

Fig 2.

H-5

9803-9420-3

747-680-1

H-5

Section H - Steering Emergency Steering System Description Page left intentionally blank

H-6

9803-9420-3

H-6

Section H - Hydraulic Steering Hydraulic Steering Unit Dismantling and Assembly

Hydraulic Steering Unit Dismantling and Assembly

Fig 3.

H-7

9803/9420

H-7

Section H - Hydraulic Steering Hydraulic Steering Unit Dismantling and Assembly

Dismantling Use the numerical sequence on K Fig 3. ( T H-7) as a guide to dismantling. Before removing items 3-11 to 3-14, rotate the spool and sleeve assembly within the housing until the pin 3-21 is horizontal. Push the spool and sleeve assembly from the housing just far enough to free the gland bushing 3-11.

Inspecting Examine all contact surfaces and replace any parts that have scratches, wear or other damage that could cause leakage. Do not use abrasive or try to file or grind the surfaces. Clean all metal parts with a solvent and blow dry with air.

Assembling 1

Assemble the check valve Lower check ball retainer 4-20 into the housing. Make sure the retainer is straight in the valve hole and not on its edge. Fit check ball 4-19 into housing. Lubricate and fit O rings (4-A 11.1 mm (5/8 in.) 4-B 15.9 mm (7/ 16 in.)) to check seat 4-18. Install check valve seat 418 into the housing open end first; push the seat fully into the housing taking care not to twist and damage the O-rings. Fit the set screw 4-17 and tighten to 11 Nm (8.1 lbf ft2).

Fig 4. 2

Assemble the spool and sleeve Assemble the spool 5-23 and sleeve 5-24 so that on completion the spring slots 5-A line up at the same end. Rotate the spool when sliding the parts together and test for free rotation.

Note: When fitted the top of the set screw should be slightly below the housing top surface.

Fig 5.

H-8

9803/9420

H-8

Section H - Hydraulic Steering Hydraulic Steering Unit Dismantling and Assembly 3

Fit the spring assembly Make sure the spring slots are lined up and insert the spring installation tool (Eaton part number 60057) through the slots. Assemble a set of low torque springs 6-22, extend edge downward, with a pair of spring spacers 6-B between two sets of centering springs 6-C. Insert one end of the spring set into the installation tool. Compress protruding springs and push set into the slot at the same time withdraw the installation tool. Centre the spring set in the spool and sleeve assembly so that they push down evenly and are flush with the upper surface of the assembly. Fit pin 6-21 to the assembly making sure it is flush both sides of the sleeve 6-24. Fig 7. 5

Fit the drive end seals a

Place the housing 3-25 upright on a clean lint free cloth. Lubricate all seals before assembly. Fit seals 8-16 and the bearing race components 8-14 into the housing.

Fig 6. 4

Installing the spool and sleeve assembly Position the spool and sleeve assembly so that the splined end of the spool enters the valve housing as shown. Push the assembly gently into place with a slight rotating action until the parts are flush at the insertion end face 7A. Check for free rotation of the spool and sleeve assembly within the housing by applying finger tip force to the spool splined end. Fig 8.

Note: Do not move the spool and sleeve assembly beyond the flush position because the pin 6-21 may drop into the housing discharge groove.

H-9

9803/9420

b Assemble the Teflon seal components 9-13 (seal 9-A, 'O' ring 9-B and back up ring 9-C) above the bearing race 9-14.

H-9

Section H - Hydraulic Steering Hydraulic Steering Unit Dismantling and Assembly

Fig 10. 6 Fig 9. c

Fit the dust seal 10-12, flat smooth side down, into the gland bushing 10-11. Assemble the gland seal bushing over the splined end of the spool 10-15 and tap the bushing into place with a soft faced hammer, making sure the bushing is flat against the bearing race. Fit the retaining ring 10-10 pressing it into position around the spool sleeve 10-24 with a screwdriver blade.

Fitting the meter end seal and drive Insert seal 11-9 into housing 11-25. Fit spacer plate 11-7 together with its seal 11-8 and align with housing bolt holes. Rotate the sleeve and spool assembly 1115 until it is seen that the pin 11-21 is parallel with face 11-A. Fit the drive 11-6 making sure it is fully engaged with the pin. Mark the drive head as shown at 11-B.

Fig 11.

H - 10

9803/9420

H - 10

Section H - Hydraulic Steering Hydraulic Steering Unit Dismantling and Assembly 7

Time and fit the meter Fit seal 12-4 into the groove on the meter 12-3. Position the meter so that the seal is away from the housing 12-25 and align the meter valleys as shown at 12-C. Reference lines 12-A, 12-B and 12-C should be parallel. Fit the meter over the drive head 12-6 and align the bolt holes without disengaging from the drive.

Fig 13.

Fig 12. 8

Fit and secure the end cap Fit any drive spacers 13-5 that are required. Locate the end cap 13-2 over the meter and align the bolt holes. Fit seven cap screws 13-1 and pre tighten to 17 Nm (12.5 lbf ft). Finally, viewed from face 13-A torque tighten the screws to 31 Nm (22.9 lbf ft) in the sequence shown.

H - 11

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H - 11

Section H - Hydraulic Steering Hydraulic Steering Unit Dismantling and Assembly Page left intentionally blank

H - 12

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H - 12

Section H - Steering

Steering Column Removal and Installation Removal

At the rear of the steering column, remove the screws T (x4) from the upper shroud U.

Adjust the position of the column switch gaiters Z.

Remove the upper shroud U.

Remove the securing plate F.

Remove the tilt adjustment lever G from the steering column.

Remove the switch X securing screws (x2) from the steering column.

Remove the lower shroud securing screws V (x2).

Remove the lower shroud W.

Remove the EMS unit AA.

Disconnect the electrical connectors from the rear of the EMS unit AA.

Remove the nut and the buzzer AH.

Remove the EMS housing nuts AI and washers (x4).

Remove the EMS housing AJ and move the electrical connectors through the slot.

Remove the screws (x2) from the switch panel AB.

Adjust the position of the switch panel AB to disconnect the electrical connectors from the rear.

Remove the screws (x3) from the right hand trim panel AC.

Remove the screws (x3) from the left hand trim panel AD.

Lift the floor mat and remove the screw from the left side of the front trim panel AF.

Move the electrical connectors through the slot in the front trim panel.

9803-9420-3

H-13

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Install the articulation strut A.

Fig 1.

P002110

Remove the centre plate B from the steering wheel.

Mark the position of the steering wheel C and the steering column to help with the installation procedure.

Remove the securing nut D and washer E.

Remove the securing screws Y (x4).

H-13

Section H - Steering Steering Column Removal and Installation 26

Remove the front trim panel AF.

Remove the securing pins K (x2).

Remove the steering column clamp bolt Q and nut R.

Put a mark on the steering column AG and flexi coupling S to help with the installation procedure.

Remove the securing clips J (x2). 31

Remove the steering column assembly AG.

AA AH

T AI

V W

RPM

40 30 50

SETUP SELECT

MANUAL

km/h mph

- +

Z AD

AC AE AF

Fig 2.

H-14

9803-9420-3

P005750

H-14

Section H - Steering Steering Column Removal and Installation

C B D E AG

F H G

J K S L M N

R P Fig 3.

H-15

9803-9420-3

P005760

H-15

Section H - Steering Steering Column Removal and Installation

Installation The installation procedure is the opposite of the removal procedure. 1

Make sure to align the column AG and flexi coupling S marks. Also align the marks on the steering wheel C and column AG.

Torque tighten the steer valve bolts A to 43 Nm.

Torque tighten the flexi coupling securing bolts B to 43 Nm.

Torque tighten the column clamp bolt C to 43 Nm.

A P005780

Fig 4. 5

Torque tighten the steering wheel nut D to 50 Nm.

Fig 5.

H-16

P005790

9803-9420-3

H-16

Section H - Steering

Steering Ram Removal and Installation Removal

Put a container below the steering ram G to collect the hydraulic fluid.

Make the machine safe with the loader arms lowered. Refer to Prepare the Machine for Maintenance, Routine Maintenance.

Install the blanking caps onto the hydraulic hoses B to prevent contamination and excessive fluid loss.

Install the articulation strut A.

Support the steering ram G.

Remove the securing bolt C and washer D from the front pivot pin E.

Remove the pivot pin E from the bottom. Make sure to keep the shims F.

Do the steps 8 - 10 at the rear of the steering ram G.

Remove the steering ram G from the machine.

Fig 1.

P002110

When the pressure is released, do not operate the starter switch as this may pressurise the steering system.

Attach labels to the hydraulic hoses B. (To help install the steering ram G).

Disconnect the hydraulic hoses B.

H-17

9803-9420-3

H-17

Section H - Steering Steering Ram Removal and Installation

B E B

Fig 2.

P005890

Installation The installation procedure is the opposite of the removal procedure. 1

Examine the shims F, replace if worn or damaged.

Check the level of the hydraulic oil, add as necessary.

Check the steering ram G and hydraulic hoses B for leaks.

H-18

9803-9420-3

H-18

Section K Engine Section 1 - General Information Section 2 - Care and Safety Section 3a - Routine Maintenance Section 3b - Routine Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine

Publication No.

9803/9420-3

Section K - Engine

Notes:

K-0

9803/9420-3

K-0

Section K - Engine Contents Page No. Technical Data 434S from Serial No. 124400 ................................................................. K - 1 435S ....................................................................................................... K - 2 Troubleshooting Possible faults ........................................................................................ K - 3 Engine and Transmission Removal and Installation ........................................................................ K - 9 Sump Drain Plug 435S Machines ..................................................................................... K - 15 Aftertreatment System (435S Machine) Introduction ........................................................................................... K - 17 Removal and Installation ...................................................................... K - 18 Clean .................................................................................................... K - 20

K-i

Section K - Engine Contents

K - ii

Page No.

K - ii

Section K - Engine

Technical Data 434S from Serial No. 124400 Type

QSB6.7/SO 75928 Tier 3 434S from Serial No. 124400

Bore

Info not available

Stroke

Info not available

Cylinder Capacity

6.7 litre

Gross Power Output at 2200 rev/min

220 hp (164 Kw)

Compression Ratio

17.2: 1

Idling Speed

850 ± 25 rev/min

Rated Speed (Full Load)

2200 rev/min

Max. No-Load Speed

2430 rev/min

Max. Net Torque at 1500 rev/min

949 Nm

Fuel System Injection Pump Type

Bosch CP3.3 common rail

Governing

Electronic

ISOSetting Code

N/A

Injection Timing

Electronic

Induction System Air Cleaner Type

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

Restriction Indicator

Vacuum switch on air cleaner inlet

Lubrication System Oil Pump Type

Concentric gear

Oil Pressure at maximum rated speed

55.1 psi @ 2200 rev/min

Oil Pressure at idle speed

10 psi (0.7 bar) @ 850 ± 20 rev/min

Oil Capacity With Filter

17.5 litre

Cooling System Coolant Pressure Cap Setting

15 psi (1.03 bar) max

Coolant Temperature (Normal)

82 ºC - 110 ºC (179 - 203 ºF)

Thermostat Opens at

88 ºC

Thermostat Fully Open at

96 ºC

Capacity

35 litre (7.7 UK gal)

K-1

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K-1

Section K - Engine Technical Data 435S

435S Type

QSB 6.7 Tier 4i 435S

Bore

107mm (4.21in)

Stroke

124mm (4.88in)

Cylinder Capacity

6.7 litre

Gross Power Output at 2200 rev/min

220 hp (164 Kw)

Compression Ratio

17.2: 1

Idling Speed

700 +/-20 rev/min

Rated Speed (Full Load)

2200 rev/min

Max. No-Load Speed

2430 rev/min

Max. Net Torque at 1500 rev/min

945 Nm

Fuel System Injection Pump Type

Bosch HP Common Rail

Governing

Electronic

ISOSetting Code

N/A

Injection Timing

Electronic

Induction System Air Cleaner Type

2 stage, dry element

Maximum Air Cleaner Restriction

635 mm (25 in) H2O

Restriction Indicator

Vacuum switch on air cleaner inlet

Lubrication System Oil Pump Type

Concentric gear

Oil Pressure at maximum rated speed

55.1 psi @ 2200 rev/min

Oil Pressure at idle speed

10 psi (0.7 bar) @ 850 ± 20 rev/min

Oil Capacity With Filter

17.5 litre

Cooling System Coolant Pressure Cap Setting

15 psi (1.03 bar) max

Coolant Temperature (Normal)

82 ºC - 110 ºC (179 - 203 ºF)

Thermostat Opens at

88 ºC

Thermostat Fully Open at

97 ºC

Capacity

35 litre (7.7 UK gal)

K-2

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K-2

Section K - Engine

Troubleshooting Possible faults Stop the engine immediately when:

– The colour of the exhaust fumes suddenly darkens – The oil pressure indicator light comes on while the engine is running

– The engine RPMs suddenly increase and decrease – A sudden and unusual noise is heard Table 1. Fault

Possible Cause

The engine does not start

No fuel Discharged battery Cable connections are uncertain or incorrect Tank cap vent hole is clogged Fuel filter is clogged Air or water leaks in the fuel system Blocked fuel line Defective fuel feeding pump Defective starting motor Defective glow plugs Burnt fuse on the pre-heating glow plugs Defective glow plug control relay Defective starting switch Broken or loose supplementary start-up spring Incorrect tuning of the injection components Governor linkage is incorrectly set Binding of the injection pump control rod Rings are worn or sticking Incorrectly sealed intake valve Worn cylinder

K-3

9803-9420-3

K-3

Section K - Engine Troubleshooting Possible faults Fault

Possible Cause

Engine starts but stops suddenly

Damaged cylinder head-gasket No fuel Idle is too low Blocked fuel filter Fuel cap vent is blocked Water or air in the fuel system Blocked fuel line Blocked air filter Broken or disconnected governor spring Defective fuel pump Binding of the injection pump control rod

Poor acceleration

Overloaded Blocked air filter Defective fuel feeding pump Hardened pump control rod Air filter is clogged Fuel filter is clogged Tank cap vent hole is clogged Governor spring broken or unhooked Air or water leaks in the fuel system Incorrect tuning of injection components

Unsteady speed

Low idle speed Oil level is too high Blocked fuel line Air or water leaks in the fuel system Fuel filter is clogged Defective fuel feeding pump Injector is not adjusted Damaged injector Injection pump valve is damaged Incorrect tuning of the injection components Hardened pump control rod Governor linkage is incorrectly set Cracked or broken pre-combustion chamber Air filter is clogged

K-4

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K-4

Section K - Engine Troubleshooting Possible faults Fault

Possible Cause

Black smoke

Overloaded Injector is not adjusted Oil sump suction line is clogged Air in the oil suction line Worn oil pump Cracked or broken pre-combustion chamber Oil sump draining pipe is clogged Incorrect tuning of the injection components Worn or damaged pumping element

White smoke

Excessive idle operation Incomplete run-in Air or water leaks in the fuel system Oil level is too high Injector is not adjusted Damaged injector Injection pump valve is damaged Incorrect tuning of injection components Defective glow plugs Defective thermostatic valve Worn cylinder Rings are worn or sticking

Low oil pressure

Defective pressure gauge or pressure switch Oil sump suction line is clogged Air in the oil suction line Oil pressure by-pass valve are blocked or dirty Worn oil pump Worn main connecting rod-rocker arm bearings Insufficient coolant

K-5

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K-5

Section K - Engine Troubleshooting Possible faults Fault

Possible Cause

Engine overheats

Defective fan, radiator or radiator plug Defective thermostatic valve Coolant leaking from the radiator, hoses, crankcase, or water pump Blockage inside the radiator or coolant ducts Defective or worn water pump Overloaded Oil level is too high Air in the oil suction line Injector is not adjusted Incorrect tuning of the injection components Oil sump suction line is clogged

Inadequate performance

Air or water leaks in the fuel system Tank vent hole is clogged Oil level is too high Oil level is low Defective fuel feeding pump Damaged injector Injector is not adjusted Hardened pump control rod Incorrect tuning of the injection components Worn or damaged pumping element Injection pump valve is damaged Governor linkage is incorrectly set Air in the oil suction line Oil sump suction line is clogged Worn oil pump Defective hydraulic tappets

Excessive oil consumption

Alternator fan belt is loose or torn Radiator exchange surface is clogged Defective spray nozzles (turbo engines only) Incorrectly sealed intake valve Worn cylinder Worn main con. rod-rocker arm bearings Damaged cylinder head gasket Damaged injector

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Section K - Engine Troubleshooting Possible faults Fault

Possible Cause

High engine noise

Injection pump valve is damaged Worn or damaged pumping element Cracked or broken pre-combustion chamber Rings are worn or sticking Cracked or broken pre-combustion chamber Air filter is clogged Incorrect tuning of the injection components Defective hydraulic tappets Defective timing system Damaged cylinder head gasket

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Section K - Engine Troubleshooting Possible faults Page left intentionally blank

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Section K - Engine

Engine and Transmission Removal and Installation Removal

Remove the Engine, Transmission and Pump 1

Make the machine safe.

Install the articulation strut A.

Remove the centre undershield. Refer Undershield, Removal and Installation.

Important: The air conditioning system is a closed-loop system and contains pressurised refrigerant. Do not disconnect any part of the system until a refrigeration engineer or a trained person discharges the system. You can be severely frostbitten or injured by escaping refrigerant. Important: Do not operate the air conditioning system when there is no refrigerant in the system. This will damage the compressor. 10

Disconnect the electrical connector from the gear pump.

Disconnect the hydraulic hoses B from the pump.

P002110

Fig 1.

Disconnect the battery cables.

Chock the wheels.

Remove the cab. Refer to Cab Removal and Installation.

Remove the rear bodywork. Refer Bodywork, Removal and Installation.

Drain the cooling system. Refer to Cooling Draining.

Remove the propshafts. Refer to Propshafts, Removal and Installation.

K-9

P010840

Fig 2. 12

Disconnect the hoses C from the emergency steer pump.

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K-9

Rear

Section K - Engine Engine and Transmission Removal and Installation

L K

C C P010870

Fig 5. 19

Disconnect the air-conditioning hoses M from the air compressor N.

P010850

Fig 3. 13

Loosen the clip D and disconnect the suction hose E from the main hydraulic pump.

Remove the flange bolts F and disconnect the hoses G from the main hydraulic pump.

Disconnect the hoses H from the main hydraulic pump.

Disconnect the electrical connector I from the main hydraulic pump.

G H P010880

Fig 6.

I 20

Disconnect the cooler hoses O from the transmission.

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K-10

F H D E

P010860

Fig 4. 17

Disconnect the hose J from the fuel filter assembly L.

Remove the bolts K (x4), then remove the fuel filter assembly L from the machine.

K-10

Section K - Engine Engine and Transmission Removal and Installation 25

Remove the engine mounting bolts S, nuts T and spacers U (x 2) from the front of the engine.

O S

U T

P010940

Fig 7.

P010950

Disconnect the cables from the starter motor.

Remove the bolt P, then disconnect the engine earth cable Q from the chassis.

Attach suitable lifting equipment to the engine and transmission lifting eyes and support the engine.

Note: Make sure that all the connectors are released.

Remove the engine mounting nuts and bolts R from the rear of the engine.

Fig 9. Carefully lift the engine and transmission assembly from the machine.

Q P R

R P010890

Fig 8.

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Section K - Engine Engine and Transmission Removal and Installation Separate the Transmission, Engine and Pump Assembly 1

Mount the engine/transmission and pump assembly on a suitable stand.

Support the weight of the transmission K.

Remove the bolts J (x12).

Remove the transmission K from the engine.

Support the pump C and remove the mounting bolts A (x4) and washers B (x4).

Remove the pump C from the transmission system.

H J

A B

P010960

Fig 10. 4

Remove the bolts D, cover plate E and the plastic cover F.

P010920

Fig 12. Note: Use a suitable tool to turn the flywheel to get access to the components. 5

Remove the flywheel to flexi-coupling bolts G (x4) through the cut-out in the casing.

F G

D E P010910

Fig 11. 6

Remove the bolts H and attach the lifting eye I to the transmission casing. Tighten the bolts H to the torque of TBA Nm.

Attach suitable lifting equipment to the three lifting eyes I.

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Section K - Engine Engine and Transmission Removal and Installation

Installation

Note: Make sure to install the clips in the correct locations and phase.

Connect the Transmission, Engine and Pump Assembly

Connection is reverse of the separation procedure.

Tighten the flexi coupling bolts A (x4) to the torque of 44 Nm.

Remove the lifting eye D, then install and torque the bolts E. Refer to Section 1, Standard Torque Settings.

D E C

P010970

Fig 13. P010990

Tighten the pump mounting bolts B (x4) to the torque of 98 Nm.

Fig 15.

P010980

Fig 14. 4

Tighten the bolts C (x12) that attach the transmission housing to the engine to the torque of 43 Nm.

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K-13

Section K - Engine Engine and Transmission Removal and Installation Install the Engine and Transmission 1

Installation is the reverse of removal procedure.

Inspect the engine mount rubbers for damage or wear, replace if necessary.

Make sure to connect all the hoses, pipes and cables correctly.

Replace the hydraulic hose O-rings and seals.

Check and top-up if necessary the hydraulic fluid, engine oil, transmission oil and coolant.

Prime the fuel system.

Recharge the air-conditioning system and check for leaks.

D P011010

Fig 17. 8

Tighten the engine mounting bolts A/B to the torque of 360 Nm and nut C to 50 Nm.

B C P011000

Fig 16. 9

Tighten the engine mounting bolts D to the torque of 205 Nm.

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Section K - Engine

Sump Drain Plug 435S Machines 1

Drain Valve

Drain Hose.

Torque the drain valve 1 to 27 Nm.

1 1 333/u1674-4

Fig 18.

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Section K - Engine Sump Drain Plug 435S Machines Page left intentionally blank

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Section K - Engine Aftertreatment System (435S Machine) Introduction

Aftertreatment System (435S Machine) Introduction The materials captured in a Diesel Particulate Filter (DPF) are hazardous. The DPF must be returned to a Cummins Authorized Repair Location to be cleaned, replaced or exchanged.

The DPF weighs more than 23kg [50lb]. To prevent serious injury, make sure you have help or use the applicable lifting equipment to lift the DPF or the aftertreatment system. During the regeneration process the exhaust gas temperatures can reach 8000C (15000F) and the surface of the exhaust system can exceed 7000C (13000F). You must wait for the system to cool before you start work.

The diesel oxidation catalyst elements contained in this section are made of brittle material. Do not drop or knock the side of the aftertreatment system as this can cause damage.

I H

A D

B E G D C 333-T2158

Fig 19. A

Inlet section (contains the diesel oxidation catalyst)

Band clamp (for the mounting bracket F)

DPF section

Mounting bracket (for the differential sensor)

Outlet section

Band clamps (for the lift hooks)

Band clamps (to secure the three sections)

Lift hooks

Inlet pipe

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K - 17

Section K - Engine Aftertreatment System (435S Machine) Removal and Installation

Removal and Installation Removal

clearance for the overlapping canister sections not to come into contact with each other.

Make the machine safe. Refer to Section 3, Prepare the Machine for Maintenance.

Remove the DPF from the machine.

Disconnect the batteries. Refer to Section 3, Battery

Remove and discard the gaskets from the inlet and outlet sections.

Wait for the machine and the DPF to cool.

Open the engine covers.

Loosen the retaining-nut, then remove the exhaust gas temperature sensor J from the DPF.

Put a block of wood below the DPF B on the engine to help support its weight.

Loosen the nuts on the differential pressure sensor tubes K, then remove the tubes from the DPF.

To help align the three aftertreatment sections during the installation procedure, draw an orientation reference line across:

To help align the differential pressure sensors during the installation procedure, mark the direction of the ports of the differential pressure sensor on the DPF.

Loosen the nut on the band clamp E of the mounting bracket F for the differential pressure sensor.

Remove the mounting bracket and its band clamp from the DPF.

Loosen the nuts on band clamps G of the lift hooks H.

Remove the lift hooks and their band clamps from the DPF.

each of the band clamps.

b the three aftertreatment sections c 7

the connection points to the tail-pipe.

Disconnect the electrical connector from the DPF temperature sensor interface-module.

Disconnect the electrical connector from the DPF differential pressure sensor.

Disconnect the diesel oxidation catalyst (exhaust gas temperature sensor) connector from the DPF temperature sensor interface-module.

The DPF is heavy, get a second person or the applicable lifting equipment to help with the removal.

Disconnect the inlet pipe I.

Apply thread lubricant to the threads of the band clamps D.

Loosen the nuts on the band clamps D. Do not use a compressed air tool to loosen the nuts, as this will damage the threads.

Remove the band clamps from the inlet and outlet flanges of the DPF.

The inlet A and the DPF B sections have an interlock design. Separate the sections by at least 51mm [2in.] in the axial direction to give enough clearance for the overlapping sections not to come into contact with each other. Any contact can cause damage to the insulation and/or the body joints.

333-T2158-1

Fig 20.

333-T2158-2

Fig 21.

Separate the DPF B and the outlet C sections by at least 51mm [2in.] in the axial direction to give enough

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Section K - Engine Aftertreatment System (435S Machine) Removal and Installation

Installation

Put the differential pressure sensor mounting bracket F and band clamp E in position on the DPF B, then loosely install its nut.

Make sure the gaskets are aligned correctly before the band clamps are positioned over the beaded joints.

Apply a layer of anti-seize compound to the threads of the band clamps.

Apply a layer of anti-seize compound to the threads of the mounting bracket F.

The DPF B is heavy, get a second person to help with the installation.

Apply a layer of Loctite copper or silver anti-seize compound or the equivalent, to the threads on the differential pressure sensor tubes.

Put the DPF in position.

Do not let the Loctite enter the inside of the differential pressure sensor tubes, this can cause a blockage.

Note: To prevent any insulation damage, carefully move and position the DPF to prevent any misalignment during its installation onto the diesel oxidation catalyst.

The minimum Loctite anti-seize temperature range specification is 8700C [16000F].

Loosely tighten the band clamps D to hold the DPF B in position.

Note: Before nuts on the differential pressure sensor tube are tightened, make sure the tubes do not touch each other or any other machine components.

Make sure the aftertreatment system is aligned correctly so that the differential pressure sensor is installed in the position recorded during its removal.

Install the differential pressure sensor tubes K.

Tighten the band clamps to secure the DPF in position. Torque to 20Nm (177in-lb).

If necessary, install the p-clip or the tube clamp that holds the exhaust gas filter pressure sensor tube on the aftertreatment system.

Connect the inlet pipe I.

Gently tap around the circumference of the band clamps with a rubber mallet to make sure the band clamps are installed correctly.

Tighten the nut on the upstream differential pressure sensor tube. Torque to 31Nm (23ft-lb).

Tighten the nut on the downstream differential pressure sensor tube nut. Torque to 17Nm (150in-lb).

Tighten the band clamps again. Torque to 20Nm (177in-lb).

If necessary, tighten the p-clip or the tube clamp bolt. Torque to14Nm (124in-lb).

Connect the diesel oxidation catalyst (exhaust gas temperature sensor) connector to the DPF temperature sensor interface-module.

Align, then tighten the differential pressure sensor mounting bracket F. Torque to 7Nm (62in-lb).

Connect the electrical connector to the DPF differential pressure sensor.

Apply a layer of Loctite copper or silver grade antiseize compound or the equivalent, to the thread on the exhaust gas temperature sensor J.

Connect the electrical connector to the DPF temperature sensor interface-module.

Install the exhaust gas temperature sensor.

Connect the batteries.

Tighten the retaining-nut that secures the sensor J to the DPF. Torque to 30Nm (22ft-lb).

Operate the engine at peak system load for five minutes to make sure the aftertreatment system operates correctly.

Put the lift hooks H with their band clamps G in position on the DPF B.

Check the system for leaks.

Tighten the band clamps to secure the lift hooks in position. Torque to 7Nm (62 in-lb).

Install the new gaskets on the inlet and outlet sections of the DPF.

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Section K - Engine Aftertreatment System (435S Machine) Clean

Clean All of the maintenance and the cleaning of the DPF must be done by a Cummins Authorized Repair Locations and personnel. The DPF is not 100 percent efficient. Some accumulation of the exhaust residue/soot is normal and does not indicate a malfunctioning DPF. A heavy accumulation of the exhaust residue/soot can indicate a malfunctioning DPF. If the DPF is being replaced because of black smoke and the exhaust stack has a heavy accumulation of black soot, clean the last 152 to 254mm (6 to 10in.) of the exhaust system outlet. If the DPF is being replaced because of progressive damage from the engine oil or fuel, clean the tail-pipe from the turbocharger outlet to the diesel oxidation catalyst. Remove any residual gasket material from the flanges on the DPF with a scraping tool. Do not: – Steam clean the inlet of the diesel oxidation catalyst. – Use a grinder to remove residual gasket material as this may damage the flange and cause the connection to leak. – Use an open flame to remove any accumulation of soot from the face of the DPF. – Scrape off any accumulation of soot from the face of the DPF. – Drop pieces of gasket material into the DPF. Examine the: – DPF body joint insulation for visible wear at the DPF inlet and outlet. Replace the DPF if there is excessive fraying or cuts. – Band clamps and mounting straps for signs of overextension. The band clamp must not be bent or damaged. – Lift hook straps for cracks, damaged threads or bends. Replace a damaged lift hook strap. – DPF, replace a cracked or damaged DPF.

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