JCB 506-36, 507-42, 509-42, 510-56, 512-56, 514-56, 516-42 Loadall Service Manual – PDF Download by www.heydownloads.com

Service Manual 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813/1800-2

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

Section 1 General Information Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813/1800-2

Section 1 - General Information

Notes:

1-0

9813/1800-2

1-0

Section 1 - General Information Contents Page No. Applications Introduction ............................................................................................. 1-1-1 Tables ..................................................................................................... 1-1-2 Use Introduction ............................................................................................. 1-2-1 Scope ..................................................................................................... 1-2-2 Format .................................................................................................... 1-2-3 Left and Right Sides ............................................................................... 1-2-4 Hydraulic Schematic Codes ................................................................... 1-2-5 Machine Identification Introduction ............................................................................................. 1-3-1 Related Topics ........................................................................................ 1-3-2 Machine Identification Plate .................................................................... 1-3-3 Component Identification Plates ............................................................. 1-3-7 Torque Settings Introduction ............................................................................................. 1-4-1 Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-4-2 Hydraulic Connections ............................................................................ 1-4-6 `Positional Type' Hydraulic Adaptors .................................................... 1-4-10 Service Tools Introduction ............................................................................................. 1-5-1 Numerical List ......................................................................................... 1-5-2 Tool Detail Reference ............................................................................. 1-5-5 Rivet Nuts ............................................................................................. 1-5-27 Slide Hammer Kit .................................................................................. 1-5-29 Service Consumables Introduction ............................................................................................. 1-6-1 Sealing and Retaining Compounds ........................................................ 1-6-2 Fuel Introduction ............................................................................................. 1-7-1 Related Topics ........................................................................................ 1-7-2 Acceptable and Unacceptable Fuels ...................................................... 1-7-3 Stall Speed Combinations Introduction ............................................................................................. 1-8-1 Related Topics ........................................................................................ 1-8-2 Specifications ......................................................................................... 1-8-3

1-i

Section 1 - General Information Contents

1-ii

Page No.

1-ii

Section 1-1 - General Information

Applications Introduction This manual contains topics that relate to some or all JCB Machine Group Loadall machines in the 5C group. There are several machine 5C model codes in the family. 5C

Model Code

Model Name

506-36

507-42

509-42

510-56

512-56

514-56

Machine variants: There are different machine variants within the same model name. This happens because of market requirements, or when the machine specification changes after a period of time. Use the applications tables to see which topics relate to which machine models and variants. Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models Note: For full details of machine identification refer to Section 1 - Machine Identification. K Tables ( T 1-1-2) K Section 1 - General Information ( T 1-1-2) K Section 2 - Care and Safety ( T 1-1-2) K Section 3 - Routine Maintenance ( T 1-1-3) K Section B - Body and Framework ( T 1-1-3) K Section C - Electrics ( T 1-1-4) K Section E - Hydraulics ( T 1-1-5) K Section F - Transmission ( T 1-1-7) K Section G - Brakes ( T 1-1-8) K Section H - Steering ( T 1-1-9) K Section K - Engine ( T 1-1-10) K Section M - Electronic Data Systems ( T 1-1-11)

1-1-1

9813/1800-2 (1-14-08)

1-1-1

Section 1-1 - General Information Applications Tables

Tables Section 1 - General Information Machine models Topic Ref

Title

Variant

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

1-2

Use

All Machines

1-3

Machine Identification

All Machines

1-4

Torque Settings

All Machines

1-5

Service Tools

All Machines

1-6

Service Consumables

All Machines

1-7

Fuel

All Machines

1-8

Stall Speed Combinations

All Machines

Section 2 - Care and Safety Machine models Topic Ref

Title

2-1

Safety Notices

All Machines

2-2

General Procedures

All Machines

1-1-2

Variant

9813/1800-2 (1-14-08)

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

1-1-2

Section 1-1 - General Information Applications Tables

Section 3 - Routine Maintenance Machine models Topic Ref

Title

3-1

Maintenance

Variant

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ All Machines

Section B - Body and Framework Machine models Topic Ref Title

VARIANT

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

Cab Heating and Ventilation SYSTEM

Cab Air Conditioning SYSTEM

Cab

Air Conditioning Condenser

Cab HV and HVAC Unit

Air Conditioning Binary Switch

Heater Valve

Fuel Tank

Engine Cover

B10

Mudguards

z z z z z z z z

B11

Stabilisers

B12

RAS SYSTEM

B13

Interlock SYSTEM

B14

Boom

B15

RAS ECU

B16

Interlock Components

z z z z z

z z z z z z z z z z z z z z

1-1-3

9813/1800-2 (1-14-08)

1-1-3

Section 1-1 - General Information Applications Tables

Section C - Electrics Machine models Topic Ref Title

Fuses and Relays

Schematics

Electrical Harness SYSTEM

Battery Charging SYSTEM

Alternator (C-04-02)

Battery

1-1-4

VARIANT

Engine serial number from U0193212

9813/1800-2 (1-14-08)

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z z z z

1-1-4

Section 1-1 - General Information Applications Tables

Section E - Hydraulics Machine models Topic Ref Title

Systems and Schematics

Parallel Hydraulic SYSTEM (E-0132)

LSP Hydraulic SYSTEM (E-01-31)

Parallel Circuit Operation (E-60-01)

LSP Circuit Operation (E-60-12)

MRV/LSRV Operation

ARV Operation

Parallel Lift Operation

Boom Pressure Balance System

E10

Universal Hydraulic Faults

E11

Parallel Circuit Faults

E12

Flowshare Servo Circuit Faults

E13

Hydraulic System Pressure Tests

E14

Pump Flow Tests - Gearpump

E15

Flowshare Control Valve

E16

Parallel Control Valve - 2 Section

E17

Parallel Control Valve - 5 Section

E18

Pilot Pressure Supply Valve

E19

Servo Control Valves

E20

Gearpump Operation

E21

Gearpump Removal and Replacement

E22

VARIANT

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z

z z z z z z z z z z z z z z

z z z z z z z z z z z z z

z z z z

z z z z z

Hydraulic Cooling Fan Motor - Fixed Speed

E23

Extension Ram

E24

Lift Rams

E25

Tilt Ram

E26

Displacement Ram

z z z z

1-1-5

9813/1800-2 (1-14-08)

1-1-5

Section 1-1 - General Information Applications Tables Machine models Topic Ref Title

VARIANT

E27

Sway Ram

E28

Stabiliser Rams

E29

RAS Rams

E30

Ram Maintenance

E31

Sway Ram Circuit - Bleed Procedure

1-1-6

9813/1800-2 (1-14-08)

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z

z z z

z z z z z

1-1-6

Section 1-1 - General Information Applications Tables

Section F - Transmission Machine models Topic Ref Title

Configuration

Wheels and Tyres

Front Axles

VARIANT

z z

Rear Axles

z z z

z z z z z z

z z z z

SD80 3 Piece Steer Drive Axle SD55 1 Piece Steer Drive Axle

PS750 Mk 4 Gearbox SYSTEM

Torque Converter Operation

Gearbox Systems Fault Finding

Flushing The Transmission Oil

Torque Converter Stall Tests

F10

PS750 Mk4 Gearbox - Hydraulic Testing

F11

Torque Converter

F12

PS750 Mk 4 Gearbox

F13

Bevel Gearbox

F14

Transmission Oil Cooler - Liquid to PS750 Liquid

F15

Propshafts

1-1-7

z z z

SD80 3 Piece Steer Drive Axle SD70 3 Piece Steer Drive Axle

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

9813/1800-2 (1-14-08)

1-1-7

Section 1-1 - General Information Applications Tables

Section G - Brakes Machine models Topic Ref Title

VARIANT

Single Axle Service Brakes SYSTEM

Twin Axle Service Brakes SYSTEM

External Park Brake SYSTEM

Park Brake Calliper

Park Brake Disc

Park Brake Switch

Servo Exhauster Unit

Servo Unit - Single Axle Brakes

Servo Unit - Twin Axle Brakes

G10

Master Cylinder

z z z z z z z Machines with Single Axle Service Brakes System Machines with Twin Axle Service Brakes System

1-1-8

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

9813/1800-2 (1-14-08)

z z z z z z

1-1-8

Section 1-1 - General Information Applications Tables

Section H - Steering Machine models Topic Ref Title

Steering SYSTEM

Hydraulic Steering Unit

Priority Valve

Manual Steer Mode SYSTEM

Manual Steer Mode Valve

Steer Rams

Steering Column

1-1-9

VARIANT

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z z z z z z

9813/1800-2 (1-14-08)

z z z z z z z

1-1-9

Section 1-1 - General Information Applications Tables

Section K - Engine Machine models Topic Ref Title

Engine Start/Stop SYSTEM

Cold Start Heater SYSTEM

Starter Motor

Cooling Pack (SH,SL,DH)

Coolant Expansion Tank

Throttle Position Sensor (TPS) (K-07-21)

Air Cleaner Housing

Exhaust Silencer

Fuel Cooler Matrix

K10

JCB EcoMax

VARIANT

55kW (SL) 81kW (SH)

506-36 5CD 507-42 5CE 509-42 5CF

510-56 5CG 512-56 5CH 514-56 5CJ

z z z z z z

z z z z z

z z z

93kW (SH) 108kW (DH)

1-1-10

9813/1800-2 (1-14-08)

1-1-10

Section 1-1 - General Information Applications Tables

Section M - Electronic Data Systems Machine models Topic Ref

Title

Variant

CANbus SYSTEM

Blank

Fault Code SYSTEM

Servicemaster SYSTEM

Servicemaster Tool Set

JCB EcoMax (SH,SL,SH) Engine Set Up Tool

JCB EcoMax (SH,SL,SH) Engine Diagnostic Tool

Cluster (LMS) Set Up Tool

Datalogger Tool User Guide

M10

Machine Diagnostics Tool

M11

Immobiliser Set Up Tool User Guide

M12

Immobiliser Diagnostics User Guide

M13

Pulse Width Modulation Theory

M14

Electronic Control Unit Theory

M15

Blank

M16

Blank

M17

Devices

M18

Electronic Controllers

506-36 5CD

510-56 5CG 512-56 5CH 514-56 5CJ

z z z z z

Immobiliser ECU

z z z z z z z z z z z z z

Livelink ECU

z z z z z

LMS ECU

RAS ECU M19

507-42 5CE 509-42 5CF

z z z

Brake System Devices Park Brake Switch Footbrake Operated Switch Footbrake Pressure Transducer

1-1-11

9813/1800-2 (1-14-08)

1-1-11

Section 1-1 - General Information Applications Tables Machine models Topic Ref

Title

Variant

506-36 5CD

507-42 5CE 509-42 5CF

510-56 5CG 512-56 5CH 514-56 5CJ

Charge Pressure Transducer Transmission Disconnect (Footbrake Dump) Switch M20

Blank

M21

Engine and Fuel System Devices Fuel Level Sender Coolant Temperature Switch Vacuum Switch Fuel Lift Pump WIF Sensor TMAF Sensor Inlet Manifold Heater/Cold Start Relay Alternator Throttle Position Sensor Engine Compartment Fuse/Relay Box Power Hold Relay Engine ECU Start Signal Relay Fuel Lift Pump Relay Exhaust Gas Re Circulation (EGR) Actuator Variable Geometry Turbo (VGT) Actuator

M22

81, 93 and 108 kW engines

General Control Devices Ignition Switch Info Operator Switch Neutral Start Relay Centre Cluster Warning Panel

z z z z z z z z z z z z z z z z z z

z z z z z

Operator Present Switch Direction Indicator/Turn Signal Lamps

1-1-12

9813/1800-2 (1-14-08)

1-1-12

Section 1-1 - General Information Applications Tables Machine models Topic Ref

Title

Variant

506-36 5CD

507-42 5CE 509-42 5CF

510-56 5CG 512-56 5CH 514-56 5CJ

Trailer Turn Signal Lamp Circuit Hazard Lamps Joystick (Thumbwheel and Button Type) Joystick (Button Type)

M23

Blank

M24

Blank

M25

Blank

M26

Blank

z z z z z

M27

Stabiliser and Sway Devices

Right Hand Column Switch

z z z z z

z z

Stabiliser Deployed Sensor Stabiliser Isolation Solenoid (S1)

z z

z z z

z z z z z

Stabiliser Isolation Solenoid (S2) Stabiliser Isolation Switch Stabiliser, Sway Relay Sway/Fan Selector Solenoid (Sway Isolation Solenoid (S1) Sway/Fan Selector Solenoid (Sway Isolation Solenoid (S2) Sway Direction Solenoid (S1) Sway Direction Solenoid (S2) Sway Switch (S1) Sway Switch (S2) M28

Blank

M29

Blank

M30

Device Harness Interconnections

M31

Device Ground Points

1-1-13

9813/1800-2 (1-14-08)

1-1-13

Section 1-1 - General Information Applications Tables

Page left intentionally blank

1-1-14

9813/1800-2 (1-14-08)

1-1-14

Section 1-2 - General Information

Use Introduction This topic contains information about the structure of the manual and how to use the manual. K Scope ( T 1-2-2) K Personnel ( T 1-2-2) K Applications ( T 1-2-2) K Newest Data ( T 1-2-2) K Format ( T 1-2-3) K Left and Right Sides ( T 1-2-4) K Hydraulic Schematic Codes ( T 1-2-5) K Colour Codes ( T 1-2-5)

1-2-1

1-01-03 Issue 01

1-2-1

Section 1-2 - General Information Use Scope

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

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

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

1-2-2

1-01-03 Issue 01

1-2-2

Section 1-2 - General Information Use Format

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

General Information - Use the Applications Tables at the front of the section to see which topic in the manual is applicable to which machine model. The section also includes general information such as torque settings and service tools.

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

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

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

Attachments

Body and Framework...etc.

The sections contain topics. Each topic is a self contained set of data about a machine SYSTEM or Device. Some topics are only applicable to some machine models. Use the Applications Tables in this section to see which topic is applicable to which machine model. Each topic contains data such as specifications, descriptions, fault finding and test procedures. Device topics also contain removal, replacement, dismantle and assemble procedures. Some topics contain procedures and specifications for different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures. Each topic also contains a Related Topics table. This table lists all the topics that contain related data. For example a hydraulic SYSTEM contains devices such as valves and pumps. These devices have their own topics and they are listed in the SYSTEM related topics table.

1-2-3

1-01-03 Issue 01

1-2-3

Section 1-2 - General Information Use Left and Right Sides

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

1-2-4

1-01-03 Issue 01

1-2-4

Section 1-2 - General Information Use Hydraulic Schematic Codes

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

Red

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

Pink

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

Orange

Blue

Green

Light Green

Yellow

1-2-5

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

Neural: Neutral circuit pressure.

Exhaust:

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

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

1-01-03 Issue 01

1-2-5

Section 1-2 - General Information Use Hydraulic Schematic Codes

Page left intentionally blank

1-2-6

1-01-03 Issue 01

1-2-6

Section 1-3 - General Information

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

K Related Topics ( T 1-3-2) K Machine Identification Plate ( T 1-3-3) K Typical Product Identification Number (PIN) ( T 1-3-3) K European Tractor Type Approved Builds ( T 1-3-5) K Component Identification Plates ( T 1-3-7) K Typical Engine Identification Number ( T 1-3-7) K Transmission Identification Numbers ( T 1-3-8) K ROPS/FOPS and OECD Certification Plates ( T 1-3-11)

1-3-1

1-02-07 Issue 02

1-3-1

Section 1-3 - General Information Machine Identification Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections

Topic Titles

Sub Titles

Applications

ALL

Table 2. Related Topics in Publication 9813/1400 - Personnel Platform Supplement The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics. Sections

Section Titles

Topic Titles

ALL

1-3-2

1-02-07 Issue 02

1-3-2

Section 1-3 - General Information Machine Identification Machine Identification Plate

Machine Identification Plate The machine has an identification plate mounted as shown. K Fig 1. ( T 1-3-3). The serial numbers of the machine and its major units are stamped on the plate. Note: The machine model and build specification is indicated by the PIN. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.

GET

Gatersleben, Germany

PUN

Pune, India

SHA

Shanghai, China

JBP

JCB Branded Products

Machine Model (3 Digits) Standard Builds 5AA = 531-70 5AB = 535-95 5AC = 536-60 5AD = 541-70

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

5AF = 540-170 5AG = 550-140 5AH = 533-105 5AL = 540-140 5AM = 550-170 5AN = 535-125 HiViz 5AP = 535-140 HiViz 5AR = 536-70 5AS = 526-56 5AT = 527-58 Low Cab 5AV = 527-58 High Cab 5AW = 550-80 5AX = 540-200 5CD = 506-36 5CE = 507-42 5CF = 509-42

Fig 1.

5CG = 510-56

420811

5CH = 512-56 5CJ = 514-56

Typical Product Identification Number (PIN)

5MN = 535-125 MP(1) 5MP = 535-140 MP(1) (1) Man Platform Variant - Refer to Service Manual Supplement 9813/1400

T011100-C1

World Manufacturer Identification (3 Digits)

European Tractor Type Approved Builds: 5TA = 531-70

5TD = 535-95

JCB

5TB = 541-70

5TE = 536-70

GEO

Georgia, US

5TC = 536-60

5TW = 550-80

HAR

Haryana, India

SOR

Sorocaba, Brazil

1-3-3

5UW = 550U80

1-02-07 Issue 02

1-3-3

Section 1-3 - General Information Machine Identification Machine Identification Plate 3

Engine Type (1 Digit) JCB Dieselmax (Tier 3): P = Turbocharged and intercooled, 85kW (114Hp) R = Turbocharged and intercooled, 97kW (130Hp) S = Turbocharged, 74.2kW (100Hp) T = Turbocharged, 63kW (85Hp) V = Turbocharged and intercooled, 108 kW (145Hp) JCB Ecomax (Tier 4): W = Turbocharged and intercooled,55kW (74Hp) X = Turbocharged and intercooled, 81kW (109Hp) Y = Turbocharged and intercooled,93kW (125Hp) Z = Turbocharged and intercooled, 108kW (145Hp)

Gearbox Model (1 Digit) Table 3. Powershift/SyncroShuttle Transmission E = 3 Speed (PS750) J = 6 Speed (PS760) F = 3 Speed (PS760)

M = 4 Speed (SS700)

G = 4 Speed (PS750)

N = 4 Speed (PS750 - 40 KPH)

H = 4 Speed (PS760) Table 4. HydroStatic Transmission P = 20 Kph R = 25 Kph S = 34 kph T = 40 Kph 5

Randomly generated check letter (1 Digit)

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

1-3-4

1-02-07 Issue 02

1-3-4

Section 1-3 - General Information Machine Identification Machine Identification Plate European Tractor Type Approved Builds

332-d6975-4

Fig 2. Table 5. Machines with SA/SB/SC/SD/SE/SF Engines 531-70 535-95 536-60 536-70

Item A

Total Permissible Mass

Permissible Front Axle Load(1)

541-70

550-80

kg (lb)

8200 (18073)

8500 (18734)

8200 (18073)

8350 (18403)

8400 (18513)

TBA

From 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) To C

6600 (14550)

7300 (16093)

6200 (13668)

7000 (15432)

TBA TBA

Permissible Rear Axle Load(1) From 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) To

Unbraked Towable Mass

Independently Braked Towable Mass

Inertia Braked Towable Mass

Towable Mass Fitted with a Proportional Assisted Braking System

1-3-5

TBA

6600 (14550)

7300 (16093)

6200 (13668)

7000 (15432)

TBA

750 (1653)

TBA

6000 (13227)

TBA

3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716)

TBA

10 Tonne Hydraulic Hitch

10000 (22040)

TBA

Rockinger/Tractor Hitch

17800 (39231)

17100 (37699)

17800 (39231)

17250 (38019)

17200 (37909)

TBA

1-02-07 Issue 02

1-3-5

Section 1-3 - General Information Machine Identification Machine Identification Plate (1) Dependent on tyres option. Table 6. Machines with SH/SL/DH Engines 5TA 5TB 5TC 5TD Item A

Total Permissible Mass

Permissible Front Axle Load(1)

5TE

5UW

531-70

535-95

536-60

536-70

541-70

550-80

kg (lb)

9000 (19836)

10250 (22591)

9000 (19836)

10250 (22591)

12005 (26459)

From 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) To C

6580 (14502)

7500 (16530)

6400 (14105)

7500 (16530)

9000 (19836)

Permissible Rear Axle Load(1) From 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) 2400 (5291) To

Unbraked Towable Mass

Independently Braked Towable Mass

Inertia Braked Towable Mass

Towable Mass Fitted with a Proportional Assisted Braking System

6580 (14502)

7500 (16530)

6400 (14105)

7500 (16530)

9000 (19836)

750 (1653)

6000 (13227)

3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716) 3500 (7716)

10 Tonne Hydraulic Hitch

10000 (22040)

9800 (21819)

10000 (22040)

9360 (20629)

9800 (21819)

7660 (16882)

Rockinger/Tractor Hitch

17800 (39231)

16700 (37027)

17800 (39231)

15300 (33721)

16700 (37027)

11200 (24684)

(1) Dependent on tyres option.

1-3-6

1-02-07 Issue 02

1-3-6

Section 1-3 - General Information Machine Identification Component Identification Plates

Component Identification Plates Typical Engine Identification Number Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). The data label contains important engine information and includes the engine identification number E. A typical engine identification number is explained as follows:

320/40001

00001

Engine Type SD = turbocharged SE = electronic common turbocharged and intercooled.

rail

fuel

injection,

SF = turbocharged and intercooled.

Fig 3. Engine

C007280-C5.jpg

SH = 4.4 litre electronic common rail fuel injection with Variable Geometry Turbocharger (81kW, 93kW) SL = 4.4 litre electronic common rail fuel injection with Fixed Geometry Turbocharger (55kW) DH = 4.8 litre electronic common rail fuel injection with Variable Geometry Turbocharger (108kW) 2

Engine part number

Country of manufacture U = United Kingdom

Engine Serial Number

Year of Manufacture

The last three parts of the engine identification number are stamped on the cylinder block at position B. U

1-3-7

00001

1-02-07 Issue 02

1-3-7

Section 1-3 - General Information Machine Identification Component Identification Plates

Transmission Identification Numbers

Axles (550-80 Machines)

Axles (Excluding 550-80 Machines)

The axles have a serial number stamped on a data plate label A as shown.

The transmission components have a serial number stamped on a data plate A as shown.

To view to the front axle data plate remove the cover B and the plate will be visible through hole C.

C A Fig 4. Front Axle

A710840-C1

C107510

Fig 6. Front Axle

A710830-C1

Fig 5. Rear Axle

C107520

Fig 7. Rear Axle

1-3-8

1-02-07 Issue 02

1-3-8

Section 1-3 - General Information Machine Identification Component Identification Plates Gearbox The transmission components have a serial number stamped on a data plate A as shown.

C007640

Fig 10. SS700 Transmission

Fig 8. PS750 Powershift Transmission

Fig 9. PS760 Powershift Transmission

1-3-9

263370-C1

A401030-C2

1-02-07 Issue 02

1-3-9

Section 1-3 - General Information Machine Identification Component Identification Plates HydroStatic Transmission Components

Speed.

Transmission Pump

Power.

Transmission Motor 1

Motor Serial Number (6 Digits) Each motor has a unique serial number.

Date of manufacture.

Ordering Code

Code

Machine

AA4VG56

20 and 34 kph

AA10VG63

25 kph

AA4VG71

40 kph

Type

C094930

Fig 11. 1

C094920

Fig 12.

Pump Serial Number (8 Digits) Each motor has a unique serial number.

Direction of rotation - looking at the shaft.

Date of manufacture.

1-3-10

1-02-07 Issue 02

1-3-10

Section 1-3 - General Information Machine Identification Component Identification Plates

ROPS/FOPS and OECD Certification Plates

Definition of terms: ROPS Roll Over Protection Structure

Machines built to ROPS/FOPS standards have an identification label A fitted to the inside of the cab. Machines built to ROPS/FOPS and OECD standards have identification label B fitted to the inside of the cab.

FOPS

Falling Objects Protection Structure

OECD Organisation for Economic Co-operation and Development.

Fig 13. 526-56 and 527-58 machines

1-3-11

1-02-07 Issue 02

T016800-3-C1

1-3-11

Section 1-3 - General Information Machine Identification Component Identification Plates

Fig 14. Other Machines

1-3-12

1-02-07 Issue 02

445911-5

1-3-12

Section 1-4 - General Information

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

K Zinc Plated Fasteners and Dacromet Fasteners ( T 1-4-2) K Introduction ( T 1-4-2) K Bolts and Screws ( T 1-4-2) K Hydraulic Connections ( T 1-4-6) K 'O' Ring Face Seal System ( T 1-4-6) K 'Torque Stop' Hose System ( T 1-4-9) K `Positional Type' Hydraulic Adaptors ( T 1-4-10) K Fitting Procedure ( T 1-4-10)

1-4-1

1-05-01 Issue 01

1-4-1

Section 1-4 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Zinc Plated Fasteners and Dacromet Fasteners T11-002

Introduction

Bolts and Screws

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

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

The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-4-2).

Torque settings are given for the following conditions:

Fastener Type

Table 1. Fastener Types Colour Part No. Suffix

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

Condition 1 – Un-lubricated fasteners – Zinc fasteners

Zinc and Yellow

Golden finish

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

Dacromet

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

– Yellow plated fasteners

Condition 2

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.

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

Verbus Ripp Bolts

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

1-4-2

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

1-05-01 Issue 01

1-4-2

Section 1-4 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1

Bolt Size

Condition 2

in.

kgf m

lbf ft

kgf m

lbf ft

1/4

6.3

7/16

11.2

1.1

8.3

10.0

1.0

7.4

5/16

7.9

1/2

22.3

2.3

16.4

20.0

2.0

14.7

3/8

9.5

9/16

40.0

4.1

29.5

36.0

3.7

26.5

7/16

11.1

5/8

64.0

6.5

47.2

57.0

5.8

42.0

1/2

12.7

3/4

98.00

10.0

72.3

88.0

9.0

64.9

9/16

14.3

13/16

140.0

14.3

103.2

126.0

12.8

92.9

5/8

15.9

15/16

196.0

20.0

144.6

177.0

18.0

130.5

3/4

19.0

1 1/8

343.0

35.0

253.0

309.0

31.5

227.9

7/8

22.2

1 15/16

547.0

55.8

403.4

492.0

50.2

362.9

25.4

1 1/2

814.0

83.0

600.4

732.0

74.6

539.9

1 1/8

31.7

1 7/8

1181.0

120.4

871.1

1063.0

108.4

784.0

1 1/4

38.1

2 1/4

1646.0

167.8

1214.0

1481.0

151.0

1092.3

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

Bolt Size ISO Metric Thread

kgf m

Condition 2

lbf ft

kgf m

lbf ft

5.8

0.6

4.3

5.2

0.5

3.8

9.9

1.0

7.3

9.0

0.9

6.6

24.0

2.4

17.7

22.0

2.2

16.2

M10

47.0

4.8

34.7

43.0

4.4

31.7

M12

83.0

8.5

61.2

74.0

7.5

54.6

M16

205.0

20.9

151.2

184.0

18.8

135.7

M20

400.0

40.8

295.0

360.0

36.7

265.5

M24

690.0

70.4

508.9

621.0

63.3

458.0

M30

1372.0

139.9

1011.9

1235.0

125.9

910.9

M36

2399.0

244.6

1769.4

2159.0

220.0

1592.4

1-4-3

1-05-01 Issue 01

1-4-3

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

Bolt Size ISO Metric Thread

kgf m

Condition 2 lbf ft

kgf m

lbf ft

8.1

0.8

6.0

7.3

0.7

5.4

13.9

1.4

10.2

12.5

1.3

9.2

34.0

3.5

25.0

30.0

3.0

22.1

M10

67.0

6.8

49.4

60.0

6.1

44.2

M12

116.0

11.8

85.5

104.0

10.6

76.7

M16

288.0

29.4

212.4

259.0

26.4

191.0

M20

562.0

57.3

414.5

506.0

51.6

373.2

M24

971.0

99.0

716.9

874.0

89.1

644.6

M30

1930.0

196.8

1423.5

1737.0

177.1

1281.1

M36

3374.0

344.0

2488.5

3036.0

309.6

2239.2

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

Bolt Size

Condition 2

ISO Metric Thread

kgf m

lbf ft

kgf m

lbf ft

9.8

1.0

7.2

8.8

0.9

6.5

16.6

1.7

12.2

15.0

1.5

11.1

40.0

4.1

29.5

36.0

3.7

26.5

M10

80.0

8.1

59.0

72.0

7.3

53.1

M12

139.0

14.2

102.5

125.0

12.7

92.2

M16

345.0

35.2

254.4

311.0

31.7

229.4

M20

674.0

68.7

497.1

607.0

61.9

447.7

M24

1165.0

118.8

859.2

1048.0

106.9

773.0

M30

2316.0

236.2

1708.2

2084.0

212.5

1537.1

M36

4049.0

412.9

2986.4

3644.0

371.6

2687.7

1-4-4

1-05-01 Issue 01

1-4-4

Section 1-4 - 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

1-4-5

ISO Metric Thread

kgf m

lbf ft

2.0

0.2

1.5

6.0

0.6

4.5

11.0

1.1

8.0

19.0

1.9

14.0

46.0

4.7

34.0

M10

91.0

9.3

67.0

M12

159.0

16.2

117.0

M16

395.0

40.0

292.0

M18

550.0

56.0

406.0

M20

770.0

79.0

568.0

M24

1332.0

136.0

983.0

1-05-01 Issue 01

1-4-5

Section 1-4 - 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

1-4-6

in.

kgf m

lbf ft

1/4

19.0

18.0

1.8

13.0

3/8

22.0

31.0

3.2

23.0

1/2

27.0

49.0

5.0

36.0

5/8

30.0

60.0

6.1

44.0

3/4

32.0

81.0

8.2

60.0

38.0

129.0

13.1

95.0

1 1/4

50.0

206.0

21.0

152.0

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

SAE Tube Size

Thread Size

kgf m

lbf ft

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

1-05-01 Issue 01

1-4-6

Section 1-4 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

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

BSP Hose Size in.

1-4-7

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

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

1/8

14.0

14.0 - 16.00

1.4 - 1.6

10.3 - 11.8

1/4

19.0

24.0 - 27.0

2.4 - 2.7

17.7 - 19.9

3/8

22.0

33.0 - 40.0

3.4 - 4.1

24.3 - 29.5

1/2

27.0

44.0 - 50.0

4.5 - 5.1

32.4 - 36.9

5/8

30.0

58.0 - 65.0

5.9 - 6.6

42.8 - 47.9

3/4

32.0

84.0 - 92.0

8.6 - 9.4

61.9 - 67.8

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

1-05-01 Issue 01

kgf m

lbf ft

1-4-7

Section 1-4 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-4-8

in.

kgf m

lbf ft

1/8

20.0

2.1

15.0

1/4

34.0

3.4

25.0

3/8

75.0

7.6

55.0

1/2

102.0

10.3

75.0

5/8

122.0

12.4

90.0

3/4

183.0

18.7

135.0

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

1-05-01 Issue 01

1-4-8

Section 1-4 - General Information Torque Settings Hydraulic Connections

'Torque Stop' Hose System

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

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

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

1-4-9

in.

kgf m

lbf ft

1/8

14.0

1.4

10.0

1/4

19.0

27.0

2.7

20.0

3/8

22.0

40.0

4.1

30.0

1/2

27.0

55.0

5.6

40.0

5/8

30.0

65.0

6.6

48.0

3/4

32.0

95.0

9.7

70.0

38.0

120.0

12.2

89.0

1 1/4

50.0

189.0

19.3

140.0

1 1/2

55.0

244.0

24.9

180.0

1-05-01 Issue 01

1-4-9

Section 1-4 - General Information Torque Settings `Positional Type' Hydraulic Adaptors

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

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

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

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

Fig 4.

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

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

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

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

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

Fig 5.

1-4-10

1-05-01 Issue 01

1-4-10

Section 1-5 - General Information

Service Tools Introduction 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 or, in some instances, can be manufactured locally from the specifications given in this section. 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.

K Numerical List ( T 1-5-2) K Tool Detail Reference ( T 1-5-5) K Rivet Nuts ( T 1-5-27) K Slide Hammer Kit ( T 1-5-29)

1-5-1

1-06-03 Issue 01

1-5-1

Section 1-5 - General Information Service Tools Numerical List

Numerical List Some tools are supplied as kits or sets. Cross references are given to tables showing the kit contents. Part Number:

Description:

Tool Detail Reference:

Bonded Washers - see tool detail reference for content

K Fig 41. ( T 1-5-16)

Electrical Repair Kit - see tool detail reference for content

K Fig 24. ( T 1-5-10)

Female Cone Blanking Plugs - see tool detail reference for content

K Fig 38. ( T 1-5-16)

Female Connectors - see tool detail reference for content

K Fig 40. ( T 1-5-16)

Hydraulic Hand Pump Equipment - see tool detail reference for content

K Fig 44. ( T 1-5-17)

Male Adaptors BSP x BSP - see tool detail reference for content

K Fig 34. ( T 1-5-14)

Male Cone Blanking Caps - see tool detail reference for content

K Fig 39. ( T 1-5-16)

Pressure Test Point `T' Adaptors - see tool detail reference for content

K Fig 36. ( T 1-5-15)

Pressure Test Point Adaptors - see tool detail reference for content

K Fig 35. ( T 1-5-14)

Rivet Nut Tool - see tool detail reference for content

K Fig 1. ( T 1-5-5)

32mm Crows foot spanner

K Fig 70. ( T 1-5-25)

19mm Crows foot spanner

K Fig 71. ( T 1-5-25)

17mm Crows foot ring spanner

K Fig 72. ( T 1-5-25)

10mm Modified ball end allen key

K Fig 76. ( T 1-5-26)

8mm Modified ball end allen key

K Fig 77. ( T 1-5-26)

8mm Modified ball end allen key

K Fig 78. ( T 1-5-26)

8mm Modified allen key

K Fig 79. ( T 1-5-26)

320/20050

Engine Lifting Bracket Kit

K Fig 66. ( T 1-5-23)

332/E0800 Variflow pump test lead

K Fig 33. ( T 1-5-14)

332/E7911

Exhaust fitting clamp

K Fig 64. ( T 1-5-23)

332/F1311

SS700 Cableshift Neutral Locking Tool

K Fig 63. ( T 1-5-22)

332/F7768

Cab Filter Protection Plate (527-58 Low Cab Machines)

K Fig 23. ( T 1-5-9)

332/G2732 HydroStatic Transmission motor lifting eye

K Fig 74. ( T 1-5-26)

332/G2739 527-58 Control valve lifting eye

K Fig 73. ( T 1-5-25)

332/G2802 HydroStatic Transmission pump lifting eye - 20, 30 and 40 kph machines

K Fig 75. ( T 1-5-26)

332/G2855 HydroStatic Transmission pump lifting eye - 25 kph machines

K Fig 75. ( T 1-5-26)

332/H0931 Cab Filter Protection Plate (527-58 High Cab Machines)

K Fig 23. ( T 1-5-9)

4104/1310

Hand Cleaner

K Fig 15. ( T 1-5-8)

460/15708

Flow Test Adaptor (Powershift) - Other components required, see tool detail

K Fig 47. ( T 1-5-18)

718/20235

USB PC Cable

K Fig 69. ( T 1-5-25)

718/20236

Serial PC Cable

K Fig 69. ( T 1-5-25)

1-5-2

1-06-03 Issue 01

1-5-2

Section 1-5 - General Information Service Tools Numerical List Part Number:

Description:

Tool Detail Reference:

718/20237

Machine Cable

K Fig 69. ( T 1-5-25)

728/26500

USB DLA

K Fig 69. ( T 1-5-25)

892/00011

Spool Clamp

K Fig 50. ( T 1-5-19)

892/00167

Ram Protection Sleeve for 90 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/00180

Seal Fitting Tool - Hydraulic Steer Unit

K Fig 51. ( T 1-5-19)

892/00229

Flow Meter

892/00253

Hydraulic Pressure Test Kit - see tool detail reference for content

K Fig 30. ( T 1-5-13)

892/00268

Flow Monitoring Unit - Other components required, see tool detail

K Fig 28. ( T 1-5-12)

892/00301

Flow test adaptor - Synchro Shuttle - Other components required

K Fig 60. ( T 1-5-22)

892/00334

Ram Seal Fitting Tool

K Fig 55. ( T 1-5-21)

892/00349

Crimp Tool

K Fig 26. ( T 1-5-11)

892/00350

Butane Heater Assembly

K Fig 25. ( T 1-5-10)

892/00351

Splice 0.5-1.5 mm (Red)

K Fig 27. ( T 1-5-11)

892/00352

Splice 1.5-2.5 mm (Blue)

K Fig 27. ( T 1-5-11)

892/00353

Splice 3.0-6.0 mm (Yellow)

K Fig 27. ( T 1-5-11)

892/00812

Drive Coupling Spanner

K Fig 61. ( T 1-5-22)

892/00822

Splined Bolt Socket

K Fig 59. ( T 1-5-22)

892/00842

Glass Lifter

K Fig 3. ( T 1-5-6)

892/00843

Folding Stand for Holding Glass

K Fig 4. ( T 1-5-6)

892/00844

Long Knife

K Fig 17. ( T 1-5-8)

892/00845

Cartridge Gun

K Fig 5. ( T 1-5-6)

892/00846

Glass Extractor (Handles)

K Fig 6. ( T 1-5-6)

892/00847

Nylon Spatula

K Fig 7. ( T 1-5-6)

892/00848

Wire Starter

K Fig 8. ( T 1-5-6)

892/00849

Braided Cutting Wire

K Fig 9. ( T 1-5-7)

892/00881

Valve Spool Seal Fitting Tool

K Fig 45. ( T 1-5-17)

892/00893

Torque Converter Alignment Tool

K Fig 62. ( T 1-5-22)

892/00905

LMI Test Box

K Fig 21. ( T 1-5-9)

892/00948

Nitrogen Charging Kit (without gauge)

K Fig 49. ( T 1-5-18)

892/00949

Gauge

K Fig 49. ( T 1-5-18)

892/00964

Test Point 1/8 BSP (Powershift)

K Fig 42. ( T 1-5-17)

892/00965

Test Point 3/8 BSP (Powershift)

K Fig 43. ( T 1-5-17)

892/01016

Ram Protection Sleeve for 25 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01017

Ram Protection Sleeve for 30 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01018

Ram Protection Sleeve for 40 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01019

Ram Protection Sleeve for 50 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01020

Ram Protection Sleeve for 50 mm Rod Diameter

K Fig 54. ( T 1-5-21)

1-5-3

1-06-03 Issue 01

1-5-3

Section 1-5 - General Information Service Tools Numerical List Part Number:

Description:

Tool Detail Reference:

892/01021

Ram Protection Sleeve for 60 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01022

Ram Protection Sleeve for 60 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01023

Ram Protection Sleeve for 65 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01024

Ram Protection Sleeve for 70 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01025

Ram Protection Sleeve for 75 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01026

Ram Protection Sleeve for 80 mm Rod Diameter

K Fig 54. ( T 1-5-21)

892/01027

Piston Seal Assembly Tool

K Fig 57. ( T 1-5-21)

892/01174

Data Link Adaptor Kit

K Fig 69. ( T 1-5-25)

892/01268

Digital Pressure Gauge 0-400 bar

K Fig 46. ( T 1-5-17)

892/01382

Engine Lift Spreader Bar

K Fig 67. ( T 1-5-23)

892/01271

Hose for Digital Pressure Gauge 892/01268

K Fig 46. ( T 1-5-17)

926/15500

Rubber Spacer Blocks

K Fig 10. ( T 1-5-7)

992/01100

Glazing Tool

K Fig 16. ( T 1-5-8)

992/04000

Torque Multiplier

K Fig 58. ( T 1-5-22)

992/04800

Flange spanner

K Fig 65. ( T 1-5-23)

992/09100

Spool Clamp

K Fig 50. ( T 1-5-19)

992/09300

Hexagon Spanner 55 mm A/F

K Fig 56. ( T 1-5-21)

992/09400

Hexagon Spanner 65 mm A/F

K Fig 56. ( T 1-5-21)

992/09500

Hexagon Spanner 75 mm A/F

K Fig 56. ( T 1-5-21)

992/09600

Hexagon Spanner 85 mm A/F

K Fig 56. ( T 1-5-21)

992/09700

Hexagon Spanner 95 mm A/F

K Fig 56. ( T 1-5-21)

992/09900

Hexagon Spanner 115 mm A/F

K Fig 56. ( T 1-5-21)

992/10000

Hexagon Spanner 125 mm A/F

K Fig 56. ( T 1-5-21)

992/12300

12V Mobile Oven

K Fig 11. ( T 1-5-7)

992/12400

24V Static Oven (2 Cartridge)

K Fig 12. ( T 1-5-7)

992/12800

Cut-Out Knife

K Fig 13. ( T 1-5-7)

992/12801

`L' Blades

K Fig 14. ( T 1-5-7)

993/68100

Slide Hammer Kit - see tool detail reference for content

K Fig 2. ( T 1-5-5)

993/85700

Battery Tester

K Fig 22. ( T 1-5-9)

TBA

Hexagon Spanner 105 mm A/F

K Fig 56. ( T 1-5-21)

1-5-4

1-06-03 Issue 01

1-5-4

Section 1-5 - General Information Service Tools Tool Detail Reference

Tool Detail Reference 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 1. Rivet Nut Tool

Fig 2. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

993/68107

Bar - M20 x M20 X 800 mm

993/68102

End Stops

993/68108

Adaptor - M20 x 7/8" UNF

993/68103

Adaptor - M20 x 5/8" UNF

993/68109

Adaptor - M20 x M12

993/68104

Adaptor - M20 x 1" UNF

993/68110

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

993/68105

Adaptor - M20 x M20

993/68111

Adaptor - M20 x 1/2" UNF

993/68106

Adaptor - M20 x M24

1-5-5

1-06-03 Issue 01

1-5-5

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 3. 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 6. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K Fig 9. ( T 1-5-7).

Fig 7. 892/00847 Nylon Spatula

Fig 4. 892/00843 Folding Stand Essential for preparing new glass prior to installation.

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

Fig 8. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. K Fig 9. ( T 1-5-7).

Fig 5. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

1-5-6

1-06-03 Issue 01

1-5-6

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 9. 892/00849 Braided Cutting Wire

Fig 12. 992/12400 Static Oven 240V

Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 6. ( T 1-5-6). 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 10. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 13. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 11. 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).

1-5-7

Fig 14. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K Fig 13. ( T 1-5-7). Unit quantity = 5 off.

1-06-03 Issue 01

1-5-7

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 15. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

Fig 18. 892/00298 Fluke Meter

Fig 19. 892/00285 Hydraulic Temperature Probe Fig 16. 992/01100 Glazing Tool, used to insert aperture seal expansion strip.

Fig 20. 892/00284 Venture Microtach Digital Tachometer Fig 17. 892/00844 Long Knife Used to give extended reach for normally inaccessible areas.

1-5-8

1-06-03 Issue 01

1-5-8

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 21. 892/00905 LMI Test Box For testing load moment indicator system

Fig 22. 993/85700 Battery Tester

Fig 23. 527-58 Cab Filter Protection Plate High Cab Machines

332/H0931

Low Cab Machines

332/F7768

1-5-9

1-06-03 Issue 01

1-5-9

Section 1-5 - General Information Service Tools Tool Detail Reference K Electrical Repair Kit ( T 1-5-10) 1

Electrical Repair Kit

7212/0002

2 Way Pin Housing

7212/0004

2 Way Pin Retainer

7212/0003

2 Way Socket Retainer

7212/0001

2 Way Socket Connector

7213/0002

3 Way Pin Housing

7213/0004

3 Way Pin Retainer

7213/0003

3 Way Socket Retainer

7213/0001

3 Way Socket Connector

7213/0006

3 Way Pin Housing (DT)

7213/0008

3 Way Pin Retainer (DT)

7213/0007

3 Way Socket Retainer (DT)

7213/0005

3 Way Socket Connector (DT)

7214/0002

4 Way Pin Housing

7214/0004

4 Way Pin Retainer

7214/0003

4 Way Socket Retainer

7214/0001

4 Way Socket Connector

7216/0002

6 Way Pin Housing

7216/0004

6 Way Pin Retainer

7216/0003

6 Way Socket Retainer

7216/0001

6 Way Socket Connector

7218/0002

8 Way Pin Housing

7218/0004

8 Way Pin Retainer

7218/0003

8 Way Socket Retainer

7218/0001

8 Way Socket Connector

7219/0002

10 Way Pin Housing

7219/0004

10 Way Pin Retainer

7219/0003

10 Way Socket Retainer

7219/0001

10 Way Socket Connector

7219/0006

14 Way Pin Housing

7219/0008

14 Way Pin Retainer

7219/0007

14 Way Socket Retainer

7219/0005

14 Way Socket Connector

7210/0001

Dummy Plug

7210/0002

Wire Seal (1.4 - 2.2 mm dia.)

7210/0003

Wire Seal (2.2 - 2.9 mm dia.)

1-5-10

Fig 24. Electrical Repair Kit

Fig 25. 892/00350 Butane Heater Assembly

1-06-03 Issue 01

1-5-10

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 26. 892/00349 Crimp Tool

Fig 27. Splice 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)

1-5-11

1-06-03 Issue 01

1-5-11

Section 1-5 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 29. ( T 1-5-12).

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 28. 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 29. 998/11046 JCB ServiceMaster Flow Test Kit

1-5-12

1-06-03 Issue 01

1-5-12

Section 1-5 - 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 31. ( T 1-5-13).

892/00201

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

892/00202

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

892/00203

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

892/00254

Replacement Hose

993/69800

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

892/00706

Test Probe

892/00347

Connector - Hose to gauge

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

0-600 Bar Pressure Transduce x2

998/11056

0-100 Bar pressureTransducer x2

998/11057

RPM Tachometer (includes fixed cable, 2 meters)

998/11058

5 Meter Connecting Cable

998/11059

M16 Metric Adaptors for Test Points x4

998/11060

400mm Test Hose 90Â° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

892/00280

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

892/00279

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

892/00346

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

892/00347

Connector

892/00254

Hose

Fig 30. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 31. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

Fig 32. Hydraulic Circuit Test Gauges and Connections

1-5-13

1-06-03 Issue 01

1-5-13

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 33. 332/E0800 Variflow Pump Test Lead Male Adapters - BSP x BSP 1606/2052

3/8 in. x 1/4 in.

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

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

1606/0004

1/2 in. x 1/4 in.

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

Fig 34. Male Adaptors

1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

Male Adapters - BSP x NPT (USA only)

1606/0009

3/4 in. x 1/2 in.

816/00439

3/8 in. x 1/4 in.

1604/2055

3/4 in. x 3/4 in.

816/00440

1/2 in. x 1/4 in.

1606/0012

3/4 in. x 1 in.

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

1606/0014

3/4 in. x 1.1/4 in.

816/15008

1606/0015

1 in. x 1.1/4 in.

892/00255

1/4 in. BSP x Test Point

892/00256

3/8 in. BSP x Test Point

892/00257

1/2 in. BSP x Test Point

1/2 in. x 3/8 in.

Fig 35. Pressure Test Adapters

1-5-14

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

1-06-03 Issue 01

1-5-14

Section 1-5 - 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 36. Pressure Test 'T' Adapters

1-5-15

1-06-03 Issue 01

1-5-15

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 37. '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 38. 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 39. 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 40. Female Connectors

Fig 41. Bonded Washers

1-5-16

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

1-06-03 Issue 01

1-5-16

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 42. 892/00964 Test Point 1/8 BSP

Fig 43. 892/00965 Test Point 3/8 BSP 892/00223

Hand Pump

892/00137

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

892/00274

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

892/00262

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

892/00706

Test Probe

892/00278

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

892/00279

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

Fig 44. Hand Pump Equipment

Fig 45. 892/00881 Valve Spool Seal Fitting Tool

C068360

Fig 46. 892/01268 Digital Pressure Gauge 0-400 bar 892/01271

1-5-17

1-06-03 Issue 01

Hose for pressure gauge

1-5-17

Section 1-5 - General Information Service Tools Tool Detail Reference

3 4 6 5

Fig 48. 892/00301 Flow Test Adaptor Note: Components listed as follows also required:

Item

Description

892/00920 Adaptor

892/00302 Adaptor

A313250-C1

Fig 47. 460/15708 Flow Test Adaptor Note: Components listed below also required: Item

Description

460/15707 Banjo bolt

2401/0222 O-ring

2403/0110 O-ring

2403/0108 O-ring

1604/0004 Adaptor - 2 off

1406/0018 Sealing washer - 2 off Fig 49. Nitrogen Charging Kit

1-5-18

892/00948

Charging Kit (without gauge)

892/00949

Gauge

1-06-03 Issue 01

1-5-18

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 50. Spool Clamps 992/09100

Spool Clamp

892/00011

Spool Clamp

Fig 51. 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

JS07050

Fig 52. Ram Piston Nut Removal/Fitting Spanner

1-5-19

993/99512

Spanner 55 mm A/F

993/99513

Spanner 60 mm A/F

993/99514

Spanner 65 mm A/F

993/99515

Spanner 70 mm A/F

993/99516

Spanner 75 mm A/F

993/99517

Spanner 85 mm A/F

993/99518

Spanner 90 mm A/F

993/99519

Spanner 100 mm A/F

993/99520

Spanner 110 mm A/F

993/99521

Spanner 115 mm A/F

SSP0046

Spanner 80 mm A/F

SSP0047

Spanner 95 mm A/F

1-06-03 Issue 01

1-5-19

Section 1-5 - General Information Service Tools Tool Detail Reference 993/99525

Rig Assembly (not including spanners and ram)

993/99522

Anchor Side Plate (supplied loose unwelded)

993/99523

Anchor Cross unwelded)

Member

(supplied

loose

993/99524

Ram Eye End Modification Plate Assembly

556/43400

Lift Ram

545/18000

Lynch Pin

811/50232

1.1/4in Pivot Pin

Fig 53. Ram Piston Nut Removal/Fitting Rig

1-5-20

1-06-03 Issue 01

1-5-20

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 54. 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 55. 892/00334 Ram Seal Fitting Tool 5mm

m 3m

110mm 175mm 3o

Fig 56. 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

1-5-21

1.4

Fig 57. 892/01027 Piston Seal Assembly Tool

1-06-03 Issue 01

1-5-21

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 61. 892/00812 Drive Coupling Spanner

Fig 58. 992/04000 Torque Multiplier

Fig 62. 892/00893 Torque Converter Alignment Tool Fig 59. 892/00822 Splined Bolt Socket

For use with 11â&#x20AC;? torque converters

Fig 60. 892/00301 Flow Test Adaptor Fig 63. 332/F1311 Neutral Locking Tool

Note: Components listed as follows also required Item

Description

892/00920 Adaptor

892/00302 Adaptor

1-5-22

For use with SS700 Cableshift Transmission

1-06-03 Issue 01

1-5-22

Section 1-5 - General Information Service Tools Tool Detail Reference

Fig 66. 320/20050 Lifting Bracket Kit

Fig 64. 332/E7911 Exhaust Fitting Clamp

Note: Brackets are designed to lift only the engine. They MUST NOT be used to lift the engine and transmission assembly. To lift engine and transmission as a complete assembly use a suitable Engine and Transmission lifting frame. K Engine and Transmission Lifting Frame ( T 1-5-24)

Fig 67. 892/01382 Engine Lift Spreader Bar- SH,SL and DH Engines only

Fig 65. 992/04800 Flange Spanner

1-5-23

Note: The spreader bar is designed to lift only the engine. It MUST NOT be used to lift the engine and transmission assembly. To lift engine and transmission as a complete assembly use a suitable Engine and Transmission lifting frame. K Engine and Transmission Lifting Frame ( T 1-5-24)

1-06-03 Issue 01

1-5-23

Section 1-5 - General Information Service Tools

60 mm

300 mm

970 mm

1030 mm

m m

Tool Detail Reference

A 400 mm

m 0 10

440 mm

10 mm

Fig 68. Engine and Transmission Lifting Frame When removing the engine and transmission assembly suitable lifting equipment must be used. The engine and transmission assembly weighs 1000 kg excluding the main hydraulic pump assembly. Presently there is no approved lifting frame available from JCB Service. K Fig 68. ( T 1-5-24). The drawing shows guide dimensions for fabricating a frame that can be made locally from mild steel bar. The frame should be designed to lift the assembly by supporting the bottom of the engine between the sump and flywheel housing on plate A. Important: Before using such a frame you must make sure it is tested and complies with all local regulations relating to lifting equipment. Note: This frame is to be used for lifting the engine and transmission as a complete assembly only. For lifting the engine refer to the engine brackets and spreader bar. K 320/20050 Lifting Bracket Kit ( T 1-5-23), K 892/01382 Engine Lift Spreader Bar- SH,SL and DH Engines only ( T 1-5-23)

1-5-24

1-06-03 Issue 01

1-5-24

Section 1-5 - General Information Service Tools Tool Detail Reference

D Fig 70. 32mm Crows foot spanner (Used for transmission pump suction hose connector)

C Fig 71. 19mm Crows foot spanner (Used for transmission pump hoses connections)

Fig 72. 17mm Crows foot ring spanner Fig 69. 892/01174 Data Link Adaptor Kit A

USB PC Cable

718/20235

Serial PC Cable

718/20236

USB DLA

728/26500

Machine Cable

718/20237

(Used for transmission motor flange to propshaft bolts)

Kit 892/01174 (includes items A,B,C and D)

Fig 73. Control Valve lifting Eye 332/G2739

1-5-25

1-06-03 Issue 01

Lifting eye

1-5-25

Section 1-5 - General Information Service Tools Tool Detail Reference

A Fig 76. 10mm Modified Ball End Allen Key Dimension

Size mm

inches

155

6.1

Fig 74. Transmission Motor lifting Eye 332/G2732

Lifting eye

A Fig 77. 8mm Modified Ball End Allen Key Dimension A

Size mm

inches

125

4.9

Fig 75. Transmission Pump lifting Eye 332/G2802

Lifting eye - 20, 30 and 40 kph machines

332/G2855

Lifting eye - 25 kph machines

A Fig 78. 8mm Modified Ball End Allen Key Dimension

Size mm

inches

2.9

A Fig 79. 8mm Modified Allen Key Dimension A

1-5-26

1-06-03 Issue 01

Size mm

inches

0.6

1-5-26

Section 1-5 - General Information Service Tools Rivet Nuts

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 80A is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread 80-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 80. 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 1-5-27) 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 1-5-28). 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.

1-5-27

1-06-03 Issue 01

1-5-27

Section 1-5 - General Information Service Tools Rivet Nuts

Fitting Procedure

(smooth bulge) seating itself against the body/ framework 83-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 81-A.

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

Fig 83. Fig 81. 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 82-B.

Fig 82. 4

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

Hold handle 83-C and at the same time draw the mandrel into the installation tool by turning nut 83-D. The rivet nut will contract in length and form an 'upset'

1-5-28

1-06-03 Issue 01

1-5-28

Section 1-5 - General Information Service Tools Slide Hammer Kit

Slide Hammer Kit TB-003

Fig 84. Typical M/c. Installation The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be 'knocked through'. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins. The adaptors 84-A that form part of the kit have a screwed thread at each end. One of the threads will always be M20 size, this is to accommodate the end stops, items 84-B and 84-C. The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.

Fit an end stop 84-B onto the other end of the adaptor (M20 thread size), make sure that the adaptor threads are fully engaged.

Fit the 'slide bar' 84-E into the end stop. Again make sure that the threads are fully engaged.

Fit the 'slide hammer', item 84-F, onto the slide bar as shown.

Finally, fit another end stop, item 84-C, at the end of the slide bar, as shown. The slide hammer kit is now ready to use.

Fitting Procedure 1

Prepare the pivot pin, for instance, if fitted, remove the pivot pin retaining bolt.

Determine the thread size of the pivot pin and then fit the appropriate adaptor 84-A as shown. Use the spanner flats 84-D to securely fit the adaptor.

To extract the pivot pin, slide the hammer along the bar until it contacts end stop 84-C. Repeat this step until the pivot pin is released.

To remove the slide hammer kit, reverse steps 2 to 7.

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1-06-03 Issue 01

1-5-29

Section 1-5 - General Information Service Tools Slide Hammer Kit

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1-06-03 Issue 01

1-5-30

Section 1-6 - General Information

Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start work make sure that the consumables show in the tables are available.

K Sealing and Retaining Compounds ( T 1-6-2)

1-6-1

1-07-01 Issue 01

1-6-1

Section 1-6 - General Information Service Consumables Sealing and Retaining Compounds

Sealing and Retaining Compounds T11-001_4

Table 1. 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

1-6-2

1-07-01 Issue 01

1-6-2

Section 1-7 - General Information

Fuel Introduction This topic contains information fuel types and use with JCB EcoMax engines. When investigating engine related faults find out what types and sources of fuel are used by the operator.

K Related Topics ( T 1-7-2) K Acceptable and Unacceptable Fuels ( T 1-7-3)

1-7-1

1-8-02 Issue 01

1-7-1

Section 1-7 - General Information Fuel Related Topics

Topic Titles

Sub Titles

Machine Identification

ALL

ALL (Care and Safety)

ALL

Service Schedules

ALL

Fuel

ALL

(1)

(1) You must obey all of the relevant care and safety procedures.

1-7-2

1-8-02 Issue 01

1-7-2

Section 1-7 - General Information Fuel Acceptable and Unacceptable Fuels

Acceptable and Unacceptable Fuels Refer to Section 3 - Routine Maintenance for fuel specifications. K Related Topics ( T 1-7-2)

1-7-3

1-8-02 Issue 01

1-7-3

Section 1-7 - General Information Fuel Acceptable and Unacceptable Fuels

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1-7-4

1-8-02 Issue 01

1-7-4

Section 1-8 - General Information

Stall Speed Combinations Introduction If the operator reports poor machine performance the stall speed test is a very useful way to quickly and easily determining if the engine, transmission or hydraulic system is faulty. Do the stall speed tests to help diagnose which system is at fault. Refer to the applicable section (Hydraulics, Transmission or Engine) for details of the test procedures.

K Related Topics ( T 1-8-2) K Specifications ( T 1-8-3)

1-8-1

1-15-04 Issue 01

1-8-1

Section 1-8 - General Information Stall Speed Combinations Related Topics

Topic Titles

Sub Titles

Machine Identification

ALL (Care and Safety)(1)

ALL

Service Schedules

ALL

(1) You must obey all of the relevant care and safety procedures.

1-8-2

1-15-04 Issue 01

1-8-2

Section 1-8 - General Information Stall Speed Combinations Specifications

Specifications K Table 2. Stall Speed Combinations ( T 1-8-4). Tests carried out at the factory record the correct engine r.p.m. (stall speed) when under maximum load from the transmission and hydraulic systems. The figures relate to tests conducted at an ambient of 25 0C and barometric pressure of 100 kPa (sea level). Note that changes in ambient temperature, pressure and humidity and fuel grade will affect engine power and hence the stall figures. As an example, at 10,000 ft the power reduction of a naturally aspirated engine could be 29% and for a turbo engine 8%. Note: The figures apply to `bedded-in' engines, i.e. engines that have done a minimum of 250 working hours, therefore they should not be used for pre-delivery inspection (PDI) checks. All figures are recorded with the transmission oil at 60째C (140 째F) and the hydraulic oil at 55 째C (131 째F). Figures achieved should be within +/- 100 rpm from the figures given in the table.

1-8-3

1-15-04 Issue 01

1-8-3

Section 1-8 - General Information Stall Speed Combinations Specifications Table 2. Stall Speed Combinations SL SH

Engine Build Code Engine Power

Model

55kW 4 Speed PS750

81kW 4 Speed PS750

55kW 4 Speed PS750 (4 Speed SS700(1))

81kW 4 Speed PS750/PS764

506-36 5CD 507-42 5CE 509-42 5CF 510-56 5CG 512-56 5CH 514-56 5CJ

531-70 5AA 535-95 5AB 541-70 5AD 533-105 5AH 540-140 5AL 535-125 5AN 535-140 5AP 536-70 5AR 526-56 5AS

531-70 5A(T)A 535-95 5AB(TD) 536-60 5A(T)C 541-70 5A(T)D 540-170 5AF 550-140 5AG 533-105 5AH 540-140 5AL 550-1705AM 535-125 5AN 535-140 5AP 536-70 5AR(TE) 526-56 5AS

Hydraulic System: Gearpump

Variflow Engine Stall Speeds r.p.m. Torque Converter Only

1710

1970

Hydraulics (M.R.V.) Only

2085

2324

1322

1682

LSP Variflow

LSP Electro Servo

Combined Converter + M.R.V.

(2)

Combined Converter + L.S.R.V.

(1) 526-56 Machines only (2) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service operated until the relief valve is lifted.

1-8-4

1-15-04 Issue 01

1-8-4

Section 1-8 - General Information Stall Speed Combinations Specifications Engine Build Code Engine Power Model

Table 3. Stall Speed Combinations SH SH 93kW 4 Speed PS764

93kW 6 Speed PS766

108kW 4 Speed 108kW 6 Speed PS764 PS766

531-70 5A(T)A 531-70 5A(T)A 531-70 5A(T)A 531-70 5A(T)A 535-95 5AB(TD) 535-95 5AB(TD) 535-95 5AB(TD) 535-95 5AB(TD) 536-60 5A(T)C 536-60 5A(T)C 536-60 5A(T)C 536-60 5A(T)C 541-70 5A(T)D 541-70 5A(T)D 541-70 5A(T)D 541-70 5A(T)D 540-170 5AF 536-70 5AR(TE) 536-70 5AR(TE) 536-70 5AR(TE) 550-140 5AG 550-80 540-140 5AL 5AW(UW) 550-1705AM 536-70 5AR(TE) 550-80 5AW(UW)

Hydraulic System: Gearpump Variflow

z z

Engine Stall Speeds r.p.m. Torque Converter Only Hydraulics (M.R.V.) Only Combined Converter + M.R.V. (1) Combined Converter + L.S.R.V. LSP Variflow LSP Electro Servo (1) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service operated until the relief valve is lifted.

1-8-5

1-15-04 Issue 01

1-8-5

Section 1-8 - General Information Stall Speed Combinations Specifications

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1-8-6

1-15-04 Issue 01

1-8-6

Section 2 Care and Safety Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813/1800-2

Section 2 - Care and Safety

Notes:

2-0

9813/1800-2

2-0

Section 2 - Care and Safety Contents Page No. Safety Notices Introduction ............................................................................................. 2-1-1 Important Information ............................................................................. 2-1-2 Safety Check List .................................................................................... 2-1-3 Safety Decals ....................................................................................... 2-1-16 General Procedures Introduction ............................................................................................. 2-2-1 Related Topics ........................................................................................ 2-2-3 Parking the Machine and Making it Safe ................................................ 2-2-4 Boom Safety Strut (P1) ........................................................................... 2-2-6 Boom Safety Strut (P2) ........................................................................... 2-2-9 Venting the Hydraulic Pressure ............................................................ 2-2-12 Venting the Brake System Pressure ..................................................... 2-2-14 Connecting/Disconnecting Hydraulic Hoses ......................................... 2-2-15 Quick Release Couplings ..................................................................... 2-2-16 Hydraulic Contamination ...................................................................... 2-2-18 Battery Disconnection/Connection ....................................................... 2-2-20 Battery Charging System Precautions .................................................. 2-2-21 Removing and Replacing Components ................................................ 2-2-22 Hydraulic Rams .................................................................................... 2-2-24 Gas Hydraulic Bladder Accumulators ................................................... 2-2-26

2-i

Section 2 - Care and Safety Contents

2-ii

Page No.

2-ii

Section 2-1 - Care and Safety

Safety Notices Introduction In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

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

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

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

2-1-1

2-01-06 Issue 01

2-1-1

Section 2-1 - Care and Safety Safety Notices Important Information

Important Information T1-042

The Operator Manual

Safety Warnings

!MWARNING You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator Manual. You must understand and follow the instructions in the Operator Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. INT-1-4-2

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

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

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

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

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

2-1-2

2-01-06 Issue 01

2-1-2

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

Safety Check List Safety - Yours and Others INT-1-3-1_3

All machinary 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.

For more information about cleanliness requirements and fuel types refer to Section 1 - General Information.

!MCAUTION Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instruction will lead to dirt entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair. ENG-1-7

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

Common Rail (SE/SH/DH/SL Engine) Specific In addition to the general safety notices and general good workshop practices issued in this section and throughout the manual, there are specific points to note when completing maintenance on engine equipment:

Diesel Fuel Quality Important: The potential for engine damage due to the use of incorrect or contaminated fuel is much greater with common rail injection technology than with mechanical injection systems.

2-1-3

2-01-06 Issue 01

2-1-3

Section 2-1 - Care and Safety Safety Notices Safety Check List Effects of Contamination

Common Rail Safety Checklist

Once inside the system, fuel circuit contaminants greatly effect the performance and life of the fuel injection equipment. For example, contaminants in the fuel pump will develop internal wear to cause internal leakage and hence lower discharges. Use of poor quality fuels and poor maintenance could also lead to contaminants entering the fuel injectors. There is a possibility of catastrophic equipment failure if debris should prevent the injectors from fully closing. The main contaminants can be classified as follows: These contaminations can appear during manufacture. assembly and operation.

The following safety checklist is intended to help remind you of safety procedures and practices relating to a common rail engine.

– Solid Particles - sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc. – Liquid - usually water and incompatible oils and gases. – Gases - Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid. It is critical that the machine is thoroughly cleaned prior to completing any maintenance work. The main filter is rated at 2 micron = 0.002 mm (0.0007874 in). Listed are a few typical comparisons of micron size: – Red Blood Cell = 8 microns (0.008 mm, 0.000315 in). – Human Hair = 70 microns (0.07 mm, 0.00275 in). – Grain of Salt = 100 microns (0.1 mm, 0.00394 in). – The smallest particle visible to the naked eye is 40 microns (0.00157 in) approximately.

SAFETY IS YOUR RESPONSIBILITY – Do make sure the engine and surrounding area has been thoroughly cleaned prior to completing any maintenance tasks. – Do complete all work in accordance with the Service Manual procedures. – Do disconnect both the battery positive (+) and battery negative (-) cables prior to completing any welding on the machine. – Do use the recommended grade of fuel (EN590). The fuel injection pump, injector or other parts of the fuel system can be damaged if you use a fuel or fuel additives not recommended by JCB. Refer to Section 1 - Acceptable and Unacceptable Fuels. – Do make sure all the necessary new parts are available before starting any maintenance work. – Do not `crack' the injector high pressure fuel lines to bleed the fuel system. The system operates at pressures in excess of 1200 bar (17400lbs/in2). – Do not steam clean the electronic control unit (ECU) or the ECU connectors. – Do not touch the ECU connector pins, this will eliminate the possibility of damage caused by electrostatic discharge. – Do not leave any fuel connections `open' for any extended period of time. – Do not open any new parts packaging until the part is ready to be fitted. Unnecessary exposure will increase the risk of contamination. – Do not reuse high pressure fuel pipes. Reusing the pipes will lead to potential fuel leaks. – Do not attempt to remove and replace the rail pressure sensor or high pressure valve. It is not possible to refit these components without the risk of fuel leaks. If the valve or sensor is diagnosed as faulty then a new common rail assembly must be fitted.

2-1-4

2-01-06 Issue 01

2-1-4

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

!MWARNING

General Safety

!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

8-1-2-4

!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.

!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

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

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.

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

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

2-1-5

2-01-06 Issue 01

2-1-5

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

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

!MWARNING 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

2-1-6

2-01-06 Issue 01

2-1-6

Section 2-1 - 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

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

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

!MWARNING

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

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

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

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

5-2-6-5

!MWARNING

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

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

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

2-1-7

2-01-06 Issue 01

2-1-7

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

!MWARNING

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

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

INT-2-2-6

INT-2-1-1

!MWARNING

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

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

INT-2-2-8

INT-2-2-9_1

!MDANGER

!MWARNING

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

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

INT-2-2-10

!MWARNING

5-3-1-12_3

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

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

!MWARNING

INT-2-1-14

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

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

2-1-8

2-01-06 Issue 01

2-1-8

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

!MWARNING

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

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.

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.

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.

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

!MCAUTION 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. 5-5-1-1_2

!MWARNING

INT-3-2-7_2

!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

!MCAUTION Fork Spacing Loads can fall off incorrectly spaced forks. Always space the forks correctly for the load. Make sure the forks are completely under the load before lifting. 5-1-4-2

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

!MCAUTION One-Fork Lifting A load lifted on one fork can slip off. Never lift a load with one fork. 5-1-4-3

!MCAUTION

2-4-5-2_1

!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

Unloading Never unload the forks by stopping the machine suddenly. Follow the procedures in the Operator Manual for unloading. 5-1-4-4_2

!MCAUTION Uneven Ground Loads stacked on uneven ground can topple. Never stack loads on uneven ground. 5-1-4-5

2-1-9

2-01-06 Issue 01

2-1-9

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

!MWARNING

Scaffolding Overloaded scaffolding can collapse. Never load scaffolding beyond the regulation capacity.

Powershift Transmission Do not change from a high gear to a low gear (for instance, 4th to 1st) in one sudden movement when the machine is moving. Otherwise the machine will rapidly decelerate, you or others could be killed or seriously injured. When selecting lower gears, allow the engine speed to drop before each gear change.

5-1-4-6

!MCAUTION Overhead Clearance A raised boom can strike overhead objects. Always check for overhead clearance before raising the boom. 5-1-5-1

2-1-1-9_1

!MCAUTION Passengers Passengers in or on the machine can cause accidents. Do not carry passengers.

!MWARNING Boom/Travelling Operating the boom while travelling can cause accidents. You will not have total control of the machine. Never operate the boom while travelling.

INT-2-2-2_1

5-1-5-2

!MDANGER Forks/Working Platform Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Never use the forks as a working platform. 5-1-5-3

!MWARNING Forks/Turning The forks extend beyond the end of the boom. Make sure there is enough clearance for the forks when making turns. 5-1-5-4

!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

2-1-10

2-01-06 Issue 01

2-1-10

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

!MWARNING

Maintenance Safety

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

!MWARNING 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.

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3

!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

!MWARNING Fuel Fuel is flammable; keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions. INT-3-2-2_3

INT-3-1-3_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

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

2-1-11

2-01-06 Issue 01

2-1-11

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

!MCAUTION

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

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

INT-3-2-14

INT-3-2-12

!MWARNING

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

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-3-2-4

INT-3-3-2_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

!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

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

!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

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

2-1-12

2-01-06 Issue 01

2-1-12

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

!MWARNING

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.

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.

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

area

with

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

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

!MWARNING

!MWARNING 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. INT-3-1-15_2

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

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

HYD-1-3_3

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

2-1-13

2-01-06 Issue 01

2-1-13

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

!MWARNING

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

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-3-1-17

INT-3-1-8_2

!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

!MWARNING

!MDANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear personal protective equipment (PPE). INT-3-2-1_4

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

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

!MCAUTION

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

Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

When disconnecting the battery, disconnect the earth (-) lead first.

INT-3-1-14

INT-3-1-9

!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.

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. 2-3-2-7_2

0125

!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. INT-3-2-8

2-1-14

2-01-06 Issue 01

2-1-14

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

!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

!MCAUTION You must apply the park brake before you operate the attachment. 13-3-1-17

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

!MWARNING Boom Maintenance Strut A raised boom can drop suddenly and cause serious injury. Before working under a raised boom, fit the boom maintenance strut. See Boom Maintenance Strut, MAINTENANCE section. 5-1-5-7_2

2-1-15

2-01-06 Issue 01

2-1-15

Section 2-1 - Care and Safety Safety Notices Safety Decals

Safety Decals Introduction

!MWARNING 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 refer to the machine operator manual. 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.

2-1-16

2-01-06 Issue 01

2-1-16

Section 2-2 - Care and Safety

General Procedures Introduction When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury and reduce the risk of component failure. As part of the procedures in this manual you will need to do some general procedures. Two examples of these general procedures are; parking the machine and making it safe, and venting hydraulic pressure. These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a cross reference to this section so that you can refer to the detailed procedures. K Parking the Machine and Making it Safe ( T 2-2-4) K Boom Safety Strut (P1) ( T 2-2-6)(1) K Boom Safety Strut (P2) ( T 2-2-9)(1) K Venting the Hydraulic Pressure ( T 2-2-12) K Venting the Brake System Pressure ( T 2-2-14) K Connecting/Disconnecting Hydraulic Hoses ( T 2-2-15) K Introduction ( T 2-2-15) K Connecting the Hoses ( T 2-2-15) K Disconnecting the Hoses ( T 2-2-15) K Quick Release Couplings ( T 2-2-16) K Hydraulic Contamination ( T 2-2-18) K Hydraulic Fluid Quality ( T 2-2-18) K Effects of Contamination ( T 2-2-18) K Cleaning Operation ( T 2-2-18) K Contaminant Standards ( T 2-2-19) K Filters ( T 2-2-19) K Battery Disconnection/Connection ( T 2-2-20) K Disconnection ( T 2-2-20) K Connection ( T 2-2-20) K Removing and Replacing Components ( T 2-2-22) K Battery Charging System Precautions ( T 2-2-21) K Hydraulic Rams ( T 2-2-24) K Installation ( T 2-2-24) K Caution During Use ( T 2-2-24) K Maintenance, Inspection Points ( T 2-2-24) K Gas Hydraulic Bladder Accumulators ( T 2-2-26) (1) Specification variants. Make sure you refer to the correct specification.

2-2-1

2-02-06 Issue 01

2-2-1

Section 2-2 - Care and Safety General Procedures Introduction Table 1. Specification Variants - Boom Safety Strut Specifications

Machine Model Application

(1)

531-70, 535-95, 536-60, 541-70, 533- 506-36, 507-42, 509-42, 510-56, 512105, 536-70, 533-105, 536-70, 55056, 514-56 80, 540-170, 550-170, 540-140, 550140, 535-125 HiViz, 535-140 HiViz, 526-56, 527-58, 540-200 K Boom Safety Strut (P1) ( T 2-2-6)

z z

K Boom Safety Strut (P2) ( T 2-2-9)

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

2-2-2

2-02-06 Issue 01

2-2-2

Section 2-2 - Care and Safety General Procedures Related Topics

Related Topics Table 2. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections

Topic Titles

Sub Titles

General Information

ALL

Safety Notices

ALL

Maintenance

Access Panels

2-2-3

2-02-06 Issue 01

2-2-3

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

Parking the Machine and Making it Safe Introduction

!MWARNING Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. 8-3-1-1

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

T015850-1

Fig 1.

3-3-1-1

Make the machine safe before you start a maintenance procedure.

Refer to all of the warnings and information in the Safety Notices topic. K Related Topics ( T 2-2-3) When lifting a machine make sure the jack is positioned on the correct point. On a Loadall these are on the front and rear axle casings C. Note: Before jacking the rear axle make sure the axle has wedges added between the axle and the chassis oscillation stop to stop the axle from oscillating. Ensure the jack is placed on a firm and level surface and that the jack is of a suitable capacity for the load. Only jack one point at a time.

Fig 2.

320610-C1

You can complete most of the maintenance procedures with the boom lowered (Position A). Unless a maintenance procedure instructs you differently, you must lower the boom. Refer to How to Make the Machine Safe (Boom Lowered). If you lift the boom to get access for maintenance (Position B), you must install the maintenance strut on the boom. Refer to How to Make the Machine Safe (Boom Lifted). Important: Until the hydraulic pressure is fully released on 550-80 machines the boom lower and retract service are still operative when the engine is not running. Make sure

2-2-4

2-02-06 Issue 01

2-2-4

Section 2-2 - Care and Safety General Procedures Parking the Machine and Making it Safe that the boom is lowered or supported fully on the safety strut. 1

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

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

If necessary install the boom safety strut. K Boom Safety Strut (P1) ( T 2-2-6)

Stop the engine and apply the park brake.

Vent the hydraulic pressure. Hydraulic Pressure ( T 2-2-12)

If necessary vent the brake system pressure (550-80 and 527-58 machines). K Venting the Brake System Pressure ( T 2-2-14)

Remove the starter key.

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

If procedures include work on the electrical system disconnect the battery. K Battery Disconnection/ Connection ( T 2-2-20)

K Venting

the

2-2-5

2-02-06 Issue 01

2-2-5

Section 2-2 - Care and Safety General Procedures Boom Safety Strut (P1)

Boom Safety Strut (P1) Note: If you lift the boom to get access for maintenance, you must install the maintenance strut on the boom. Note: The stowage position of the Boom Safety strut varies according to machine model/variant. All possible strut stowage positions A are shown in the following figures: – K Fig 3. ( T 2-2-6) – K Fig 4. ( T 2-2-6) – K Fig 5. ( T 2-2-6) – K Fig 6. ( T 2-2-6)

Fig 4.

Fig 5.

Fig 3. 527-58 Machines

T012120-2

C093690

Fig 6.

2-2-6

807540-1

2-02-06 Issue 01

266520-B1

2-2-6

Section 2-2 - Care and Safety General Procedures Boom Safety Strut (P1)

Installing

!MWARNING You could be killed or injured if the boom drops while you are working under it. Fit the safety strut as instructed before doing any maintenance work with the boom raised. Keep people away from the machine while you fit or remove the strut. 5-3-1-2_1

Before installing the safety strut remove any load on the forks and make sure that buckets or attachments are empty. 1

Fully retract the boom (unless it necessary to extend it for maintenance). Lift the boom sufficiently to install the strut.

Stop the engine. Make sure the park brake is engaged and the transmission is in neutral. Remove the starter key.

Fig 7.

263560-B1

!MCAUTION You will have to climb onto the machine to fit or remove the strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine. Do not use the exhaust as a handhold. It can burn you. 5-3-1-4_1

Remove the strut from its stowage position A.

Put the strut B around the lift ram piston rod. Use the strap to attach it to the ram piston rod.

To prevent boom creeping down and causing injury the boom must be lowered onto the strut.

Note: Lower the boom carefully, to prevent possible damage to the strut. Stop as soon as the weight of the boom is on the strut. 6

Disconnect the battery operation of the engine.

If necessary, put chocks against the two sides of the wheels before you get below the machine.

2-2-7

prevent

accidental

2-02-06 Issue 01

2-2-7

Section 2-2 - Care and Safety General Procedures Boom Safety Strut (P1)

Removing

Lift the boom to remove the weight from the strut.

Stop the engine. Make sure the park brake is engaged and the transmission is in neutral. Remove the starter key.

Remove the strut.

Attach the strut to its stowage position.

2-2-8

2-02-06 Issue 01

2-2-8

Section 2-2 - Care and Safety General Procedures Boom Safety Strut (P2)

Boom Safety Strut (P2) Note: If you lift the boom to get access for maintenance, you must install the maintenance strut on the boom.

Installing the Maintenance Strut

Lower the strut C so that the cut out E locates with the pipe on the lift ram. Place the strut C around the lift cylinder piston rod D. Secure the strut in position with hand bolt B.

!MWARNING

You could be killed or injured if the boom drops while you are working under it. Fit the boom maintenance strut as instructed before doing any maintenance work with the boom raised.

Lower the boom carefully onto the strut. Stop as soon as the weight of the boom is on the strut.

Keep people away from the machine while you fit or remove the boom maintenance strut. 5-3-1-2_2

Park the machine on level, solid ground with the wheels in the straight ahead position. If necessary, refer to Stopping and Parking the Machine. Remove loads from the forks and empty buckets or attachments.

Fully retract the boom. Raise the boom just far enough to install the strut C. Stop the engine and remove the starter key.

Use the steps A for access to the strut. Undo the hand bolt B and remove the strut from its stowage position X.

Note: Some machines have two steps on the chassis and no step on the axle.

2-2-9

2-02-06 Issue 01

2-2-9

Section 2-2 - Care and Safety General Procedures Boom Safety Strut (P2)

Fig 8.

2-2-10

2-02-06 Issue 01

C084250

2-2-10

Section 2-2 - Care and Safety General Procedures Boom Safety Strut (P2)

Removing the Maintenance Strut

!MWARNING You could be killed or injured if the boom drops while you are working under it. Fit the boom maintenance strut as instructed before doing any maintenance work with the boom raised. Keep people away from the machine while you fit or remove the boom maintenance strut. 5-3-1-2_2

Park the machine on level, solid ground with the wheels in the straight ahead position. If necessary, refer to Stopping and Parking the Machine.

Raise the boom just enough to allow the strut to removed.

Stop the engine and remove the starter key.

Use the steps A for access and support the strut C. Undo the hand bolt B and lift the strut clear of the steel pipe on the lift ram.

Note: Some machines have two steps on the chassis and no step on the axle. 5

Secure the strut with hand bolt B in its stowage position X.

2-2-11

2-02-06 Issue 01

Fig 9.

C084260

2-2-11

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

Venting the Hydraulic Pressure

!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

Important: This procedure is only to be used before disconnecting hydraulic hoses. Before removing other hydraulic components refer to the correct Removal procedure. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Operate the controls to remove the hydraulic pressure from the service hose lines. The procedure varies according to machine model/variant: a

550-80 machines - turn the starter key to the ON position.

Note: Make sure that the pressure is vented correctly. Electrical and pilot services have a limited amount of accumulated pressure available for venting. 3

If necessary, open rear cover A to get access to the filler cap B. Refer to Section 3 - Access Panels, Rear Cover (if fitted).

Clean the top of the tank around the filler cap B.

!MCAUTION Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. 5-3-4-8

!MCAUTION Do not run the engine with the hydraulic tank filler cap removed. 5-3-4-1

Slowly remove filler cap B to allow the system to vent fully and prevent oil being forced out of the filler neck.

Important: Until the hydraulic pressure is fully released the boom lower and retract service are still operative when the engine is not running. Make sure that the boom is lowered or supported fully on the safety strut. K Parking the Machine and Making it Safe ( T 2-2-4) Operate the boom raise/lower hydraulic services until the pressure is released. b Manually operated hydraulic services - operate the controls of the service to be disconnected. c

Electrical and servo operated hydraulic services -turn the starter key to the ON position. A710870-5

Operate the controls of the service to be disconnected.

Fig 10. Machines with External Sight Gauge

Important: To release the hydraulic pressure from the 550-80 machines and electrical/servo operated services the battery must be connected while you operate the controls.

2-2-12

2-02-06 Issue 01

2-2-12

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

732370-5

Fig 11. Machines without External Sight Gauge

2-2-13

2-02-06 Issue 01

2-2-13

Section 2-2 - Care and Safety General Procedures Venting the Brake System Pressure

Venting the Brake System Pressure

Important: Important, this operation MUST be carried out before any attempt is made to disconnect hydraulic connections, including the brake pressure switch. 1

Park the machine and make it safe. K Parking the Machine and Making it Safe ( T 2-2-4).

If necessary install the boom safety strut. K Boom Safety Strut (P1) ( T 2-2-6). Stop the engine.

Turn the starter key switch to ON but do not start the engine.

Press the brake pedal until there is no resistance felt.

Note: This may take several pumps, depending on the length of time since the engine was last run. 5

Turn the starter switch to the OFF position and remove the key.

2-2-14

2-02-06 Issue 01

2-2-14

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

Connecting/Disconnecting Hydraulic Hoses Introduction

Disconnecting the Hoses

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

Disconnect the hoses. a

Make sure to park the machine and make it safe. Obey the care and safety procedures.

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

Vent the hydraulic and/or braking pressure as applicable. the Hydraulic Pressure ( T 2-2-12) K Venting K Venting the Brake System Pressure ( T 2-2-14) 2

Connecting the Hoses 1

For Quick Release Couplings see the procedures Release in this section. K Quick Couplings ( T 2-2-16)

Check for leaks. See step 2, K Connecting the Hoses ( T 2-2-15)

Connect the hoses. a

For Quick Release Couplings refer to the correct data. K Quick Release Couplings ( T 2-2-16)

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

!MWARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_3

Check for leaks as follows: a

Start the engine.

b Operate the controls to pressurise the required hose. c

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

2-2-15

2-02-06 Issue 01

2-2-15

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

Quick Release Couplings T4-001_2

Connecting and Disconnecting

wedge underneath the sleeve and destroy the coupling.

Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will be fitted with a female coupling A and a male coupling B. The optional attachment hoses will also be fitted with a female coupling A and a male coupling B. K Fig 12. ( T 2-2-17). The quick release couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly. The recommendations listed below should always apply when using flat face quick release couplings. Finally, please read the correct fitting and releasing procedures before installing or removing any optional attachment fitted with quick release couplings.

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

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

!MWARNING

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

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

Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses.

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

2-2-16

2-02-06 Issue 01

2-2-16

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

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

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

Make sure that ball 12-C in the female coupling is located in one of its slots.

Fit the male coupling into the female coupling; To ensure that the coupling is not accidentally released, rotate sleeve 12-E half a turn and make sure that the locking ball 12-C does not align with the slot 12-D.

Disconnecting Quick Release Couplings 1

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

Align the slot 12-D with ball 12-C.

Pull back sleeve 12-E to release the coupling.

Fig 12.

2-2-17

2-02-06 Issue 01

2-2-17

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

Hydraulic Contamination TE-002_3

Hydraulic Fluid Quality

Procedure

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

Connect the cleaning unit in place of the hydraulic filter. K Fig 13. ( T 2-2-18). Run the system for sufficient time to pump all the hydraulic fluid through the unit. Disconnect the cleaning unit and reconnect the filter. Top up the system with clean hydraulic fluid as required.

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

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

Liquid - usually water and incompatible oils and greases.

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

Fig 13. Cleaning Unit

S168050-1

These contaminants can appear during manufacture, assembly and operation.

Cleaning Operation The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a cleaning unit. K Fig 13. ( T 2-2-18). General Bulletin 011 also refers.

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

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

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

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2-02-06 Issue 01

2-2-19

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

Battery Disconnection/Connection

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

Disconnection 1

Park the machine and make it safe. Obey the care and safety procedures.

Get access to the battery. Refer to Section 3 Access Panels. K Related Topics ( T 2-2-3)

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

Connection 1

Check the battery. a

If the terminal is dirty, clean the post.

Fig 14.

797650

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

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

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

Close and lock the access panels.

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2-02-06 Issue 01

2-2-20

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

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

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

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

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

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

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

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2-02-06 Issue 01

2-2-21

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

Removing and Replacing Components

!MCAUTION

Introduction T3-062_2

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

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

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

Detergents Avoid using full strength detergent - always dilute detergents as per the manufacturer's recommendations, otherwise damage to the paint finish may occur. Always adhere to local regulations regarding the disposal of debris created from machine cleaning.

Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3

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

Original Components Always Install new oil seals, gaskets, etc. Components showing obvious signs of wear or damage should be replaced with new ones.

Pressure Washing and Steam Cleaning

!MWARNING

Before re-installing original components do the following:

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

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

â&#x20AC;&#x201C; Clean components using the applicable cleaning materials. â&#x20AC;&#x201C; Inspect components for signs of excessive wear or defects. â&#x20AC;&#x201C; Check the component specifications such as wear limits where applicable.

New Components Ensure that the correct new components are installed. Do not substitute components from another machine. Components may look the same but may not be interchangeable. Refer to the JCB parts systems.

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2-02-06 Issue 01

2-2-22

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

Torques and Fixings When replacing components always tighten the applicable fixings to the correct torque. For the torque setting to be effective do the following before installing the fixings: – Ensure that all the applicable component assemblies are correct. – Ensure that the applicable fixings are to the correct specification. If necessary discard the original fixings and replace them with new ones. The relevant procedures indicate when this is necessary. – Ensure that the applicable fixings and threaded holes are free from contamination. This includes; dirt, debris, old sealants and compounds, fluids and lubricants. This manual provides reference to the correct torque settings as follows: – Where no torque setting is given in the applicable procedure, use the standard torque setting. To obtain the correct standard torque setting refer to Section 1 - Torque Settings. – Where torque settings are given in the applicable procedure use the settings given. These settings may be different to the standard torque settings in the case of special fixings for example.

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2-02-06 Issue 01

2-2-23

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

Hydraulic Rams Installation 1

Precautions when installing the ram on the machine. a

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

When painting the machine, mask the ram. a

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

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

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

Maintenance, Inspection Points

Install the ram only when it is clean. 1

Caution During Use 1

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

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

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

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

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

Welding after installing the ram may result in damage. a

Warm up sufficiently before beginning work. a

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

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

Use only under designated conditions. a

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

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

2-2-24

Carry out daily maintenance and inspection.

2-02-06 Issue 01

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

Use genuine JCB parts when replacing parts.

2-2-24

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

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

Caution during dismantling and reassembly. a

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

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

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

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2-02-06 Issue 01

2-2-25

Section 2-2 - Care and Safety General Procedures Gas Hydraulic Bladder Accumulators

Gas Hydraulic Bladder Accumulators Some hydraulic/transmission and or braking circuits and valve blocks are fitted with gas hydraulic bladder type accumulators. Before removing accumulators make sure hydraulic pressure is vented. K Venting the Hydraulic Pressure ( T 2-2-12) K Venting the Brake System Pressure ( T 2-2-14) Even when the hydraulic pressure is vented the accumulator still contains pressurised nitrogen gas. DO NOT attempt to discharge the gas pressure.

!MWARNING Use only nitrogen gas to charge accumulators. The use of any other gas can cause the accumulators to explode. Remember that although nitrogen is not poisonous you can be killed by suffocation if it displaces the air in your workplace. Do not allow excessive quantities of nitrogen to be discharged into the atmosphere. B-3-1-6

DO NOT transport accumulators charged with pressurised gas by air freight.

Replacement

Replacement accumulators are generally supplied in a discharged state with no nitrogen gas. A label attached to the accumulator indicates the gas charge state.

Charging

4 7

K Fig 15. ( T 2-2-26) Important: The following charging procedure is only applicable to accumulators supplied in a discharged state.

To carry out the charging procedure the following is required: â&#x20AC;&#x201C; Pressurised bottle of nitrogen gas with a suitable pressure reducing valve (3). â&#x20AC;&#x201C; Correct gas bottle adaptor depending on territory.

Fig 15.

â&#x20AC;&#x201C; Charging kit 892/00239. Refer to Section 1. Operating charge pressures; accumulators are charged to different operating pressures depending on the application. For the correct charge pressure refer to the applicable system specifications. Before fitting a replacement accumulator charge it with nitrogen gas as follows:

C110540-C2

Hold the accumulator upright and remove the plastic cap from the top of the accumulator.

Note: Some accumulators are supplied with a measured quantity of oil inside the gas chamber. Take care to prevent oil loss. 2

Using a suitable allen key, slowly remove the filler plug 2. Lightly oil the sealing washer beneath. Replace the washer and plug. Loosen the plug by 1/8 of a turn.

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2-02-06 Issue 01

2-2-26

Section 2-2 - Care and Safety General Procedures Gas Hydraulic Bladder Accumulators 3

Connect the accumulator adaptor 1 (from kit 892/ 00239) to the accumulator. Connect the charging unit 6 to the accumulator adaptor. Connect the charging hose to the pressure regulator 3 using the correct adaptor. Set the pressure regulator 3 to the minimum pressure.

Via the charging tool knob 7, open the filler plug 2 by three turns.

Open the discharge valve 5 on the charging unit.

9 10

Carefully open the nitrogen gas bottle valve 4 and confirm that the nitrogen gas flows freely.

Shut the gas bottle valve and the discharge valve 5. 6

Carefully open the gas bottle valve. Slowly increase the pressure using the gas bottle pressure regulator and watching the gauge 8 on the charging unit, allow nitrogen to flow until the pressure reading reaches 4 bar (72.5 psi) ABOVE the operating charge pressure.

Fig 16. 12

Important: DO NOT exceed the maximum working pressure of the accumulator. The maximum working pressure is marked on the accumulator body. Close the gas bottle valve. 7

Wait 10 minutes to dissipate the heat generated during charging.

Reduce the pressure in the accumulator to the specified operating charge pressure by carefully opening and closing the discharge valve 5. Turn the knob 7 to shut the filler plug 2 and tighten to a torque of 20 Nm (15 lb ft).

Release the pressure from the charging hose by opening the discharge valve 5.

C110550-C1.eps

K Fig 16. ( T 2-2-27) Remove the discharged state label 10 and attach the pressurised warning label 11 at position 9 on the accumulator. Install the accumulator and make sure pressurised warning label is clearly visible.

the

Disconnect the charging unit and adaptor from the accumulator. 10

Check the gas-tightness of filler plug 2 by pouring some oil around it.

Replace the plastic cap.

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Section 2-2 - Care and Safety General Procedures Gas Hydraulic Bladder Accumulators

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Section 3 Routine Maintenance Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813/1800-2

Section 3 - Routine Maintenance

Notes:

3-0

9813/1800-2

3-0

Section 3 - Maintenance Contents Page No. Maintenance Related Topics ........................................................................................ 3-1-1 Introduction ............................................................................................. 3-1-2 Health and Safety ................................................................................... 3-1-3 Lubricants ...........................................................................................3-1-3 Battery ................................................................................................3-1-5 Service Schedules .................................................................................. 3-1-7 Introduction .........................................................................................3-1-7 How to Use the Service Schedules ....................................................3-1-7 Calendar Equivalents .........................................................................3-1-7 Pre-start Cold Checks, Service Points and Fluid Levels ....................3-1-8 Functional Test and Final Inspection ................................................3-1-11 Fluids, Lubricants and Capacities ......................................................... 3-1-13 Coolant Mixtures ..............................................................................3-1-13 Fuel ...................................................................................................... 3-1-15 Acceptable and Unacceptable Fuels ................................................3-1-15 Usage and Effects of Fuels ..............................................................3-1-18 Sulphur Content ...............................................................................3-1-19 Effects of Fuel Contaminates ...........................................................3-1-19 Prepare the Machine for Maintenance ................................................. 3-1-20 Cleaning the Machine ........................................................................... 3-1-21 Introduction .......................................................................................3-1-21 Preparing the Machine for Cleaning .................................................3-1-21 Cleaning the Machine .......................................................................3-1-22 Checking for Damage ........................................................................... 3-1-25 Check the Machine Body and Structure ...........................................3-1-25 Check the Tires ................................................................................3-1-25 Check the Seat and Seat Belt ..........................................................3-1-25 Check the Hydraulic Hoses and Fittings ..........................................3-1-25 Check the Electrical Circuits .............................................................3-1-26 Checking the ROPS/FOPS Structure ...............................................3-1-26 Greasing ............................................................................................... 3-1-28 Introduction .......................................................................................3-1-28 Preparing the Machine for Greasing ................................................3-1-28 Every 50 Hours .................................................................................3-1-29 Every 500 Hours ...............................................................................3-1-31 Every 1000 Hours .............................................................................3-1-34 Oiling .................................................................................................... 3-1-35 Park Brake Cable .............................................................................3-1-35 Control Levers ..................................................................................3-1-35 Boom Chains ....................................................................................3-1-36 Access Panels ...................................................................................... 3-1-37 Battery Cover ...................................................................................3-1-37 Engine Cover ....................................................................................3-1-38 Undershield ......................................................................................3-1-39 Rear Boom Cover .............................................................................3-1-40 Central Access Panels .....................................................................3-1-41 Cab Heater and Air Conditioning .......................................................... 3-1-42 Changing the Air Intake Filter ...........................................................3-1-42 Boom .................................................................................................... 3-1-43 Boom Chains ....................................................................................3-1-43 Brakes .................................................................................................. 3-1-47 Park Brake ........................................................................................3-1-47 Foot Brake ........................................................................................3-1-49

3-i

Section 3 - Maintenance Contents Contents Page No. Electrical System .................................................................................. 3-1-50 Battery ..............................................................................................3-1-50 Jump Starting the Engine .................................................................3-1-51 Fuses ................................................................................................3-1-52 Primary Fuses ..................................................................................3-1-53 Relays ..............................................................................................3-1-54 Engine Compartment Fuse and Relay Box ......................................3-1-55 Engine .................................................................................................. 3-1-56 Oil and Filter .....................................................................................3-1-56 Cooling System ................................................................................3-1-59 Crankcase Ventilation .......................................................................3-1-61 Front End Accessory Drive Belt .......................................................3-1-62 Air Filter ............................................................................................3-1-64 Fuel System .......................................................................................... 3-1-66 Introduction .......................................................................................3-1-66 Water Separator and Engine Fuel Filter ...........................................3-1-67 Bleeding the System ........................................................................3-1-71 Hydraulic System .................................................................................. 3-1-72 Introduction .......................................................................................3-1-72 Releasing the Hydraulic Pressure ....................................................3-1-73 Oil and Filter .....................................................................................3-1-74 Hose Burst Protection Valves ...........................................................3-1-77 Transmission ........................................................................................ 3-1-79 Gearbox ............................................................................................3-1-79 Axles .................................................................................................3-1-81 Tires and Wheels .................................................................................. 3-1-85 Tire Ballast ........................................................................................3-1-85 Tire Inflation ......................................................................................3-1-85 Wheel Nuts .......................................................................................3-1-86 Wheel Alignment .................................................................................. 3-1-87 Introduction .......................................................................................3-1-87 Manual Steer Mode Selector ............................................................3-1-87 Wear Pads ............................................................................................ 3-1-88 Boom Wear Pad Clearance ..............................................................3-1-88 Windshield Washer ............................................................................... 3-1-90 Checking the Level ...........................................................................3-1-90 Fire Extinguisher (if fitted) ..................................................................... 3-1-91 Checking the Fire Extinguisher ........................................................3-1-91

3-ii

Section 3-1 - Routine Maintenance

Maintenance Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections

Topic Titles

Sub Titles

Fuel

Acceptable and Unacceptable Fuels

Machine Identification

ALL

ALL (Care and Safety)(1)

Safety Notices Parking the Machine and Making it Safe General Procedures, Battery Disconnection/ Connection

Boom

ALL

Fuses and Relays

ALL

External Park Brake SYSTEM

Test Procedures

(1) You must obey all of the relevant care and safety procedures. Table 2. Related Topics in the Machine Operator Handbook The table lists other topics contained in a separate document. Make sure that you refer to the correct document. Sections

Topic Titles

Sub Titles

Specifications

Tire Sizes and Pressures

3-1-1

9813/1800-2 (3-41-03)

3-1-1

Section 3-1 - Routine Maintenance Maintenance Introduction

Introduction Important: The Routine Maintenance procedures in this topic are typical. Always refer to the correct Operator Manual for the applicable schedules and procedures. Note: For full details of machine identification refer to Section 1 - Machine Identification.

3-1-2

9813/1800-2 (3-41-03)

3-1-2

Section 3-1 - Routine Maintenance Maintenance Health and Safety

Health and Safety Lubricants T3-060U_3

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

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

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

Handling

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

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

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

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

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

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

Waste Disposal

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

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

3-1-3

Wash your skin thoroughly with soap and water.

b Using a nail brush will help. c

Use special hand cleansers to help clean dirty hands.

d Never use gasoline, diesel fuel, or kerosene for washing.

9813/1800-2 (3-41-03)

3-1-3

Section 3-1 - Routine Maintenance Maintenance Health and Safety 3

Avoid skin contact with oil soaked clothing.

Don't keep oily rags in pockets.

Wash dirty clothing before re-use.

Throw away oil-soaked shoes.

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

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

Fires

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

3-1-4

9813/1800-2 (3-41-03)

3-1-4

Section 3-1 - Routine Maintenance Maintenance Health and Safety

!MCAUTION

Battery T3-061U

!MWARNING

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulfuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zippers 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 ground (-) lead first.

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

!MWARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use an approved battery tester. INT-3-1-8_2

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. 5-3-4-12U

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

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

3-1-5

9813/1800-2 (3-41-03)

3-1-5

Section 3-1 - Routine Maintenance Maintenance Health and Safety Warning Symbols

First Aid - Electrolyte

The following warning symbols may be found on the battery.

Do the following if electrolyte: Gets into your eyes

Symbol

Meaning

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

Keep away from children.

Is swallowed A289230-1

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

Shield eyes.

Gets onto your skin

A289260-1

No smoking, no naked flames, no sparks.

Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

3-1-6

9813/1800-2 (3-41-03)

3-1-6

Section 3-1 - Routine Maintenance Maintenance Service Schedules

Service Schedules Introduction

How to Use the Service Schedules T3-036-2

T3-012_3

A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.

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

!MWARNING

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

Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe, it should be correctly parked on level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery when you are not using electrical power. If you do not take these precautions you could be killed or injured. 8-3-1-1

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. 795390-1

Calendar Equivalents Every 10 Hours = Daily

T3-051

Every 50 Hours = Weekly Every 500 Hours = Six Months Every 1000 Hours = Yearly Every 2000 Hours = 2 Years Every 6000 Hours = 6 Years

3-1-7

9813/1800-2 (3-41-03)

3-1-7

Section 3-1 - Routine Maintenance Maintenance Service Schedules

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

100(1)

500

1000 1500 2000 8000

ENGINE

Oil level

- Check

Coolant Quality/ level

- Check

Coolant or Oil Leaks

- Check

Water Sedimentor

- Check for Contamination and Drain

Fuel Filter (machine mounted)

- Change

Oil and Filter

- Change

(2) (3)

All Hoses - Condition

- Check

Radiator (4)

- Clean

Front End Accessory Drive (FEAD) Belt Condition

- Check

Fuel Filter (engine mounted)

- Change

Air Cleaner Outer Element (4)

- Change

Crankcase Ventilation Filter

- Change

Air Cleaner Inner Element

- Change

Valve Clearances

- Check and Adjust

Oil Filler and Dipstick O-rings

- Change

Cooling system

- Drain and Fill

Front End Accessory Drive (FEAD) Belt

- Change

Injectors(5)

- Change

Injector(s) Leak-Off Rail (5)

- Change

High Pressure Fuel Lines(5)

- Change

(5)

TRANSMISSION, AXLES AND STEERING Transmission Mount Security

- Check

Transmission Oil Level

- Check

Transmission Oil

- Change

Transmission Oil Filter

- Change

(6)

Axle Mount Security

- Check

Axle(s) Oil Level

- Check

3-1-8

9813/1800-2 (3-41-03)

3-1-8

Section 3-1 - Routine Maintenance Maintenance Service Schedules Operation Axle(s) Oil Hub Oil Level (Without Oil Immersed Brakes)

Hub Oil (With Oil Immersed Brakes)(7)

- Change

1000 1500 2000 8000

- Grease

- Check

- Check - Security - Check

Tire Pressures/Condition

- Check

Wheel Alignment

- Check

Transmission Strainer

- Clean

Axle Pivots and Linkages(8)

500

Wheel Nut Security

Drive Shafts and Universal Joints(8)

100(1)

- Check - Change

Steering Stops (if fitted)

- Change

Hub Oil (Without Oil Immersed Brakes)(7)

Axle Breather(s)

- Security and Grease

HYDRAULICS Oil Level Oil(5) Oil Filter Suction Strainer Pilot Filter (if fitted)

- Sample, Change - Change

- Clean - Change

BRAKES Brake System Fluid Level Brake System Fluid

- Check

- Change

ELECTRICS Battery Electrolyte Level (if applicable)

- Check

Battery Terminals for Condition and Tightness

- Check

BODYWORK AND CAB Lift/Displacement/Tilt/Steer Cylinder Pivot Pins

- Grease

Extension Cylinder Piston Rod Pivot Pin

- Grease

All Other Pivot Pins

- Grease

Fire Extinguisher (if fitted)

- Check

Wing Mirrors Condition and Security

- Check

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9813/1800-2 (3-41-03)

3-1-9

Section 3-1 - Routine Maintenance Maintenance Service Schedules

ROPS/FOPS Structure

Operation

100(1)

500

- Check

Doors and Hinges

- Lubricate

Control Lever Linkages

- Lubricate

Windshield Washer Fluid Level

- Check

Cab Heater Fresh Air Filter (if fitted)

- Change

Boom Wear Pad Runways

- Waxoyl

Inner Boom Hoses

- Grease

Boom Wear Pad Clearance (9)

- Check/Adjust

Boom Wear Pad Condition and Security (Replace if required)(9)

- Check/Adjust

1000 1500 2000 8000

ATTACHMENTS Carriage Lock Pins

- Grease

REGISTRATION/CERTIFICATION SWL Stickers (UK) and Flip Chart

- Renew as Required

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil) every 250 hours. Change the engine oil and filter every 250 hours. (3) When the engine is operated with 20% biodiesel change the engine oil and filter every 250 hours. Refer to Technical Data, Fuel System Data, for more information about operating the engine with biodiesel. (4) If operating in dusty adverse working environments, do these jobs more frequently. (5) These jobs must be done by a qualified engineer. (6) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (7) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted. (8) The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice. (9) If operating under arduous conditions, check the boom wear pads every 250 hours.

3-1-10

9813/1800-2 (3-41-03)

3-1-10

Section 3-1 - Routine Maintenance Maintenance Service Schedules

Functional Test and Final Inspection Operation

100(1)

500

1000 2000 6000

ENGINE - Check and Adjust

Idle Speed(2) Torque Converter Stall Speed

(2)

- Check - Check and Adjust

Max. No-Load Speed(2) Exhaust System Security(2)

- Check

Air Inlet System Security

- Check

TRANSMISSION, AXLES AND STEERING Steering - Operation/Phasing

- Check

2WD/4WD Selection (if fitted)

- Check

Transmission Operation

- Check

Forward/Reverse/Gear - Selection/ Operation

- Check

Torque Converter Main Line Pressure(2)

- Check

Neutral Start Operation

- Check

Clutch Disconnect/Dump Button

- Check

HYDRAULICS

Fan Motor Speed (If fitted)

- Check

Attachment Operation/Remote Servo (if fitted)

- Check

Piston Rods Chrome

- Check

- Check and Adjust

MRV Pressure at Max RPM(2) Operation of All Services

- Check

Hose Burst Protection Valves (if fitted) ARV Pressure at 750 RPM

- Check - Check and Adjust

(2)

- Check and Adjust

Steer Circuit MRV Pressure(2) (2)

Parallel Lift/Lower

Chassis Leveling (Sway) Cut-out (if fitted)(2)

- Check

Boom Raise Cut-out (if fitted)(2)

- Check

Stabilizer Leg Cut-out (if fitted)

3-1-11

(2)

9813/1800-2 (3-41-03)

3-1-11

Section 3-1 - Routine Maintenance Maintenance Service Schedules Operation

100(1)

500

- Check

1000 2000 6000

BRAKES Foot Brake - Operation Park Brake

- Check/Adjust

ELECTRICS Alternator - Output(2)

- Check

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

- Check

Stabilizer Indicators

- Check

- Test

- Check

BODYWORK AND CAB Inclinometer (if fitted)(2)

- Check

Glazing for Correct Fit/Leaks

- Check

Seat/Seat Belts

- Check

Air Conditioning (if fitted)

- Check

Forks

- Fit and Check Security

Generally for damage, leaks and wear

- Check

BOOM CHAIN SERVICING Boom Chains

- Oil

Boom Chains - Tension

- Check/Adjust

Boom Chains - Wear and Defects

- Check

Boom Roller - Wear

- Check

(2)(3)

Boom Roller Pivot Pin (with Grease Point)

- Grease

RAS SYSTEM Operation(2) ELECTRONIC DATA LOG Fault code log(2) Service log

(2)

- Record

LIFTING EQUIPMENT Fit for Purpose Test(4) (1) (2) (3) (4)

- Complete

First 100 Hours Service only, to be completed by your JCB Distributor. Jobs which should only be done by a specialist. If operating under arduous conditions, complete this operation every 250 hours. This may be required every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes.

3-1-12

9813/1800-2 (3-41-03)

3-1-12

Section 3-1 - Routine Maintenance Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities ITEM

CAPACITY

Table 3. FLUID/LUBRICANT

JCB Part Number Container Size(1)

US Gal (Liters) Fuel Tank

35 (132)

Diesel Oil (Refer to Fuels)

- MIN

3.3 (12.5)

-10°C to +50°C (14°F to 122°F)

- MAX

3.9 (15)

JCB Cold Climate Engine Oil EP 5W40

Engine (Coolant)(3)

5.3 (20)

Gearbox

5 (19)

Engine (Oil)

JCB Engine Oil EP 15W40

(2)

4001/2605

20 liters

4001/2705

20 liters

JCB Antifreeze HP/Coolant + Water (Refer to Coolant Mixtures)

4006/1120

20 liters

JCB Transmission Fluid EP 10W(4)

4000/2505

20 liters

JCB Gear Oil HP Plus

4000/2205(5)

20 liters

JCB Gear Oil HP Plus

4000/2205(5)

20 liters

JCB Hydraulic Fluid HP15(6)

4002/0503

5 liters

JCB Multigrade Hydraulic Fluid

4002/2020

20 liters

JCB Special HP Grease

4003/2017

400g

-20°C to +50°C (-4°F to 122°F)

-32ºC to 40ºC (-25ºF to 104ºF) Front Axle Housing

4.7 (18)

Hubs (x2)

0.5 (2)

Rear Axle Housing

3.4 (13)

Hubs (x2)

0.5 (2)

Brake System Hydraulic Tank

(7)

34 (128)

Grease Points

(8)

JCB Special MPL-EP Grease

4003/1501

400g

Wear Pad Runways

JCB Waxoyl

4004/0502

5 liters

Boom Hoses

JCB Special Slide Lubricant

4003/1115

400g

JCB Chain Lubricant

4004/0237A

300ml

(8)

Boom Chains

(1) For information about the different container sizes that are available (and their part numbers), contact your JCB Dealer. (2) Do not use ordinary engine oil (3) It is recommended that the cooling system be filled at a maximum rate of 6 liters per minute. If the fill rate is any higher than this then there is a possibility of air becoming trapped in the system. (4) Friction modified oils must not be used (eg Dexron ATF type). (5) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD). (6) !CAUTION: Do not use ordinary brake fluid. (7) This is nominal tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill with all cylinders closed. Watch level sight glass when filling. (8) JCB Special HP Grease is the recommended specification grease. If JCB Special MPL-EP Grease is used, all 50 hour greasing operations must be carried out at ten (10) hour intervals; all 500 hour greasing operations must be carried out at 50 hour intervals.

!MWARNING

Coolant Mixtures T3-009_3

Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period.

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

Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.

7-3-4-4_1

3-1-13

9813/1800-2 (3-41-03)

3-1-13

Section 3-1 - Routine Maintenance Maintenance Fluids, Lubricants and Capacities You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on water hardness, contact your local water authority. The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. 50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °F) Important: Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point. If you use any other brand of antifreeze: – Ensure that the antifreeze complies with International Specification ASTM D6210. – Always read and understand the manufacturer's instructions. – Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used. – Ensure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

3-1-14

9813/1800-2 (3-41-03)

3-1-14

Section 3-1 - Routine Maintenance Maintenance Fuel

Fuel Acceptable and Unacceptable Fuels Important: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.

Fuel Groups The major world fuels standards are divided into four categories. Those that are fully accepted as suitable fuels, those that are acceptable from a â&#x20AC;&#x153;warrantyâ&#x20AC;? point of view, but may have undesirable affects on the expected life of the engine performance changes from original specification, those that will lead to reduce the expected life, and lastly those that are viewed as unacceptable for use. (Note: fuels shown on the same line as each other are considered equivalents). The lists below are not exhaustive of all diesel fuel standards encountered in the marketplace. If comment is required on the suitability of fuel standards not on the list, requests with, if possible, specification details showing at least the key characteristics described above should be forwarded to JCB Service for assessment and comment.

3-1-15

9813/1800-2 (3-41-03)

3-1-15

Section 3-1 - Routine Maintenance Maintenance Fuel Fuel Specification

Advice

Service Comments

The following fuel grades are preferred and may be used with no restrictions or conditions:

For fuel with unspecified parameters, EN590 values apply.

Group 1 EN590 Diesel fuel types - Auto/C0/C1/C2/ C3/C4 BS2869:2006 Class A2

Fuel grades within each standard must be appropriate to the ambient temperature.

ASTM D975-08a Grade 2, US DF2 (military equivalent) JIS K2204:2007 Grades 1, 2 and 3 and Special Grade 3

Appropriate level of fuel cleanliness at the FIE inlet after filtration has to be ensured by the customer

Group 2 Group1 fuels with HFFR WSD in the range 460-520 Âľm .

The following fuels are not preferred and may be used but may lead to reduced FIE life and / or loss of performance:

ASTM D975-91 Class 1-1DA The Ecomax dealer, or JCB Power Systems Applications department, should be consulted for further guidance. Biodiesel is very problematic to store; fuel in storage has to be very carefully managed to ensure that it does not deteriorate during this period.

B20 Biodiesels can cause serious problems for engines. JCB Ecomax Stage 3a / Tier 3 engines have been developed to run with biodiesels up to 20% mix (B20), but NOT with higher biodiesel proportion. The biodiesel content of this mix must be to ASTM D6751, DIN 51606, or ISO 14214 standards. Using a B20 blend of biodiesel requires caution and additional servicing of the engine is required.(1)

No warranty liability will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.

Group 3 AVTUR FS11 (NATO F34, JP8, MIL T83133, The following fuels are not preferred DEF STAN 91-87, DERD 2463) and may be used only with AVCAT FS11 (NATO F44, JP5, MIL T5624, appropriate additives and will lead to reduced FIE life and / or loss of DERD 2452, AVTOR) performance: JET A1 (NATO F35, DEF STAN 91-91, DERD 2494) AVCAT (NATO F43, JP5 without additives) JET A (ASTM D1655) ASTM D3699 Kerosene JP7 (MIL T38219 XF63) NATO F63 Group 4 - Unacceptable Unmodified Vegetable Oils and Biodiesels over 20% concentration (1) See your JCB Dealer for advice on service requirements.

3-1-16

9813/1800-2 (3-41-03)

3-1-16

Section 3-1 - Routine Maintenance Maintenance Fuel Additives The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. Note: These products are given as examples only. The information is derived from the manufacturers data. The products are not recommended or endorsed by JCB. Contact your JCB dealer for further advice. – Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels. – Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm. – Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%).

Service Requirements for use of B20 Biodiesel – The engine oil must be a grade CH4 as minimum specification.

Note: If performance related issues are to be reported to JCB Service, and the engine has been run on biodiesel, then the fuel system must be filled with standard diesel (at least 2 x tank fills) to EN590 specification and relevant stall speeds recorded prior to making the report. Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels. Using a B20 blend of biodiesel requires caution and additional servicing of the engine is required. K Service Requirements for use of B20 Biodiesel ( T 3-1-17) Failure to follow the additional recommended service requirements may lead to a warranty claim being declined. Failures resulting from the incorrect use of biodiesels or other fuel additives are not defects of the JCB Ecomax engine workmanship and therefore will not be supported by JCB Warranty.

– Do not leave unused B20 biodiesel in the fuel tank for extended periods (top up each day). – Make sure that 1 in 5 fuel tank fills use standard diesel to EN590 specification, this will help to prevent `gumming'. – Make sure regular oil sampling is completed (look for excessive unburnt fuel content, water or wear particles. – Change the engine oil and filter more frequently (as a minimum half the recommended intervals), or as indicated by oil sampling. – Change the fuel filters more frequently (as a minimum half the recommended intervals), or if there are engine performance related issues. – Make sure the fuel is stored correctly, care must be taken to make sure no water enters the machine fuel tank (or the storage tank). Water will encourage micro-bacterial growth. – Make sure that the fuel pre-filter is drained DAILY (not every week as currently advised). – Use heater kits in low ambient temperature territories. – The biodiesel must meet the following standards: ASTM D6751, DIN 51606, ISO 14214 Note: If necessary use a test kit to confirm the fuel specification. Testing kits are available (not from JCB currently), use the internet as a source for the kits.

3-1-17

9813/1800-2 (3-41-03)

3-1-17

Section 3-1 - Routine Maintenance Maintenance Fuel

Usage and Effects of Fuels

can cause fuel system corrosion and early fuel filter blocking. Biodiesels must be stored to exclude water absorption and oxidation. It will be necessary to consult and seek advice from your fuel supplier, the effectiveness of conventional antibacterial additives when used in biodiesel is still being investigated in the fuel industry. A high percentage biodiesel mixture (>20%) can lead to fuel gelling and filter blocking in low temperature operation, it may also effect the power and performance of the engine.

Note: The information that follows does not indicate types of fuel that are acceptable or unacceptable. K Acceptable and Unacceptable Fuels ( T 3-1-15).

Acceptable Fuels 1

Ultra Low Sulphur Diesel (EN590) Available throughout the UK, Europe and North America since March 1999. This fuel has a maximum sulphur content of 0.001% (0.0015% in North America) by weight and a further reduction in the natural lubricity and aromatic content than experienced with low sulphur diesel. Major oil producers will add lubrication improvers and also maintain the total aromatic content to an acceptable level.

To minimise the risk of engine damage when using a B20 mix, there are additional service requirements. K Service Requirements for use of B20 Biodiesel ( T 3-1-17) If the recommended actions are not taken there may be the following consequences:- low temperature filter clogging- injectors lacquering / stickingdeterioration of seals and rubber hoses- corrosion of metal parts in the fuel system- engine performance problems. These risks will be increased if the fuel has been poorly stored, that is deteriorated through oxidation and / or water absorption.

B20 Biodiesel -7-20% Biodiesel refers to pure fuel before it is blended with diesel fuel K B100 - Chemically Modified Vegetable Oils (FAME/VOME) ( T 3-1-18). When biodiesel is blended with diesel fuel it is referred to as B5, B20 etc., where the number indicates the percentage of biodiesel in the fuel, for example B5 contains 5% biodiesel. Biodiesel has different characteristics than mineral based fuels, this could lead to seals swelling, fuel system corrosion and seal damage. Biodiesels will `cloud' at higher temperatures than mineral based fuels. To explain Cloud Point - the lowest temperature at which fluid can flow and performs its functions is referred to as Pour Point. Just prior to reaching its Pour Point the diesel fluid becomes `cloudy' due to crystallization of waxy constituents - this is know as Cloud Point. Using diesel at temperature below its cloud point can result in filter clogging. To prevent this happening preheating will be required. Using B20 biodiesel can result in unburnt fuels accumulating in the engine oil, ultimately this can affect the engine oil efficiency and lead to engine damage (with standard diesel any unburnt fuel evaporates off the lubricating oil).

Unacceptable Fuels 3

B100 - Chemically Modified Vegetable Oils (FAME/ VOME) These fuels have been derived from a wide range of vegetable oils and animal fats, resulting in better stability, viscosity and cetane number than those produced from unmodified vegetable oils, but it is recognised that there are potential problems associated with the finished fuel characteristics. These oils are less stable than mineral oil derived fuels when stored and they will readily degrade producing fatty acids, methanol and water, none of which are desirable in the FIE. These effects are known to be accelerated when the fuel is stored in the presence of air and water together. An extract `common statement' from the FIE manufactures specifies that â&#x20AC;&#x153;The fuel injection equipment manufacturers can accept no liability whatsoever for failure attributable to operating their products with fuels for which the products were not designed, and no warranties or representations are

The natural properties of biodiesel make it a good medium for micro bacterial growth, these microbes

3-1-18

9813/1800-2 (3-41-03)

3-1-18

Section 3-1 - Routine Maintenance Maintenance Fuel made as to the possible effects of running these products with such fuels”. The three most common Fame types are RME Rapeseed methyl ester (preferred crop in Europe), SME - Soyabean methyl ester (preferred crop in USA). Less common FAME's can be derived from animal fats (e.g. modified beef extracts) and reclaimed cooking oils. 4

Unmodified Vegetable Oils Burned in diesel engines neat or used as an extender to mineral derived fuel. When these are subjected to heat in the fuel injection system they form sticky deposits that can be found inside the fuel pump and a hard lacquer in the injectors where exposure to even higher temperatures takes place.

Sulphur Content

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

Effects of Fuel Contaminates The effect of dirt, water and other contaminants in diesel can be disastrous for injection equipment: – Dirt - A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to greater leakage, uneven running and poor fuel delivery. – Water - water can enter fuel through poor storage or careless handling, and will almost inevitably condense in fuel tanks. The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt, causing rapid wear, corrosion and in severe cases, even seizure. It is vitally important that water is prevented from reaching the fuel injection equipment. The filter/water trap must be drained regularly. – Wax - Wax is precipitated from diesel when the ambient temperature falls below that of the fuel's cloud point, causing a restriction in fuel flow resulting in rough engine running. Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity and limit wax formation.

ENG-3-2

Chemical Contamination It should be noted that exposure of fuel to surfaces containing Copper (Cu), Zinc (Zn) or Lead (Pb) con adversely affect fuel quality and should be minimised.

3-1-19

9813/1800-2 (3-41-03)

3-1-19

Section 3-1 - Routine Maintenance Maintenance Prepare the Machine for Maintenance

Prepare the Machine for Maintenance Refer to Section 2 - General Procedures for details of preparing the machine for maintenance. K Related Topics ( T 3-1-1)

3-1-20

9813/1800-2 (3-41-03)

3-1-20

Section 3-1 - Routine Maintenance Maintenance Cleaning the Machine

Cleaning the Machine

!MCAUTION

Introduction T3-062_3

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

Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned.

The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system. Ensure that the engine air intake, alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3_2

When cleaning is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.

Important: Do not aim the water jet directly at bearings, oil seals, the engine air intake or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors.

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

Use a low pressure water jet and brush to soak off caked mud or dirt.

Detergents

Use a pressure washer to remove soft dirt and oil.

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

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

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

Pressure Washing and Steam Cleaning

Preparing the Machine for Cleaning 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

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

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

Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape.

Remove the undershield.

13-3-2-10_2

When cleaning around the engine and radiator, debris will be released more easily if the undershields are removed. Refer to Access Panels, Undershield.

3-1-21

9813/1800-2 (3-41-03)

3-1-21

Section 3-1 - Routine Maintenance Maintenance Cleaning the Machine

Cleaning the Machine

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

!MWARNING

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

8-3-4-8

Pay particular attention to: 1

If the radiator tubes/fins get clogged the radiator will be less efficient. a

Open the engine cover and remove undershield. Refer to Access Panels.

the

b Use a soft bristle brush Y to remove all unwanted material from the rear of radiator A. c

Release fastener B and pull the condenser C away from the radiator. Use the soft bristle brush to remove all unwanted material from the two sides of condenser C and the front of the radiator. Then push back the condenser and lock in position with fastener B.

Fig 1. 2

C126410-C1

Engine

!MWARNING Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. ENG-8-5_2

d Remove the loosened material is out of the engine compartment.

3-1-22

9813/1800-2 (3-41-03)

3-1-22

Section 3-1 - Routine Maintenance Maintenance Cleaning the Machine Important: Stop the engine and allow it to cool for at least one hour. DO NOT attempt to clean any part of the engine while it is running.

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

When the pressure washing is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.

Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned.

Before working on specific areas of the engine use a compressed air jet to dry off any moisture. When the area is dry use a soft clean brush to remove any sand or grit particles that remain.

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

Before carrying out any service procedures that require components to be removed, the engine must be properly cleaned.

Make sure that the electrical system is isolated.

b Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape. 3 c

Cover the alternator with a plastic bag to prevent water ingress.

Boom chains. Do not aim the jet wash directly at the boom chains.

!MCAUTION

d Seal the engine air intake, exhaust and breather system. e

Make sure that the oil filler caps and dipstick are correctly installed.

Use a low pressure water jet and brush to soak off caked mud or dirt.

You must climb on the machine to install or remove the central access panels. Take care, especially if the machine is wet. Remove mud and oil before you climb on the machine. Do not put your body weight on the central access panels. 5-3-4-11

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

g Apply an approved cleaning and degreasing agent with a brush. Obey the manufacturers instructions. h Use a pressure washer to remove the soft dirt and oil. Important: DO NOT aim the water jet directly at oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors.

3-1-23

9813/1800-2 (3-41-03)

3-1-23

Section 3-1 - Routine Maintenance Maintenance Cleaning the Machine

Fig 2.

C075220-C1

Debris can collect under the boom. K Fig 2. ( T 31-24). Remove all combustible material.

When you have finished cleaning the machine, install the undershield.

3-1-24

9813/1800-2 (3-41-03)

3-1-24

Section 3-1 - Routine Maintenance Maintenance Checking for Damage

Checking for Damage Check the Machine Body and Structure T3-063_5

Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Pay particular attention to the following: – Inspect all lifting point welds.

– Signs of distortion (bulges) – Cuts or wear – Embedded objects (nails, etc.) Install the valve caps firmly to prevent dirt from entering the valve. Inspect the tire valve for leaks, when you check the tire pressures.

Check the Seat and Seat Belt

– Inspect all pivot point welds. – Inspect the condition of all pivot pins. – Check pivot pins are correctly in place and secured by their locking devices. Check steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass and mirrors. Replace damaged items. Check all lamp lenses for damage. Check all attachment teeth are undamaged and secure. Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary. Note damaged paintwork for future repair.

When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years. 2-3-1-7_1

Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly. Check that the belt mounting bolts are undamaged, correctly fitted and tightened. Check seats are undamaged and secure. Check seat adjustments for correct operation.

Check the Tires

!MWARNING

T3-008_2

T3-065U_2

Check the Hydraulic Hoses and Fittings

!MWARNING

T3-072

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

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.

13-2-1-2U_2

INT-3-3-2_4

Always drive with consideration for the condition of the tires. Incorrect tyre pressures will affect the stability of the machine. Check the tires daily for the correct tire pressure and signs of damage. For example:

Inspect the hoses regularly for:

3-1-25

9813/1800-2 (3-41-03)

3-1-25

Section 3-1 - Routine Maintenance Maintenance Checking for Damage

Checking the ROPS/FOPS Structure

– Damaged hose ends – Chafed outer covers

!MWARNING

– Ballooned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again.

Replacement hoses must be of the same size and standard.

INT-2-1-9_6

Check the Electrical Circuits

For assistance, contact your JCB distributor. Failure to take these precautions could result in death or injury to the operator.

T3-099

Inspect the electrical circuits regularly for: – Damaged connectors – Loose connections

Check the structure for damage.

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

Make sure that the ROPS/FOPS mounting bolts A are tightened to the correct torque setting.

– Chafing on wiring harnesses – Corrosion – Missing insulation – Incorrect routing of harness Do not use the machine if one or more of these faults are found. You must make sure that the electrical circuit is repaired immediately.

3-1-26

9813/1800-2 (3-41-03)

Item A

Table 4. Torque Settings Nm (lbf ft) 205 (151)

3-1-26

Section 3-1 - Routine Maintenance Maintenance Checking for Damage

Fig 3.

3-1-27

9813/1800-2 (3-41-03)

C016650-1

3-1-27

Section 3-1 - Routine Maintenance Maintenance Greasing

Greasing Introduction

Preparing the Machine for Greasing T3-028_2

You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for the correct intervals. Note: The machine must always be greased after pressure washing or steam cleaning.

Make the machine safe before you start a greasing procedure. Refer to Prepare the Machine for Maintenance. Important: You can complete most of the greasing procedures with the boom lowered. If you lift the boom to get access for greasing, you must install the maintenance strut on the boom.

Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient. Stop greasing when fresh grease appears at the joint. Use only the recommended type of grease. Do not mix different types of grease, keep them separate. In the following illustrations, the grease points are numbered. Count off the grease points as you grease each one. Refit the dust caps after greasing. Note: Where applicable, refer to the manufacturers manual for instructions on the maintenance of optional attachments.

3-1-28

9813/1800-2 (3-41-03)

3-1-28

Section 3-1 - Routine Maintenance Maintenance Greasing

Every 50 Hours

Fig 4.

3-1-29

9813/1800-2 (3-41-03)

C077700-C1

3-1-29

Section 3-1 - Routine Maintenance Maintenance Greasing

Fig 5. Additional Grease Points for 510-56, 512-56 and 514-56 Machines Only

3-1-30

9813/1800-2 (3-41-03)

C077710-C2

3-1-30

Section 3-1 - Routine Maintenance Maintenance Greasing

Every 500 Hours

Extend the boom fully.

Boom

Remove the boom rear cover A. Refer to Access Panels, Rear Boom Cover.

!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.

Spray Waxoyl evenly over the boom wear pad runways 1 and 2.

Apply slide lubricant to inner hoses and hose runs.

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.

Allow 2-3 hours drying time before retracting the boom.

Machines with a 3-stage boom. K Fig 8. ( T 3-1-32). a

5-3-1-9

Apply grease to the boom roller pivot pins 3 and 4.

Machines with a 4-stage boom. K Fig 9. ( T 3-1-32). a

Fully retract the boom to get access to grease point 7. Apply grease to the boom roller pivot pin 7.

b Grease point 8 is accessed through the right side of the boom. Extend the boom assembly until the holes in the boom align with the grease nipple. Apply grease to the boom roller pivot pin 8. c 7

Fig 6.

Install the boom rear cover A.

269841-1

Fig 7.

3-1-31

Apply grease to the boom roller pivot pins 5 and 6.

9813/1800-2 (3-41-03)

200660-3

3-1-31

Section 3-1 - Routine Maintenance Maintenance Greasing

Fig 8. 3-Stage Boom

Fig 9. 4-Stage Boom

3-1-32

9813/1800-2 (3-41-03)

254910-1

C088160

3-1-32

Section 3-1 - Routine Maintenance Maintenance Greasing Drive Shafts

Fig 10.

3-1-33

9813/1800-2 (3-41-03)

263620-1

3-1-33

Section 3-1 - Routine Maintenance Maintenance Greasing

Every 1000 Hours Boom Extension Cylinder Pivot Pins

Fig 11.

3-1-34

9813/1800-2 (3-41-03)

T018020-7-C1

3-1-34

Section 3-1 - Routine Maintenance Maintenance Oiling

Oiling The following points should be lightly oiled with engine oil at the periods stated in the Service Schedules:

Control Levers 1

Make the machine safe with the boom lifted. Refer to Prepare the Machine for Maintenance.

Remove the central access panels B then C to expose the chassis access hole. Refer to Access Panels, Central Access Panels.

Oil the clevis D at the end of each control rod E.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Park Brake Cable

!MWARNING Oil on the brake disc will reduce brake effectiveness. Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer's safety instructions. If the pads are oily, new ones must be fitted. 2-3-2-3_3

Oil the clevis A at the brake end of the cable.

Fig 13.

C075220-C3

Fig 12.

3-1-35

9813/1800-2 (3-41-03)

3-1-35

Section 3-1 - Routine Maintenance Maintenance Oiling

Boom Chains The boom drive chains should be sprayed with JCB Chain Lubricant at the periods stated in the Service Schedules. Note: Spray the chain with an even coating, avoid over oiling. 1

Remove the boom rear cover A. Refer to Access Panels, Rear Boom Cover.

Spray the drive chains 1 with JCB Chain Lubricant while the boom is being extended.

With the boom extended spray the drive chains 2 with JCB Chain Lubricant.

Install the boom rear cover A.

Fig 14.

Fig 15.

3-1-36

9813/1800-2 (3-41-03)

269841-4

200660-2

3-1-36

Section 3-1 - Routine Maintenance Maintenance Access Panels

Access Panels Battery Cover Opening and Closing Get access to the battery and the primary fuses by opening the battery cover A. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Hold the battery cover, then remove the bolts B.

Lower the cover.

To close the cover, complete steps 2 and 3 in reverse.

Tighten the bolts B to a torque of 25Nm (17.7 lbf ft).

Fig 16.

3-1-37

9813/1800-2 (3-41-03)

T015880-2

3-1-37

Section 3-1 - Routine Maintenance Maintenance Access Panels

Engine Cover Opening and Closing Get access to the engine by opening the engine cover A.

!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 Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit.

Fig 17.

C122270

10-1-1-40

Important: Before you stop the engine, you must allow the engine to operate at low idle for four minutes. The delay allows the coolant temperature to stabilise before you open the engine cover. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Unlock and release catch B. Allow the cover to raise on its gas strut. Keep hold of the cover while it rises.

Pull the cover down and engage catch B. We recommend you lock the engine cover.

Note: We recommend that you lock the engine cover to prevent theft and tampering.

3-1-38

9813/1800-2 (3-41-03)

3-1-38

Section 3-1 - Routine Maintenance Maintenance Access Panels

Undershield

Removal and Replacement When cleaning around the engine and radiator, debris will be released more easily if the undershield A is removed.

!MWARNING

You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Fig 18.

C126360

Block all four wheels before getting under the machine. 2-3-2-1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Get access to the undershield (found below the engine compartment).

Hold the undershield A then remove the bolts B.

Lower the undershield to the ground.

Use the bolts B to attach the undershield to the machine.

3-1-39

9813/1800-2 (3-41-03)

3-1-39

Section 3-1 - Routine Maintenance Maintenance Access Panels

Rear Boom Cover Removal and Replacement Remove the rear boom cover A to get access to the wear pad runways and boom chains. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Hold the boom cover, then remove the bolts B.

Lower the cover.

To install the cover, complete steps 2 and 3 in reverse.

Fig 19.

3-1-40

9813/1800-2 (3-41-03)

269841-3

3-1-40

Section 3-1 - Routine Maintenance Maintenance Access Panels

Central Access Panels Removal and Replacement

!MCAUTION You must climb on the machine to install or remove the central access panels. Take care, especially if the machine is wet. Remove mud and oil before you climb on the machine. Do not put your body weight on the central access panels. 5-3-4-11

Make the machine safe with the boom lifted. Refer to Prepare the Machine for Maintenance.

Remove the four bolts D. Lift off the panel A.

Disengage the panel B from the location spigots E. Lift off the panel.

Remove the two bolts F. Lift off panel C.

To replace the panels complete steps 2, 3 and 4 in reverse.

3-1-41

9813/1800-2 (3-41-03)

Fig 20.

C075220-3

3-1-41

Section 3-1 - Routine Maintenance Maintenance Cab Heater and Air Conditioning

Cab Heater and Air Conditioning Changing the Air Intake Filter P5-3014

Important: In dusty conditions the filter will require cleaning/changing more often than detailed in the service schedule.

!MWARNING Boom Maintenance Strut A raised boom can drop suddenly and cause serious injury. Before working under a raised boom, fit the boom maintenance strut. See Boom Safety Strut, MAINTENANCE section. 5-1-5-7_2

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Make the machine safe with the boom lifted. Refer to Prepare the Machine for Maintenance.

Remove screw A and cover B to gain access to filter C.

Remove the filter C.

Fig 21.

A711630-2

Note: Do not try to clean the filter. If the filter was clogged, change it more often. 4

Carefully fit the new filter into its housing. Ensure that the tab D locates behind the edge of panel E before fitting screw A.

3-1-42

9813/1800-2 (3-41-03)

3-1-42

Section 3-1 - Routine Maintenance Maintenance Boom

Boom Boom Chains Adjustment 3-Stage Boom 1

Position the machine on firm level ground, apply the park brake. Raise the boom to the horizontal position and fully retract the boom.

If any of the chains have been replaced, you must set the adjustment screws to the dimensions shown. Table 5.

Adjustment Screw

Dimension Y

A (Extend Chain)

24mm (0.95 in)

B (Retract Chain)

20mm (0.8 in)

With the boom fully retracted, measure dimension X. The initial setting is 3 - 15mm (0.1 - 0.6 in). If necessary, adjust the chains to obtain the initial setting dimension X: If dimension X is too great, shorten the retract chain with adjustment nut A. If dimension X is too small, shorten the retract chain with adjustment nut B.

Important: Tighten the extend chains equally to maintain the same tension in both chains. 4

Extend the boom.

Spray the chains with JCB Chain Lubricant.

Retract the boom and recheck dimension X. If necessary, repeat step 3.

Fully extend the boom and then retract by 50 mm (2.0 in).

Fig 22. 8

C088380-1

Measure the gap Z between the under side of the extend chain and the top of the intermediate boom at the mid-point of the span. K Fig 23. ( T 3-1-44). If necessary, adjust extend chains equally at A to obtain 56 to 66 mm (2.2 to 2.6 in). Make sure the end links are staggered to prevent fretting.

3-1-43

9813/1800-2 (3-41-03)

3-1-43

Section 3-1 - Routine Maintenance Maintenance Boom Note: If the end link threads or the nuts are damaged the complete end link must be replaced.

Fig 23.

C012710-2

After the correct measurement has been obtained extend and retract the boom several times and recheck the gap Z. Adjust the extend chains as necessary.

On completion fit new split pins if the old split pins have been removed.

Note: Once the retract chain has been adjusted, the extend chains can be checked and adjusted as necessary. The retract chain must not be altered while adjusting the extend chains.

3-1-44

9813/1800-2 (3-41-03)

3-1-44

Section 3-1 - Routine Maintenance Maintenance Boom 4-Stage Boom 1

Position the machine on firm level ground, apply the park brake. Raise the boom to the horizontal position and fully retract the boom.

If any of the chains have been replaced, you must set the adjustment screws to the dimensions shown. Table 6.

Adjustment Screw

Dimension Y

A (Extend Chain)

24mm (0.95 in)

B (Retract Chain)

20mm (0.8 in)

With the boom fully retracted measure dimension X and Y. The correct initial settings are: X = 560 to 572 mm (22.0 to 22.5 in) Y = 10 to 22 mm (0.4 to 0.87 in)

If necessary, adjust the chains to obtain the correct initial setting dimensions: If the dimension is too great, shorten the retract chain with adjustment nut A. If the dimension is too small, shorten the extend chains with adjustment nuts B.

Note: Remove the rear boom cover to get access to the adjustment nuts A.

Fig 24.

Important: Each boom section has two extend chains. Tighten the extend chain adjusters equally to maintain the same tension in both chains. 5

Extend the boom.

Spray the chains with JCB Chain Lubricant.

Retract the boom and recheck dimension X and Y. If necessary, repeat step 4. Fully extend the boom and then retract by 50.8 mm (2.0 in).

Measure the gap Z between the under side of the extend chain and the top of the intermediate boom at the mid-point of the span.

3-1-45

If necessary, adjust extend chains equally at B. The correct dimension is 93 to 103 mm (3.6 to 4 in) for the intermediate boom and 68 to 78 mm (2.6 to 3.7 in) for the inner boom. 10

C076900-1

Make sure the end links are staggered to prevent fretting.

Note: If the end link threads or the nuts are damaged the complete end link must be replaced.

9813/1800-2 (3-41-03)

3-1-45

Section 3-1 - Routine Maintenance Maintenance Boom

Fig 25.

C012710-2

After the correct measurement has been obtained extend and retract the boom several times and recheck the gap Z. Adjust the extend chains as necessary.

On completion fit new split pins if the old split pins have been removed.

Note: Once the retract chain has been adjusted, the extend chains can be checked and adjusted as necessary. The retract chain must not be altered while adjusting the extend chains.

3-1-46

9813/1800-2 (3-41-03)

3-1-46

Section 3-1 - Routine Maintenance Maintenance Brakes

Brakes Park Brake

Testing the Park Brake

!MWARNING

Introduction

!MWARNING

T3-071

Do not use a machine with a faulty park brake.

T3-087

Before testing the park brake make sure the area around the machine is clear of people. 2-2-4-5

3-2-3-10_2

â&#x20AC;&#x201C; The park brake must be fully engaged when the lever is vertical.

!MWARNING Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the park brake.

A339340

â&#x20AC;&#x201C; The park brake warning light must come on when the park brake is engaged and forward or reverse is selected (starter switch at I).

3-2-3-11

Make sure that you obey all health and safety precautions before you test or adjust the park brake. If you have any queries concerning the park brake test or adjustment procedures, consult your local JCB distributor.

Enter the machine. Fasten your seat belt (if fitted) and park the machine on a level dry surface.

Fully apply park brake.

Start the engine and raise the attachments to the appropriate travel position.

Select fourth gear.

Push down hard on foot brake pedal.

Select forward drive. The park brake warning light must illuminate.

!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

Test the park brake as follows: a

Move the park brake lever fractionally forward until the park brake warning light is just extinguished.

b Slowly release the foot brake pedal. c

3-1-47

9813/1800-2 (3-41-03)

If the machine has not moved, use the accelerator to gradually increase the engine speed to approximately 1500 RPM. The machine should not move.

3-1-47

Section 3-1 - Routine Maintenance Maintenance Brakes Note: Do not do this test for longer than 20 seconds.

Park Brake Adjustment

!MWARNING

d Reduce engine speed to idle and select neutral.

Return the park brake lever to the fully on position.

Lower attachments and stop the engine.

Over adjustment of the park brake could result in the park brake not fully releasing. 0011

If the machine moved during the test, adjust the park brake and repeat the test. Refer to Park Brake Adjustment.

Disengage the park brake (lever horizontal). Failure to disengage the park brake fully will result in excessive wear of the park brake mechanism.

Pull and turn handle grip A clockwise, half a turn.

Test the park brake. Refer to Testing the Park Brake.

If the brake fails the test, repeat steps 1, 2 and 3. If there is no more adjustment and pin B is at the end of its travel get the brake checked by your JCB dealer.

Fig 26.

3-1-48

9813/1800-2 (3-41-03)

A347580A-4

3-1-48

Section 3-1 - Routine Maintenance Maintenance Brakes

Foot Brake Checking the Foot Brake Fluid Level

!MWARNING Faulty brakes can kill. If you have to top up the brake reservoir frequently, get the brake system checked by your JCB Dealer. Do not use the machine until the fault has been put right. 2-3-2-5_1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Remove the clip A from the plate B.

Open the cover C to get access to the brake fluid reservoir D.

The correct fluid level is marked on the reservoir. If necessary, add fluid as in Step 5.

Fig 27.

T020390-1

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

Remove the reservoir cap E. Do not use ordinary brake fluid. Carefully pour in the fluid until it reaches the FLUID LEVEL mark. Avoid spilling it. Wipe up any spillage.

Install the reservoir cap E.

Close then lock the cover with the clip A, as shown. K Fig 27. ( T 3-1-49).

3-1-49

9813/1800-2 (3-41-03)

Fig 28.

T015450-2

3-1-49

Section 3-1 - Routine Maintenance Maintenance Electrical System

Electrical System Battery

Checking the Electrolyte Level

Battery Disconnection/Connection

Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below.

T3-020_2

!MWARNING

T3-019U_3

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

Get access to the battery. See Access Panels.

Disconnect and remove battery. See Battery Disconnection/Connection.

Disconnection 1

Get access to the battery. See Access Panels.

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

Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6

Connection 1

!MWARNING

Check the battery. a

Remove covers A. Look at the level in each cell. The electrolyte should be 6 mm (1/4 in) above the plates. Top up if necessary with distilled water or de-ionized water.

If the terminal is dirty, clean the post.

Fig 29. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper. c

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

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

Close and lock the access panels.

3-1-50

Fig 30. 4

Refit battery.

Close and lock the access panels.

9813/1800-2 (3-41-03)

3-1-50

Section 3-1 - Routine Maintenance Maintenance Electrical System

Jump Starting the Engine

!MWARNING

The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now. The engine will not start unless the park brake is on.

Set all switches in the cab to off.

Connect the booster cables as follows:

T3-021U

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

Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels.

b Connect the positive booster cable to the positive (+) terminal on the machine battery. Connect the other end of this cable to the positive (+) terminal of the booster supply.

When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This prevents any chance of sparks near the battery.

Set all the machine switches to their OFF positions before connecting the external power supply. Even with the starter switch set to off some circuits will be energised when the external power supply is connected. Do not connect the booster (slave) supply directly across the starter motor. Doing this by-passes the neutral gear safety switch. If the machine is in gear, it may 'runaway' and kill or injure bystanders. Use only sound jump leads with securely attached connectors. Connect one jump lead at a time. The machine has a negative ground electrical system. Check which battery terminal is positive (+) before making any connections. Keep metal watch straps and jewelry away from the jump lead connectors and the battery terminals - an accidental short could cause serious burns and damage equipment.

Connect the negative (-) booster cable to a good frame ground on the machine, away from and below the battery.

Note: A good frame ground is part of the main frame, free from paint and dirt. Do not use a pivot pin for an ground. d Connect the other end of this cable to the negative (-) terminal on the booster supply. 4

Do the Pre-Start Checks.

Start the engine.

!MWARNING When the engine is running, there are rotating parts in the engine compartment. Before disconnecting the cables, make sure that you have no loose clothing (cuffs, ties etc.) which could get caught in rotating parts. 2-2-4-3

Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system. If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply.

Unlock and open the battery cover.

Disconnect the negative booster cable from the machine frame ground. Then disconnect it from the booster supply. Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.

Close and lock the battery cover.

4-2-2-3U_1

3-1-51

9813/1800-2 (3-41-03)

3-1-51

Section 3-1 - Routine Maintenance Maintenance Electrical System

Fuses For fuse and relay locations and identification refer to Section C - Fuses and Relays. K Related Topics ( T 31-1)

3-1-52

9813/1800-2 (3-41-03)

3-1-52

Section 3-1 - Routine Maintenance Maintenance Electrical System

Primary Fuses For fuse and relay locations and identification refer to Section C - Fuses and Relays. K Related Topics ( T 31-1)

3-1-53

9813/1800-2 (3-41-03)

3-1-53

Section 3-1 - Routine Maintenance Maintenance Electrical System

Relays For fuse and relay locations and identification refer to Section C - Fuses and Relays. K Related Topics ( T 31-1)

3-1-54

9813/1800-2 (3-41-03)

3-1-54

Section 3-1 - Routine Maintenance Maintenance Electrical System

Engine Compartment Fuse and Relay Box For fuse and relay locations and identification refer to Section C - Fuses and Relays. K Related Topics ( T 31-1)

3-1-55

9813/1800-2 (3-41-03)

3-1-55

Section 3-1 - Routine Maintenance Maintenance Engine

Engine Oil and Filter Checking the Oil Level 1

Get access to the engine. Refer to Access Panels, Engine Cover.

Check that the oil level is between the maximum and minimum marks on the dipstick A.

!MWARNING Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control. GEN-1-18

If necessary, add the recommended oil through the filler B to the maximum level.

Fit filler cap and dipstick, make sure that they are fully inserted and tightened.

B A

Fig 31.

3-1-56

C125210-C1

9813/1800-2 (3-41-03)

3-1-56

Section 3-1 - Routine Maintenance Maintenance Engine Changing the Oil and Filter

Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil.

Operate the engine until the oil pressure low warning light has extinguished. Check for oil leakage. When the oil has cooled, check the oil level again, and if necessary top up with clean engine oil.

K Fig 32. ( T 3-1-58) 1

Get access to the engine. Refer to Access Panels, Engine Cover.

Place a container of suitable size beneath the sump drain plug C.

!MCAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug. 13-3-1-15

Remove drain plug C and its 'O' ring D. Let the oil drain out, then clean and refit the drain plug with a new 'O' ring. Torque tighten the plug to 40 - 60 Nm (30 - 44 lbf ft).

Loosen and remove filter housing drain plug E. Let the oil fully drain. Refit the plug. Torque tighten the plug to 40 - 60 Nm (30 - 44 lbf ft).

Unscrew the filter canister F, using a chain wrench if necessary.

Clean the seal face of the filter head G.

Smear the seal H on the new filter canister with clean engine oil.

Screw in the new filter canister - hand tight only.

Through one of the filler points B, fill the engine with the recommended oil to the MAX mark on the dipstick A. Wipe off any spilt oil, refit the filler cap and make sure it is secure.

3-1-57

9813/1800-2 (3-41-03)

3-1-57

Section 3-1 - Routine Maintenance Maintenance Engine

B A

H G

E Fig 32.

3-1-58

9813/1800-2 (3-41-03)

C125210-C2

3-1-58

Section 3-1 - Routine Maintenance Maintenance Engine

Cooling System

Checking the Coolant Level Visually check the coolant level daily. Check the quality of the antifreeze mixture every year before the cold weather starts. Change it every two years.

!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

Get access to the engine. Refer to Access Panels, Engine Cover.

The coolant level should be between the MIN and the MAX marks on coolant reservoir.

Note: If the level in the expansion bottle is low, then continue with steps 3 to 4. 3

Fig 33.

C125210-C3

Carefully loosen cap A on the coolant reservoir. Let any pressure escape before removing the cap. Fill with pre-mixed water/antifreeze until it reaches the correct level.

Note: To prevent air becoming trapped in the cooling system, do not exceed the maximum fill-rate shown. Refer to Fluids, Lubricants and Capacities. 4

Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and checks for leaks.

3-1-59

9813/1800-2 (3-41-03)

3-1-59

Section 3-1 - Routine Maintenance Maintenance Engine Changing the Coolant

Get access to the engine. Refer to Access Panels, Engine Cover.

Carefully loosen cap A on the coolant reservoir. Let any pressure escape before removing the cap.

Place a container of suitable size beneath the radiator.

Disconnect the bottom hose from the radiator.

Flush the system using clean water. After flushing, reconnect the bottom hose to the radiator.

Use the recommended mix of clean, soft water and antifreeze. Fill to the MIN level on coolant reservoir.

Fig 34.

C125210-C3

Note: To prevent air becoming trapped in the cooling system, do not exceed the maximum fill-rate shown. Refer to Fluids, Lubricants and Capacities. 7

Refit the filler cap. Make sure it is tight.

Run the engine for a while, to raise the coolant to working temperature and pressure.

Note: Make sure the cab heater control is in the hot position. This will ensure the coolant mixture circulates through the entire cooling system. 9

Stop the engine. Check for leaks. Check the coolant level and top up if necessary.

3-1-60

9813/1800-2 (3-41-03)

3-1-60

Section 3-1 - Routine Maintenance Maintenance Engine

Crankcase Ventilation Changing the Filter Element The filter element must be changed at the recommended interval. 1

Get access to the engine. Refer to Access Panels, Engine Cover.

Rotate cover B and lift off.

Lift out the filter element C and discard it.

Clean the inside of the filter housing D. Remove all oil and sludge contamination.

Make sure that the oil drain in the bottom of the filter housing is not blocked with sludge. If necessary remove the drain pipe at the engine. Make sure that the drain pipe non-return ball valve at the bottom of the filter housing is fitted and free to move.

Fit a new filter element C.

Important: Install the correct type of filter element. 7

Install the filter cover B.

Fig 35.

3-1-61

9813/1800-2 (3-41-03)

C126410-C2

3-1-61

Section 3-1 - Routine Maintenance Maintenance Engine

Front End Accessory Drive Belt Introduction The front end accessory drive belt (FEAD) drives the alternator, water pump and the air conditioning compressor (if fitted). The belt is automatically kept in tension so will not need to be adjusted.

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

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

Fig 36.

C122210-C2

0094

To get access to the drive belt for maintenance: 1

Open the engine cover. Refer to Access Panels, Engine Cover.

Remove the drive belt guard B. K Fig 36. ( T 31-62).

Important: When maintenance is complete, make sure that the guard is installed. Do not operate the machine unless the guard is installed correctly.

3-1-62

9813/1800-2 (3-41-03)

3-1-62

Section 3-1 - Routine Maintenance Maintenance Engine Inspecting the Drive Belt At the recommended service interval, visually inspect the belt for damage. 1

Get access to the drive belt. Refer to Front End Accessory Drive Belt, Introduction.

Inspect the belt for cracks, fraying or missing pieces (as shown at C).

Fit a new belt as required. Refer to Changing the Drive Belt.

Changing the Drive Belt 1

Get access to the drive belt. Refer to Front End Accessory Drive Belt, Introduction.

Use a 16mm (5/8 in.) socket located on the hexagon spigot nut D, carefully rotate the tensioner against the spring force in direction E. Do not use excessive force or the tensioner will be damaged.

Keep holding the tensioner against the spring force and lift the belt off the tensioner pulley A.

Slowly release the spring force by rotating the tensioner unit in the opposite direction.

Before fitting a new belt, check that the tensioner roller and fan pulley rotate smoothly and that there is no play in the bearings.

Fit the new drive belt K Fig 37. ( T 3-1-63).

around

the

Use a 16mm (5/8 in.) socket located on the hexagon spigot nut D, carefully rotate the tensioner against the spring force in direction E. Do not use excessive force or the tensioner will be damaged.

Keep holding the tensioner against the spring force and lift the belt around the tensioner pulley A.

pulleys.

E Fig 37.

3-1-63

9813/1800-2 (3-41-03)

T063720-C1

3-1-63

Section 3-1 - Routine Maintenance Maintenance Engine

Air Filter

Changing the Air Filter Elements

!MCAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates.

2-3-3-1

Note: Do not attempt to wash or clean the elements - they must only be renewed. Note: A new inner element must be fitted at least every other time the outer element is changed. As a reminder, mark the inner element with a felt tipped pen each time the outer element is changed. 1

Get access to the engine. Refer to Access Panels, Engine Cover.

Unclip and remove the prefilter element C.

Remove main element D. Take care not to tap or knock the element.

If the safety element E is to be changed, lift up pulls and remove safety element E.

Clean inside the housing F, and housing C. Make sure the air holes G are clear.

Check that the aspirator hose is securely fitted and is in good condition.

Insert the new elements E and D into the housing, pushing them firmly in so that they are fully seated.

Re-fit prefilter element C ensuring the aspirator hose mates with the spigot.

3-1-64

9813/1800-2 (3-41-03)

C G

Fig 38.

C126370-C1

3-1-64

Section 3-1 - Routine Maintenance Maintenance Engine Vacuum Indicator The vacuum indicator A (found in the engine compartment) monitors the flow of air through the air filter. The position indicator progressively fills the window B as the level of restriction increases. You must complete a check of the air filter when the position indicator moves into the red zone C. Remove all unwanted material from the filter elements, the dust valve and the air filter hoses. Note: If the air filter becomes blocked during machine operation, the Air Filter Blocked light comes ON. To reset the vacuum indicator, push the (yellow) button D.

Fig 39.

3-1-65

T020420-1

9813/1800-2 (3-41-03)

3-1-65

Section 3-1 - Routine Maintenance Maintenance Fuel System

Fuel System Introduction

!MWARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates your skin, get medical help immediately. 0177

!MCAUTION Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. INT-3-3-12

!MCAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air. 2-3-3-11

3-1-66

9813/1800-2 (3-41-03)

3-1-66

Section 3-1 - Routine Maintenance Maintenance Fuel System

Water Separator and Engine Fuel Filter Introduction To get access to the water separator A and engine fuel filter for maintenance: 1

Open the engine cover. Refer to Access Panels, Engine Cover.

3-1-67

9813/1800-2 (3-41-03)

3-1-67

Section 3-1 - Routine Maintenance Maintenance Fuel System Draining the Water Separator and Engine Fuel Filter If there is water in the fuel or if the cab warning light illuminates, drain the water separator and engine filter as detailed. 1

Drain off any water in the water separator bowl C by turning tap D.

If there is sediment in the bowl after draining, support the bowl and release the locking ring E.

Wash the bowl in clean fuel.

Refit the bowl, secure in position with locking ring E.

Important: Ensure the seal is seated correctly before refitting the bowl. Refer to Changing the Water Separator Pre-Filter.

E D C

Fig 40.

3-1-68

9813/1800-2 (3-41-03)

C126350-C1

3-1-68

Section 3-1 - Routine Maintenance Maintenance Fuel System Changing the Water Separator Pre-Filter T3-076

Get access to the Water Separator. Refer to Water Separator and Engine Fuel Filter, Introduction.

Drain and remove the water separator bowl C. Refer to Draining the Water Separator and Engine Fuel Filter.

To remove the filter element A, release locking ring B and discard element.

Fit new element and secure in position with locking ring B.

Refit the bowl, secure in position with locking ring B.

Important: Ensure the seal D is seated correctly before refitting the bowl. 6

Make sure that the electrical connector E is correctly fitted.

Fig 41.

3-1-69

9813/1800-2 (3-41-03)

C007030-5

3-1-69

Section 3-1 - Routine Maintenance Maintenance Fuel System Changing the Engine Fuel Filter Element 1

Park and make the machine safe in accordance with the machine handbook instructions.

!MCAUTION Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair. ENG-1-7

Thoroughly clean the outside of the filter housing and around the filter head.

Loosen the drain tap B and allow the water/fuel to drain into a suitable container.

Unscrew the filter element counter clockwise.

Lightly oil the element seals and install a new filter element A. Make sure that the filter flange touches the filter head. Tighten to a torque of 25-35 N m.

Bleed the fuel System ( T 3-1-71)

3-1-70

system.

K Bleeding

A Fig 42.

C126340

the

9813/1800-2 (3-41-03)

3-1-70

Section 3-1 - Routine Maintenance Maintenance Fuel System

Bleeding the System Electronic Fuel Injection System The engine installation features an electrically operated fuel lift pump A. The system is designed to bleed automatically when the lift pump is operated. Make sure that as much air is removed from the fuel as possible before starting the engine.

!MWARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. 13-3-2-16

Important: Do not attempt to bleed the high pressure fuel system by loosening high pressure pipe connections even when the engine is not running. To bleed the fuel system follow the correct procedure. Bleed the system as follows: 1

Turn on the starter switch to start the fuel lift pump A. Do not start the engine. Allow the pump to run for 30 seconds.

Turn off the starter switch to stop the fuel lift pump A. Wait 10 seconds and then turn the starter switch to start the pump. Do not start the engine. Allow the pump to run for 30 seconds.

Repeat step 2 twice more before starting the engine.

Start the engine and make sure it runs smoothly.

3-1-71

9813/1800-2 (3-41-03)

Fig 43.

C126350-C2

3-1-71

Section 3-1 - Routine Maintenance Maintenance Hydraulic System

Hydraulic System

!MCAUTION

Introduction

!MWARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools (less than 40Â°C) before beginning maintenance. 8-3-4-10

Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. INT-3-3-12

INT-3-1-10_3

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

3-1-72

9813/1800-2 (3-41-03)

3-1-72

Section 3-1 - Routine Maintenance Maintenance Hydraulic System

Releasing the Hydraulic Pressure 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Operate the controls to remove the hydraulic pressure from the service hose lines. a

For manually operated services, operate the controls (several times) of the service to be disconnected.

b For electrical and servo operated services, turn the starter key to the ON position. Operate the controls (several times) of the service to be disconnected. Important: To release the hydraulic pressure from the electrical and servo operated services the battery must be connected while you operate the controls. 3

Clean the top of the tank around the filler cap B. Fig 44.

!MCAUTION

T015942-C1

Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. 5-3-4-8

!MCAUTION Do not run the engine with the hydraulic tank filler cap removed. 5-3-4-1

Slowly remove filler cap B to allow the system to vent fully and prevent oil being forced out of the filler neck.

Note: The filler cap includes a side mounted barrel lock that is operated by the starter key C. 5

Check that the seal in good condition and correctly installed in the cap. Replace if necessary.

3-1-73

9813/1800-2 (3-41-03)

3-1-73

Section 3-1 - Routine Maintenance Maintenance Hydraulic System

Oil and Filter Checking the Oil Level 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

!MCAUTION If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately. 12-5-1-4

The fluid must be visible in the sight gauge A. If the fluid is not visible, continue to step 3.

Vent the hydraulic system. Refer to Releasing the Hydraulic Pressure.

Add recommended fluid through the filler neck.

Install then lock the filler cap.

Fig 45.

T015942-10

Note: When the key is removed the cap turns and can not be undone.

3-1-74

9813/1800-2 (3-41-03)

3-1-74

Section 3-1 - Routine Maintenance Maintenance Hydraulic System Changing the Filter Element

Make the machine safe with the boom lifted. Refer to Prepare the Machine for Maintenance.

Vent the hydraulic system. Refer to Releasing the Hydraulic Pressure.

Clean the top of the tank around the filter.

Either disconnect hose K or undo clip to enable cover plate removal.

Remove the element assembly: a

Pull on handle E, the element G should separate from its canister F. Discard the old element.

d Remove and discard seal H. e

Clean the inside of canister F.

Remove screws A. Remove the cover plate B and gasket C, discard the gasket.

b Remove spring D. c

Hold handle E and pull the element assembly from the hydraulic tank. Fig 47. 7

399341-5

Fit the new element. a

Fit a new seal H.

b Make sure that seal J is fitted in the new element. c

Push the element G into its canister F and rotate the element 90Â° to lock it into position. Check that the element has locked into position by pulling on handle E.

d Install the element assembly in the hydraulic tank.

Fig 46. 6

Fit spring D and gasket C.

Fit cover plate B and tighten screws A.

g Check oil level and replenish as required through filler. Fit and tighten the filler cap.

T015942-7

Remove the element from its canister:

Install then lock the filler cap B.

Note: When the key is removed the cap turns and can not be undone.

Hold canister F.

b Hold handle E and rotate the element G 90Â° counter clockwise.

3-1-75

9813/1800-2 (3-41-03)

3-1-75

Section 3-1 - Routine Maintenance Maintenance Hydraulic System Changing the Pilot Filter Element

Make the machine safe with the boom lifted. Refer to Prepare the Machine for Maintenance.

Vent the hydraulic system. Refer to Releasing the Hydraulic Pressure.

Remove the central access panels A then B to expose the chassis access hole. Refer to Access Panels, Central Access Panels.

Note: The pilot filter is located at the front of the chassis access hole. 4

Unscrew end cap C.

Remove element with associated seals and discard.

Fit new element, together with new seals.

Refit cap C, torque tighten to 25Nm (18 lbf ft).

Install the central access panels B then A.

Install then lock the filler cap B.

Fig 48.

C075220-C2

Note: When the key is removed the cap turns and can not be undone. 10

Run the engine and check for leaks.

3-1-76

9813/1800-2 (3-41-03)

3-1-76

Section 3-1 - Routine Maintenance Maintenance Hydraulic System

Hose Burst Protection Valves

should slow as the engine slows and stop as the engine stops.

Checking the Hose Burst Protection Valves

If the boom continues moving after the engine has stopped, the hose burst protection valve is faulty. Do not use the machine until the fault has been put right.

Introduction P5-3001U_2

The hose burst protection valves 'lock' to prevent uncontrolled movement of the cylinder pistons if hydraulic pressure fails or a hose bursts. The valves are mounted directly on the cylinder.

Carriage Tilt Cylinder 1

Pick up a load on the forks. (For example a pack of bricks or some hay bales.) Tilt the carriage fully back. Make sure the park brake is engaged and the transmission is in neutral.

Position the boom clear of the ground, just far enough to allow the carriage to be tilted forward.

With the engine running at mid speed, operate the control lever to tilt the carriage forward. While the carriage is moving, switch off the engine. Carriage movement should slow as the engine slows and stop as the engine stops.

!MWARNING Keep people clear of the machine while you do these checks. 5-3-4-2

Check each movement in turn. Important: Ensure the machine is parked on firm level ground before carrying out the following procedures. Boom Lift Cylinders

If the carriage continues moving after the engine has stopped, the hose burst protection valve is faulty. Do not use the machine until the fault has been put right.

P5-3031U

Start the engine. Make sure the park brake is engaged, the transmission is in neutral.

Raise the boom to about 45Â°.

Stabilizer Cylinder (if fitted) P5-3003U_4

With the engine running at mid speed, operate the control lever to lower the boom. While the boom is moving, switch off the engine. Boom movement should slow as the engine slows and stop as the engine stops. If the boom continues moving after the engine has stopped, both boom hose burst protection valves are faulty. Do not use the machine until the fault has been put right.

Start the engine. Make sure the park brake is engaged and the transmission is in neutral.

Lower the stabilizers. Ensure the stabilizer legs are in the down position and the weight of the machine is supported (i.e. the front wheels are clear of the ground X).

Boom Extension Cylinder 1

Start the engine. Make sure the park brake is engaged and the transmission is in neutral.

Raise the boom fully. Extend the boom fully.

With the engine running at mid speed, operate the control lever to retract the boom. While the boom is retracting, switch off the engine. Boom movement Fig 49.

3-1-77

9813/1800-2 (3-41-03)

797600

3-1-77

Section 3-1 - Routine Maintenance Maintenance Hydraulic System 3

Stop the engine. Operate the stabilizer controls. Check that the front wheels of the machine do not lower to the ground. If the machine moves when the stabilizer controls are moved with the engine stopped, the hose burst protection valves are faulty. Do not use the machine until the fault has been put right.

Sway Cylinder (if fitted) P5-3004U_3

Start the engine. Make sure the park brake is engaged and the transmission is in neutral.

Sway the machine body approximately halfway to the left and release the sway control.

Stop the engine. Operate the sway control to the left. Check that the machine does not sway.

Repeat steps 1 - 3 for right sway.

If the body moves when the sway control is moved with the engine stopped, the hose burst protection valves are faulty. Do not use the machine until the fault has been put right.

3-1-78

9813/1800-2 (3-41-03)

3-1-78

Section 3-1 - Routine Maintenance Maintenance Transmission

Transmission Gearbox

Checking the Oil Level 1

Start then operate the engine at low idle for four minutes. The delay allows the oil to fill the filter, pump, torque converter, oil cooler and hoses.

Switch OFF the engine and remove the starter key.

Open the engine cover. Refer to Access Panels, Engine Cover. Before you complete a check of the oil level, you must wait as shown on the instructional label A.

Note: The instructional label shows the time in seconds. 4

Check that the oil level is between the end of the dipstick and maximum mark on the dipstick B.

Fig 50.

C122210-C4

Add oil as necessary. Fill through the dipstick tube to maximum dipstick level. Use only the recommended oil.

3-1-79

9813/1800-2 (3-41-03)

3-1-79

Section 3-1 - Routine Maintenance Maintenance Transmission Changing the Oil and Filter 4-Speed Powershift Transmission P5-3017_2

The transmission oil should be drained through the suction strainer aperture to flush out any particles which fall off the strainer during its removal. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

!MCAUTION When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer. 2-3-4-1

Place a container, of suitable size beneath the suction strainer. Remove bolts D. Pull out the strainer E and its gasket F. Allow the oil to drain into the container. Be aware that the oil may be hot.

Clean the strainer with a suitable solvent. Follow the solvent manufacturer's instructions on safety.

Fit the strainer E and a new gasket F. Apply JCB Threadlocker and Sealer to bolts D before fitting and tightening them. Torque tighten the bolts to 10 Nm (7 lbf ft).

Unscrew and remove the filter B. Some machines feature a remote chassis mounted filter as shown at X. Fit the new filter: a

Smear seal C with transmission oil.

b Screw the filter on until it just contacts the filter head. c 6

Turn the filter at least another 3/4 of a turn.

Fig 51.

C011560-C2

Fill the system with new oil through the dipstick/filler. Do not fill past the top mark on the dipstick.

Note: Fit only a genuine supplied JCB filter, otherwise damage to the system may be incurred through contamination.

3-1-80

9813/1800-2 (3-41-03)

3-1-80

Section 3-1 - Routine Maintenance Maintenance Transmission

Axles Checking the Axle Oil Level

Fig 52.

795230-4-C1

!MCAUTION The axle oil level must be checked with the machine level, otherwise a false indication of the amount of oil in the axle will be given. 16-3-5-3

!MCAUTION It is not recommended that the machine be driven with the axle partially filled with oil. 2-3-4-7

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Clean the area around fill/level plug A, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. Add recommended oil if necessary.

Clean and refit the plug and its washer.

3-1-81

9813/1800-2 (3-41-03)

3-1-81

Section 3-1 - Routine Maintenance Maintenance Transmission Changing the Axle Oil

Fig 53. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Place a container of suitable size beneath plug B to catch the oil. Remove the drain plug B and its seal. Allow oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed). Fit drain plug B and its washer.

795230-4-C1

!MCAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

Fill with recommended oil through fill/level hole A. Clean and refit plug A and its seal.

3-1-82

9813/1800-2 (3-41-03)

3-1-82

Section 3-1 - Routine Maintenance Maintenance Transmission Oil Immersed Brakes

Set the machine level, with the wheels just clear of the ground. Manually rotate the wheels to bring the OIL LEVEL mark on the hubs to the vertical position, with the fill/level plugs 55-C at the bottom.

Drain the oil:

The axle oil is used to lubricate the brake components, and to cool the brake plates. It is important that the oil is changed regularly as specified in the service schedule - the lubricating properties of the oil will reduce as a result of brake wear.

Consult your JCB Distributor for advice if necessary.

Place a container of suitable size beneath plug 55-C to catch the oil.

!MCAUTION

Checking the Hub Oil Levels T3-011_2

Check each hub separately.

Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

Park the machine on level ground with the OIL LEVEL mark horizontal. There is a tolerance of 5 mm (0.2 in) above or below the horizontal.

Engage the park brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

Clean the area around the fill/level plug 54-C. Remove the plug. Oil should be level with the bottom of the hole. If necessary, add the recommended oil. Clean the plug before refitting it.

b Remove fill/level plugs 55-C. Allow time for the oil to drain out. 3

Set OIL LEVEL marks to the horizontal. a

Fill the hubs with recommended axle oil, through the fill/level holes 55-C. Oil should be level with the bottom of the fill/level hole.

b Clean and refit fill/level plugs 55-C.

Fig 55. Fig 54.

Changing the Hub Oil Change the oil in each hub separately

3-1-83

9813/1800-2 (3-41-03)

3-1-83

Section 3-1 - Routine Maintenance Maintenance Transmission Checking the Front Axle Breather Axles with inboard brakes are fitted with a breather which allows pressure within the axle to vent to atmosphere. Pressure within the axle can affect braking efficiency if the breather is blocked. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Check breather A is not damaged and that cap B is in place and free to rotate.

Position hole C towards the road wheel before fitting a new breather.

Fig 56.

3-1-84

9813/1800-2 (3-41-03)

3-1-84

Section 3-1 - Routine Maintenance Maintenance Tires and Wheels

Tires and Wheels Tire Ballast

Tire Inflation

Before you start a maintenance procedure on a tire or a wheel assembly, you must identify if tire ballast is installed. If the tire contains ballast, you must obey the following warnings.

Introduction

Note: A decal is used to show if tire ballast (A) or tire sealant (B) is installed.

!MWARNING

T3-066U

An exploding tire can kill. Inflated tires can explode if over-heated or over-inflated. Follow the instructions given when inflating the tires. Do not cut or weld the rims. Use a tire/wheel specialist for all repair work. 2-3-2-7U_2

!MWARNING Wheels and tires are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury. 13-3-1-7U_1

Fig 57.

T025150-1

Always try to maintain your tire pressure to the recommended settings. Using your machine with underinflated tires means: – Decreasing the machines stability

!MWARNING

– Higher tire temperatures

Tire Ballast Installing tire ballast requires special equipment and training. Have the job done by your JCB Dealer or a tire specialist.

– Excessive strain of the tire fabric – More bulging of the sidewalls – Shortens the tires life. Using the machine with over inflated tires is dangerous:

Non-approved tire ballast can cause damage to the machine's drive train and structures. It will also affect manufacturer's warranty.

Do not cut or weld on the rim of an inflated tire.

For advice consult your JCB Distributor. 5-3-2-7U_5

After checking or amending the tire pressure always replace and secure the valve cap.

!MWARNING Installing and removing a wheel with tire ballast requires special equipment and training. Have the job done by your JCB Dealer or a tire specialist. 5-3-2-8U_2

– It causes excessive tensile loads in the fabric: this makes a tire more susceptible to cuts and punctures.

Always deflate the tire before removing foreign obstacles from the tread.

Procedure T3-067U_2

These instructions are for adding air to a tire which is already inflated. If the tire has lost all its air pressure, call

3-1-85

9813/1800-2 (3-41-03)

3-1-85

Section 3-1 - Routine Maintenance Maintenance Tires and Wheels in a qualified tire mechanic. The tire mechanic should use a tire inflation cage and the correct equipment to do the job. 1

If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 psi) above the recommended tire pressure. For recommended tires and pressures for your machine, see Specfications, Tire Sizes and Pressures.

b Use an air hose fitted with a self-locking air chuck and remote shut-off valve.

On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. Every day, before starting work, check that the wheel nuts are tight. Tighten the wheel nuts (in a diagonal sequence) to the torque value shown. Table 7.

Add the air. a

T3-014_3

!MWARNING

Prepare the equipment. a

Checking the Wheel Nut Torques

Prepare the wheel. Before you add air to the tire, make sure it is correctly fitted on the machine or installed in a tire inflation cage. K Fig 58. ( T 3-1-86).

Wheel Nuts

Make sure that the air hose is correctly connected to the tire valve. Clear other people from the area. Stand behind the tread of the tire while adding the air.

Front

Rear

Nm (lbf ft)

680 (500)

b Inflate the tire to the recommended pressure. Do not over-inflate.

Fig 58.

3-1-86

A089570-1

9813/1800-2 (3-41-03)

3-1-86

Section 3-1 - Routine Maintenance Maintenance Wheel Alignment

Wheel Alignment Introduction

Manual Steer Mode Selector

!MDANGER

T3-038

Stop the machine. Select the neutral position on the forward/reverse lever.

Failure to align the steering before selecting the required steer mode will cause the machine to steer incorrectly.

Use the lever A to select 4-wheel steer B.

5-2-6-7

!MWARNING

Turn the steering wheel until the rear wheels are pointing in the straight ahead position.

Use the lever A to select 2-wheel steer C.

Failure to phase 4-wheel steer at least once per day may mean a reduction in steering effectiveness.

Turn the steering wheel until the front wheels are pointing in the straight ahead position.

All wheels are now pointing straight ahead, select the steer mode required and continue in the normal manner.

5-2-1-6

The steering must be re-phased: 1

At least once per day.

If having difficulty in steering.

After travelling for 15 miles (24 km) or more on the road (in 2-wheel steer).

Fig 59.

3-1-87

9813/1800-2 (3-41-03)

T015920-2

3-1-87

Section 3-1 - Routine Maintenance Maintenance Wear Pads

Wear Pads Boom Wear Pad Clearance 3-Stage Boom Table 8. Boom (Front and Rear) Measurement

Location

Maximum Gap

Vertical clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Vertical clearance - Intermediate boom to Inner boom

3.0mm (0.12in)

Total side clearance - Intermediate boom to Inner boom

3.0mm (0.12in)

Total side clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Contact your JCB Distributor if the wear pad clearances exceed the maximum stated dimensions.

Fig 60.

3-1-88

C066340-C1

9813/1800-2 (3-41-03)

3-1-88

Section 3-1 - Routine Maintenance Maintenance Wear Pads 4-Stage Boom Table 9. Boom (Front and Rear) Measurement

Location

Maximum Gap

Total side clearance - 2nd Intermediate boom to Inner boom

3.0mm (0.12in)

Vertical clearance - 2nd Intermediate boom to Inner boom

3.0mm (0.12in)

Total side clearance - 2nd Intermediate boom to Intermediate boom

3.0mm (0.12in)

Vertical clearance - 2nd Intermediate boom to Intermediate boom

3.0mm (0.12in)

Total side clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Vertical clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Fig 61. 4-Stage Boom

A372600-C1

Contact your JCB Distributor if the wear pad clearances exceed the maximum stated dimensions.

3-1-89

9813/1800-2 (3-41-03)

3-1-89

Section 3-1 - Routine Maintenance Maintenance Windshield Washer

Windshield Washer Checking the Level The washer bottle A is found to the left of the operator seat. 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Get access to the washer bottle A.

Remove the washer bottle cap B.

Fill the washer bottle with a suitable liquid. The liquid should contain a de-icing fluid to prevent freezing. Do not use engine coolant antifreeze.

Install the washer bottle cap B. Fig 62.

3-1-90

9813/1800-2 (3-41-03)

T015910-2

3-1-90

Section 3-1 - Routine Maintenance Maintenance Fire Extinguisher (if fitted)

Fire Extinguisher (if fitted) T3-022

Checking the Fire Extinguisher Check the fire extinguisher for damage, security and signs of leaking. Check that the gauge A indicates that the extinguisher is charged i.e. the needle is in the GREEN segment. Note: If the needle is in or very near the RED segment at either end of the gauge, the extinguisher must be serviced or replaced. Make sure the safety pin B is fitted and secure. The extinguisher should be serviced every 12 months by a suitably qualified person.

Fig 63.

3-1-91

9813/1800-2 (3-41-03)

3-1-91

Section 3-1 - Routine Maintenance Maintenance Fire Extinguisher (if fitted)

Page left intentionally blank

3-1-92

9813/1800-2 (3-41-03)

3-1-92

Section B Body and Framework Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813/1800-2

Section B - Body and Framework

Notes:

B-0

9813/1800-2

B-0

Section B - Body and Framework Contents Page No. Applications Table ....................................................................................................... B0-1 Cab Heating and Ventilation SYSTEM Introduction ............................................................................................. Related Topics ........................................................................................ Component Location .............................................................................. Operation Overview ................................................................................ Electrical Operation and Schematics ...................................................... Fault Finding ...........................................................................................

B1-1 B1-2 B1-3 B1-4 B1-5 B1-6

Cab Air Conditioning SYSTEM Introduction ............................................................................................. B2-1 Related Topics ........................................................................................ B2-2 Specifications ......................................................................................... B2-3 Refrigerant .............................................................................................. B2-4 Component Locations ............................................................................ B2-11 Operation Overview .............................................................................. B2-12 Electrical Operation and Schematics .................................................... B2-17 Fault Finding and Diagnostics .............................................................. B2-18 Test Procedures .................................................................................... B2-28 Compressor Drive Belt - Adjustment .................................................... B2-29 Cab Introduction ............................................................................................. B3-1 Related Topics ........................................................................................ B3-3 Removal and Replacement .................................................................... B3-5 Air Conditioning Condenser - Cooling Pack Mounted Introduction ............................................................................................. B4-1 Related Topics ........................................................................................ B4-2 Removal and Replacement .................................................................... B4-3 Cab HV and HVAC Unit Introduction ............................................................................................. B5-1 Related Topics ........................................................................................ B5-3 Freeze Thermostat (HVAC Unit) ............................................................ B5-4 Removal and Replacement (P1) ............................................................ B5-5 Removal and Replacement (P2) ............................................................ B5-7 Removal and Replacement (P3) ............................................................ B5-9 Heater Air Intake (Snorkel) ................................................................... B5-12 Air Conditioning Binary Switch Introduction ............................................................................................. Related Topics ........................................................................................ Testing .................................................................................................... Removal and Replacement ....................................................................

B6-1 B6-2 B6-3 B6-4

Heater Valve Introduction ............................................................................................. B7-1 Related Topics ........................................................................................ B7-2 Removal and Replacement .................................................................... B7-3 Fuel Tank Introduction ............................................................................................. B8-1

B-i

Section B - Body and Framework Contents Page No. Related Topics ........................................................................................ B8-2 Specifications ......................................................................................... B8-3 Removal and Replacement .................................................................... B8-4 Engine Cover Introduction ............................................................................................. B9-1 Related Topics ........................................................................................ B9-2 Removal and Replacement .................................................................... B9-3 Mudguards Introduction ........................................................................................... B10-1 Related Topics ...................................................................................... B10-2 Removal and Replacement .................................................................. B10-3 Stabilisers Introduction ............................................................................................ B11-1 Related Topics ....................................................................................... B11-2 Leg Removal and Replacement (P1) .................................................... B11-3 Leg Removal and Replacement (P2) .................................................... B11-5 Leg Removal and Replacement (P3) .................................................... B11-7 Frame Removal and Replacement ........................................................ B11-9 Checking Pressure Switch Operation .................................................. B11-12 RAS SYSTEM Introduction ........................................................................................... B12-1 Related Topics ...................................................................................... B12-2 Operation Overview .............................................................................. B12-3 Hydraulic Operation and Schematics ................................................... B12-6 Electrical Operation and Schematics .................................................... B12-8 Electrical Connectors .......................................................................... B12-15 Fault Finding ....................................................................................... B12-17 Test Procedures .................................................................................. B12-20 Bleed Procedure ................................................................................. B12-22 Interlock SYSTEM Introduction ........................................................................................... B13-1 Related Topics ...................................................................................... B13-2 Operation Overview .............................................................................. B13-3 Hydraulic Operation and Schematics ................................................... B13-5 Electrical Operation and Schematics .................................................... B13-7 Electrical Connectors .......................................................................... B13-12 Fault Finding ....................................................................................... B13-14 Boom Introduction ........................................................................................... B14-1 Related Topics ...................................................................................... B14-2 Specifications ....................................................................................... B14-3 Operation Overview .............................................................................. B14-5 Hydraulic Operation and Schematics ................................................. B14-12 Wear Pads and Shims ........................................................................ B14-20 Chain Maintenance ............................................................................. B14-33 Extend Chains Removal and Replacement - 3 Stage Boom .............. B14-42 Retract Chain Removal and Replacement - 3 Stage Boom ............... B14-44 Extend Chains Removal and Replacement - 4 Stage Boom .............. B14-46 Retract Chains Removal and Replacement - 4 Stage Boom .............. B14-49

B-ii

Section B - Body and Framework Contents Page No. Angle Indicator Removal and Replacement ....................................... B14-52 Pivot Shims ......................................................................................... B14-53 Boom Removal and Replacement ...................................................... B14-54 Boom Hose Removal and Replacement (3 Stage Boom) .................. B14-56 Boom Hose Removal and Replacement (4 Stage Boom) .................. B14-59 RAS ECU Introduction ........................................................................................... Related Topics ...................................................................................... Overview ............................................................................................... Removal and Replacement ..................................................................

B15-1 B15-2 B15-3 B15-4

Interlock Components Introduction ........................................................................................... B16-1 Related Topics ...................................................................................... B16-2 Removal and Replacement .................................................................. B16-3

B-iii

Section B - Body and Framework Contents

B-iv

Page No.

B-iv

Section B0 - Body and Framework Applications Table

Applications Table Important: The machine model names are NOT referred to in the topics. You must refer to the applications table for the applicable machine models. Table entries shaded grey indicate a topic not included in this issue of the manual.

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref Title

VARIANT

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

Cab Heating and Ventilation SYSTEM

Cab Air Conditioning SYSTEM

Cab

Air Conditioning Condenser

Cab HV and HVAC Unit

Air Conditioning Binary Switch

Heater Valve

Fuel Tank

Engine Cover

B10

Mudguards

z z z z z z z z

B11

Stabilisers

B12

RAS SYSTEM

B13

Interlock SYSTEM

B14

Boom

B15

RAS ECU

B16

Interlock Components

z z z z z

z z z z z z z z z z z z z z

B0-1

9813/1800-2 (AB-00-06)

B0-1

Section B0 - Body and Framework Applications Table

Page left intentionally blank

B0-2

9813/1800-2 (AB-00-06)

B0-2

Section B1 - Body and Framework

Cab Heating and Ventilation SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T B1-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T B1-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T B1-2) K Component Location ( T B1-3) K Operation Overview ( T B1-4) K Electrical Operation and Schematics ( T B1-5) K Fault Finding ( T B1-6)

B1-1

B-02-09 Issue 01

B1-1

Section B1 - Body and Framework Cab Heating and Ventilation SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Cab HV and HVAC Unit

Heater Valve

Cab Air Conditioning SYSTEM

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

ALL ALL

(1)

ALL ALL (2)

ALL

(1) You must obey all of the relevant care and safety procedures. (2) Machines with air conditioning only

B1-2

B-02-09 Issue 01

B1-2

Section B1 - Body and Framework Cab Heating and Ventilation SYSTEM Component Location

Component Location HVAC SYSTEM

MACHINES ALL

Heater filter

Part of HVAC unit

Recirculation filter

Part of HVAC unit

Heater unit

Fixed to cab - RHS

Blower unit

Part of HVAC unit

Heater water valve

Fixed to chassis inside engine compartment

B1-3

B-02-09 Issue 01

B1-3

Section B1 - Body and Framework Cab Heating and Ventilation SYSTEM Operation Overview

Operation Overview Fresh air is supplied to the cab interior through the cab air vents D. The heater and ventilation unit A (HV) uses a blower fan to increase the air speed. The air can also be heated by the heat exchange matrix housed within the HV unit.

The heater valve regulates the flow of hot engine coolant through the HV unit. The hot engine coolant flows through the heat exchange matrix and the fan blows air over the fins of the matrix, warming the air. Item

On machines with air conditioning the unit also houses the air conditioning evaporator matrix to become a combined heating, ventilation and air conditioning unit (HVAC). For details of the air conditioning system refer to Section B Cab Air Conditioning SYSTEM. K Related Topics ( T B1-2) The machine operator can control the air temperature and speed from within the cab on the heater control panel E. For operation of the heater controls refer to the applicable Operator Manual.

Heater and ventilation unit (HV)

Heater valve

Electrical connector

Cab heater vents

Heater Control panel(1)

(1) Typical heater control panel is shown. Refer to the applicable Operator Manual for machine specific controls.

The operator uses the fan speed switch to select the blower fan speed. The temperature control knob is connected to a cable which operates the heater valve B.

C B

Fig 1.

B1-4

B-02-09 Issue 01

C119080

B1-4

Section B1 - Body and Framework Cab Heating and Ventilation SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics The heater controls and heater unit are connected to the Panel Harness

Key

Key 1

Heater Fan Switch

Heater Connector

Secondary Fuse Box A

HVAC Unit

L M H

2 1 2 3 4 5 6

Fig 2.

B1-5

B-02-09 Issue 01

C124580-C2

B1-5

Section B1 - Body and Framework Cab Heating and Ventilation SYSTEM Fault Finding

Fault Finding Tables Fault(s) K Table 2. Blower operates on fan speed 3 only ( T B1-6) K Table 3. Blower does not operate ( T B1-6)

Possible Cause

Table 2. Blower operates on fan speed 3 only Action

Blower resistor failed.

Renew resistor.

Blower motor failed.

Renew complete blower motor unit.

Possible Cause Fuse blown.

B1-6

Table 3. Blower does not operate Action Replace fuse and re-test.

B-02-09 Issue 01

B1-6

Section B2 - Body and Framework

Cab Air Conditioning SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T B2-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T B2-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T B2-2) K Specifications ( T B2-3) K Refrigerant ( T B2-4) K Component Locations ( T B2-11) K Operation Overview ( T B2-12) K Electrical Operation and Schematics ( T B2-17) K Fault Finding and Diagnostics ( T B2-18) K Test Procedures ( T B2-28) K Compressor Drive Belt - Adjustment ( T B2-29)

B2-1

B-03-08 Issue 01

B2-1

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Maintenance

Cab Heating and Ventilation System

Air Conditioning Binary Switch

ALL

Air Conditioning Condensor - Cooling Pack Mounted

ALL

Air Conditioning Condensor - Roof Mounted

ALL

Cab HV and HVAC Unit

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

ALL ALL

(1)

Front End Accessory Drive Belt (2)

ALL

(1) You must obey all of the relevant care and safety procedures. (2) Reference for the cab heating and ventilation (HV) part of the HVAC system.

B2-2

B-03-08 Issue 01

B2-2

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Specifications

Specifications HVAC SYSTEM

MACHINES ALL

Binary Pressure Switch Settings: Low Pressure (bar)

High Pressure (bar)

Thermostatic Switch Settings: Cut out (Â°C)

0.2 to 1.4

Cut in (Â°C)

3.4 to 4.8

Refrigerant: Type

R-134a

Charge amount

(1)

- maximum (Kg)

1.0

Charge amount

(2)

- maximum (Kg)

1.7

Discharging and charging procedures

K Refrigerant Charging and Discharging ( T B2-6)

Oil: Type

PolyAlkylene Glycol (PAG) K PAG Type Refrigerant Oil ( T B2-4)

Charge amounts : (3)

Complete system (ml)

42.6

Condenser remove and replace (ml)

28.4 ml

Evaporator remove and replace (ml)

56.8 ml

Hoses remove and replace (ml)

8.5 ml

Receiver drier remove and replace (ml)

14.2 ml

Compressor remove and replace (ml)

None - pre charged

(1) Systems with cooling pack mounted condenser. (2) Systems with roof mounted condenser (3) The quantity of oil replaced should be the same as that taken out during `Recovery' procedure.

B2-3

B-03-08 Issue 01

B2-3

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Refrigerant

Refrigerant Safety Procedures The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by service personnel with specialist knowledge of air conditioning systems. The following guidelines should be adhered to by all personnel servicing the air conditioning system.

poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced. 6

When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches. When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point.

When checking the state of the refrigerant, it is necessary to run the engine. Extreme care must be taken to avoid moving engine parts such as fans, pulleys and belts.

Use caution when working near exposed evaporator fins. Painful cuts can be inflicted by the edges of the fins. Also, damage to the fins will reduce the efficiency of the system.

Make sure pressure cylinders are not over filled, particularly when recovering refrigerant.

Disconnect battery before doing any work.

!MWARNING The air conditioning system is a closed loop system and contains pressurized 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. 4-3-4-1U_2

!MCAUTION Do not operate the air conditioning system when there is no refrigerant in the system, otherwise the compressor will be damaged. 4-3-4-4

It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. It is illegal to discharge the refrigerant into the atmosphere but as a precaution in case of accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a well ventilated area. Containers of refrigerant should be stored in a cool environment away from direct sunlight.

!MWARNING Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit. BF-1-9

Do not perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses).

Do not steam clean refrigerant system components.

When charging or discharging the refrigerant system, no smoking or naked flames should be allowed in the immediate vicinity. The refrigerant does not give off a

B2-4

!MWARNING PAG type oil is an irritant.It can cause skin irritation. Breathing PAG vapour can cause irritation of the eyes, nose and lungs. Prolonged inhalation can cause drowsiness. BF-1-11

!MWARNING PAG oil vapour is extremely flammable. Do not smoke or eat near PAG contaminated material. Exercise caution when working around hot and moving engine parts. BF-1-12

PAG Type Refrigerant Oil TB-007

The system requires a PAG type refrigerant oil to lubricate the compressor. The oil mixes with the refrigerant and is carried around the system. It is important that the recommended grade of refrigerant oil is used. Mineral oil is not suitable for R134a refrigerant systems. Do not mix oil types. The compressor is supplied with an oil charge, but additional oil will be required when the receiver drier is

B-03-08 Issue 01

B2-4

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Refrigerant replaced. The oil is added to the compressor through the oil filling plug before the evacuation procedure is started. Only use fresh, unused oil. Oil that has been exposed to the air will have absorbed water.

R134a Refrigerant TB-006

Refrigerants are the basic ingredient of all air conditioning systems and are used to transfer the heat energy around the system. Refrigerant type R134a is used in the air conditioning system. It's full chemical name is: 1, 1, 1, 2-Tetraflouroethane (CH2FCF2) R134a is a HFC (HydrFlouroCarbon) and is non-toxic, non-flammable and non-explosive at normal atmospheric temperature and pressure. It can be flammable under certain pressure and air mixtures. Due to environmental concerns, the use of ozone depleting chlorofluorocarbons (CFCs) in the air conditioning systems is being gradually phased out. The R-12 refrigerant used in some systems contains CFCs. Air conditioning systems using R-134a refrigerant are not compatible with systems using R-12 refrigerant. No attempt should be made to charge R-134a systems with R12 refrigerant. Important: Refer to the safety procedures within this section before handling refrigerants. Good installation practice is required to avoid the release of refrigerant into the atmosphere. Refrigerant R134a contains no chlorine and has an Ozone Depleting Potential (ODP) of zero, and a Global Warming Potential (GWP) of 0.1.

B2-5

B-03-08 Issue 01

B2-5

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Refrigerant

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 1-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.

!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

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 1-A connected to the system low pressure port. Do Not connect the red hose 1-B. Make sure that both valves are closed.

Connect the yellow hose 1-C to the 'Javac' unit filter 1-D.

Connect the filter 1-D to the 'Javac' unit 1-E.

Connect the 'Javac' unit 1-E to an empty receiver bottle 1-F. Weigh the bottle before and after filling to assess system capacity.

Fig 1. Refrigerant Recovery

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

Switch on 'Javac' unit 1-E and open the low pressure manifold valve.

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B-03-08 Issue 01

B2-6

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Refrigerant 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 B2-6).

the

system.

Close all valves and connect the manifold as shown. Connect the blue hose 2-A to the system low pressure port and the red hose 2-B to the high pressure port.

Connect the yellow hose 2-C to the vacuum pump 2D.

Fig 2. Evacuating

Note: If the Electronic Vacuum Gauge 2-E is used Vacuum connected as shown. K Electronic Gauge ( T B2-8), for further information. 4

Open manifold valves.

Switch on the vacuum pump 2-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.

B2-7

B-03-08 Issue 01

B2-7

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Refrigerant 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 3. 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).

B2-8

B-03-08 Issue 01

B2-8

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Refrigerant 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 4-A connected to the oil injector 4E and the red hose 4-B to the system high pressure port.

Connect the yellow hose 4-C to the vacuum pump 4D.

Connect the other end of the oil injector 4-E to the system low pressure point 4-F.

Switch on the vacuum pump 4-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 4. Relubricating

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

B2-9

B-03-08 Issue 01

B2-9

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Refrigerant 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 5-A to system low pressure and the red hose 5-B to system high pressure. Connect the yellow hose 5-C to the refrigerant cylinder 5-D.

Invert single valve cylinder on the scales 5-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 5. 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 5-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 5-F can be used around the replenishing cylinder. 4

Close all valves and remove the equipment.

B2-10

B-03-08 Issue 01

B2-10

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Component Locations

Component Locations HVAC SYSTEM

MACHINES ALL

HVAC unit

Fixed to cab - RHS

Thermostatic Expansion Valve (TEV)

Part of HVAC unit

Evaporator matrix

Part of HVAC unit

Compressor

Fixed to engine - RHS

Binary switch

Fixed to pipe next to compressor

Receiver drier

Fixed to chassis inside engine compartment

Condenser - cooling pack mount

Part of machine cooling pack inside engine compartment

Condenser - roof mount

Fixed to a frame fixed at the rear of the cab roof. Includes electric cooling fans

B2-11

B-03-08 Issue 01

B2-11

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Operation Overview

Operation Overview

C119100-C1

Fig 6. Item

Item A

Thermostatic Expansion Valve

Condenser (Cooling pack mounted)

Evaporator Matrix

Condenser (Roof mounted)

Compressor

Front End Accessory Drive Belt (FEAD)

Heater/Air Conditioning Control Panel(1)

Heater/Air Conditioning Vents

B2-12

(1) Typical heater control panel is shown. Refer to the applicable Operator Manual for machine specific controls.

B-03-08 Issue 01

B2-12

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Operation Overview To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system delivers cool, dehumidified air into the cab. Cooling is provided by passing the warm ambient air, together with re circulated air, over an evaporator matrix in the air conditioning unit.

Refrigeration Cycle K Fig 7. ( T B2-13) and K Fig 8. ( T B2-14) The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system. The major components of the system are the compressor A, condenser matrix B, receiver drier C, binary pressure switch E, thermostatic expansion valve F and evaporator matrix G. Operate the air conditioning as described in the Operator Handbook. Air conditioning system power is generated from the engine, via an electromagnetic clutch to the compressor. Switches, connected in series, are included in the clutch supply line, all must be closed for the clutch and therefore the air conditioning system to operate.

become saturated and the receiver drier will need to be renewed. The high temperature, high pressure refrigerant is forced by compressor action into the Thermostatic Expansion Valve (TEV) F, which meters the amount of refrigerant entering the evaporator. In the Thermostatic Expansion Valve the refrigerant instantaneously expands to become a low pressure, low temperature liquid. The refrigerant is drawn through the evaporator matrix G by the suction of the compressor. The temperature of refrigerant is now considerably below that of the air being drawn across the evaporator matrix by the blowers. Heat is transferred from the ambient and re circulated air to the refrigerant, causing the low pressure liquid to vaporise and become a low pressure gas. Moisture in the air condenses on the evaporator matrix and is drained away via condensate. Cool de-humidified air is emitted through air vents into the cab. The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.

The compressor A draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. This process also increases the refrigerant temperature. High pressure refrigerant is forced from the compressor to the condenser B. Ambient air is drawn across the condenser by the engine - driven cooling fan. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content. The refrigerant passes through the receiver drier C, which contains a desiccant to remove moisture from the system. The receiver drier serves as a reservoir for refrigerant and also includes a filter to remove foreign particles from the system.

Fig 7.

C067580

Note: The receiver drier can only hold a limited amount of moisture, additional moisture can lead to icing and ultimately blockage of the thermostatic expansion valve. If the air conditioning system has been left open or has been leaking for a prolonged period of time, the desiccant will

B2-13

B-03-08 Issue 01

B2-13

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Operation Overview Schematic

F A

Fig 8. Refrigeration Cycle

C131090.eps

Component Key: A

Compressor

Condenser matrix (Refrigerant changes to liquid)

Receiver drier

Binary Switches

Expansion valve

Evaporator (Refrigerant changes to Gas/Vapour)

Heat

Refrigerant is in Liquid State

Refrigerant is in Gas State

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B-03-08 Issue 01

B2-14

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Operation Overview

System Control

2 open and the compressor clutch disengages, closing down the refrigeration cycle.

The system is a manual control type and is set to ON or OFF by switch 1. There is no automatic control of the cab air temperature. The heater control and blower fan control operate as stated in the Cab Heating and Ventilation Topic. K Related Topics ( T B2-2) Refrigerated air will be heated by the heater matrix If the heater control is not set to â&#x20AC;&#x2DC;coldâ&#x20AC;&#x2122;. Control of the system is achieved by activating and deactivating the compressor electromagnetic clutch. When current is fed to the field coil of the compressor clutch, a magnetic field develops between the field coil and the armature which pulls the field coil, complete with clutch assembly, onto the compressor rotor. Since the clutch assembly is turned constantly by the crankshaft pulley drive belt, the compressor armature turns, starting the refrigeration cycle. Current is fed to the field coil through a series of switches: 1

The manual A/C ON/OFF switch 1 in the control console.

The high and low level binary pressure switch 2 located in the pipework adjacent to the compressor The switch is not adjustable.

The freeze protection thermostat switch 3 located inside the HVAC unit. The switch is not adjustable.

When the A/C switch 1 is set to ON the refrigeration system is active. The system operates within fixed temperature and pressure limits controlled by freeze protection thermostat switch 3 and binary pressure switch 2. The system does not respond to changes in the cab air temperature. If the compressor runs continuously condensate on the evaporator matrix will freeze and the system will not be effective. The freeze protection thermostat switch 3 has its sensor probe inserted in the evaporator matrix. When the temperature of the probe is near 0 0C the thermostat switch contacts open. The compressor clutch disengages, closing down the refrigeration cycle. As the temperature of the probe increases the thermostat switch contacts close. The compressor clutch engages and refrigeration re-starts.

Fig 9. Typical components

C094770

If the refrigerant pressure exceeds the upper pressure limit or falls below the lower limit, the contacts of binary switch

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B-03-08 Issue 01

B2-15

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Operation Overview

Maintenance The air conditioning system needs to be checked regularly to ensure efficient and safe operation. Before commencing any service operations, carry out a basic service check as described below: 1

Start the engine and operate at fast idle speed (1000 RPM).

Switch on the air conditioning and set to maximum cooling.

Note: The cab temperature needs to be above 20°C. At low ambient temperatures it may be necessary to operate the heating system to prevent the air conditioning system switching off. 3

Operate the engine at operating temperature for five to ten minutes.

Close the cab door and windows and allow the internal temperature to stabilize.

Measure the temperature at the evaporator outlets. The temperature should change as the compressor clutch cycles in and out. The outlet temperature with the clutch engaged should be significantly below ambient (4°C to 10°C) rising by 6°C to 8°C when the clutch disengages.

Stop the engine when the tests are complete.

Off-Season Operation During the off-season, the air conditioning system should be operated for at least five minutes every month to circulate the oil in the system to lubricate the fittings and seals. When operating the system, ensure that: 1

Engine idle speed is greater than 1000 RPM.

Ambient temperature is greater than 0°C.

Cab temperature is greater than 20°C.

The engine is at normal operating temperature.

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B2-16

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics The HVAC controls and HVAC unit are connected to the Panel Harness

Key

Key 1

Heater Fan Switch

Air Conditioning Switch A

Air Conditioning Switch B

Secondary Fuse Box A

Heater Connector

Binary Switch A

Binary Switch B

Air Conditioning Compressor clutch solenoid

Freeze Protection Thermostat

Blower Motor

Blower Motor Resistor

2A 3

2B L M H

1 2 3 4 5 6

Fig 10.

B2-17

B-03-08 Issue 01

C124580-C1

B2-17

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics

Fault Finding and Diagnostics Fault Finding Introduction The system will not function in very low ambient temperatures, therefore fault finding 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.

Tables Fault(s) K Table 2. Poor performance ( T B2-18) K Table 3. Warm or slightly cool air emitted from unit ( T B2-18) K Table 4. Compressor clutch continually cuts out ( T B2-18) K Table 5. Poor Performance - Compressor Function Tests ( T B2-19) K Table 6. Compressor Not Achieving 24 bar Pressure ( T B2-19) K Table 7. No air conditioning ( T B2-20) Table 2. Poor performance Action

Possible Cause Condenser matrix air flow restricted.

Remove debris from matrix using compressed air.

HVAC Unit Air Intake filter blocked.

Refer to Section 3 - Routine Maintenance. K Related Topics ( T B2-2)

Compressor drive belt too slack.

Check condition of front end accessory drive belt (FEAD) and auto tensioner mechanism.

Low system pressure.

Discharge and recharge the system.

Possible Cause

Table 3. Warm or slightly cool air emitted from unit Action

Expansion valve stuck open or closed.

Possible Cause

Renew expansion valve.

Table 4. Compressor clutch continually cuts out Action

Condenser matrix blockage.

Remove debris from matrix or

Overcharging of refrigerant system.

Discharge and recharge the system.

Blocked expansion valve or condenser.

Clear blocked component.

Compressor fault.

Do compressor function tests. K Table 5. Poor Performance - Compressor Function Tests ( T B2-19)

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B2-18

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics Check 1

Table 5. Poor Performance - Compressor Function Tests Yes

Is the compressor rotation smooth?

Check 2.

Renew compressor.

Check 3.

Rectify electrical problem.

Check 4.

Renew compressor.

Compressor is functioning correctly.

Follow the pressure fault finding chart. K Table 6. Compressor Not Achieving 24 bar Pressure ( T B2-19)

With the engine having been turned off for 5 minutes, turn the compressor shaft by turning the armature plate by hand. Check for smooth rotation. Grinding or hanging during shaft rotation is caused by a broken component within the compressor. 2

Is the field coil receiving greater than 7.5 V? This test should be conducted with the electrical system on and clutch engaged. Unplug the electrical connector and measure on the machine side.

Note: Reversing polarity will short diode resulting in blown fuses. 3

Is the field coil resistance between 3 and 4 ohms? Coil resistance out of this range will not engage or will cause fused circuits to open. Unplug the electrical connector, measure on compressor side.

Is compressor capable of producing 24 bar or more? To check this do the pressure tests. K System Diagnosis using Test Gauges ( T B2-21) Excessive high pressure can be artificially produced by preventing air flow across the condensor. Preventing air flow through the condensor minimises heat removal from the system resulting in high pressure.

Reason

Table 6. Compressor Not Achieving 24 bar Pressure Test

Low refrigerant charge - possible leakage, suction and discharge pressure are low.

Discharge and recharge the system.

System high pressure side blockage - flow to the compressor is Check suction pressure is stopped or limited. 0.35 bar or less. Compressor failure - internal compressor damage.

B2-19

Action Repair leak. Check system pressures.(1) Compressor is functioning correctly. Remove system blockage.

Renew compressor. Suction pressure high, Discharge pressure low, do compressor function tests. K Table 5. Poor Performance Compressor Function Tests ( T B2-19)

B-03-08 Issue 01

B2-19

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics Reason

Test

Action

Test performed below 10 ºC - Low ambient temperature limits pressure.

Move machine to area where temperature is higher.

Check system pressures. K System Diagnosis using Test Gauges ( T B2-21)

(1) Compressors with dirt/oil build up at hose connections are most likely to have damaged ‘O’ rings. Check for leaks and replace ‘O’ rings.

Check

Table 7. No air conditioning Yes

Are the controls set correctly, i.e. air conditioning selected, Check 2. heater control set to coldest position and blower switched on?

Reset controls and retest.

Is the air conditioning (evaporator) blower working?

Check 4.

Is the compressor running (visual check of pulley/clutch)? Check 10.

Is the air conditioning fuse(s) blown? For details of the electrical circuit and connections, see K Electrical Operation and Schematics ( T B2-17).

Renew fuse(s) and retest.

Check 9.

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

Check 6.

Check 7.

Does the compressor clutch engage with binary pressure Replace binary pressure switch assembly bypassed? switch assembly.

Check 8.

Does the clutch engage with freeze thermostat switch bypassed?

Renew freeze thermostat switch and retest.

Check all electrical connections.

Is there a 12V supply at the compressor?

Renew the compressor clutch and re-test.

Renew the compressor relay and re-test.

Are blower switch and wiring OK?

Renew blower unit complete.

Renew switch or wiring.

Is the system correctly charged with refrigerant OK?

Check 11.

Charge check required by refrigeration engineer or suitably trained person.

Is condensor air flow blocked?

Clean condensor and radiator.

Check 12.

Is evaporator air flow blocked?

Clean/Replace HVAC Unit Air Intake filter.Refer to Section 3 - Routine Maintenance. K Related Topics ( T B2-2)

If necessary replace the evaporator

B2-20

Check 3.

B-03-08 Issue 01

Check 5.

Call in refrigeration engineer or suitably trained person.

B2-20

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics

System Diagnosis using Test Gauges The condition of the air conditioning system can be checked by attaching a manifold gauge block 11-A to the service ports 11-B.

This section gives an overview of the following conditions: K Normally Functioning Air Conditioning System ( T B2-22) K Low R-134a Charge ( T B2-23) K Poor Refrigerant Circulation ( T B2-23)

11-A

Manifold Gauge Block

11-B

Service Ports

11-C

Low Pressure/Temperature Gas (Blue)

11-D

High Pressure/Temperature Gas (Red)

11-E

High Pressure Liquid

Low Side Gauge

High Side Gauge

K No Refrigerant Circulation ( T B2-24) K Insufficient Cooling of Condenser or Refrigerant Overcharge ( T B2-24) K Air in System ( T B2-25) K Expansion Valve Improperly Mounted ( T B2-25) K Compressor Malfunction ( T B2-26) K Some Moisture in the System ( T B2-26) K Further Diagnosis ( T B2-27)

Fig 11. Typical Installation

B2-21

B-03-08 Issue 01

714360-C2

B2-21

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics Normally Functioning Air Conditioning System

Normally Functioning Air Conditioning System Gauge Readings ( T B2-22).

Normal gauge readings will depend on system components and ambient conditions. K Table 8.

Make sure that the valves are closed and the readings are stable and that the system has a full charge.

Ambient Temp °C (°F)

Table 8. Normally Functioning Air Conditioning System Gauge Readings Relative Suction Pressure (Low Side) Discharge Pressure (High Side) Humidity %

Vent Temp °C (°F)

18 (64.4)

1.32 bar (1.34 kgf cm2)(19 lbf in2)

8.76 bar (9 kgf cm2)(127 lbf in2)

8 (46.4)

25 (77)

1.53 bar (1.56 kgf cm )(22 lbf in )

10.8 bar (11 kgf cm )(156.6 lbf in )

32 (89.6)

1.3 bar (1.33 kgf cm )(18.6 lbf in )

13.5 bar (13.77 kgf cm )(195.8 lbf in )

3.6 (38.5)

38 (100.4) 40

1.5 bar (1.53 kgf cm )(21.75 lbf in )

16.3 bar (16.6 kgf cm )(236.4 lbf in )

5.6 (42)

46 (114.8)

1.9 bar (1.94 kgf cm2)(27.56 lbf in2)

19.8 bar (20.19 kgf cm2)(287.2 lbf in2)

11.9 (53.4)

8.8 (47.8)

Example - The pressures on the manifold at 25 °C and 55% relative humidity with the engine at 1500 rpm, the blower on maximum, the heater turned off with the door closed and 10 minutes allowed for stabilisation, should be approximately:

Gauge

Table 9. Gauge Readings Pressure

Low Side LS

Normal: 1.53 bar (1.56 kgf/cm2) (22.2 lbf/in2)

High Side HS

Normal: 10.8 bar (11 kgf/cm2) (156.6 lbf/in2)

Fig 12.

715220-1

Typically, the high pressure is 6 - 8 times the low pressure.

B2-22

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B2-22

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics Low R-134a Charge

Poor Refrigerant Circulation

Fig 13.

Gauge

715220-1

Table 10. Gauge Readings Pressure

Fig 14.

Gauge

A268040-1

Table 11. Gauge Readings Pressure

Low Side LS

Low: 0.5 bar (0.5 kgf cm2)(7.25 lbf in2)

Low Side LS

Zero to negative: -1.0 bar (-1.1 kgf cm2)(-15 lbf in2)

High Side HS

Low: 9.8 bar (10 kgf cm2)(142 lbf in2)

High Side HS

Low: 5.4 bar (5.5 kgf cm2)(78 lbf in2)

Other Symptoms Diagnosis System slightly low on R-134a, due to leak or incorrect charge.

Receiver Drier - Frost on tubes from receiver-drier to evaporator unit. Diagnosis

Correction Refrigerant flow obstructed by dirt, receiver-drier clogged. 1

Leak test system.

Evacuate air con. system

Repair system leaks.

Charge system with R-134a.

Operate system and check performance.

Correction

B2-23

Evacuate air con. system.

Replace receiver-drier.

Charge system with R-134a.

Operate system and check performance.

B-03-08 Issue 01

B2-23

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics No Refrigerant Circulation

Fig 15.

Gauge

Insufficient Cooling of Condenser or Refrigerant Overcharge

A268040-1

Fig 16.

Table 12. Gauge Readings Pressure

Low Side LS High Side HS

Zero to negative: -1.0 bar (-1.1 kgf cm2)(-15 lbf in2)

Gauge

A268060-1

Table 13. Gauge Readings Pressure

Low Side LS

High: 13.0 bar (3.0kgf cm2)(43 lbf in2)

High Side HS

High: 22.1 bar (22.5 kgf cm2)(320 lbf in2)

Low: 5.4 bar (5.5 kgf cm2)(78 lbf in2)

Other Symptoms Receiver Drier - Frost or moisture on tubes before and after receiver-drier.

Diagnosis

Refrigerant overcharge, condenser cooling fins clogged with dirt or cooling fans malfunctioning.

Refrigerant flow obstructed by dirt, moisture or gas leakage from expansion valve heat sensing tube.

Correction

Correction 1

Evacuate air Con. 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.

B2-24

Clean condenser cooling fins.

Check cooling fan operation.

Evacuate air con. system

Charge system with R-134a.

Operate system and check performance.

B-03-08 Issue 01

B2-24

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics Air in System

Expansion Valve Improperly Mounted

Fig 17.

Gauge

A268070-1

Table 14. Gauge Readings Pressure

Fig 18.

Gauge

715230-1

Table 15. Gauge Readings Pressure

Low Side LS

High: 2.8 bar (2.8kgf cm2)(40 lbf in2)

Low Side LS

High: 3.5 bar (3.5kgf cm2)(50 lbf in2)

High Side HS

High: 22.1 bar (22.5 kgf cm2)(320 lbf in2)

High Side HS

High: 22.1 bar (22.5 kgf cm2)(320 lbf in2)

Other Symptoms

Pipes - Low pressure pipes are hot to the touch.

Pipes - Large amount of frost on low side pipes.

Diagnosis

Air is present in the system, possible from inadequate evacuation procedure.

Excessive refrigerant in low side pipes possible from expansion valve being opened too wide.

Correction

Evacuate air con. system.

Leak test system.

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

Evacuate air con. system.

Repair system leaks.

Charge system with R-134a.

Operate system and check performance.

B2-25

B-03-08 Issue 01

B2-25

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics Compressor Malfunction

Fig 19.

Gauge

Some Moisture in the System

A268090-1

Table 16. Gauge Readings Pressure

Fig 20.

Gauge

Low Side LS

High: 4.9 bar (35.0kgf cm2)(71 lbf in2)

High Side HS

Low: 8.3 bar (8.5 kgf cm2)(121 lbf in2)

Table 17. Gauge Readings Pressure

Low Side LS

Normal, then sometimes drops to below zero: -2.1 bar (-2.1kgf cm2)(30 lbf in2)

High Side HS

Normal, then sometimes goes high: 14.8 bar (15.0 kgf cm2)(214 lbf in2)

Diagnosis Internal compressor leak or compressor mechanically broken.

A268020-1

Diagnosis

Correction

Moisture in system freezes, temporarily stopping cycle, normal system operation returns when ice melts.

Evacuate air con. system.

Correction

Repair or replace compressor.

Evacuate air con. system.

Charge system with R-134a.

Replace receiver-drier.

Operate system and check performance.

Remove moisture by repeatedly evacuating system.

Charge system with R-134a.

Operate system and check performance.

B2-26

B-03-08 Issue 01

B2-26

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Fault Finding and Diagnostics Further Diagnosis Table 18. High Pressure

Low Pressure

Too High

Too Low

Compressor running continuously

Condenser Dirty

Too High

Normal to Too High

Compressor running continuously

Engine overheating

Normal to Too High

Normal

Compressor running continuously

Air or foreign matter in system or excess refrigerant.

Too High

Too Fast

Too Short

Normal to Too Low

Normal to

Too Slow or Too Low

Too long or continuously

Normal to Too Low

Too High

Too Fast

Too Short

Normal to Too Low

Too High

Compressor running continuously

Compressor faulty

Normal to Too Low

Normal to Too High

Compressor running continuously

Low pressure line blocked

Normal to Too Low

Normal

Too Fast

Too Short

Normal

Normal to Too Low

Normal

Too Fast

Too short

Insufficient refrigerant

Normal to Too Low

Normal

Too Fast

Too Short

Too Long

Evaporator feed line blocked

B2-27

Cycle

Engage

B-03-08 Issue 01

Disengage

Normal

Possible Cause

Excess refrigerant

Normal or Non - Dirt or excess refrigerant oil in existent circuit Normal

Faulty thermostat

Evaporator blocked

B2-27

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Test Procedures

Test Procedures Leak Testing

!MWARNING

TB-004

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

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.

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 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

B2-28

B-03-08 Issue 01

B2-28

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Compressor Drive Belt - Adjustment

Compressor Drive Belt - Adjustment The air conditioning compressor is driven by the front end accessory drive belt (FEAD). The belt is automatically kept in tension so will not need to be adjusted. At the recommended service interval, visually inspect the belt for damage. Refer to Section 3 - Routine Maintenance. K Related Topics ( T B2-2).

B2-29

B-03-08 Issue 01

B2-29

Section B2 - Body and Framework Cab Air Conditioning SYSTEM Compressor Drive Belt - Adjustment

Page left intentionally blank

B2-30

B-03-08 Issue 01

B2-30

Section B3 - Body and Framework

Cab Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T B3-3) K Removal and Replacement ( T B3-5) K Roller Blind (P1) ( T B3-5)(1) K Roller Blind (P2) ( T B3-6)(1) K Fabric Roof Liner ( T B3-7) K Steel Roof Liner ( T B3-8) K Floor Mat ( T B3-9) K Instrument Panels ( T B3-10)(1) K Door Handle Removal and Replacement ( T B3-15) K Door Removal and Replacement ( T B3-16) K Screen Guard ( T B3-17) K Roof Guard ( T B3-18) K Wiper Motor Front ( T B3-19) K Wiper Motor Rear ( T B3-20) K Wiper Motor Roof ( T B3-21) K Cab (P1) ( T B3-22)(1) K Cab (P2) ( T B3-26)(1) (1) Specification variants. Make sure you refer to the correct specification.

B3-1

B-04-07 Issue 01

B3-1

Section B3 - Body and Framework Cab Introduction Table 1. Specification Variants - Roller Blind Machine Model Application

Specifications(1)

506-36, 507-42, 509-42, 510-56, 512- 531-70, 535-95, 536-60, 541-70, 53356, 514-56, 526-56 105, 536-70, 533-105, 536-70, 55080, 540-170, 550-170, 540-140, 550140, 535-125 HiViz, 535-140 HiViz, 527-58, 540-200 K Roller Blind (P1) ( T B3-5)

z z

K Roller Blind (P2) ( T B3-6)

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

Specifications(1)

Table 2. Specification Variants - Instrument Panel, Heater Controls Machine Model Application 531-70, 535-95, 536-60, 541-70, 533105, 536-70, 533-105, 536-70, 55080, 540-170, 550-170, 540-140, 550140, 506-36, 507-42, 509-42, 510-56, 512-56, 514-56, 535-125 HiViz, 535140 HiViz, 540-200

K Fig 7. Heater Controls (S1) ( T B3-10)

526-56, 527-58

z z

K Fig 8. Heater Controls (S2) ( T B3-10)

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information. Table 3. Specification Variants - Cab Specifications

Machine Model Application

(1)

506-36, 507-42, 509-42, 510-56, 51256, 514-56, 526-56, 531-70, 535-95, 536-60, 541-70, 533-105, 536-70, 533-105, 536-70, 550-80, 540-170, 550-170, 540-140, 550-140, 535-125 HiViz, 535-140 HiViz, 540-200 K Cab (P1) ( T B3-22)

527-58

z z

K Cab (P2) ( T B3-26)

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

B3-2

B-04-07 Issue 01

B3-2

Section B3 - Body and Framework Cab Related Topics

Related Topics Table 4. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

ROPS/FOPS (and OECD) Structure

Checking the ROPS/FOPS (and OECD) Structure

Engine

Checking the Coolant Level

Cab Air Conditioning SYSTEM

Refrigerant Charging and Discharging

Servo Control Valve

Removal and Replacement

Electro Servo Control Lever

Control Lever - Parallel Single Lever Control

Hydraulic Control Valve

Service Brakes SYSTEM

Bleeding

Park Brake SYSTEM

ALL

Power Brake Valve

ALL

Steering Column

Removal and Replacement

Steer Mode Valve

Removal and Replacement

Throttle Pedal and Cable

Removal and Replacement

Throttle Pedal Sensor

ALL

Hand Throttle

ALL

ALL ALL

(1)

(2)

Removal and Replacement

(2) (2)

Removal and Replacement ALL

(3)

(1) You must obey all of the relevant care and safety procedures. (2) If fitted (3) Refer to the applications table in Section E for the correct control valve for your machine. Table 5. Service Tools The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number

Description

892/00843(1)

Glass Stand

892/00842

Glass Lifters

892/00845

Cartridge Gun

892/00847

Nylon Spatula

(1)

992/12300

Mobile Oven 12V

992/12400(1)

Static Oven 240V

992/12600(1)

Static Oven 240V

4104/1310

Hand Cleaner

926/15500

Rubber Spacer Blocks

992/12800

Cut-Out Knife

992/12801

`L' Blades

892/00846(1)

Glass Extractor (Handles)

(1) (1) (1)

(1) (1) (1) (1)

B3-3

B-04-07 Issue 01

B3-3

Section B3 - Body and Framework Cab Related Topics The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number

Description

892/00848(1)

Wire Starter

892/00849(1)

Braided Cutting Wire

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

B3-4

B-04-07 Issue 01

B3-4

Section B3 - Body and Framework Cab Removal and Replacement

Removal and Replacement Roller Blind (P1)

Support the blinds.

Removal

Remove trim panel screws A from each end of the blind.

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Note: Some machine variants only have 2 securing screws at each side of the blind as shown at X.

Make sure that both blinds are fully retracted.

Detach the trim panel B to remove the blind assembly C.

A A

A X B A

Fig 1.

C119270

Replacement Replacement is the opposite of the removal procedure.

B3-5

B-04-07 Issue 01

B3-5

Section B3 - Body and Framework Cab Removal and Replacement

Roller Blind (P2) Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Make sure that both blinds are fully retracted.

Support the blinds.

Remove trim panel screws A from each end of the trim panel B.

A Fig 2. 5

A C119290

Detach the trim panel B and remove the blind assembly C.

Replacement Replacement is the opposite of the removal procedure.

B3-6

B-04-07 Issue 01

B3-6

Section B3 - Body and Framework Cab Removal and Replacement

Fabric Roof Liner Note: Take care during the removal and replacement procedure. Make sure your hands and clothes are clean. The roof liner is easily damaged.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

With the aid of one more person hold the roof liner B and remove the screws A.

Lower the liner to get access to the electrical connectors at the interior lights C and audio speakers D.

Note: Not all machines have audio speakers. 4

Disconnect the electrical connectors at the interior lights and audio speakers.

Remove the roof liner.

Note: Put the roof liner into a clean plastic bag and keep it in a safe place. The roof liner is easily damaged.

Replacement Replacement is the opposite of the removal procedure.

Fig 3.

B3-7

C048100

B-04-07 Issue 01

B3-7

Section B3 - Body and Framework Cab Removal and Replacement

Steel Roof Liner Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

With the aid of one more person hold the roof liner B and remove the screws A.

Lower the liner to get access to the electrical connectors at the interior lights C and audio speakers D.

Note: Not all machines have audio speakers. 4

Disconnect the electrical connectors at the interior lights and audio speakers.

Remove the roof liner.

Note: Put the roof liner into a clean plastic bag and keep it in a safe place. The roof liner is easily damaged.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; If there were seals attached to the panel make sure these are in good condition. If damaged - replace.

B C

A A Fig 4.

B3-8

C119300

B-04-07 Issue 01

B3-8

Section B3 - Body and Framework Cab Removal and Replacement

Floor Mat Removal and Replacement Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the nuts B and remove the pedal pads A from the machine.

Remove the bolts E and retaining plate F.

Remove the screws D and kick strips C.

Remove the trim retainers G from the front section of the mat.

Remove the mat from the machine.

Replacement Replacement is the opposite of the removal procedure.

B A D

C D

G Fig 5.

B3-9

C097170-C1

B-04-07 Issue 01

B3-9

Section B3 - Body and Framework Cab Removal and Replacement

Instrument Panels

Heater Control Panel

Centre Warning Light Panel

Removal

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the two screws A that hold the heater control panel in place, disconnect all connections and remove the panel.

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3) Remove the two screws A that hold the centre display panel in place, disconnect all connections and remove the panel.

00:00:05

Fig 7. Heater Controls (S1)

Fig 6.

C124070-C3

445611-C4

Replacement Replacement is the opposite of the removal procedure. Fig 8. Heater Controls (S2)

T016820-1-C1

Replacement Replacement is the opposite of the removal procedure.

B3-10

B-04-07 Issue 01

B3-10

Section B3 - Body and Framework Cab Removal and Replacement Left Hand Switch Panel

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the two screws A that hold the left hand switch panel B in place, disconnect all connections and remove the panel.

To remove the rotary switch E: a

Remove the knob C from the front of the panel D.

b Mark the position of the switch housing E in relation to the trim panel D. c

Unscrew the locknut F and remove the switch E from the panel D.

F Fig 10.

C124510-C3

Replacement

Replacement is the opposite of the removal procedure.

During the replacement procedure do this work also: Fig 9.

B3-11

C067070

â&#x20AC;&#x201C; Make sure to align the switch housing correctly with the panel to make sure the switch is in the correct position for all of the switch settings.

B-04-07 Issue 01

B3-11

Section B3 - Body and Framework Cab Removal and Replacement Right Hand Instrument Panel Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the radio E (if fitted).

Remove the three screws D that hold the main switch and instrument panel in place, disconnect all connections and remove the panel.

Note: Do not touch the electrical connector pins on electronic type instruments C. Put protective caps on the harness connectors and the connectors on the instruments.

E D

D Fig 11.

432710-C6

Replacement Replacement is the opposite of the removal procedure.

B3-12

B-04-07 Issue 01

B3-12

Section B3 - Body and Framework Cab Removal and Replacement Front Trim Panel Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

F G

Remove the steering wheel. Refer to Section H Steering Column. K Related Topics ( T B3-3) Remove the two button head screws A, remove the steering column lower surround.

Fig 13. 6

Remove the heater control Panel. K Heater Control Panel ( T B3-10)

Remove the radio (if fitted).

Remove the Right Hand Instrument Panel. K Right Hand Instrument Panel ( T B3-12)

Remove the left hand switch panel. K Left Hand Switch Panel ( T B3-11)

Remove the centre display panel. K Centre Warning Light Panel ( T B3-10)

Remove screws L, N, P, R and remove the upper right hand panel M, carefully feeding the harness through the aperture.

12 9

C119250

3 6

00:00:05

Note: Screw item P is removed from the front of the panel, i.e. the opposite side to that shown. 0-

Fig 12.

Remove screws H, K, and Q. Remove the lower left hand panel J.

445611-1

Remove the two button head screws B and two screws C, remove the steering column upper surround.

If the steer mode select switch has a lockable surround - remove as follows: K Fig 13. ( T B3-13) a

Remove the two screws that secure the steer Mode Select switch panel F.

b Disconnect all connections and remove the panel. c

B3-13

Remove the steer mode control knob G

B-04-07 Issue 01

B3-13

Section B3 - Body and Framework Cab Removal and Replacement

N R

Fig 14.

B3-14

B-04-07 Issue 01

C119260-C1.eps

B3-14

Section B3 - Body and Framework Cab Removal and Replacement

Door Handle Removal and Replacement

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Support the outer handle unit D.

Remove screws E from the inside of the door and lift away the cover plate F.

Disconnect the latch assembly from the handle lever C.

Slightly tilt the handle unit D to unhook the unit from the door assembly. Retain gasket A and trim plate B.

F E

E E

Fig 15.

C093950-C1

Replacement Replacement is the opposite of the removal procedure.

B3-15

B-04-07 Issue 01

B3-15

Section B3 - Body and Framework Cab Removal and Replacement

Door Removal and Replacement K Fig 16. ( T B3-16) and K Fig 17. ( T B3-16)

If necessary remove the hinge assembly B by removing the nuts from inside the cab.

Do procedures 2 to 6 for the lower part of door 16-E. (Two piece door assembly only)

If necessary the door catch assembly F can be removed by removing the nuts, bolts and locking plate.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Divide the doors by releasing the locking handle 16A. (Two piece door assembly only)

Make sure that the door D is supported.

Use a thin punch and a hammer to tap securing pin G from the hinge assemblies B.

Use a punch and a hammer to tap hinge pin C from the hinge assemblies B.

Do procedures 3 and 4 for all other hinges on door D.

F Fig 17. Single Piece Door Assembly

C075460

Replacement Replacement is the opposite of the removal procedure.

Fig 16. Two Piece Door Assembly 7

C046850-C1

Carefully remove the door D from the hinge assembly B.

B3-16

B-04-07 Issue 01

B3-16

Section B3 - Body and Framework Cab Removal and Replacement

Screen Guard

Removal

Removal and Replacement

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Support the guard A.

Remove the upper nuts D, bolts C and washers B.

Remove the lower nuts H and washers G and F.

Remove the guard A from the machine.

B C

Replacement

Replacement is the opposite of the removal procedure.

A F G H

F Fig 18.

B3-17

C095710

B-04-07 Issue 01

B3-17

Section B3 - Body and Framework Cab Removal and Replacement

Roof Guard

Removal and Replacement

Remove the rear mounting bolt A and unscrew the front guard mounting bolts B from the windscreen guard.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Fig 19.

C046890-C2

Replacement Replacement is the opposite of the removal procedure.

B3-18

B-04-07 Issue 01

B3-18

Section B3 - Body and Framework Cab Removal and Replacement

Wiper Motor Front Removal and Replacement Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the front trim panel. Refer to Instrument Panels. K Instrument Panels ( T B3-10)

Disconnect the wiper motor electrical connector A

Remove the tube B at the cab bulkhead adapter.

Remove the nuts C and pull the wiper arm assembly D off the motor shafts.

With the aid of one more person hold the wiper motor E and at the same time remove the nuts F.

Remove the wiper motor E.

Replacement Note: If the wiper motor is defective it must be replaced. It is not possible to repair a defective wiper motor. Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Torque tighten the nut C. K Table 6. Torque Settings ( T B3-19)

Item C

Table 6. Torque Settings Nm kgf m 25

2.5

lbf ft 18.4

Fig 20.

B3-19

B-04-07 Issue 01

C045680.jpg

B3-19

Section B3 - Body and Framework Cab Removal and Replacement

Wiper Motor Rear Removal and Replacement Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the wiper motor cover A.

Disconnect the wiper motor electrical connector B.

Flip up cover C.

Remove both locknuts and grommet assembly D and pull the wiper arm assembly off from the motor shaft

With the aid of one more person hold the wiper motor F from inside the cab and remove locknut E.

Remove the wiper motor F.

Note: If the wiper motor is defective it must be replaced. It is not possible to repair a defective wiper motor.

Fig 21.

C047640.jpg

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Torque tighten the nut E. K Table 7. Torque Settings ( T B3-20) Note: To avoid damage to the glass do not over tighten nut E.

Item E

B3-20

Table 7. Torque Settings Nm kgf m 25

2.5

lbf ft 18.4

B-04-07 Issue 01

B3-20

Section B3 - Body and Framework Cab Removal and Replacement

Wiper Motor Roof

Removal and Replacement

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the cab Liner ( T B3-7)

Remove the wiper motor cover A.

Disconnect the wiper motor electrical connector B

Flip up cover C.

Remove both locknuts and grommet assembly D and pull the wiper arm assembly off from the motor shaft.

With the aid of one more person hold the wiper motor F from inside the cab and at the same time remove locknut E.

Remove the wiper motor F.

roof

liner.

K Fabric

Roof

B A Fig 22.

C047670

Item E

B3-21

Table 8. Torque Settings Nm kgf m 25

2.5

lbf ft 18.4

B-04-07 Issue 01

B3-21

Section B3 - Body and Framework Cab Removal and Replacement

!MWARNING

Cab (P1) K Items 1 to 9 ( T B3-24), K Items 10 to 23 ( T B3-25)

Removal Note: Make sure to label all hoses/pipes and electrical connectors before removal to aid identification when replacing.

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

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

If applicable, once the system has been discharged, disconnect the air conditioning hoses at the thermostatic expansion valve (TEV) 18.

Note: Some machines are fitted with a cab roof mounted air conditioning condenser. Disconnect the condenser hoses at the rear of the cab. 9

Disconnect engine throttle cable (if fitted). Refer to Section K - Throttle Cable. K Related Topics ( T B3-3)

GEN-4-1_1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

Disconnect the throttle pedal electrical connectors (if fitted). Refer to Section K- Throttle Pedal Sensor. K Related Topics ( T B3-3)

Raise the boom and fit the safety strut, see Section 2 - Boom Safety Strut. K Related Topics ( T B3-3)

Vent all residual hydraulic and braking pressure, see Section 2 - General Procedures. K Related Topics ( T B3-3)

Ensure all wheels are chocked and release parking brake. Disconnect parking brake cable 1. Refer to Section G- Parkbrake SYSTEM. K Related Topics ( T B3-3)

On machines with dual lever controls 10 - disconnect the control levers from the control valve connection rods. Refer to Section E - Control Valve. K Related Topics ( T B3-3)

On machines with Parallel Servo Control Levers 11, label and disconnect the hoses at the servo control valves. Disconnect the control levers 12 and 13 from the control valve connection rods. Refer to Section E - Hydraulics. K Related Topics ( T B3-3)

Disconnect the manual steer mode valve cable (if fitted) from the lever 14. Refer to Section H - Manual Steer Mode Valve. K Related Topics ( T B3-3)

Disconnect the chassis electrical Disconnect the cab earth strap 5.

Undo the fuel filler hose clip 9. Loosen the fuel tank filter hose on fuel tank filler neck 8 so that the two separate at step 21.

Remove the battery cover and disconnect the battery.

Remove the bolts and remove the cab front cover 3.

Disconnect all hydraulic hoses from steering unit 4. Cap all open ports to prevent loss of fluid and ingress of dirt.

Remove heater cover 16 (if fitted). Undo the hose clips and disconnect heater hoses 17.

Important: If the machine is fitted with air conditioning, DO NOT attempt to disconnect any air conditioning hoses until the refrigerant has been discharged. Charging and discharging the system requires special equipment and training. If necessary, use the services of a specialist refrigeration engineer.

B3-22

B-04-07 Issue 01

harness

B3-22

Section B3 - Body and Framework Cab Removal and Replacement 17

Disconnect the braking system components: a

– Torque tighten the cab mounting bolts, see Section 3 Routine Maintenance. K Related Topics ( T B3-3)

550-80 Machines Refer to Section G - Power Brake Valve for details of disconnecting the brake valve. K Related Topics ( T B3-3)

b All other machines: On machines with cab mounted brake servo, disconnect the brake pipe 20 and servo hose 19 (shown at 21). Cap all open hoses and pipes to prevent fluid loss and ingress of dirt. Disconnect brake pipe 23 at the master cylinder (shown at 22). Cap all open hoses and pipes to prevent fluid loss and ingress of dirt. 18

Disconnect hitch cable 7 (if fitted).

Unscrew and remove cab mounting bolts 2.

Attach appropriate lifting equipment to the ROPS and FOPS cage.

Carefully lift the cab from the machine, ensuring that all connections have been released and are clear of any obstruction. Cap off fuel tank filler neck 8 to prevent contamination.

– Bleed the brakes, see Section G - Brakes. K Related Topics ( T B3-3) – Adjust the throttle pedal and cable (if fitted), see Section H- Throttle Pedal and Cable. K Related Topics ( T B3-3) – If applicable, recharge the air conditioning system, see Section B - Air Conditioning SYSTEM. K Related Topics ( T B3-3) – Check the hydraulic fluid level. Section 3 - Hydraulic SYSTEM. K Related Topics ( T B3-3) – Make sure that all cables are connected and correctly adjusted. Make sure that they are routed and secured correctly. – Make sure that all electrical and hydraulic services operate correctly.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

B3-23

B-04-07 Issue 01

B3-23

Section B3 - Body and Framework Cab Removal and Replacement

8 7

3 4

Fig 23. Items 1 to 9

B3-24

B-04-07 Issue 01

2 C119310

B3-24

Section B3 - Body and Framework Cab Removal and Replacement

10 10 17

18 16 14 13 13

11 12 12

23 20

22 Fig 24. Items 10 to 23

B3-25

B-04-07 Issue 01

C119320

B3-25

Section B3 - Body and Framework Cab Removal and Replacement

Cab (P2)

Removal

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B3-3)

If applicable, once the system has been discharged, disconnect the air conditioning hoses at the thermostatic expansion valve (TEV) R.

Raise the boom and fit the safety strut, see Section 2 - Boom Safety Strut. K Related Topics ( T B3-3)

Disconnect the condenser pipes B at the condenser.

Vent all residual hydraulic and braking pressure, see Section 2 - General Procedures. K Related Topics ( T B3-3)

Remove the hose clamps C.

Disconnect engine throttle cable (Machines with SD/ SF) Engines. Refer to Section K - Throttle Cable. K Related Topics ( T B3-3)

Disconnect throttle pedal sensor electrical connectors (Machines with SH/SL/SF) Engines. Refer to Section K - Throttle Pedal Sensor. K Related Topics ( T B3-3)

Remove the battery covers and disconnect the battery. Refer to Section 3 - Routine Maintenance. K Related Topics ( T B3-3)

Remove the cab undershield. Refer to Section 3 Routine Maintenance. K Related Topics ( T B3-3)

Remove the deckplate. Refer to Section 3 - Routine Maintenance. K Related Topics ( T B3-3)

Ensure all wheels are chocked and release parking brake.

Remove the bolts and remove the cab front cover A.

Remove the floor mat. K Floor Mat ( T B3-9)

Working at the park brake caliper, disconnect clevis K, note which of the three holes on the actuating lever L is used.

Disconnect the bulkhead electrical connectors V.

Disconnect the inching pedal electrical connectors U (if fitted).

Remove clip or loosen locknut H as applicable. Disconnect the cable J from the bracket. Note the cable routing to the underside of the cab.

Disconnect the brake flexi pipe P from the chassis connector. Cap the pipe and adaptor to prevent loss of fluid and contamination.

Disconnect the cab earth strap M.

Disconnect hitch cable T (if fitted).

Disconnect all hydraulic hoses from steering unit N. Cap all open ports to prevent loss of fluid and contamination Undo the hose clips and disconnect heater hoses S.

B3-26

B-04-07 Issue 01

B3-26

Section B3 - Body and Framework Cab Removal and Replacement 24

Disconnect the washer hoses.

Remove the plate on the front left and rear mount.

Remove the control lever. Refer to Section E Control Lever - Electro Servo. K Related Topics ( T B3-3)

Remove the screws D and Varispeed/Hand throttle control panel F. Disconnect the electrical connector E from the chassis harness.

B3-27

B-04-07 Issue 01

B3-27

Section B3 - Body and Framework Cab Removal and Replacement

B C F

V G

H U

K L

T G R S

N P

Fig 25.

B3-28

B-04-07 Issue 01

C097170

B3-28

Section B3 - Body and Framework Cab Removal and Replacement 28

Disconnect the manual steer mode cable (if fitted). Refer to Section H - Manual Steer Mode Valve. K Related Topics ( T B3-3)

Unscrew and remove cab mounting bolts and nuts G.

Attach appropriate lifting equipment to the ROPS and FOPS cage.

Carefully lift the cab from the machine, ensuring that all connections have been released and are clear of any obstruction.

Replacement

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Torque tighten the cab mounting bolts, see Section 3 Routine Maintenance. K Related Topics ( T B3-3) Note: On low cab machines the right rear cab mounting bolt is orientated as at 1. To aid installation it is acceptable to install the bolt as shown at 2. K Fig 26. ( T B3-29)

Fig 27.

C097170-C3

– Make sure that all cables are connected and correctly adjusted. Make sure that they are routed and secured correctly. – Make sure that all electrical and hydraulic services operate correctly. – Bleed the brakes, see Section G - Brakes. K Related Topics ( T B3-3)

Fig 26.

C107110

– Do a check of the cab mounting rubbers. If damaged or worn replace. – Use the cab filter protection plate W between the filter gasket X and cab whilst the cab is lowered onto the chassis. The lower part of the plate locates in the slot in the chassis Y. For tool details refer to Section 1 Service Tools. K Related Topics ( T B3-3)

B3-29

– If applicable, recharge the air conditioning system, see Section B - Air Conditioning SYSTEM. K Related Topics ( T B3-3) – Check the throttle cable adjustment. Refer to Section K - Throttle Pedal and Cable. K Related Topics ( T B3-3) – Check hand throttle operation and adjust if necessary. Refer to Section K - Hand Throttle. K Related Topics ( T B3-3) – Check the parkbrake adjustment and adjust if necessary. Refer to Section 3 - Routine Maintenance. K Related Topics ( T B3-3)

B-04-07 Issue 01

B3-29

Section B3 - Body and Framework Cab Removal and Replacement

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B3-30

B-04-07 Issue 01

B3-30

Section B4 - Body and Framework

Air Conditioning Condenser - Cooling Pack Mounted Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

K Related Topics ( T B4-2) K Removal and Replacement ( T B4-3) K Removal ( T B4-3) K Replacement ( T B4-4)

B4-1

B-06-08 Issue 01

B4-1

Section B4 - Body and Framework Air Conditioning Condenser - Cooling Pack Mounted Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Cab Air Conditioning SYSTEM

ALL

Chassis Panels

Engine Cover

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

B4-2

B-06-08 Issue 01

B4-2

Section B4 - Body and Framework Air Conditioning Condenser - Cooling Pack Mounted Removal and Replacement

Removal and Replacement

C119760

Fig 1. Note: Before removing the condenser matrix, discharge the system. Refer to the Cab Air Conditioning SYSTEM topic. K Related Topics ( T B4-2) The condenser matrix A is mounted onto the cooling pack in the engine compartment. If the condenser is being removed only to gain access to the cooling pack, this can be done without disconnecting the air conditioning hoses i.e. with the system fully charged. Having removed the nuts C the condenser can be carefully laid to one side leaving the hoses still connected. Take care not to kink the hoses. Do not allow the condenser to hang on the hoses unsupported. Removal of the condenser matrix will require the assistance of a refrigeration engineer or suitably trained person since the refrigerant needs to be drained from the system.

B4-3

Removal 1

Park the machine and make it safe. See Section 2 General Procedures.

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

Lift the engine cover.

Disconnect and remove the battery.

B-06-08 Issue 01

B4-3

Section B4 - Body and Framework Air Conditioning Condenser - Cooling Pack Mounted Removal and Replacement

Make sure that the air conditioning system is fully discharged. K Related Topics ( T B4-2)

Put a label on the hoses before disconnecting to aid identification when replacing.

Disconnect the air conditioning hoses at the pipe stubs B on the side of the condenser. Plug the hose ends to prevent ingress of dirt and loss of fluid.

Note: To prevent damaging to the condenser when removing or installing the hoses, it is necessary that the hexagon flats on the pipe stubs B must be held with a spanner whilst loosening or tightening the hose nuts. When removing components or hoses, retain any lubricant within the component/hose and fill the system with the same amount of clean lubricant (PAG Oil). 7

Remove nuts C and carefully lift the condenser matrix from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; After replacement recharge the system. K Related Topics ( T B4-2) â&#x20AC;&#x201C; Operate the air conditioning and check the hose connections for leaks. In the cab, set the air conditioning to maximum cooling and check that cooled air comes from the vents.

B4-4

B-06-08 Issue 01

B4-4

Section B5 - Body and Framework

Cab HV and HVAC Unit Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T B5-3) K Freeze Thermostat (HVAC Unit) ( T B5-4) K Removal ( T B5-4) K Replacement ( T B5-4) K Removal and Replacement (P1) ( T B5-5)(1) K Removal ( T B5-5) K Replacement ( T B5-6) K Removal and Replacement (P2) ( T B5-7)(1) K Removal ( T B5-7) K Replacement ( T B5-8) K Removal and Replacement (P3) ( T B5-9)(1) K Removal ( T B5-9) K Replacement ( T B5-11) K Heater Air Intake (Snorkel) ( T B5-12)(1) K Removal ( T B5-12) K Replacement ( T B5-13) (1) Procedure variant. Make sure you refer to the correct procedure.

B5-1

B-07-06 Issue 02

B5-1

Section B5 - Body and Framework Cab HV and HVAC Unit Introduction Procedures(1)

Table 1. Procedure Variants Machine Model Application 531-70, 531-T70, 53595, 535-T95, 536-60, 536-T60, 541-70, 541T70, 533-105, 536-70, 536-T70, 550-80, 540170, 550-170, 540140, 550-140, 535-125 HiViz, 535-140 HiViz, 506-36, 507-42, 50942, 510-56, 512-56, 514-56, 540-200

K Removal and Replacement (P1) ( T B5-5)

526-56

527-58

z z

K Removal and Replacement (P2) ( T B5-7)

z z

K Removal and Replacement (P3) ( T B5-9) K Heater Air Intake (Snorkel) ( T B5-12)

(1) The table lists procedure variants and the applicable machine models. Use the table to make sure you refer to the correct information.

B5-2

B-07-06 Issue 02

B5-2

Section B5 - Body and Framework Cab HV and HVAC Unit Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)(1)

ALL

Engine

Changing the Coolant

Cab Heating and Ventilation SYSTEM

ALL

Cab Air Conditioning SYSTEM

ALL

Heater Valve

Removal and Replacement

Chassis Panels

Chassis Side Cover

Cab Side Cover

ALL

(2)

(1) You must obey all of the relevant care and safety procedures. (2) HVAC unit only

B5-3

B-07-06 Issue 02

B5-3

Section B5 - Body and Framework Cab HV and HVAC Unit Freeze Thermostat (HVAC Unit)

Freeze Thermostat (HVAC Unit)

C094750

Fig 1.

Removal 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B5-3)

Undo twelve screws 1 and lift off the HVAC unit cover 2.

Undo two fixing bolts 5 then remove the two electrical connectors 4.

Carefully remove the thermostat 8 and its sensor 6. Note the routing of the sensor probe. Do not make sharp bends in the sensor probe.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; If a new thermostat is to be installed carefully remove the protective sleeve 9 from the sensor 10. Do not make sharp bends in the sensor probe. â&#x20AC;&#x201C; Make sure the HVAC cover sealing gasket locates correctly.

B5-4

B-07-06 Issue 02

B5-4

Section B5 - Body and Framework Cab HV and HVAC Unit Removal and Replacement (P1)

Removal and Replacement (P1) IMPORTANT: This procedure is only applicable to some machine models. Refer to the table at the front of this topic for the applicable machine models. K Table 1. Procedure Variants ( T B5-2) HV Unit The heating and ventilation unit (HV) contains a blower unit and heat exchanger matrix. It is located beneath the right front side of the cab. HVAC Unit The heating, ventilation and air conditioning unit (HVAC) is the same as the HV unit but also contains an evaporator matrix and thermostat. Note: Put a label on all hoses before removal to aid replacement.

Disconnect the air conditioning hoses at the expansion valve G (if fitted).

Undo clip K and disconnect cable L from the heater shut off valve.

Remove bolts H and J securing the air conditioning (HVAC) unit to the machine. Carefully remove the unit sufficiently to access the electrical harness connector at the rear. Disconnect the electrical connector.

Note: The electrical harness connector is located behind the unit and cannot be disconnected until the unit is pulled away from the machine. 8

Remove the unit from the machine.

Removal

To remove the unit it is necessary to evacuate (discharge) the refrigerant from the system. Refer to the Cab Air Conditioning SYSTEM topic. K Related Topics ( T B5-3) Get access to the thermostatic expansion valve by lowering the unit without disconnecting the hoses. In this instance it is not necessary to evacuate the refrigerant. 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B5-3)

Drain the cooling system.

Remove cab side cover (if fitted) to get access to the air conditioning (HVAC) unit. Refer to Section B Cab Side Cover. K Related Topics ( T B5-3)

Disconnect the heater hoses at the heater tap E, and heater hose at the heater matrix F.

B5-5

B-07-06 Issue 02

Fig 2. Typical Installation

715680-1

B5-5

Section B5 - Body and Framework Cab HV and HVAC Unit Removal and Replacement (P1)

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Make sure that the expansion valve M is fitted correctly with the diaphragm N located below the valve.

Fig 3.

C119380

Recharge the air conditioning system and check for leaks. Refill the cooling system and check for leaks.

B5-6

B-07-06 Issue 02

B5-6

Section B5 - Body and Framework Cab HV and HVAC Unit Removal and Replacement (P2)

Removal and Replacement (P2) IMPORTANT: This procedure is only applicable to some machine models. Refer to the table at the front of this topic for the applicable machine models. K Table 1. Procedure Variants ( T B5-2)

Undo clip K and disconnect cable L from the heater shut off valve.

Remove the cab. Refer to the Cab topic. K Related Topics ( T B5-3)

HV Unit The heating and ventilation unit (HV) contains a blower unit and heat exchanger matrix. It is located beneath the right front side of the cab.

Remove the chassis side cover (if fitted). Refer to Section B - Chassis Panels. K Related Topics ( T B5-3)

HVAC Unit The heating, ventilation and air conditioning unit (HVAC) is the same as the HV unit but also contains an evaporator matrix and thermostat.

Remove bolts H and J securing the air conditioning (HVAC) unit to the cab. Carefully remove the unit sufficiently to access the electrical harness connector at the rear. Disconnect the electrical connector.

Note: Put a label on all hoses before removal to aid replacement.

Note: The electrical harness connector is located behind the unit and cannot be disconnected until the unit is pulled away from the cab.

Removal

!MWARNING

Remove the unit from the machine.

To remove the unit it is necessary to evacuate (discharge) the refrigerant from the system. Refer to the Cab Air Conditioning SYSTEM topic. K Related Topics ( T B5-3) 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B5-3)

Drain the cooling system.

Remove cab side cover (if fitted) to get access to the air conditioning (HVAC) unit. Refer to Section B Cab Side Cover. K Related Topics ( T B5-3)

Disconnect the heater hoses at the heater tap E, and heater hose at the heater matrix F.

Disconnect the air conditioning hoses at the expansion valve G (if fitted).

B5-7

B-07-06 Issue 02

Fig 4. Typical Installation

715680-1

B5-7

Section B5 - Body and Framework Cab HV and HVAC Unit Removal and Replacement (P2)

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Make sure that the expansion valve M is fitted correctly with the diaphragm N located below the valve. – Recharge the air conditioning system and check for leaks. – Refill the cooling system and check for leaks.

Fig 5.

B5-8

C119380

B-07-06 Issue 02

B5-8

Section B5 - Body and Framework Cab HV and HVAC Unit Removal and Replacement (P3)

Removal and Replacement (P3) IMPORTANT: This procedure is only applicable to some machine models. Refer to the table at the front of this topic for the applicable machine models. K Table 1. Procedure Variants ( T B5-2)

Disconnect the air conditioning hoses at the expansion valve G (if fitted).

Undo clip K and disconnect cable L from the heater shut off valve.

Remove the cab. Refer to the Cab topic. K Related Topics ( T B5-3)

HVAC Unit The heating, ventilation and air conditioning unit (HVAC) is the same as the HV unit but also contains an evaporator matrix and thermostat.

Remove the chassis side cover (if fitted). Refer to Section B - Chassis Panels. K Related Topics ( T B5-3)

Note: Put a label on all hoses before removal to aid replacement.

Remove bolts H and J securing the air conditioning (HVAC) unit to the cab.

Removal

Remove the bolts A.

Remove the brackets B and C to disconnect the heater unit from the air intake D.

Carefully remove the unit sufficiently to access the electrical harness connector at the rear. Disconnect the electrical connector.

HV Unit The heating and ventilation unit (HV) contains a blower unit and heat exchanger matrix. It is located beneath the right front side of the cab.

To remove the unit it is necessary to evacuate (discharge) the refrigerant from the system. Refer to the Cab Air Conditioning SYSTEM topic. K Related Topics ( T B5-3)

Note: The electrical harness connector is located behind the unit and cannot be disconnected until the unit is pulled away from the cab. 13

Remove the unit from the cab.

K Fig 6. ( T B5-10) 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B5-3)

Drain the cooling system.

Remove cab side cover (if fitted) to get access to the air conditioning (HVAC) unit. Refer to Section B Cab Side Cover. K Related Topics ( T B5-3)

Disconnect the heater hoses at the heater tap E, and heater hose at the heater matrix F.

B5-9

B-07-06 Issue 02

B5-9

Section B5 - Body and Framework Cab HV and HVAC Unit Removal and Replacement (P3)

A D

Fig 6.

B5-10

B-07-06 Issue 02

C130880.eps

B5-10

Section B5 - Body and Framework Cab HV and HVAC Unit Removal and Replacement (P3)

Replacement

W M

X N

Fig 8. Fig 7.

C097170-C3

C119380

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Make sure that the expansion valve M is fitted correctly with the diaphragm N located below the valve. – Use the cab filter protection plate W between the filter gasket X and cab whilst the cab is lowered onto the chassis. The lower part of the plate locates in the slot in the chassis Y. For tool details refer to Section 1 Service Tools. K Related Topics ( T B5-3) – Recharge the air conditioning system and check for leaks. – Refill the cooling system and check for leaks.

B5-11

B-07-06 Issue 02

B5-11

Section B5 - Body and Framework Cab HV and HVAC Unit Heater Air Intake (Snorkel)

Heater Air Intake (Snorkel) Removal

A E D

C130880-C1.eps

Fig 9. 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B5-3)

Remove the chassis side cover (if fitted). Refer to Section B - Chassis Panels. K Related Topics ( T B5-3)

Remove the cab side cover (if fitted). Refer to Section B - Cab Side Cover. K Related Topics ( T B5-3)

Remove the bolts A.

Remove the brackets B and C to disconnect the heater unit from the air intake D.

B5-12

Remove the bolts E securing the intake D to the machine.

Remove the intake from the machine.

B-07-06 Issue 02

B5-12

Section B5 - Body and Framework Cab HV and HVAC Unit Heater Air Intake (Snorkel)

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Torque tighten the intake bolts E. K Table 3. Torque Settings ( T B5-13) â&#x20AC;&#x201C; Use the cab filter protection plate H between the filter gasket F and cab whilst replacing the intake. The lower part of the plate locates in the slot in the chassis G. For tool details refer to Section 1 - Service Tools. K Related Topics ( T B5-3)

Item E

B5-13

Table 3. Torque Settings Nm kgf m 24

2.4

lbf ft 17.7

B-07-06 Issue 02

B5-13

Section B5 - Body and Framework Cab HV and HVAC Unit Heater Air Intake (Snorkel)

Page left intentionally blank

B5-14

B-07-06 Issue 02

B5-14

Section B6 - Body and Framework

Air Conditioning Binary Switch Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

K Related Topics ( T B6-2) K Removal and Replacement ( T B6-4) K Removal ( T B6-4) K Replacement ( T B6-4)

B6-1

B-08-05 Issue 01

B6-1

Section B6 - Body and Framework Air Conditioning Binary Switch Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Cab Air Conditioning SYSTEM

ALL (1)

ALL ALL

(1) You must obey all of the relevant care and safety procedures.

B6-2

B-08-05 Issue 01

B6-2

Section B6 - Body and Framework Air Conditioning Binary Switch Testing

Testing The binary pressure switch is located in the air conditioning system pipework. For location refer to the Cab Air Conditioning SYSTEM topic. K Related Topics ( T B6-2) Before testing the binary pressure switch A it is important to check the refrigerant charge level. If the refrigerant charge level is satisfactory, test the switch as described below: 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B6-2)

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

Fig 1.

B6-3

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.

C067580-C1

B-08-05 Issue 01

B6-3

Section B6 - Body and Framework Air Conditioning Binary Switch Removal and Replacement

Removal and Replacement Removal To remove the binary switch, proceed as follows:

!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

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T B6-2)

Discharge the air conditioning system. Refer to the Cab Air Conditioning SYSTEM topic. K Related Topics ( T B6-2)

Fig 2.

C067580-C1

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

Replacement 1

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

Reconnect the harness connectors B.

Charge the air conditioning system. Refer to the Cab Air Conditioning SYSTEM topic. K Related Topics ( T B6-2)

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

B6-4

B-08-05 Issue 01

B6-4

Section B7 - Body and Framework

Heater Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

K Related Topics ( T B7-2) K Removal and Replacement ( T B7-3) K Removal ( T B7-3) K Replacement ( T B7-3)

B7-1

B-09-04 Issue 01

B7-1

Section B7 - Body and Framework Heater Valve Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Engine

Checking the Coolant Level

Cab Heating and Ventilation SYSTEM

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

B7-2

B-09-04 Issue 01

B7-2

Section B7 - Body and Framework Heater Valve Removal and Replacement

Removal and Replacement The cab heater valve A is part of the heater assembly installed on the external part of the cab.

Removal 1

Park the machine and make it safe. Lift the boom and fit the safety strut. Obey the care and safety procedures. K Related Topics ( T B7-2)

Make sure that the engine cannot be started.

If the engine is hot let it cool for one hour.

Seal the heater hoses B with clamps.

Put aligned marks on the control cable outer C and valve body D.

Remove the clip E.

Note: There will be some leakage of engine coolant when the hoses B are removed. Be prepared. 7

Loosen the clips F and remove the hoses B at the valve.

Disconnect the control cable G at the valve lever H.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Align the marks on the control cable outer C and valve body D and then replace clip E. – Do an engine coolant level check. Refer to Section 3 - Engine. K Related Topics ( T B7-2)

Fig 1.

C045530

When the replacement procedure is complete do this work also: – Start the engine and operate the cab heater at the maximum temperature. Operate the engine for 5 minutes. – Stop the engine and see if there are coolant leaks.

B7-3

B-09-04 Issue 01

B7-3

Section B7 - Body and Framework Heater Valve Removal and Replacement

Page left intentionally blank

B7-4

B-09-04 Issue 01

B7-4

Section B8 - Body and Framework Fuel Tank Introduction

Fuel Tank Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T B8-2) K Specifications ( T B8-3) K Removal and Replacement ( T B8-4) K Side Mounted (P1) ( T B8-4)(1) K Side Mounted (P2) ( T B8-6)(1) K Rear Mounted ( T B8-9) K Fuel Level Sender - Side Mounted Tank (P1) ( T B8-10)(1) K Fuel Level Sender - Side Mounted Tank (P2) ( T B8-11)(1) K Fuel Level Sender - Rear Mounted Tank ( T B8-12) (1) Specification variants. Make sure you refer to the correct specification. Table 1. Procedure Variants Machine models Procedure

K Side Mounted (P1) ( T B8-4)

531-70, 531-T70, 535-95, 535-T95, 536-60, 536-T60, 541-70, 541-T70, 533-105, 536-70, 536-T70, 550-80, 540-170, 550-170, 540140, 550-140, 535-125 HiViz, 535-140 HiViz, 540200

506-36, 507-42, 509-42, 510-56, 512-56, 514-56

z z

K Side Mounted (P2) ( T B8-6)

K Rear Mounted ( T B8-9) K Fuel Level Sender - Side Mounted Tank (P1) ( T B8-10)

z z

K Fuel Level Sender - Side Mounted Tank (P2) ( T B8-11)

K Fuel Level Sender - Rear Mounted Tank ( T B8-12)

B8-1

526-56

B-10-07 Issue 01

B8-1

Section B8 - Body and Framework Fuel Tank Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Routine Maintenance

Fluids, Lubricants and Capacities

Routine Maintenance

Access Panels

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

B8-2

B-10-07 Issue 01

B8-2

Section B8 - Body and Framework Fuel Tank Specifications

Specifications Refer to Section 3 - Fluids, Lubricants and Capacities for the fuel tank capacities for each machine variant. K Related Topics ( T B8-2)

B8-3

B-10-07 Issue 01

B8-3

Section B8 - Body and Framework Fuel Tank Removal and Replacement

Removal and Replacement Side Mounted (P1)

Disconnect the electrical connections D from the fuel sender.

For other machines refer to the correct procedure. K Table 1. Procedure Variants ( T B8-1)

Remove the fuel tank from machine.

Removal

Replacement

Park the machine and make it safe. Obey the General Safety procedures, see Section 2 - General Procedures. K Related Topics ( T B8-2)

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

!MWARNING

– Make sure hoses C are fitted to the correct tank connectors.

– If the tank sender unit has been removed, it should be installed with the float arm pointing to the front of the machine.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

K Fig 1. ( T B8-5)

– Fill the tank with clean fuel, refer to Section 3 Fluids, Lubricants and Capacities. K Related Topics ( T B8-2) – Make sure all connections are tight and check for leaks. – Bleed the fuel system. Refer to Section 3 - Fuel System. K Related Topics ( T B8-2)

Remove the steps A and battery cover B.

Remove the fuel tank belly guard J (if fitted) by removing the four securing bolts and washers K and removing the guard.

Disconnect and remove the battery.

Remove the drain plug X and drain fuel tank contents into a suitable clean container.

Slacken the clip E that attaches the filler pipe to the tank.

Support the tank, remove nuts F and bolts G to remove the holding straps H.

Carefully lower the fuel tank from the machine making sure not to put strain on the fuel hoses C.

Put a label on the fuel feed and return hoses before disconnecting to aid identification when replacing.

Disconnect the fuel feed and return hoses C.

B8-4

– Use a new seal when installing the drain plug X.

B-10-07 Issue 01

B8-4

Section B8 - Body and Framework Fuel Tank Removal and Replacement

J K Fig 1. Fuel Tank - Side Mounted

B8-5

B-10-07 Issue 01

C098100-C1.eps

B8-5

Section B8 - Body and Framework Fuel Tank Removal and Replacement

Side Mounted (P2)

For other machines refer to the correct procedure. K Table 1. Procedure Variants ( T B8-1)

Removal Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B8-2)

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

C119390

Fig 3.

GEN-4-1_1

Place a container which is able to hold the correct capacity below the fuel tank. K Specifications ( T B8-3)

Drain the fuel tank by removing drain plug N.

Undo the screws A and C and remove the fuel tank upper mounting bracket B.

Label the fuel feed and return hoses before disconnecting to ensure correct replacement.

Disconnect the fuel hoses D.

Disconnect the fuel sender electrical connector E.

A G

B C

J Fig 4.

X Fig 2.

B8-6

T015440-1-C1

B-10-07 Issue 01

C119400

If a fuel tank guard H is fitted remove the two securing bolts J. The guard is removed with the tank.

B8-6

Section B8 - Body and Framework Fuel Tank Removal and Replacement 8

Working under the tank M support the tank mounting tray P and remove bolts K and L.

Lift the tank slightly to clear the chassis rail and pull the tank out from under the cab in the direction shown at X.

Remove the tank guard H (if fitted) by removing the bolts F and G.

K L

K K

Q J

P Fig 5.

B8-7

B-10-07 Issue 01

C119410

B8-7

Section B8 - Body and Framework Fuel Tank Removal and Replacement Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Use the bracket Q as a guide when sliding the tank under the cab. The tank may need lifting slightly to locate the front lip on the chassis rail. – Make sure hoses are fitted the correct way round. – If the tank sender unit has been removed, it should be refitted with the float arm orientated towards the front of the machine. – Use a new seal when refitting the drain plug. – Refill with clean fuel, refer to Section 3 - Fluids, Lubricants and Capacities. K Related Topics ( T B8-2) – Make sure all connections are tight and check for leaks. – Bleed the fuel system. Refer to Section 3 - Fuel System. K Related Topics ( T B8-2)

Item

Table 3. Torque Settings Nm kgf m

lbf ft

A(1)

2.24

16.2

8.46

61.2

2.24

16.2

8.46

61.2

4.8

34.6

2.24

16.2

8.46

61.2

(1)

(1) To avoid damage to the threads in the tank make sure that this torque figure is not exceeded.

B8-8

B-10-07 Issue 01

B8-8

Section B8 - Body and Framework Fuel Tank Removal and Replacement

Rear Mounted For other machines refer to the correct procedure. K Table 1. Procedure Variants ( T B8-1)

Removal Park the machine and make it safe. Vent the hydraulic pressure. Obey the General Safety procedures, see Section 2 - General Procedures. K Related Topics ( T B8-2) 1

Remove the rear cover. See Section 3 - Access Panels. K Related Topics ( T B8-2)

Remove the drain plug and drain fuel tank contents into a suitable clean container.

Put a label on the fuel feed and return hoses before disconnecting to help identification when replacing.

Disconnect the fuel feed and return hoses G.

Disconnect the electrical connector from the fuel sender unit F.

Disconnect the hydraulic hoses E.

Remove the bolts A and C to remove the holding straps B.

Lift the fuel tank D from the machine.

Replacement

Fig 6. Fuel Tank

C075080

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Make sure hoses E and G are fitted to the correct tank connectors. – Use a new seal when installing the drain plug. – Fill the tank with clean fuel, refer to Section 3 Fluids, Lubricants and Capacities. K Related Topics ( T B8-2) – Make sure all connections are tight and check for leaks. – Bleed the fuel system. Refer to Section 3 - Fuel System. K Related Topics ( T B8-2)

B8-9

B-10-07 Issue 01

B8-9

Section B8 - Body and Framework Fuel Tank Removal and Replacement

Fuel Level Sender - Side Mounted Tank (P1)

Replacement Replacement is the opposite of the removal procedure.

For other machines refer to the correct procedure. K Table 1. Procedure Variants ( T B8-1)

During the replacement procedure do this work also: – Replace the ‘O’ ring F.

Removal 1

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures. K Related Topics ( T B8-2) Carefully lower the fuel tank from the machine making sure not to put strain on the fuel hoses. K Side Mounted (P1) ( T B8-4).

– Before replacing the fuel level sender unit the float must be reset. Move the float G to the top of its travel and then let it to fall down to the lowest point of travel. – Make sure to install the fuel level sender unit with the pipe connections A and C pointing to the front of the machine as shown at X. – Torque tighten the bolts E. K Table 4. Torque Settings ( T B8-10) – Bleed the fuel system. Refer to Section 3 - Fuel System. K Related Topics ( T B8-2)

Disconnect the fuel sender electrical connector B.

Put a label on the fuel feed and return hoses before disconnecting to help identification when replacing.

Disconnect the fuel feed and return hoses from the sender unit connectors A and C.

Remove bolts E and carefully lift the fuel level sender unit D out of the tank.

Item E

(1)

Table 4. Torque Settings Nm kgf m 5

lbf ft

0.5

3.6

(1) To avoid damage to the threads in the tank make sure that this torque figure is not exceeded.

D C B

E G

Fig 7.

B8-10

B-10-07 Issue 01

C098110

B8-10

Section B8 - Body and Framework Fuel Tank Removal and Replacement

Fuel Level Sender - Side Mounted Tank (P2)

For other machines refer to the correct procedure. K Table 1. Procedure Variants ( T B8-1)

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B8-2)

Undo the screws A and C and remove the fuel tank upper mounting bracket B.

Disconnect the fuel feed and return hoses D. Label each hose before disconnecting to ensure correct replacement.

Disconnect the fuel sender electrical connector E.

Unscrew the sender unit F from the fuel tank G.

F E G Fig 9.

Replacement

Item

Table 5. Torque Settings Nm kgf m

lbf ft

2.24

16.2

8.46

61.2

(1)

Replacement is the opposite of the removal procedure.

C067930-C3

During the replacement procedure do this work also: â&#x20AC;&#x201C; Inspect the gasket to make sure it is clean and in good condition. If in doubt, renew the gasket.

(1) To avoid damage to the threads in the tank make sure that this torque figure is not exceeded.

â&#x20AC;&#x201C; Bleed the fuel system. Refer to Section 3 - Fuel System. K Related Topics ( T B8-2)

A B C

Fig 8.

B8-11

T015440-1-C2

B-10-07 Issue 01

B8-11

Section B8 - Body and Framework Fuel Tank Removal and Replacement

Fuel Level Sender - Rear Mounted Tank

For other machines refer to the correct procedure. K Table 1. Procedure Variants ( T B8-1)

Replacement

Removal

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Carry out General Safety procedures, see Section 2 - General Procedures. K Related Topics ( T B8-2)

Remove the rear cover. See Section 3 - Access Panels. K Related Topics ( T B8-2)

Unscrew the sender unit F from the fuel tank G.

Put a label on the fuel feed and return hoses before disconnecting to help identification when replacing.

Disconnect the fuel feed and return hoses D.

Disconnect the fuel sender electrical connector E.

– Before replacing the fuel level sender unit the float must be reset. Move the float to the top of its travel and then let it to fall down to the lowest point of travel. – Make sure to install the fuel level sender unit with the pipe connections D pointing to the front of the machine as shown. – Examine the gasket to make sure it is clean and in good condition. If not install a new gasket. – Bleed the fuel system. Refer to Section 3 - Fuel System. K Related Topics ( T B8-2)

Fig 10. 526-56 Machines

B8-12

B-10-07 Issue 01

C075050

B8-12

Section B9 - Body and Framework

Engine Cover Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T B9-2) K Removal and Replacement ( T B9-3) K Removal ( T B9-3) K Replacement ( T B9-3)

B9-1

B-11-15 Issue 01

B9-1

Section B9 - Body and Framework Engine Cover Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

B9-2

B-11-15 Issue 01

B9-2

Section B9 - Body and Framework Engine Cover Removal and Replacement

Removal and Replacement Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B9-2)

Open the engine cover 1 fully. Support the cover using suitable overhead lifting equipment.

!MWARNING Beware of the hot exhaust system even with the engine stopped. ENG-4-3

Remove gas strut mount securing nut 4 and remove the strut from the support bracket 3.

Remove the hinge bolts 2.

Using the lifting equipment manoeuvre the engine cover 1 clear of the machine.

Support the pod base 5.

Remove the bolts and washers 6 and lower the pod 5 complete with guards to the ground.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Torque tighten bolts 2. â&#x20AC;&#x201C; Torque tighten strut mount securing nut 4.

Item

Table 2. Torque Settings Nm kgf m

lbf ft

1.83

13.2

1.83

13.2

B9-3

B-11-15 Issue 01

B9-3

Section B9 - Body and Framework Engine Cover Removal and Replacement

Fig 1.

B9-4

B-11-15 Issue 01

C122130

B9-4

Section B10 - Body and Framework

Mudguards Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

K Related Topics ( T B10-2) K Removal and Replacement ( T B10-3) K Top Guard Assembly ( T B10-3) K Complete Mud Guard Assembly ( T B10-4)

B10-1

B-11-12 Issue 01

B10-1

Section B10 - Body and Framework Mudguards Related Topics

Topic Titles

Applications

ALL (Care and Safety)

Wheels and Tyres

Sub Titles ALL (1)

ALL ALL

(1) You must obey all of the relevant care and safety procedures.

B10-2

B-11-12 Issue 01

B10-2

Section B10 - Body and Framework Mudguards Removal and Replacement

Removal and Replacement Top Guard Assembly Removal 1

Remove the bolts A, nuts D and washers releasing the lower saddle clamps C.

Lift off the mudguard cover B.

C C098120

Fig 1.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Torque tighten the nuts D. K Table 3. Torque Settings ( T B10-4)

Item D

B10-3

Table 2. Torque Settings Nm kgf m 28

2.8

lbf ft 20.6

B-11-12 Issue 01

B10-3

Section B10 - Body and Framework Mudguards Removal and Replacement

Complete Mud Guard Assembly

C A

B D

B F E

C098120-C2.eps

Fig 2.

Removal

Replacement

Replacement is the opposite of the removal procedure.

Remove the roadwheel if greater access required see Section F - Wheel Removal and Replacement. K Related Topics ( T B10-2)

Remove the top guard assembly K Top Guard Assembly ( T B10-3)

Remove the mounting arm bolts D, nuts A and washers B.

Remove the arm assembly C.

Remove the support bracket nuts E.

Remove the bracket F from the trunnion studs.

B10-4

During the replacement procedure do this work also: â&#x20AC;&#x201C; Torque tighten the nuts E. K Table 3. Torque Settings ( T B10-4)

Item E

(1)

E(2)

Table 3. Torque Settings Nm kgf m

lbf ft

139 - 154

14.1 - 15.7

102.5 - 113.5

9.9

(1) 550-80 machines (2) Other machines

B-11-12 Issue 01

B10-4

Section B11 - Body and Framework Stabilisers Introduction

Stabilisers Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T B11-2) K Leg Removal and Replacement (P1) ( T B11-3)(1) K Leg Removal and Replacement (P2) ( T B11-5)(1) K Leg Removal and Replacement (P3) ( T B11-7)(1) K Frame Removal and Replacement ( T B11-9)(1) K Checking Pressure Switch Operation ( T B11-12) (1) Specification variants. Make sure you refer to the correct specification. Table 1. Specification Variants - Stabilisers Machine Model Application

Specifications(1)

533-105, 540-170, 540-140, 550-140, 550-170, 535-125 540-200 HiViz, 535-140 HiViz, 540-200 K Leg Removal and Replacement (P1) ( T B11-3)

K Leg Removal and Replacement (P2) ( T B11-5) K Leg Removal and Replacement (P3) ( T B11-7) K Frame Removal and Replacement ( T B11-9)

510-56, 512-56, 514-56

Machines up to May 2012 Machines from May 2012

z z

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

B11-1

B-12-06 Issue 01

B11-1

Section B11 - Body and Framework Stabilisers Related Topics

Topic Titles

Sub Titles

Applications

ALL

Torque Settings

Zinc Plated and Dacromet Fasteners

ALL (Care and Safety)(1)

ALL

Greasing

Hydraulic System

Checking the Hydraulic Fluid Level

(1) You must obey all of the relevant care and safety procedures.

B11-2

B-12-06 Issue 01

B11-2

Section B11 - Body and Framework Stabilisers Leg Removal and Replacement (P1)

Leg Removal and Replacement (P1) Removal

To remove pressure switch remove the switch B and washer C from the ram.

Note: The illustration and procedure describes removal of one stabiliser leg The procedure for the second leg is identical. 1

Lower the boom and carriage to the ground.

Lower the stabilisers as far as the ground. Do not allow them to support the machine.

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T B11-2)

H D

E F G

INT-3-1-11_2

Fig 2.

Fig 1.

Remove the ram pivot pin securing nut and bolt H.

Use the slide hammer kit to remove the ram pivot pin D, refer to Service Tools - Section 1. K Related Topics ( T B11-2)

C080310

!MWARNING

Support the ram F and the stabiliser leg G.

Put a label on each hydraulic hose to aid identification when replacing.

Disconnect and plug stabiliser ram hydraulic hoses.

Disconnect the pressure switch harness connector A.

B11-3

C119440-C2

This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

B-12-06 Issue 01

Remove the leg pivot pin securing nut and bolt.

B11-3

Section B11 - Body and Framework Stabilisers Leg Removal and Replacement (P1) 12

Use the slide hammer kit to remove the leg pivot pin E, refer to Service Tools - Section 1. K Related Topics ( T B11-2)

Withdraw the complete stabiliser leg G and ram F from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure so this work also: â&#x20AC;&#x201C; Grease the ram and leg pivot pins. K Related Topics ( T B11-2) â&#x20AC;&#x201C; Fit a new washer C. â&#x20AC;&#x201C; Check the hydraulic Topics ( T B11-2)

B11-4

fluid

level.

K Related

B-12-06 Issue 01

B11-4

Section B11 - Body and Framework Stabilisers Leg Removal and Replacement (P2)

Leg Removal and Replacement (P2) Removal

To remove pressure switch remove the switch B and washer C from the ram.

Note: The illustration and procedure describes removal of one stabiliser leg The procedure for the second leg is identical. 1

Lower the boom and carriage to the ground.

Lower the stabilisers as far as the ground. Do not allow them to support the machine.

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T B11-2)

H J

D E

INT-3-1-11_2

F G

Fig 3.

C080310

Fig 4.

C119440-C1

Support the ram F and the stabiliser leg G.

Remove the screws J which secure the ram pivot pin retaining plates H.

Put a label on each hydraulic hose to aid identification when replacing.

Use the slide hammer kit to remove the ram pivot pin D, refer to Service Tools - Section 1. K Related Topics ( T B11-2)

Disconnect and plug stabiliser ram hydraulic hoses.

Disconnect the pressure switch harness connector A.

B11-5

B-12-06 Issue 01

B11-5

Section B11 - Body and Framework Stabilisers Leg Removal and Replacement (P2)

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Use the slide hammer kit to remove the leg pivot pin E, refer to Service Tools - Section 1. K Related Topics ( T B11-2)

Withdraw the complete stabiliser leg G and ram F from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure so this work also: – Grease the ram and leg pivot pins. K Related Topics ( T B11-2) – Fit a new washer C. – Check the hydraulic Topics ( T B11-2)

B11-6

fluid

level.

K Related

B-12-06 Issue 01

B11-6

Section B11 - Body and Framework Stabilisers Leg Removal and Replacement (P3)

Leg Removal and Replacement (P3) Removal

K G

M L N

P E

C130570.eps

Fig 5. Note: The illustration and procedure describes removal of one stabiliser leg The procedure for the second leg is identical.

Note: The stabiliser feet are not identical. If removing the feet make sure to put a mark on them to help identify which side of the machine they belong to. 1

B11-7

B-12-06 Issue 01

Lower the boom and carriage to the ground.

B11-7

Section B11 - Body and Framework Stabilisers Leg Removal and Replacement (P3) 2

Lower the stabilisers as far as the ground. Do not allow them to support the machine.

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T B11-2)

Support the stabiliser leg P.Put a label on each hydraulic hose to help identification when reconnecting.

Disconnect and plug stabiliser ram hydraulic hoses A.

Remove the pressure switch cover securing screws B.

Lift the pressure switch cover D away from the ram to get access to the pressure switch harness connector C.

Disconnect the pressure switch harness connector C.

To remove the stabiliser harness: a

Remove the leg pivot pin securing nut and bolt M.

Use the slide hammer kit to remove the leg pivot pin N, refer to Service Tools - Section 1. K Related Topics ( T B11-2)

Withdraw the complete stabiliser leg and ram from the stabiliser frame L.

fluid

level.

K Related

Unscrew the securing nuts E.

b Slide the harness through the slot Gin the bracket H. 10

Remove the ram pivot pin securing nut and bolt J.

Use the slide hammer kit to remove the ram pivot pin K, refer to Service Tools - Section 1. K Related Topics ( T B11-2)

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

B11-8

B-12-06 Issue 01

B11-8

Section B11 - Body and Framework Stabilisers Frame Removal and Replacement

Frame Removal and Replacement The procedures that follow describe the removal and replacement of the stabiliser frame A assembled with stabiliser legs B, feet D and rams C.

The procedures do not include removal and replacement of the nose fabrication E. It is unlikely that the nose fabrication will require removal from the chassis. Use the correct lifting equipment. The stabiliser assembly weighs approximately 700 Kg (1543 lb).

A B

D Fig 6.

B11-9

B-12-06 Issue 01

D C075190-C1

B11-9

Section B11 - Body and Framework Stabilisers Frame Removal and Replacement

Removal K Fig 7. ( T B11-10) and K Fig 8. ( T B11-11)

Put supports under the chassis on both sides of the machine.

Attach the correct lifting equipment to the stabiliser frame A.

Undo the bolts B. Move plate H to get access to the electrical connector J. Uncouple the connector.

Label the hydraulic hoses and disconnect the hoses from the inside of bulkhead connectors C.

Pull the hoses and electrical harness back through the aperture D.

Remove the frame to axle fasteners E. Keep the washers K.

Use the lifting equipment to pull the assembly forward and disengage the pivot F from the nose fabrication H.

Remove the spacer assemblies G.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Check the condition of the pivot bush X. If necessary replace the bush with a new one. – Check the condition of the pivot pin F. If necessary replace the pin with a new one. – Fit the spacer assemblies G correctly as shown at X. – Washers K are hardened. You must use the correct washers. – Torque tighten the 1 inch UNF fasteners E to the correct torque. – Grease the stabiliser frame pivot. Fig 7.

C075190-C4

– Check the hydraulic fluid level.

Lower the stabilisers but keep them clear of the ground.

Park the machine and make it safe. Fit the boom maintenance strut. Obey the care and safety procedures. K Related Topics ( T B11-2)

B11-10

– Check the operation of the stabilisers.

B-12-06 Issue 01

B11-10

Section B11 - Body and Framework Stabilisers Frame Removal and Replacement

Fig 8.

B11-11

B-12-06 Issue 01

C075190

B11-11

Section B11 - Body and Framework Stabilisers Checking Pressure Switch Operation

Checking Pressure Switch Operation The pressure switches (if fitted) are pre-set and must not be adjusted. To check for correct operation, raise and lower each stabiliser in turn. Ensure that the applicable indicator light illuminates when the stabiliser is making firm ground contact and extinguishes when the stabiliser is raised clear of the ground.

Fig 9.

B11-12

C079330-C1

B-12-06 Issue 01

B11-12

Section B12 - Body and Framework

RAS SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T B12-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T B12-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T B12-2) K Operation Overview ( T B12-3) K Hydraulic Operation and Schematics ( T B12-6) K Operation - Mode 1 - Locked ( T B12-6) K Operation - Mode 3 - Unlocked ( T B12-6) K Operation - Mode 2 - Cushioned ( T B12-6) K Schematic ( T B12-6) K Electrical Operation and Schematics ( T B12-8) K Control Devices ( T B12-8) K Actuated Devices ( T B12-12) K Electrical Connectors ( T B12-15) K Fault Finding ( T B12-17) K Diagnostic `Blink' Codes ( T B12-17) K Test Procedures ( T B12-20) K Bleed Procedure ( T B12-22)

B12-1

B-13-02 Issue 01

B12-1

Section B12 - Body and Framework RAS SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Routine Maintenance

ALL

Hydraulic System

Checking the Oil Level

Interlock SYSTEM

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Hydraulic System

ALL

Parallel Control Valve

ALL

RAS Rams

ALL

Speed Sensors

ALL

ALL (1)

ALL

CANbus SYSTEM

Electrical Operation and Schematics

Servicemaster Tool Set

RAS Diagnostics Tool - User Guide

Fault Code SYSTEM

Fault Code List - RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes

(1) You must obey all of the relevant care and safety procedures. Table 2. Service Tools The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number

Description

332/D1039

Bleeding cap

2 x bleed hoses and quick release couplings

B12-2

B-13-02 Issue 01

B12-2

Section B12 - Body and Framework RAS SYSTEM Operation Overview

Operation Overview Some machines are fitted with the JCB Rear Axle Stabilisation (RAS) system. The system is fully automatic and controls the oscillation of the machine's rear axle. Two hydraulic actuators lock or unlock axle oscillation as required. In addition to the lock and unlock modes the system also features a cushioned mode for controlled oscillation of the rear axle. Cushioned mode allows the rear axle to adjust slowly to changes in terrain as the machine moves. It also allows the rear axle to adjust if the lateral angle of the machine is changed when the sway and stabiliser functions operate. There are several modes of RAS operation:

– Mode 1 Locked - The RAS rams prevent rear axle oscillation on its chassis pivot. – Mode 2 Cushioned - The rear axle is free to oscillate at a preset rates on its chassis pivot. – Mode 3 Unlocked - The rear axle is free to oscillate on its chassis pivot. Central to the system is the RAS ECU. The ECU controls the system. There are no operator controls. The system is designed to change the mode of rear axle oscillation in relation to the machine status. For example when the machine is stationary the rear axle is locked. Sway and stabiliser functions are also monitored by the RAS system. When sway or stabilisers operate the ECU sets the correct cushioned rate. Switch and sensor inputs enable to ECU to calculate the machine status. Outputs control the RAS hydraulic rams via proportional solenoid control valves.

Machine Status

RAS Mode

Engine stopped, ignition OFF

1 - Locked

Stationary, engine running

1 - Locked

Engine running, ground speed more than zero but less than 4 kph(1)

2 - Cushioned (rate changes in relation to ground speed)

Engine running, ground speed more than 4 kph(1)

3 - Unlocked

Sway ram operation

2 - Cushioned (preset rate)

Stabiliser operation

2 - Cushioned (preset rate)

(2)

(1) Example value, actual value can be different. (2) 510/512 machines only. The instrument cluster includes RAS indicator LEDs to show the status of the RAS system. There is no indicator LED illuminated when the system is unlocked (mode 3). RAS Mode 1 - Locked (green LED comes ON)

B12-3

2 - Cushioned (green LED FLASHES)

LED Indicator RAS fault K Fault Finding ( T B12-17)

B-13-02 Issue 01

B12-3

Section B12 - Body and Framework RAS SYSTEM Operation Overview Key K Fig 1. ( T B12-5) Item

Description

RAS ECU

RAS Rams

RAS Ram control valve

Proportional solenoid control valve

Dual Output Transmission speed sensor(1)

Sway spool switch

Left stabiliser spool switch

8(2)

Right stabiliser spool switch

9(1)

Stabiliser pressure transducers (left and right)

(2)

(1) Machines built before April 2010 have an external auxiliary speed sensor and a single output transmission speed sensor. Later machines with a PS750 Mk IV gearbox have a gearbox mounted dual output speed sensor. (2) 510/512 machines only.

B12-4

B-13-02 Issue 01

B12-4

Section B12 - Body and Framework RAS SYSTEM Operation Overview

8 6 1

4 Fig 1.

B12-5

B-13-02 Issue 01

C094890-C1

B12-5

Section B12 - Body and Framework RAS SYSTEM Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Operation - Mode 1 - Locked When the RAS ECU operates the system in mode 1 the rear axle is not free to oscillate. The solenoids of proportional control valves 2B and 3B are de-energised and oil is trapped in the rams 4 and 5 locking them in position. In hot environments the trapped oil expands. System relief valves 2C and 3C open at a preset pressure to prevent damage. Oil is vented to the hydraulic tank 7 until the pressure reduces.

Operation - Mode 2 - Cushioned

The solenoids of proportional control valves 2B and 3B are fully energised and oil flows between the rams 4 and 5 via valves 2B and 3B as the axle oscillates. The control valves 2B and 3B only allow oil flow in one direction, as it flows from the head side of rams 4 and 5. Oil flows to the head side of the rams via check valves 2A and 3A. Oil from the pilot pressure supply valve 1 maintains the system pressure.

Schematic Key K Fig 2. ( T B12-7)

When the RAS ECU operates the system in mode 2 the rear axle 6 will oscillate at a controlled rate. The solenoids of proportional control valves 2B and 3B are energised by means of a PWM (pulse width modulated) signal. This causes the control valves 2B and 3B to not fully open, restricting the oil flow between rams 4 and 5. The speed of the rams is controlled together with the oscillation rate of the axle. RAS ECU changes the PWM signal in relation to the machine status. For example if the ground speed of the machine changes the RAS ECU changes the PWM signal. This causes the control valves to open or close gradually. When sway or stabilisers operate the ECU opens the control valves to a pre-set value. This allows the rear axle to adjust as the lateral angle of the machine changes. The control valves 2B and 3B only control the oil flow in one direction, as it flows from the head side of rams 4 and 5. Oil flows to the head side of the rams via check valves 2A and 3A.

Item

Description

Pilot pressure supply valve

Left RAS control valve block:

Check valve

Proportional solenoid control valve

System relief valve

Right RAS control valve block:

Check valve

Proportional control valve

System relief valve

Left RAS hydraulic cylinder

Right RAS hydraulic cylinder

Rear axle

Hydraulic tank

Oil from the pilot pressure supply valve 1 maintains the system pressure.

Operation - Mode 3 - Unlocked When the RAS ECU operates the system in mode 3 the rear axle 6 is free to oscillate.

B12-6

B-13-02 Issue 01

B12-6

Section B12 - Body and Framework RAS SYSTEM Hydraulic Operation and Schematics PILOT VALVE

B A

ACC TP2

30 BAR

0.5 BAR

P1 P3

TP1

P2 PILOT FILTER

RASLH MANIFOLDBLOCK

RASLH CYLINDER

QR2

QR1

RASRH MANIFOLDBLOCK

RASRH CYLINDER

5 6 Fig 2. Hydraulic Schematic

B12-7

B-13-02 Issue 01

C069610

B12-7

Section B12 - Body and Framework RAS SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page. K Electrical Connectors ( T B12-15) The RAS ECU controls the RAS proportional control valve solenoids by means of a PWM signal. The ECU determines the correct PWM signal by comparing information from control devices with data stored in the ECU memory. The RAS ECU also controls the stabiliser, sway and boom interlocks. Refer to the Interlocks topic. K Related Topics ( T B12-2)

Control Devices K Electrical Schematic 507, 509 - Control Devices ( T B12-10) K Electrical Schematic 510, 512 - Control Devices ( T B12-11) The RAS ECU 4018 uses input from control devices to determine the following machine parameters: Ground speed

The system checks for a valid speed sensor input: Machines from April 2010:The ECU uses the signals from transmission speed sensor 5018 to determine the machine ground speed. One signal is transmitted to the RAS ECU. The other signal is transmitted on the CANbus to the LMS display ECU.The ECU compares the two speed sensor signals Machines before April 2010: (not shown) The ECU uses the input from the transmission mounted single output speed sensor. The ECU compares the transmission speed sensor signal to a signal from the transmission auxiliary speed sensor. The signal from the auxiliary sensor is transmitted on the CANbus by the LMS display ECU. If the speed sensor input is not valid the system the ECU compares the speed sensor signals to a speed value calculated from the current gear ratio and engine speed. The engine speed value is transmitted on the CANbus.

Transmission set to neutral

The ECU uses inputs from the drive select column switch 1013 and the park brake switch 1057 to determine when the transmission is set to neutral.

Sway service operation The ECU uses an input from sway valve spool switch 1058 to detect sway ram operation. Stabiliser status

The ECU uses an input from stabiliser valve spool switches 1063 and 1064 to detect stabiliser ram operation. Inputs from pressure transducers 1062A and 1062B detect if the stabiliser is retracted or deployed.

CAN bus

CAN messages are received from the LMS display ECU 4020. This enables the RAS ECU to validate inputs and monitor other aspects of the machine status. These include: Transmission speed sensor value Engine speed Transmission switch position (FNR) Transmission gear select switch position (1,2,3,4) Engine running

B12-8

B-13-02 Issue 01

B12-8

Section B12 - Body and Framework RAS SYSTEM Electrical Operation and Schematics Key

Device

RAS ECU Connector Pins

1013

Column Switch L/H

9A, 10A, 21A

16B, 17B, 27B, 28B

1057

Park brake Switch

20A, 32A

24B

1058

Sway spool switch

1A, 6A

13B

1062A(1)

Right stabiliser pressure transducer

22A

30B

1062B

Left stabiliser pressure transducer

1063

(1)

Left stabiliser spool switch

13A

22B, 25B

1064

(1)

Right stabiliser spool switch

24A

26B, 3B

4013

LMS Display ECU Connector J2 (Black)

4018A

RAS ECU connector 1 (black)

4018B

RAS ECU connector 2 (white)

4020

LMS ECU connector 2

5018

Dual Output Transmission speed sensor

14A

33B

8000

Harness interconnections

9001

Secondary fuse box A

11A

9003

Secondary fuse box C

9004

Secondary fuse box D

2A, 3A, 4A, 5A, 6A

-003

Earth point, cab harness

15A, 16A, 17A

(1)

29B, 18B

(2)

22B

(1) 510/512 machines only. (2) Machines built before April 2010 have 2 single output speed sensors.

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B-13-02 Issue 01

B12-9

Section B12 - Body and Framework RAS SYSTEM Electrical Operation and Schematics

8020

FUSE

15A 16A 17A

11A

9001

8020 -003 10

22B 2A 3A

8019

FUSE

9004

8020

9003

1 12

16B

1013

ECU

8004 8016 38

9001

1058

CAN H

8034 33A CAN L

8034 8016 8004 8021 B

14A 33B

8035

8004

5018

1 3

17B

34A 18

FUSE

8022

28B

4 13

13B

27B

1057

24B

10A 21A

N 6 R 10

20A

F 4

-003 5

32A

FUSE

8020

22A

4A 5A

4018A/B

19 13

ECU

8035 8004 B FUSE

9001

4020

16 SP9

+VE

-VE

Fig 3. Electrical Schematic 507, 509 - Control Devices

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B-13-02 Issue 01

C066880-C1

B12-10

Section B12 - Body and Framework RAS SYSTEM Electrical Operation and Schematics

FUSE

11A

9001

2A 3A 4A 5A

FUSE

9004

6A 10A 6

FUSE

9003

F 4

21A

N 6 R 10

15A 16A 17A

22B

1 12

27B

4 13

16B

20A

28B

32A

17B

8004 8016 38

9001

8034 C

8034 8016 8004 8021

5018 8035 8004 B FUSE

14A

ECU

8035

26B

SC14 27

13A 22B CAN H 34A

25B

29B

18B 13

ECU

13B

22A

30B

4018A/B

1064

8004

1063

8004

1058

66 67

8026

4020

2 19

ECU

CAN L 33A SP9

8027

8004

24A 3B

33B

9001

1057

24B

1013 FUSE

-003

8004

8023

2 3 1

4 4

4013 52

8025

1062A FUSE

9001

3 44

4 4

1062B

+VE

Fig 4. Electrical Schematic 510, 512 - Control Devices

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B-13-02 Issue 01

-VE C076420-C1

B12-11

Section B12 - Body and Framework RAS SYSTEM Electrical Operation and Schematics

Actuated Devices K Electrical Schematic 507, 509 - Actuated Devices ( T B12-13) K Electrical Schematic 510, 512 - Actuated Devices ( T B12-14) The RAS ECU 4018 actuates the following devices: RAS proportional solenoid control valves

The ECU controls the RAS left and right control valve solenoids 3051 and 3052 with a PWM signal.

RAS diagnostic LED

The ECU sends a signal to the LMS display ECU 4013 in the right hand instrument cluster to activate the RAS diagnostic LED if there is a fault with the system.

RAS mode LEDs

The ECU sends a signal to the LMS display ECU 4013 in the right hand instrument cluster to activate the RAS mode LEDs via the CANbus.

The LMS display ECU 4013 actuates the following devices: Left and right RAS isolation relays

If there is a critical RAS system fault the ECU energises the left and right isolation relays 2051 and 2052. The solenoids 3051 and 3052 are de-energised and the RAS system is set to mode 1 (locked).

Key

Device

RAS ECU Connector Pin

2051

RAS isolation relay - Left cylinder

35A

2052

RAS isolation relay - Right cylinder

12A

3051

RAS Left cylinder control valve solenoid

3052

RAS Right cylinder control valve solenoid

4018A

RAS ECU connector 1 (black)

4018B

RAS ECU connector 2 (white)

4013

LMS Display ECU connector J2 (Black)

8000

Harness interconnections

9001

Secondary fuse box A

11A

9003

Secondary fuse box C

2A, 3A, 4A, 5A, 6A

-003

Earth point, cab harness

15A, 16A, 17A

B12-12

B-13-02 Issue 01

23B 12B

22B

B12-12

Section B12 - Body and Framework RAS SYSTEM Electrical Operation and Schematics

FUSE

8020

15A 16A 17A

11A

9001

8020 -003 10

22B 2A

FUSE

9004

8020

22A

8019

-003

4A 5A

27A

8019

ECU

4013

ECU

5 35A

8019 10

23B

8022

8019 9

2051 2

8022 13

3051

12A

8021

34A

CAN L

33A

12B

8022

2052 2

+VE

4018A/B

8021 3

4 CAN H

10 7 9

8022 12

3052 -VE

Fig 5. Electrical Schematic 507, 509 - Actuated Devices

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B-13-02 Issue 01

C069480

B12-13

Section B12 - Body and Framework RAS SYSTEM Electrical Operation and Schematics

FUSE

15A 16A 17A

11A

-003

22B

9001 2A FUSE

4A 5A

9004

27A

ECU

4013

ECU

35A

2051 23B

8004

8004 62

3051

12A

+VE

CAN H

34A

CAN L

33A

10 7 9

2052 12B

8004

4018A/B

8004 55

3052 -VE

Fig 6. Electrical Schematic 510, 512 - Actuated Devices

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B-13-02 Issue 01

C076410

B12-14

Section B12 - Body and Framework RAS SYSTEM Electrical Connectors

Electrical Connectors The table shows the harness connectors that connect to the electrical devices. The connectors are shown looking at the mating face when disconnected. Remember that the drawings show the harness connectors NOT the device connectors. Use the table and the relevant electrical schematic to identify the pins in the harness connectors. Continuity checks on the harness wires can be carried out using a multi-meter. Do not touch ECU connector pins. Do not use a multi-meter on ECU connector pins. Device Description

Location

1013

Column Switch L/H

A cable and connector connects to the panel harness at the steering column below the steering wheel.

1057

Parkbrake Switch

Located on the parkbrake lever.

1058

Sway spool switch

Parallel valve block

1062A

Right stabiliser pressure switch

Located on the stabiliser cylinder body.

1062B

Left stabiliser pressure switch

Located on the stabiliser cylinder body.

1063

Left stabiliser spool switch Parallel valve block

1064

Right stabiliser spool switch

Parallel valve block

2000

Relays

Refer to Section C - Fuses and Relays. K Related Topics ( T B12-2)

B12-15

Harness Connector

B-13-02 Issue 01

B12-15

Section B12 - Body and Framework RAS SYSTEM Electrical Connectors 3051

RAS Left cylinder control valve solenoid

3052

RAS Right cylinder control Located on the right RAS hydraulic ram. valve solenoid

4013

LMS display connector J2

4018A

4018B

RAS Interface 1 (black)

RAS Interface 2 (white)

Located on the left RAS hydraulic ram.

The ECU connectors are located behind the LMS display unit. Be sure to identify the correct connector. Connector J2 is coloured Black.

The ECU is fitted below the operators seat. The panel harness connector connects directly to the ECU. 12 23 35

1 13

12 23 35

1 13

The ECU is fitted below the operators seat. The panel harness connector connects directly to the ECU.

5018

Dual Output Speed Sensor Located on the gearbox casing

8000

Harness interconnections

Refer to Section C - Electrical Harness SYSTEM. K Related Topics ( T B12-2)

9000

Fuses

Refer to Section C - Fuses and Relays. K Related Topics ( T B12-2)

B12-16

B-13-02 Issue 01

B12-16

Section B12 - Body and Framework RAS SYSTEM Fault Finding

Fault Finding Diagnostic `Blink' Codes In addition to the blink codes explained here, the Loadall Monitoring System (LMS) logs fault codes relating to the RAS system. Refer to Section M. K Related Topics ( T B12-2)

Note: On some machines the RAS ECU also controls the machine boom and stabiliser interlocks. Some blink codes are related to these systems, not the RAS system.

The RAS ECU has the facility to detect faults with the RAS system. When a fault is detected the RAS diagnostic LED A blinks a series of long flashes followed by a series of short flashes. For example if the light illuminates 3 times for 1 second periods followed by 4 times for 0.5 second periods the code is 3-4. Fig 7. Blink Code

C075470-C2

Cause/Fault

Action

1-1

FNR column switch - open circuit

1-2

FNR column switch - short circuit

Check related wires and connectors between the RAS ECU input and the switch

1-4

Park brake switch fault - open circuit

1-3

Park brake switch fault - short circuit

1-5

Sway spool switch fault - open circuit

1-6

Sway spool switch fault - short circuit

1-7

Left stabiliser spool switch fault - open circuit

1-8

Left stabiliser spool switch fault - short circuit

2-1

Right stabiliser spool switch fault - open circuit

2-2

Right stabiliser spool switch fault - short circuit

Long flash - short flash

B12-17

B-13-02 Issue 01

Check related wires and connectors between the RAS ECU and the normally closed and normally open switch contacts Check related wires and connectors between the RAS ECU and the normally closed and normally open switch contacts Check related wires and connectors between the RAS ECU and the normally closed and normally open switch contacts Check related wires and connectors between the RAS ECU and the normally closed and normally open switch contacts

B12-17

Section B12 - Body and Framework RAS SYSTEM Fault Finding Blink Code

Cause/Fault

Action

2-5

Transmission speed sensor fault

Check related wires and connectors between the RAS ECU output and the sensor. Check sensor installation at the gearbox. Replace the sensor with a new one.

2-8

Foot brake relay coil fault - shorted to battery voltage Replace the relay with a new one. Check related wires and connectors between the RAS ECU and the relay coil. Foot brake relay coil fault - open circuit

2-7 2-6 3-3

3-2

Foot brake relay coil fault - shorted to ground

RAS Valve fault - ECU output short to battery voltage Check related wires and connectors - RAS can continue to operate when ground speed is between the RAS ECU and the RAS less than the pre-set value proportional valve coils. Replace the valve coil with a new one RAS Valve fault - ECU output short to ground. RAS can continue to operate when ground speed is less than the pre-set value

3-1

RAS Valve fault - ECU output open circuit. RAS can continue to operate when ground speed is less than the pre-set value

3-6

RAS Valve fault - ECU output short to battery voltage. Check related wires and connectors RAS switches to mode 1 - locked when ground speed between the RAS ECU and the RAS is more than the pre-set value proportional valve coils. Replace the valve coil with a new one RAS Valve fault - ECU output short to ground. RAS

3-5

switches to mode 1 - locked when ground speed is more than the pre-set value 3-4

RAS Valve fault - ECU output open circuit. RAS switches to mode 1 - locked when ground speed is more than the pre-set value

4-1

Sway spool switch fault - switch power output from ECU shorted to battery voltage

3-8

Sway spool switch fault - switch power output from ECU shorted to ground

3-7

Sway spool switch fault - switch power output from ECU open circuit

4-4

Left stabiliser spool switch fault - switch power output Check related wires and connectors from ECU shorted to battery voltage between the RAS ECU and the normally Left stabiliser spool switch fault - switch power output closed and normally open switch contacts from ECU shorted to ground

4-3 4-2

Left stabiliser spool switch fault - switch power output from ECU open circuit

4-7

Right stabiliser spool switch fault - switch power output from ECU shorted to battery voltage

4-6

Right stabiliser spool switch fault - switch power output from ECU shorted to ground

4-5

Right stabiliser spool switch fault - switch power output from ECU is open circuit

B12-18

B-13-02 Issue 01

Check related wires and connectors between the RAS ECU output and the switch common contact

B12-18

Section B12 - Body and Framework RAS SYSTEM Fault Finding Blink Code

Cause/Fault

Action

5-5

RAS diagnostic LED circuit fault - output from ECU shorted to battery voltage

5-4

RAS diagnostic LED circuit fault - output from ECU shorted to ground

Check related wires and connectors between the RAS ECU and the LMS ECU.

5-3

RAS diagnostic LED circuit fault - output from ECU is open circuit

5-6

Foot brake switch fault - open circuit

5-7

Foot brake switch fault - short circuit

6-2

Foot brake switch fault - switch power output from ECU shorted to battery voltage

6-1

Foot brake switch fault - switch power output from ECU shorted to ground

5-8

Foot brake switch fault - switch power output from ECU is open circuit

8-8

RAS isolation relay fault - LMS display ECU output shorted to ground

8-7

Check related wires and connectors between the RAS ECU and the normally closed and normally open switch contacts Check related wires and connectors between the RAS ECU output and the switch common contact

Check related wires and connectors between the LMS ECU and the RAS RAS isolation relay fault - LMS display ECU output is isolation relays open circuit

9-7

RAS isolation relay fault - RAS ECU ground output shorted to battery voltage

9-6

RAS isolation relay fault - RAS ECU ground output shorted to ground

9-5

RAS isolation relay fault - RAS ECU ground output is open circuit

9-8

Gear position column switch fault - open circuit

10-1

Gear position column switch fault - short circuit

10-3

Park brake relay coil fault - shorted to battery voltage Replace the relay with a new one. Check related wires and connectors between Park brake relay coil fault - open circuit the RAS ECU and the relay coil.

10-2 10-5

Park brake switch fault - switch power output from ECU shorted to battery voltage

10-4

Park brake switch fault - switch power output from ECU open circuit

10-6

CAN fault

Check related wires and connectors between the RAS ECU and the RAS isolation relays

Check related wires and connectors between the RAS ECU input and the switch

Check related wires and connectors between the RAS ECU output and the switch common contact Check related CAN bus wires and connectors

10-7

CAN fault - RAS switches to mode 1 - locked

10-8

RAS ECU memory fault - ECU operating with default Use JCB Servicemaster to load the data correct data onto the ECU

B12-19

B-13-02 Issue 01

B12-19

Section B12 - Body and Framework RAS SYSTEM Test Procedures

Test Procedures The RAS ECU continually tests for valid inputs from the system electrical devices. If there is a fault the ECU alerts the operator with a blink code. K Diagnostic `Blink' Codes ( T B12-17). The RAS ECU is not able to detect hydraulic system leakage. If there are external or internal leaks the system will not function correctly. Do the following test procedure to test the RAS system for hydraulic leakage.

Leak Test Procedure (With Use of Servicemaster Diagnostics) The test procedure that follows requires use of JCB Servicemaster. You must have the correct software installed on a lap top computer. If the JCB Servicemaster tool is not available follow the alternative procedure. K Leak Test Procedure (Without Use of Servicemaster Diagnostics) ( T B12-21) 1

Make sure that there is no air in the system. K Bleed Procedure ( T B12-22)

Connect Servicemaster to the machine and start the RAS Diagnostics service tool software. Refer to Section M.

Park the machine and make it safe. Lower the boom to the travel position. Obey the care and safety procedures. K Related Topics ( T B12-2)

Put a 150 mm (6 in) thick block in front of the right side front wheel.

Use your Servicemaster lap top computer. Click on the `TEST HOLD' button. This de-activates the software.

Use the sway control to slowly sway the chassis to the left. RAS will enter a cushion mode and the right side front wheel will return to the ground.

With all four wheels on the ground, use the sway control to level the machine (0°).

Park the machine and make it safe. Obey the care and safety procedures.

Put the 150mm (6 in) thick block in front of the left side front wheel. Repeat steps 5 to 13.

If the left or right side wheel does not remain clear of the ground (step 8), there is hydraulic leakage. Find and rectify the cause of hydraulic leakage. If the left side wheel failed the test check the right side RAS ram components and circuit. If the right side wheel failed the test check the left side RAS ram components and circuit. – Inspect the RAS system hose and pipework for external leaks. Rectify defective hose and pipework. – Remove the RAS ram. Dismantle the ram and reseal. Refer to Section E. – Renew the RAS ram check valve. Refer to Section E.

Start the engine. Drive the machine slowly onto the block. Set the drive control to N. Set the park brake to ON.

Use the sway control to level the machine (0°).

Use your Servicemaster lap top computer. Go to the diagnostics tool. Click on the `TEST HOLD' button.

Select 2nd gear. Set the drive control to F and drive the machine slowly off the block. If the RAS system is working correctly the right side front wheel will stay clear of the ground.

Stop the machine. Set the drive control to N. Set the park brake to ON.

B12-20

– Renew the RAS ram relief valve. Refer to Section E. – Renew the RAS ram proportional solenoid valve. Refer to Section E. Note: During disconnection of RAS system hydraulic components air can enter the system. After the reconnection of components bleed the system to remove the air. K Bleed Procedure ( T B12-22)

B-13-02 Issue 01

B12-20

Section B12 - Body and Framework RAS SYSTEM Test Procedures

Leak Test Procedure (Without Use of Servicemaster Diagnostics)

If the left or right side wheel does not remain clear of the ground (step 10), there is hydraulic leakage.

Make sure that there is no air in the system. K Bleed Procedure ( T B12-22)

Park the machine and make it safe. Lower the boom to the travel position. Obey the care and safety procedures. K Related Topics ( T B12-2)

Put a 150 mm (6 in) thick block in front of the right side front wheel.

Start the engine. Drive the machine slowly onto the block. Set the drive control to N. Set the park brake to ON.

Find and rectify the cause of hydraulic leakage. If the left side wheel failed the test check the right side RAS ram components and circuit. If the right side wheel failed the test check the left side RAS ram components and circuit – Inspect the RAS system hose and pipework for external leaks. Rectify defective hose and pipework. – Remove the RAS ram. Dismantle the ram and reseal. Refer to Section E. – Renew the RAS ram check valve. Refer to Section E.

Use the sway control to level the machine (0°). Stop the engine and remove the starter key.

Remove the valve covers and disconnect the electrical connectors A at the proportional control valves on the left and right side RAS rams.

Start the engine. Check that the RAS diagnostic LED B is ON. Select 2nd gear. Set the drive control to F and drive the machine slowly off the block. If the RAS system is working correctly the right side front wheel will stay clear of the ground.

Stop the machine. Set the drive control to N. Set the park brake to ON. Stop the engine and remove the starter key.

Connect the electrical connectors A at the proportional control valves on the left and right side RAS rams.

Start the engine. Check that the RAS diagnostic LED B is OFF. Use the sway control to slowly sway the chassis to the left. RAS will enter a cushion mode and the right side front wheel will return to the ground.

With all four wheels on the ground, use the sway control to level the machine (0°).

Park the machine and make it safe. Obey the care and safety procedures.

Put the 150mm (6 in) thick block in front of the left side front wheel. Repeat steps 4 to 12.

Fig 8.

Fig 9.

B12-21

B-13-02 Issue 01

C082820

C075470-C3

B12-21

Section B12 - Body and Framework RAS SYSTEM Bleed Procedure

Bleed Procedure K Fig 10. ( T B12-23)

Do not stop the engine. Disconnect the bleed hose from the left ram bleed point A.

Use the sway control to level machine. Keep the wheels straight and slowly drive off the block F.

Reposition the block F in front of the left front wheel. Drive the machine slowly onto the block and set the park brake to ON. Set the drive selector to N.

– Two hydraulic bleed hoses D with the correct quick release couplings for use with the RAS bleed points A and B.

Use the sway control to sway the machine fully to the right. Shown at R.

– A system of connecting the bleed hoses to the hydraulic tank. Use special tank cap C. K Service Tools ( T B12-2).

Do not stop the engine. Disconnect the bleed hose from the right ram bleed point B.

Slowly drive off the block F and stop the engine. Disconnect the bleed hoses D at the hydraulic tank. Replace the dust covers on the bleed point couplings A and B.

Check the hydraulic Topics ( T B12-2)

During disconnection of RAS system hydraulic components air can enter the system. After the reconnection of components bleed the system to remove the air. Before you start the procedure obtain the following:

It is preferable to use the special tank cap C. If the cap is not available the ends of the bleed hoses can be put through the hydraulic tank filler neck and into the oil. Make sure that the hoses cannot come out of the tank filler neck. Important: Oil will flow from the bleed hoses at a pressure of 30 bar. Make sure that the bleed hoses are correctly retained inside the hydraulic tank filler neck. When possible always use the special tank cap C.

oil

level.

K Related

– A 100 mm (4 in) thick block F. Note: During the procedure that follows all the machine wheels must touch the ground or block F at all times. 1

Park the machine and make it safe. Lower the boom. Obey the care and safety procedures. K Related Topics ( T B12-2)

Fit the bleed hoses D at the RAS ram bleed points A and B and hydraulic tank filler tube.

Start the engine. Use the sway control to sway the machine fully from left to right three times.

Place block F in front of the right front wheel. Drive the machine slowly onto the block and set the park brake to ON. Set the drive selector to N.

Use the sway control to sway the machine fully to the left. Shown at L.

B12-22

B-13-02 Issue 01

B12-22

Section B12 - Body and Framework RAS SYSTEM Bleed Procedure

L B

C D

F Fig 10.

B12-23

B-13-02 Issue 01

C069960

B12-23

Section B12 - Body and Framework RAS SYSTEM Bleed Procedure

Page left intentionally blank

B12-24

B-13-02 Issue 01

B12-24

Section B13 - Body and Framework

Interlock SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T B13-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T B13-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T B13-2) K Operation Overview ( T B13-3) K Introduction ( T B13-3) K Component Location ( T B13-3) K Hydraulic Operation and Schematics ( T B13-5) K Electrical Operation and Schematics ( T B13-7) K Electrical Connectors ( T B13-12) K Fault Finding ( T B13-14) K Diagnostic Blink Codes ( T B13-14) K Hydraulic System Faults ( T B13-14)

B13-1

B-13-03 Issue 01

B13-1

Section B13 - Body and Framework Interlock SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

RAS SYSTEM

ALL

Stabilisers

Checking Pressure Transducer Operation

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Parallel Hydraulic System

Fault Finding

Parallel Control Valve - 5 Section

ALL

Stabiliser Rams

ALL

(1) You must obey all of the relevant care and safety procedures.

B13-2

B-13-03 Issue 01

B13-2

Section B13 - Body and Framework Interlock SYSTEM Operation Overview

Operation Overview Introduction

Component Location

Machines with four stage booms incorporate a system of interlocks. The system prevents the operation of the machine beyond pre-set limits until the boom and stabiliser legs are correctly positioned by the operator.

Item

Table 2. Key to Components K Fig 1. ( T B13-4)

Stabiliser pressure transducers (left and right)

Left stabiliser spool switch

To Deactivate Interlock

Right stabiliser spool switch

Stabiliser deployed indicator lights

Boom angle more than 60°

Stabiliser isolation Lower boom to less than 60°

Boom angle proximity switch - 60° (stabiliser isolation)

Stabilisers retracted

Boom raise angle Deploy stabilisers limited to 60° (indicator lights maximum must come ON)

Boom angle proximity switch - 60°

Boom extend proximity switch

Sway spool switch

Sway / stabiliser isolation valve

Boom lift pilot pressure supply isolation valve

ECU 4018

Stabiliser isolation switch

Machine Status Active Interlock

Boom angle Sway isolation more than 60° and extended more than 6.5 m (21 ft)

Retract boom to less than 6.5m (21 ft) OR lower boom to less than 60°

INTERLOCK LOGIC

C079210-C2

The system logic is controlled by ECU 4018. The ECU receives inputs from several types of switches. The ECU energises hydraulic solenoid valves to isolate the boom raise, sway and stabiliser services when applicable.

B13-3

B-13-03 Issue 01

B13-3

Section B13 - Body and Framework Interlock SYSTEM Operation Overview

12 11

2 1 3 8 9 10

Fig 1.

B13-4

B-13-03 Issue 01

C069790-C1

B13-4

Section B13 - Body and Framework Interlock SYSTEM Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Lift Pilot Pressure Supply Isolation Valve When the lift pilot pressure supply solenoid valve 6 is energised there is pilot pressure at the lift valve spool 9. The lift spool operates when the operator moves the servo control lever. When the lift pilot pressure supply solenoid valve 6 is deenergised, the valve isolates pilot pressure supply to the lift valve spool 9. The lift spool remains in the neutral position when the operator moves the servo control lever. Operation of the solenoid 6 is controlled by ECU 4018.

Item K Fig 2. ( T B13-5) K Fig 3. ( T B13-5) 1

Pilot pressure pump supply

Pilot pressure supply valve

Pilot pressure reducing valve

Pilot pressure enable solenoid

Tank return

Lift pilot pressure supply isolation valve

Servo control lever

Flowshare control valve

Lift Valve spool

Lift ram

Fig 2. Lift pilot pressure supply valve open

Fig 3. Lift pilot pressure supply valve closed

B13-5

B-13-03 Issue 01

C078410

C078410-C1

B13-5

Section B13 - Body and Framework Interlock SYSTEM Hydraulic Operation and Schematics

Sway/Stabiliser Isolation Valve When the sway/stabiliser isolation valve solenoid 3 is energised oil from the main pump flows to the sway and stabiliser valve spools 4, 5 and 6. The sway and stabiliser services can operate. When the sway/stabiliser isolation valve solenoid 3 is deenergised oil from the main pump cannot flow to the sway and stabiliser valve spools 4, 5 and 6. If the operator moves the control levers, lockout valves in the hydraulic circuit prevent the rams moving due to loads from the machine mass. Refer to the machine hydraulic schematic. K Related Topics ( T B13-2) Operation of the sway/stabiliser isolation valve solenoid 3 is controlled by ECU 4018.

Some machine functions require sway operation at the same time as stabiliser isolation. For sway operation oil must also flow to the stabiliser spools 5 and 6 from the main pump. If the operator moves a stabiliser lever from its neutral position inputs from the stabiliser spool switches cause ECU 4018 to de-energise the valve solenoid 3. Sway service is only resumed when the stabiliser levers are returned to the neutral position. Item

K Fig 4. ( T B13-6) K Fig 5. ( T B13-6)

Parallel control valve block

Pump supply to parallel valve block

Sway/stabiliser isolation valve

Sway valve spool

Right stabiliser valve spool

Left stabiliser valve spool

! "

C078420-C1

Fig 4. Sway/stabiliser isolation valve energised

! "

Fig 5. Sway/stabiliser isolation valve not energised

B13-6

B-13-03 Issue 01

C078420

B13-6

Section B13 - Body and Framework Interlock SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page. K Electrical Connectors ( T B13-12) ECU 4018 controls the boom safety interlock system. The ECU receives inputs from control devices. The ECU uses a program stored in its memory to determine outputs. The ECU outputs energise hydraulic solenoid isolation valves when interlocks are applicable. The operator can isolate the stabiliser services by means of a switch in the cab. The input from this switch is connected to ECU 4018. The operator can isolate the stabiliser services by means of a switch in the cab. The input from this switch is connected the ECU 4018.

Control Devices K Electrical Schematic - Control Devices ( T B13-9) The ECU 4018 uses input from control devices to determine the following machine parameters: Boom angle more than or less than 60Â°

Inputs from chassis mounted proximity switches are used to detect if the boom angle is more than or less than 60Â°.

Boom extended more than or less than 6.5 m (21 ft)

Input from a boom mounted proximity switch is used to detect if the boom is extended more than or less than 6.5 m (21 ft).

Sway service operation Input from sway valve spool switch 1058 detects sway ram operation. When the service spool is moved from its neutral position the switch (1058) contacts change state. Stabiliser status

Inputs from pressure transducers 1062A and 1062B detect if the stabiliser is retracted or deployed. The transducers have digital and analog outputs. The ECU compares the outputs to check for valid signals. If the transducer signals are not as expected the ECU sends an error message. The analog signals are used by the LMS display ECU to control the stabiliser deployed LEDs.

Stabiliser service operation

Input from stabiliser valve spool switches 1063 and 1064 detect stabiliser ram operation. When the service spool is moved from its neutral position the switch (1063 or 1064) contacts change state.

Cab stabiliser isolation switch status

Input from switch 1042A is used to detect if the operator has set the stabiliser operation to ON or OFF. When the input is high the ECU allows operation. When the input is low the ECU isolates stabiliser operation.

B13-7

B-13-03 Issue 01

B13-7

Section B13 - Body and Framework Interlock SYSTEM Electrical Operation and Schematics K Electrical Schematic - Control Devices ( T B13-9) Key

Device

1042A Stabiliser isolation switch 1058

Sway spool switch

1062A Right stabiliser pressure transducer 1062B Left stabiliser pressure transducer 1063

Left stabiliser switch

1064

Right stabiliser switch

1065

Boom angle proximity switch - 60Â° (stabiliser isolation)

1066

Boom angle proximity switch - 60Â°

1067

Boom extend proximity switch

4013

LMS display connector J2

4018A ECU connector 1 (black) 4018B ECU connector 2 (white) 8000

Harness interconnections

9000

Fuses

B13-8

B-13-03 Issue 01

B13-8

Section B13 - Body and Framework Interlock SYSTEM Electrical Operation and Schematics

FUSE

9001

22B

6A 21B

1 14

9004

1042A N

8027

1064

15B 27A

14B

3B 26B

8004

1063

7B 19B

13A 31B 22B

8004

1058

2 8

1065

8004

3 16

25B 6B

8004

ECU

-003

4A 5A

9004 FUSE

15A 16A 17A

FUSE

11A

32B

20B 13B

8004 -003 1

1066

8004 8028 4

8028 4

1067

65 29B 18B

ECU

22A

30B

4018A/B 8026

8004

8023

4013

1 4

8025

1062A FUSE

9001

3 1 4 51

1062B

+VE

Fig 6. Electrical Schematic - Control Devices

B13-9

B-13-03 Issue 01

-VE C078350

B13-9

Section B13 - Body and Framework Interlock SYSTEM Electrical Operation and Schematics

Actuated Devices K Electrical Schematic - Actuated Devices ( T B13-11) The ECU 4018 activates the devices as follows: Sway/Stabiliser isolation valve

When the sway/stabiliser isolation solenoid valve 3054 is energised the stabiliser and sway services are active. The ECU energises relay 2054 to energise solenoid valve 3054. Some machine functions require sway operation at the same time as stabiliser isolation. The isolation valve 3054 can only allow or isolate both services at the same time. The ECU allows sway operation only by energising the valve when the sway spool is moved away from neutral. If a stabiliser spool moves away from neutral at the same time the ECU de-energises valve 3054. Sway service is only resumed when the stabiliser levers are returned to the neutral position. K Control Devices ( T B13-7)

Boom raise pilot isolation valve

B13-10

When the boom lift pilot isolation solenoid valve 3055 is energised the boom lift service is active. The ECU energises relay 2053 to energise solenoid valve 3055.

B-13-03 Issue 01

B13-10

Section B13 - Body and Framework Interlock SYSTEM Electrical Operation and Schematics Key

Device

Key

2053

Boom lift isolation relay

4018A ECU connector 1 (black)

2054

Sway / Stabiliser isolation relay

4018B ECU connector 2 (white)

3054

Sway/ Stabiliser isolation valve solenoid

8000

Harness interconnections

3055

Lift pilot pressure supply isolation valve solenoid

9000

Fuses

FUSE

9001 FUSE

9004

Device

11A 2A

3A 4A 5A

8004

ECU

8004 36

3054

8004

8004 5

3055 26

2053 25

4 2 5

7 9

4018A/B

2054

-VE

+VE

Fig 7. Electrical Schematic - Actuated Devices

B13-11

B-13-03 Issue 01

C079270

B13-11

Section B13 - Body and Framework Interlock SYSTEM Electrical Connectors

Location

1042A

Stabiliser isolation switch

Located on the instrument panel. Remove the switch to get access to the connector.

1058

Sway spool switch

Located on the parallel valve block sway valve spool

1062A

Right stabiliser pressure transducer

Located on the stabiliser cylinder body

1062B

Left stabiliser pressure transducer

Located on the stabiliser cylinder body

1063

Left stabiliser switch

Located on the parallel valve block left stabiliser valve spool

1064

Right stabiliser switch

Located on the parallel valve block right stabiliser valve spool

1065

Boom proximity switch 60Â° (stabiliser isolation)

Inside face of the right side chassis near the boom pivot

1066

Boom proximity switch 60Â°

Inside face of the left side chassis near the boom pivot

B13-12

Harness Connector

B-13-03 Issue 01

B13-12

Section B13 - Body and Framework Interlock SYSTEM Electrical Connectors 1067

Boom extend proximity Switch

TBA

2000

Relays

Refer to Section C - Fuses and Relays. K Related Topics ( T B13-2)

3054

Sway/ stabiliser isolation valve solenoid

Located on the Parallel Valve Block

3055

Lift pilot pressure supply isolation valve solenoid

Located on the pilot pressure supply valve.

4013

LMS display connector J2

The ECU connectors are located behind the LMS display unit. Be sure to identify the correct connector. Connector J2 is coloured Black.

4018A

4018B

ECU connector1 (black)

ECU connector 2 (white)

The ECU is fitted below the operators seat. The panel harness connector connects directly to the ECU. 12 23 35

1 13

12 23 35

1 13

The ECU is fitted below the operators seat. The panel harness connector connects directly to the ECU.

8000

Harness interconnections

Refer to Section C - Electrical Harness SSYTEM. K Related Topics ( T B13-2)

9000

Fuses

Refer to Section C - Fuses and Relays. K Related Topics ( T B13-2)

B13-13

B-13-03 Issue 01

B13-13

Section B13 - Body and Framework Interlock SYSTEM Fault Finding

Fault Finding Diagnostic Blink Codes The ECU 4018 controls the boom and stabiliser interlocks. For system faults refer to the RAS System topic in this section. K Related Topics ( T B13-2)

Hydraulic System Faults The hydraulic system fault finding procedures are covered in another topic in this manual. K Related Topics ( T B13-2)

B13-14

B-13-03 Issue 01

B13-14

Section B14 - Body and Framework

Boom Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T B14-2) K Specifications ( T B14-3) K 3-Stage Boom ( T B14-3) K 4-Stage Boom ( T B14-4) K Operation Overview ( T B14-5) K Hydraulic Operation and Schematics ( T B14-12) K Wear Pads and Shims ( T B14-20) K 3 Stage Boom ( T B14-20) K 4 Stage Boom ( T B14-26) K Chain Maintenance ( T B14-33) K Adjustment - 3 Stage boom ( T B14-34) K Adjustment - 4 Stage Boom ( T B14-36) K Chain Component Inspection ( T B14-38) K Wear Limits ( T B14-41) K Extend Chains Removal and Replacement - 3 Stage Boom ( T B14-42) K Retract Chain Removal and Replacement - 3 Stage Boom ( T B14-44) K Extend Chains Removal and Replacement - 4 Stage Boom ( T B14-46) K Retract Chains Removal and Replacement - 4 Stage Boom ( T B14-49) K Angle Indicator Removal and Replacement ( T B14-52) K Pivot Shims ( T B14-53) K Boom Removal and Replacement ( T B14-54) K Boom Hose Removal and Replacement (3 Stage Boom) ( T B14-56) K Boom Hose Removal and Replacement (4 Stage Boom) ( T B14-59)

B14-1

B-15-11 Issue 02

B14-1

Section B14 - Body and Framework Boom Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Service Schedules

Boom Chain Servicing

Greasing

Every 50Hours

Hydraulic System

Checking the Hydraulic Fluid Level

Access Panels

Rear Boom Cover

Applications

ALL

Hydraulic System

ALL

Extension Ram

Removal and Replacement

Lift Rams

Removal and Replacement

Displacement Ram

Removal and Replacement

(1) You must obey all of the relevant care and safety procedures.

B14-2

B-15-11 Issue 02

B14-2

Section B14 - Body and Framework Boom Specifications

Specifications Boom Wear Pad Clearance 3-Stage Boom Table 2. Boom (Front and Rear) Measurement

Location

Vertical clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Vertical clearance - Intermediate boom to Inner boom

3.0mm (0.12in)

Total side clearance - Intermediate boom to Inner boom

3.0mm (0.12in)

Total side clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Fig 1. 3-Stage Boom

Maximum Gap

C066340-C1

Contact your JCB Distributor if the wear pad clearances exceed the maximum stated dimensions.

B14-3

B-15-11 Issue 02

B14-3

Section B14 - Body and Framework Boom Specifications 4-Stage Boom Table 3. Boom (Front and Rear) Measurement

Location

Maximum Gap

Total side clearance - 2nd Intermediate boom to Inner boom

3.0mm (0.12in)

Vertical clearance - 2nd Intermediate boom to Inner boom

3.0mm (0.12in)

Total side clearance - 2nd Intermediate boom to Intermediate boom

3.0mm (0.12in)

Vertical clearance - 2nd Intermediate boom to Intermediate boom

3.0mm (0.12in)

Total side clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Vertical clearance - Outer boom to Intermediate boom

3.0mm (0.12in)

Fig 2. 4-Stage Boom

A372600-1-C1

Contact your JCB Distributor if the wear pad clearances exceed the maximum stated dimensions.

B14-4

B-15-11 Issue 02

B14-4

Section B14 - Body and Framework Boom Operation Overview

Operation Overview The telescopic boom has three sections. A single hydraulic extension ram B operates the intermediate section. The inner section extends and retracts by means of a system of chains.

Twin lift rams C operate the boom raise and lower function. A single displacement ram D is hydraulically connected to the tilt ram A and operates a parallel lift feature. Clearance between the boom sections is maintained by sets of wearpads and shims.

Fig 3.

B14-5

B-15-11 Issue 02

C069030

B14-5

B14-6

On 4 stage booms there is an extra intermediate boom section, also operated by chains.

As the ram moves the intermediate boom section a system of chains extend or retract the inner boom section.

The telescopic boom function is actuated by a single hydraulic extension ram R which extends or retracts the intermediate boom section 2.

Telescopic Operation

Fig 4. Boom Extend (4 Stage Boom)

At the same time the chain roller B attached to boom section 2, causes extension chains C to pull boom section 3 out from boom section 2.

When the controls are moved to extend the boom, hydraulic ram R extends. The piston rod A pushes the boom section 2 out from boom section 1.

Boom Extend (4 Stage Boom)

All the boom sections extend/retract at the same time.

2nd intermediate boom(1) Inner boom

3 4 (1) 4 stage boom only

1st intermediate boom

Table 4. Boom Section Key Outer boom

C088240

At the same time the chain roller D attached to boom section 3, causes extension chain E to pull boom section 4 out from boom section 3.

Section B14 - Body and Framework Boom

Operation Overview

B-15-11 Issue 02

B14-6

When the controls are moved to retract the boom, hydraulic ram R retracts. The piston rod A pulls boom section 2 inside inner boom 1.

Boom Retract (4 Stage Boom)

B14-7 Fig 5. Boom Retract (4 Stage Boom)

At the same time the chain roller H attached to boom section 3, causes retraction chain J to pull boom section 4 inside boom section 3.

At the same time the chain roller F attached to boom section 2, causes retraction chain G to pull boom section 3 inside boom section 2. 2nd intermediate boom(1) Inner boom

3 4 (1) 4 stage boom only

1st intermediate boom

Table 5. Boom Section Key Outer boom

C088250

Section B14 - Body and Framework Boom

Operation Overview

B-15-11 Issue 02

B14-7

B14-8 When the boom extends the extend ram A pulls boom section 2 out from inside the outer boom 1. At the same time the chain system extends the inner boom 3.

When the boom extends and retracts, the hydraulic hoses and pipes connected to the tilt and auxiliary services extend and retract at the same time.

Fig 6.

The hydraulic hoses are clamped to the outer boom and inner boom sections and are pulled out with the boom sections

Extend

Hydraulic Hoses and Pipes (3 Stage Boom)

Intermediate boom Inner boom

2 3

Table 6. Boom Section Key Outer boom

C130620_C3.eps

Guide roller B is fixed to boom section 2. The guide roller controls the hoses as they transfer from inside the outer boom 1 to inside the boom section 3.

Section B14 - Body and Framework Boom

Operation Overview

B-15-11 Issue 02

B14-8

When the boom retracts the extend ram A pulls boom section 2 inside the outer boom 1. At the same time the chain system retracts the inner boom 3.

Retract

B14-9 Fig 7.

Guide roller B is fixed to boom section 2. The guide roller controls the hoses as they transfer from inside boom section 3 to inside the outer boom 1.

The hydraulic hoses are clamped to the outer boom and inner boom sections and are pulled out with the boom sections

Inner boom

Intermediate boom

Table 7. Boom Section Key Outer boom

C130620-C3.eps

Section B14 - Body and Framework Boom

Operation Overview

B-15-11 Issue 02

B14-9

B14-10

When the boom extends the extend ram A pulls boom section 2 out from inside the outer boom 1. At the same time the chain system extends boom section 3 and inner boom 4.

Extend

When the boom extends and retracts, the hydraulic hoses and pipes connected to the tilt and auxiliary services extend and retract at the same time.

Hydraulic Hoses and Pipes (4 Stage Boom)

Fig 8.

4 3

Guide roller B is fixed to boom section 2. The guide roller controls the hoses as they transfer from inside the outer boom 1 to inside the boom section 2.

The hydraulic hoses are pulled out with the boom sections by the inner boom pipe assembly C, which is fixed to the rear of boom section 3. A guide bracket at the front of the pipe assembly moves inside the inner boom as it extends. The guide bracket is fitted with nylon wear pads. Inner boom

2nd intermediate boom

1st intermediate boom

Table 8. Boom Section Key Outer boom

C130620_C1

Section B14 - Body and Framework Boom

Operation Overview

B-15-11 Issue 02

B14-10

B14-11

The hydraulic hoses are pulled in with the boom sections by the inner boom pipe assembly C, which is

When the boom retracts the extend ram A pulls boom section 2 inside the outer boom 1. At the same time the chain system retracts boom section 3 and inner boom 4.

Retract

Fig 9.

Guide roller B is fixed to boom section 2. The guide roller controls the hoses as they transfer from inside boom section 2 to inside the outer boom 1.

fixed to the rear of boom section 3. A guide bracket at the front of the pipe assembly moves inside the inner boom as it retracts. The guide bracket is fitted with nylon wear pads.

C 2 B

2nd intermediate boom

3 Inner boom

1st intermediate boom

2 4

Table 9. Boom Section Key Outer boom

C130620

Section B14 - Body and Framework Boom

Operation Overview

B-15-11 Issue 02

B14-11

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Boom Extend and Retract Operation The extension circuit has a regenerative and hose burst protection valve A. The valve is part of the extension ram.

Fig 10.

C068100-C1

Note: On machines fitted with a 4 stage boom, the regenerative valve/hose burst protection valve A is located in an alternative position on the extension ram.

B14-12

B-15-11 Issue 02

B14-12

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics Regeneration Operation The illustration shows boom extend service selected at spool 2F, oil is supplied to the extension cylinder 12 via the combined load hold check valve and regenerative valve assembly 18. The valve assembly houses the retract load hold check valve 18A, extend load hold check valve 18C and the regenerative check valve 18B. Oil is fed to the load hold check valve 18A, the pressurised oil opens the check valve for the oil to act on the head side of the extension ram 12, to extend the cylinder. With the forks of the machine lightly loaded, the pressure required to extend the boom remains below the relief valve 18E setting. Oil displaced from rod side of extension cylinder 12 flows to the valve assembly 18. The combined pilot pressure from V1 and C1 is felt under piston of check valve 18D which opens. Because passage back to tank via extension spool 2F is blocked by the closed relief valve 18E, the pressurised oil opens the check valve 18B to supplement pump flow in extending the extension cylinder 12.

B14-13

B-15-11 Issue 02

B14-13

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics

Fig 11. Boom Extend Regenerative

B14-14

B-15-11 Issue 02

A271470-C1

B14-14

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics Boom Extend High Pressure Operation

the extension cylinder 12 is diverted back to tank via control spool 2F.

Should the pressure required to extend the boom increase check valve 18B is held on its seat by the oil that flows to the head side of the extension cylinder 12. The inlet pressure via internal pilot galleries from inlet cavity V1 opens the relief valve 18E, the displaced oil from

The relief valve 18D senses a pressure drop via pilot galleries from return line port C1 and closes, thus the passage of oil to the head side of the extension cylinder 12 is blocked.

Fig 12. Boom Extend High Pressure

B14-15

B-15-11 Issue 02

A271480-C1

B14-15

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics Boom Retract Operation When boom retract is selected as at 2F, system pressure enters combined load hold check valve and regenerative valve assembly 18 at V2, the pressure opens check valve 18C and oil flows to the rod side of extension cylinder 12.

Pressure is felt under piston of check valve 18G via pilot line from port V2 and check valve 18F, check valve 18G opens and displaced oil from the extension cylinder 12 is diverted back to tank via control spool 2F.

Fig 13. Boom Retract

B14-16

B-15-11 Issue 02

A271490-C1

B14-16

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics Boom Extend - Hose Burst Operation In the event of a hose burst or other leakage in the feed to the head side of the cylinder 12, back pressure will hold

check valve 18A, 18B firmly on their seat, thus trapping a column of oil in the cylinder head side circuit which will prevent the load from retracting.

Fig 14. Hose Burst Operation

B14-17

B-15-11 Issue 02

A271500-C1

B14-17

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics

Boom Raise and Lower Operation Boom Raise Cycle

A437010-C3

Fig 15. Boom Raise Cycle When lift spool 2D is selected, oil feeds lift ram load hold check-valves 8A. Oil flows through free flow direction of load hold check valves 8A and the lift rams 8 raise the boom.

Auxiliary relief valve (ARV) 2J opens to protect the tilt ram from over pressurisation. The anti-cavitation feature of valve 2H ensures that, in these circumstances, the tilt and displacement rams will not cavitate.

Oil is forced out of the rod side of displacement ram 9 as the boom rises. The oil cannot flow past the tilt spool 2F, as the spool is not selected. Instead, it flows to the rod side of tilt ram 10. The pilot pressure in the load hold check valve 10 A increases and the valve opens. This allows oil to flow from the head side of the tilt ram to the head side of the displacement ram. This has the effect of allowing the tilt ram to extend in proportion to boom lift, keeping the forks parallel with the ground. Displacement/lift link valve 20 is fitted between lift spool 2D and tilt spool 2F. The function of this valve is to allow a restricted flow of oil into the tilt circuit to increase the lift force available by utilising the displacement ram.

B14-18

B-15-11 Issue 02

Fig 16.

C069040

B14-18

Section B14 - Body and Framework Boom Hydraulic Operation and Schematics Boom Lower Cycle

A437010-C4

Fig 17. Boom Lower Cycle When raise/lower spool 2D is selected, oil feeds the rod side of lift rams 8. Oil displaced from the head side of the lift rams raises pilot pressure in the load hold check valves 8A and allows oil out of the lift rams back to tank, lowering the boom. As the boom lowers, oil is forced from the head side of the displacement ram 9. The oil cannot flow past tilt spool 2F, as the spool is not selected. Instead, it flows through free flow direction of load hold check valve 10A to the head side of the tilt ram 10. This has the effect of allowing the tilt ram to retract in proportion to boom lower, keeping the forks parallel with the ground.

Fig 18.

C069040

Displaced oil from the displacement ram closes the check valve in displacement/lift link valve 20. Auxiliary relief valve (ARV) 2H opens to protect the tilt ram from over pressurisation. The anti-cavitation feature of valve 2J ensures that, in these circumstances, the tilt and displacement rams will not cavitate.

B14-19

B-15-11 Issue 02

B14-19

Section B14 - Body and Framework Boom Wear Pads and Shims

Wear Pads and Shims 3 Stage Boom

the correct number of washers for the thickness of shims. K Adding Washers ( T B14-23)

Shims 21-B are fitted under the pads for adjustment of boom clearance. Partly worn pads may be shimmed to restore correct boom clearance.

Note: Do not fit spring washers.

Shim intermediate boom 19-A to outer boom 19-B then repeat the procedure for inner 19-C to intermediate boom 19-A. K Lower Wear Pads - Shimming ( T B14-21) K Top Wear Pads - Shimming ( T B14-22) K Side Wear Pads - Shimming ( T B14-22) Fig 20.

Fig 21. Typical Installation

Fig 19. 3 Stage Boom

259401-1

S343451-1

259403-1

Renew the wear pads when, or before they are worn down to depth of chamfer as shown at 20-A. Make sure wear pads are fitted the correct way round to prevent fouling. The wear pad bolts 21-A are not all the same. Make sure you use the correct bolts for each wear pad. The number of washers 21-C under the bolt 21-A changes depending on the shim thickness 21-B. Make sure you fit

B14-20

B-15-11 Issue 02

B14-20

Section B14 - Body and Framework Boom Wear Pads and Shims Lower Wear Pads - Shimming

Rear Lower Wear Pads

Front Lower Wear Pads

Rest forks on the ground then remove the boom rear cover.

Raise boom slightly so that forks are just off the ground.

Measure distances between boom lower faces which must be in the limit given. K Boom Wear Pad Clearance ( T B14-3)

Measure distances between boom lower faces which must be in the limit given. K Boom Wear Pad Clearance ( T B14-3) If this dimension is less than the limit shims must be fitted under the lower wear pads to restore the dimension.

If this dimension is less than the limit shims must be fitted under the lower wear pads to restore the dimension. Raise boom slightly so that forks are just off the ground and place wedges under the inner boom.

Rest the forks on the ground so that there is no weight on the lower wear pads.

Remove wear pad bolts A and add shims B as required.

Measure total thickness of shims under each pad.

Add or remove plain washers C under heads of wear pad bolts A to ensure a thread engagement of 8-12mm. K Adding Washers ( T B14-23).

Add or remove the correct number of plain washers C under heads of wear pad bolts A to ensure a thread engagement of 8-12mm. K Adding Washers ( T B14-23)

Note: Do not fit spring washers.

Remove wedges, refit shims and torque tighten bolts A.

Refit shims and torque tighten bolts A. Item Item A

Table 10. Torque Settings Nm lbf ft 98

kgf m

Table 11. Torque Settings Nm lbf ft 98

B14-21

Fig 23. Typical Installation Fig 22. Typical Installation

kgf m

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B-15-11 Issue 02

B14-21

Section B14 - Body and Framework Boom Wear Pads and Shims Top Wear Pads - Shimming

Side Wear Pads - Shimming

Note: The following procedure applies to both front and rear top wear pads.

Note: The following procedure applies to both front and rear side wear pads.

Raise the boom until the inner boom is resting on the lower wear pads.

Measure distances between the boom side faces which must be in the limit given. K Boom Wear Pad Clearance ( T B14-3)

Measure distances between the boom upper faces which must be in the limit given. K Boom Wear Pad Clearance ( T B14-3) If this dimension is less than the limit shims must be fitted under the top wear pads to restore the dimension.

If this dimension is less than the limit shims must be fitted under the side wear pads to restore the dimension. Slacken side wear pad bolts A and shim as required. Divide number of shims equally each side to ensure that inner boom runs centrally within the outer boom.

Fit or remove shims B to obtain correct vertical clearance. Measure total thickness of shims under each pad. Measure total thickness of shims under each pad. Add or remove the correct number of plain washers C under heads of wear pad bolts A to ensure a thread engagement of 8-12mm. K Adding Washers ( T B14-23).

Add or remove the correct number of plain washers C under heads of wear pad bolts A to ensure a thread engagement of 8-12mm. K Adding Washers ( T B14-23). Note: Do not fit spring washers.

Note: Do not fit spring washers. Refit shims and torque tighten bolts A. Refit shims and torque tighten bolts A.

Item A

Table 12. Torque Settings Nm lbf ft 98

Fig 24. Typical Installation

B14-22

Item kgf m

Table 13. Torque Settings Nm lbf ft 98

kgf m 10

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B-15-11 Issue 02

Fig 25. Typical Installation

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B14-22

Section B14 - Body and Framework Boom Wear Pads and Shims Adding Washers K Fig 27. ( T B14-24). Table 14. Intermediate to Outer Boom Detail Shim Thickness Number of K Fig 27. ( T 26-B Washers 26-C B14-24) L

K, H, N

Detail

0 to 1.7

1.7 to 4.2

4.2 to 6.7

6.7 to 9.3

0 to 1.5

1.5 to 4.0

4.0 to 6.5

6.5 to 9.0

0 to 2.0

2.0 to 4.5

4.5 to 7.0

7.0 to 9.5

Fig 26. Typical Installation

S343451-1

Table 15. Inner to Intermediate Boom Shim Thickness Number of Washers 26-B 26-C

K, M, R

G, J, P

B14-23

0 to 1.5

1.5 to 4.0

4.0 to 6.5

6.5 to 9.0

0 to 2.0

2.0 to 4.5

4.5 to 7.0

7.0 to 9.5

B-15-11 Issue 02

B14-23

Section B14 - Body and Framework Boom Wear Pads and Shims

Fig 27. 3 Stage Boom Shimming

B14-24

B-15-11 Issue 02

C066340

B14-24

Section B14 - Body and Framework Boom Wear Pads and Shims Checking the Boom Carriage Alignment

Make sure that the difference in shim thickness of shims D and E does not exceed 3.2 mm.

When the boom is assembled do a check of the carriage alignment. To make sure that the measurement is accurate:

Make sure that the maximum wear pad clearance B does not exceed the stated maximum. K Boom Wear Pad Clearance ( T B14-3)

– Make sure that the tyre pressures are correct. – Make sure that the machine is parked on flat level ground. – Check the inclinometer A to make sure that the chassis is level.

Fig 28. Measure the left and right side carriage height from the ground to the top of the carriage as shown and note the dimensions X and Y.

F D

E Fig 30.

C094520-C3.eps

Fig 29.

C127590.eps

If there is a difference between dimension X and dimension Y the front lower wear pads C and F can be shimmed. Refer to the wear pad shimming procedure to add/remove shims D or E as required to align the carriage. K Front Lower Wear Pads ( T B14-21)

B14-25

B-15-11 Issue 02

B14-25

Section B14 - Body and Framework Boom Wear Pads and Shims

4 Stage Boom Shims 32-B are fitted under the pads for adjustment of boom clearance. Partly worn pads may be shimmed to restore correct boom clearance. On 4 stage machines shim 1st intermediate boom to the outer boom then repeat the procedure for the 2nd intermediate boom to the 1st intermediate boom and the inner to 2nd intermediate boom. K Lower Wear Pads - Shimming ( T B14-27) Fig 32. Typical Installation

K Top Wear Pads - Shimming ( T B14-28)

S343451-1

K Side Wear Pads - Shimming ( T B14-28) Renew the wear pads when, or before they are worn down to depth of chamfer as shown at 31-A. Make sure wear pads are fitted the correct way round to prevent fouling. The wear pad bolts 32-A are not all the same. Make sure you use the correct bolts for each wear pad. K Wear Pad Fixings ( T B14-30) The number of washers 32-C under the bolt 32-A changes depending on the shim thickness 32-B. Make sure you fit the correct number of washers for the thickness of shims. K Adding Washers ( T B14-29) Note: Do not fit spring washers.

Fig 31.

B14-26

259401-1

B-15-11 Issue 02

B14-26

Section B14 - Body and Framework Boom Wear Pads and Shims Lower Wear Pads - Shimming

Rear Lower Wear Pads

Front Lower Wear Pads

Rest forks on the ground then remove the boom rear cover.

Raise boom slightly so that forks are just off the ground.

Measure distances between boom lower faces which must be in the limit given. K 4-Stage Boom ( T B14-4)

Measure distances between boom lower faces which must be in the limit given. K 4-Stage Boom ( T B14-4) If this dimension is less than the limit shims must be fitted under the lower wear pads to restore the dimension.

Rest the forks on the ground so that there is no weight on the lower wear pads.

Remove wear pad bolts A and add shims B as required.

Measure total thickness of shims under each pad.

Add or remove plain washers C under heads of wear pad bolts A to ensure a thread engagement of 8-12mm. K Adding Washers ( T B14-29).

Add or remove the correct number of plain washers C under heads of wear pad bolts A to ensure a thread engagement of 8-12mm. K Adding Washers ( T B14-29)

Note: Do not fit spring washers. Remove wedges, refit shims and torque tighten bolts A. K Wear Pad Fixings ( T B14-30)

Note: Do not fit spring washers. Refit shims and torque tighten bolts A. K Wear Pad Fixings ( T B14-30)

Fig 34. Typical Installation Fig 33. Typical Installation

B14-27

S343451-1

B-15-11 Issue 02

B14-27

Section B14 - Body and Framework Boom Wear Pads and Shims Top Wear Pads - Shimming

Side Wear Pads - Shimming

Note: The following procedure applies to both front and rear top wear pads.

Note: The following procedure applies to both front and rear side wear pads.

Raise the boom until the inner boom is resting on the lower wear pads.

Measure distances between the boom side faces which must be in the limit given. K 4-Stage Boom ( T B14-4)

Measure distances between the boom upper faces which must be in the limit given. K 4-Stage Boom ( T B14-4)

If this dimension is less than the limit shims must be fitted under the side wear pads to restore the dimension.

If this dimension is less than the limit shims must be fitted under the top wear pads to restore the dimension.

Slacken side wear pad bolts A and shim as required. Divide number of shims equally each side to ensure that inner boom runs centrally within the outer boom.

Add or remove the correct number of plain washers C under heads of wear pad bolts A to ensure a thread engagement of 8-12mm. K Adding Washers ( T B14-29). Note: Do not fit spring washers.

Note: Do not fit spring washers. Refit shims and torque tighten bolts A. K Wear Pad Fixings ( T B14-30)

Fig 35. Typical Installation

B14-28

Refit shims and torque tighten bolts A. K Wear Pad Fixings ( T B14-30)

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B-15-11 Issue 02

Fig 36. Typical Installation

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B14-28

Section B14 - Body and Framework Boom Wear Pads and Shims Adding Washers K Fig 38. ( T B14-31). Note: FR denotes towards boom front and RR denotes towards boom rear. Table 16. Intermediate to Outer Boom Shim Thickness Number of Detail 26-B Washers 26-C K Fig 38. ( T B14-31) G

B14-29

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

0 to 3 mm

3 to 6 mm

6 to 9 mm

9 to 12 mm

0 to 3 mm

3 to 6 mm

6 to 9 mm

9 to 12 mm

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

Table 17. Inner to Intermediate Boom Detail Shim Thickness Number of Washers K Fig 38. 26-B 26-C ( T B14-3 1) J

B-15-11 Issue 02

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

0 to 2.5 mm

2.5 to 5.5 mm

5.5 to 8.5 mm

8.5 to 11.5 mm

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

0 to 1 mm

1 to 4 mm

4 to 7 mm

7 to 9 mm

0 to 2 mm

2 to 5 mm

5 to 8 mm

5 to 11 mm

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

0 to 1 mm

1 to 3 mm

3 to 5 mm

5 to 7 mm

B14-29

Section B14 - Body and Framework Boom Wear Pads and Shims

Fig 37. Typical Installation

S343451-1

Wear Pad Fixings Table 18. Bolt/Screw Specifications Torque Settings

Item K Fig 38. ( T B14-31)

lbf ft

Bolt M12 x 45 Tuff Lok

734

Bolt M12 x 60

734

Bolt M12 x 40 Tuff Lok

734

Set Screw M10 x 45

415

Set Screw M10 x 35 Tuff Lok

415

Set Screw M10 x 25 Tuff Lok

415

Bolt M12 x 50 Tuff Lok

734

B14-30

B-15-11 Issue 02

B14-30

Section B14 - Body and Framework Boom

Fig 38. 4 Stage Boom Shimming

C076940

Wear Pads and Shims

B14-31

B-15-11 Issue 02

B14-31

Section B14 - Body and Framework Boom Wear Pads and Shims Checking the Boom Carriage Alignment

Make sure that the difference in shim thickness of shims D and E does not exceed 3.2 mm.

When the boom is assembled do a check of the carriage alignment. To make sure that the measurement is accurate:

Make sure that the maximum wear pad clearance B does not exceed the stated maximum. K Boom Wear Pad Clearance ( T B14-3)

– Make sure that the tyre pressures are correct. – Make sure that the machine is parked on flat level ground. – Check the inclinometer A to make sure that the chassis is level.

Fig 39. Measure the left and right side carriage height from the ground to the top of the carriage as shown and note the dimensions X and Y.

F D

E Fig 41.

C094520-C3.eps

Fig 40.

C127590.eps

B14-32

B-15-11 Issue 02

B14-32

Section B14 - Body and Framework Boom Chain Maintenance

Chain Maintenance Introduction Inspect the chains at the correct intervals. Do the chain maintenance procedures at the correct intervals. Refer to the correct Service Schedule. K Related Topics ( T B14-2) Important: Do the chain inspection and maintenance procedures at more frequent intervals on machines operating in extreme environmental conditions or machines subjected to shock loads. Important: When a chain is removed for inspection, it must be re-fitted in exactly the same working position. Important: Renew defective chains and associated components IMMEDIATELY. DO NOT USE the machine until the chains and components are replaced with new ones. Follow the correct chain maintenance procedures: K Adjustment - 3 Stage boom ( T B14-34) K Adjustment - 4 Stage Boom ( T B14-36) K Chain Component Inspection ( T B14-38) K Wear Limits ( T B14-41)

B14-33

B-15-11 Issue 02

B14-33

Section B14 - Body and Framework Boom Chain Maintenance

Adjustment - 3 Stage boom If extend or retract chains have been replaced, you must set the chain adjusters to the correct initial dimensions before adjusting the chains. K Extend Chains Removal and Replacement - 3 Stage Boom ( T B14-42) K Retract Chain Removal and Replacement - 3 Stage Boom ( T B14-44) 1

Position the machine on firm level ground, apply the park brake. Raise the boom to the horizontal position and fully retract the boom.

With the boom fully retracted, measure dimension X. The correct initial setting is: 506-36 Machines: 3 to 15mm (0.1 to 0.6 in). 507-42 and 509-42 Machines: 10 to 20 mm (0.4 to 0.8 in)

If necessary, adjust the chains to obtain the correct initial setting dimension: If the dimension is too great, shorten the retract chain chain with adjustment nut A. If the dimension is too small, shorten the extend chains with adjustment nuts B.

Important: Tighten the extend chains equally to maintain the same tension in both chains. 4

Extend the boom.

Spray the chains with JCB Chain Lubricant.

Retract the boom and recheck dimension X. If necessary, repeat step 3.

Fully extend the boom and then retract by 50.0 mm (2.0 in).

B14-34

Fig 42. 8

B-15-11 Issue 02

C088380

K Fig 43. ( T B14-35) Measure the gap Z between the under side of the extend chain and the top of the

B14-34

Section B14 - Body and Framework Boom Chain Maintenance intermediate boom at the mid-point of the chain length. The correct gap is: 506-36 Machines: 56 to 66 mm (2.2 to 2.6 in) 507-42 and 509-42 Machines: 35 to 45 mm (1.3 to 1.7 in) If necessary, adjust extend chains equally with adjustment nuts A. Note: If the end link threads or the nuts are damaged the complete end link must be replaced. 9

After the correct measurement has been obtained extend and retract the boom several times and recheck the gap Z. Adjust the extend chains as necessary.

On completion fit new split pins if the old split pins have been removed.

Fig 43.

B14-35

C012710-2

B-15-11 Issue 02

B14-35

Section B14 - Body and Framework Boom Chain Maintenance

Adjustment - 4 Stage Boom If extend or retract chains have been replaced, set the chain adjusters to the correct initial dimensions before adjusting the chains. K Extend Chains Removal and Replacement - 4 Stage Boom ( T B14-46) K Retract Chains Removal and Replacement - 4 Stage Boom ( T B14-49) K Fig 44. ( T B14-36) 1

Position the machine on firm level ground, apply the park brake. Raise the boom to the horizontal position and fully retract the boom.

With the boom fully retracted measure dimension X and Y. The correct initial settings are: X = 560 to 572 mm (22.0 to 22.5 in) Y = 26 to 38mm (1.02 to 1.5 in)

Note: Remove the rear boom cover to get access to the adjustment nuts A. Important: Each boom section has two extend chains Tighten the extend chain adjusters equally to maintain the same tension in both chains. Fig 44.

Extend the boom.

Spray the chains with JCB Chain Lubricant.

Retract the boom and recheck dimension X and Y. If necessary, repeat step 3.

Fully extend the boom and then retract by 50 mm (2.0 in).

B14-36

B-15-11 Issue 02

C076900-C2.eps

K Fig 45. ( T B14-37) Measure the gap Z between the under side of the extend chains and the top of the

B14-36

Section B14 - Body and Framework Boom Chain Maintenance intermediate booms at the mid point of the chain length. The correct gap is 83 to 93 mm (3.2 to 3.6 in) for the 1st intermediate boom 1 and 58 to 68 mm (2.2 to 2.6 in) for the 2nd intermediate boom 2. If necessary, adjust extend chains equally with adjustment nuts B. Note: If the end link threads or the nuts are damaged the complete end link must be replaced.

Fig 45.

C012710-2

After the correct measurement has been obtained extend and retract the boom several times and recheck the gap Z. Adjust the extend chains as necessary.

On completion fit new chain adjuster split pins if the old split pins have been removed.

B14-37

B-15-11 Issue 02

B14-37

Section B14 - Body and Framework Boom Chain Maintenance

Chain Component Inspection

cleaning will remove lubricant from the internal bearing surfaces and seriously reduce the service life on the chain.

Important: Before inspecting chain components it may be necessary to clean them. Use paraffin or a paraffin derivative to clean the chain. DO NOT use chemical solvents. DO NOT steam clean. Use of solvents or steam

Important: DO NOT attempt to repair defective chain components with components from another chain. Inspect components for wear and defects listed in the table. K Table 19. ( T B14-38)

Table 19. Inspection

Action

Pitting due to rust or corrosion

Check the chain links and pins.

If one or more component has pitting on its surface renew the chain.

Tight chain joints

The chains must be disconnected from the boom to If one or more joint is tight, renew the chain. inspect for tight chain joints. Articulate each link, if it does not pivot under its own weight the joint is tight.

C080510

Missing link plates

Do not attempt to replace missing link plates. If one or more link plate is missing, renew the chain.

C080520

Cracked or fractured link plates

Small fatigue fractures and cracks are difficult to see. Make sure the chain is clean.

If one or more link plate is defective, renew the chain.

C080530

Loose pins with enlarged pin holes

If one or more pin or link plate is defective, renew the chain.

C080480

B14-38

B-15-11 Issue 02

B14-38

Section B14 - Body and Framework Boom Chain Maintenance Inspection

Action

Protruding or rotated pins

If one or more pin is defective, renew the chain.

C080490

Wear or damage Check for defects caused by impact with other to the outer faces components. of the link plates or pin heads

If one or more pin or link plate is defective renew the chain. Inspect the machine for defects that may be causing chain damage or abnormal chain wear. Rectify as applicable.

C080550

Wear on the link plate edges

This wear is caused by the chain running over the chain guide rollers and is normal over time.

Chain elongation

Elongation is caused by wear between the pins and Check the chain, follow the correct procedure. plates and is normal over time. Make sure the chain K Wear Limits ( T B14-41) If the chain exceeds the wear limit, renew the chain. does not exceed the wear limit.

Anchor locking integrity

Check the anchor pin A and clevis B for wear Renew a defective anchor pin or clevis. If the damage and corrosion. Check the locking split pins clevis is integral with the chain, renew the C. chain. Replace damaged or missing split pins.

Check the chain, follow the correct procedure. K Wear Limits ( T B14-41) If one or more link exceeds the wear limit, renew the chain.

C C080570

B14-39

B-15-11 Issue 02

B14-39

Section B14 - Body and Framework Boom Chain Maintenance Inspection Chain guide rollers

B14-40

Action Check the rollers for worn bearings and grooving caused by the chains.

B-15-11 Issue 02

Renew defective components as applicable.

B14-40

Section B14 - Body and Framework Boom Chain Maintenance

!MCAUTION

Wear Limits Measure the nominal chain pitch A and read off the corresponding wear limits from the table. K Table 20. Wear Limits ( T B14-41). Check that link plate depth B is not less than specified, particularly on sections of the chain which run over pulleys. Examine chain over its full length to find a minimum of three sections having the most wear (usually sections which run over a pulley). Lay each section on a flat surface and ensure that the chain is in tension. Measure the length C for the number of links specified. K Table 20. Wear Limits ( T B14-41). Chains exceeding these dimensions must be renewed.

The practice of joining chain lengths is not recommended and chains from different manufacturers must not be used together on the same application. If a chain requires shortening, it is imperative that the pin to be extracted has its head completely removed and deburred so as not to score the link bore. Chains should ideally be renewed in pairs as in the event of a single chain breakage the stress imposed at the time of breakage usually causes the unbroken chain to stretch. Because chains are made from heat-treated steel, they MUST NOT BE ANNEALED. 9-3-4-5

Table 20. Wear Limits Min. Plate Depth B

Nominal Pitch A mm 19

(1)

25.4

(2)

Max. Length C (measure 25 links)

0.75

16.89

0.665

485

19.1

22.69

0.893

648

25.5

Fig 46.

A309890-1

(1) 19 mm pitch chains are fitted to all machines. (2) 25.4 mm pitch chains are fitted to 510-56, 512-56 and 514-56 machines only. Note: Length C is for 25 links. Important: Renew defective chains and associated components IMMEDIATELY. DO NOT USE the machine until the chains and components are replaced with new ones. Follow the correct procedures.

B14-41

B-15-11 Issue 02

B14-41

Section B14 - Body and Framework Boom Extend Chains Removal and Replacement - 3 Stage Boom

Extend Chains Removal and Replacement - 3 Stage Boom Important: Chains should ideally be renewed in pairs as in the event of a single chain breakage the stress imposed at the time of breakage usually causes the unbroken chain to stretch. Important: Record the working position of the chains on the machine before removal. If a chain is to be re-fitted it must be fitted in its original working position.

Replacement K Fig 47. ( T B14-43) 1

Keep chains clean, do not let them drag on the ground when fitting.

Use the cords used during removal to pull the chains from the front to the rear of the boom.

Removal

Note: Nyloc nut type adjusters must not be re-used. K Fig 47. ( T B14-43) 1

Raise the boom to the horizontal position and fully retract the boom. Support the front end of the boom.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B14-2)

Remove boom rear cover.

Fasten the chains at the top front, fit new adjuster nuts B, do not tighten at this stage.

Remove cord, fasten the chains at the rear, fit new adjuster nuts B. Turn adjuster nuts B to set the chains to the correct initial position. K Table 21. ( T B14-42) Table 21.

Remove split pins A and adjuster nuts B from extend chains top front and inside the boom rear.

Adjustment Extend chains, both ends

Note: Nyloc nut type adjusters must not be re-used. 5

Tie strong cords C of sufficient length to the rear of the extend chains. The cords will be used during the replacement procedure.

Note: Put wire through the hole in the chain adjuster in place of split pin A, then attach the cord to the wire. This will allow the cord to pass through the chain adjuster brackets. 6

Carry out the chain adjustment procedure. K Adjustment - 3 Stage boom ( T B14-34)

From the front of the machine pull the chains out of the boom. Make sure the cords are accessible at both ends of the boom.

Inspection Inspect chain components for defects and wear. K Chain Component Inspection ( T B14-38)

B14-42

B-15-11 Issue 02

B14-42

Section B14 - Body and Framework Boom Extend Chains Removal and Replacement - 3 Stage Boom

201650-C1

Fig 47.

B14-43

B-15-11 Issue 02

B14-43

Section B14 - Body and Framework Boom Retract Chain Removal and Replacement - 3 Stage Boom

Retract Chain Removal and Replacement - 3 Stage Boom Important: Chains should ideally be renewed in pairs as in the event of a single chain breakage the stress imposed at the time of breakage usually causes the unbroken chain to stretch.

Important: Record the working position of the chains on the machine before removal. If a chain is to be re-fitted it must be fitted in its original working position.

Fasten the chain at the rear, fit new adjuster nut B.

Remove cord, fasten the chain at the front, fit adjuster nut B.

Turn adjuster nuts B to set the chain to the correct initial setting. K Table 22. ( T B14-44)

Removal

Note: Nyloc nut type adjusters must not be re-used.

K Fig 48. ( T B14-45) 1

Raise the boom to the horizontal position and fully retract the boom. Support the front end of the boom.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B14-2)

Remove split pins A and adjusters B from retract chain bottom front and inside the boom rear.

Tie strong cord C of sufficient length to front of the retract drive chain. The cord will be used during the replacement procedure.

Table 22. Adjustment Screw Retract chain, both ends

Note: Put wire through the hole in the chain adjuster in place of split pin A, then attach the cord to the wire. This will allow the cord to pass through the chain adjuster brackets. 5

Use the cord used during removal to pull the chain from the rear to the front of the boom.

Carry out the adjustment procedure. K Adjustment 3 Stage boom ( T B14-34)

From the rear of the machine pull the chain out of the boom. Make sure the cord is accessible at both ends of the boom.

Inspection Inspect chain components for defects and wear. K Chain Component Inspection ( T B14-38)

Replacement K Fig 48. ( T B14-45) 1

Keep chains clean, do not let them drag on the ground when fitting.

B14-44

B-15-11 Issue 02

B14-44

Section B14 - Body and Framework Boom Retract Chain Removal and Replacement - 3 Stage Boom

Fig 48.

B14-45

B-15-11 Issue 02

201640-C1

B14-45

Section B14 - Body and Framework Boom Extend Chains Removal and Replacement - 4 Stage Boom

Extend Chains Removal and Replacement - 4 Stage Boom K Fig 49. ( T B14-48)

Outer Extend Chains

Important: All chains should ideally be replaced in the event of a single chain breakage as the stress imposed at the time of breakage usually causes the unbroken chains to stretch.

Remove split pins F and adjustment nut E from the outer extend chain D at the front of the outer boom H.

Do step 1 for the other outer extend chain L.

Important: Record the working position of the chains on the machine before removal. If a chain is to be re-fitted it must be fitted in its original working position.

Remove split pins and adjustment nut R from the outer extend chain D at the rear of the outer boom H.

Do step 3 for the other outer extend chain L.

Removal 1

Raise the boom to the horizontal position and fully retract the boom. Support the front end of the boom.

Tie strong cord of sufficient length to the rear of chains D and L. The cords will be used during the replacement procedure.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B14-2)

Note: Put wire through the hole in the chain adjuster in place of split pins, then attach the cord to the wire. This will allow the cord to pass through the chain adjuster brackets.

Remove the boom Topics ( T B14-2)

rear

cover.

K Related

Inner Extend Chains 1

From the front of the machine pull the chains out of the boom. Make sure the cords are accessible at both ends of the boom.

Inspection

Remove split pins C and adjustment nut B from the inner extend chain A at the front of the 1st intermediate boom M.

Do step 1 for the other inner extend chain Q.

Remove split pins and adjustment nut S from the inner extend chain A at the rear of the 1st intermediate boom M.

Do step 3 for the other inner extend chain Q.

Tie strong cord of sufficient length to the rear of chains A and Q. The cords will be used during the replacement procedure

Inspect chain components for defects and wear. K Chain Component Inspection ( T B14-38)

Note: Put wire through the hole in the chain adjuster in place of split pins, then attach the cord to the wire. This will allow the cord to pass through the chain adjuster brackets. 6

From the front of the machine pull the chains out of the boom. Make sure the cords are accessible at both ends of the boom.

B14-46

B-15-11 Issue 02

B14-46

Section B14 - Body and Framework Boom Extend Chains Removal and Replacement - 4 Stage Boom

Replacement

Table 23. Adjustment

Keep chains clean, do not let them drag on the ground when fitting.

Extend Chains – Outer Extend Chain rear anchors R

At the front of the boom, attach the chains to the cord used during removal.

40 mm (1.5 in)

From the rear of the machine use the cords to pull the chains through the boom. Note: Nyloc nut type adjusters must not be re-used. – Inner Extend Chain front anchors B

Inner Extend Chains

– Inner Extend Chain rear anchors S

Fasten the chain A at the front of the 1st intermediate boom M, fit a new adjustment nut B, do not tighten at this stage.

Do step 1 for the other inner extend chain Q.

Remove cord, fasten the chain A at the rear of the 1st intermediate boom M, fit a new adjustment nut S, do not tighten at this stage.

Do step 3 for the other inner extend chain Q.

Turn adjustment nuts B and S to set the chains to the Chain correct initial position. K Initial Setting ( T B14-47)

– Outer Extend Chain Front Anchors E

Carry out the adjustment procedure. K Adjustment 4 Stage Boom ( T B14-36)

Outer Extend Chains 1

Fasten the chain D at the front of the outer boom H, fit adjustment nut E, do not tighten at this stage.

Do step 1 for the other outer extend chain L.

Remove cord, fasten the chain D at the rear of the outer boom H, fit adjustment nut R, do not tighten at this stage.

Do step 3 for the other outer extend chain L.

Turn the chain adjustment nuts E and R to set the chains to the correct initial position. K Initial Chain Setting ( T B14-47)

Initial Chain Setting 1

Set the chains to the correct initial position. K Table 23. ( T B14-47)

B14-47

B-15-11 Issue 02

B14-47

Section B14 - Body and Framework Boom Extend Chains Removal and Replacement - 4 Stage Boom

Fig 49.

B14-48

B-15-11 Issue 02

C088160-C1

B14-48

Section B14 - Body and Framework Boom Retract Chains Removal and Replacement - 4 Stage Boom

Retract Chains Removal and Replacement - 4 Stage Boom K Fig 50. ( T B14-51)

Outer Retract Chain

Important: All chains should ideally be replaced in the event of a single chain breakage as the stress imposed at the time of breakage usually causes the unbroken chains to stretch.

Remove split pin D and nut E.

Important: Record the working position of the chains on the machine before removal. If a chain is to be re-fitted it must be fitted in its original working position.

Raise the boom to the horizontal position. Extend the boom until the front inner retract chain anchor G is accessible. Support the front end of the boom.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B14-2)

Remove the boom Topics ( T B14-2)

rear

cover.

K Related

Inner Retract Chain

Remove split pin H and adjustment nut J from the outer retract chain anchor K at the front of the outer boom.

Tie strong cord of sufficient length to the front of the retract chain. The cord will be used during the replacement procedure.

Note: Put wire through the hole in the chain adjuster in place of split pin H, then attach the cord to the wire. This will allow the cord to pass through the chain adjuster brackets. 4

Remove split pin D and adjustment nut E from the inner retract chain C at the rear of the boom.

Remove split pin H and adjustment nut J from the inner retract chain anchor G at the front of the 1st intermediate boom. Tie strong cord of sufficient length to the front of the retract chain. The cord will be used during the replacement procedure.

Note: Put wire through the hole in the chain adjuster in place of split pin H, then attach the cord to the wire. This will allow the cord to pass through the chain adjuster brackets. 4

Disconnect the inner retract chain C. Remove the chain roller pivot and roller N.

Removal

Remove split pin F and adjustment nut A from the outer retract chain B at the rear of the boom. To get access to nut A:

From the rear of the machine pull the chain out of the boom. Make sure the cord is accessible at both ends of the boom.

Inspection Inspect chain components for defects and wear. K Chain Component Inspection ( T B14-38)

Replacement Keep chains clean, do not let them drag on the ground when fitting. At the rear of the boom, attach the chains to the cord used during removal. From the front of the machine use the cords to pull the chains through the boom. Note: Nyloc nut type adjusters must not be re-used.

B14-49

B-15-11 Issue 02

B14-49

Section B14 - Body and Framework Boom Retract Chains Removal and Replacement - 4 Stage Boom Outer Retract Chain

Initial Chain Setting

Fasten the chain B at the anchor K at the front of the outer boom, fit a new adjustment nut J, do not tighten at this stage.

Remove cord, fasten the chain B at the rear of the boom, fit a new adjustment nut A. Turn the nut to set the chain anchor L to the correct dimension of 65 mm (2.5 in). K Initial Chain Setting ( T B14-50)

Set the chains to the correct initial position. K Table 24. ( T B14-50) Table 24.

Adjustment Screw Retract chains K Fig 50. ( T B14-51) â&#x20AC;&#x201C; Outer retract chain front anchor K â&#x20AC;&#x201C; Inner retract chain front anchor G and rear anchor M

Turn adjustment nut J to set the chain anchor K to the Chain correct initial position K Initial Setting ( T B14-50)

Inner Retract Chain 1

If chain roller N has been removed, refit the roller and its pivot.

Fasten the chain C at the anchor G at the front of the 1st intermediate boom, fit a new adjustment nut J, do not tighten at this stage.

Remove cord, fasten the chain C at the rear of the boom, fit a new adjustment nut E, do not tighten at this stage.

Turn the adjustment nuts J and E to set the chain to the correct initial position K Initial Chain Setting ( T B14-50)

â&#x20AC;&#x201C; Outer retract chain rear anchor L

B14-50

B-15-11 Issue 02

Carry out the adjustment procedure. K Adjustment 4 Stage Boom ( T B14-36)

B14-50

Section B14 - Body and Framework Boom Retract Chains Removal and Replacement - 4 Stage Boom

Fig 50.

B14-51

B-15-11 Issue 02

C088160-C4.eps

B14-51

Section B14 - Body and Framework Boom Angle Indicator Removal and Replacement

Angle Indicator Removal and Replacement Removal K Fig 51. ( T B14-52) 1

Slacken the locknuts A.

Remove bolt B and the pointer arm C.

To detach dial E remove bolts D.

Fig 51.

C046900

Replacement Replacement is the opposite of the removal procedure. Note: If dial scale is worn this can be replaced by removing decal F and replacing with new decal. Note: Grease pivot bolt B to ensure smooth operation of pointer arm C.

B14-52

B-15-11 Issue 02

B14-52

Section B14 - Body and Framework Boom Pivot Shims

Pivot Shims

249790-1

Fig 52. Note: The illustration shows the boom viewed from the rear of the machine. 1

Measure X and Y.

Use the following illustration to calculate the total gap Z: Total Gap Z = X + Y The total gap Z must not be more than 3mm.

If necessary add the correct quantity of shims to get the correct measurement. Add the shims equally at the two sides to make sure the boom is central on the pivot.

Fig 53.

C079130

Note: If new shims are necessary, install â&#x20AC;&#x153;handledâ&#x20AC;? shims A. When these have been installed and the gap Z is correct snap the handle C from the shim A at the crease B.

B14-53

B-15-11 Issue 02

B14-53

Section B14 - Body and Framework Boom Boom Removal and Replacement

Boom Removal and Replacement Removal Machines with boom angle proximity switches. Remove the proximity switches before removing the boom. Proximity switches can be damaged by vibration when removing and installing the boom pivot pin. 1

Remove any attachments.

Raise the boom to the horizontal position and fully retract the boom. Support the boom.

Park the machine and make it safe. Vent the hydraulic system. Obey the care and safety procedures. K Related Topics ( T B14-2)

Remove boom Topics ( T B14-2)

Support boom with appropriate lifting equipment.

Disconnect hydraulic hoses from boom to base. Label hoses for identification.

Disconnect hydraulic hoses to hose burst protection valve.

Disconnect boom extend proximity switch electrical connectors from chassis harness.

Disconnect the lift ram from the boom: a

rear

cover.

K Related

Fig 54. 10

C067410

Disconnect the displacement ram from the boom: a

Remove the bolt D.

b Using the slide hammer kit, see Section 1 Service Tools. K Related Topics ( T B14-2) withdraw pivot pin D. Lower the displacement ram onto suitable packing material to protect the piston rod.

Remove the bolt A.

b Using the slide hammer kit, see Section 1 Service Tools. K Related Topics ( T B14-2) withdraw pivot pin B. Lower the displacement ram onto suitable packing material to protect the piston rod.

D Fig 55.

B14-54

B-15-11 Issue 02

C067600-C1.eps

Remove bolt E.

B14-54

Section B14 - Body and Framework Boom Boom Removal and Replacement 12

Using the slide hammer kit, see Section 1 - Service Tools. K Related Topics ( T B14-2) withdraw pivot pin F.

F E C067560-C1.eps

Fig 56. 13

Remove boom from machine with appropriate lifting equipment.

If necessary remove hoses from boom. K Boom Hose Removal and Replacement (4 Stage Boom) ( T B14-59)

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Re-shim the boom Shims ( T B14-53).

required.

K Pivot

– Grease pivot pins with the correct grease. K Related Topics ( T B14-2). – Check the hydraulic Topics ( T B14-2)

B14-55

fluid

level.

K Related

B-15-11 Issue 02

B14-55

Section B14 - Body and Framework Boom Boom Hose Removal and Replacement (3 Stage Boom)

Boom Hose Removal and Replacement (3 Stage Boom)

Fig 57.

Removal

C130700.jpg

Disconnect the two tilt service hose connectors 6 and two auxiliary service hydraulic hose connectors 7 at the boom nose.

Remove attachments from the boom.

Raise the boom to the horizontal position and fully retract the boom. Support the boom.

Remove the bolts 8 that clamp the outer pipes to the boom.

Park the machine and make it safe. Vent the hydraulic system. Obey the care and safety procedures. K Related Topics ( T B14-2)

Remove the bolts 11 that secure the clamps 12.

Remove boom Topics ( T B14-2)

rear

cover.

K Related

Note: The hoses and pipes are clamped to the boom sections - make sure to remove all clamps and clamping bolts.

If the same hoses are to be re-fitted, record the hose locations. The hoses must be installed in the same locations.

B14-56

B-15-11 Issue 02

B14-56

Section B14 - Body and Framework Boom Boom Hose Removal and Replacement (3 Stage Boom)

10 11 13

15 16 C130690.eps

Fig 58. 8

Disconnect the four hydraulic hoses 3 from the pipes 5 at connections 4.

Remove the bolt 13 and guide pin 14 from the roller bracket 15.

If using new hoses:

Working under the boom carefully pull the hoses from inside the outer boom. Feed the hoses past the guide roller 16 at the rear of the boom.

For New Hoses:

Attach male to male adaptors to the hose end connectors 6 and 7.

b Attach new hoses to the hose adaptors at 6 and 7 - this will enable the new hoses to be pulled through the boom when the old hoses are removed. This will also prevent contamination.

15 10

For Old Hoses:

If reusing the old hoses: a a

Disconnect the old hoses from the new hoses and remove the adaptor.

Undo the string and remove the hoses.

Tie some string to the end of each hose for use when pulling the hoses back inside the boom during replacement.

Remove the two bolts 1 and hose retaining plate 2.

B14-57

B-15-11 Issue 02

B14-57

Section B14 - Body and Framework Boom Boom Hose Removal and Replacement (3 Stage Boom)

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Make sure the hoses are routed correctly. Do not cross the hoses over. – Make sure to tension the hoses - pull them tight inside the boom until the white marks 10 on the hoses 9 align with the clamps 12 - this prevents the hoses becoming damaged when moving inside the boom. For New Hoses: – Use the old hoses connected to the new hoses to pull the new hoses through the boom. For Old Hoses: – Use the string to pull the hoses inside the boom.

B14-58

B-15-11 Issue 02

B14-58

Section B14 - Body and Framework Boom Boom Hose Removal and Replacement (4 Stage Boom)

Boom Hose Removal and Replacement (4 Stage Boom) Outer Hoses

Removal

Disconnect the old hoses from the new hoses and remove the adaptor.

For Old Hoses:

Remove attachments from the boom.

Raise the boom to the horizontal position and fully retract the boom. Support the boom.

Park the machine and make it safe. Vent the hydraulic system. Obey the care and safety procedures. K Related Topics ( T B14-2)

Replacement is the opposite of the removal procedure.

Remove boom Topics ( T B14-2)

For New Hoses:

rear

cover.

K Related

If the same hoses are to be re-fitted, record the hose locations. The hoses must be installed in the same locations. 5

Disconnect the two tilt service hoses and two auxiliary service hydraulic hoses at the bulkhead plates 2 and 4, located at rear of the boom.

Remove the six hose clamps 1 and the two hose clamps 9 from the underside of the boom and release the hydraulic hoses.

Disconnect the four hydraulic hoses 6 at the pipe matrix 5.

If using new hoses: a

Undo the string and remove the hoses.

Replacement

During the replacement procedure do this work also:

â&#x20AC;&#x201C; Use the old hoses connected to the new hoses to pull the new hoses through the boom. For Old Hoses: â&#x20AC;&#x201C; Use the string to pull the hoses inside the boom. Make sure the hoses are routed correctly. Do not cross the hoses over.

Attach male to male adaptors to the hose end connectors X.

b Attach new hoses to the hose adaptors at X - this will enable the new hoses to be pulled through the boom when the old hoses are removed. This will also prevent contamination. 9

If reusing the old hoses: a

Tie some string to the end of each hose for use when pulling the hoses back inside the boom during replacement.

Remove the two hose clamps 3.

Remove the guide pin 7.

Working under the boom carefully pull the hoses from inside the outer boom. Feed the hoses past the guide roller 8 at the rear of the boom.

For New Hoses:

B14-59

B-15-11 Issue 02

B14-59

Section B14 - Body and Framework Boom

Fig 59.

C130630

Boom Hose Removal and Replacement (4 Stage Boom)

B14-60

B-15-11 Issue 02

B14-60

Section B14 - Body and Framework Boom Boom Hose Removal and Replacement (4 Stage Boom)

Inner Hoses

For New Hoses: a

Removal

Disconnect the old hoses from the new hoses and remove the adaptor.

Remove attachments from the boom.

Raise the boom to the horizontal position and fully retract the boom. Support the boom.

Park the machine and make it safe. Vent the hydraulic system. Obey the care and safety procedures. K Related Topics ( T B14-2)

Replacement

Remove boom Topics ( T B14-2)

During the replacement procedure do this work also:

rear

cover.

K Related

Undo the string and remove the hoses.

Replacement is the opposite of the removal procedure.

For New Hoses:

If the same hoses are to be re-fitted, record the hose locations. The hoses must be installed in the same locations. 5

For Old Hoses:

â&#x20AC;&#x201C; Use the old hoses connected to the new hoses to pull the new hoses through the boom.

Disconnect the two tilt service hydraulic hoses 7 and two auxiliary service hydraulic hoses 6 at the front of the boom.

For Old Hoses:

If using new hoses:

Make sure the hoses are routed correctly. Do not cross the hoses over.

â&#x20AC;&#x201C; Use the string to pull the hoses inside the boom.

Attach male to male adaptors to the hose end connectors 6 and 7.

b Attach new hoses to the hose adaptors at 6 and 7 this will enable the new hoses to be pulled through the boom when the old hoses are removed. This will also prevent contamination. 7

If reusing the old hoses: a

Tie some string to the end of each hose for use when pulling the hoses back inside the boom during replacement.

Disconnect the four hydraulic hoses 5 at the pipe matrix 3 at the rear of the boom.

Remove the nut and bolt 4 and release the pipe matrix 3 from the 2nd intermediate boom section.

Pull out the pipe matrix together with the hoses from the rear of the boom. Make sure that the string is routed through the boom and each end is accessible.

Disconnect the other end of the tilt and auxiliary service hydraulic hoses at positions 1 and 2 of the pipe matrix 3.

B14-61

B-15-11 Issue 02

B14-61

Section B14 - Body and Framework Boom

Fig 60.

C130630_C1

Boom Hose Removal and Replacement (4 Stage Boom)

B14-62

B-15-11 Issue 02

B14-62

Section B15 - Body and Framework

RAS ECU Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T B15-2) K Overview ( T B15-3) K Introduction ( T B15-3) K Removal and Replacement ( T B15-4) K Removal ( T B15-4) K Replacement ( T B15-4)

B15-1

B-16-01 Issue 01

B15-1

Section B15 - Body and Framework RAS ECU Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

RAS SYSTEM

ALL

(1) You must obey all of the relevant care and safety procedures.

B15-2

B-16-01 Issue 01

B15-2

Section B15 - Body and Framework RAS ECU Overview

Overview Introduction The RAS ECU controls the operation of the rear axle stability (RAS) system. The RAS ECU 2 is mounted to a bracket 1 which is attached to the underside of the drivers seat platform.

Fig 1.

Fig 2.

B15-3

B-16-01 Issue 01

C066650-C1

C06660-C1

B15-3

Section B15 - Body and Framework RAS ECU Removal and Replacement

Removal and Replacement Before renewing the ECU note the following: The ECU is a non serviceable part. Any units returned under warranty found to have been tampered with will invalidate any claim. ECU's are configured at the factory for each machine variant and are not interchangeable between machines.

Although the part numbers may be the same, the internal software can be different. DO NOT interchange ECU's between machines. Before renewing the ECU carry out all the relevant fault finding and diagnostics to make sure that the ECU is defective. Units returned under warranty found not to be faulty will invalidate any claim.

Removal

C066660-C2

Fig 3. 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T B15-2)

Support the RAS ECU 4 and bracket 2.

Remove the four bolts 1 which secure the ECU bracket 2 to the underside of the drivers seat platform.

Remove and discard the cable tie.

Remove the four bolts 5 and nuts 6 which secure the ECU 4 to the mounting bracket 2.

Remove the ECU 4 from the bracket 2.

Disconnect the ECU harness connectors and position them away from the ECU.

During the replacement procedure do this work also: â&#x20AC;&#x201C; Install a new cable tie through the slots 3 to secure the harness to the bracket 2. â&#x20AC;&#x201C; To ensure correct installation, the ECU harness connectors have different key slot positions.

Replacement Replacement is the opposite of the removal procedure.

B15-4

B-16-01 Issue 01

B15-4

Section B16 - Body and Framework

Interlock Components Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T B16-2) K Removal and Replacement ( T B16-3) K Boom Extend Proximity Switch ( T B16-3) K Boom Angle Sensors ( T B16-4)

B16-1

B-13-04 Issue 01

B16-1

Section B16 - Body and Framework Interlock Components Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

B16-2

B-13-04 Issue 01

B16-2

Section B16 - Body and Framework Interlock Components Removal and Replacement

Removal and Replacement Boom Extend Proximity Switch Removal

C117520-C1

Fig 1. 1

Carry out General Safety procedures, see Section 2 - General Procedures.

Lower the boom to the ground.

Disconnect the sensor harness connector from the boom harness connector.

Replacement is the opposite of the removal procedure.

Remove the bolts D.

Remove the sensor B and backplate C from the machine.

Remove the screws A and remove the sensor B from the backplate C.

B16-3

Replacement

During the replacement procedure do this work also: â&#x20AC;&#x201C; Make sure to route the harness correctly and replace the harness securing clips.

B-13-04 Issue 01

B16-3

Section B16 - Body and Framework Interlock Components Removal and Replacement

Boom Angle Sensors Removal

C117520

Fig 2. 1

Carry out General Safety procedures, see Section 2 - General Procedures.

Lower the boom to the ground.

Disconnect the sensor harness connector from the boom harness connector.

Replacement Replacement is the opposite of the removal procedure.

Remove the bolts A.

During the replacement procedure do this work also: â&#x20AC;&#x201C; Make sure to route the harness correctly and replace the harness securing clips.

Note: Make sure to retain the shim D if fitted. 5

Remove the sensor C and cover B from the machine.

B16-4

B-13-04 Issue 01

B16-4

Section C Electrics Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813/1800-2

Section C - Electrics

Notes:

C-0

9813/1800-2

C-0

Section C - Electrics Contents Page No. Applications Table ....................................................................................................... C0-1 Fuses and Relays Introduction ............................................................................................. C1-1 Access and Location .............................................................................. C1-3 Fuses - (S1) ............................................................................................ C1-4 Fuses - (S2) ............................................................................................ C1-6 Fuses - (S3) ............................................................................................ C1-7 Fuses - (S4) ............................................................................................ C1-9 Primary Fuses ...................................................................................... C1-10 Engine Compartment Fuse and Relay Box .......................................... C1-11 Relays - (S1) ......................................................................................... C1-12 Relays - (S2) ......................................................................................... C1-13 Relays - (S3) ......................................................................................... C1-14 Relays - (S4) ......................................................................................... C1-15 Fusebox Pin Number Identification (S1) ............................................... C1-16 Fusebox Pin Number Identification (S2) ............................................... C1-17 Relay Base Pin Number Identification .................................................. C1-18 Schematics Introduction ............................................................................................. C2-1 Overview ................................................................................................. C2-2 506-36, 507-42, 509-42 .......................................................................... C2-3 510-56, 512-56, 514-56 ........................................................................ C2-26 Electrical Harness SYSTEM Introduction ............................................................................................. C3-1 Related Topics ........................................................................................ C3-2 Earth Points ............................................................................................ C3-3 Wire Numbers and Functions ................................................................. C3-5 Harness Interconnections and Drawings ................................................ C3-7 Test Procedures .................................................................................... C3-63 Wiring Harness Repair ......................................................................... C3-67

C-i

Battery Charging SYSTEM Introduction ............................................................................................. Related Topics ........................................................................................ Specifications ......................................................................................... Operation Overview ................................................................................ Electrical and Electronic Systems .......................................................... Test Procedures ......................................................................................

C4-1 C4-2 C4-3 C4-4 C4-6 C4-7

Alternator (C-04-02) Introduction ............................................................................................. Related Topics ........................................................................................ Specifications ......................................................................................... Electrical Operation and Schematics ...................................................... Removal, Inspection and Replacement ..................................................

C5-1 C5-2 C5-3 C5-4 C5-5

Battery Introduction ............................................................................................. Related Topics ........................................................................................ Specifications ......................................................................................... Maintenance ...........................................................................................

C6-1 C6-2 C6-3 C6-4

C-i

Section C - Electrics Contents Page No. Test Procedures ...................................................................................... C6-7 Disconnection and Connection ............................................................... C6-9 Removal and Replacement (S1) .......................................................... C6-10 Removal and Replacement (S2) .......................................................... C6-11 Removal and Replacement (S3) .......................................................... C6-12

C-ii

Section C0 - Electrics Applications Table

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref Title

Fuses and Relays

Schematics

Electrical Harness SYSTEM

Battery Charging SYSTEM

Alternator (C-04-02)

Battery

C0-1

VARIANT

Engine serial number from U0193212

9813/1800-2 (AC-00-08)

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z z

z z

C0-1

Section C0 - Electrics Applications Table

Page left intentionally blank

C0-2

9813/1800-2 (AC-00-08)

C0-2

Section C1 - Electrics Fuses and Relays Introduction

Fuses and Relays Introduction This topic contains information for identification and location of fuses and relays. Use the information together with the electrical schematics given in the topics. The fuse and relays are identified together with their connector numbers. The connector numbers are referred to in other sections of this manual. K Access and Location ( T C1-3) K Fuses - (S1) ( T C1-4)(1) K Fuses - (S2) ( T C1-6)(1) K Fuses - (S3) ( T C1-7)(1) K Relays - (S4) ( T C1-15)(1) K Primary Fuses ( T C1-10) K Engine Compartment Fuse and Relay Box ( T C1-11) K Relays - (S1) ( T C1-12)(1) K Relays - (S2) ( T C1-13)(1) K Relays - (S3) ( T C1-14)(1) K Relays - (S4) ( T C1-15)(1) K Fusebox Pin Number Identification (S1) ( T C1-16)(1) K Fusebox Pin Number Identification (S2) ( T C1-17)(1) K Relay Base Pin Number Identification ( T C1-18) (1) Specification variants. Make sure you refer to the correct specification. Table 1. System Variants Machine models System

K Fuses - (S1) ( T C1-4) K Fuses - (S2) ( T C1-6)

531-70, 531-T70, 535-95, 535-T95, 536-60, 536-T60, 541-70, 541-T70, 533-105, 536-70, 536-T70, 550-80, 540-140, 535-125 HiViz, 535-140 HiViz

506-36, 507-42, 509-42, 510-56, 512-56, 514-56

540-170, 550-170, 550-140, 550-140

z z z

K Fuses - (S3) ( T C1-7)

C1-1

526-56

C-09-07 Issue 01

C1-1

Section C1 - Electrics Fuses and Relays Introduction Machine models System

531-70, 531-T70, 535-95, 535-T95, 536-60, 536-T60, 541-70, 541-T70, 533-105, 536-70, 536-T70, 550-80, 540-140, 535-125 HiViz, 535-140 HiViz

506-36, 507-42, 509-42, 510-56, 512-56, 514-56

526-56

540-170, 550-170, 550-140, 550-140

K Fuses - (S4) ( T C1-9) K Relays - (S1) ( T C1-12)

z z

K Relays - (S2) ( T C1-13)

K Relays - (S3) ( T C1-14)

z z

K Relays - (S4) ( T C1-15) K Fusebox Pin Number Identification (S1) ( T C1-16) K Fusebox Pin Number Identification (S2) ( T C1-17)

C1-2

z z

C-09-07 Issue 01

C1-2

Section C1 - Electrics Fuses and Relays Access and Location

Access and Location

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

Note: Additional fuses and relays are fitted in the engine compartment.K Engine Compartment Fuse and Relay Box ( T C1-11)

8-3-3-5

The electrical circuits are protected by fuses A. The fuses are located in a fuse box inside the door. They are in four banks. Each fuse position in each bank is numbered. If a fuse ruptures, find out why and rectify the fault before fitting a new one. To access the fuses, unscrew the two fasteners and remove cover B.

Fig 1.

810830-1

Note: Additional fuse links are fitted at the battery positive terminal K Primary Fuses ( T C1-10)

C1-3

C-09-07 Issue 01

C1-3

Section C1 - Electrics Fuses and Relays Fuses - (S1)

Fuses - (S1) Table 2.

1A 2A 3A 4A 5A 6B 7B 8B 9B 10B

11H 12H 13H 14C 15C 16D 17D 18B 19B 20B

Fuse No.

10B

Reversing alarm/lights

21H 22H 23H 24H 25H 26D 27D 28D 29D 30D

31B 32C 33C 34C 35C 36C 37G 38G 39G 40

11H

Rear/roof Wiper

12H

Front wiper

13H

Brake Lights

14C

Dipped Beam

15C

Main beam

16D

Left Hand Sidelights

7.5

17D

Right Hand Sidelights

18B

12 Volt accessory socket

19B

Starter Relay

20B

Auxiliary 2

21H

Heated Windows

22H

Gauge Master Warning

23H

Park Brake Warning Light

24H

Engine Running

25H

Operator Present Switch

26D

Sidelights

27D

Headlight flasher, horn

28D

Beacon

7.5

29D

Interior Light

30D

Hazard lights

31B

Neutral start

32C

Fog Light

33C

Boom worklight

34C

Roadlights

35C

Front worklamps

36C

Rear worklamps

37G

Drive

38G

Heated seat, face fan

39G

Radio

Livelink

41E 42E 43E 44E 45E 46E 47E 48E 49E 50E Fig 2.

333-f4350-1-F.eps

Note: All the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

C1-4

Circuit

Auxiliary

Auxiliary/Hitch hydraulics

Air Conditioning

Immobiliser

Heater

Indicators

Air Conditioning

Starter Relay

Drive

C-09-07 Issue 01

Rating (Amps) 5

3 30 3 20

5 15 5 5 25

C1-4

Section C1 - Electrics Fuses and Relays Fuses - (S1) Fuse No.

Circuit

41E

Smooth Ride System (SRS)

42E

Transmission

43E

Livelink

44E

Trailer Indicator

45E

Instruments

46E

Transmission

47E

Livelink

48E

Longitudinal Load Moment Indicator (LLMI)

49E

Instruments

50E

Smooth Ride System (SRS)

C1-5

Rating (Amps) 20

C-09-07 Issue 01

C1-5

Section C1 - Electrics Fuses and Relays Fuses - (S2)

Fuses - (S2) Table 3.

Fuse No.

Sway hydraulics

Transmission Speed Sensor

Rear Axle Stabilization (RAS) (if fitted)

Stabilizer transducer supply (if fitted)

Cab heater

Turn signals

Longitudinal Load Moment Indicator (LLMI)

Instruments

7.5

Hydraulic Isolation

Reversing alarm/lights

Rear/roof wiper

Front wiper

Fog light

Dipped beam

High beam

Left hand sidelights

7.5

Right hand sidelights

Cell phone/cigarette lighter

Spare

Starter relay

Engine shut-off solenoid (ESOS)

Transmission

Transmission dump

Brake lights

Parking lights

Headlight flasher, horn

Beacon

7.5

Interior light, radio

Four-way flashers

Neutral start

Spare

Rear axle stabilization (RAS)

Roadlights

Front worklamps

Rear worklamps

Stabilizer isolation (if fitted)

Heated seat, Face fan

Radio

Spare

40 Fig 3.

333-D7697-Sht1

Note: All the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

C1-6

C-09-07 Issue 01

Circuit

Rating (Amps)

3 15

10 5

C1-6

Section C1 - Electrics Fuses and Relays Fuses - (S3)

Fuses - (S3) IMPORTANT: This procedure is only applicable to some machine models. Refer to the table at the front of this topic for the applicable machine models.

40 333-f2023-1-sheet1.eps

Fig 4. Table 4. Fuse No.

Circuit

Horn

Face Level Fan

Heater/Air Conditioning Fan

Rear/Roof Wiper/Washer

LiveLink

Auxiliary/Hitch Hydraulics

Transmission Dump

Heated Seat

Boom Worklight

TBA

Neutral start

Immobiliser and 12V Auxiliary Output

Reverse Fan, Parkbrake, Operator Present Switch

Reverse Alarm/Lights

Brake Lights

Air Conditioning

LiveLink, Immobiliser

Worklights (Front)

Worklights (Rear)

C1-7

Rating (Amps)

Fuse No.

Circuit

Direction Indicators

Sidelights

Roadlights

Dip Beam

Main Beam

Fog Lights

Column Switches

Beacon

7.5

Interior Light, Instruments

7.5

Radio

Hazard lights

Smooth Ride System (SRS)

Transmission

Longitudinal Load Moment Indicator (LLMI)

Smooth Ride System (SRS)

LiveLink

Driveshaft

Single Lever Control

Instruments

C-09-07 Issue 01

Rating (Amps)

10 5 10 5 10

C1-7

Section C1 - Electrics Fuses and Relays Fuses - (S3) Fuse No.

Circuit

Rating (Amps)

Engine ECU

Immobiliser

Note: All the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

C1-8

C-09-07 Issue 01

C1-8

Section C1 - Electrics Fuses and Relays Fuses - (S4)

Fuses - (S4) Fuse No.

Circuit

Steer mode

10F

Reversing alarm/lights

11F

Rear/roof Wiper

12F

Front wiper

13A

Fog light

14A

Dipped Beam

15A

Main beam

16B

Sidelights

7.5

18C

17B

Sidelights

19C

18C

12 Volt accessory socket

10F

20C

19C

Transmission

20C

LLMC (LCS ECU)

21C

31C

21C

Ignition

22C

32A

22C

Immobiliser and Livelink

23C

Transmission

23C

33A

24C

Immobiliser

24C

34A

25C

Brake lights

25C

35H

26B

Roadlights

26B

36H

27B

Headlight flasher, horn

28B

Beacon

7.5

27B

37E

29B

Instruments

28B

38E

30B

Hazard lights

29B

39E

31C

Neutral start

32A

Air Conditioning

30B

40E

33A

Boom worklight

34A

Roadlights

35H

Front worklamps

Note: All the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

36H

Rear worklamps

37E

Transmission

38E

Heated seat, face fan

Table 5.

39E

Radio

40E

Radio/LiveLink

11F

12F

13A

14A

15A

16B

17B

Fig 5.

817-f7442-1-F.eps

Fuse No.

Circuit

Sway

Boom 4th Extension

Heated Windows

Air Conditioning

Heater/Air Conditioning Fan

Direction Indicators

Longitudinal Load Moment Indicator (LLMI)

Instruments

C1-9

Rating (Amps)

C-09-07 Issue 01

Rating (Amps)

5 15

15 3 20

C1-9

Section C1 - Electrics Fuses and Relays Primary Fuses

Primary Fuses To further protect the machine wiring harnesses and electrical circuits, a primary fuse box is fitted as shown. Remember to check the main circuit fuses as well as the primary fuses shown on this page. To get access to the fuses: 1

Make the machine safe with the boom lowered. Refer to Prepare the Machine for Maintenance.

Open the battery cover. Refer to Access Panels, Battery Cover.

Note: Your machine may not be equipped with all the fuses shown. Table 6. Fuse Circuit No.

Rating (Amps)

TBA

C1-10

C-09-07 Issue 01

Fig 6. Battery Positive Terminal

C122290-C2.eps

C1-10

Section C1 - Electrics Fuses and Relays Engine Compartment Fuse and Relay Box

Engine Compartment Fuse and Relay Box To further protect the machine wiring harnesses and electrical circuits, a fuse link box is fitted as shown. Remember to check the main circuit fuses as well as the link box fuses shown on this page.

Circuit

Power Hold Relay

Starter Inhibit

Fuel Pump

Power Hold Relay

Fuel Pump

Starter Solenoid

Fuel Pump ECU - 40

Spare

F10

ECU - 49

ECU - 53

F11

F10

HC-Doser / Spare

F12

F11

Lambda Sensor / Spare

F12

WF Sensor

F13

Empty / Spare

F14

Engine Power Supply

F14

F15

Engine Power Supply

F16

Engine ECU - 60

F15

F17

Engine ECU - 57

F16

F17

Fig 7.

C1-11

Table 7. Fuse No.

C125880

C-09-07 Issue 01

C1-11

Section C1 - Electrics Fuses and Relays Relays - (S1)

Relays - (S1) Table 8.

Relay Circuit No.

1 2 3 4 5 6 7

8 Fig 8.

333-f4350-1-R.eps

Note: All the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown.

C1-12

Ignition

Left Trailer Flash

Trailer Indicator

Roadlights

Reverse Alarm and Lamp

Not Used

Ignition

Right Trailer Flash

Engine Running

Not Used

Boom Worklight

Roof Air Conditioning Fans

Transmission Dump

Rear Worklights

Not Used

Brake Lights

Air Conditioning

Neutral Start

Front Worklights

Not Used

C-09-07 Issue 01

C1-12

Section C1 - Electrics Fuses and Relays Relays - (S2)

Relays - (S2) Table 9.

Relay Circuit No.

1 2 3 4 5 6 7 8 Fig 9.

333-D7967-sht1-C1

Note: All the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown.

C1-13

Neutral start

Parkbrake lamp

Ignition 3

Rear worklight

Stabilizer isolation

Rear Axle Stabilization (RAS) solenoid return isolation control (if fitted)

Parkbrake lamp

Roadlights

Neutral start

Engine running

Ignition 4

Front worklight

2WD Brake

Rear Axle Stabilization (RAS) solenoid return isolation control (if fitted)

Transmission dump

Brake lights

Ignition 1

Reverse

Drive

Forward high/low

Sway isolation (if fitted)

Forward

Ignition 2

Driveshaft

Reverse high/low

Lift isolation (if fitted)

C/D6

Flasher unit

C-09-07 Issue 01

C1-13

Section C1 - Electrics Fuses and Relays Relays - (S3)

Relays - (S3) IMPORTANT: This procedure is only applicable to some machine models. Refer to the table at the front of this topic for the applicable machine models.

Fig 10.

333-f2023-1-sheet1R.eps

Table 10. Relay Circuit No. A1

Ignition

Engine Running

Roadlights

Neutral Start

Brakelights

Reverse Alarm/Lights

Boom worklight

Spare

Rear worklights

TBA

Front Worklights

Transmission Dump

TBA

Spare

Ignition

TBA

Spare

C1-14

C-09-07 Issue 01

C1-14

Section C1 - Electrics Fuses and Relays Relays - (S4)

Relays - (S4) IMPORTANT: This procedure is only applicable to some machine models. Refer to the table at the front of this topic for the applicable machine models.

Fig 11.

817-f7442-1-R.eps

Note: All the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown.

C1-15

Table 11. Relay Circuit No. A1

Ignition

Steer Mode

Ignition

Rear worklights

Spare

Roadlights

Direction Indicators

Sway isolation

Ignition

Engine running

Ignition

Front worklights

Stabiliser Isolation (Raise/Lower)

Air Conditioning

2WD

Boom worklight

Stabiliser isolation (raise/lower)

Left hand stabiliser

Lift isolation

Extension boost

Brake lights

Steer Mode

Right hand stabiliser

Stabiliser lift unloader

4th boom extension

Ignition

Air Conditioning

Spare

Ignition

Neutral Start

Reverse Lights/Alarm

Spare

C-09-07 Issue 01

C1-15

Section C1 - Electrics Fuses and Relays Fusebox Pin Number Identification (S1)

Fusebox Pin Number Identification (S1)

E 1

Fig 12.

C1-16

C119820

C-09-07 Issue 01

C1-16

Section C1 - Electrics Fuses and Relays Fusebox Pin Number Identification (S2)

Fusebox Pin Number Identification (S2)

20 C119820-C1

Fig 13.

C1-17

C-09-07 Issue 01

C1-17

Section C1 - Electrics Fuses and Relays Relay Base Pin Number Identification

Relay Base Pin Number Identification The relay mounting bases are connected to the Panel Harness. Specific location and connector number will change. Each relay base can hold 2 relays. Pins 1-5 being

used for relay position B and pins 6-10 being used for relay position A. Therefore each relay could have alternative pin numbers due to its position in relay base.

7 8

2 10

4 1 2

7 6 9

Fig 14.

C1-18

C-09-07 Issue 01

C123840

C1-18

Section C2 - Electrics

Schematics Introduction This topic contains electrical schematics for the complete system. Detailed schematics for individual systems are given throughout the manual. Use the schematics together with the correct electrical harness drawings to see connector pin details. Refer to Section C. K Overview ( T C2-2) K 506-36, 507-42, 509-42 ( T C2-3) K Sheets ( T C2-3) K Component Keys ( T C2-22) K 510-56, 512-56, 514-56 ( T C2-26) K Sheets ( T C2-26) K Component Keys ( T C2-45)

C2-1

9813/1800-2 (C-10-10)

C2-1

C2-2

9813/1800-2 (C-10-10)

Fuse box B

Relay

Harness interconnection

Horn

Splice

CP27

CP18

CP06 / MF01

MF40A / RL15A

MF33

SRL2

Earth

SMF3

MF22

- ve earth

energised

closed

+ ve supply

State

1-2

Pins(2)

600A

600ET

600EL

871

118

Wire No.

Fig 1. Example - Horn Energised

Sheet

Use the applicable schematic set to trace wires and connections between electrical devices. In most cases it will be necessary to trace wires across more than one schematic sheet.

Connects to chassis earth point

completes circuit to horn

Power supply from 7.5 A fuse

Explanation

C126900

The example shows how to follow a typical set of wires from a power supply (+ ve) through to the path to earth (- ve).

(1) Item identification code is the same as the connector code shown on the applicable harness drawing. (2) The pin number is the same as the pin number of the harness connector shown on the applicable harness drawing. (3) Splices are not normally accessible. Splices are inside the harness sheath and not visible on the outside.

Harness interconnection

Splice

MF40A / RL15A

(3)

Description

SHEET 7

Item(1)

SHEET 14

This section contains sets of electrical schematics for different machine variants.

Overview

Section C2 - Electrics Schematics Overview

C2-2

Section C2 - Electrics Schematics 506-36, 507-42, 509-42

506-36, 507-42, 509-42 Sheets K Sheet 1 - Fusebox A P001 Ignition ( T C2-4) K Sheet 2 - Fusebox B P002 ( T C2-5) K Sheet 3 - Fusebox C P003 ( T C2-6) K Sheet 4 - Fusebox D P004 ( T C2-7) K Sheet 5 - Speed Sensors, Immobiliser and Transmission Control ( T C2-8) K Sheet 6 - Right Hand Cluster Connectors, P055 and P056 ( T C2-9) K Sheet 7 - Instruments - Warning Lamps ( T C2-10) K Sheet 8 - Road Lamps, Reverse Alarm, Trailer Electrics ( T C2-11) K Sheet 9 - Wipers and Motors ( T C2-12) K Sheet 10 - Work Lamps, Rotating Beacon, Heated Seat and Interior Lamp ( T C2-13) K Sheet 11 - Air Conditioning ( T C2-14) K Sheet 12 - In Cab Entertainment ( T C2-15) K Sheet 13 - RAS Controller ( T C2-16) K Sheet 14 - RAS Interface ( T C2-17) K Sheet 15 - RAS Chassis / Panel ( T C2-18) K Sheet 16 - CAN Architecture ( T C2-19) K Sheet 17 - T4i Engine (Starter and Fuel Pump) ( T C2-20) K Sheet 18 - T4i Engine (Sensors) ( T C2-21)

C2-3

9813/1800-2 (C-10-10)

C2-3

C2-4

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 2. Sheet 1 - Fusebox A P001 Ignition

160-E8028-1 Sheet 1

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-4

C2-5

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 3. Sheet 2 - Fusebox B P002

160-E8028-1 Sheet 2

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-5

C2-6

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 4. Sheet 3 - Fusebox C P003

160-E8028-1 Sheet 4

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-6

C2-7

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 5. Sheet 4 - Fusebox D P004

160-E8028-1 Sheet 4

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-7

C2-8

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 6. Sheet 5 - Speed Sensors, Immobiliser and Transmission Control

160-E8028-1 Sheet 5

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-8

C2-9

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 7. Sheet 6 - Right Hand Cluster Connectors, P055 and P056

160-E8028-1 Sheet 6

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-9

C2-10

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 8. Sheet 7 - Instruments - Warning Lamps

160-E8028-1 Sheet 7

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-10

C2-11

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 9. Sheet 8 - Road Lamps, Reverse Alarm, Trailer Electrics

160-E8028-1 Sheet 8

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-11

C2-12

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 10. Sheet 9 - Wipers and Motors

160-E8028-1-Sheet 9

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-12

C2-13

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 11. Sheet 10 - Work Lamps, Rotating Beacon, Heated Seat and Interior Lamp

160-E8028-1 Sheet 10

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-13

C2-14 K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 12. Sheet 11 - Air Conditioning

160-E8028-1 Sheet 11

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

9813/1800-2 (C-10-10)

C2-14

C2-15

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 13. Sheet 12 - In Cab Entertainment

160-E8028-1 Sheet 12

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-15

C2-16

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 14. Sheet 13 - RAS Controller

160-E8028-1 Sheet 13

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-16

C2-17

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 15. Sheet 14 - RAS Interface

160-E8028-1 Sheet 14

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-17

C2-18

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 16. Sheet 15 - RAS Chassis / Panel

160-E8028-1 Sheet 15

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-18

C2-19

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 17. Sheet 16 - CAN Architecture

160-E8028-1 Sheet 16

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-19

C2-20

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 18. Sheet 17 - T4i Engine (Starter and Fuel Pump)

160-E8028-1 Sheet 17

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-20

C2-21

9813/1800-2 (C-10-10)

K Component Keys ( T C2-22)

K Sheets ( T C2-3)

Fig 19. Sheet 18 - T4i Engine (Sensors)

160-E8028-1 Sheet 18

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-21

C2-22 Interior Light (+ve)

9813/1800-2 (C-10-10)

Engine Supply Starter Motor Stabiliser Isolation Valve Chassis Harness to Panel Harness Connector Chassis Earth Fuel Level Sender Transmission Speed Sensor Transmission Connector Transmission Dump Horn Reverse Alarm Hydraulic Isolation Engine Pod Harness Connector Starter Motor Solenoid

C004 C005 C006 C007 C008 C010 C011 C013 C014 C015 C016 C017 C018 C032 C033

K Table 15. ‘ST’ Starter Motor Harness ( T C2-24)

K Table 16. `S' Splices ( T C2-24)

K Table 17. ‘T’ Transmission Harness ( T C2-25)

Table 1. ‘A’ Rear Cab Harness Cab/Panel Harness Connector

Heated Seat

Air Suspension Seat

Rear Wiper

Worklight LH

Earth

Beacon

Worklight RH

K Table 14. ‘RL’ Rear Lights Harness ( T C2-24)

K Table 13. ‘RL’ Stabiliser / Headlights ( T C2-24)

K Table 12. ‘RA’ RAS Chassis Harness ( T C2-24)

K Table 11. ‘PA’ RAS Panel Harness ( T C2-24)

K Table 10. ‘P’ Panel Harness ( T C2-23)

Table 4. ‘C’ Grid Heater Relay to Heater Power Lead C001 TBA

Rear Lights

Accelerator

C003

K Table 9. ‘L’ Air Filter Link Harness ( T C2-23)

K Table 8. ‘L’ Rear Worklights Harness ( T C2-23)

K Table 7. ‘E’ Engine Pod Harness ( T C2-23) L/H Headlight

TBA

B003

C002

CE006

TBA

B002

C001

Crank Speed Sensor ELTEK

CE005

CE016

Shield Cut End

CE093

Shield Cut End 2

CE091

Shield Cut End 3

Engine ECU Connector CE092

Fuel Inlet Metering Valve

CE040

CE045

Injector number 1

CE037

CE044

Machine Interface Connector

CE035

Injector number 4

HP Fuel Pressure Regulator

CE033

CE043

VGT Actuator

CE032

Injector number 3

Fuel Temperature Sensor

CE030

CE042

Rail Pressure Sensor

CE026

Injector number 2

Comp in Pressure Sensor

CE021

CE041

Oil Temperature Sensor Exhaust Temperature Sensor

CE020

Oil Pressure Switch

Intercooler Out Temperature Sensor

CE015 CE019

Exhaust Manifold Pressure Sensor Intake Throttle Valve

CE011

EcoMax CAN Terminator

EGR Actuator

CE008 CE010

Cam Position Sensor

CE007

Coolant Temp Sensor

TMAP

CE001B Accelerometer 2 CE002

Park Brake Switch

TBA

Table 5. ‘CE’ Engine Harness CE001A Accelerometer 1

C002

Table 2. ‘B’ Twin Primary Fuse Link B001 TBA

Interior Light (-ve)

AK1 AK2

Roof Wiper

Table 3. ‘C’ Chassis Harness R/H headlight

K Table 6. ‘CS’ Grid Heater Fuse Link Lead ( T C2-23)

K Table 5. ‘CE’ Engine Harness ( T C2-22)

K Table 4. ‘C’ Grid Heater Relay to Heater Power Lead ( T C2-22)

K Table 3. ‘C’ Chassis Harness ( T C2-22)

K Table 2. ‘B’ Twin Primary Fuse Link ( T C2-22)

K Table 1. ‘A’ Rear Cab Harness ( T C2-22)

Component Keys

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-22

C2-23

9813/1800-2 (C-10-10)

Parkbrake/2 Wheel Drive Relay Stabiliser Isolation Relay Chassis Harness Connector Air Conditioning switch +ve Air Conditioning Switch -ve Hazard Switch Roof Wiper Switch

P019 P019 P020 P023 P024 P025 P026

L002

L001

Parkbrake Relay

P018

Table 8. ‘L’ Rear Worklights Harness L001 Worklight

Engine Harness

Table 9. ‘L’ Air Filter Link Harness Air Filter

Panel Harness Connector

Engine Running Relay

P018

Air Con Compressor

E025

Roadlamps Relay

P017

Air Con Binary Switch 2

E024-2

Brakelights Relay

P017

Air Con Binary Switch 1

E024-1

Forward High/Low Relay

E023

Reverse High/Low Relay

EcoMax CANbus Resistor

E020 P014

Grid Heater

E014 P014

Fan Speed Sensor

E013 Driveshaft Relay

Proportional Fan Solenoid

E012

P013

Reversing Fan Solenoid

E011

Drive Relay

Transmission Oil Temp

E010

Front Working Lamps Relay

P011

P013

Powertrain CANbus Resistor

E009

Ignition Relay 4

P010

Parkbrake Warning Lamp Relay

Chassis Harness Connector

E008

Ignition Relay 3

P010

Transmission Dump Relay

TMAF

E007

Reverse Drive Relay

P009

P012

Lambda Sensor

E006

Ignition Relay 2

P009

P012

Air Filter Vacuum Switch

E005

Rear Working Lamps Relay

Engine Harness Connector

E004

P011

Fuel Pump

Engine ECU Connector

E003 Forward Drive Relay

Ignition Relay 1

P006

Agglomerator

E002

Flasher Relay

Neutral Start Relay

P005

P008

Secondary Fuse Box D

P004

Table 7. ‘E’ Engine Pod Harness Fuse/Relay Box

P006

Secondary Fuse Box C

P003

E001

Secondary Fuse Box B

P002

TBA

CS5

Table 10. ‘P’ Panel Harness Secondary Fuse Box A

P001

Table 6. ‘CS’ Grid Heater Fuse Link Lead CS1 TBA

Ignition Switch Ignition Switch Primary Fuse Primary Fuse

P058 P059 P060 P061 P062

P066

Spare

P071

Face Level Fan -ve Washer Pump

P069

P068

Face Level Fan +ve

Footbrake

P065 P067

Primary Fuse Blue Primary Fuse Grey

P064

Diode Gate

R/H Column Switch

P057

P063

RHC Connector J2 Rear Cab Harness Connector

P056

RHC Connector J1

P055

Diode Gate

P042

Centre Cluster Warning Lights

L/H Column Switch

P041

P052

Earth

P040

Info Button

Earth

P039

Diagnostic Connector

Heater Switch

P038

P046

Heater Connector

P037

P043

Stabiliser Isolation Switch

P032 Indicator Diode

Beacon Switch

P030

P036

Worklamps Switch

P029

P034

Fog Lamp Switch Roadlights Switch

P028

Rear Wiper Switch

P027

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-23

C2-24

9813/1800-2 (C-10-10)

Hour Meter -ve

Hour Meter Signal

RAS Interface 1

RAS Interface 2

RAS Link 1

RAS Link 2

RAS LH/RH Relay

Ground Speed

P099

P100

P101

P102

P103

P104

P105

P106

RAS Interface 2

Ground Speed R/H Feedback

Parkbrake

RAS Controller J1

RAS Controller J2

CAN

CAN Terminator

PA003

PA004

PA005

PA006

PA007

PA008

PA009

Table 12. ‘RA’ RAS Chassis Harness RA001 Panel Connector

RAS Interface 1

PA002

Table 11. ‘PA’ RAS Panel Harness PA001 Panel Connector

Hydraulic Isolation Switch

Hour Meter +ve

P098

Immobiliser Link

P094

P097

Immobiliser

P093

Worklamps

P088

Terminating Resistor

Radio

P082

Engine Supply

Auxiliary Socket Illumination

P078

P092

Auxiliary Socket

P077

P091

Front Wiper Motor

P076

Right Stabiliser Link

Left Stabiliser Link

Ground

Inloader Valve

Right Stabiliser Switch

Left Stabiliser Switch

Sway Switch

Right RAS Cylinder

Left RAS Cylinder

Right Rear Lamp

RL003

K Fig 11. ( T C2-13) K Fig 11. ( T C2-13) K Fig 10. ( T C2-12)

SB SC

W Terminal

ST06

Charge Lead

ST05

Table 16. `S' Splices K Fig 10. ( T C2-12)

D+ Terminal

ST04

Charge Lead

ST03

Table 15. ‘ST’ Starter Motor Harness ST01 Chassis Harness Connector

Left Rear Lamp

RL002

Table 14. ‘RL’ Rear Lights Harness Chassis Connector

Chassis Harness Connector

RL005

RL001

Left Headlight

Right Headlight

RL003 RL004

Left Stabiliser Transducer

RL002

Table 13. ‘RL’ Stabiliser / Headlights RL001 Right Stabiliser Transducer

RA010

RA009

RA008

RA007

RA006

RA005

RA004

RA003

RA002 K Fig 9. ( T C2-11) K Fig 9. ( T C2-11) K Fig 9. ( T C2-11) K Fig 6. ( T C2-8) K Fig 9. ( T C2-11) K Fig 9. ( T C2-11) K Fig 9. ( T C2-11) K Fig 9. ( T C2-11) K Fig 9. ( T C2-11) K Fig 2. ( T C2-4) K Fig 4. ( T C2-6) K Fig 8. ( T C2-10) K Fig 10. ( T C2-12) K Fig 10. ( T C2-12)

SC03 SC04 SC05 SC06 SC07 SC08 SC09 SC10 SC12 SP1 SP10 SP13 SP16 SP17

K Fig 4. ( T C2-6) K Fig 6. ( T C2-8) K Fig 6. ( T C2-8) K Fig 6. ( T C2-8) K Fig 6. ( T C2-8) K Fig 6. ( T C2-8)

SP23 SP25 SP26 SP27 SP28 SP29

SP34

SP33

SP32

SP30

K Fig 6. ( T C2-8)

K Fig 4. ( T C2-6)

K Fig 6. ( T C2-8)

K Fig 2. ( T C2-4)

K Fig 11. ( T C2-13)

SP22

SP3

K Fig 11. ( T C2-13)

K Fig 3. ( T C2-5)

K Fig 2. ( T C2-4) SP21

SP20

SP19

K Fig 3. ( T C2-5)

K Fig 9. ( T C2-11)

SC01

SP18

K Fig 12. ( T C2-14)

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-24

C2-25

9813/1800-2 (C-10-10)

K Fig 8. ( T C2-10)

K Fig 2. ( T C2-4)

K Fig 8. ( T C2-10)

K Fig 4. ( T C2-6)

K Fig 8. ( T C2-10)

K Fig 6. ( T C2-8)

K Fig 15. ( T C2-17)

K Fig 2. ( T C2-4)

K Fig 8. ( T C2-10)

K Fig 2. ( T C2-4)

K Fig 15. ( T C2-17)

K Fig 14. ( T C2-16)

K Fig 9. ( T C2-11)

K Fig 6. ( T C2-8)

SP39

SP41

SP5

SP6

SP61

SP62

SP63

SP64

SP65

SP66

SP7

SP8

SP9

SRA1

SRA2

SRA3

SRA4

SRA5

SRL1

SRL2

SRL3

SRL4

ST2

Transmission Oil Pressure

Reverse Low Solenoid

Reverse High Solenoid

Mainshaft Solenoid

T003

T004

T005

T006

Table 17. ‘T’ Transmission Harness Chassis Harness Connector

K Fig 10. ( T C2-12)

SP38

T001

K Fig 10. ( T C2-12)

SP37

T010

T009

T008

T007

4 Wheel Drive Solenoid

Forward High Solenoid

Forward Low Solenoid

Layshaft Solenoid

Section C2 - Electrics Schematics

506-36, 507-42, 509-42

C2-25

Section C2 - Electrics Schematics 510-56, 512-56, 514-56

510-56, 512-56, 514-56 Sheets K Sheet 1 - Fusebox A P001 ( T C2-27) K Sheet 2 - Sensors Fusebox B P002 ( T C2-28) K Sheet 3 - Fusebox C P003 ESOS ( T C2-29) K Sheet 4 - Fusebox D P004 Ignition ( T C2-30) K Sheet 5 - Speed Sensors, Immobiliser and Transmission Control ( T C2-31) K Sheet 6 - Right Hand Cluster Connectors, P055, P056 ( T C2-32) K Sheet 7 - Instruments - Warning Lamps ( T C2-33) K Sheet 8 - Road Lamps, Reverse Alarm, Trailer Electrics ( T C2-34) K Sheet 9 - Wipers and Motors ( T C2-35) K Sheet 10 - Work Lamps, Rotating Beacon, Heated Seat, Interior Lamp ( T C2-36) K Sheet 11 - Air Conditioning, Cold Start ( T C2-37) K Sheet 12 - In Cab Entertainment ( T C2-38) K Sheet 13 - Rear Axle Stabilisation ECU Connectors, Stabiliser Isolation ( T C2-39) K Sheet 14 - Stabiliser Transducers, Boom Proximity Switches ( T C2-40) K Sheet 15 - Rear Axle Stabilisation Chassis Connections, Stabiliser Switches ( T C2-41) K Sheet 16 - CAN Architecture ( T C2-42) K Sheet 17 - Engine Including Start Circuit ( T C2-43) K Sheet 18 - Engine Circuit (Sensors) ( T C2-44)

C2-26

9813/1800-2 (C-10-10)

C2-26

C2-27

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 20. Sheet 1 - Fusebox A P001

160-E8085-1 Sheet 1

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-27

C2-28

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 21. Sheet 2 - Sensors Fusebox B P002

160-E8085-1 Sheet 2

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-28

C2-29

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 22. Sheet 3 - Fusebox C P003 ESOS

160-E8085-1 Sheet 3

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-29

C2-30

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 23. Sheet 4 - Fusebox D P004 Ignition

160-E8085-1 Sheet 4

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-30

C2-31

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 24. Sheet 5 - Speed Sensors, Immobiliser and Transmission Control

160-E8085-1-Sheet 5

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-31

C2-32

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 25. Sheet 6 - Right Hand Cluster Connectors, P055, P056

160-E8085-1-Sheet 6

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-32

C2-33

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 26. Sheet 7 - Instruments - Warning Lamps

160-E8085-1 Sheet 7

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-33

C2-34

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 27. Sheet 8 - Road Lamps, Reverse Alarm, Trailer Electrics

160-E8085-1 Sheet 8

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-34

C2-35

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 28. Sheet 9 - Wipers and Motors

160-E8085-1 Sheet 9

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-35

C2-36

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 29. Sheet 10 - Work Lamps, Rotating Beacon, Heated Seat, Interior Lamp

160-E8085-1 Sheet 10

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-36

C2-37

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 30. Sheet 11 - Air Conditioning, Cold Start

160-E8085-1 Sheet 11

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-37

C2-38

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 31. Sheet 12 - In Cab Entertainment

160-E8085-1-Sheet 12

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-38

C2-39

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 32. Sheet 13 - Rear Axle Stabilisation ECU Connectors, Stabiliser Isolation

160-E8085-1 Sheet 13

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-39

C2-40

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 33. Sheet 14 - Stabiliser Transducers, Boom Proximity Switches

160-E8085-1-Sheet14

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-40

C2-41

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 34. Sheet 15 - Rear Axle Stabilisation Chassis Connections, Stabiliser Switches

160-E8085-1 Sheet 15

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-41

C2-42

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 35. Sheet 16 - CAN Architecture

160-E8085-1-Sheet16

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-42

C2-43

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 36. Sheet 17 - Engine Including Start Circuit

160-E8085-1-Sheet 17

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-43

C2-44

9813/1800-2 (C-10-10)

K Component Keys ( T C2-45)

K Sheets ( T C2-26)

Fig 37. Sheet 18 - Engine Circuit (Sensors)

160-E8085-1-Sheet 18

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-44

C2-45

9813/1800-2 (C-10-10)

Table 18. ‘A’ Rear Cab Harness Cab/Panel Harness Connector

Heated Seat

Air Suspension Seat

Rear Wiper

K Table 37. ‘T’ Transmission Harness ( T C2-48)

K Table 36. `S' Splices ( T C2-47)

K Table 35. ‘S’ Stabiliser Link Harness ( T C2-47)

K Table 34. ‘ST’ Starter Motor Harness ( T C2-47)

K Table 33. ‘RL’ Stabiliser / Headlights Harness ( T C2-47)

K Table 32. ‘RL’ Rear Lights Harness ( T C2-47)

K Table 31. ‘RL’ Stabiliser Harness ( T C2-47)

K Table 30. ‘RA’ RAS Chassis Harness ( T C2-47)

K Table 29. ‘R’ Stabiliser Harness ( T C2-47)

K Table 28. ‘PA’ RAS Panel Harness ( T C2-47)

K Table 27. ‘P’ Panel Harness ( T C2-46)

K Table 26. ‘L’ Air Filter Link Harness ( T C2-46)

K Table 25. ‘L’ Rear Worklights Harness ( T C2-46)

K Table 24. ‘E’ Engine Pod Harness ( T C2-46)

K Table 23. ‘CS’ Grid Heater Fuse Link Lead ( T C2-46)

K Table 22. ‘CE’ Engine Harness ( T C2-45)

K Table 21. ‘C’ Chassis Harness ( T C2-45)

K Table 20. ‘B’ Boom Harness ( T C2-45)

K Table 19. ‘B’ Twin Primary Fuse Link ( T C2-45)

K Table 18. ‘A’ Rear Cab Harness ( T C2-45)

Component Keys

Park Brake Switch

Fuel Level Sender Transmission Speed Sensor

C009 C010 C011

Horn Reverse Alarm

C016 C017

Transmission Dump

45º Proximity Switch

C008

C015

Chassis Earth

C007

Transmission Connector

Chassis Harness to Panel Harness Connector

C005

C014

Starter Motor

C004

Rear Lights

Engine Supply

C003

C013

Accelerator

C001

B002 Table 21. ‘C’ Chassis Harness Front Chassis Connector

Chassis Harness Connector

B001

TBA

B003 Table 20. ‘B’ Boom Harness Proximity Switch

TBA

B002

Table 19. ‘B’ Twin Primary Fuse Link B001 TBA

Interior Light (+ve) Interior Light (-ve)

AK2

Roof Wiper

AJ AK1

Worklight RH

Beacon

Earth

AF AG

Worklight LH

Starter Motor Solenoid

C033

Exhaust Temperature Sensor Comp in Pressure Sensor Rail Pressure Sensor Fuel Temperature Sensor VGT Actuator

CE021 CE026 CE030 CE032 CE033

Oil Temperature Sensor

Oil Pressure Switch CE020

CE019

Intercooler Out Temperature Sensor

Intake Throttle Valve

CE015 CE016

Exhaust Manifold Pressure Sensor

EcoMax CAN Terminator

EGR Actuator

Cam Position Sensor

CE011

CE010

CE008

CE007

Coolant Temp Sensor

Crank Speed Sensor ELTEK

CE005 CE006

TMAP

CE002

CE001B Accelerometer 2

Table 22. ‘CE’ Engine Harness CE001A Accelerometer 1

Stabiliser Isolation Valve Engine Pod Harness Connector

C032

Left Stabiliser Switch

C027 C029

Right Stabiliser Switch

Sway Switch

Lift Isolation Solenoid

Boom Extend Proximity Switch

Left RAS Ram

Right RAS Ram

60º Proximity Switch

Hydraulic Isolation

C026

C025

C024

C023

C021

C020

C019

C018

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-45

C2-46

Machine Interface Connector

Injector number 1

Injector number 2

Injector number 3

Injector number 4

Fuel Inlet Metering Valve

Engine ECU Connector

Shield Cut End 2

Shield Cut End 3

Shield Cut End

CE037

CE040

CE041

CE042

CE043

CE044

CE045

CE091

CE092

CE093

Agglomerator

Fuel Pump

Engine ECU Connector

Engine Harness Connector

Air Filter Vacuum Switch

Lambda Sensor

TMAF

Chassis Harness Connector

Powertrain CANbus Resistor

Transmission Oil Temp

Reversing Fan Solenoid

Proportional Fan Solenoid

Fan Speed Sensor

Grid Heater

EcoMax CANbus Resistor

E003

E004

E005

E006

E007

E008

E009

E010

E011

E012

E013

E014

E020

E023

Table 24. ‘E’ Engine Pod Harness Fuse/Relay Box

TBA

E002

E001

CS5

Table 23. ‘CS’ Grid Heater Fuse Link Lead CS1 TBA

HP Fuel Pressure Regulator

CE035 Air Con Compressor

Air Con Binary Switch 2

Air Con Binary Switch 1

Ignition Relay 1 Forward Drive Relay Flasher Relay Ignition Relay 2 Reverse Drive Relay Ignition Relay 3 Ignition Relay 4 Front Working Lamps Relay Rear Working Lamps Relay Transmission Dump Relay Parkbrake Warning Lamp Relay Drive Relay Driveshaft Relay Reverse High/Low Relay Forward High/Low Relay

P006 P008 P009 P009 P010 P010 P011 P011 P012 P012 P013 P013 P014 P014

Secondary Fuse Box D

P004 P006

Secondary Fuse Box C

P003 Neutral Start Relay

Secondary Fuse Box B

P002

P005

Table 27. ‘P’ Panel Harness Secondary Fuse Box A

Engine Harness

Table 26. ‘L’ Air Filter Link Harness Air Filter

Panel Harness Connector

P001

L002

L001

L002

Table 25. ‘L’ Rear Worklights Harness L001 Worklight

E025

E024-2

E024-1

Roadlights Switch Worklamps Switch Beacon Switch

P029 P030 P032

9813/1800-2 (C-10-10)

P060

P059

P058

P057

P056

P055

P052

P046

P043

P042

P041

P040

P039

P038

P037

P036

Ignition Switch

R/H Column Switch

Rear Cab Harness Connector

RHC Connector J2

RHC Connector J1

Centre Cluster Warning Lights

Diagnostic Connector

Info Button

Diode Gate

L/H Column Switch

Earth

Heater Switch

Heater Connector

Indicator Diode

Stabiliser Isolation Switch

Fog Lamp Switch

P028

P034

Rear Wiper Switch

Roof Wiper Switch

Hazard Switch

Air Conditioning Switch -ve

Air Conditioning switch +ve

Chassis Harness Connector

Parkbrake Relay

Engine Running Relay

Roadlamps Relay

Brakelights Relay

P027

P026

P025

P024

P023

P020

P019

P018

P017

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-46

C2-47

9813/1800-2 (C-10-10)

Worklamps

Terminating Resistor

Engine Supply

Immobiliser

Immobiliser Link

Hydraulic Isolation Switch

Hour Meter +ve

Hour Meter -ve

Hour Meter Signal

Boom Raise Return, Sway/Stab Isolation Return Relay

L/H and R/H RAS Return Relay

RAS ECU J1

RAS ECU J2

Parkbrake

P088

P091

P092

P093

P094

P097

P098

P099

P100

P101

P105

P106

P107

P109

PA002

RAS Interface 1

Table 28. ‘PA’ RAS Panel Harness PA001 Panel Connector

Radio

P082

Washer Pump

P069

Auxiliary Socket Illumination

Face Level Fan -ve

P068

P078

Face Level Fan +ve

P067

Auxiliary Socket

Footbrake

P066

P077

Primary Fuse Grey

P065

Spare

Primary Fuse Blue

P064

Front Wiper Motor

Diode Gate

P063

P076

Primary Fuse

P062

P071

Primary Fuse

P061

Chassis Harness Connector

RL005

Ground Left Stabiliser Link Right Stabiliser Link

RA008 RA009 RA010

Left Rear Lamp Right Rear Lamp

RL002 RL003

Table 32. ‘RL’ Rear Lights Harness Chassis Connector

Chassis Harness Connector

RL005

RL001

Left Stabiliser Transducer

RL002

Table 31. ‘RL’ Stabiliser Harness RL001 Right Stabiliser Transducer

Right Stabiliser Switch

Left Stabiliser Switch

RA005 Inloader Valve

Sway Switch

RA004

RA007

Right RAS Cylinder

RA003

RA006

Left RAS Cylinder

RA002

Table 30. ‘RA’ RAS Chassis Harness RA001 Panel Connector

Left Stabiliser Transducer

Table 29. ‘R’ Stabiliser Harness Right Stabiliser Transducer

CAN Terminator

CAN

RAS Controller J2

RAS Controller J1

RL002

RL001

PA009

PA008

PA007

PA006

Parkbrake

Ground Speed R/H Feedback

PA004 PA005

RAS Interface 2

PA003

Left Headlight Chassis Harness Connector

RL004 RL005

K Fig 27. ( T C2-34)

SC05

SP17

SP16

SP10

SC12

SC09

SC08

K Fig 28. ( T C2-35)

K Fig 22. ( T C2-29)

K Fig 33. ( T C2-40)

K Fig 27. ( T C2-34)

K Fig 24. ( T C2-31)

K Fig 27. ( T C2-34)

SC04 SC06

K Fig 30. ( T C2-37)

K Fig 27. ( T C2-34)

K Fig 30. ( T C2-37)

K Fig 28. ( T C2-35)

K Fig 29. ( T C2-36)

SC02

SC01

Table 36. `S' Splices K Fig 28. ( T C2-35)

Stabiliser Harness Connector

S002

Table 35. ‘S’ Stabiliser Link Harness Pressure Switch

W Terminal

Charge Lead

D+ Terminal

Charge Lead

S001

ST06

ST05

ST04

ST03

Table 34. ‘ST’ Starter Motor Harness Chassis Harness Connector

Right Headlight

RL003

ST01

Left Stabiliser Transducer

RL002

Table 33. ‘RL’ Stabiliser / Headlights Harness RL001 Right Stabiliser Transducer

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-47

C2-48

9813/1800-2 (C-10-10)

K Fig 29. ( T C2-36)

K Fig 22. ( T C2-29)

K Fig 23. ( T C2-30)

K Fig 24. ( T C2-31)

K Fig 20. ( T C2-27)

K Fig 24. ( T C2-31)

K Fig 22. ( T C2-29)

K Fig 24. ( T C2-31)

K Fig 20. ( T C2-27)

K Fig 28. ( T C2-35)

K Fig 26. ( T C2-33)

K Fig 20. ( T C2-27)

K Fig 26. ( T C2-33)

K Fig 22. ( T C2-29)

K Fig 26. ( T C2-33)

K Fig 24. ( T C2-31)

K Fig 32. ( T C2-39)

SP22

SP23

SP24

SP25

SP26

SP27

SP28

SP29

SP3

SP30

SP32

SP33

SP34

SP35

SP37

SP38

SP39

SP41

SP5

SP6

SP61

SP62

SP63

SP64

SP65

SP66

K Fig 32. ( T C2-39)

K Fig 29. ( T C2-36)

SP21

SP68

K Fig 21. ( T C2-28)

SP20

K Fig 33. ( T C2-40)

K Fig 20. ( T C2-27)

SP19

SP67

K Fig 21. ( T C2-28)

SP18

Mainshaft Solenoid Layshaft Solenoid Forward Low Solenoid Forward High Solenoid 4 Wheel Drive Solenoid

T008 T009 T010

Reverse High Solenoid

T005 T007

Reverse Low Solenoid

T004 T006

Transmission Oil Pressure

Table 37. ‘T’ Transmission Harness Chassis Harness Connector

K Fig 24. ( T C2-31)

K Fig 27. ( T C2-34)

K Fig 33. ( T C2-40)

K Fig 27. ( T C2-34)

K Fig 33. ( T C2-40)

K Fig 27. ( T C2-34)

K Fig 20. ( T C2-27)

K Fig 26. ( T C2-33)

K Fig 33. ( T C2-40)

K Fig 26. ( T C2-33)

T003

T001

ST2

SRL5

SRL4

SRL3

SRL2

SRL1

SP9

SP8

SP73

SP72

SP7

Section C2 - Electrics Schematics

510-56, 512-56, 514-56

C2-48

Section C3 - Electrics

Electrical Harness SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T C3-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T C3-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T C3-2) K Earth Points ( T C3-3) K Wire Numbers and Functions ( T C3-5) K Harness Interconnections and Drawings ( T C3-7) K Interconnections ( T C3-7) K Harness Identification ( T C3-8) K Drawings ( T C3-11) K Test Procedures ( T C3-63) K How to Use a Multimeter ( T C3-63) K Measuring DC Voltage ( T C3-64) K Measuring Resistance ( T C3-64) K Measuring Continuity ( T C3-65) K Measuring Frequency ( T C3-65) K Testing a Diode or a Diode Wire ( T C3-66) K Wiring Harness Repair ( T C3-67)

C3-1

9813/1800-2 (C-03-09)

C3-1

Section C3 - Electrics Electrical Harness SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Service Tools

ALL

Fuses and Relays

ALL

Schematics

ALL

Section M - Device Harness Interconnections

ALL

Description

892/00298(1)

Fluke Meter 85

AVO 2002

or 892/00350

AVO 2003 (1)

Butane Heater assembly

892/00349(1)

Crimp tool

892/00351(1)

Splice 0.5-1.5 mm (Red)

892/00352

(1)

Splice 1.5-2.5 mm (Blue)

892/00353

(1)

Splice 3.0-6.0 mm (Yellow)

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

C3-2

9813/1800-2 (C-03-09)

C3-2

Section C3 - Electrics Electrical Harness SYSTEM Earth Points

Earth Points K Earth Points ( T C3-4). The illustration shows the machine electrical earth point locations. This can be useful Item

Description

when tracing electrical faults, typically when several electrical devices are malfunctioning. Location

Cables and Straps A

Earth cable, battery to chassis.

Under cab, and battery compartment.

Earth strap, cab to chassis.

Remove external lower front panel from cab.

Earth cable, starter motor to chassis.

Inside engine compartment.

Earth cable, engine block to chassis.

Inside engine compartment, cable bolted to engine at the rear of the cylinder block.

Harness Earths -001

Earth point, chassis harness.

Inside engine compartment.

-003

Earth point, cab harness.

Remove cab instrument panels. Access required to the cab frame on the right side of the steering column.

Earth point, cab rear harness.

Remove cab roof lining.

-004 -006

C3-3

9813/1800-2 (C-03-09)

C3-3

Section C3 - Electrics Electrical Harness SYSTEM Earth Points

Fig 1. Earth Points

C3-4

9813/1800-2 (C-03-09)

C066960-C1

C3-4

Section C3 - Electrics Electrical Harness SYSTEM Wire Numbers and Functions

Wire Numbers and Functions This section details the allocation of wire numbers and the identification of wires in the wiring harness.

Fig 2. Typical Wire and Harness Number K Fig 2. ( T C3-5). 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.

S164111-2

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 C3-5).

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).

C3-5

9813/1800-2 (C-03-09)

C3-5

Section C3 - Electrics Electrical Harness SYSTEM Wire Numbers and Functions

Wires 000-199

Wires 800-999

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

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

– Wires 000 - 099 are allocated to unfused ignition feeds.

Wires In Splices

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 4. ( T C3-6).

Wires 200-399

Note: The letters I, O, Q and S are not used.

– Wires 100 - 199 are allocated to fused ignition feeds.

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.

Wires 600-799 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 3. ( T C3-6). This symbol is printed onto the wire, it may however be omitted from harness drawings.

Fig 3.

Fig 4.

T011680

General Points 1

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.

700050-1

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.

C3-6

9813/1800-2 (C-03-09)

C3-6

C3-7

Refer to Section M - Device Harness Interconnections topic for details of harness interconnections. K Related Topics ( T C3-2)

Interconnections

Harness Interconnections and Drawings

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-7

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings

Harness Identification

For machine, engine and transmission identification refer to Section 1 - Introduction.

Make sure to identify the correct machine specification.

For hydraulic system identification refer to Section ESystems and schematics.

Table 4. Specification Variants - Panel Harness Machine Model Application

Harness Number(1)

506-36 507-42 5CD 5CE K 721/C9292 Issue 3 ( T C3-42)

509-42 5CF

510-56 5CG

512-56 5CH

514-56 5CH

z z

K 721/D9067 Issue 3 ( T C3-35)

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct procedures. Table 5. Specification Variants - Chassis Harness Machine Model Application

Harness Number(1)

506-36 507-42 5CD 5CE K 721/C9295 Issue 3 ( T C3-50)

509-42 5CF

510-56 5CG

512-56 5CH

514-56 5CH

z z

K 721/C9296 Issue 3 ( T C3-53)

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct procedures.

Harness Number(1)

Table 6. Specification Variants - Rear Cab Harness Machine Model Application 514-56 507-42 5CH 5CE

K 721/12005 Issue 2 ( T C3-58)

509-42 5CF

510-56 5CG

512-56 5CH

514-56 5CH

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct procedures.

Harness Number

Table 7. Specification Variants - Stabiliser Harness Machine Model Application 506-36 507-42 5CD 5CE

510-56 5CG

K 332/D7008 Issue 1 ( T C3-20)

C3-8

509-42 5CF

9813/1800-2 (C-03-09)

512-56 5CH

514-56 5CH

C3-8

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings Table 8. Specification Variants - Boom Harness Machine Model Application

Harness Number

506-36 507-42 5CD 5CE

509-42 5CF

K 332/D7010 Issue 1 ( T C3-17)

Harness Number

K 721/12107 Issue 1 ( T C3-18)

509-42 5CF

K 332/D8489 Issue 1 ( T C3-15)

512-56 5CH

514-56 5CJ

509-42 5CF

510-56 5CG

512-56 5CH

514-56 5CJ

509-42 5CF

510-56 5CG

512-56 5CH

514-56 5CJ

512-56 5CH

514-56 5CJ

512-56 5CH

514-56 5CJ

Table 12. Specification Variants - Stabiliser Harness Machine Model Application 506-36 507-42 5CD 5CE

509-42 5CF

510-56 5CG

K 332/D7008 Issue 1 ( T C3-20)

Table 13. Specification Variants - Stabiliser Link Harness Machine Model Application 506-36 507-42 5CD 5CE

509-42 5CF

510-56 5CG

K 332/D7009 Issue 1 ( T C3-21) Table 14. Specification Variants - Transmission Harness Applicability

K 721/C7537 Issue 3 ( T C3-23)

C3-9

Table 11. Specification Variants - RAS Chassis Harness Machine Model Application 506-36 507-42 5CD 5CE

Harness Number

Table 10. Specification Variants - RAS Panel Harness Machine Model Application

K 332/D8490 Issue 1 ( T C3-13)

Harness Number

510-56 5CG

506-36 507-42 5CD 5CE

Harness Number

514-56 5CJ

K 332/D7007 Issue 1 ( T C3-19)

Harness Number

512-56 5CH

Table 9. Specification Variants - Stabiliser/Headlights Harness Machine Model Application 506-36 507-42 5CD 5CE

Harness Number

510-56 5CG

9813/1800-2 (C-03-09)

Gearbox PS750

C3-9

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings Table 15. Specification Variants - Engine Pod Harness Harness Number Engine K 721/C5852 Issue 6 ( T C3-25)

SH, SL, DH

Table 16. Specification Variants - Engine Harness Harness Number Engine K 320/09653 Issue 1 ( T C3-29)

SH, SL, DH

Table 23. Specification Variants - Rear Lights Harness Harness Number Engine K 332/C1776 Issue 1 ( T C3-12)

SH, SL, DH

Table 24. Specification Variants - LiveLink Harness Harness Number Engine K 721/C0140 Issue 1 ( T C3-61)

SH, SL, DH

Table 17. Specification Variants - Starter Motor Harness Harness Number Engine K 721/C7691 Issue 2 ( T C3-32)

SH, SL, DH

Table 18. Specification Variants - Twin Primary Fuse Link Harness Number Engine K 718/E0626 Issue 1 ( T C3-34)

SH, SL, DH

Table 19. Specification Variants - Rear Worklights Harness Number Engine K 332/D8520 Issue 1 ( T C3-22)

SH, SL, DH

Table 20. Specification Variants - Air Filter Link Harness Number Engine K 721/E0800 Issue 1 ( T C3-49)

SH, SL, DH

Table 21. Specification Variants - Grid Heater Fuse Link Lead Harness Number Engine K 718/E0209 Issue 3 ( T C3-56)

SH, SL, DH

Table 22. Specification Variants - Grid Heater Relay to Heater Power lead Harness Number Engine K 718/E0210Issue 3 ( T C3-57)

C3-10

SH, SL, DH

9813/1800-2 (C-03-09)

C3-10

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings

Drawings Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness.

C3-11

9813/1800-2 (C-03-09)

C3-11

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings 332/C1776 Issue 1 K Fig 5. ( T C3-12)

RL001

Chassis Connector

RL002

Left Rear Lamp

RL003

Right Rear Lamp

Key to Connectors:

Fig 5.

332-C1776-1

K 332/C1776 Issue 1 ( T C3-12)

C3-12

9813/1800-2 (C-03-09)

C3-12

C3-13 Ground Speed R/H Feedback Parkbrake RAS Controller J1

PA004 PA005 PA006

Key to Connectors:

PA001

Panel Connector

9813/1800-2 (C-03-09)

K 332/D8490 Issue 1 ( T C3-13)

Fig 6.

RAS Interface 2

PA003

K Fig 6. ( T C3-13)

RAS Interface 1

PA002

332/D8490 Issue 1 PA009

PA008

PA007 CAN Terminator

CAN

RAS Controller J2

332-D8490-1-1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-13

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings

Fig 7.

332-D8490-1-2

K 332/D8490 Issue 1 ( T C3-13)

C3-14

9813/1800-2 (C-03-09)

C3-14

C3-15

Panel Connector

Left RAS Cylinder

Right RAS Cylinder

Sway Switch

Left Stabiliser Switch

Right Stabiliser Switch

Inloader Valve

Ground

Left Stabiliser Link

Right Stabiliser Link

RA001

RA002

RA003

RA004

RA005

RA006

RA007

RA008

RA009

RA010

Key to Connectors:

K Fig 8. ( T C3-16)

332/D8489 Issue 1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-15

Section C3 - Electrics Electrical Harness SYSTEM

C3-16

9813/1800-2 (C-03-09)

K 332/D8489 Issue 1 ( T C3-15)

Fig 8.

332-D8489-1-1

Harness Interconnections and Drawings

C3-16

K Fig 9. ( T C3-17)

332/D7010 Issue 1 B001

C3-17 K 332/D7010 Issue 1 ( T C3-17)

Fig 9.

Proximity Switch

Key to Connectors:

B002

Chassis Harness Connector

332-D7010-1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-17

K Fig 11. ( T C3-19)

721/12107 Issue 1

C3-18 Left Headlight Chassis Harness Connector

RL004 RL005

Right Stabiliser Transducer Left Stabiliser Transducer

RL001 RL002

K 721/12107 Issue 1 ( T C3-18)

Fig 10.

Right Headlight

RL003

Key to Connectors:

d-721-12107(2)

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-18

K Fig 11. ( T C3-19)

332/D7007 Issue 1

C3-19 Left Headlight Chassis Harness Connector

RL004 RL005

Right Stabiliser Transducer Left Stabiliser Transducer

RL001 RL002

9813/1800-2 (C-03-09)

K 332/D7007 Issue 1 ( T C3-19)

Fig 11.

Right Headlight

RL003

Key to Connectors:

332/D7007-1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-19

K Fig 12. ( T C3-20)

332/D7008 Issue 1 Chassis Harness Connector

RL005

RL001

C3-20

9813/1800-2 (C-03-09)

K 332/D7008 Issue 1 ( T C3-20)

Fig 12.

Right Stabiliser Transducer

Left Stabiliser Transducer

RL002

Key to Connectors:

332-D7008-1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-20

K Fig 13. ( T C3-21)

332/D7009 Issue 1 S001

C3-21 K 332/D7009 Issue 1 ( T C3-21)

Fig 13.

Pressure Switch

Key to Connectors:

S002

Stabiliser Harness Connector

332-D7009-1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-21

K Fig 14. ( T C3-22)

332/D8520 Issue 1 L001

C3-22 Fig 14. K 332/D8520 Issue 1 ( T C3-22)

Worklight

Key to Connectors:

L002

Panel Harness Connector

332-D8520-1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-22

C3-23

Reverse High Solenoid

Mainshaft Solenoid

Layshaft Solenoid

Forward Low Solenoid

Forward High Solenoid

4 Wheel Drive Solenoid

T007

T008

T009

T010

Reverse Low Solenoid

T004

T006

Transmission Oil Pressure

T003

T005

Chassis Harness Connector

T001

Key to Connectors:

K Fig 15. ( T C3-24)

721/C7537 Issue 3

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-23

Section C3 - Electrics Electrical Harness SYSTEM

C3-24

9813/1800-2 (C-03-09)

K 721/C7537 Issue 3 ( T C3-23)

Fig 15.

721-C7537-3.eps

Harness Interconnections and Drawings

C3-24

C3-25

9813/1800-2 (C-03-09)

Chassis Harness Connector

Powertrain CANbus Resistor

Transmission Oil Temp

Reversing Fan Solenoid

Proportional Fan Solenoid

Fan Speed Sensor

Grid Heater

E009

E010

E011

E012

E013

E014

E020

Air Con Compressor

TMAF

E008

E025

Lambda Sensor

E007

Air Con Binary Switch 2

Air Filter Vacuum Switch

E006

E024-2

Engine Harness Connector

E005

EcoMax CANbus Resistor

Engine ECU Connector

E004

Air Con Binary Switch 1

Fuel Pump

E003

E024-1

Agglomerator

E002

E023

Fuse/Relay Box

E001

Key to Connectors:

K Fig 16. ( T C3-26)

721/C5852 Issue 6

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-25

Section C3 - Electrics Electrical Harness SYSTEM

C3-26

9813/1800-2 (C-03-09)

K 721/C5852 Issue 6 ( T C3-25)

Fig 16.

721-C5852-6-Sheet 1

Harness Interconnections and Drawings

C3-26

Section C3 - Electrics Electrical Harness SYSTEM

C3-27

9813/1800-2 (C-03-09)

K 721/C5852 Issue 6 ( T C3-25)

Fig 17.

721-C5852-6-Sheet 2

Harness Interconnections and Drawings

C3-27

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings

Fig 18.

721-C5852-6-Sheet 3

K 721/C5852 Issue 6 ( T C3-25)

C3-28

9813/1800-2 (C-03-09)

C3-28

C3-29

9813/1800-2 (C-03-09)

Injector number 4

Fuel Inlet Metering Valve

Engine ECU Connector

CE043

CE044

CE045

Shield Cut End 2

Injector number 3

CE042

CE091

Injector number 2

CE041

Comp in Pressure Sensor

CE026

Injector number 1

Exhaust Temperature Sensor

CE021

Machine Interface Connector

Oil Temperature Sensor

CE020

CE040

Oil Pressure Switch

CE019

CE037

Intercooler Out Temperature Sensor

CE016

HP Fuel Pressure Regulator

Intake Throttle Valve

CE015

CE035

Exhaust Manifold Pressure Sensor

CE011

VGT Actuator

EcoMax CAN Terminator

CE010

CE033

EGR Actuator

CE008

Rail Pressure Sensor

Cam Position Sensor

CE007

Fuel Temperature Sensor

Coolant Temp Sensor

CE006

CE032

Crank Speed Sensor ELTEK

CE005

CE030

TMAP

CE002

CE001B Accelerometer 2

CE001A Accelerometer 1

Key to Connectors:

K Fig 19. ( T C3-30)

320/09653 Issue 1 Shield Cut End 3 Shield Cut End

CE092 CE093

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-29

Section C3 - Electrics Electrical Harness SYSTEM

C3-30

9813/1800-2 (C-03-09)

K 320/09653 Issue 1 ( T C3-29)

Fig 19.

320-09653-1sheet1

Harness Interconnections and Drawings

C3-30

Section C3 - Electrics Electrical Harness SYSTEM

C3-31

9813/1800-2 (C-03-09)

K 320/09653 Issue 1 ( T C3-29)

Fig 20.

320-09653-1sheet2

Harness Interconnections and Drawings

C3-31

K Fig 21. ( T C3-32)

721/C7691 Issue 2

C3-32 Charge Lead W Terminal

ST05 ST06

Chassis Harness Connector Charge Lead

ST01 ST03

9813/1800-2 (C-03-09)

K 721/C7691 Issue 2 ( T C3-32)

Fig 21.

D+ Terminal

ST04

Key to Connectors:

721-C7691-2-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-32

K Fig 22. ( T C3-33)

721/C9280 Issue 1 Hitch Switch

P095

P001

C3-33

9813/1800-2 (C-03-09)

K 721/C9280 Issue 1 ( T C3-33)

Fig 22.

Panel Harness Connector

Rear Auxiliary Switch

P027

Key to Connectors:

721-C9280-1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-33

K Fig 23. ( T C3-34)

718/E0626 Issue 1

Fig 23.

TBA

B003

B001

C3-34

9813/1800-2 (C-03-09)

K 718/E0626 Issue 1 ( T C3-34)

TBA

B002

Key to Connectors:

718-E0626-1-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-34

C3-35

9813/1800-2 (C-03-09)

P023

Air Conditioning switch +ve

Footbrake Face Level Fan +ve

P067

Primary Fuse Grey E & F

P066

P065

Chassis Harness Connector

P020

Primary Fuse Blue G & H

P064

Parkbrake Relay

P019

Diode Gate

P063

Parkbrake Relay

P018

Primary Fuse A & B

Engine Running Relay

P062

P018

Primary Fuse C & D

P061

Roadlamps Relay

P017

Ignition Switch

P060

Brakelights Relay

P017

Ignition Switch

P059

Forward High/Low Relay

P014

R/H Column Switch

P058

Reverse High/Low Relay

P014

Rear Cab Harness Connector

P057

Driveshaft Relay

P013

RHC Connector J2

P056

Drive Relay

P013

RHC Connector J1

P055

Parkbrake Warning Lamp Relay

P012

Centre Cluster Warning Lights

Transmission Dump Relay

P052

P012

Diagnostic Connector

P046

Rear Working Lamps Relay

P011

Info Button

P043

Front Working Lamps Relay

P011

Diode Gate

Ignition Relay 4

P010

P042

Ignition Relay 3

L/H Column Switch

P041

P010

Earth

P040

Reverse Drive Relay

P009

Earth

P039

Ignition Relay 2

P009

Heater Switch

Flasher Relay

P008

P038

Ignition Relay 1

Heater Connector

P037

P006

Indicator Diode

P036

Forward Drive Relay

P006

Stabiliser Isolation Switch

Neutral Start Relay

P005

P034

Secondary Fuse Box D

P004

Beacon Switch

Secondary Fuse Box C

P003 P032

Secondary Fuse Box B

P002

Roadlights Switch

Fog Lamp Switch

P028

Secondary Fuse Box A

P001 Worklamps Switch

Rear Wiper Switch

P027

Key to Connectors:

P030

Roof Wiper Switch

P026

P029

Hazard Switch

P025

K Fig 24. ( T C3-36)

Air Conditioning Switch -ve

P024

721/D9067 Issue 3

Boom Raise Return, Sway/Stab Isolation Return Relay L/H and R/H RAS Return Relay RAS ECU J1 RAS ECU J2 Parkbrake

P105 P106 P107 P109

Hour Meter Signal

Hour Meter -ve

Hour Meter +ve

Hydraulic Isolation Switch

Immobiliser Link

Immobiliser

Engine Supply

Terminating Resistor

Worklamps

Radio

Auxiliary Socket Illumination

Auxiliary Socket

Front Wiper Motor

Spare

Washer Pump

Face Level Fan -ve

P101

P100

P099

P098

P097

P094

P093

P092

P091

P088

P082

P078

P077

P076

P071

P069

P068

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-35

Section C3 - Electrics Electrical Harness SYSTEM

C3-36

9813/1800-2 (C-03-09)

K 721/D9067 Issue 3 ( T C3-35)

Fig 24.

721-D9067-3-SHT1

Harness Interconnections and Drawings

C3-36

Section C3 - Electrics Electrical Harness SYSTEM

C3-37

9813/1800-2 (C-03-09)

K 721/D9067 Issue 3 ( T C3-35)

Fig 25.

721-D9067-3-SHT2

Harness Interconnections and Drawings

C3-37

Section C3 - Electrics Electrical Harness SYSTEM

C3-38

9813/1800-2 (C-03-09)

K 721/D9067 Issue 3 ( T C3-35)

Fig 26.

721-D9067-3-SHT3

Harness Interconnections and Drawings

C3-38

Section C3 - Electrics Electrical Harness SYSTEM

C3-39

9813/1800-2 (C-03-09)

K 721/D9067 Issue 3 ( T C3-35)

Fig 27.

721-D9067-3-SHT4

Harness Interconnections and Drawings

C3-39

Section C3 - Electrics Electrical Harness SYSTEM

C3-40

9813/1800-2 (C-03-09)

K 721/D9067 Issue 3 ( T C3-35)

Fig 28.

721-D9067-3-SHT5

Harness Interconnections and Drawings

C3-40

Section C3 - Electrics Electrical Harness SYSTEM

C3-41

9813/1800-2 (C-03-09)

K 721/D9067 Issue 3 ( T C3-35)

Fig 29.

721-D9067-3-SHT6

Harness Interconnections and Drawings

C3-41

C3-42

Rear Working Lamps Relay

Transmission Dump Relay

Parkbrake Warning Lamp Relay

Drive Relay

Driveshaft Relay

Reverse High/Low Relay

Forward High/Low Relay

Brakelights Relay

Roadlamps Relay

Engine Running Relay

Parkbrake Relay

Parkbrake/2 Wheel Drive Relay

Stabiliser Isolation Relay

P011

P012

P013

9813/1800-2 (C-03-09)

P014

P017

P018

P019

P020

Chassis Harness Connector

Primary Fuse C&D Primary Fuse A&B Diode Gate Primary Fuse Blue G&H

P061 P062 P063 P064

Footbrake

Ignition Switch

P060

P066

Ignition Switch

P059

Primary Fuse Grey E&F

R/H Column Switch

P058

P065

RHC Connector J2

P055 Rear Cab Harness Connector

RHC Connector J1

P052

P057

Centre Cluster Warning Lights

P046

P056

Info Button Diagnostic Connector

P043

Diode Gate

P042

Front Working Lamps Relay

P011

L/H Column Switch

Ignition Relay 4

P010

P041

Ignition Relay 3

Earth

P040

P010

Earth

P039

Reverse Drive Relay

P009

Heater Switch

P038

Ignition Relay 2

P009

Heater Connector

Flasher Relay

P008

P037

Ignition Relay 1

Indicator Diode

P036

P006

Stabiliser Isolation Switch

P034

Forward Drive Relay

P006

Beacon Switch

P032

Neutral Start Relay

P005

Worklamps Switch

Secondary Fuse Box D

P004

P030

Secondary Fuse Box C

P003

Fog Lamp Switch

Secondary Fuse Box B

P002 Roadlights Switch

Rear Wiper Switch

P027

Secondary Fuse Box A

P001 P029

Roof Wiper Switch

P026

Key to Connectors: P028

Air Conditioning Switch -ve Hazard Switch

K Fig 30. ( T C3-43) P025

Air Conditioning switch +ve

P023 P024

721/C9292 Issue 3

P106

P105

P104

P103

P102

P101

P100

P099

P098

P097

P094

P093

P092

P091

P088

P082

P078

P077

P076

P071

P069

P068

P067

Ground Speed

RAS LH/RH Relay

RAS Link 2

RAS Link 1

RAS Interface 2

RAS Interface 1

Hour Meter Signal

Hour Meter -ve

Hour Meter +ve

Hydraulic Isolation Switch

Immobiliser Link

Immobiliser

Engine Supply

Terminating Resistor

Worklamps

Radio

Auxiliary Socket Illumination

Auxiliary Socket

Front Wiper Motor

Spare

Washer Pump

Face Level Fan -ve

Face Level Fan +ve

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-42

Section C3 - Electrics Electrical Harness SYSTEM

C3-43

9813/1800-2 (C-03-09)

K 721/C9292 Issue 3 ( T C3-42)

Fig 30.

721-C9292-3-SHT1

Harness Interconnections and Drawings

C3-43

Section C3 - Electrics Electrical Harness SYSTEM

C3-44

9813/1800-2 (C-03-09)

K 721/C9292 Issue 3 ( T C3-42)

Fig 31.

721-C9292-3-SHT2

Harness Interconnections and Drawings

C3-44

Section C3 - Electrics Electrical Harness SYSTEM

C3-45

9813/1800-2 (C-03-09)

K 721/C9292 Issue 3 ( T C3-42)

Fig 32.

721-C9292-3-SHT3

Harness Interconnections and Drawings

C3-45

Section C3 - Electrics Electrical Harness SYSTEM

C3-46

9813/1800-2 (C-03-09)

K 721/C9292 Issue 3 ( T C3-42)

Fig 33.

721-C9292-3-SHT4

Harness Interconnections and Drawings

C3-46

Section C3 - Electrics Electrical Harness SYSTEM

C3-47

9813/1800-2 (C-03-09)

K 721/C9292 Issue 3 ( T C3-42)

Fig 34.

721-C9292-3-SHT5

Harness Interconnections and Drawings

C3-47

Section C3 - Electrics Electrical Harness SYSTEM

C3-48

9813/1800-2 (C-03-09)

K 721/C9292 Issue 3 ( T C3-42)

Fig 35.

721-C9292-3-SHT6

Harness Interconnections and Drawings

C3-48

K Fig 36. ( T C3-49)

721/E0800 Issue 1 L001

C3-49 Fig 36. K 721/E0800 Issue 1 ( T C3-49)

Air Filter

Key to Connectors:

L002

Engine Harness

721-E0080-1-SHEET

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-49

C3-50

R/H headlight

L/H Headlight

Accelerator

Engine Supply

Starter Motor

Stabiliser Isolation Valve

Chassis Harness to Panel Harness Connector

Chassis Earth

Fuel Level Sender

Transmission Speed Sensor

Rear Lights

Transmission Connector

Transmission Dump

Horn

Reverse Alarm

Hydraulic Isolation

Engine Pod Harness Connector

Starter Motor Solenoid

C001

C002

C003

C004

C005

C006

C007

C008

C010

C011

C013

C014

C015

C016

C017

C018

C032

C033

Key to Connectors:

K Fig 37. ( T C3-51)

721/C9295 Issue 3

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-50

Section C3 - Electrics Electrical Harness SYSTEM

C3-51

9813/1800-2 (C-03-09)

K 721/C9295 Issue 3 ( T C3-50)

Fig 37.

721-C9295-3-SHT1

Harness Interconnections and Drawings

C3-51

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings

Fig 38.

721-C9295-3-SHT2

K 721/C9295 Issue 3 ( T C3-50)

C3-52

9813/1800-2 (C-03-09)

C3-52

C3-53

9813/1800-2 (C-03-09)

Left Stabiliser Switch

Stabiliser Isolation Valve

Engine Pod Harness Connector

Starter Motor Solenoid

C032

C033

Left RAS Ram

C021

C029

Right RAS Ram

C020

C027

60ยบ Proximity Switch

C019

Right Stabiliser Switch

Hydraulic Isolation

C018

C026

Reverse Alarm

C017

Sway Switch

Horn

C016

C025

Transmission Dump

C015

Boom Extend Proximity Switch

Transmission Connector

C014

Lift Isolation Solenoid

Rear Lights

C013

C024

Transmission Speed Sensor

C011

C023

45ยบ Proximity Switch

Fuel Level Sender

C010

Chassis Earth

C008

C009

Starter Motor

Chassis Harness to Panel Harness Connector

Engine Supply

C004

C007

Accelerator

C003

C005

Front Chassis Connector

C001

Key to Connectors:

K Fig 39. ( T C3-54)

721/C9296 Issue 3

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

C3-53

Section C3 - Electrics Electrical Harness SYSTEM

C3-54

9813/1800-2 (C-03-09)

K 721/C9296 Issue 3 ( T C3-53)

Fig 39.

721-C9296-3-SHT1

Harness Interconnections and Drawings

C3-54

Section C3 - Electrics Electrical Harness SYSTEM Harness Interconnections and Drawings

Fig 40.

721-C9296-3-SHT2

K 721/C9296 Issue 3 ( T C3-53)

C3-55

9813/1800-2 (C-03-09)

C3-55

Section C3 - Electrics Electrical Harness SYSTEM

K 718/E0209 Issue 3 ( T C3-56).

TBA CS5 Key to Connectors:

TBA

718/E0209 Issue 3

CS1

Fig 41.

718-E0209

Harness Interconnections and Drawings

C3-56

9813/1800-2 (C-03-09)

C3-56

Section C3 - Electrics Electrical Harness SYSTEM

K 718/E0210Issue 3 ( T C3-57).

TBA C002 Key to Connectors:

TBA

718/E0210Issue 3

C001

Fig 42.

718-E0210-1

Harness Interconnections and Drawings

C3-57

9813/1800-2 (C-03-09)

C3-57

C3-58

Interior Light (-ve)

Park Brake Switch

AK2

Beacon

Interior Light (+ve)

Earth

AK1

Worklight LH

Worklight RH

Rear Wiper

Roof Wiper

Air Suspension Seat

Heated Seat

Cab/Panel Harness Connector

Key to Connectors:

K Fig 43. ( T C3-59)

721/12005 Issue 2

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-58

Section C3 - Electrics Electrical Harness SYSTEM

C3-59

9813/1800-2 (C-03-09)

K 721/12005 Issue 2 ( T C3-58)

Fig 43.

721-12005-1-1

Harness Interconnections and Drawings

C3-59

Section C3 - Electrics Electrical Harness SYSTEM

C3-60

9813/1800-2 (C-03-09)

K 721/12005 Issue 2 ( T C3-58)

Fig 44.

721-12005-1-2

Harness Interconnections and Drawings

C3-60

C3-61

CANbus

Ignition Supply

Battery Fuse + VE

Battery Fuse - VE

Battery + VE

Battery - VE

LL002

LL003

LL004

LL005

LL006

LL007

LiveLink ECU

LL001

Key to Connectors:

721/C0140 Issue 1

Section C3 - Electrics

Electrical Harness SYSTEM

Harness Interconnections and Drawings

9813/1800-2 (C-03-09)

C3-61

Section C3 - Electrics Electrical Harness SYSTEM

C3-62

9813/1800-2 (C-03-09)

K 721/C0140 Issue 1 ( T C3-61).

Fig 45.

721-C0140-1

Harness Interconnections and Drawings

C3-62

Section C3 - Electrics Electrical Harness SYSTEM Test Procedures

Test Procedures How to Use a Multimeter 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 47. AVO 2003

Fig 46. FLUKE 85

S153070-1

Fig 48. A Typical Analogue Meter

C3-63

A171900-1

A171890-1

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 ‘Ω’.

When making measurements ensure that the test probes have a good clean contact with bare metal,

9813/1800-2 (C-03-09)

C3-63

Section C3 - Electrics Electrical Harness SYSTEM Test Procedures free from grease, dirt, and corrosion as these can cause a false reading. 3

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.

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

Measuring DC Voltage

On the FLUKE 85. i

Select the correct range on the multimeter. a

On the FLUKE 85. Turn the switch to position 46-B.

b On the AV0 2003. Move the right slider switch to position 47-A, and the left hand slider switch to the appropriate range. c

b On the AV0 2003. i

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.

C3-64

Turn the switch to position 46-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 46-G to change the reading to ÎŠ. Touch the meter lead probes together and press the REL3 key on the meter to eliminate the lead resistance from the meter reading.

9813/1800-2 (C-03-09)

Move the right hand slider switch to position 47-B, and the left hand slider switch to the appropriate Ohms (ÎŠ) range.

On an analogue meter. i

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

C3-64

Section C3 - Electrics Electrical Harness SYSTEM Test Procedures

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 46-J.

Turn the selector switch to position 46-A and depress 46-G repeatedly until 46-F is highlighted on the top row of the display.

Press button 46-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 46-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 46-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 47-B, and the left hand slider switch to position 47-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.

C3-65

9813/1800-2 (C-03-09)

C3-65

Section C3 - Electrics Electrical Harness SYSTEM Test Procedures

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 kΩ, 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 46-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 300-400Ω, 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 47-A, and the left hand slider switch to position 47-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.

C3-66

9813/1800-2 (C-03-09)

C3-66

Section C3 - Electrics Electrical Harness SYSTEM Wiring Harness Repair

Wiring Harness Repair

!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 25. 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 25. ( T C3-67), 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 49.

ELEC-2-2

C3-67

S744080

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 49. ( T C3-67). Note that each of the splices detailed is colour-coded to make size and range

9813/1800-2 (C-03-09)

C3-67

Section C3 - Electrics Electrical Harness SYSTEM 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 50. ( T C3-68). a

seal

the

Remove the cap 51-A from the end of the disposable gas cartridge 51-B.

Fig 52.

S189490-3

d Turn the small ring 53-E so that the air holes at 53F are completely closed. Fig 50.

S189490-1

b Before assembling the gas cartridge to the reflector element 52-C, turn the red ring 52-D to the left, (in the direction of the minus sign marked on the ring).

Fig 53. e Fig 51. c

C3-68

S189490-2

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 52. ( T C3-68). A click will be heard.

S189490-4

Turn the red ring 54-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.

9813/1800-2 (C-03-09)

C3-68

Section C3 - Electrics Electrical Harness SYSTEM Wiring Harness Repair i

Fig 54. f

Side wings 56-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).

S189490-5

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Fig 56.

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 55-E until the air holes at 55-F are completely open. The tool is ready for use.

S189490-7

Side wings 57-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 57.

S189490-8

h To switch off the heater, turn the red ring 57-D to the left (in the direction of the minus sign). Fig 55.

S189490-6

g The heater can be used in two modes:

C3-69

9813/1800-2 (C-03-09)

C3-69

Section C3 - Electrics Electrical Harness SYSTEM Wiring Harness Repair

Page left intentionally blank

C3-70

9813/1800-2 (C-03-09)

C3-70

Section C4 - Electrics

Battery Charging SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T C4-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T C4-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T C4-2) K Specifications ( T C4-3) K Operation Overview ( T C4-4) K Electrical and Electronic Systems ( T C4-6) K Test Procedures ( T C4-7) K Charging Circuit Test ( T C4-7) K Alternator Charging Test ( T C4-8)

C4-1

C-01-05 Issue 01

C4-1

Section C4 - Electrics Battery Charging SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Cab

Instrument Panels

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Alternator

ALL

Battery

ALL

Applications

ALL

Description

892/00298

Fluke Meter 85

892/00285

100 amp Shunt

(1) (1)

AVO 2002 AVO 2003 (1) Tool available from JCB Service, refer to Section 1 - Service Tools

C4-2

C-01-05 Issue 01

C4-2

Section C4 - Electrics Battery Charging SYSTEM Specifications

Specifications

C4-3

System Type

12 Volt, negative earth

Battery (Single installation)

For battery specification refer to the Battery specification label.

Alternator

95 Amp nominal output

C-01-05 Issue 01

C4-3

Section C4 - Electrics Battery Charging SYSTEM Operation Overview

Operation Overview

C080330

Fig 1. Item

Description

Item

Description

Alternator

LMS Display Panel

Front End Accessory Drive Belt (FEAD)

Battery

Centre Display Panel

C4-4

C-01-05 Issue 01

C4-4

Section C4 - Electrics Battery Charging SYSTEM Operation Overview The positive terminal of the battery is connected to the machine primary fuses, the starter motor and alternator. two connections supply primary fuses. The negative terminal of the battery is connected to the chassis of the machine to provide an “earth” for the electrical systems and devices. When the engine is running the front end accessory drive belt (FEAD) drives the alternator. The power generated keeps the battery charged which in turn feeds all the electrical devices and systems. At the rear of the alternator are three terminals. – The W terminal supplies a signal to the loadall monitoring system (LMS). – The D+ terminal supplies a splice which supplies power to the LMS ECU and the centre warning light cluster. If there is a charging fault this signal will operate a warning light on the centre display panel. – The B+ terminal returns the charge to the battery via a common connection on the starter motor relay switch terminal.

Fig 2.

C4-5

C066910

C-01-05 Issue 01

C4-5

Section C4 - Electrics Battery Charging SYSTEM Electrical and Electronic Systems

Electrical and Electronic Systems For details about electrical and electronic systems refer to Section M- Applications. K Related Topics ( T C4-2)

C4-6

C-01-05 Issue 01

C4-6

Section C4 - Electrics Battery Charging SYSTEM Test Procedures

Test Procedures Charging Circuit Test 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.

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.

Fig 3.

'Oil pressure' and 'No charge' warning lights should glow. If any light fails, K Check 1 ( T C4-7). 4

Start the engine; all warning lights should extinguish rapidly. If the 'No charge' warning light remains ON, K Check 2 ( T C4-7).

322680-1-C1.eps

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.

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 for blown filament. 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 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 still fails to light, check the cable for continuity. If the bulb now lights, check the alternator for a defective regulator. K Alternator Charging Test ( T C4-8)

C4-7

C-01-05 Issue 01

Fig 4.

332690-1

If the voltage is correct, check the alternator. K Alternator Charging Test ( T C4-8)

C4-7

Section C4 - Electrics Battery Charging SYSTEM Test Procedures

Alternator Charging Test

AVO 2002

– Red lead to volts (middle) socket on meter. – Black lead to negative on meter. – RH slider to DC voltage. – LH slider. K Fig 5. ( T C4-8).

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.

Fig 5. 1

S08346-1

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, turn off the engine and switch on the lights for 3 minutes before commencing the test.

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.

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.

Defective regulator.

d Defective rectifier.

Connect the leads to the meter and set the meter to the relevant range as follows.

C4-8

Start the engine and run at maximum speed. Meter should show maximum alternator output in Amps (see K Specifications ( T C4-3)).

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.

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

C-01-05 Issue 01

C4-8

Section C5 - Electrics

Alternator (C-04-02) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T C5-2) K Specifications ( T C5-3) K Electrical Operation and Schematics ( T C5-4) K Removal, Inspection and Replacement ( T C5-5) K Removal ( T C5-5) K Inspection ( T C5-5) K Replacement ( T C5-6)

C5-1

C-04-02 Issue 01

C5-1

Section C5 - Electrics Alternator (C-04-02) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Care and Safety

ALL

Routine Maintenance

ALL

Battery Charging SYSTEM

ALL

C5-2

C-04-02 Issue 01

C5-2

Section C5 - Electrics Alternator (C-04-02) Specifications

Specifications Type

12V 95amp Alternator

No Load Speed

1100 rpm

Maximum Speed Permanent

15000 rpm

Intermittent

18000 rpm

Weight

5.7 Kg

C5-3

C-04-02 Issue 01

C5-3

Section C5 - Electrics Alternator (C-04-02) Electrical Operation and Schematics

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

electrical demand. The rectifier converts the AC output from the alternator to a DC supply for the machine battery.

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. When the engine is started, the engine driven accessory drive 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 and rectifier. The regulator varies the field current in accordance with

Key

K Fig 1. ( T C5-4)

Voltage Regulator

B+

B+ Alternator Terminal

Rectifier

D-

D- Alternator Terminal

Alternator Windings

Lamp Terminal (Replaces D+)

W Alternator Terminal

L L

Fig 1.

C5-4

C-04-02 Issue 01

C119590

C5-4

Section C5 - Electrics Alternator (C-04-02) Removal, Inspection and Replacement

Removal, Inspection and Replacement The alternator assembly is non serviceable. If the alternator is defective replace it with a new or exchange item.

A 743750-C1

B 743750-C1

Fig 2.

Removal

K Fig 2. ( T C5-5) and K Fig 3. ( T C5-6) 1

Inspection

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T C5-2)

Disconnect the negative (-) lead followed by the positive (+) lead from the battery terminals.

Remove the alternator (accessory) drive belt, see Section 3 - Routine Maintenance. K Related Topics ( T C5-2).

Disconnect the electrical leads from the alternator terminals L, B+ and W. Label the leads to ensure they are refitted in the correct positions on assembly.

C5-5

Undo the bolts A and B. Lift the alternator away from the cylinder block mounting.

C-04-02 Issue 01

Check the brushes for wear. Renew the alternator if the length is less than 8 mm (0.3 in).

C5-5

Section C5 - Electrics Alternator (C-04-02) Removal, Inspection and Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – It is not necessary to adjust the position of the alternator in order to tension the drive belt, as the accessory drive belt arrangement is self-tensioning. – Torque tighten bolts A and B, K Table 2. Torque Settings ( T C5-6). – Be sure to reconnect the electrical leads to the alternator in the correct positions. Clean the connections and torque tighten the nuts.

C119590-C1

Fig 3.

Item A, B

Table 2. Torque Settings Nm kgf m

lbf ft

TBA

9 - 13

0.9 - 1.3

6.6 - 9.5

2.7 - 3.8

0.3 - 0.38

2 - 2.8

2.7 - 3.8

0.3 - 0.38

2 - 2.8

B+

C5-6

C-04-02 Issue 01

C5-6

Section C6 - Electrics Battery Introduction

Battery Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T C6-2) K Specifications ( T C6-3) K Maintenance ( T C6-4) K Test Procedures ( T C6-7) K High Rate Discharge Test ( T C6-7) K Specific Gravity Testing ( T C6-8) K Disconnection and Connection ( T C6-9) K Removal and Replacement (S1) ( T C6-10)(1) K Removal and Replacement (S2) ( T C6-11)(1) K Removal and Replacement (S3) ( T C6-12)(1) (1) Procedure variant. Make sure you refer to the correct procedure.

Procedures(1)

Table 1. Procedure Variants Machine Model Application 527-58

K Removal and Replacement (S1) ( T C6-10)

531-70, 531-T70, 535-95, 535T95, 536-60, 536-T60, 541-70, 541-T70, 533-105, 536-70, 536T70, 550-80, 540-170, 550-170, 540-140, 550-140, 535-125 HiViz, 535-140 HiViz, 540-200, 526-56

506-36, 507-42, 509-42, 510-56, 512-56, 514-56,

z z

K Removal and Replacement (S2) ( T C6-11)

K Removal and Replacement (S3) ( T C6-12)

(1) The table lists procedure variants and the applicable machine models. Use the table to make sure you refer to the correct information.

C6-1

C-05-04 Issue 02

C6-1

Section C6 - Electrics Battery Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Routine Maintenance

ALL (1)

ALL Electrics

(1) You must obey all of the relevant care and safety procedures. Table 3. Service Tools The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number

Description

993/85700

Battery Tester

(1)

Hydrometer (1) Tool available from JCB Service, refer to Section 1 - Service Tools

C6-2

C-05-04 Issue 02

C6-2

Section C6 - Electrics Battery Specifications

Specifications Battery

C6-3

- Cold crank amps for 30 seconds at 1.2 volts per cell or 1000 cca higher at -18 0C (0 0F)

C-05-04 Issue 02

C6-3

Section C6 - Electrics Battery Maintenance

Maintenance To ensure that the battery provides optimum performance the following steps should be observed: 1

Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.

When applicable - never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates. Use only distilled water for topping up.

Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) - this condition makes recharging the battery very difficult.

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: â&#x20AC;&#x201C; Never boost-charge a maintenance free battery. â&#x20AC;&#x201C; Never charge a maintenance free battery at a voltage in excess of 15.8 Volts. â&#x20AC;&#x201C; Never continue to charge a maintenance free battery after it begins to gas.

C6-4

C-05-04 Issue 02

C6-4

Section C6 - Electrics Battery Maintenance

!MCAUTION

Battery

!MWARNING

T3-061

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.

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

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

C6-5

C-05-04 Issue 02

C6-5

Section C6 - Electrics Battery Maintenance Warning Symbols

First Aid - Electrolyte

The following warning symbols may be found on the battery.

Do the following if electrolyte: Gets into your eyes

Symbol

Meaning

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

Keep away from children.

Is swallowed A289230-1

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

Shield eyes.

Gets onto your skin

A289260-1

No smoking, no naked flames, no sparks.

Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

C6-6

C-05-04 Issue 02

C6-6

Section C6 - Electrics Battery Test Procedures

Test Procedures High Rate Discharge Test

Note: Do not hold the switch in the LOAD position for more than 10 seconds.

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 (Test the specific gravity which should be 1.23 to 1.25 for ambient temperature up to 27°C). K Specific Gravity Testing ( T C6-8) Ensure that the battery is completely disconnected from the machine.

Check the results against the table: Table 4. Tester Readings and Remedies Battery Tester Readings Remedy CHECK: 0 - 12.6 volts

Renew battery

LOAD: Less than 6 volts CHECK: 6 - 12.4 volts

Recharge and re-test. If LOAD: less than 9 Volts and tests still unsatisfactory falls steadily but remains in renew battery. yellow zone. CHECK: less than 10 volts LOAD: Less than 3 volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

CHECK: more than 11 volts Charge battery which will probably recover. LOAD: 6 - 10 volts

Fig 1. Battery Tester

C096270

Check: 1

Connect the battery tester to the battery. Ensure that the positive terminal is connected first.

Use rocker switch A to select the correct battery voltage.

Hold switch B to the ‘Check’ position. The battery noload voltage should be at least 12.4 volts.

Test: 1

Hold down switch B to the ‘Load’ position for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

C6-7

C-05-04 Issue 02

C6-7

Section C6 - Electrics Battery Test Procedures

Specific Gravity Testing The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15°C (60°F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing.

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15°C (60°F) a 'correction factor' must be applied to the reading obtained. Add 0.07 per 10°C (18°F) if the temperature is higher than 15°C (60°F) and subtract the same if the temperature is lower.

Table 5. 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

C6-8

C-05-04 Issue 02

C6-8

Section C6 - Electrics Battery Disconnection and Connection

Disconnection and Connection Refer to Section 3 - Routine Maintenance. K Related Topics ( T C6-2)

C6-9

C-05-04 Issue 02

C6-9

Section C6 - Electrics Battery Removal and Replacement (S1)

Removal and Replacement (S1)

!MCAUTION

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

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

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

INT-3-1-9

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T C6-2)

Remove the hand nuts 5 and battery cover 4.

Follow the procedure for disconnection of the battery, refer to Section 3 - Routine Maintenance. K Related Topics ( T C6-2)

Make sure that all battery connection wires are clear of battery top cover.

Disconnect battery clamp 2 by removing handnuts 1.

Lift clamp 2 clear of battery 3.

Remove battery 3 from compartment ensuring that you do not use the access cover to support the weight of the battery.

Fig 2.

Replacement

C131520.eps

Replacement is the opposite of the removal procedure.

C6-10

C-05-04 Issue 02

C6-10

Section C6 - Electrics Battery Removal and Replacement (S2)

Removal and Replacement (S2)

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

!MWARNING Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T C6-2)

Get access to the battery - refer to Section 3 Routine Maintenance. K Related Topics ( T C6-2)

Follow the procedure for disconnection of the battery, refer to Section 3 - Routine Maintenance. K Related Topics ( T C6-2)

Make sure that all battery connection wires are clear of battery top cover.

Disconnect battery clamp 2 by removing handnuts 1.

Lift clamp 2 clear of battery 3.

Remove battery 3 from compartment ensuring that you do not use the access cover to support the weight of the battery.

Fig 3.

C131530.eps

Replacement Replacement is the opposite of the removal procedure.

C6-11

C-05-04 Issue 02

C6-11

Section C6 - Electrics Battery Removal and Replacement (S3)

Removal and Replacement (S3)

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

INT-3-1-9

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T C6-2)

Get access to the battery - refer to Section 3 Routine Maintenance. K Related Topics ( T C6-2)

Follow the procedure for disconnection of the battery, refer to Section 3 - Routine Maintenance. K Related Topics ( T C6-2)

Make sure that all battery connection wires are clear of battery top cover.

Disconnect battery clamp 3 by removing handnuts 2.

Lift clamp 3 clear of battery 1.

Remove battery 1 from compartment ensuring that you do not use the access cover to support the weight of the battery.

2 3

Fig 4.

C131540.eps

Replacement Replacement is the opposite of the removal procedure.

C6-12

C-05-04 Issue 02

C6-12

Section E Hydraulics Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813-1800-2

Section E - Hydraulics

Notes:

E-0

9813-1800-2

E-0

Section E - Hydraulics Contents Page No. Applications Table ....................................................................................................... E0-1 Systems and Schematics Introduction ............................................................................................. Related Topics ........................................................................................ Systems .................................................................................................. Schematics .............................................................................................

E1-1 E1-2 E1-3 E1-7

Parallel Hydraulic SYSTEM (E-01-32) Introduction ............................................................................................. E2-1 Related Topics ........................................................................................ E2-2 Specifications ......................................................................................... E2-3 Operation Overview ................................................................................ E2-9 Fault Finding ......................................................................................... E2-16 Test Procedures .................................................................................... E2-17 LSP Hydraulic SYSTEM (E-01-31) Introduction ............................................................................................. E3-1 Related Topics ........................................................................................ E3-2 Specifications ......................................................................................... E3-3 Operation Overview ................................................................................ E3-7 Fault Finding .......................................................................................... E3-11 Test Procedures .................................................................................... E3-12 Parallel Circuit Operation (E-60-01) Introduction ............................................................................................. E4-1 Related Topics ........................................................................................ E4-2 Descriptions ............................................................................................ E4-3 LSP Circuit Operation (E-60-12) Introduction ............................................................................................. E5-1 Related Topics ........................................................................................ E5-2 Descriptions ............................................................................................ E5-3 Main Relief Valve (MRV)/Load Sense Relief Valve (LSRV) Operation Introduction ............................................................................................. E6-1 Related Topics ........................................................................................ E6-2 Operation Overview ................................................................................ E6-3 Auxiliary Relief Valve (ARV) Operation Introduction ............................................................................................. E7-1 Related Topics ........................................................................................ E7-2 Operation Overview ................................................................................ E7-3 Parallel Lift Operation (E-60-05) Introduction ............................................................................................. Related Topics ........................................................................................ Parallel Lift (S1) ...................................................................................... Parallel Lift (S2) ......................................................................................

E8-1 E8-2 E8-3 E8-6

Boom Pressure Balance SYSTEM Introduction ............................................................................................. E9-1 Related Topics ........................................................................................ E9-2 Lift Pressure Balance System (S1) ......................................................... E9-3

E-i

Section E - Hydraulics Contents Page No. Lift Pressure Balance System (S2) ......................................................... E9-5 Tilt/Lift/Extension Ram Counterbalance Valves (S1) ............................ E9-10 Extension Ram Counterbalance Valves (S2) ....................................... E9-14 Universal Hydraulic Circuit Faults Introduction ........................................................................................... E10-1 Related Topics ...................................................................................... E10-2 Fault Finding ......................................................................................... E10-3 Parallel Circuit Faults Introduction ............................................................................................ E11-1 Related Topics ....................................................................................... E11-2 Fault Finding .......................................................................................... E11-3 Flowshare Servo Circuit Faults Introduction ........................................................................................... E12-1 Related Topics ...................................................................................... E12-2 Fault Finding ......................................................................................... E12-3 Hydraulic SYSTEM Pressure Tests (E-61-12) Introduction ........................................................................................... E13-1 Related Topics ...................................................................................... E13-2 Test Procedures .................................................................................... E13-3 Pump Flow Tests - Gearpump (E-61-03) Introduction ........................................................................................... E14-1 Related Topics ...................................................................................... E14-2 Checking Pump Flow ............................................................................ E14-3 Flowshare Control Valve Introduction ........................................................................................... E15-1 Related Topics ...................................................................................... E15-2 Component Location ............................................................................ E15-3 Hydraulic Operation and Schematics ................................................... E15-4 Removal and Replacement .................................................................. E15-7 Dismantle and Assemble .................................................................... E15-10 Parallel Control Valve - 2 Section Introduction ........................................................................................... Related Topics ...................................................................................... Hydraulic Operation and Schematics ................................................... Removal ............................................................................................... Replacement ........................................................................................ Dismantle and Assemble ......................................................................

E16-1 E16-2 E16-3 E16-4 E16-5 E16-6

Parallel Control Valve - 5 Section Introduction ........................................................................................... Related Topics ...................................................................................... Hydraulic Operation and Schematics ................................................... Removal and Replacement .................................................................. Dismantle and Assemble ......................................................................

E17-1 E17-2 E17-3 E17-5 E17-7

Pilot Pressure Supply Valve Introduction ........................................................................................... E18-1 Related Topics ...................................................................................... E18-2

E-ii

Section E - Hydraulics Contents Page No. Operation Overview .............................................................................. E18-3 Hydraulic Operation and Schematics ................................................... E18-4 Electrical Operation and Schematics .................................................... E18-6 Removal and Replacement .................................................................. E18-7 Servo Control Valves Introduction ........................................................................................... E19-1 Related Topics ...................................................................................... E19-2 Removal and Replacement .................................................................. E19-3 Gearpump Operation Introduction ........................................................................................... Related Topics ...................................................................................... Component Location ............................................................................ Operation Overview .............................................................................. Hydraulic Operation and Schematics ...................................................

E20-1 E20-2 E20-3 E20-4 E20-6

Gearpump Removal and Replacement Introduction ........................................................................................... E21-1 Related Topics ...................................................................................... E21-2 Removal and Replacement .................................................................. E21-3 Dismantle, Inspection and Assemble ................................................... E21-5 Steering Priority Valve ........................................................................ E21-12 Hydraulic Cooling Fan Motor - Fixed Speed Introduction ........................................................................................... Related Topics ...................................................................................... Specifications ....................................................................................... Operation Overview .............................................................................. Removal and Replacement .................................................................. Dismantle, Inspection and Assemble ...................................................

E22-1 E22-2 E22-3 E22-4 E22-5 E22-7

Extension Ram Introduction ........................................................................................... E23-1 Related Topics ...................................................................................... E23-2 Removal and Replacement .................................................................. E23-3 Lift Rams Introduction ........................................................................................... E24-1 Related Topics ...................................................................................... E24-2 Removal and Replacement .................................................................. E24-3 Tilt Ram Introduction ........................................................................................... E25-1 Related Topics ...................................................................................... E25-2 Removal and Replacement .................................................................. E25-3 Displacement Ram Introduction ........................................................................................... E26-1 Related Topics ...................................................................................... E26-2 Removal and Replacement .................................................................. E26-3 Sway Ram Introduction ........................................................................................... E27-1 Related Topics ...................................................................................... E27-2

E-iii

Section E - Hydraulics Contents Page No. Removal and Replacement .................................................................. E27-3 Stabiliser Rams Introduction ........................................................................................... E28-1 Related Topics ...................................................................................... E28-2 Removal and Replacement .................................................................. E28-3 RAS Rams Introduction ........................................................................................... Related Topics ...................................................................................... Removal and Replacement .................................................................. Dismantle and Assembly ......................................................................

E29-1 E29-2 E29-3 E29-5

Ram Maintenance Introduction ........................................................................................... E30-1 Related Topics ...................................................................................... E30-2 Operation Overview .............................................................................. E30-3 Single Piston Rams .............................................................................. E30-6 Piston Head Retention ......................................................................... E30-11 Twin Piston, 4 Stage Boom Outer Ram .............................................. E30-12 Extension Ram Make-Up Valve (if fitted) ............................................ E30-21 Sway Circuit - Bleed Procedure Introduction ........................................................................................... E31-1 Related Topics ...................................................................................... E31-2 Bleed Procedure ................................................................................... E31-3

E-iv

Section E0 - Hydraulics Applications Table

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref Title

VARIANT

Systems and Schematics

Parallel Hydraulic SYSTEM (E-0132)

LSP Hydraulic SYSTEM (E-01-31)

Parallel Circuit Operation (E-60-01)

LSP Circuit Operation (E-60-12)

MRV/LSRV Operation

ARV Operation

Parallel Lift Operation

Boom Pressure Balance System

E10

Universal Hydraulic Faults

E11

Parallel Circuit Faults

E12

Flowshare Servo Circuit Faults

E13

Hydraulic System Pressure Tests

E14

Pump Flow Tests - Gearpump

E15

Flowshare Control Valve

E16

Parallel Control Valve - 2 Section

E17

Parallel Control Valve - 5 Section

E18

Pilot Pressure Supply Valve

E19

Servo Control Valves

E20

Gearpump Operation

E21

Gearpump Removal and Replacement

E22

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z

z z z z z z z z z z z z z z

z z z z z z z z z z z z z

z z z z

z z z z z

Hydraulic Cooling Fan Motor - Fixed Speed

E23

Extension Ram

E24

Lift Rams

E25

Tilt Ram

z z z

E0-1

9813-1800-2 (AE-00-06)

E0-1

Section E0 - Hydraulics Applications Table Machine models Topic Ref Title

VARIANT

E26

Displacement Ram

E27

Sway Ram

E28

Stabiliser Rams

E29

RAS Rams

E30

Ram Maintenance

E31

Sway Ram Circuit - Bleed Procedure

E0-2

9813-1800-2 (AE-00-06)

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z

z z z

z z z z z z

E0-2

Section E1 - Hydraulics

Systems and Schematics Introduction This topic contains information about all of the hydraulics system. For detailed information about each system and device refer to the applicable TOPIC in this section. K Related Topics ( T E1-2) K Systems ( T E1-3) K Operation Overview ( T E1-3) K Component Location ( T E1-5) K Schematics ( T E1-7) K 506-36 ( T E1-8) K 507-42, 509-42 ( T E1-10) K 510-56 ( T E1-12) K 512-56, 514-56 ( T E1-14)

E1-1

E-00-09 Issue 01

E1-1

Section E1 - Hydraulics Systems and Schematics Related Topics

File ID All files

(1)

Applications

AE-00-01

Section B - RAS System Section B - Stabilisers Generic Descriptions Flowshare Hydraulic System

E-01-00

Parallel Hydraulic System

E-01-02

GearPump Operation

E-60-06

MRV/LSRV Operation

E-60-03

ARV Operation

E-60-04

Pressure Compensator Operation

E-60-08

Generic Procedures Pump Flow Test (GearPumps)

E-61-03

Devices Parallel Control Valve 2 Section

E-06-29

Parallel Control Valve 5 Section

E-06-30

Flowshare Control Valve

E-06-28

Main Pump - Gearpump - Removal and Replacement

E-61-09

Servo Control Valve

E-09-16

Pilot Pressure Supply Valve

E-10-15

Hydraulic Cooling Fan Motor - Fixed Speed

E-12-06

Hydraulic Cooling Fan Motor - Variable Speed

E-12-07

(1) You must obey all of the relevant care and safety procedures.

E1-2

E-00-09 Issue 01

E1-2

Section E1 - Hydraulics Systems and Schematics Systems

Systems Operation Overview

Control Valves

K Fig 1. ( T E1-6)

The system has two main control valve blocks. A flowshare type valve 1 and a parallel type valve 2.

The main components of the hydraulic system are the tank, the pump, the control valves and hydraulic rams.

The spools in the parallel valve are manually operated.

Some hydraulic service are operated by a flowshare system and others by a parallel type system. Both systems are supplied with oil from the same hydraulic pump. As well as providing the main hydraulic services the system also operates a hydraulic steering system. Refer to Section H - Steering. K Related Topics ( T E1-2) Some machines also have a hydraulically controlled rear axle stability system (RAS). Refer to Section B - Body and Framework. Some machines have hydraulically operated stabilisers. Refer to Section B - Body and Framework. For more detailed information on the hydraulic systems and components refer to the applicable system topic:

The spools in the flowshare valve are operated by pilot oil pressure.

Pilot Pressure Supply Valve The pilot pressure supply valve 4 supplies variable hydraulic pilot pressure to the servo control valves 6 and 7. For details of the valve location and operation refer to the applicable Pilot Pressure Supply Valve topic. K Related Topics ( T E1-2)

Servo Control Valves Control levers operate servo control valves 6 and 7 to direct the pilot pressure oil to the pilot operated valve spools on the flowshare valve 1.

Load Sensing K LSP Hydraulic SYSTEM (E-01-31) ( T E3-1) All the hydraulic services are connected to a hydraulic load sense circuit. When no services are operated, there is no demand for flow from the hydraulic system, the oil from the gearpump flows to the inlet-outlet section of the flowshare control valve and directly back to tank 10 via filter 9.

K Parallel Hydraulic SYSTEM (E-01-32) ( T E2-1)

Hydraulic Pump Oil is drawn from the hydraulic tank 10 by the hydraulic pump assembly 3. The pump assembly is mounted on the rear of the bevel gearbox and is driven by the engine. The pump has three sections, 3A, 3B and 3C. Oil from the larger pump section 3A flows direct to the control valve blocks 1 and 2. Pump section 3C has an integral priority valve which always gives priority demand to the steer circuit. With the steering in the straight ahead position (i.e. with no steering demand), oil from pump section 3C flows through the priority valve and joins with the flow from 3A to feed the control valve blocks 1 and 2. Oil from pump section 3B flows directly to the cooling fan hydraulic motor 8 and via filter 5 to the pilot pressure supply valve 4. For details of the Gearpump hydraulic operation refer to the Gearpump Operation topic. K Related Topics ( T E1-2)

E1-3

When a service is operated, the system senses the demand and pressure adjusts to a value sufficient to operate the service. The load sense feature also incorporates the main pressure relief function, which is controlled by the load sense relief valve. For ARV and LSRV operation refer to the Auxiliary Relief Valve Operation or Main Relief Valve/Load Sense Relief Valve topics. K Related Topics ( T E1-2)

Pressure Compensation (Flowshare) Each service spool of the flowshare valve 1 incorporates a pressure compensator valve. When services are operated simultaneously the system ensures consistent operating speed of all the services operated by the valve. Operating

E-00-09 Issue 01

E1-3

Section E1 - Hydraulics Systems and Schematics Systems speed is consistent even when the limit of the hydraulic pump performance is approached. Compensator valves are used to share the hydraulic flow between the operating hydraulic services. Refer to Section E - Pressure Compensator Operation. K Related Topics ( T E1-2)

E1-4

E-00-09 Issue 01

E1-4

Section E1 - Hydraulics Systems and Schematics Systems

Component Location K Fig 1. ( T E1-6) Table 2. Component Key Item

Description

Control valve block

Parallel valve with manual spools

Pump assembly

Three section gearpump 3A, 3C, 3B

Pilot pressure supply valve

Supplies oil at pilot pressure to the servo control valves

Hydraulic oil filter

Positioned in the servo pilot valve feed line

Servo control valve

Two axis control lever

Servo control valve

Single axis control lever

Fan motor

Driven by pump section 3B

Hydraulic oil filter

Positioned in the return line to tank

Hydraulic tank

Oil from pump section 3A

Flowshare valve with servo spools

Table 3. Hydraulic Connections Colour Key Oil from pump section 3C

Oil from pump section 3B

Oil at pilot pressure

Oil suction line from the tank to the pump sections Return to tank

E1-5

E-00-09 Issue 01

E1-5

Section E1 - Hydraulics Systems and Schematics Systems

Fig 1. Component Location

E1-6

E-00-09 Issue 01

C068110

E1-6

E1-7

E-00-09 Issue 01

Filter by-pass

Pump suction strainer

Tank

Pump assembly

Main pump

Fan pump

Steer pump

Priority valve

Test point(s)

Flowshare Valve block

Flushing valve

Load sense relief valve (LSRV)

Lift spool

Extension spool

Tilt spool

Tilt auxiliary relief valve (ARV)

Extend auxiliary relief valve (ARV)

Load hold check valves (LHCVs)

LSRV pressure test point

Pressure compensator valve

Steer unit assembly

Return line filter

Pressure cap breather

Component Key:

K Fig 2. ( T E1-8)

Schematic - 506-36

Auxiliary 1 boom quick release couplings One way restrictors Pilot operated check-valve Front steer rams Rear steer rams Steer Mode Valve Servo control lever - twin axis Servo control lever - single axis Pilot pressure supply valve

11A 11B 12 13 14 15 16 17

Check Valve

9C Sway Ram

Regenerative valve

Counter-balance valve

Extension ram

Regenerative valve - if fitted

Counter-balance valve

Lift ram

Auxiliary spool

Tilt ram

Sway spool

Parallel valve block

Displacement ram

Relief valve

Non-return valve Cooling fan motor

Relief valve

3C 4

Shock valves (option) - if fitted

3B 3D

Steer valve

Schematics

17F

17E

17D

17C

17B

17A

Isolation valve - servo control levers

Fan supply pressure test point

Pilot pressure test point

Pilot Filter

Relief valve

Accumulator

Section E1 - Hydraulics Systems and Schematics Schematics

E1-7

Section E1 - Hydraulics Systems and Schematics

Fig 2. 506-36

332-c5224-10-sheet1

Schematics

E1-8

E-00-09 Issue 01

E1-8

E1-9

Lift spool

Extension spool

Tilt spool

Tilt auxiliary relief valve (ARV)

Extend auxiliary relief valve (ARV)

Load hold check valves (LHCVs)

LSRV pressure test point

Pressure compensator valve

Steer unit assembly

Steer valve

Shock valves (option) - if fitted

Priority valve

Steer pump

Load sense relief valve (LSRV)

Fan pump

Main pump

Flushing valve

Pump assembly

Tank

Flowshare Valve block

Pump suction strainer

Filter by-pass

Test point(s)

Return line filter

Pressure cap breather

Component Key:

K Fig 2. ( T E1-8)

Schematic - 507-42, 509-42

E-00-09 Issue 01

Servo Control Lever - Twin Axis Servo Control Lever - Single Axis Pilot pressure supply valve Accumulator Relief valve

15 16 17 17A 17B

Fan supply pressure test point

Steer Mode Valve

17E

Rear steer rams

Pilot Filter

Front steer rams

Pilot Pressure Test Point

Pilot operated check-valve

11B

17D

One way restrictors

11A

17C

Auxiliary 1 boom quick release couplings Sway Ram

Check Valve

9C 11

Regenerative valve

9B 10

Counter-balance valve

Extension ram

9 9A

Counter-balance valve

Tilt ram

Lift ram

Auxiliary Spool

Regenerative valve - if fitted

Sway Spool

Displacement ram

Parallel valve block

Relief valve

Non-return valve Cooling fan motor

Relief valve

17F

RAS Check Valve

RH RAS quick release coupling

R/H RAS ram

R/H RAS manifold block

L/H RAS quick release coupling

L/H RAS ram

L/H RAS manifold block

Isolation valve - servo control levers

Section E1 - Hydraulics Systems and Schematics Schematics

E1-9

Section E1 - Hydraulics Systems and Schematics

Fig 3. 507-42, 509-42

332-d0698-9-sheet1

Schematics

E1-10

E-00-09 Issue 01

E1-10

E1-11

E-00-09 Issue 01

Tilt spool

Tilt auxiliary relief valve (ARV)

Extend auxiliary relief valve (ARV)

Load hold check valves (LHCVs)

LSRV pressure test point

Pressure compensator valve

Steer unit assembly

Steer valve

Shock valves (option) - if fitted

Relief valve

Extension spool

Lift spool

Priority valve

Steer pump

Load sense relief valve (LSRV)

Fan pump

Main pump

Flushing valve

Pump assembly

Tank

Flowshare valve block

Pump suction strainer

Filter by-pass

Test point(s)

Return line filter

Pressure cap breather

Component Key:

K Fig 4. ( T E1-12)

Schematic - 510-56

One way restrictors Pilot operated check-valve Front steer rams Rear steer rams Steer Mode Valve Servo control lever - twin axis Servo control lever - single axis Pilot pressure supply valve Accumulator

11A 11B 12 13 14 15 16 17 17A

Pilot Filter

Sway Ram

17C

Auxiliary 1 boom quick release couplings

Relief valve

Check Valve

17B

Regenerative valve

Tilt ram

Counter-balance valve

Displacement ram

Regenerative valve - if fitted

Extension ram

Counter-balance valve

Lift ram

Counter-balance valve

Stabiliser and sway isolation valve

Left stabiliser spool

Sway spool

5A Auxiliary spool

Parallel valve block

Right stabiliser spool

Relief valve

Cooling fan motor

Non-return valve

24B

24A

17G

17F

17E

17D

Bi Directional Steer Return Check Valve

RAS Check Valve

Left stabiliser ram

Stabiliser pressure switch

Stabiliser lock cut out valve

Right stabiliser ram

RH RAS Quick Release Coupling

R/H RAS Ram

R/H RAS Manifold Block

L/H RAS Quick Release Coupling

L/H RAS Ram

L/H RAS Manifold Block

Isolation valve - lift spool pilot pressure

Isolation valve - servo control levers

Fan Supply Pressure Test Point

Pilot Pressure Test Point

Section E1 - Hydraulics Systems and Schematics Schematics

E1-11

Section E1 - Hydraulics Systems and Schematics

Fig 4. 510-56

332-d0983-10-sheet1

Schematics

E1-12

E-00-09 Issue 01

E1-12

E1-13

E-00-09 Issue 01

Tilt spool

Tilt auxiliary relief valve (ARV)

Extend auxiliary relief valve (ARV)

Load hold check valves (LHCVs)

LSRV pressure test point

Pressure compensator valve

Steer unit assembly

Steer valve

Shock valves (option) - if fitted

Relief valve

Extension spool

Lift spool

Priority valve

Steer pump

Load sense relief valve (LSRV)

Fan pump

Main pump

Flushing valve

Pump assembly

Tank

Flowshare valve block

Pump suction strainer

Filter by-pass

Test point(s)

Return line filter

Pressure cap breather

Component Key:

K Fig 5. ( T E1-14)

Schematic - 512-56, 514-56

11A 11B 12 13 14 15 16 17 17A

Pilot Filter

Sway Ram

17C

Auxiliary 1 boom quick release couplings

Relief valve

Check Valve

17B

Regenerative valve

Tilt ram

Counter-balance valve

Displacement ram

Regenerative valve - if fitted

Extension ram

Counter-balance valve

Lift ram

Counter-balance valve

Stabiliser and sway isolation valve

Left stabiliser spool

Sway spool

5A Auxiliary spool

Parallel valve block

Right stabiliser spool

Relief valve

Cooling fan motor

Non-return valve

24B

24A

17G

17F

17E

17D

Bi Directional Steer Return Check Valve

RAS Check Valve

Left stabiliser ram

Stabiliser pressure switch

Stabiliser lock cut out valve

Right stabiliser ram

RH RAS Quick Release Coupling

R/H RAS Ram

R/H RAS Manifold Block

L/H RAS Quick Release Coupling

L/H RAS Ram

L/H RAS Manifold Block

Isolation valve - lift spool pilot pressure

Isolation valve - servo control levers

Fan Supply Pressure Test Point

Pilot Pressure Test Point

Section E1 - Hydraulics Systems and Schematics Schematics

E1-13

Section E1 - Hydraulics Systems and Schematics

Fig 5. 512-56, 514-56

333-f7277-2-sheet1.eps

Schematics

E1-14

E-00-09 Issue 01

E1-14

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Introduction

Parallel Hydraulic SYSTEM (E-01-32) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E2-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E2-2) For information about related electrical and electronic devices refer to Section M. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E2-2) K Specifications ( T E2-3) K Parallel Service Valve Block - 2 Section ( T E2-3) K Parallel Service Valve Block - 5 Section ( T E2-4) K Cooling Fan Motor ( T E2-6) K Hose and Pipework ( T E2-7) K Hydraulic Pressure Test Points ( T E2-8) K Operation Overview ( T E2-9) K Servo Control Valves ( T E2-12) K Component Location ( T E2-10) K Electrical and Electronic Systems ( T E2-15) K Fault Finding ( T E2-16) K Electronic Fault Codes ( T E2-16) K Test Procedures ( T E2-17)

E2-1

E-01-32 Issue 01

E2-1

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Related Topics

File ID All files

(1)

Applications

AE-00-06

Systems and Schematics

E-00-09

Generic Descriptions Parallel Circuit Operation

E-60-01

Parallel Lift Operation

E-60-05

GearPump Operation

E-60-06

Generic Procedures Pump Flow Test (GearPumps)

E-61-03

Bleed Procedure - Sway Ram Circuit

E-61-02

MRV/LSRV Pressure Testing

E-61-06

ARV Pressure Testing

E-61-05

Generic Fault Finding Procedures Universal Faults

E-62-01

Parallel Circuit Faults

E-62-02

Devices Control Valve - 2 Section

E-06-29

Control Valve - 5Section

E-06-30

Main Pump - Gearpump Removal and Replacement

E-61-09

Servo Pilot Pressure Supply Valve

E-10-15

Servo Control Valves

E-09-16

Hydraulic Cooling Fan Motor - Fixed Speed

E-12-06

Electrical and Electronic Devices Devices - Applications(2) Fault Code SYSTEM (1) You must obey all of the relevant care and safety procedures. (2) Refer to Section M for related electrical and electronic devices.

E2-2

E-01-32 Issue 01

E2-2

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Specifications

Specifications Parallel Service Valve Block - 2 Section Type:

2 Spool, parallel service, double acting spools.

Spool 1

Auxiliary Service

Manually Operated

Spool 2

Sway Service

Manually Operated

Relief Valve Pressures: K Fig 1. ( T E2-3). bar

kgf/cm2

lbf/in2

LSRV (Mounted within flowshare valve block).

260

265

3770.9

Auxiliary Relief Valve C

140

142

2030

Auxiliary Relief Valve D

140

142

2030

C056750-C1

Fig 1. 2 Section Parallel Control Valve Block

E2-3

E-01-32 Issue 01

E2-3

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Specifications

Parallel Service Valve Block - 5 Section Type:

5 Section, 4 Spool, parallel service, double acting spools.

Spool 1

Auxiliary service

Manually operated

Spool 2

Sway service

Manually operated

Spool 3

Stabiliser

Manually operated

Spool 4

Stabiliser

Manually operated

Section 5

Isolation valve (spools 2, 3 and 4)

Electrical solenoid operation

Relief Valve Pressures: K Fig 2. ( T E2-4). bar

kgf/cm2

lbf/in2

LSRV (Mounted within flowshare valve block).

260

265

3770.9

Auxiliary Relief Valve C

140

142

2030

Auxiliary Relief Valve D

140

142

2030

C065760-C1

Fig 2. 5 Section Parallel Control Valve Block

E2-4

E-01-32 Issue 01

E2-4

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Specifications

Hydraulic Pump Table 2. 110 litres/min Type

Gear pump

Mounting:

Gearbox

Direction of Rotation:

Anti-clockwise

Theoretical displacement:

cc/rev

cu in/rev

Main services pump (mounting flange end)

1.77

Steering pump

1.16

Cooling fan pump

0.98

litres/min

UK gal/min

US gal/min

Main services pump (mounting flange end)

57.4

12.6

15.1

Steering pump

37.6

8.3

9.9

Cooling fan pump

31.7

7.0

bar

kg/cm

port EF

265

270

3840

port P

200

204

2900

Flow at 2200 rev/min and system pressure (90% min. displacement):

Maximum Pressure:

Maximum Speed:

3000 rev/min

Minimum Speed:

500 rev/min

Weight:

33.3 kg (73.4 lbs)

E2-5

E-01-32 Issue 01

8.4 2

lb/in2

E2-5

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Specifications

Cooling Fan Motor

E2-6

E-01-32 Issue 01

E2-6

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Specifications

Hose and Pipework

A E

G Fig 3. A

Hydraulic tank

Parallel Control Valve

Filter

Servo Valve

Fan supply pump

Main hydraulic supply pump

Fan Return Pipework

Flowshare Control Valve

Steer Circuit Return

E2-7

E-01-32 Issue 01

C113120

E2-7

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Specifications

Hydraulic Pressure Test Points For hydraulic pressure test point locations refer to the Hydraulic System Pressure Tests and Pump Flow Test (Gearpumps) topics. K Related Topics ( T E2-2)

E2-8

E-01-32 Issue 01

E2-8

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Operation Overview

Operation Overview The sway, stabiliser and auxiliary hydraulic services are operated by a parallel hydraulic valve. The other hydraulic services are operated by a flowshare valve. The parallel valve is a closed centre type and utilises the load sense and flushing valves in the flowshare valve block.

E2-9

E-01-32 Issue 01

E2-9

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Operation Overview

Component Location K Fig 4. ( T E2-11) Table 3. Component Key Item

Description

Pump assembly

Fan section

Gearpump

Steering section

Gearpump

Main hydraulic supply section

Gearpump

Priority valve

Steering

Control lever (Single axis)

Control lever

Control valve block

Parallel valve with manual spools

2 Section parallel control valve block

5 Section parallel control valve block

Flowshare valve inlet/outlet section

The system is connected to the load sense components in the inlet/outlet section of the flowshare valve.

Hydraulic oil filter

Positioned in the return line to tank

Hydraulic tank

E2-10

Three section gearpump

E-01-32 Issue 01

E2-10

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Operation Overview

C067780-C5

Fig 4. Component Location

E2-11

E-01-32 Issue 01

E2-11

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Operation Overview

Servo Control Valves

1 down which connects the selected service port to the pressure port `P'.

There are two types of servo control valves fitted to the machine. K Fig 5. ( T E2-12). â&#x20AC;&#x201C; Two axis A (This controls the extend/retract and lift/ lower hydraulic services) â&#x20AC;&#x201C; Single Axis B (This controls the tilt/crowd hydraulic service.)

Fig 5.

The spool 7-1 regulates the incoming hydraulic servo pressure to balance the pressure in the service port with the force of the control spring. The interaction of the spool and control spring in this way means that the joystick will produce a pilot pressure in the selected service port which is proportional to the position of the control lever.

C065840

Twin Axis Control Valve

Fig 6.

C065860

The servo control valve operate as direct acting pressure regulating valves, which consist of the control lever and four proportional pilot control valve capsules. Each pilot valve capsule consists of a spool 7-1 with a control spring, a plunger 7-2 and plunger return spring 7-3. In neutral, the control lever is kept central by the force of the plunger return springs 7-3. In this position the joystick service ports are connected to the tank port `T' via the drillings 7 -X in the spools. When the control lever is operated, the relevant plunger 72 pushes on the return spring 7-3 and the spool control spring. The spool control spring in turn moves the spool 7-

E2-12

E-01-32 Issue 01

E2-12

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Operation Overview

Fig 7.

C052030-C1

Table 4. Colour Key to Oil Flow and Pressure Servo Exhaust

E2-13

E-01-32 Issue 01

E2-13

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Operation Overview Single Axis Control Valve The single axis control valve works in the same way as the twin axis valve. The valve only has two proportional pilot control valve capsules. K Twin Axis Control Valve ( T E2-12)

Fig 8.

E2-14

C065880

E-01-32 Issue 01

E2-14

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Operation Overview

Electrical and Electronic Systems For details about electrical and electronic systems refer to Section C and Section M.

E2-15

E-01-32 Issue 01

E2-15

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Fault Finding

Fault Finding For related fault finding information refer to the Generic Fault Finding topics listed. K Related Topics ( T E2-2)

Electronic Fault Codes Machines with an electronic instruments system will log some system faults as a fault code. These fault codes can be accessed with the correct diagnostics software tool, using a laptop computer connected to the machine CAN system. Refer to Section M - Fault Code SYSTEM.

E2-16

E-01-32 Issue 01

E2-16

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Test Procedures

Test Procedures For related test and circuit bleeding procedures refer to the Generic Procedures topics listed. K Related Topics ( T E2-2)

E2-17

E-01-32 Issue 01

E2-17

Section E2 - Hydraulics Parallel Hydraulic SYSTEM (E-01-32) Test Procedures

Page left intentionally blank

E2-18

E-01-32 Issue 01

E2-18

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Introduction

LSP Hydraulic SYSTEM (E-01-31) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E3-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E3-2) For information about related electrical and electronic devices refer to Section M. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E3-2) K Specifications ( T E3-3) K Flowshare Control Valve Block ( T E3-3) K Hydraulic Pump ( T E3-4) K Cooling Fan Motor ( T E3-4) K Hose and Pipework ( T E3-5) K Hydraulic Pressure Test Points ( T E3-6) K Operation Overview ( T E3-7) K Component Location ( T E3-8) K Electrical and Electronic Systems ( T E3-10) K Fault Finding ( T E3-11) K Electronic Fault Codes ( T E3-11) K Test Procedures ( T E3-12)

E3-1

E-01-31 Issue 01

E3-1

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Related Topics

File ID All files

(1)

Applications

AE-00-06

Systems and Schematics

E-00-09

Generic Descriptions LSP Circuit Operation

E-60-12

Parallel Lift Operation

E-60-05

GearPump Operation

E-60-06

Pressure Compensator Operation

E-60-10

Generic Procedures Pump Flow Test (GearPumps)

E-61-03

LSP Circuit Testing

E-61-07

Bleed Procedure - Sway Ram Circuit

E-61-02

ARV Pressure Testing

E-61-05

Generic Fault Finding Procedures Universal Faults

E-62-01

Flowshare Servo Circuit Faults

E-62-05

Devices Flowshare Control Valve

E-06-28

Main Pump - Gearpump Removal and Replacement

E-61-09

Servo Pilot Pressure Supply Valve

E-10-15

Servo Control Valves

E-09-16

Hydraulic Cooling Fan Motor - Fixed Speed

E-12-06

E3-2

E-01-31 Issue 01

E3-2

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Specifications

Specifications Flowshare Control Valve Block Type:

3 Spool, load sense - pressure compensated, double acting spools.

Spool 1

Carriage Tilt Service

Pilot Operated

Spool 2

Boom Extend & Retract Service

Pilot Operated

Spool 3

Lift & Lower Service

Pilot Operated

Relief Valve Pressures: bar

kgf/cm2

lbf/in2

260

265

3770.9

2L - Boom Extend Ram Head Side

200 (215(2))

203 (219(2))

2900.7 (3118(2))

2J - Carriage Tilt Ram Head Side

240

244.7

3480.9

2H - Carriage Tilt Ram Rod Side

275

280.4

3988.5

2C - Load Sense Relief Valve (1) Auxiliary Relief Valves (ARV's)

(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 Â°C (122 Â°F) to ensure an accurate reading. (2) Machines from serial number 1402062 will be set to 215 bar. Pilot Pressure Range:

bar

kgf/cm2

lbf/in2

All Machines

10 - 30

10.2 - 30.6

145 - 435

Fig 1.

E3-3

E-01-31 Issue 01

C065680

E3-3

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Specifications

Hydraulic Pump Refer to the Parallel Hydraulic SYSTEM topic for details. K Related Topics ( T E3-2)

Cooling Fan Motor Refer to the Parallel Hydraulic SYSTEM topic for details. K Related Topics ( T E3-2)

E3-4

E-01-31 Issue 01

E3-4

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Specifications

Hose and Pipework

A E

G Fig 2. A

Hydraulic tank

Parallel Control Valve

Filter

Servo Valve

Fan supply pump

Main hydraulic supply pump

Fan Return Pipework

Flowshare Control Valve

Steer Circuit Return

E3-5

E-01-31 Issue 01

C113120

E3-5

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Specifications

Hydraulic Pressure Test Points For hydraulic pressure test point locations refer to the Hydraulic System Pressure Tests and Pump Flow Test (Gearpumps) topics. K Related Topics ( T E3-2)

E3-6

E-01-31 Issue 01

E3-6

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Operation Overview

Operation Overview The JCB Flowshare hydraulic system differs in many important aspects to that of the normal hydraulic system. Before attempting to service or fault find the system ensure that you read and understand all the descriptions in this section. The flowshare system operates the boom lift/lower, tilt/ crowd and extend/retract services. The other services such as the auxiliary hydraulics are operated by a parallel type hydraulic system. Both systems are supplied with oil flow from the same hydraulic pump. When using multiple services on a parallel system one or more services may suffer from an unequal flow causing them to slow down or lose power. A flowshare system makes sure that all services receive sufficient flow to continue operation.

E3-7

E-01-31 Issue 01

E3-7

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Operation Overview

Component Location K Fig 3. ( T E3-9) Table 2. Component Key Item

Description

Pump assembly

Fan section

Gearpump - cooling fan motor and pilot valve supply

Steering section

Gearpump

Main hydraulic supply section

Gearpump

Priority valve

Steering

Three section gearpump

Servo control valve (Two axis)

Servo control lever (Lift and Extend services)

Servo control valve (Single axis)

Servo control lever (Tilt service)

Control valve block

Flowshare valve with pilot spools

LSRV

Load sense relief valve

Pilot pressure supply valve

Supplies hydraulic oil at a reduced pressure to operate the control valve spools.

Hydraulic oil filter

Positioned in the pilot valve feed line

Hydraulic oil filter

Positioned in the return line to tank

Hydraulic tank

E3-8

E-01-31 Issue 01

E3-8

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Operation Overview

C067780

Fig 3. Component Location

E3-9

E-01-31 Issue 01

E3-9

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Operation Overview

Electrical and Electronic Systems For details about electrical and electronic systems refer to Section C and Section M.

E3-10

E-01-31 Issue 01

E3-10

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Fault Finding

Fault Finding For related fault finding information refer to the Generic Fault Finding topics listed. K Related Topics ( T E3-2)

E3-11

E-01-31 Issue 01

E3-11

Section E3 - Hydraulics LSP Hydraulic SYSTEM (E-01-31) Test Procedures

Test Procedures For related test and circuit bleeding procedures refer to the Generic Procedures topics listed. K Related Topics ( T E3-2)

E3-12

E-01-31 Issue 01

E3-12

Section E4 - Hydraulics

Parallel Circuit Operation (E-60-01) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E4-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E4-2) This topic is intended to help you understand what the system does and how it works.

K Related Topics ( T E4-2) K Descriptions ( T E4-3) K Neutral ( T E4-3) K Service Operation ( T E4-5) K Main System Pressure Relief ( T E4-6)

E4-1

E-60-01 Issue 01

E4-1

Section E4 - Hydraulics Parallel Circuit Operation (E-60-01) Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Systems and Schematics

(1) You must obey all of the relevant care and safety procedures.

E4-2

E-60-01 Issue 01

E4-2

Section E4 - Hydraulics Parallel Circuit Operation (E-60-01) Descriptions

Descriptions The schematic diagrams show a typical system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E4-2) Note: Pressures quoted are for illustration purposes only. Refer to the Hydraulic SYSTEM topic for the correct pressures for machine variant. Table 2. Colour Key to Oil Flow and Pressure Full Pressure Load Sense Line Servo Neutral Exhaust Note: For illustration purposes the isolation proportional solenoid H and the Variable Orifice pilot valve J are shown with the service valve spool E receiving full hydraulic supply. Depending on the state of the LLMC system the Variable Orifice pilot valve J and isolation proportional solenoid H may be operative to stop or restrict flow to the service valve spool E. For LLMC system operation and components refer to Section B - Longitudinal Load Moment SYSTEM. K Related Topics ( T E4-2) Note: For illustration purposes a double gearpump is shown.

Neutral K Fig 1. ( T E4-4) Oil from the primary pump B flows to the inlet-outlet section of the control valve D through the valve spool E and returns to tank A.

E4-3

E-60-01 Issue 01

E4-3

Section E4 - Hydraulics Parallel Circuit Operation (E-60-01)

Fig 1. Neutral

C106780

Descriptions

E4-4

E-60-01 Issue 01

E4-4

E4-5

K Fig 2. ( T E4-5)

Service Operation

E-60-01 Issue 01

Fig 2. One Service Operated

When a service is operated, boom extend for example, the movement of the control lever and its mechanical linkages operate the valve spool E. The hydraulic oil flows through the valve spool E to the extend ram G.

C106780-C1

Oil from the other side of the ram G flows across the service spool E and back to tank A.

Section E4 - Hydraulics

Parallel Circuit Operation (E-60-01) Descriptions

E4-5

E4-6

When a service ram reaches the end of its stroke, or the service meets resistance and generates pressure above a specified pressure, the main relief valve K

K Fig 3. ( T E4-6)

Main System Pressure Relief

E-60-01 Issue 01

Fig 3. Main System Pressure Relief

The control valve block inlet section also includes the valves which are used for the LLMC System. For details of this system and components refer to Section B - Longitudinal Load Moment SYSTEM. K Related Topics ( T E4-2)

opens and oil is dumped to tank, preventing further pressure rise.

Exhaust

Neutral

Full Pressure

C106780-C2

Table 3. Colour Key to Oil Flow and Pressure

Section E4 - Hydraulics

Parallel Circuit Operation (E-60-01) Descriptions

E4-6

Section E5 - Hydraulics

LSP Circuit Operation (E-60-12) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E5-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E5-2) This topic is intended to help you understand what the system does and how it works.

K Related Topics ( T E5-2) K Descriptions ( T E5-3) K Neutral ( T E5-3) K Service Operation ( T E5-5) K Multiple Service Operation ( T E5-7) K Main System Pressure Relief ( T E5-7)

E5-1

E-60-12 Issue 01

E5-1

Section E5 - Hydraulics LSP Circuit Operation (E-60-12) Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Systems and Schematics

(1) You must obey all of the relevant care and safety procedures.

E5-2

E-60-12 Issue 01

E5-2

Section E5 - Hydraulics LSP Circuit Operation (E-60-12) Descriptions

Descriptions The schematic diagrams show a typical system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E5-2) Note: Pressures quoted are for illustration purposes only. Refer to the Hydraulic SYSTEM topic for the correct pressures for machine variant. Table 2. Colour Key to Oil Flow and Pressure Full Pressure Load Sense Line Servo Neutral Exhaust

Neutral K Fig 1. ( T E5-4) Oil from the primary pump 1A flows to the inlet-outlet section of the control valve 3. When the main system pressure reaches a preset limit the spring 3B in flushing valve 3A is overcome and oil is returned back to tank. Oil from secondary pump 1C supplies the steer circuit and the main hydraulic system via steer priority valve 1D. When the steering is operated the priority valve spool moves to divert all the oil flow from secondary pump 1C to the steering circuit. Oil from pump 1B flows to the pilot pressure supply valve 4 and the fan motor 2. The valve supplies pilot pressure oil to the servo control lever.

E5-3

E-60-12 Issue 01

E5-3

Section E5 - Hydraulics LSP Circuit Operation (E-60-12)

Fig 1. Neutral

C065720-C1

Descriptions

E5-4

E-60-12 Issue 01

E5-4

Section E5 - Hydraulics LSP Circuit Operation (E-60-12) Descriptions

Service Operation K Fig 2. ( T E5-6) When a service is operated, boom extend for example, the movement of the control lever allows pilot pressure oil to actuate the service spool 3E. Oil passes across the service spool to the applicable pressure compensator valve 3F. The valve opens and diverts oil to the load sense gallery and load hold check valve 3D. Pressure in the load sense gallery increases and the flushing valve 3A begins to close. Main system pressure continues to rise until load hold check valve 3D opens and the boom extend ram 5 operates. The main system pressure will now be equal to the load sense pressure (load from the boom lift ram) plus the force of flushing valve spring 3B. Oil from the other side of the ram 5 flows across the service spool and back to tank in the normal way.

E5-5

E-60-12 Issue 01

E5-5

Section E5 - Hydraulics LSP Circuit Operation (E-60-12)

Fig 2. One service Operated

C065720-C2

Descriptions

E5-6

E-60-12 Issue 01

E5-6

Section E5 - Hydraulics LSP Circuit Operation (E-60-12) Descriptions

Multiple Service Operation In the normal hydraulic system the services are connected in parallel, this means that when multiple services are operated simultaneously, the speed of one service can be affected by the operating pressure of another service. This is not the case with flowshare. The pressure compensator valves for each service react to the differing load pressures. For example, when a pressure compensator valve is subjected to a higher load sense pressure from another service, it reacts to reduce the flow to its service, ensuring that the associated ram operates at a constant speed, regardless of the increase in the main system pressure.

Main System Pressure Relief K Fig 3. ( T E5-8) The maximum main system pressure is controlled by limiting the maximum load sense pressure. When a service ram reaches the end of its stroke, or the service meets resistance and generates pressure above a preset value in the load sense line, the load sense relief valve 3C opens and load sense oil is dumped to tank, preventing further pressure rise. The flushing valve 3A operates as normal.

E5-7

E-60-12 Issue 01

E5-7

Section E5 - Hydraulics LSP Circuit Operation (E-60-12)

Fig 3. Main System Pressure Relief

C065720-C3

Descriptions

E5-8

E-60-12 Issue 01

E5-8

Section E6 - Hydraulics

Main Relief Valve (MRV)/Load Sense Relief Valve (LSRV) Operation Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E6-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E6-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E6-2) K Operation Overview ( T E6-3)

E6-1

E-60-03 Issue 01

E6-1

Section E6 - Hydraulics Main Relief Valve (MRV)/Load Sense Relief Valve (LSRV) Operation Related Topics

Topic Titles

Sub Titles

Applications

ALL

E6-2

E-60-03 Issue 01

E6-2

Section E6 - Hydraulics Main Relief Valve (MRV)/Load Sense Relief Valve (LSRV) Operation Operation Overview

Operation Overview

Fig 1. The relief valve 2A is situated in the control valve 2, which bridges either: â&#x20AC;&#x201C; the Neutral and Exhaust galleries (Parallel Control Valves)

C021880-C3.eps

A service has been selected and the pressure generated exceeds the setting of the R.V. Pressure acts on the periphery of the hollow poppet B which is forced downwards against the spring, venting pressure into the exhaust gallery EX.

â&#x20AC;&#x201C; or the Load Sense and Exhaust Galleries (Flowshare Control Valves) It is designed to prevent the circuitry from damage that could be caused by excessive pressures. 1

Valve at Rest:

The services are in neutral and pressure in the neutral gallery N is not sufficient to operate the R.V. which is held closed by its spring A. 2

Poppet Opens:

E6-3

E-60-03 Issue 01

E6-3

Section E6 - Hydraulics Main Relief Valve (MRV)/Load Sense Relief Valve (LSRV) Operation Operation Overview

Page left intentionally blank

E6-4

E-60-03 Issue 01

E6-4

Section E7 - Hydraulics

Auxiliary Relief Valve (ARV) Operation Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E7-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E7-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E7-2) K Operation Overview ( T E7-3)

E7-1

E-60-04 Issue 01

E7-1

Section E7 - Hydraulics Auxiliary Relief Valve (ARV) Operation Related Topics

Topic Titles

Sub Titles

Applications

ALL

E7-2

E-60-04 Issue 01

E7-2

Section E7 - Hydraulics Auxiliary Relief Valve (ARV) Operation Operation Overview

Operation Overview

S Fig 1.

C021910-C3.eps

The Auxiliary Relief Valves (A.R.V.'s) are situated in the control valve to limit potentially damaging pressures within specified services due to external loadings. A.R.V.'s may also be used to limit the maximum pressure in a specified service to less than the L.S.R.V. setting. 1

Valve at Rest:

A service is selected but pressure in the service gallery S has not reached the setting of the A.R.V. which is held closed by its spring. 2

Poppet Opens:

The setting of the A.R.V. is exceeded by the service pressure which causes the poppet to rise against spring force allowing the pressure to be vented into the exhaust gallery EX. 3

Anti-cavitation Mode:

When a service is operated in such a way that low pressure, or cavitation, exists in the service line S, the relatively high pressure oil in the exhaust gallery EX acts on the lower poppet and flows into the service gallery to make up the deficiency.

E7-3

E-60-04 Issue 01

E7-3

Section E7 - Hydraulics Auxiliary Relief Valve (ARV) Operation Operation Overview

Page left intentionally blank

E7-4

E-60-04 Issue 01

E7-4

Section E8 - Hydraulics

Parallel Lift Operation (E-60-05) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E8-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E8-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E8-2) K Parallel Lift (S1) ( T E8-3)(1) K Ram Operation ( T E8-3) K Boom Raise Cycle ( T E8-4) K Boom Lower Cycle ( T E8-5) K Parallel Lift (S2) ( T E8-6)(2) K Ram Operation ( T E8-6) K Boom Raise Cycle ( T E8-7) K Boom Lower Cycle ( T E8-9) (1) Machines with single displacement ram at the rear of the boom pivot. (2) Machines with one or two displacement rams forward of the boom pivot.

E8-1

E-60-05 Issue 01

E8-1

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Systems and Schematics

E8-2

E-60-05 Issue 01

E8-2

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S1)

Parallel Lift (S1) The schematic diagrams show a typical system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E8-2)

Ram Operation The parallel lift system operates when the boom raises or lowers. When the boom ram C raises or lowers the boom displacement ram A extends or retracts. Oil displaced by the ram A flows to the tilt ram D which extends or retracts keeping the forks E parallel with the ground.

C094840

Fig 1. Single displacement ram at the rear of the boom pivot.

E8-3

E-60-05 Issue 01

E8-3

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S1)

Boom Raise Cycle

ram raises pilot pressure in HBCV 10A. This allows oil to feed back to the rod side of the displacement ram.

When lift spool 2D is selected, the neutral circuit is blocked and oil feeds lift ram hose-burst check-valve 8A. Oil flows through free flow direction of hose burst check valve (HBCV) 8A and lifts the boom. Oil is forced out of the head side of displacement ram 9 as the boom rises. The oil cannot flow past the tilt spool 2F, as the spool is not selected. Instead, it flows to the head side of tilt ram 10. Oil displaced from the rod side of the tilt

Displacement/lift link valve 20 is fitted between lift spool 2D and tilt spool 2F. The function of this valve is to allow a restricted flow of oil into the tilt circuit to increase the lift force available by utilising the displacement ram. Auxiliary relief valve (ARV) 2J opens to protect the tilt ram from over pressurisation. The anti-cavitation feature of valve 2H ensures that, in these circumstances, the tilt and displacement rams will not cavitate.

Fig 2. Boom Raise Cycle (Single displacement ram at the rear of the boom pivot)

E8-4

E-60-05 Issue 01

416480-1

E8-4

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S1)

Boom Lower Cycle

flow direction of HBCV 10A to the rod side of the tilt ram 10.

When raise/lower spool 2D is selected, the neutral circuit is blocked and oil feeds the rod side of lift ram 8. Oil displaced from the head side of the lift ram raises pilot pressure in HBCV 8A and allows oil out of the lift ram back to tank, lowering the boom. As the boom lowers, oil is forced from the rod side of the displacement ram 9. The oil cannot flow past tilt spool 2F, as the spool is not selected. Instead, it flows through free

A B

Fig 3. Boom Lower Cycle (Single displacement ram at the rear of the boom pivot)

E8-5

E-60-05 Issue 01

416490-1

E8-5

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S2)

Parallel Lift (S2) The schematic diagrams show a typical system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E8-2)

C083280-C2

Fig 4. Displacement ram forward of the boom pivot B

E8-6

E-60-05 Issue 01

E8-6

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S2)

Boom Raise Cycle K Fig 5. Boom Raise Cycle (Machines with Single Displacement Ram) ( T E8-8) K Fig 6. Boom Raise Cycle (Machines with Two Displacement Rams) ( T E8-8) When lift spool 2D is selected, the neutral circuit is blocked and oil feeds lift ram hose-burst check-valve 8A. Oil flows through free flow direction of hose burst check valve (HBCV) 8A and lifts the boom. Oil is forced out of the rod side of displacement ram 9 as the boom rises. The oil cannot flow past the tilt spool 2F, as the spool is not selected. Instead, it flows to the rod side of tilt ram 10. Oil displaced from the head side of the tilt ram raises pilot pressure in HBCV 10A. This allows oil to feed back to the head side of the displacement ram. Displacement/lift link valve 20 is fitted between lift spool 2D and tilt spool 2F. The function of this valve is to allow a restricted flow of oil into the tilt circuit to increase the lift force available by utilising the displacement ram. Auxiliary relief valve (ARV) 2J opens to protect the tilt ram from over pressurisation. The anti-cavitation feature of valve 2H ensures that, in these circumstances, the tilt and compensating rams will not cavitate. This has the effect of allowing the tilt ram to extend in proportion to boom lift, keeping the forks parallel with the ground.

E8-7

E-60-05 Issue 01

E8-7

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S2)

Fig 5. Boom Raise Cycle (Machines with Single Displacement Ram)

Fig 6. Boom Raise Cycle (Machines with Two Displacement Rams)

E8-8

E-60-05 Issue 01

416480-1-C3

710631-2-C2

E8-8

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S2)

Boom Lower Cycle K Fig 7. Boom Lower Cycle (Machines with Single Displacement Ram) ( T E8-10) K Fig 8. Boom Lower Cycle (Machines with Two Displacement Rams) ( T E8-10) When raise/lower spool 2D is selected, the neutral circuit is blocked and oil feeds the rod side of lift ram 8. Oil displaced from the head side of the lift ram raises pilot pressure in HBCV 8A and allows oil out of the lift ram back to tank, lowering the boom. As the boom lowers, oil is forced from the head side of the displacement ram 9. The oil cannot flow past tilt spool 2F, as the spool is not selected. Instead, it flows through free flow direction of HBCV 10A to the head side of the tilt ram 10. Oil displaced from the rod side of the tilt ram feeds back to the rod side of the displacement ram. This has the effect of allowing the tilt ram to retract in proportion to boom lower, keeping the forks parallel with the ground. Displaced oil from the displacement ram closes the check valve in displacement/lift link valve 20. Auxiliary relief valve (ARV) 2H opens to protect the tilt ram from over pressurisation. The anti-cavitation feature of valve 2J ensures that, in these circumstances, the tilt and compensating rams will not cavitate.

E8-9

E-60-05 Issue 01

E8-9

Section E8 - Hydraulics Parallel Lift Operation (E-60-05) Parallel Lift (S2)

A B

Fig 7. Boom Lower Cycle (Machines with Single Displacement Ram)

Fig 8. Boom Lower Cycle (Machines with Two Displacement Rams)

E8-10

E-60-05 Issue 01

416490-1-C3

710632-2-C2

E8-10

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Introduction

Boom Pressure Balance SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E9-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E9-2) For information about related electrical and electronic devices refer to Section M. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E9-2) K Lift Pressure Balance System (S1) ( T E9-3)(1) K Lift Pressure Balance System (S2) ( T E9-5)(1) K Tilt/Lift/Extension Ram Counterbalance Valves (S1) ( T E9-10)(1) K Extension Ram Counterbalance Valves (S2) ( T E9-14)(1) (1) System variant. Make sure you refer to the correct procedure. Table 1. Specification Variants - Counterbalance System Schematic(1)

Variant

K Lift Pressure Balance System (S1) ( T E9-3)

Machines with Electro Servo Hydraulic Systems up to May 2012

K Lift Pressure Balance System (S2) ( T E9-5)

Machines with Electro Servo Hydraulic Systems from May 2012

K Tilt/Lift/Extension Ram Counterbalance Valves All Machines excluding 540-170 (S1) ( T E9-10) K Extension Ram Counterbalance Valves (S2) ( T E9-14)

540-170

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

E9-1

E-35-17 Issue 02

E9-1

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Applications

ALL

Systems and Schematics

ALL

Smooth Ride System

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E9-2

E-35-17 Issue 02

E9-2

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Lift Pressure Balance System (S1)

Lift Pressure Balance System (S1) Operation Overview To hold the lift ram in position and for it not to lower under its own weight a counter balance valve is used. K Tilt/Lift/ Extension Ram Counterbalance Valves (S1) ( T E9-10) When operating the Crowd and boom raise hydraulic services there are rare occasions when the flow may divert through the displacement ram circuit and cause the boom to raise under the power of the displacement ram.

A pressure balance system ensures positive hydraulic pressure is maintained in the rod side of the lift ram circuit. This ensures correct operation of the boom service preventing the displacement ram raising the boom. A hydraulic counterbalance valve is installed in the rod side of the lift ram circuit. The valve operates to ensure positive pressure (100 bar) is maintained in the rod side of the lift ram when the boom is raising. The counterbalance valve 1 is located on the counterbalance valve block 2. The valve block 2 is located on the chassis. K Component Location ( T E9-3)

Component Location

Fig 1.

E9-3

E-35-17 Issue 02

C129050.eps

E9-3

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Lift Pressure Balance System (S1)

Hydraulic Operation and Schematics The schematic diagrams show a typical system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E9-2)

4 3 1

6 5 7

Fig 2.

C129000-C8.eps

Table 3. Item 1

Lift Control Valve Spool

Tilt Control Valve Spool

Counterbalance Valve

Lift Ram

Tilt Ram

Check Valve

Displacement Ram

Electrical Operation There are no electrical devices used in this system.

E9-4

E-35-17 Issue 02

E9-4

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Lift Pressure Balance System (S2)

Lift Pressure Balance System (S2) Operation Overview To hold the lift ram in position and for it not to lower under its own weight a counter balance valve is used. K Tilt/Lift/ Extension Ram Counterbalance Valves (S1) ( T E9-10) When operating the Crowd and boom raise hydraulic services there are rare occasions when the flow may divert through the displacement ram circuit and cause the boom to raise under the power of the displacement ram. Pressure monitoring of the lift ram full bore (rod end) maintains a minimum pressure ensuring correct operation of the boom service. A pressure transducer is installed in the full bore (rod end) side of the lift ram circuit. If the pressure in the circuit is less than 10 bar and the crowd and lift service operate at the same time the hydraulic ECU responds by deselecting the crowd service. This allows the pressure to increase in the lift ram circuit. When the pressure in the circuit raises to more than 20 bar the hydraulic ECU responds by restoring normal operation of the crowd service. On machines with SRS the SRS pressure transducer is used. For details of the SRS system refer to the SRS SYSTEM topic. K Related Topics ( T E9-2) On machines without SRS a pressure transducer is installed.

E9-5

E-35-17 Issue 02

E9-5

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Lift Pressure Balance System (S2) Component Location

Fig 3.

C129040.eps

Key 1

Pressure Transducer

Lift Ram

E9-6

E-35-17 Issue 02

E9-6

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Lift Pressure Balance System (S2)

Electrical Operation

– K Machines with SD,SE and SF Engines ( T E9-8) – K Machines with SH,SL and DH Engines ( T E9-9)

On machines with SRS the SRS pressure transducer is used. For details of the SRS system refer to the SRS SYSTEM topic. K Related Topics ( T E9-2)

1 2

4 3

Fig 4. Connector Pins

E9-7

E-35-17 Issue 02

C125070

E9-7

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Lift Pressure Balance System (S2) Machines with SD,SE and SF Engines

J1-14 J1-28

ECU

1 J2-29

4 J2-21

V 12

V 5

4.5 0.7 0.5

X C125080-C3.eps

Fig 5. V

Output (Volts)

SRS Pressure Transducer

Pressure (Bar)

Pin 3 switch output signal

Hydraulic ECU

Pin 4 variable output signal

Harness Connector SR02 Connectors

Pins

SR02

Details

i001

Chassis Harness to Boom Harness Connector.

Hydraulic Control ECU Connector J2.

C023 C018

E9-8

Hydraulic Control ECU Connector J1.

E-35-17 Issue 02

E9-8

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Lift Pressure Balance System (S2) Machines with SH,SL and DH Engines

J5-7 J5-14

ECU

1 J5-16

4 J2-17

V 12

V 5

4.5 0.7 0.5

X C125080-C4.eps

Fig 6. V

Output (Volts)

SRS Pressure Transducer

Pressure (Bar)

Pin 3 switch output signal

Hydraulic ECU

Pin 4 variable output signal

Harness Connector SR02 Connectors

Pins

SR02

i001

C049

C046

E9-9

Details Chassis Harness to Boom Harness Connector. Hydraulic Control ECU Connector J5. 17

Hydraulic Control ECU Connector J2.

E-35-17 Issue 02

E9-9

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Tilt/Lift/Extension Ram Counterbalance Valves (S1)

Tilt/Lift/Extension Ram Counterbalance Valves (S1) Operation Overview The lift, extend and counterbalance valve.

tilt

ram

circuits

include

spool will move the boom or carriage and the weight will not affect it. Therefore when the lift/lower or crowd/dump services are not operated the valve is closed effectively locking the ram in position regardless of load.

When there is a load on the carriage the weight of the load could cause the boom to lower or dump. This would be dangerous as the load could lower suddenly or fall off the carriage. To prevent this, counterbalance valves are fitted to make sure that only the pressure of flow from the control valve

Key

K Fig 7. ( T E9-10)

Extend Ram Counterbalance Valve

Tilt Ram Counterbalance Valve

Lift Ram Counterbalance Valve

Component Location

Fig 7.

E9-10

E-35-17 Issue 02

C129010.jpg

E9-10

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Tilt/Lift/Extension Ram Counterbalance Valves (S1)

Hydraulic Operation and Schematics Valve Schematic

Fig 8. Key

K Fig 8. ( T E9-11)

Lift and Extend Counterbalance Valves

Tilt Counterbalance Valve

E9-11

E-35-17 Issue 02

C129010-C1.eps

E9-11

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Tilt/Lift/Extension Ram Counterbalance Valves (S1) System Schematic The schematic diagrams show a typical system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E9-2) K Fig 9. ( T E9-12) This illustration shows no hydraulic service operated. There is a load on the carriage and the weight of this load

is trying to compress the ram 4. The counterbalance valve housing 1 contains two valves to prevent the ram compressing due to the pressure in the ram returning to tank. The check valve 2 only allows flow when the piston end service is operated. The pressure valve 3 will only open and allow a return to tank when there is pressure in the + line feeding the piston side of the ram. If there is no pressure in this line the valve 3 will remain closed and the ram is locked in position.

4 1 2

_ 3 +

C129020-C1.eps

Fig 9. K Fig 10. ( T E9-12) In this illustration the rod side service spool in the control valve is operated. Pressure is supplied to retract the ram

4. When the pressure in the + line is greater than the pressure from the spring 3a, the pressure valve 3 opens and allows the pressure from the piston side of the ram to return to tank. The check valve 2 remains closed.

4 1 _

3 + Fig 10.

E9-12

E-35-17 Issue 02

C129020-C2.eps

E9-12

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Tilt/Lift/Extension Ram Counterbalance Valves (S1) the ram 4. The check valve 2 opens to supply the ram. The pressure valve 3 remains closed.

K Fig 11. ( T E9-13) In this illustration the piston side service spool in the control valve is operated. Pressure is supplied to extend

4 1 2 + 3 _ C129020-C3.eps

Fig 11. Piston side service operated

Electrical Operation There are no electrical devices used in this system.

E9-13

E-35-17 Issue 02

E9-13

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Extension Ram Counterbalance Valves (S2)

Extension Ram Counterbalance Valves (S2) Operation Overview The extend ram circuits include a counterbalance valve.

Key

K Fig 7. ( T E9-10)

Inner Extend Ram Counterbalance Valve

Outer Extend Ram Counterbalance Valve

The counterbalance valves are used to prevent unwanted/ unexpected boom movement due to imbalance of pressures acting upon the ram.

Component Location

Fig 12.

E9-14

E-35-17 Issue 02

C130440.eps

E9-14

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Extension Ram Counterbalance Valves (S2)

Hydraulic Operation and Schematics Valve Schematic

Fig 13. Key

K Fig 8. ( T E9-11)

Inner Extend Ram Counterbalance Valve

Outer Extend Ram Counterbalance Valve

C129010-C2

Electrical Operation There are no electrical devices used in this system.

E9-15

E-35-17 Issue 02

E9-15

Section E9 - Hydraulics Boom Pressure Balance SYSTEM Extension Ram Counterbalance Valves (S2)

Page left intentionally blank

E9-16

E-35-17 Issue 02

E9-16

Section E10 - Hydraulics

Universal Hydraulic Circuit Faults Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E10-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E10-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E10-2) K Fault Finding ( T E10-3)

E10-1

E-62-01 Issue 01

E10-1

Section E10 - Hydraulics Universal Hydraulic Circuit Faults Related Topics

Topic Titles

Sub Titles

Service Tools

ALL

ALL (Care and Safety)(1)

ALL

Electrical Schematics

ALL

Electrical Harness SYSTEM

ALL

Applications

ALL

Systems and Schematics

ALL

Devices - Applications

ALL

Fault Code SYSTEM

ALL

(1) You must obey all of the relevant care and safety procedures.

E10-2

E-62-01 Issue 01

E10-2

Section E10 - Hydraulics Universal Hydraulic Circuit Faults Fault Finding

Fault Finding Note: This topic refers to hydraulic test procedures. For these procedures refer to the applicable Hydraulic SYSTEM topic. K Related Topics ( T E10-2) Fault Descriptions:

Tables

K Table 2. ONE service fails, or is slow to operate. ( T E10-3) K Table 3. The engine tends to stall when hydraulics are under load. ( T E10-3) K Table 5. Parallel lift faulty ( T E10-4) K Table 6. Ram creep ( T E10-4) Table 2. ONE service fails, or is slow to operate. Possible Cause

Action

LLMC Active

Ensure operator fully understand the characteristics of the LLMC system.

Boom and stabiliser interlocks engaged.(1)

Educate the operator. Ensure operator fully understands the characteristics of the interlock system(1).

Associated service pipework or hoses leaking, damaged, trapped or kinked.

Check pipework and hoses, replace as required.

Auxiliary relief valve (ARV) out of adjustment or defective.

Check and adjust as required.

Associated ram leaking.

Carry out ram leakage checks, renew seals as required.

Associated service spool not operating correctly.

– Manual Spools: Check that the control lever and associated linkage is operating the spool to full displacement, rectify as required. – Servo Operated Spools: Check the condition of the related harness wiring and connectors for damage. Check the solenoid coil for open or short circuits. Measure the solenoid coil resistance. Renew the solenoid coil. – Servo Operated Spools: Check the condition of the related harness wiring and connectors for damage. Renew the electronic control lever assembly.

Pressure compensator piston sticking due to contamination. Dismantle and inspect the associated pressure compensator piston. Service spool or associated load hold check valves damaged or sticking due to contamination.

Dismantle and inspect the associated service spool or load hold check valves.

Electronic fault

Use Servicemaster to determine the problem. Refer to Section M. K Related Topics ( T E10-2)

Counterbalance valve not working correctly.

Check operation of applicable counterbalance valve.

Counterbalance pressure sensor (lift ram) not working correctly

Check operation of lift ram pressure sensor.

(1) 510-56, 512-56, 540-170 and 550-170 Machines. Table 3. The engine tends to stall when hydraulics are under load. Possible Cause

Action

Main Relief Valve (MRV) or Load sense relief valve (LSRV) Check and adjust as required. out of adjustment or defective.

E10-3

E-62-01 Issue 01

E10-3

Section E10 - Hydraulics Universal Hydraulic Circuit Faults Fault Finding Possible Cause

Action

Poor engine performance.

– Check engine performance. – Check engine High and Low idle speeds. – Check MRV/LSRV setting and adjust as required. – Check ARV setting and adjust as required. – Machines with Variflow Pump: Variflow pump fault.

Possible Cause

Table 4. Forks creep down Remedy

Circuit hosed incorrectly. Has any work been completed on Check circuit. Re-route the hoses if necessary. the machine recently? Tilt ram HBCV leaking, tilt ram seals leaking, control valve spool leaking or valve block section leaking internally.

Check for leakage in the tilt ram circuit.

Counterbalance valve not working correctly.

Check operation of applicable counterbalance valve.

Possible Cause

Table 5. Parallel lift faulty Remedy

Displacement/lift link valve broken or leaking.

– Examine valve; is ball OK? Fit blank to isolate valve from circuit. – Fit latest type valve. – Check pipes, tilt spool, HBCV for missing ball.

Tilt section ARVs set incorrectly, causing oil to exit from tilt/ Check tilt ARV setting. Adjust if required. compensating ram circuit. Tilt section ARVs could be sticking open due to contamination.

Clean or new as required.

Leaking seals in tilt ram or compensation ram.

Check tilt/compensation rams for leakage (use hand pump if available). Renew seals as required.

Counterbalance valve not working correctly.

Check operation of applicable counterbalance valve.

Counterbalance pressure sensor (lift ram) not working correctly

Check operation of lift ram pressure sensor.

Possible Cause

Table 6. Ram creep Action

Associated ram or pipe lines from ram leaking.

Check and rectify as required.

Check valve.

Check operation and rectify as required.

Counterbalance valve not working correctly.

Check operation of applicable counterbalance valve.

Counterbalance pressure sensor (lift ram) not working correctly

Check operation of lift ram pressure sensor.

E10-4

E-62-01 Issue 01

E10-4

Section E11 - Hydraulics

Parallel Circuit Faults Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E11-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E11-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E11-2) K Fault Finding ( T E11-3)

E11-1

E-62-02 Issue 01

E11-1

Section E11 - Hydraulics Parallel Circuit Faults Related Topics

Topic Titles

Sub Titles

ALL (Care and Safety)

Electrical Schematics

ALL

Electrical Harness SYSTEM

ALL

Applications

ALL

Systems and Schematics

ALL

Devices - Applications

ALL

Fault Code SYSTEM

ALL

(1)

(1) You must obey all of the relevant care and safety procedures.

E11-2

E-62-02 Issue 01

E11-2

Section E11 - Hydraulics Parallel Circuit Faults Fault Finding

Fault Finding Note: This topic refers to hydraulic test procedures. For these procedures refer to the applicable Hydraulic SYSTEM topic. K Related Topics ( T E11-2)

Note: This topic refers to electrical test procedures. For these procedures refer to Section M-Applications. K Related Topics ( T E11-2)

Tables Fault: K Table 2. Lack of power at all hydraulic functions ( T E11-3) K Table 3. All mechanically operated hydraulic services slow to operate ( T E11-3) K Table 4. All solenoid/servo operated hydraulic services slow to operate ( T E11-3) K Table 5. 3 stage boom extend retract system ( T E11-4) Table 2. Lack of power at all hydraulic functions Action

Possible Cause Insufficient hydraulic fluid.

Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, renew as required.

Engine performance.

Check engine performance.

MRV setting incorrect.

Check and adjust as required.

Low pump flow.

– Check pump flow. – Check for external leaks, renew seals. – Priority valve sticking, see Section H - Steering. K Related Topics ( T E11-2) – Renew pump. Table 3. All mechanically operated hydraulic services slow to operate Action

Possible Cause

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Check pipe lines and renew as required.

MRV setting incorrect.

Check and adjust as required.

Low pump flow.

– Check pump flow. – Check for external leaks, renew seals. – Priority valve sticking, see Section H - Steering. K Related Topics ( T E11-2) – Renew pump.

Possible Cause

Table 4. All solenoid/servo operated hydraulic services slow to operate Action

K Table 3. All mechanically operated hydraulic services slow to operate ( T E11-3). Low pilot pressure.

– Check that the pressure maintenance valve is not sticking open. – Check the pressure reducing valve. – Check servo pressure.

Solenoid power supply not present.

E11-3

Check fuse 2.

E-62-02 Issue 01

E11-3

Section E11 - Hydraulics Parallel Circuit Faults Fault Finding Action

Table 5. 3 stage boom extend retract system Yes

Is the machine experiencing boom extend or retract problems?

Go to 2

Bleed air from hydraulic cylinders. OK now?

Done

Go to 3

Does the inner/intermediate boom extend or retract?

Go to 7

Go to 4

Pressure test hydraulic pump. Rectify if required. OK now? Done

Go to 5

Check MRV in valve block and for leakage passed pistons Done in both rams. Investigate and rectify as required. OK now?

Go to 6

Replace hose-burst check valve(s) on inner/outer extension ram(s). OK now?

Done

Go to 7

Are the inner/intermediate booms over-running after deselecting extend lever or is there an unexpected surge after a retract operation?

Go to 8

Go to 9

Renew motor spool in extend slice. See TI 5/197. OK now? Done

Do the inner/intermediate booms go out of phase?

Go to 10

Go to 2

Does the operator periodically fully retract inner and intermediate booms to re-phase hydraulic cylinders?

Go to 12

Go to 11

Fully retract inner and intermediate booms to re-phase hydraulic cylinders. OK now?

Done

Go to 12

Does the inner boom fully retract leaving intermediate boom slightly extended?

Go to 13

Go to 14

Strip inner extension cylinder and ensure make-up valve in Done piston head is intact and free from contamination. If the valve is damaged, replace with improved type. Adjust make-up valve and bleed cylinders. OK now?

Go to 2

Does the outer boom fully retract leaving intermediate boom slightly extended?

Go to 2

Strip outer extension cylinder and ensure make-up valve in Done piston head is intact and free from contamination. If the valve is damaged, replace with improved type. Adjust make-up valve and bleed cylinders. OK now?

Go to 15

Done

Go to 2

Note: The forks will continue to crowd back when the boom reaches maximum elevation angle, if the lift lever is not deselected on machines fitted with displacement link valve. This is normal and is caused by oil bleeding from the lift circuit to the tilt circuit.

E11-4

E-62-02 Issue 01

E11-4

Section E12 - Hydraulics

Flowshare Servo Circuit Faults Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E12-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E12-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E12-2) K Fault Finding ( T E12-3)

E12-1

E-62-05 Issue 01

E12-1

Section E12 - Hydraulics Flowshare Servo Circuit Faults Related Topics

Topic Titles

Sub Titles

ALL (Care and Safety)

Electrical Schematics

ALL

Electrical Harness SYSTEM

ALL

Applications

ALL

Systems and Schematics

ALL

Devices - Applications

ALL

Fault Code SYSTEM

ALL

(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E12-2

E-62-05 Issue 01

E12-2

Section E12 - Hydraulics Flowshare Servo Circuit Faults Fault Finding

Fault Finding Note: This topic refers to hydraulic test procedures. For these procedures refer to the applicable Hydraulic SYSTEM topic. K Related Topics ( T E12-2)

E12-3

E-62-05 Issue 01

E12-3

Section E12 - Hydraulics Flowshare Servo Circuit Faults Fault Finding

Tables Fault: K Table 2. Lack of power at all hydraulic functions ( T E12-4) K Table 3. All services slow to operate ( T E12-4) K Table 4. ONE service fails, or is slow to operate. ( T E12-4)

Possible Cause

Table 2. Lack of power at all hydraulic functions Action

Insufficient hydraulic fluid.

Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, renew as required.

Flushing valve piston within the control valve block inlet section sticking open due to contamination.

Dismantle and inspect the flushing valve piston. Refer to the Control Valve Topic.

Engine performance.

Check engine performance.

MRV setting incorrect.

Check and adjust as required.

Low pump flow.

– Check pump flow. – Check for external leaks, renew seals. – Priority valve sticking, see Section H - Steering. – Renew pump.

Possible Cause

Table 3. All services slow to operate Action

Insufficient hydraulic fluid.

Check for leaks and top up as required.

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Check pipe lines and renew as required.

Flushing valve piston within the control valve block inlet section sticking open due to contamination.

Dismantle and inspect the flushing valve piston. Refer to the Control Valve Topic.

MRV setting incorrect.

Check and adjust as required.

Low pump flow.

– Check pump flow. – Check for external leaks, renew seals. – Priority valve sticking, see Section H - Steering. – Renew pump.

Possible Cause

Table 4. ONE service fails, or is slow to operate. Action Educate the operator. Ensure operator fully understands the characteristics of the interlock system.

Boom and stabiliser interlocks engaged.(1)

Refer to K Related Topics ( T E12-2) Associated service pipework or hoses leaking, damaged, trapped or kinked.

Check pipework and hoses, replace as required.

Auxiliary relief valve (ARV) out of adjustment or defective.

Check and adjust as required.

Associated ram leaking.

Carry out ram leakage checks, renew seals as required.

E12-4

E-62-05 Issue 01

E12-4

Section E12 - Hydraulics Flowshare Servo Circuit Faults Fault Finding Possible Cause

Action

Associated service spool not operating correctly.

Check the servo control lever for correct operation.

Dismantle and inspect the associated service spool or load hold check valves.

Counterbalance valve not working correctly.

Check operation of applicable counterbalance valve.

Counterbalance pressure sensor (lift ram) not working correctly

Check operation of lift ram pressure sensor.

(1) 510-56, 512-56 and 514-56 Machines

E12-5

E-62-05 Issue 01

E12-5

Section E12 - Hydraulics Flowshare Servo Circuit Faults Fault Finding

Page left intentionally blank

E12-6

E-62-05 Issue 01

E12-6

Section E13 - Hydraulics

Hydraulic SYSTEM Pressure Tests (E-61-12) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E13-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E13-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E13-2) K Test Procedures ( T E13-3) K Checking Pump Flow ( T E13-3) K Testing Load Sense Relief Valve (LSRV) ( T E13-4) K Relief Valve Adjustment ( T E13-5) K Testing Auxiliary Relief Valve (ARV's) ( T E13-6) K Checking the Pilot Pressure ( T E13-7)

E13-1

E-61-12 Issue 01

E13-1

Section E13 - Hydraulics Hydraulic SYSTEM Pressure Tests (E-61-12) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Hydraulic System

Checking the Hydraulic Fluid Level

Longitudinal Load Moment SYSTEM

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Applications

ALL

Systems and Schematics

ALL

Pump Flow Test (Gear Pumps)

ALL

GearPump Operation

ALL

GearPump - Removal and Replacement

ALL

Applications

ALL

ALL ALL

(1)

Description

892/00268(1)

Flow Monitoring Kit and Relevant Adaptors

892/00253

Hydraulic Pressure Test Kit and Relevant Adaptors

892/00270

Load Valve

(1) (1)

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

E13-2

E-61-12 Issue 01

E13-2

Section E13 - Hydraulics Hydraulic SYSTEM Pressure Tests (E-61-12) Test Procedures

Test Procedures For system specifications and pressures refer to the applicable hydraulic system topic.

Checking Pump Flow To check pump flow refer to the Pump Flow Test (Gear Pumps) topic. K Related Topics ( T E13-2)

E13-3

E-61-12 Issue 01

E13-3

Section E13 - Hydraulics Hydraulic SYSTEM Pressure Tests (E-61-12) Test Procedures

Testing Load Sense Relief Valve (LSRV)

The maximum pressure that can be achieved within the main hydraulic system is set by the load sense relief valve (LSRV) B at the control valve block inlet section. To check the load sense relief valve setting carry out the procedure described below:

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to the main system pressure test point A (located behind the cab as shown).

Fig 2. 2 Fig 1.

C067780-C1

!MWARNING

C080580

With the engine running at 1500 rpm, check the load sense relief valve setting by operating the boom lower service and hold the boom ram fully closed. Note the maximum reading on the pressure gauge. The maximum pressure should be as stated in specifications.

Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Make sure that the hydraulic fluid is at working temperature, i.e. 50Â°C (122Â°F).

E13-4

E-61-12 Issue 01

E13-4

Section E13 - Hydraulics Hydraulic SYSTEM Pressure Tests (E-61-12) Test Procedures

Relief Valve Adjustment 1

If the maximum pressure is incorrect, adjust the relief valve as described below: a

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E13-2)

b Remove the plastic cap from the load sense relief valve. Loosen the locknut and turn the adjuster screw clockwise to increase pressure and counter-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required.

E13-5

E-61-12 Issue 01

E13-5

Section E13 - Hydraulics Hydraulic SYSTEM Pressure Tests (E-61-12) Test Procedures

Testing Auxiliary Relief Valve (ARV's) Important: The engine must not be run at maximum speed as a significant increase in pressure will be recorded. 1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E13-2)

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to the test point.

Start the engine and bring the hydraulic system upto working temperature 50ยบ C (122ยบ F).

Set the engine to idle rev/min. and operate the relevant service to full travel. Hold while checking the maximum gauge reading which should be as stated in specifications.

If the pressure is incorrect, adjust the relevant A.R.V. K Relief Valve Adjustment ( T E13-5)

E13-6

E-61-12 Issue 01

E13-6

Section E13 - Hydraulics Hydraulic SYSTEM Pressure Tests (E-61-12) Test Procedures

Checking the Pilot Pressure

Make sure that the hydraulic oil is at working temperature, i.e. 50Â°C (122Â°F). 1

Connect a 0 - 70 bar (0 - 1000 lbf/in2) pressure gauge to the pilot pressure test point A (at the pilot pressure supply valve as shown).

C066490-C1

Fig 3. 506-36, 507-42 and 509-42 Machines

With the engine running at 1500 rpm, check the reading on the pressure gauge. The pilot pressure should be as stated below: 30 bar (30.6 kgf/cm2, 435 lbf/in2)

Note: The pilot pressure regulating valve B is factory set and sealed with a plastic tamper proof cap. Important: The extent of permissible servicing is the renewal of the solenoid coil. Further dismantling of the valve is not recommended. If the valve is suspected as being faulty it must be renewed as a complete assembly. Note also that the pilot circuit accumulator is a non serviceable part and is sealed for life. It is not possible to recharge the accumulator with nitrogen. Fig 4. 510-56, 512-56 and 514-56 Machines

E13-7

E-61-12 Issue 01

C078380

E13-7

Section E13 - Hydraulics Hydraulic SYSTEM Pressure Tests (E-61-12) Test Procedures

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E13-8

E-61-12 Issue 01

E13-8

Section E14 - Hydraulics

Pump Flow Tests - Gearpump (E-61-03) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T E14-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T E14-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E14-2) K Checking Pump Flow ( T E14-3) K Double Pump ( T E14-3) K Triple Pump ( T E14-5)

E14-1

E-61-03 Issue 01

E14-1

Section E14 - Hydraulics Pump Flow Tests - Gearpump (E-61-03) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Hydraulic System

Checking the Hydraulic Fluid Level

Applications

ALL

Systems and Schematics

ALL

GearPump Operation

ALL

GearPump - Removal and Replacement

ALL

Applications

ALL

ALL ALL

(1)

Description

892/00268(1)

Flow Monitoring Kit and Relevant Adaptors

892/00253(1)

Hydraulic Pressure Test Kit and Relevant Adaptors

892/00270

Load Valve

(1)

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

E14-2

E-61-03 Issue 01

E14-2

Section E14 - Hydraulics Pump Flow Tests - Gearpump (E-61-03) Checking Pump Flow

Checking Pump Flow Double Pump The separate sections of the gear pump assembly supply hydraulic oil to the main services circuits, to the steering circuit and to the hydraulic cooling fan circuit. To determine the source of a problem i.e pump, steer circuit or services circuit, measure the output flow at system pressure from each pump outlet port in turn.

A326060-1

Fig 1. Test Equipment 3

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

Connect a flow meter A, 0-400 bar (0-6000 lbf/in2) pressure gauge B and load valve C into the discharge line from each pump section in turn as described below:

GEN-4-1_1

Main Service Pump (Section 1)

Carry out General Safety procedures, see Section 2 General Procedures. K Related Topics ( T E14-2)

Disconnect hose D from the pump. Fit the flow meter and load valve between hose D and the pump.

INT-3-1-11_2

Vent the hydraulic pressure, see Section 2 - General Procedures. K Related Topics ( T E14-2)

Fig 2.

E14-3

E-61-03 Issue 01

C119800

E14-3

Section E14 - Hydraulics Pump Flow Tests - Gearpump (E-61-03) Checking Pump Flow Cooling Fan Pump (Section 2) a

Disconnect hose E from the pump. Fit the flow meter and load valve between hose E and the pump.

Check the flow reading which should be as stated in Specifications. If the flow reading is low or you are unable to obtain the pressure required, refer to the Fault Finding topic. For testing the Priority Valve, see Section H Steering. K Related Topics ( T E14-2)

!MWARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS-1-2

Fig 3.

After completing the test, switch OFF the engine and allow to cool before disconnecting the test equipment and reconnecting the hydraulic hoses.

C119800-C1

Note: Make sure the load valve and flow meter is installed the correct way round i.e. with the direction arrow pointing away from the pump.

!MCAUTION Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT), before starting the following pressure test. Failure to do this could damage the pump. HYD-4-4_1

Start the engine and bring the hydraulic system up to working temperature 50ยบ C (122ยบ F).

Select the steering and control valve block spools to the neutral position.

Set the engine speed to 2200 rev/min., then carefully adjust the load valve 1-C so that the gauge reading increases to 240 bar (3500 lbf/in2).

E14-4

E-61-03 Issue 01

E14-4

Section E14 - Hydraulics Pump Flow Tests - Gearpump (E-61-03) Checking Pump Flow

Triple Pump

Main Service Pump (Section 1)

The separate sections of the gear pump assembly supply hydraulic oil to the main services circuits, to the steering circuit and to the hydraulic cooling fan circuit. To determine the source of a problem i.e pump, steer circuit or services circuit, measure the output flow at system pressure from each pump outlet port in turn.

Fit the flow meter and load valve in the discharge line 5-A at an applicable place in the hose and pipework. (There must be no other hydraulic connections between the pump and the load valve.)

b Disconnect the hose from the steer priority valve port. 5-B. Cap the open hose. Connect a slave hose 5-C to the hydraulic tank. Slowly remove the hydraulic tank filler cap and place the end of the slave hose inside the filler tube as shown.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Carry out General Safety procedures, see Section 2 General Procedures. K Related Topics ( T E14-2)

Fig 5.

Vent the hydraulic pressure, see Section 2 - General Procedures. K Related Topics ( T E14-2)

Steering Pump (Section 2) a

Fig 4. Test Equipment 3

C075060

Fit the flow meter and load valve in the discharge line 6-A at an applicable place in the hose and pipework. (There must be no other hydraulic connections between the pump and the load valve.)

A326060-1

Connect a flow meter 4-A, 0-400 bar (0-6000 lbf/in2) pressure gauge 4-B and load valve 4-C into the discharge line from each pump section in turn as described below:

E14-5

E-61-03 Issue 01

E14-5

Section E14 - Hydraulics Pump Flow Tests - Gearpump (E-61-03) Checking Pump Flow

!MCAUTION Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT), before starting the following pressure test. Failure to do this could damage the pump. HYD-4-4_1

Fig 6.

Start the engine and bring the hydraulic system upto working temperature 50ยบ C (122ยบ F).

Select the steering and control valve block spools to the neutral position.

Set the engine speed to 2200 rev/min., then carefully adjust the load valve 4-C so that the gauge reading increases to 240 bar (3500 lbf/in2).

Check the flow reading which should be as stated in Specifications.

C075060-C1

Cooling Fan Pump (Section 3) a

Fit the flow meter and load valve in the discharge line 7-A at an applicable place in the hose and pipework. (There must be no other hydraulic connections between the pump and the load valve.)

If the flow reading is low or you are unable to obtain the pressure required, refer to the Fault Finding topic. For testing the Priority Valve, see Section H Steering. K Related Topics ( T E14-2)

!MWARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS-1-2

Fig 7.

C075060-C2

Note: Make sure the load valve and flow meter is installed the correct way round i.e. with the direction arrow pointing away from the pump.

E14-6

E-61-03 Issue 01

Fig 8.

A326080-C2

E14-6

Section E14 - Hydraulics Pump Flow Tests - Gearpump (E-61-03) Checking Pump Flow 8

After completing the test, switch OFF the engine and allow to cool before disconnecting the test equipment and reconnecting the hydraulic hoses.

E14-7

E-61-03 Issue 01

E14-7

Section E14 - Hydraulics Pump Flow Tests - Gearpump (E-61-03) Checking Pump Flow

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E14-8

E-61-03 Issue 01

E14-8

Section E15 - Hydraulics

Flowshare Control Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E15-2) K Component Location ( T E15-3) K Hydraulic Operation and Schematics ( T E15-4) K Removal ( T E15-7) K Replacement ( T E15-8) K Dismantle and Assemble ( T E15-10) K Valve Block Sections ( T E15-10) K Dismantle ( T E15-10) K Assemble ( T E15-10) K Spool Removal ( T E15-13) K Spool Inspection ( T E15-13) K Spool Assembly ( T E15-13) K Load Sense Relief Valve ( T E15-15) K Auxiliary Relief Valves (ARV's) ( T E15-16) K Flow Regulator Valve ( T E15-17) K Pressure Compensator Valves ( T E15-18) K Load Hold Check Valves ( T E15-19)

E15-1

E-06-28 Issue 02

E15-1

Section E15 - Hydraulics Flowshare Control Valve Related Topics

Topic Titles

Sub Titles

Applications

ALL

Torque Settings

ALL (Care and Safety)

Hydraulic System

Checking the Hydraulic Fluid Level

Applications

ALL

Flowshare Hydraulic SYSTEM

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E15-2

E-06-28 Issue 02

E15-2

Section E15 - Hydraulics Flowshare Control Valve Component Location

Component Location Component Key: K Fig 1. ( T E15-3) 1

Boom Lift/Lower Spool

Load sense relief valve

Boom Extend/Retract Spool

L.S. relief valve drain port

Carriage Tilt/Crowd Spool

Flow regulator valve

Auxiliary relief valve

Flushing valve housing

Service ports

Inlet port

Pressure compensating valves

Tank port

Load sense port

Fig 1.

E15-3

E-06-28 Issue 02

C026310-C3

E15-3

Section E15 - Hydraulics Flowshare Control Valve Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Item 1A

Flushing Valve

Flushing Valve Spring

LSRV

Load Hold Check Valve

Tilt Spool

Pressure Compensation Valve

Tilt Head Side Auxiliary Relief Valve

Tilt Rod Side Auxiliary Relief Valve

Extend Spool

Extend Head Side Auxiliary Relief Valve

Lift Spool

E15-4

E-06-28 Issue 02

E15-4

Section E15 - Hydraulics Flowshare Control Valve Hydraulic Operation and Schematics

Fig 2. Flowshare Valve Block Schematic

E15-5

E-06-28 Issue 02

C065690-C1

E15-5

Section E15 - Hydraulics Flowshare Control Valve Hydraulic Operation and Schematics

Individual Valve Slice

Oil from the main hydraulic pump arrives at the inlet gallery P. When the relevant service spool D is selected, the spool moves against the force of the centring spring E, allowing the oil to flow to move the required service. When the service spool D is de-selected the centring spring returns the spool to the neutral position. When one or more services are selected the pressure compensator valves F detect the service generating the highest pressure and allows the pump to deliver oil at sufficient pressure to move the load. Load hold check valves G prevent the load falling back if the load pressure is greater than the pump pressure. The closed centre design ensures consistent service operation regardless of load.

Fig 4. Fig 3. Pilot Operated Spool

C068740

A405000-C1

K Fig 3. ( T E15-6) The control valve has pilot operated spools. The service spools are of a closed-centre design and incorporate pressure compensating valves F, for each service.

E15-6

E-06-28 Issue 02

E15-6

Section E15 - Hydraulics Flowshare Control Valve Removal and Replacement

Removal and Replacement Removal

Incorrect handling will result in permanent damage to the valve assembly. The valve block should be lifted by holding either end of the valve body 5-C.

With the valve block suitably supported, undo the mounting bolts 5-A. Carefully lift the valve block 5-C clear of the mounting bracket 5-D.

Park the machine and make it safe. Install the boom maintenance strut. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E15-2)

Gain access to the valve and disconnect and blank any hoses or pipes which may interfere with the removal of the valve assembly.

Disconnect the pilot control hoses from the valve spools at 5-B.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

E15-7

E-06-28 Issue 02

E15-7

Section E15 - Hydraulics Flowshare Control Valve Removal and Replacement

Fig 5.

C067780-C4

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Operate the machines hydraulic system. Check for correct operation and leaks. – Torque tighten the Settings ( T E15-9)

hoses.K Table 2.

Torque

Note: For hose connectors with no specified torque setting - use the JCB Standard torque setting. Refer to Section 1 - Torque Settings. K Related Topics ( T E15-2) – Check the hydraulic Topics ( T E15-2)

fluid

level.

K Related

– After replacement, check LSRV and ARV pressures. K Related Topics ( T E15-2)

E15-8

E-06-28 Issue 02

E15-8

Section E15 - Hydraulics Flowshare Control Valve Removal and Replacement

Fig 6. Table 2. Torque Settings Nm kgf m

Item 1

24-27

2 3

lbf ft

2.4-2.75

17.7-19.9

115-126

11.7-12.8

84.8-93

84-92

8.5-9.3

62-68

84-92

8.5-9.3

62-68

122

12.4

E15-9

C130710.jpg

E-06-28 Issue 02

E15-9

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Dismantle and Assemble Valve Block Sections K Fig 7. ( T E15-12). The valve block is a `sectional' type, which is made up of a number of separate sections. The illustration is intended as a guide to identifying the components. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable. Make sure that components are assembled in their original positions. Great care should be taken when dismantling and assembling a valve to avoid the following: – Contamination

– Clean the valve components in an appropriate solvent. Ensure that the mating faces of the valve sections are thoroughly clean before assembly. – Renew the Ò' rings located between the valve sections. Make sure the Ò' ring seals are not trapped or damaged. – Check the Load Hold Check Valve Ò' rings and replace if necessary. K Load Hold Check Valves ( T E15-19). – Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. – If the tie rods 5 were unscrewed from the inlet section 4, apply JCB Threadlocker and Sealer to the threads before refitting. Apply JCB Threadlocker and Sealer to the threads of nuts 1.

– Damage to spools – Damage to seal grooves Any of the above may result in possible problems with the operation of the valve.

Item

Table 3. Torque Settings Nm kgf m

lbf ft

25.8

3.6

Dismantle 1

Remove the valve block from the machine.

Remove the three tie rod nuts 1.

Carefully separate and remove the end plate 2 followed by the remaining service sections 3. If the inlet section 4 is to be replaced, remove and retain the tie rods 5.

Assemble Assembly is the opposite of the dismantling procedure. During the assembly procedure do this work also:

E15-10

E-06-28 Issue 02

E15-10

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble Component Key: 1

Tie Rod Nuts

End Plate

Service Sections

Inlet - Outlet Section

Tie Rods

Load Hold Check Valves

Pressure Compensator Valves

Service Spool - Pilot Operated

Flushing Valve

Load Sense Relief Valve

Flow Regulator Valve

Auxiliary Relief Valve (ARV)

Blanking Plug

E15-11

E-06-28 Issue 02

E15-11

Section E15 - Hydraulics Flowshare Control Valve

Fig 7. Valve Components

C027810-C2

Dismantle and Assemble

E15-12

E-06-28 Issue 02

E15-12

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Spool Removal

– Clean the valve components in an appropriate solvent.

K Fig 8. ( T E15-14). It is possible to remove a spool without removing the valve block from the machine.

– Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. – Renew 'O' ring 3.

– Spool Orientation: The spool may have a ring A machined into it, which must be positioned downwards.K Fig 8. ( T E15-14).

Item

Table 4. Torque Settings Nm kgf m

lbf ft 7.4

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Before commencing work, ensure that the exterior of the valve block and the working area are thoroughly cleaned and free of possible sources of contamination. 1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E15-2)

Disconnect and blank any hoses or pipes which may interfere with the removal of the spool.

Disconnect and blank the pilot hoses connected to the end caps 2 at each end of the spool.

Remove the screws 1 and carefully lift off the end cap 2. Retrieve the spring 4 and spring retainer 5, then withdraw the spool 6 from the valve body.

Note: When removing 'O' Rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL 'O' Rings and back-up rings. DO NOT use worn or damaged items.

Spool Inspection Inspect the valve components for scratches, pitting, corrosion or any other type of damage. Replace as necessary.

Spool Assembly Assembly is the opposite of the dismantling procedure. During the assembly procedure do this work also:

E15-13

E-06-28 Issue 02

E15-13

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Fig 8.

E15-14

E-06-28 Issue 02

C007750-C3

E15-14

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Load Sense Relief Valve

– Make sure the tamper proof cap 5 supplied with the valve is fitted.

The load sense relief valve is not serviceable. Replace the complete valve if it is defective.

– Replace all 'O' rings and back-up rings.

Important: Do not remove or damage the tamper proof cap as this may invalidate a warranty claim.

– Lubricate the parts with JCB Hydraulic Fluid before assembling. – Adjust the LSRV pressure setting as required. K Related Topics ( T E15-2)

Removal 1

Remove the valve assembly 4 from the valve block.

Remove the `O' rings 1 & 3 and thrust ring 2.

Item 4

Table 5. Torque Settings Nm kgf m 45

4.5

lbf ft 33

Note: When removing 'O' Rings and seals, use a rounded tool that will not cause any damage to the seal grooves. Discard all 'O' Rings and back-up rings. Do not use worn or damaged items.

Fig 9.

C051640

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

E15-15

E-06-28 Issue 02

E15-15

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Auxiliary Relief Valves (ARV's) The auxiliary relief valves are not serviceable. The complete valve must be replaced if it is defective. Important: Do not remove or damage the tamper proof cap as this may invalidate a warranty claim.

Removal 1

Remove the valve assembly 5 from the valve block.

Remove the `O' rings 2 & 4 and thrust ring 3.

If necessary remove the check valve assembly 1. See K Load Hold Check Valves ( T E15-19).

Note: When removing 'O' Rings and seals, use a rounded tool that will not cause any damage to the seal grooves. Discard all 'O' Rings and back-up rings. Do not use worn or damaged items.

Replacement Replacement is the opposite of the removal procedure. Fig 10.

During the replacement procedure do this work also:

C051630

– Make sure the tamper proof cap 6 supplied with the valve is fitted. – Replace all 'O' rings and back-up rings. – Lubricate the parts with JCB Hydraulic Fluid before assembling. – Adjust the ARV pressure setting as required. K Related Topics ( T E15-2)

Item 5

E15-16

Table 6. Torque Settings Nm kgf m 70

7.13

lbf ft 52

E-06-28 Issue 02

E15-16

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Flow Regulator Valve

Note: If any part other than `O' rings are damaged the entire valve must be renewed.

K Fig 11. ( T E15-17).

Assemble

Removal

Assembly is the opposite of the dismantling procedure.

It is possible to remove a valve without removing the valve block from the machine.

During the assembly procedure do this work also:

!MWARNING

– Clean the valve components in an appropriate solvent.

– Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. – Renew all 'O' rings and back-up rings. – Make sure to fit filter gauze 5 the correct way round.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E15-2)

Disconnect and blank any hoses or pipes which may interfere with the removal of the flow regulator valve.

Unscrew the flow regulator valve from the valve block. Cover the ports to prevent the ingress of dirt and remove to a clean working area.

Dismantle 1

Unscrew and remove top plug 1.

Carefully remove shims 2, spring 3 and piston 4.

Inspection 1

Fig 11. Flow Regulator Valve

Inspect the valve components for scratches, pitting, corrosion or any other type of damage. Clean the filter gauze 5 fitted in the end of the valve body.

E15-17

A403850-1

Item

Table 7. Torque Settings Nm kgf m

lbf ft

14.8

E-06-28 Issue 02

E15-17

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Pressure Compensator Valves Removal

To gain access to the pressure compensator valves, remove the middle tie rod from the hole A (leaving the valve block sections held together with the remaining two tie rods). Fig 12.

In order to remove the middle tie rod, it may be necessary to undo the valve block securing nuts, and pull the valve block away from the chassis. 2

Use an 8mm Allen key to remove the compensator plug 1.

Use a magnet to extract the compensator valve 2 from its bore.

Inspect the valve components for scratches, pitting, corrosion or any other type of damage. Replace as necessary.

764750-C3

Item

Table 8. Torque Settings Nm kgf m

lbf ft

44.3

6.1

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Clean the valve components in an appropriate solvent. – Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. – Renew all 'O' rings and back-up rings. – Apply JCB Threadlocker and Sealer to the threads of the tie rod, and tie rod nut before fitting.

E15-18

E-06-28 Issue 02

E15-18

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

Load Hold Check Valves Removal

Fig 13.

764740-C3

GEN-4-1_1

Remove the valve block machine.K Removal ( T E15-7).

from

the

To gain access to the load hold check valves, separate the valve block sections. K Valve Block Sections ( T E15-10).

Use an Allen key to remove the load hold check valve plug 1.

Remove spring 2 and poppet 3.

Inspect the valve components for scratches, pitting, corrosion or any other type of damage. Ensure good condition of seating faces on poppets 3, and on the mating faces in the valve block. Replace as necessary.

Item

Table 9. Torque Settings Nm kgf m

lbf ft

22.1

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Clean the valve components in an appropriate solvent. – Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. – Renew all 'O' rings and back-up rings. – Carefully assemble the valve block sections. K Valve Block Sections ( T E15-10).

E15-19

E-06-28 Issue 02

E15-19

Section E15 - Hydraulics Flowshare Control Valve Dismantle and Assemble

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E15-20

E-06-28 Issue 02

E15-20

Section E16 - Hydraulics

Parallel Control Valve - 2 Section Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E16-2) K Hydraulic Operation and Schematics ( T E16-3) K Removal ( T E16-4) K Replacement ( T E16-5) K Dismantle and Assemble ( T E16-6) K Valve Block Sections ( T E16-6)

E16-1

E-06-29 Issue 02

E16-1

Section E16 - Hydraulics Parallel Control Valve - 2 Section Related Topics

Topic Titles

Sub Titles

Applications

ALL

Torque Settings

ALL (Care and Safety)

Hydraulic System

Checking the Hydraulic Fluid Level

Access Panels

Central Access Panels

Applications

ALL

Parallel Hydraulic SYSTEM

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E16-2

E-06-29 Issue 02

E16-2

Section E16 - Hydraulics Parallel Control Valve - 2 Section Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Item 1

Auxiliary Service Spool

Auxiliary Relief Valve

Load Sense Check Valve

Load Hold Check Valve

Sway Service Spool

Load Sense Check Valve

Load Hold Check Valve

Load Sense Port

Pressure Port - Oil from pump

Tank Port

The 2 section control valve operates the auxiliary and sway hydraulic services. The valve spools are operated by mechanical linkages attached to control levers.

Fig 2.

Fig 1.

E16-3

C065790

C069000

E-06-29 Issue 02

E16-3

Section E16 - Hydraulics Parallel Control Valve - 2 Section Removal

Removal

Park the machine and make it safe. Fit the boom maintenance strut. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E16-2)

!MWARNING

Fig 3.

C067960-C1

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

Gain access to the valve. Remove the central access panels. Refer to Section 3 - Routine Maintenance. K Related Topics ( T E16-2)

Disconnect and plug all hydraulic hoses. Label each hose before disconnecting to ensure correct replacement.

Disconnect the control rod linkages B from the valve spools.

Disconnect the electrical connector at the valve block switch C (if fitted).

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

With the valve block suitably supported, undo the mounting screws A. Carefully lift out the valve block clear of the machine.

E16-4

E-06-29 Issue 02

E16-4

Section E16 - Hydraulics Parallel Control Valve - 2 Section Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Note: For hose connectors with no specified torque setting - use the JCB Standard torque setting. Refer to Section 1 - Torque Settings. K Related Topics ( T E16-2) – Operate the machines hydraulic system. Check for correct operation and leaks. – Check the hydraulic Topics ( T E16-2)

fluid

level.

K Related

Fig 4.

C082100

– After replacement check the operation of the mechanical control linkages A. The control levers in the cab should be vertical when in neutral. If the lever is not vertical undo locknuts B at each end of the control rod C. Turn the rod C to lengthen or shorten as required. Tighten locknuts B. Note: Some machines have cranked control rods. To adjust the rod disconnect the clevis 4-D and turn it. Make sure the control rod is phased correctly before tightening locknut 4-B.

2 C067960-C2.eps

Fig 5.

Item

Table 2. Torque Settings Nm kgf m

lbf ft

24-27

2.4-2.75

17.7-19.9

84-92

8.5-9.3

62-68

58-65

5.9-6.6

42.7-48

– Torque tighten the hose connectors.K Table 2. Torque Settings ( T E16-5)

E16-5

E-06-29 Issue 02

E16-5

Section E16 - Hydraulics Parallel Control Valve - 2 Section Dismantle and Assemble

Dismantle and Assemble Valve Block Sections

the inlet section B is to be replaced, remove and retain the tie rods A.

K Fig 6. ( T E16-6). The valve block is a `sectional' type, which is made up of a number of separate sections. The illustration is intended as a guide to identifying the components. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable. Make sure that components are assembled in their original positions.

Great care should be taken when dismantling and assembling a valve to avoid the following:

– Renew the `O' rings C located between the valve sections. Make sure the `O' ring seals are not trapped or damaged.

– Contamination

– Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

– Damage to spools – Damage to seal grooves

– If the tie rods A were removed, apply JCB Threadlocker and Sealer to the threads before refitting. Torque tighten.

Any of the above may result in possible problems with the operation of the valve.

Dismantle

Item

Table 3. Torque Settings Nm kgf m

4.4

lbf ft 32

Component Key:

Fig 6. Valve Block Components

Tie Rods

Inlet Section

Section `O' Rings

Auxiliary Relief Valve

Auxiliary Section

Sway Section

Outlet Section

Tie Rod Nuts

C080190

Remove the valve block from the machine.

Remove the three tie rod nuts G.

Carefully separate and remove the outlet section F followed by the remaining service sections E and D. If

E16-6

E-06-29 Issue 02

E16-6

Section E17 - Hydraulics

Parallel Control Valve - 5 Section Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E17-2) K Hydraulic Operation and Schematics ( T E17-3) K Removal ( T E17-5) K Replacement ( T E17-5) K Dismantle and Assemble ( T E17-7) K Valve Block Sections ( T E17-7)

E17-1

E-06-30 Issue 02

E17-1

Section E17 - Hydraulics Parallel Control Valve - 5 Section Related Topics

Topic Titles

Sub Titles

Applications

ALL

Torque Settings

ALL (Care and Safety)

Hydraulic System

Checking the Hydraulic Fluid Level

Access Panels

Central Access Panels

Applications

ALL

Parallel Hydraulic SYSTEM

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E17-2

E-06-30 Issue 02

E17-2

Section E17 - Hydraulics Parallel Control Valve - 5 Section Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Item 1

Auxiliary Service Spool

Auxiliary Relief Valve

Load Sense Check Valve

Load Hold Check Valve

Sway Service Spool

Spool Neutral Switch

Load Sense Check Valve

Load Hold Check Valve

Unloader Valve (Stabiliser isolation)

Unloader Valve Solenoid Coil

Stabiliser Service Spool

Spool Neutral Switch

Load Sense Check Valve

Load Hold Check Valve

Stabiliser Service Spool

Spool Neutral Switch

Load Sense Check Valve

Load Hold Check Valve

Pressure Port - Oil from pump

Tank Port

Load Sense Port

The 5 section control valve operates the auxiliary, sway and stabiliser hydraulic services. The valve spools are operated by mechanical linkages attached to control levers. Section 3 of the valve block isolates spool sections 2 (sway), 4 and 5 (stabilisers) from oil at pump pressure when its solenoid 3A is energised. K Related Topics ( T E17-2) Electrical switches, 2A, 4A and 5A close when the applicable spool is not in the neutral position. The switches are part of the rear axle stability system. K Related Topics ( T E17-2)

E17-3

E-06-30 Issue 02

E17-3

Section E17 - Hydraulics Parallel Control Valve - 5 Section Hydraulic Operation and Schematics

Fig 1.

C068960-C1

Fig 2.

E17-4

E-06-30 Issue 02

C065800-C2

E17-4

Section E17 - Hydraulics Parallel Control Valve - 5 Section Removal and Replacement

Removal and Replacement

!MWARNING

Removal

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Get access to the valve. Remove the central access panels. Refer to Section 3 - Routine Maintenance. K Related Topics ( T E17-2) Disconnect and plug all hydraulic hoses. Label each hose before disconnecting to ensure correct replacement.

Remove the stabiliser control lever knobs and gaiters 9 from inside the cab.

Remove the clevis pin 5 and disconnect the control rod linkages 6 from the valve spool rod 4.

Disconnect the electrical connectors 11 at to the valve block switches and isolation solenoid. Label the connectors to ensure correct replacement.

E17-5

With the valve block suitably supported, remove the mounting screws 10. Carefully lift out the valve block clear of the machine.

Replacement

During the replacement procedure do this work also: – After replacement check the operation of the mechanical control linkages 4. The control levers in the cab should be vertical when in neutral. If the lever is not vertical undo locknuts 7 at each end of the control rod 8. Turn the rod 8 to lengthen or shorten as required. Tighten locknuts 7. Note: Some machines have cranked control rods. To adjust the rod disconnect the clevis 5 and turn it. Make sure the control rod is phased correctly before tightening locknut 7. – Torque tighten the hose connectors.K Table 2. Torque Settings ( T E17-6)

INT-3-1-11_2

Replacement is the opposite of the removal procedure.

Park the machine and make it safe. Fit the boom maintenance strut. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E17-2)

!MWARNING

BF-4-1_1

Note: For hose connectors with no specified torque setting - use the JCB Standard torque setting. Refer to Section 1 - Torque Settings. K Related Topics ( T E17-2) – Operate the machines hydraulic system. Check for correct operation and leaks. – Check the hydraulic Topics ( T E17-2)

E-06-30 Issue 02

fluid

level.

K Related

E17-5

Section E17 - Hydraulics Parallel Control Valve - 5 Section Removal and Replacement

9 10

2 3

11 11 11 10

6 7

8 Fig 3.

Item

Table 2. Torque Settings Nm kgf m

lbf ft

24-27

2.4-2.75

17.7-19.9

58-65

5.9-6.6

42.7-48

84-92

8.5-9.3

62-68

E17-6

C130720.eps

E-06-30 Issue 02

E17-6

Section E17 - Hydraulics Parallel Control Valve - 5 Section Dismantle and Assemble

Dismantle and Assemble Valve Block Sections

G, H and J. If the inlet section B is to be replaced, remove and retain the tie rods A.

4K Fig 4. ( T E17-8). The valve block is a `sectional' type, which is made up of a number of separate sections. The illustration is intended as a guide to identifying the components. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable. Make sure that components are assembled in their original positions. Great care should be taken when dismantling and assembling a valve to avoid the following: – Contamination

Assemble Assembly is the opposite of the dismantling procedure. During the assembly procedure do this work also: – Clean the valve components in an appropriate solvent. Ensure that the mating faces of the valve sections are thoroughly clean before assembly. – Renew the `O' rings C located between the valve sections. Make sure the `O' ring seals are not trapped or damaged. – Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

– Damage to spools – Damage to seal grooves Any of the above may result in possible problems with the operation of the valve.

– If the tie rods A were removed, apply JCB Threadlocker and Sealer to the threads before refitting. Torque tighten.

Component Key:

Item

Tie Rods

Inlet Section

Section `O' Rings

Auxiliary Relief Valve

Auxiliary Section

Isolation Section

Sway Section

Stabiliser Section

Outlet Section

Tie Rod Nuts

Table 3. Torque Settings Nm kgf m 43

4.4

lbf ft 32

Dismantle 1

Remove the valve block from the machine.

Remove the three tie rod nuts L.

Carefully separate and remove the outlet section K followed by the remaining service sections E and F,

E17-7

E-06-30 Issue 02

E17-7

Section E17 - Hydraulics Parallel Control Valve - 5 Section Dismantle and Assemble

Fig 4. Valve Block Components

E17-8

E-06-30 Issue 02

C080200

E17-8

Section E18 - Hydraulics

Pilot Pressure Supply Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E18-2) K Operation Overview ( T E18-3) K Hydraulic Operation and Schematics ( T E18-4) K Electrical Operation and Schematics ( T E18-6) K Removal and Replacement ( T E18-7) K Removal ( T E18-7) K Replacement ( T E18-7)

E18-1

E-10-15 Issue 01

E18-1

Section E18 - Hydraulics Pilot Pressure Supply Valve Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Hydraulic System

Checking the Hydraulic Fluid Level

Stabiliser System

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Applications

ALL

Flowshare Hydraulic SYSTEM

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E18-2

E-10-15 Issue 01

E18-2

Section E18 - Hydraulics Pilot Pressure Supply Valve Operation Overview

Operation Overview 510-56, 512-56 and 514-56 Machines An additional solenoid A isolates the pilot pressure supply to the lift valve spool. This solenoid operates as a part of the stabiliser system. K Related Topics ( T E18-2).

Fig 1. Pilot Pressure Supply Valve

C066490

K Fig 1. ( T E18-3) The pilot pressure supply valve 1 is supplied from a single line tapped into the gear pump feed line to the cooling fan hydraulic motor. The pressure regulating valve maintains pilot pressure by regulating the incoming supply pressure. Oil at pilot pressure is supplied to the flowshare control valve spools.

C078380-C1

Fig 2. 510-56, 512-56 and 514-56 Pilot Pressure Supply Valve

The pressure supply valve incorporates accumulator 3 The accumulator traps and stores pilot pressure to enable the service spools to be operated for a limited period with a stopped engine. This allows for attachments to be lowered safely to the ground should the engine stop. Supply of pilot oil can be isolated from the main control valve by de-energising solenoid 2. When the valve is deenergised trapped pilot oil in the main control valve is diverted to tank. The service spools are `locked' and services cannot be operated with or without the engine running. Note: Oil stored in the accumulator 3 is isolated from the pilot system when solenoid 2 is de-energised

E18-3

E-10-15 Issue 01

E18-3

Section E18 - Hydraulics Pilot Pressure Supply Valve Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Hydraulic Circuit Operation The schematic diagrams show an overview of the system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E18-2)

Service Operation K Fig 3. ( T E18-4) The flow from the cooling fan section of the main pump flows to the pilot filter 8. The flow from the pilot filter enters the pilot pressure supply valve 3. The pilot pressure relief valve 6 decreases the pressure of the fluid.

The pilot pressure enable solenoid valve 4 isolates the pilot pressure supply. When the solenoid coil is deenergised the service spools are locked and services cannot be operated. The pump supply 2 flows back to tank at 1. When the solenoid coil is energised the pilot pressure supply flows through the solenoid 4 to the servo control valves 10. The valve has two test points. Pump supply pressure can be tested at test point 7. Pilot supply pressure can be tested at point 5. The accumulator 9 stores fluid at pilot pressure to allow a small number of operations of the hydraulic services when the engine is not running.

B A

TP2

0.5 BAR

T1 P

TP1

Fig 3. Item

K Fig 3. ( T E18-4)

Hydraulic Tank Return Line

Supply from Hydraulic Pump

Pilot Pressure Supply Valve

Pilot Pressure Enable Solenoid

Pilot Pressure Test Point

Pilot Pressure Relief Valve

Pump Supply Pressure Test Point

Pilot Filter

Pilot Pressure Accumulator

Servo Control Lever

E18-4

E-10-15 Issue 01

C066310

E18-4

Section E18 - Hydraulics Pilot Pressure Supply Valve Hydraulic Operation and Schematics

510-56, 512-56 and 514-56 Machines Lift Pilot Pressure Supply Isolation Valve The lift pilot pressure supply valve 1 isolates the pilot pressure supply to the lift valve spool. The operation of the solenoid is controlled by the ECU and the stabiliser system interlocks. K Related Topics ( T E18-2)

Item

K Fig 4. ( T E18-5) K Fig 5. ( T E18-5)

Pilot pressure reducing valve

Pilot pressure enable solenoid

Tank return

Lift pilot pressure supply valve

Servo control lever

Flowshare control valve

Item

K Fig 4. ( T E18-5) K Fig 5. ( T E18-5)

Lift Valve spool

Pilot pressure pump supply

Lift ram

Pilot pressure supply valve

Fig 4. Lift pilot pressure supply valve open

Fig 5. Lift pilot pressure supply valve closed

E18-5

E-10-15 Issue 01

C078410

C078410-C1

E18-5

Section E18 - Hydraulics Pilot Pressure Supply Valve Electrical Operation and Schematics

Electrical Operation and Schematics The schematic diagrams show a typical system. For machine specific schematics refer to Section C, Schematics. K Related Topics ( T E18-2) When the switch B set to the ON position the solenoid coil C is energised and pilot oil pressure is supplied to the servo control valves. The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page.

C119620

510-56, 512-56 and 514-56 Machines The ECU B supplies a feed to the lift pilot pressure supply isolation valve solenoid C. The boom raise return relay A provides the earth for the isolation valve solenoid. The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page.

C119630

E18-6

E-10-15 Issue 01

E18-6

Section E18 - Hydraulics Pilot Pressure Supply Valve Removal and Replacement

Removal and Replacement Removal

During the replacement procedure do this work also: â&#x20AC;&#x201C; Ensure that the hoses are reconnected to the correct ports. â&#x20AC;&#x201C; Check the hydraulic Topics ( T E18-2)

fluid

level.

K Related

â&#x20AC;&#x201C; After replacement, check the pilot pressure. Refer to the Test Procedures topic. Important: The extent of permissible servicing is the renewal of the solenoid coil E and accumulator. Further dismantling of the valve is not recommended. If the valve is suspected as being faulty it must be renewed as a complete assembly.

Fig 6.

C067780-C3

Park the machine and make it safe. Fit the boom maintenance strut. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E18-2)

Disconnect electrical harness at the solenoid electrical connector B.

Label the hoses C to ensure correct position on replacement. Disconnect the hoses. Cap all open hoses and ports.

Support the pilot valve block A. Undo and remove the 4 screws D and lift out the valve.

Replacement Note: If a new accumulator is to be installed it may require charging. Refer to Section 2 - General Procedures. K Related Topics ( T E18-2) Replacement is the opposite of the removal procedure.

E18-7

E-10-15 Issue 01

E18-7

Section E18 - Hydraulics Pilot Pressure Supply Valve Removal and Replacement

Page left intentionally blank

E18-8

E-10-15 Issue 01

E18-8

Section E19 - Hydraulics

Servo Control Valves Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E19-2) K Removal and Replacement ( T E19-3)

E19-1

E-09-16 Issue 01

E19-1

Section E19 - Hydraulics Servo Control Valves Related Topics

Topic Titles

Sub Titles

Applications

ALL

Care and Safety

ALL

ALL (Care and Safety)(1)

ALL

Hydraulic System

Checking the Hydraulic Fluid Level

Applications

ALL

Parallel Hydraulic SYSTEM

ALL

(1) You must obey all of the relevant care and safety procedures.

E19-2

E-09-16 Issue 01

E19-2

Section E19 - Hydraulics Servo Control Valves Removal and Replacement

Removal and Replacement K Fig 1. ( T E19-4).

– Ensure that the hoses are reconnected to the correct ports.

Removal

– Torque tighten hydraulic connections to 30 Nm (22 lbf ft).

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E19-2)

!MWARNING

– Torque tighten bolts D and/or E to 12Nm (9 lbf ft). – Reconnect the electrical connector (two axis control lever). – Check the hydraulic Topics ( T E19-2)

fluid

level.

K Related

It is not possible to vent all residual pressure. Loosen the connection one full turn and allow the pressure to dissipate. Keep face and hands well clear of pressurised hydraulic oil and wear protective glasses. HYD-4-3

Single Axis Control Lever: a

Label then remove hydraulic hoses C (4 off), plug exposed connections to prevent ingress of dirt and water.

b Remove nuts and bolts D (2 off), and lower the control lever through the aperture in the mounting panel. 3

Two Axis Control Lever: a

Lift the gaiter and remove nuts and bolts E (4 off). Lift the control lever sufficiently to gain access to the hydraulic hoses.

b Label then remove hydraulic hoses F (6 off), plug exposed connections to prevent ingress of dirt and water. c

Disconnect the electrical connector G and lift the control lever clear.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

E19-3

E-09-16 Issue 01

E19-3

Section E19 - Hydraulics Servo Control Valves Removal and Replacement

Fig 1. Servo Control Levers

E19-4

E-09-16 Issue 01

A363071-C1

E19-4

Section E20 - Hydraulics

Gearpump Operation Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E20-2) K Operation Overview ( T E20-4) K Component Location ( T E20-3) K Hydraulic Operation and Schematics ( T E20-6)

E20-1

E-60-06 Issue 01

E20-1

Section E20 - Hydraulics Gearpump Operation Related Topics

Topic Titles

Sub Titles

Applications

ALL

Hydraulic Systems and Schematics

ALL

E20-2

E-60-06 Issue 01

E20-2

Section E20 - Hydraulics Gearpump Operation Component Location

Component Location

Fig 1. Typical Double Pump

Fig 2. Typical Triple Pump

C119510

765510-C2

Table 2. 1

Main Services Section

Steering Section (if fitted)

Cooling Fan Section

Steering Priority Valve

E20-3

E-60-06 Issue 01

E20-3

Section E20 - Hydraulics Gearpump Operation Operation Overview

Operation Overview The pump is a gear type and driven by the engine. The separate sections of the gear pump assembly supply hydraulic oil to the main services circuits, to the steering circuit and to the hydraulic cooling fan circuit. The separate sections of the gear pump operate individually as described below: K Fig 3. ( T E20-5). The working principle of a gear pump depends on the meshing of two spur gears A and B. Oil is picked up on the suction side of the pump by the gears and carried round between the gear teeth and pump body. As the gears come into mesh the oil is forced through the outlet port, or through an internal port into the integral priority valve depending on the type of pump. Some oil is allowed to circulate behind the bushes C and D to hold them in balance against the gears and minimise oil slippage. Lubrication is provided by hydraulic oil which is directed around the unit, via oilways, by the motion of the meshing gears. For priority valve operation, refer to Section H - Steering. K Related Topics ( T E20-2)

E20-4

E-60-06 Issue 01

E20-4

Section E20 - Hydraulics Gearpump Operation Operation Overview

Fig 3. Typical Gear Pump Section

9808_6163-1

Table 3. Key to Oil Flow and Pressure Full Pressure Exhaust

E20-5

E-60-06 Issue 01

E20-5

Section E20 - Hydraulics Gearpump Operation Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Note: A typical triple pump layout is shown. For double pump schematics and machine specific details refer to the Hydraulic Systems and Schematics topic. K Related Topics ( T E20-2) Item

Item D

Priority Steer Valve

Steering Load Sense Line

Pump Main Output

Control Valve Block Secondary Feed

Main Services Pump Section

Fan and Pilot Valve Feed

Steering Service Pump Section

Test Point

Fan and Pilot Services Pump Section

Hydraulic Tank

Fig 4.

E20-6

E-60-06 Issue 01

C065900

E20-6

Section E21 - Hydraulics

Gearpump Removal and Replacement Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E21-2) K Removal and Replacement ( T E21-3) K Dismantle, Inspection and Assemble ( T E21-5) K Steering Priority Valve ( T E21-12)

E21-1

E-61-03 Issue 01

E21-1

Section E21 - Hydraulics Gearpump Removal and Replacement Related Topics

Topic Titles

Sub Titles

Applications

ALL

Hydraulic Systems and Schematics

ALL

E21-2

E-61-03 Issue 01

E21-2

Section E21 - Hydraulics Gearpump Removal and Replacement Removal and Replacement

Removal and Replacement Carry out General Safety procedures, see Section 2 General Procedures. K Related Topics ( T E21-2)

Drain the hydraulic fluid from the hydraulic tank into a suitable clean container.

Before removing and dismantling the pump, check the flow and pressure. If either of these are low and cannot be corrected at the relief valve, the appropriate pump section must be renewed completely. Renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, the pump should be removed and dismantled for re-sealing only.

Remove flange bolts A (4 off) and disconnect the suction hose flange from the pump body. Plug the open port and cap the hose to prevent loss of fluid and ingress of dirt.

Disconnect the feed hoses. Plug the open ports and cap the hoses to prevent loss of fluid and ingress of dirt. Label each hose before disconnecting to ensure correct replacement.

Triple Pump Only: Remove socket head screws C and disconnect the outlet pipe D from the pump body. Plug the open port and cap the pipe to prevent loss of fluid and ingress of dirt.

Before removing or dismantling the pump, make sure the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination.

Removal 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the boom to the ground. Stop the engine and remove the starter key, see Section 2 - General Procedures. K Related Topics ( T E21-2)

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Secure the pump using a sling around the pump body. With the pump suitably supported, undo the mounting bolts E and carefully withdraw the pump clear of the gearbox.

Retain the drive coupling.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Vent the hydraulic pressure, see Section 2 - General Procedures. K Related Topics ( T E21-2)

E21-3

E-61-03 Issue 01

Fig 1. Typical Double Pump

416111-C7

E21-3

Section E21 - Hydraulics Gearpump Removal and Replacement Removal and Replacement Item

Table 2. Torque Settings Nm Kgf. m

Ibf. ft

4.7

9.7

A313800-C5

Fig 2. Typical Triple Pump

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Ensure the pump flange and gearbox mating face are clean and free from oil and grease prior to assembly. – Use new `O' ring seals. – Fit drive coupling, engage pump drive into coupling, support the pump until bolts E have been torque tightened. K Table 2. Torque Settings ( T E21-4). Note: Mounting bolts E should be 10.9 grade M12 tuff lok, make sure the correct bolts are fitted. – Ensure the hoses are correctly installed, and phased in the same position as removal to prevent chafing. – Refill the hydraulic tank to the correct level with clean hydraulic fluid. – After fitting a new or serviced pump and before starting the engine screw the Main Relief Valve (MRV) out 4 full turns. Adjust the MRV, refer to the applicable system topic. K Related Topics ( T E21-2). – Check the fan motor speed, refer to Hydraulic SYSTEM topic. K Related Topics ( T E21-2)

E21-4

E-61-03 Issue 01

E21-4

Section E21 - Hydraulics Gearpump Removal and Replacement Dismantle, Inspection and Assemble

Dismantle, Inspection and Assemble K Fig 3. ( T E21-7)

Discard O-ring 19.

Double Pump

Remove capscrews 20 and nuts 21 holding mounting flange 22 to pump body 3.

Use a soft hammer to separate mounting flange 22 from pump body 3.

Remove circlip 23 and shaft seal 24.

Remove driveshaft 25 from pump body 3. Removal will also remove balance plate 26 complete with seal 27 and seal energiser 28. Discard the seal and seal energiser.

Remove driven gear 29 followed by balance plate 30, seal 31 and seal energiser 32. Discard the seal and seal energiser.

Discard O-ring 33.

Remove all sealant from the contact faces of the mounting flange/pump body and end cover/pump body interfaces. Wash all components and immediately apply a coating of hydraulic oil to prevent corrosion.

Before removing or dismantling the pump, check that its performance is as stated in Specifications. If the performance is below that specified, the pump should be renewed. Renewal of individual components such as gears, bearings and housings will not effect a permanent cure. If a pump's output is satisfactory but there is evidence of external leakage, it should be dismantled for re-sealing only. Prior to dismantling the unit, ensure that the exterior of the pump and the working area are thoroughly cleaned and free of possible sources of contamination. Mark all sections to ensure correct assembly and keep pump components with their relative pump section.

Dismantle 1

Remove the three capscrews 1 which attach the priority valve 2 to the pump body 3.

Remove priority valve 2 and discard O-rings 4.

Remove the four bolts 5 and washers 6 which clamp pump body 7 to pump body 3.

Inspection

Use a soft faced hammer to separate pump body 3 from pump body 7.

Remove splined coupling 8 and O-rings 9. Discard the O-rings.

Use a soft faced hammer to separate pump body 7 from end cover 10.

Remove drive gear 11 from its bore. Pushing it out of the rear body will also remove balance plate 12 complete with seal 13 and seal energiser 14. Discard the seal and seal energiser. Note the position of the driveshaft and the balance plate to ensure correct reassembly.

Generally check all pump parts for damage and/or wear. The O-ring grooves, the seal recess in the mounting flange and all sealing faces must be free of burrs and scores which could result in seal damage and hence hydraulic oil leakage.

Renew the pump if any of the following symptoms exist:

Remove driven gear 15, followed by balance plate 16 complete with seal 17 and seal energiser 18. Discard the seal and seal energiser.

E21-5

E-61-03 Issue 01

The PTFE coated bearings in the pump bodies, the mounting flange and the end cover are worn through to reveal the bronze backing.

b The gear side faces are scored. Often contaminated fluid results in a distinct wear step coincident with the gear root diameter. This can normally be felt by drawing a sharp point across the gear side face from the journal towards the tip of the gear.

E21-5

Section E21 - Hydraulics Gearpump Removal and Replacement Dismantle, Inspection and Assemble c

There is a noticeable wear groove on driveshaft 25 where shaft seal 24 runs.

Attach mounting flange 22 to pump body 3 with capscrews 20 and nuts 21.

d The balance plate faces are scored, particularly in the area adjacent to the gear root diameter.

Support the pump assembly on the mounting flange 22 (but not the driveshaft). Fit O-rings 9 into the grooves on the face of pump body 3. Install splined coupling 8.

Fit pump body 7 onto pump body 3 in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

Fit seal 17 and seal energiser 18 into balance plate 16. Ensuring that the seals do not fall out, carefully feed the balance plate into pump body 7 with the two small holes through the balance plate to the low pressure side (i.e. side with a port blank).

Fit drive gear 11 so that it locates with splined coupling 8. Fit driven gear 15.

Note: If the seal recess is scored, it is permissible to seal outside diameters with JCB Multigasket to prevent leakage.

Fit balance plate 12 in its original position (i.e. with the two small holes to the low pressure side). Fit seal 13 and seal energiser 14 into the balance plate.

Fit O-ring 19 into end cover 10.

Stand pump body 3 on its rear face. Fit seal 27 and seal energiser 28 into balance plate 26.

Apply a small amount of JCB Threadlocker and Sealer to the exposed face of pump body 7 (i.e. the face containing the clamping bolt holes).

Ensuring that the seals do not fall out, carefully feed the balance plate into the bores of pump body 3 with the two small holes through the balance plate to the low pressure side of the body (i.e. side with the large 4-bolt port pattern).

Fit end cover 10 in its original position, as marked earlier.

Install bolts 35, each with a serrated washer 6, and tighten evenly and progressively.

Insert driveshaft 25 and driven gear 29 into the original bores.

Fit balance plate 30 over the driveshaft and gear stub. Insert seal 31 and seal energiser 32 into the balance plate.

Refit the priority valve 2 to the pump body 3. Be sure to fit new `O' rings 4. Tighten the three capscrews 1 evenly and progressively.

Pour a small amount of clean JCB Special Hydraulic Fluid into the ports. Check that driveshaft 23 rotates without undue force. If excessive force is required it is possible that one or more of the balance plate seals are trapped, in which case it will be necessary to dismantle and assemble the pump again.

The driveshaft splines are worn or severely fretted.

The gear â&#x20AC;&#x153;cut-inâ&#x20AC;? area in the low pressure side of the pump body is deeper than 0.15 mm (0.006 in) or has a torn or pitted appearance.

Assemble When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. 1

Fit shaft seal 24 into mounting flange 20 with its garter spring facing into the pump. Fit circlip 23 into its groove in the flange. Coat the seal lips with high melting point grease.

Fit O-ring 33 into the groove on mounting flange 22.Apply a small amount of JCB Threadlocker and Sealer to the face of pump body 3 which seals with mounting flange 22 (i.e. the face containing the clamping bolt holes).

Carefully feed mounting flange 22 over driveshaft 25 in its original position, as marked earlier. Use a soft faced hammer to tap the flange onto its location spigot.

E21-6

E-61-03 Issue 01

E21-6

Section E21 - Hydraulics Gearpump Removal and Replacement Dismantle, Inspection and Assemble

Fig 3. Typical Double Pump

E21-7

E-61-03 Issue 01

765540-1

E21-7

Section E21 - Hydraulics Gearpump Removal and Replacement Dismantle, Inspection and Assemble

Triple Pump

Remove driven gear 19, followed by balance plate 20 complete with seal 21 and seal energiser 22. Discard the seal and seal energiser.

Discard O-ring 23.

Use a soft faced hammer to separate end cover 8 from pump body 11.

Remove drive gear 24 from its bore. Pushing it out of the pump body will also remove balance plate 25 complete with seal 26 and seal energiser 27. Discard the seal and seal energiser. Note the position of the driveshaft and the balance plate to ensure correct reassembly.Remove driven gear 28, followed by balance plate 29 complete with seal 30 and seal energiser 31. Discard the seal and seal energiser.

Mark all sections to ensure correct assembly and keep pump components with their relative pump section.

Discard O-ring 32.

Dismantle

Use a soft hammer to separate mounting flange 33 from pump body 12.

K Fig 4. ( T E21-11) Before removing or dismantling the pump, check that its performance is as stated in Specifications. If the performance is below that specified, the pump should be renewed. Renewal of individual components such as gears, bearings and housings will not effect a permanent cure. If a pump's output is satisfactory but there is evidence of external leakage, it should be dismantled for re-sealing only. Prior to dismantling the unit, ensure that the exterior of the pump and the working area are thoroughly cleaned and free of possible sources of contamination.

Remove the three capscrews A which attach the priority valve B to the pump body 11.

Remove circlip 1 and shaft seal 34.

Remove priority valve B and discard O-rings C.

Remove the four bolts 2 and serrated washers 3 which clamp the units together.

Remove driveshaft 35 from pump body 12. Removal will also remove balance plate 36 complete with seal 37 and seal energiser 38. Discard the seal and seal energiser.

Use a soft faced hammer to separate pump body 7 from end cover 8.

Remove driven gear 39 followed by balance plate 40, seal 41 and seal energiser 42. Discard the seal and seal energiser.

Remove splined coupling 9 and O-rings 10. Discard the O-rings.

Discard O-ring 43.

Use a soft faced hammer to separate pump body 11 from pump body 12.

Remove all sealant from the contact faces of the mounting flange/pump body and end cover/pump body interfaces.

Remove splined coupling 13 and O-rings 14. Discard the O-rings.

Wash all components and immediately apply a coating of hydraulic oil to prevent corrosion.

Use a soft faced hammer to separate end cover 5 from pump body 7.

Inspection

Remove drive gear 15 from its bore. Pushing it out of the rear body will also remove balance plate 16 complete with seal 17 and seal energiser 18. Discard the seal and seal energiser. Note the position of the driveshaft and the balance plate to ensure correct reassembly.

E21-8

Renew the pump if any of the following symptoms exist:

E-61-03 Issue 01

E21-8

Section E21 - Hydraulics Gearpump Removal and Replacement Dismantle, Inspection and Assemble a

The PTFE coated bearings in the pump bodies, the mounting flange and the end cover are worn through to reveal the bronze backing.

There is a noticeable wear groove on driveshaft 35 where shaft seal 34 runs.

Fit O-ring 43 into the groove on mounting flange 33.

Apply a small amount of JCB Threadlocker and Sealer to the face of pump body 12 which seals with mounting flange 33 (i.e. the face containing the clamping bolt holes).

Carefully feed mounting flange 33 over driveshaft 35 in its original position, as marked earlier. Use a soft faced hammer to tap the flange onto its location spigot.

Support the pump assembly on the mounting flange 33 (but not the driveshaft). Fit O-rings 14 into the grooves on the face of pump body 12. Install splined coupling 13.

Fit pump body 11 onto pump body 12 in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

Fit seal 30 and seal energiser 31 into balance plate 29. Ensuring that the seals do not fall out, carefully feed the balance plate into pump body 11 with the two small holes through the balance plate to the low pressure side (i.e. side with a port blank).

Fit drive gear 24 so that it locates with splined coupling 13. Fit driven gear 28.

Fit balance plate 25 in its original position (i.e. with the two small holes to the low pressure side). Fit seal 26 and seal energiser 27 into the balance plate.

Fit O-ring seal into end cover 8.

Apply a small amount of JCB Threadlocker and Sealer to the exposed face of pump body 11 (i.e. the face containing the clamping bolt holes).

Fit end cover 8 in its original position, as marked earlier.

Fit O-rings 10 into the grooves on the face of pump body 7. Install splined coupling 9.

Fit pump body 7 onto end cover 8 in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

Fit seal 20 and seal energiser 21 into balance plate 22. Ensuring that the seals do not fall out, carefully feed the balance plate into pump body 7 with the two

d The balance plate faces are scored, particularly in the area adjacent to the gear root diameter. e

The driveshaft splines are worn or severely fretted.

The gear â&#x20AC;&#x153;cut-inâ&#x20AC;? area in the low pressure side of the pump body is deeper than 0.15 mm (0.006 in) or has a torn or pitted appearance.

Assemble When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. 1

Fit shaft seal 34 into mounting flange 33 with its garter spring facing into the pump. Fit circlip 1 into its groove in the flange. Coat the seal lips with high melting point grease.

Note: If the seal recess is scored, it is permissible to seal outside diameters with JCB Multigasket to prevent leakage. 2

Stand pump body 12 on its rear face. Fit seal 37 and seal energiser 38 into balance plate 36.

Ensuring that the seals do not fall out, carefully feed the balance plate into the bores of pump body 12 with the two small holes through the balance plate to the low pressure side of the body (i.e. side with the large 4-bolt port pattern).

Insert driveshaft 35 and driven gear 39 into the original bores.

Fit balance plate 40 over the driveshaft and gear stub. Insert seal 41 and seal energiser 42 into the balance plate.

E21-9

E-61-03 Issue 01

E21-9

Section E21 - Hydraulics Gearpump Removal and Replacement Dismantle, Inspection and Assemble small holes through the balance plate to the low pressure side (i.e. side with a port blank). 20

Fit drive gear 15 so that it locates with splined coupling 9. Fit driven gear 19.

Fit balance plate 16 in its original position (i.e. with the two small holes to the low pressure side). Fit seal 17 and seal energiser 18 into the balance plate.Fit Oring 23 into end cover 5.Apply a small amount of JCB Threadlocker and Sealer to the exposed face of pump body 7 (i.e. the face containing the clamping bolt holes).

Fit end cover 5 in its original position, as marked earlier.

Install the four bolts 2, each with a serrated washer 3, and tighten evenly and progressively.

Refit the priority valve B to the pump body 11. Be sure to fit new `O' rings C. Tighten the three capscrews A evenly and progressively.

Pour a small amount of clean JCB Special Hydraulic Fluid into the ports. Check that driveshaft 35 rotates without undue force. If excessive force is required it is possible that one or more of the balance plate seals are trapped, in which case it will be necessary to dismantle and assemble the pump again.

Item 2

E21-10

Table 3. Torque Settings Nm Kgf. m 100

Ibf. ft 74

E-61-03 Issue 01

E21-10

Section E21 - Hydraulics Gearpump Removal and Replacement Dismantle, Inspection and Assemble

C A 11 B

Fig 4. Typical Triple Pump

E21-11

E-61-03 Issue 01

C024880-C1

E21-11

Section E21 - Hydraulics Gearpump Removal and Replacement Steering Priority Valve

Steering Priority Valve Removal and Replacement For more information on the priority valve See Section H Steering. K Related Topics ( T E21-2)

Dismantle, Inspection and Assemble For more information on the priority valve See Section H Steering. K Related Topics ( T E21-2)

E21-12

E-61-03 Issue 01

E21-12

Section E22 - Hydraulics

Hydraulic Cooling Fan Motor - Fixed Speed Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E22-2) K Specifications ( T E22-3) K Operation Overview ( T E22-4) K Removal and Replacement ( T E22-5) K Dismantle, Inspection and Assemble ( T E22-7)

E22-1

E-12-06 Issue 01

E22-1

Section E22 - Hydraulics Hydraulic Cooling Fan Motor - Fixed Speed Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Hydraulic System

Checking the Hydraulic Fluid Level

Applications

ALL

Hydraulic SYSTEM

ALL

(1) You must obey all of the relevant care and safety procedures.

E22-2

E-12-06 Issue 01

E22-2

Section E22 - Hydraulics Hydraulic Cooling Fan Motor - Fixed Speed Specifications

Specifications Refer to the relevant hydraulic system topic for fan motor specifications.

E22-3

E-12-06 Issue 01

E22-3

Section E22 - Hydraulics Hydraulic Cooling Fan Motor - Fixed Speed Operation Overview

Operation Overview The schematic diagrams show an overview of the system. For machine specific schematics refer to Systems and Schematics. K Related Topics ( T E22-2) The cooling fan motor is hydraulically driven. The motor turns the cooling fan and air is drawn through the radiators in the machine cooling pack. Hydraulic oil from pump section B, supplies the fan motor 6 and pilot pressure supply valve. Pressure relief valve 5 prevents component damage. Item 1

Main Pump

Hydraulic Tank

Pump Pressure Supply

Fan Motor Case Drain Line

Fan Motor Pressure Relief Valve

Fan Motor Table 2. Colour Key to Oil Flow and Pressure Full Pressure Neutral Exhaust

Fig 1.

E22-4

E-12-06 Issue 01

C066320-C2.eps

E22-4

Section E22 - Hydraulics Hydraulic Cooling Fan Motor - Fixed Speed Removal and Replacement

Removal and Replacement Before removing and dismantling the fan motor, check that its performance is as stated in the applicable SYSTEM topic. K Related Topics ( T E22-2) If the performance is below that specified, the motor should be renewed. Renewal of individual components such as gears, bearings and housings will not effect a permanent cure. If the motor performance is satisfactory but there is external leakage, it should be dismantled for re-sealing only.

Removal 1

Park the machine and make it safe. Fit the boom safety strut. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E22-2)

Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started. 2

Put a label on the hydraulic hose feed and return pipes to aid identification when replacing.

Disconnect and plug the feed and return hoses D.

Disconnect and plug the case drain hose E (if fitted).

Remove the fan guard.

Undo 4 bolts C and lift away the fan and motor assembly.

Prevent the fan from turning, release the tab washer and then undo nut A.

764200-1

Fig 2. 8

Withdraw the fan from the motor shaft. Retain the drive key (not shown).

Undo motor retaining bolts B and remove the motor.

C119690

Fig 3.

E22-5

E-12-06 Issue 01

E22-5

Section E22 - Hydraulics Hydraulic Cooling Fan Motor - Fixed Speed Removal and Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Make sure all hoses are attached to the correct ports. The case drain hose E (if fitted) must be fed in to a tank line otherwise damage to the motor will occur. â&#x20AC;&#x201C; Check the hydraulic Topics ( T E22-2)

fluid

level.

Table 3. Torque Settings Nm kgf m

Item

K Related

lbf ft

3.6

26.5

2.9

20.6

4.8

34.5

C C D

E D C

C119700-C1.eps

Fig 4.

E22-6

E-12-06 Issue 01

E22-6

Section E22 - Hydraulics Hydraulic Cooling Fan Motor - Fixed Speed Dismantle, Inspection and Assemble

Dismantle, Inspection and Assemble Do not attempt to dismantle the motor. If the motor is defective it must be renewed.

E22-7

E-12-06 Issue 01

E22-7

Section E22 - Hydraulics Hydraulic Cooling Fan Motor - Fixed Speed Dismantle, Inspection and Assemble

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E22-8

E-12-06 Issue 01

E22-8

Section E23 - Hydraulics

Extension Ram Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E23-2) K Removal and Replacement ( T E23-3) K Removal ( T E23-3) K Replacement ( T E23-4)

E23-1

E-17-05 Issue 01

E23-1

Section E23 - Hydraulics Extension Ram Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Greasing

Every 50 Hours

Hydraulic System

Checking the Hydraulic Fluid Level

Boom

Boom Chains

(1) You must obey all of the relevant care and safety procedures.

E23-2

E-17-05 Issue 01

E23-2

Section E23 - Hydraulics Extension Ram Removal and Replacement

Removal and Replacement Obey the general care and safety procedures for rams during the removal and replacement procedures. K Related Topics ( T E23-2)

Removal 1

Raise the boom to the horizontal position and fully retract the boom. Support the front end of the boom.

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E23-2)

Disconnect and plug hydraulic feed pipes A to ram.

Fig 2.

Fig 1. 4

C067830

Drive machine forward until ram is clear of bracket H.

Withdraw ram from machine.

C068100

Support the ram. Undo nut B and remove bolt C.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Withdraw pivot pin D from rear pivot.

Undo bolt F and withdraw pivot pin G from front pivot.

E23-3

E-17-05 Issue 01

E23-3

Section E23 - Hydraulics Extension Ram Removal and Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Make sure to install the ram correctly on the machine with the regenerative valve ports J positioned as shown. – Check the chain Topics ( T E23-2) – Grease the ram Topics ( T E23-2) – Check the hydraulic Topics ( T E23-2)

adjustment. pivot fluid

K Related

pins.

K Related

level.

K Related

C098220-C1

Fig 4. 510-56, 512-56 and 514-56 machines

C068100-C3

Fig 3. 506-36, 507-42 and 509-42 machines

E23-4

E-17-05 Issue 01

E23-4

Section E24 - Hydraulics

Lift Rams Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E24-2) K Removal and Replacement ( T E24-3) K Removal ( T E24-3) K Replacement ( T E24-3)

E24-1

E-18-05 Issue 01

E24-1

Section E24 - Hydraulics Lift Rams Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Greasing

Every 50 Hours

Hydraulic System

Checking the Hydraulic Fluid Level

(1) You must obey all of the relevant care and safety procedures.

E24-2

E-18-05 Issue 01

E24-2

Section E24 - Hydraulics Lift Rams Removal and Replacement

Removal and Replacement Removal Obey the general care and safety procedures for rams during the removal and replacement procedures. K Related Topics ( T E24-2) 1

Raise the boom to get access to the lower pivot of the lift ram. Fully retract the boom. Support the front end of the boom.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T E24-2)

Undo bolt A and withdraw upper pivot pin B.

Select boom lower and lower the ram until it is just closed.

Vent the hydraulic Topics ( T E24-2).

Disconnect and plug hydraulic feed pipes to ram C. Support ram.

Remove wheel to gain access to drive out lower pivot pin.

Support ram, undo bolt D and withdraw lower pivot pin E.

Remove ram from machine.

pressure.

Fig 1.

C067410

K Related

Replacement

Fig 2.

C067820

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Grease the ram Topics ( T E24-2) â&#x20AC;&#x201C; Check the hydraulic Topics ( T E24-2)

pivot fluid

pins.

K Related

level.

K Related

Fig 3.

E24-3

E-18-05 Issue 01

C067790

E24-3

Section E24 - Hydraulics Lift Rams Removal and Replacement

Page left intentionally blank

E24-4

E-18-05 Issue 01

E24-4

Section E25 - Hydraulics

Tilt Ram Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E25-2) K Removal and Replacement ( T E25-3) K Removal ( T E25-3) K Replacement ( T E25-3)

E25-1

E-19-06 Issue 01

E25-1

Section E25 - Hydraulics Tilt Ram Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Greasing

Every 50 Hours

Hydraulic System

Checking the Hydraulic Fluid Level

(1) You must obey all of the relevant care and safety procedures.

E25-2

E-19-06 Issue 01

E25-2

Section E25 - Hydraulics Tilt Ram Removal and Replacement

Removal and Replacement Removal Obey the general care and safety procedures for rams during the removal and replacement procedures. K Related Topics ( T E25-2)

C067950

Fig 1. 1

Position the boom to make sure the boom nose does not touch the floor.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T E25-2)

Undo bolt A and withdraw outer pivot pin B.

Select tilt back to close ram.

Vent the hydraulic Topics ( T E25-2).

Disconnect and plug hydraulic feed pipes to ram.

Support the ram. Undo bolt D and withdraw inner pivot pin E.

C067830-C1

Fig 2. pressure.

K Related

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Remove ram F from machine.

E25-3

â&#x20AC;&#x201C; Grease the ram Topics ( T E25-2) â&#x20AC;&#x201C; Check the hydraulic Topics ( T E25-2)

E-19-06 Issue 01

pivot fluid

pins.

K Related

level.

K Related

E25-3

Section E25 - Hydraulics Tilt Ram Removal and Replacement

Page left intentionally blank

E25-4

E-19-06 Issue 01

E25-4

Section E26 - Hydraulics

Displacement Ram Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E26-2) K Removal and Replacement ( T E26-3) K Removal ( T E26-3) K Replacement ( T E26-3)

E26-1

E-20-06 Issue 01

E26-1

Section E26 - Hydraulics Displacement Ram Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Greasing

Every 50 Hours

Hydraulic System

Checking the Hydraulic Fluid Level

(1) You must obey all of the relevant care and safety procedures.

E26-2

E-20-06 Issue 01

E26-2

Section E26 - Hydraulics Displacement Ram Removal and Replacement

Removal and Replacement Removal

Obey the general care and safety procedures for rams during the removal and replacement procedures. K Related Topics ( T E26-2) 1

Raise the boom to get access to the lower pivot of the displacement ram. Fully retract the boom. Support the front end of the boom.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T E26-2)

C119650

Fig 2.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Grease the ram Topics ( T E26-2) â&#x20AC;&#x201C; Check the hydraulic Topics ( T E26-2)

fluid

pins.

K Related

level.

K Related

C067600

Fig 1. 3

Undo bolt A and withdraw upper pivot pin B.

Select tilt back until displacement ram closes.

Vent the hydraulic Topics ( T E26-2).

Disconnect and plug hydraulic feed pipes to ram C and disconnect the remote greasing connection. Support ram.

Undo bolt D and withdraw lower pivot pin E.

Remove ram from machine.

E26-3

pivot

pressure.

K Related

E-20-06 Issue 01

E26-3

Section E26 - Hydraulics Displacement Ram Removal and Replacement

Page left intentionally blank

E26-4

E-20-06 Issue 01

E26-4

Section E27 - Hydraulics

Sway Ram Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E27-2) K Removal and Replacement ( T E27-3) K Removal ( T E27-3) K Replacement ( T E27-4)

E27-1

E-21-04 Issue 01

E27-1

Section E27 - Hydraulics Sway Ram Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Greasing

Every 50 Hours

Hydraulic System

Checking the Hydraulic Fluid Level

Bleed Procedures - Sway ram Circuit

ALL

(1) You must obey all of the relevant care and safety procedures.

E27-2

E-21-04 Issue 01

E27-2

Section E27 - Hydraulics Sway Ram Removal and Replacement

Removal and Replacement Removal

C068080-C1

Fig 1. Obey the general care and safety procedures for rams during the removal and replacement procedures. K Related Topics ( T E27-2) 1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E27-2)

E27-3

E-21-04 Issue 01

Support the chassis on both sides of the machine.

E27-3

Section E27 - Hydraulics Sway Ram Removal and Replacement 3

Disconnect and plug sway ram hydraulic hoses A. Label each hose before disconnecting to ensure correct replacement.

Support the sway ram B. Remove nut and bolt C and withdraw pivot pin D from cylinder end.

Attach suitable lifting equipment to the cylinder end of the ram. Support the ram.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Remove nut and bolt E and withdraw pivot pin F from rod end, remove the ram from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Check the hydraulic Topics ( T E27-2) – Grease the pivot Topics ( T E27-2)

fluid

points.

– Using the bleed procedures K Related Topics ( T E27-2).

E27-4

level.

bleed

K Related K Related the

ram.

E-21-04 Issue 01

E27-4

Section E28 - Hydraulics

Stabiliser Rams Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E28-2) K Removal and Replacement ( T E28-3) K Removal ( T E28-3) K Replacement ( T E28-4)

E28-1

E-22-04 Issue 01

E28-1

Section E28 - Hydraulics Stabiliser Rams Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Greasing

Every 50 Hours

Hydraulic System

Checking the Hydraulic Fluid Level

Stabiliser System

Removal and Replacement

(1) You must obey all of the relevant care and safety procedures.

E28-2

E-22-04 Issue 01

E28-2

Section E28 - Hydraulics Stabiliser Rams Removal and Replacement

Removal and Replacement Removal

F G H K

Fig 1. Stabiliser Ram (if fitted) Obey the general care and safety procedures for rams during the removal and replacement procedures. K Related Topics ( T E28-2)

E28-3

C130570-C1.eps

Note: The illustration and procedure describes removal of one stabiliser ram. The procedure for the second ram is identical.

E-22-04 Issue 01

E28-3

Section E28 - Hydraulics Stabiliser Rams Removal and Replacement Note: The stabiliser ram can be removed with the stabiliser leg still attached to the machine. 1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E28-2) Support the stabiliser leg H.Put a label on each hydraulic hose to help identification when reconnecting.

Disconnect and plug stabiliser ram hydraulic hoses A.

Remove the pressure switch cover securing screws B.

Lift the pressure switch cover D away from the ram to get access to the pressure switch harness connector C.

!MWARNING

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Grease the ram Topics ( T E28-2) â&#x20AC;&#x201C; Check the hydraulic Topics ( T E28-2)

pivot fluid

pins.

K Related

level.

K Related

Checking Pressure Switch Operation The pressure switches (if fitted) are pre-set and must not be adjusted. To check for correct operation, raise and lower each stabiliser in turn to ensure that the warning light illuminates when both stabilisers are making firm ground contact and extinguishes when one or both stabilisers are raised clear of the ground.

Remove nut and bolt E.

Use the slide hammer kit to remove the ram pivot pin F, refer to Service Tools - Section 1. K Related Topics ( T E28-2)

Remove nut and bolt J.

Use the slide hammer kit to remove the ram pivot pin K, refer to Service Tools - Section 1. K Related Topics ( T E28-2)

Lift the stabiliser ram G free from the stabiliser leg H.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

E28-4

E-22-04 Issue 01

E28-4

Section E29 - Hydraulics

RAS Rams Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E29-2) K Removal and Replacement ( T E29-3) K Removal ( T E29-3) K Replacement ( T E29-4) K Dismantle and Assembly ( T E29-5) K Dismantle ( T E29-5) K Assembly ( T E29-5)

E29-1

E-23-01 Issue 01

E29-1

Section E29 - Hydraulics RAS Rams Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Greasing

Every 50 Hours

Hydraulic System

Checking the Hydraulic Fluid Level

RAS System

Test Procedure Bleed Procedure

(1) You must obey all of the relevant care and safety procedures.

E29-2

E-23-01 Issue 01

E29-2

Section E29 - Hydraulics RAS Rams Removal and Replacement

Removal and Replacement

!MWARNING

K Fig 1. ( T E29-4) Obey the general care and safety procedures for rams during the removal and replacement procedures. K Related Topics ( T E29-2) The procedures describe removal and replacement of one ram. The procedures are identical for the left and right RAS rams. Important: The RAS rams control the oscillation of the rear axle. Removal of the rams can make the machine unstable. Support the left and right sides of the chassis before removal of the left or right side RAS ram.

Removal 1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E29-2)

Important: The normal hydraulic pressure venting procedure will not vent pressure from the RAS ram circuit. 2

Support the chassis on both sides of the machine.

Vent the hydraulic pressure from the left and right side RAS rams. Fit a vent hose to coupling L and at the same time hold the other end of the hose inside a suitable container. Pressure will vent as soon as the hose is connected at the ram. Repeat the procedure for the ram on the other side of the machine.

Important: Oil will flow from the vent hose at a pressure of 30 bar. Make sure that the vent hose is correctly retained. Important: Vent trapped hydraulic pressure from both the left and right side rams, even if only one ram is to be removed.

E29-3

Undo the two fixing screws and remove the valve cover A.

Disconnect the electrical connector B at the solenoid valve C.

Working on the inside of the chassis disconnect hydraulic hoses D. Cap the open hoses and pipes. Label each hose before disconnecting to ensure correct replacement.

Disconnect the hydraulic hose K at the solenoid valve. Cap the open hose and port.

Support the RAS ram E. Remove nut and bolt F and withdraw pivot pin G from the rod end.

Attach suitable lifting equipment to the cylinder end of the ram. Support the ram.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

E-23-01 Issue 01

Remove nut and bolt H and withdraw pivot pin J from rod end, remove the ram from the machine.

E29-3

Section E29 - Hydraulics RAS Rams Removal and Replacement

Replacement

â&#x20AC;&#x201C; Grease the ram Topics ( T E29-2)

Replacement is the opposite of the removal procedure.

â&#x20AC;&#x201C; Bleed and test the RAS system. Follow the correct procedures, refer to Section B - RAS SYSTEM. K Related Topics ( T E29-2).

During the replacement procedure do this work also:

Fig 1.

E29-4

E-23-01 Issue 01

pivot

pins.

K Related

C075740

E29-4

Section E29 - Hydraulics RAS Rams Dismantle and Assembly

Dismantle and Assembly If necessary the following components can be removed from the rams:

Disconnect the electrical connector D at the solenoid valve.

K Fig 2. ( T E29-6)

Undo nut E and remove the solenoid coil F.

Unscrew the valve cartridge G from the valve block C.

Solenoid valve

Thermal relief valve

Check valve

Thermal Relief Valve

Note: Valve block C is part of the ram. If the valve block is defective renew the complete ram. If one or more of these components are to be removed with the RAS ram still fitted to the machine, first do the procedure that follows: Important: The RAS rams control the oscillation of the rear axle. Removal of the ram components can make the machine unstable. Support the left and right sides of the chassis before removal of RAS ram components. 1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E29-2)

Important: The normal hydraulic pressure venting procedure will not vent pressure from the RAS ram circuit. 2

Support the chassis on both sides of the machine.

Vent the hydraulic pressure from the left and right side RAS rams. Fit a vent hose to coupling A and at the same time hold the other end of the hose inside a suitable container. Pressure will vent as soon as the hose is connected at the ram. Repeat the procedure for the ram on the other side of the machine.

Important: Vent trapped hydraulic pressure from both the left and right side rams, even if components from only one ram are to be removed.

Dismantle

Remove cover B. Remove dirt and debris from the valve block C.

Remove plug H.

Unscrew the valve cartridge J from the valve block C.

Check Valve 1

Remove cover B. Remove dirt and debris from the valve block C.

Unscrew the valve cartridge K from the valve block C.

Assembly Assembly is the opposite of the dismantle procedure. During the assembly procedure do this work also: â&#x20AC;&#x201C; Renew worn or defective `O' ring seals. â&#x20AC;&#x201C; Torque tighten valves and plugs to the correct value. â&#x20AC;&#x201C; Bleed and test the RAS system. Follow the correct procedures. K Related Topics ( T E29-2)

Item E

Table 2. Torque Settings Nm kgf m 5.4 - 6.8

lbf ft

0.55 - 0.69

4-5

45 - 50

4.6 - 5.1

33 - 37

5.4 - 6.8

0.55 - 0.69

4-5

40.6

4.15

Solenoid Valve 1

Remove cover B. Remove dirt and debris from the valve block C.

E29-5

E-23-01 Issue 01

E29-5

Section E29 - Hydraulics RAS Rams Dismantle and Assembly

Fig 2.

E29-6

E-23-01 Issue 01

C075740-C1

E29-6

Section E30 - Hydraulics Ram Maintenance Introduction

Ram Maintenance Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E30-2) K Operation Overview ( T E30-3) K Ram End Damping ( T E30-3)(1) K Dismantle ( T E30-6) K Assemble ( T E30-8) K JCB Ram Sealing Procedure ( T E30-9) K Piston Head Retention ( T E30-11) K Twin Piston, 4 Stage Boom Outer Ram ( T E30-12) K Extension Ram Make-Up Valve (if fitted) ( T E30-21) (1) Procedure variant. Make sure you refer to the correct procedure.

Procedures, Specifications(1)

Table 1. Procedure and Specification Variants Machine Model Application 531-70, 536-60, 541-70, 536-70, 531-T70 536-T60 541-T70 536-T70

K Ram End Damping ( T E30-3)

Option

(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

Procedures, Specifications(1)

Table 2. Procedure and Specification Variants Machine Model Application 540-170

K Twin Piston, 4 Stage Boom Outer Ram ( T E30-12)

550-170

(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

E30-1

E-24-07 (issue 01)

E30-1

Section E30 - Hydraulics Ram Maintenance Related Topics

Related Topics Table 3. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications. Sections

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

ALL ALL

(1)

(1) You must obey all of the relevant care and safety procedures. Table 4. Service Tools The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number

Description

892/00334(1)

Ram Seal Fitting Tool

892/01027

Piston Seal Assembly Tool

(2)

Ram Protection Sleeve

(2)

Hexagon Spanner

(1)

(1) Tool available from JCB Service, refer to Section 1 - Service Tools (2) For the applicable JCB part number refer to Section 1 - Service Tools

E30-2

E-24-07 (issue 01)

E30-2

Section E30 - Hydraulics Ram Maintenance Operation Overview

Operation Overview Ram End Damping

To make the ram operate smoothly, electro servo machines have a â&#x20AC;&#x153;dampingâ&#x20AC;? system.

When operating the lift and extension rams a jolt can occur when the ram is at full travel. This could cause load instability and operator discomfort.

The flow through the ram is gradually decreased as the ram moves to the end of its travel until the ram is at full travel.

Ram - Cylinder End

Fig 1. Ram Retracting (Cylinder End of Ram) A restrictor probe 1-G fitted to the end of the cylinder 1-C aligns with a groove 1-H in the piston rod 1-F. As the ram closes to full retract the probe 1-G engages with the hole 1-H in the piston rod, the damping effect is caused as the orifice plate 1-D seats on the face of the piston rod counterbore 1-E. The holes in the probe 1-G control the speed of the ram by restricting the flow of oil at a gradual rate until the ram is fully closed.

C078940-C1

rod 2-H. This flow pushes the orifice plate 2-D away from the counterbore 2-E increasing the area on which the oil pushes on the ram decreasing the pressure necessary to extend the ram (pressure spike). The flow rate, pressure, load and viscosity of the oil have an effect on the damping rate.

To extend the ram, oil goes into the feed port 2-A and through the centre of the probe 2-G to the hole in the piston

E30-3

E-24-07 (issue 01)

E30-3

Section E30 - Hydraulics Ram Maintenance Operation Overview

Fig 2. Ram Extending (Cylinder End of Ram)

C078940

Ram - Rod End The damping effect is caused by a tapered collar on the piston rod which engages with the end cap to decrease the flow of oil.

E30-4

E-24-07 (issue 01)

E30-4

Section E30 - Hydraulics Ram Maintenance Operation Overview

Fig 3.

C078950

As the ram opens to full extend the tapered collar 3-E on the piston rod 3-B engages with the end cap 3-A, the oil flows through the four holes 3-H in the end cap 3-A through the cylinder port. The ‘o’ ring 4-A compresses on the anti extrusion ring 4-B which closes the four oil galleries on the front of the end cap 3-G.The damping effect is caused by the tapered collar 3-E gradually decreasing the area between the piston rod 3-B and end cap 3-A restricting the flow of oil. To retract the ram oil flows through the feed port 3-D, this pushes the anti extrusion ring 4-B and compresses the ‘o’ ring 4-A letting oil flow through the four galleries which pushes on the piston head. Also the oil flows through the four holes in the end cap 3-H through the flats 3-F of the tapered collar 3-E. The function of the flats and oil pathways is to decrease the pressure necessary to retract the ram from full open centres (pressure spike).

Fig 4.

E30-5

C078950-C1

E-24-07 (issue 01)

E30-5

Section E30 - Hydraulics Ram Maintenance Single Piston Rams

Single Piston Rams Dismantle

The dismantle and assemble procedures for many JCB hydraulic rams are the same. BEFORE you follow the procedures given in this topic make sure they are applicable. The applicable rams are given in the related topics table. K Related Topics ( T E30-2)

Position piston rod assembly on bench in place of ram cylinder. Discard seals (items 6-2, 6-3) and wear rings (items 6-1 and 6-4) from piston head 6-6.

Extract dowel 6-5 from the piston head using the appropriate sized screw threaded into the extractor hole.

Using the correct size spanner, remove piston head 6-6 from rod 6-12 and remove `O' ring 6-7.

The procedure for dismantling and assembly of 4 stage boom outer extension rams is described later in this topic. K Twin Piston, 4 Stage Boom Outer Ram ( T E30-12) Important: The ram must be removed from the machine before you dismantle it. K Related Topics ( T E30-2)

Extension rams only: Slide spacer 6-20 off piston rod 6-12, after removal of piston 6-6. 6

Remove gland bearing and end cap 6-8 from piston rod and remove the `O' ring 6-9, wiper seal 6-11 and rod seal 6-10. 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 gland seals. Check the bore of the ram cylinder for damage.

K Fig 6. ( T E30-7) The illustration shows a ram which is not fitted with a hose burst check valve (HBCV). If a HBCV is fitted the ram dismantling/assembly procedures are unaffected and can be carried out without the need to remove the check valve. 1

Place ram assembly on a locally manufactured strip/ rebuild bench. K Fig 5. ( T E30-6)

Fig 5. 2

S263670-1

Use the correct size spanner to release end cap 6-8 and remove the piston rod assembly (items 6-1 to 612) from the cylinder 6-19.

!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

E30-6

E-24-07 (issue 01)

E30-6

Section E30 - Hydraulics Ram Maintenance Single Piston Rams

Fig 6. Typical Ram

E30-7

E-24-07 (issue 01)

S314091-1

E30-7

Section E30 - Hydraulics Ram Maintenance Single Piston Rams

Assemble 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).

Item

Table 5. Torque Settings Nm Kgf m

lbf ft

6-6

405

300

6-8

678

500

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

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 E30-9)

Important: Ensure that lubricants used during assembly do not come into contact with de-greased components or sealing/retaining compounds. 3

Fit locking dowel 6-5 to piston 6-6. K Piston Head Retention ( T E30-11)

Position cylinder 6-19 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 6-8. K Table 5. Torque Settings ( T E30-8)

Note: If hydraulic oil contacts uncured locking fluid a weakening of the bond will result. Cure times vary according to the ambient temperature. The following approximate cure time applies at 20ÂŞC 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.

E30-8

E-24-07 (issue 01)

E30-8

Section E30 - Hydraulics Ram Maintenance Single Piston Rams

JCB Ram Sealing Procedure TE-005_2

Fit new rod seals. Use seal fitting tool 7-A to fit rod seals, the size (diameter) and position of pins 7-B is determined by the diameter and radial width of the rod seal being fitted.

Fig 9.

153212-1

b Close the tool. K Fig 10. ( T E30-9). The seal must form a reniform (kidney shape). Fig 7. Seal Fitting Tool

S216250-1

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 8-A. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

Fig 10. c

S161750 Y-1

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 11. ( T E30-9). 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.

Fig 8.

S161750 X-1

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 9-A and 9-B. Fig 11. e

E30-9

E-24-07 (issue 01)

S161750 Z-1

Fit rod wiper seal 9-A into seal groove. Make sure the seal is correctly installed as shown.

E30-9

Section E30 - Hydraulics Ram Maintenance Single Piston Rams 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 13-C using the same procedure as stated for seal 13-B. Check the external grooves are visible. c

Sleeve 12-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.

d Fit the piston head retaining dowel, refer to the relevant section for torque figure and completion of ram assembly. e

Fig 12. 2

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.

Fit wear rings 14-A and 14-B. Rotate the wear rings so that the piston retention dowel is covered by the wear ring, Not as shown at 14-C.

187361-1

Fit new head piston seals. a

Use a blunt instrument 13-A (Part no. 892/01027) to lever the inner seal 13-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. Fig 14. 3

338490-1

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.

Fig 13.

E30-10

338480-1

E-24-07 (issue 01)

E30-10

Section E30 - Hydraulics Ram Maintenance Piston Head Retention

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 E30-11) 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.

Existing piston head and new rod Drill through existing hole in piston head to the diameter and depth indicated. K Drilling Dimensions ( T E30-11) 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.

New piston head and existing rod Same as Existing piston head and new rod but at 90 degrees to existing hole in rod.

E30-11

Fig 15.

A335740

Ram Size

Table 6. Drilling Dimensions Diameter X

Depth Y

50 x 25

6.02mm - 6.10mm

23mm

90 x 50

8.10mm - 8.02mm

28mm

100 x 60

12.10mm - 12.02mm

33mm

110 x 60

12.10mm - 12.02mm

33mm

120 x 60

12.10mm - 12.02mm

38mm

130 x 70

12.10mm - 12.02mm

38mm

130 x 75

12.10mm - 12.02mm

38mm

140 x 75

12.10mm - 12.02mm

48mm

160 x 80

12.10mm - 12.02mm

48mm

E-24-07 (issue 01)

E30-11

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram

Twin Piston, 4 Stage Boom Outer Ram

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device.

cylinder a space of 10 metres (30 ft) will be required. Make sure you have sufficient workshop space before attempting to dismantle the ram.

Introduction

This is a two person job, assistance will be required at several points in the process due to the weight of the components and forces required.

K Fig 16. ( T E30-12). The telescopic extension ram has 4 main components each over 4 metres in length. These will each require a working area and suitable supports when dismantling. When extracting an inner from an outer

K Fig 19. ( T E30-16). Whenever the ram is dismantled new seals must always be fitted. Ensure the correct replacement parts are available before attempting to dismantle the ram.

BF-4-1_1

D C048350

Fig 16. Telescopic Outer Ram Main Components Item

Description

Outer Cylinder

Centre Cylinder

Inner Cylinder

Feed Pipe

E30-12

E-24-07 (issue 01)

C048350

E30-12

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram

Supporting The Ram Important: The ram must be supported during the dismantling and assembly process. The ram may become unstable as work is carried out and items are removed if not correctly supported. Soft Pads must be used to protect the ram from the supports. Important: The ram must be supported in a way that ensures the weight is distributed evenly or distortion or damage may occur.

the K Removing Housing ( T E30-15).

Inner

Cylinder

K Removing the Inner Cylinder from the Outer Cylinder ( T E30-15).

the K Removing Piston ( T E30-15).

K Removing the Seal Cylinders ( T E30-15).

Inner

Housings

Seal

Cylinder

from

the

Removing the Centre Cylinder from the Outer Cylinder

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

Lifting equipment is required to move the ram and remove the cylinders. A hoist or crane with a rope (not metal) sling must be used. At various points in the procedure the ram must be prevented from turning so that components can be unscrewed. The recommended method is to use a V type clamp which distributes the clamping force evenly and therefore reduces risk of distorting any components.

Important: Leave bleed screws open throughout the dismantle and assembly procedure. This will aid in the process as no air will be trapped within the components. For locations refer to the applicable hydraulic system topic. 2

Dismantling Refer to the exploded illustration for dismantling, inspection and assembly procedures. K Fig 19. ( T E30-16) The list below shows the sequence of the main dismantling procedures. To prevent damage to the ram and its internal components be sure to dismantle in the sequence shown. 1

K Removing the Centre Cylinder from the Outer Cylinder ( T E30-13)

K Removing the Screws ( T E30-14).

K Removing the Piston ( T E30-14).

E30-13

Piston

Head

Centre

Locking

Open all bleed screws 3, 4 & 8 slowly to relieve the pressure in the cylinder.

Using a 46mm spanner loosen the union nuts 24 & 26 and remove the adaptor bolts 21 & 27 but do not remove pipes.

Note: A significant quantity of hydraulic fluid may be released during this step and a suitable container should be on hand. 3

Withdraw the centre cylinder 10 by approximately 300mm (12 in) and use a rope loop to secure it. This gives clearance to unscrew seal housing 7. Rotate the centre cylinder to help withdrawal if the seal is tight.

Using two 155-230mm C Spanners K Fig 17. ( T E30-14). (see Section 1 - Service Tools) loosen the groove nut 6.

Cylinder

E-24-07 (issue 01)

E30-13

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram d Remove locking screw using 3mm or 4mm allen key as applicable. e

C048280

Fig 17. C Spanner

Unscrew the seal housing 7 from the outer cylinder 25.

Tilt the ram to drain the remaining hydraulic fluid.

Withdraw the centre cylinder 10 from the outer cylinder 25 together with the seal housing 7 and the piston 13.

Fig 18. Piston Head Locking Screws

Some of the piston head locking screws B, are recessed below the surface of the piston. The edges of the locking screw holes have edges A which are â&#x20AC;&#x153;peenedâ&#x20AC;? over to prevent the screws from working loose. If the locking screw is not retained in a peened hole use a 4mm or 3mm Allen key as applicable to remove it. If the locking screw is retained by a peened hole follow the instructions below for removal. Plug all adjacent open ports to prevent swarf ingress and contamination.

b Using a 5mm drill bit carefully drill the locking screw hole 1 until the whole of the hexagonal socket in the screw is visible as shown at 2.

Using compressed air or cleaning fluid remove any metal swarf from the area.

E30-14

C048510-C2.eps

Removing the Centre Cylinder Piston Important: The valve may still hold some residual pressure. Make sure all internal pressure is vented.

!MCAUTION The telescopic cylinder is filled with oil and is under pressure. Vent internal hydraulic pressure before removing the counter-balance valve from the piston or damage to the valve seals can result. 0056

Using 30mm box spanner or deep socket unscrew the counterbalance valve 11 slowly in order to vent any remaining internal hydraulic pressure.

Using a 90-155mm K Fig 17. ( T E30-14). unscrew centre cylinder 10.

Withdraw the piston 13 and feed pipe 19 from the centre cylinder 10 by approximately 30cm (12in).

Important: Do not attempt to drill out the locking screw as this will damage the cylinders beyond repair. c

K Fig 18. ( T E30-14).

Removing the Piston Head Locking Screws

C048280

Note: A significant quantity of hydraulic fluid may be released during this step and a suitable container should be on hand.

Unplug ports.

E-24-07 (issue 01)

C piston

Spanner 13 from

E30-14

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram 4

Rotate piston 13 and retrieve locking pin 15A.

Place housings on a clean surface.

Remove lock screw 16 with 3mm allen key the Piston Head Locking K Removing Screws ( T E30-14).

Remove all the seals and rings from the seal housings and pistons.

Clean all components.

Unscrew the piston 17 from the inner cylinder 1.

Unscrew piston 13 from feed tube 19. Place the items on a clean surface.

Removing the Inner Cylinder Seal Housing 1

Clamp the centre cylinder 10 carefully to prevent damage and rotation.

Using 3mm allen key Remove locking screw 9.

Withdraw the inner cylinder 1 approx. 30cm to give access for seal housing removal

Unscrew the seal housing 5 from the centre cylinder 10.

Removing the Inner Cylinder from the Outer Cylinder 5

Withdraw the inner cylinder 1 from the centre cylinder 10 together with the piston 17 and seal housing 5.

Removing the Inner Cylinder Piston 1

Remove lock screw 18 with 3mm allen key the Piston Head Locking K Removing Screws ( T E30-14).

Unscrew the piston 17 from the inner cylinder 1.

Withdraw the piston 17 and inner feed tube 19 from the inner cylinder 1 and place on a clean surface.

Removing the Seal Housings from the Cylinders Before removing the seal housings, ensure the cylinder is free of burrs or debris. 1

To remove seal housing 7. Slide it along the centre cylinder 10 towards end A. This avoids damaging the housing on the locking screw holes B.

To remove seal housing 5. Slide it along the inner cylinder 1.

E30-15

E-24-07 (issue 01)

E30-15

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram

22 23 22

28 25 11

15 14 15A

13 27

10 8 17 19 20

6 7

B 9

3 2 1

4 5 2 Fig 19. 4 Stage Telescopic Extension Ram - Outer

E30-16

E-24-07 (issue 01)

C048210

E30-16

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram

Inspection 1

Examine the primary components for scoring, damage, wear, distortion, uneven surface (i.e. polished or pitted areas) and scratches. Replace all damaged parts.

Examine the components for burrs. Give special attention to the traversing diameters, locking pin holes and mounting chamfers. If minor burrs are seen, remove them by polishing with a fine grade abrasive paper.

Examine pivot bushes 22 for signs of wear or damage. Renew if necessary.

Fit outer seals 17E, 17F and 17G to the outside of the piston 17.

Fit wear ring item 17H.

C048580

Note: If a cylinder is damaged it must be renewed. New piston seals will fail after only a short period of time if the cylinder is worn or damaged.

Reseal the Centre Cylinder Seal Housing

Assembly

K Fig 22. ( T E30-19). Insert “O” ring 7A into seal housing 7.

Insert wear rings 7B and 7C into seal housing 7.

Insert seal 7D into seal housing 7 using seal fitting tool as shown K Fig 20. ( T E30-17), K Fig 21. ( T E30-17). Refer to the correct Ram Sealing procedure. K JCB Procedure ( T E30-9)

Using a press push wiper seal 7E squarely into the seal housing 7 with the rubber facing outwards from the housing.

Reseal the Pistons and Seal Housings Make sure all seals and rings are renewed.

Fig 21.

Before installation, apply a small quantity of hydraulic oil to all seals and “O” rings. Reseal the Inner Cylinder Piston 1

K Fig 22. ( T E30-19). Insert wear ring item 17D into the piston inner bore.

Insert the “O” ring 17B then inner retainer 17C.

Insert wear ring 17A.

Fig 20.

E30-17

Reseal the Inner Cylinder Seal Housing

C048570

K Fig 22. ( T E30-19). Insert wear rings 5A and 5B and ‘O’ ring 5X into the piston side 1 of the seal housing 5.

Fit “O” ring 5X and retaining ring 5C into seal housing.

Fit wear rings 5D and 5E into the rod side 2 of the seal housing 5.

Insert “O” ring 5F and retainer 5G into the seal housing.

Note: Item 5G has two different internal diameters. The smaller diameter goes into the seal housing on the rod side 2. The larger diameter must be on the piston side 1.

E-24-07 (issue 01)

E30-17

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram 5

Using JCB seal fitting tool K Fig 20. ( T E30-17) K Fig 21. ( T E30-17). (see K JCB Ram Sealing Procedure ( T E30-9). for the correct procedure using seal fitting tool) insert seals 5H and 5J into the seal housing 5.

Reseal the Centre Cylinder Piston 1

K Fig 22. ( T E30-19). Fit internal â&#x20AC;&#x153;Oâ&#x20AC;? rings 13B and 13C into the piston 13.

Fit wear ring 13A to the outside of the piston 13.

Fit seals 13D, 13E and 13F to the outside of the piston 13.

E30-18

E-24-07 (issue 01)

E30-18

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram

17A 17C

17E 17G

17B17D

17F

17H 7E

7B 7C 7D

5A 5B 5X 5C

13A

5X 5

5E 5F 5H

13B 13C 13D 13E 13F

C048510 C048510-C3.eps

Fig 22.

Ram Assembly 1

Slide the piston 17 onto the feed pipe 19 approximately 30 - 40 cm

E30-19

Using a 60mm Ram Protection Sleeve to prevent seal damage (see Service Tools, Section 1) slide seal housing 5 onto inner cylinder 1.

Slide the feed pipe 19 into the inner cylinder 1.

E-24-07 (issue 01)

E30-19

Section E30 - Hydraulics Ram Maintenance Twin Piston, 4 Stage Boom Outer Ram 4

Screw piston 17 onto inner cylinder 1. Apply JCB High Strength Threadlocker and Sealer to the locking screw 18. Fit the locking screw.

Screw the seal housing 7 onto the outer cylinder and tighten until port and adaptor bolts 21 & 27 align. Loosely attach locknut 6.

Note: K Fig 18. ( T E30-14). If the locking screw had a peened edge to retain it, use a hammer and a large diameter centre punch to distort the locking screw location hole as shown at 18-1. Remove any burrs.

Fit new seals to union nuts 24 & 26 and adaptor bolts 21 & 27 and loosely fit to the outer cylinder 25 and seal housing 7.

Using a 155-230mm C spanner K Fig 23. ( T E30-20). secure seal housing 7 with locknut 6.

Slide seal housing 7 onto the cylinder 10 (use a 105mm Ram Protection Sleeve to prevent seal damage - see Service Tools, Section 1).

Slide inner cylinder 1 and feed pipe 19 together with seal housing 5 into the centre cylinder 10 at end B.

Using a 90-155mm C Spanner K Fig 23. ( T E30-20). screw the seal housing 5 into the centre cylinder 10 and secure with screw 9 coated with JCB High Strength Threadlocker and Sealer.

Push the inner cylinder 1 far enough into the centre cylinder 10 until the feed pipe 19 protrudes out of the opposite end. Screw the Piston 13 onto the feed pipe 19.

Note: Screw the piston to the limit stop, then screw back slowly until the locking pin 15A locates in the hole in the feed pipe. 10

C048280

Fig 23. C Spanner 17

Tighten union nuts 24 & 26 and adaptor bolts 21 & 27.

Tighten all bleed screws 3,4 & 8.

Before Operating the Ram 1

The ram must not be operated in the first 24 hours after assembly. This will allow the locking fluid to harden sufficiently.

The ram must be bled prior to its initial operation. For bleed procedures refer to the applicable hydraulic system topic.

Apply JCB High Strength Threadlocker and Sealer to the locking screw 14. Fit the locking screw.

Screw piston 13 onto cylinder 10. Apply JCB High Strength Threadlocker and Sealer to screw 16. Fit the locking screw.

Replace seals and screw the counterbalance valve 11 into the piston 13. (Ensure that the top of the counter-balance valve is recessed within the piston by a minimum of 0.5mm).

Slide the centre cylinder assembly 10 with piston and all internal parts, into the outer cylinder 25.

E30-20

C048280

E-24-07 (issue 01)

E30-20

Section E30 - Hydraulics Ram Maintenance Extension Ram Make-Up Valve (if fitted)

Extension Ram Make-Up Valve (if fitted) Removal and Replacement Note: This valve is fitted to 3 stage boom machines only, and is assembled to the piston rod using locking fluid. With the valve removed check for freedom of movement of the plunger and ball. Renew 'O' ring seal. Thoroughly remove all oil, grease and dirt from threads of valve and piston rod. Apply JCB Activator and allow to dry for 15 minutes. Coat three central threads of the valve with JCB Threadlocker & Sealer (High Strength) ensuring that it does not contact 'O' ring seal. Re-assemble to piston rod ensuring that the end face is flush to 0.5 mm (0.02 in) below the end face of the piston rod as at X. Add washer 1410/0003 beneath valve if necessary. After assembly, plunger when pulled out, should protrude a minimum of 4 mm (0.16 in) from end face of piston rod as at Y.

Fig 24.

159190-1

Note: Approximately 60 minutes should elapse from fitting the valve before allowing contact with hydraulic oil.

E30-21

E-24-07 (issue 01)

E30-21

Section E30 - Hydraulics Ram Maintenance Extension Ram Make-Up Valve (if fitted)

Page left intentionally blank

E30-22

E-24-07 (issue 01)

E30-22

Section E31 - Hydraulics

Sway Circuit - Bleed Procedure Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T E31-2) K Bleed Procedure ( T E31-3)

E31-1

E-61-01 Issue 01

E31-1

Section E31 - Hydraulics Sway Circuit - Bleed Procedure Related Topics

Topic Titles

Sub Titles

Applications

ALL

Hydraulic Systems and Schematics

ALL

Hydraulic Circuit Faults

ALL

E31-2

E-61-01 Issue 01

E31-2

Section E31 - Hydraulics Sway Circuit - Bleed Procedure Bleed Procedure

Bleed Procedure The sway ram has an integral bleed valve, which can be used to bleed the sway hydraulic circuit.

K Fig 1. ( T E31-3) Get an assistant to carefully unscrew the bleed valve 1, be prepared for hydraulic oil to escape. DO NOT unscrew more than 6.5 mm (0.25 in).

Start the engine and operate the sway lever to sway the machine fully to the operatorâ&#x20AC;&#x2122;s left side. Hold the lever in this position until no more air is expelled through the bleed valve 1. Return the control lever to its neutral position. Immediately tighten the bleed valve 1 to prevent air entering the circuit.

Important: Make sure that the boom is in the lowered position when bleeding the sway ram circuit. Note: This procedure requires two people. One person to operate the sway controls and another to tighten the bleed screw when all air has been expelled. If this procedure is done by one person air may enter the cylinder due to the delay in dismounting from the cab to attend to the sway cylinder.

Park the machine and make it safe. Lower the boom. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T E31-2)

Important: Opening the sway ram bleed valve can cause the machine to sway unexpectedly. Only open the bleed valve when the machine is swayed fully to the left or the right. Important: DO NOT stand between the chassis and the wheel. You can be trapped or crushed when sway is operated.

Fig 1. Unscrewing the Bleed Valve 5

Operate the sway ram fully in both directions 10 times

Repeat steps 2, 3 and 4.

Stop the engine and remove the starter key.

Check the hydraulic Topics ( T E31-2)

Important: The bleed valve should only be completely removed from the valve body to allow cleaning of the integral 1.2mm orifice. 2

766840-C1

fluid

level.

K Related

Start the engine and operate the sway lever to sway the machine fully to the operator's left side (sway ram extended). Stop the engine and vent the hydraulic pressure. Follow the correct procedure, see Venting the Hydraulic Pressure, Section 2.

E31-3

E-61-01 Issue 01

E31-3

Section E31 - Hydraulics Sway Circuit - Bleed Procedure Bleed Procedure

Page left intentionally blank

E31-4

E-61-01 Issue 01

E31-4

Section F Transmission Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813-1800-2

Section F - Transmission

Notes:

F-0

9813-1800-2

F-0

Section F - Transmission Contents Page No. Applications Table ........................................................................................................ F0-1 CONFIGURATION Introduction .............................................................................................. F1-1 Operation Overview ................................................................................. F1-2 Wheels and Tyres Introduction .............................................................................................. F2-1 Related Topics ......................................................................................... F2-2 Specifications .......................................................................................... F2-3 Removal and Replacement ..................................................................... F2-4 Front Axles Introduction .............................................................................................. F3-1 Related Topics ......................................................................................... F3-2 Specifications .......................................................................................... F3-3 Component Identification ......................................................................... F3-4 Removal and Replacement ..................................................................... F3-6 Dismantle, Inspection and Assembly ....................................................... F3-8 Rear Axles Introduction .............................................................................................. F4-1 Related Topics ......................................................................................... F4-2 Specifications .......................................................................................... F4-3 Component Identification ......................................................................... F4-4 Removal and Replacement ..................................................................... F4-7 Dismantle, Inspection and Assembly ..................................................... F4-11 PS750 Mk IV Gearbox SYSTEM Introduction .............................................................................................. F5-1 Related Topics ......................................................................................... F5-2 Specifications .......................................................................................... F5-3 Component Identification ......................................................................... F5-4 Operation Overview ................................................................................. F5-5 Hydraulic Operation and Schematics ...................................................... F5-8 Electrical Operation and Schematics ..................................................... F5-10 Electrical Connectors ............................................................................. F5-20 Fault Finding .......................................................................................... F5-21 Torque Converter Operation Introduction .............................................................................................. F6-1 Related Topics ......................................................................................... F6-2 Component Identification ......................................................................... F6-3 Descriptions ............................................................................................. F6-4 Gearbox Systems FAULT FINDING Introduction .............................................................................................. F7-1 Related Topics ......................................................................................... F7-2 Electronic Fault Codes ............................................................................ F7-3 Gearbox `Limp Modes' (Powershift Electronic Control) ........................... F7-4 Fault Finding ............................................................................................ F7-5 Flushing the Transmission Oil Introduction .............................................................................................. F8-1

F-i

Section F - Transmission Contents Page No. Related Topics ......................................................................................... F8-2 Procedure ................................................................................................ F8-3 Torque Converter Stall Tests Introduction .............................................................................................. F9-1 Related Topics ......................................................................................... F9-2 Transmission Technical Data Check List ................................................. F9-3 Procedure ................................................................................................ F9-5 PS750 Mk IV Gearbox - Hydraulic Testing Introduction ............................................................................................ F10-1 Related Topics ....................................................................................... F10-2 Transmission Technical Data Check List ............................................... F10-3 Pressure and Flow Tests ....................................................................... F10-5 Torque Converter Introduction ............................................................................................ F11-1 Related Topics ....................................................................................... F11-2 Removal and Replacement ................................................................... F11-3 PS750 Mk IV Gearbox Introduction ............................................................................................ F12-1 Related Topics ....................................................................................... F12-2 Specifications ........................................................................................ F12-3 Oil Pressure Switch - Removal and Replacement ................................. F12-4 Solenoid Control Valves - Removal and Replacement .......................... F12-5 4 Wheel Drive Yoke and Oil Seal - Removal and Replacement ............ F12-7 Gearbox Removal and Replacement .................................................... F12-8 Gearbox Dismantle, Inspection and Assembly .................................... F12-10 Bevel Gearbox Introduction ............................................................................................ F13-1 Related Topics ....................................................................................... F13-2 Removal and Replacement ................................................................... F13-3 Dismantle, Inspection and Assembly ..................................................... F13-5 Transmission Oil Cooler - Liquid to Liquid Introduction ............................................................................................ F14-1 Related Topics ....................................................................................... F14-2 Removal, Testing and Replacement ...................................................... F14-3 Propshafts Introduction ............................................................................................ F15-1 Related Topics ....................................................................................... F15-2 Removal and Replacement ................................................................... F15-3

F-ii

Section F0 - Transmission Applications Table

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref Title

Configuration

Wheels and Tyres

Front Axles

VARIANT

z z

Rear Axles

z z z

z z z z z z

z z

SD80 3 Piece Steer Drive Axle SD55 1 Piece Steer Drive Axle

PS750 Mk 4 Gearbox SYSTEM

Torque Converter Operation

Gearbox Systems Fault Finding

Flushing The Transmission Oil

Torque Converter Stall Tests

F10

PS750 Mk4 Gearbox - Hydraulic Testing

F11

Torque Converter

F12

PS750 Mk 4 Gearbox

F13

Bevel Gearbox

F14

Transmission Oil Cooler - Liquid to PS750 Liquid

F15

Propshafts

F0-1

z z z

SD80 3 Piece Steer Drive Axle SD70 3 Piece Steer Drive Axle

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

AF-00-08 Issue 01

F0-1

Section F0 - Transmission Applications Table

Page left intentionally blank

F0-2

AF-00-08 Issue 01

F0-2

Section F1 - Transmission

CONFIGURATION Introduction This topic contains information about all of the transmission. For detailed information about each system and device refer to the applicable TOPIC in this section. K Operation Overview ( T F1-2)

F1-1

F-01-01 Issue 01

F1-1

Section F1 - Transmission CONFIGURATION Operation Overview

Operation Overview

Fig 1.

C024920-C1

The transversely mounted engine A drives a permanently engaged 90Â° bevel gearbox B. A torque converter is mounted on the output end of the bevel gearbox at C. The output from the torque converter drives an electro hydraulically controlled gearbox D (526-56 machines have the option of a Manually Controlled gearbox). Drive from the gearbox is transmitted to the steer drive front axle E, and to the steer drive rear axle F, via propshafts G. The bevel gearbox B and gearbox D share the same lubricating oil. The transmission features dedicated oil filtering and cooling systems. Drive is taken from the bevel gearbox to the main hydraulic pump J via a short splined tube. The engine incorporates a vibration damper bolted to the flywheel at K.

F1-2

F-01-01 Issue 01

F1-2

Section F2 - Transmission

Wheels and Tyres Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F2-2) K Specifications ( T F2-3) K Tyres and Tyre Pressures ( T F2-3) K Removal and Replacement ( T F2-4) K Front Wheels ( T F2-4) K Rear Wheels ( T F2-5) K Wheel Studs ( T F2-6)

F2-1

F-02-03 Issue 01

F2-1

Section F2 - Transmission Wheels and Tyres Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

F2-2

F-02-03 Issue 01

F2-2

Section F2 - Transmission Wheels and Tyres Specifications

Specifications Table 2. Tyres and Tyre Pressures Refer to the relevant Operator Handbook for tyre and pressure details.

F2-3

F-02-03 Issue 01

F2-3

Section F2 - Transmission Wheels and Tyres Removal and Replacement

Removal and Replacement Front Wheels

When the replacement procedure is complete:

Important: The wheel and tyre assembly is heavy. Get the aid of one more person to remove and replace a wheel.

â&#x20AC;&#x201C; Check the wheel nut torques are correct after every two hours of machine operation until they stay correct.

!MWARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

Item

Table 3. Torque Settings Nm kgf m

lbf ft

(1)

650

480

(2)

680

500

(1) 550-80 machines (2) Other machines

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1

Removal (one wheel) 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. K Related Topics ( T F2-2)

Make sure that the engine cannot be started.

Put chocks A under the rear wheels.

Loosen the five wheel nuts B by half a turn.

Put a jack C under the axle arm. Use the correct jack.

Use the jack to lift the machine until the front wheel D is off the ground.

Put chocks E under the axle arm.

Hold the wheel D and remove the wheel nuts B.

Remove the wheel. Fig 1.

Replacement

C045590

Note: Make sure that the mating surfaces of the wheel and axle hub are clean.

!MWARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Torque tighten the nuts B.

F2-4

F-02-03 Issue 01

F2-4

Section F2 - Transmission Wheels and Tyres Removal and Replacement

Rear Wheels

Replacement is the opposite of the removal procedure.

Important: The wheel and tyre assembly is heavy. Get the aid of one more person to remove and replace a wheel.

During the replacement procedure do this work also:

!MWARNING

â&#x20AC;&#x201C; Torque tighten the nuts B. When the replacement procedure is complete:

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. GEN-1-1

â&#x20AC;&#x201C; Check the wheel nut torques are correct after every two hours of machine operation until they stay correct.

Item

Table 4. Torque Settings Nm kgf m

lbf ft

(1)

650

480

(2)

680

500

(1) 550-80 machines (2) Other machines

Removal (one wheel) 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. K Related Topics ( T F2-2)

Make sure that the engine cannot be started.

Put chocks A under the front wheels.

Loosen the five wheel nuts B by half of one turn.

Put a jack C under the centre of the rear axle. Use the correct jack.

Use the jack to lift the machine until both rear wheels are off the ground.

Put chocks E under each end of the rear axle.

Hold the wheel D and remove the wheel nuts.

Remove the wheel.

Replacement Note: Make sure that the mating surfaces of the wheel and axle hub are clean.

Fig 2.

C045590

!MWARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

F2-5

F-02-03 Issue 01

F2-5

Section F2 - Transmission Wheels and Tyres Removal and Replacement

Wheel Studs

Put the stud 4-A into the hub carrier hole.

Removal and Replacement

Use a nut and washer to pull in the stud 4-A into the hub carrier 4-C.

The procedures that follow are for one wheel stud. The procedures are the same for all the wheel studs.

Examine the stud and make sure it is correctly installed. If the stud is loose replace the hub carrier 4C. Refer to Applications for related axle topics. K Related Topics ( T F2-2)

!MWARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

Removal 1

Remove the wheel from the hub. K Front Wheels ( T F2-4) K Rear Wheels ( T F2-5)

Push out the wheel stud 3-A.

Important: Remove all the wheel studs 3-A and discard them.

Fig 4.

Fig 3.

C045650-C1

C045650

Replacement Important: Examine the wheel stud holes 4-B in the hub carrier 4-C. If the holes are defective do not use the hub carrier. Replace the hub carrier with a new one. Refer to Applications for related axle topics. K Related Topics ( T F2-2)

F2-6

F-02-03 Issue 01

F2-6

Section F3 - Transmission

Front Axles Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F3-2) K Specifications ( T F3-3) K VAR = SD80 3 Piece Steer Drive Axle ( T F3-3) K VAR = SD70 3 Piece Steer Drive Axle ( T F3-3) K Component Identification ( T F3-4) K Removal and Replacement ( T F3-6) K Dismantle, Inspection and Assembly ( T F3-8)

F3-1

F-03-11 Issue 01

F3-1

Section F3 - Transmission Front Axles Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Maintenance

ALL

Stabiliser Frame

Removal and Replacement

Wheels and Tyres

ALL

Propshafts

ALL

Service Brakes SYSTEM

Bleeding

Steering SYSTEM

Bleeding

Steering SYSTEM

Re-Phasing

(1) You must obey all of the relevant care and safety procedures. Table 2. Related Topics in Publication 9803/8610, Transmissions The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics, refer to Designations. K Specifications ( T F3-3) Sections

Section Titles

Topic Titles

Axle Hubs

55 and 70 Series Hubs

Axle Hubs

80 Series Hub

Axle Hub Swivels and Driveshafts

55 Series Hub Swivel and Driveshaft

Axle Integral Brakes

70 Series Integral Brakes (3 Piece Axles)

Axle Drive Heads

80 Series Drive Heads (3 Piece Axles)

F3-2

F-03-11 Issue 01

F3-2

Section F3 - Transmission Front Axles Specifications

Specifications Table 3. VAR = SD80 3 Piece Steer Drive Axle Designations Hubs

80 Series

Hub swivels and drive shafts

55 Series

Drive head

80 Series 3 piece

Brakes

70 Series Integral Brakes (3 Piece Axles)

Type

JCB spiral bevel input with epicyclic hub reduction

Brakes

Oil immersed multi-plate discs, located in centre section

Steering

Steer rams

Weight (dry, with no steer rams and without wheels)

TBA

Overall Gear Ratio

18.16 : 1

Crownwheel and Pinion Ratio

3.364 : 1 (Colour code: Blue)

Hub Reduction

5.4 : 1 Table 4. VAR = SD70 3 Piece Steer Drive Axle

Designations Hubs

55 Series

Hub swivels and drive shafts

55 Series

Drive head

80 Series 3 piece

Brakes

70 Series Integral Brakes (3 Piece Axles)

Type

JCB spiral bevel input with epicyclic hub reduction

Brakes

Oil immersed multi-plate discs, located in centre section

Steering

Steer rams

Weight (dry, with no steer rams and without wheels)

TBA

Overall Gear Ratio

18.16 : 1

Crownwheel and Pinion Ratio

3.364 : 1 (Colour code: Blue)

Hub Reduction

5.4 : 1

F3-3

F-03-11 Issue 01

F3-3

F3-4

F-03-11 Issue 01

Pinion

Crownwheel

Differential unit

Drive shaft

Universal coupling

Reduction gear hub

Steer swivel trunnion bearings

Inboard oil-immersed multi-plate disc brakes

Brake actuating piston

Hydraulic brake lines

Note: Items A, B, C and D form the `drive head' part of the axle.

Yoke connection to propshaft

The axle is pin mounted to the chassis (sway axle).

The wheel hubs are connected to the halfshafts through universal joints which drive sun-and-planet gears inside the hubs.

The axle arms house the driveshafts. Specially shaped spider gears in the differential provide `torque proportioning'. This means that drive power will be kept on one wheel if the other is slipping.

VAR = SD70 Axle: No oil immersed disc brake units.

The drivehead houses the differential gearing and two oil-immersed disc brake units.

The front axle consists of a centre casing (drivehead) and two axle arms and swivel wheel hubs.

The illustration shows a typical steer drive front axle. K Fig 1. ( T F3-5).

Component Identification

Section F3 - Transmission Front Axles

Component Identification

F3-4

Section F3 - Transmission Front Axles

Fig 1. Typical Steer Drive Front Axle

C021690

Component Identification

F3-5

F-03-11 Issue 01

F3-5

Section F3 - Transmission Front Axles Removal and Replacement

Removal and Replacement

chassis. Remove the front roadwheels. Refer to the Wheels and Tyres topic. K Related Topics ( T F3-2) 5

Remove the front mud guards (if fitted).

Disconnect the brake hose C. Blank off the open connections.

Undo bolt D and remove pivot pin E.

GEN-1-1

Support the axle on a trolley jack.

Removal

Undo bolt F and remove pivot pin G.

Park the machine and make it safe. Fit the boom maintenance strut. Obey the care and safety procedures. K Related Topics ( T F3-2)

Remove the axle from the machine.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

Replacement

Note: Some machines may have shims installed on the axle mounts. Make sure to note the position and quantity of these shims before removal. Make sure to retain the shims and replace them in the correct position when replacing the axle. There may be an uneven number of shims between each side of the axle as the shims are used to adjust the machine height and make it level.

Replacement is the opposite of the removal procedure.

K Fig 2. ( T F3-7).

Before driving the machine:

Remove the front stabilisers (if fitted). K Related Topics ( T F3-2) Disconnect the propshaft coupling from the axle by unscrewing bolts A. Refer to the Propshafts topic. K Related Topics ( T F3-2)

!MWARNING When the driveshaft is disconnected the park brake will no longer function. The machine must be securely blocked to prevent any machine movement before disconnecting the driveshaft.

During the replacement procedure do this work also: – Refit the road wheels and carry out the tightness checks. Refer to the Wheels and Tyres topic. K Related Topics ( T F3-2)

– Bleed the brake system. K Related Topics ( T F3-2) – Bleed the steering Topics ( T F3-2) – Re-phase the Topics ( T F3-2)

system.

steering

system.

K Related K Related

– Grease the axle pivot. Refer to Section 3 Maintenance. K Related Topics ( T F3-2)

Item

Table 5. Torque Settings Nm kgf m

118

lbf ft 87

TRANS-1-3

Disconnect and cap the hydraulic feed hoses B to the steer rams (one hose on each ram).

Slacken off the front roadwheel retaining nuts then raise and support the front end of the machine on support stands or blocks positioned under the

F3-6

F-03-11 Issue 01

F3-6

Section F3 - Transmission Front Axles Removal and Replacement

Fig 2. SD80 Pivot Sway Axle

F3-7

F-03-11 Issue 01

C069100-C1

F3-7

Section F3 - Transmission Front Axles Dismantle, Inspection and Assembly

Dismantle, Inspection and Assembly Make sure that you identify the axle sub-assemblies designations correctly. K Specifications ( T F3-3) The procedures for dismantling, inspection and assembly are described in the Transmissions Service Manual. K Related Topics ( T F3-2)

F3-8

F-03-11 Issue 01

F3-8

Section F4 - Transmission

Rear Axles Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F4-2) K Specifications ( T F4-3) K SD80 3 Piece Steer Drive Axle - Integral Brakes ( T F4-3) K SD55 1 Piece Steer Drive Axle ( T F4-3) K Component Identification ( T F4-4) K SD80 3 Piece Steer Drive Axle - Integral Brakes ( T F4-7) K SD55 1 Piece Steer Drive Axle ( T F4-6) K Removal and Replacement ( T F4-7) K SD80 3 Piece Steer Drive Axle - Integral Brakes ( T F4-7) K SD55 1 Piece Steer Drive Axle ( T F4-9) K Dismantle, Inspection and Assembly ( T F4-11)

F4-1

F-04-11 Issue 01

F4-1

Section F4 - Transmission Rear Axles Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Maintenance

ALL

Wheels and Tyres

ALL

Propshafts

ALL

Service Brakes SYSTEM

Bleeding

Steering SYSTEM

Bleeding

Steering SYSTEM

Re-Phasing

Section Titles

Topic Titles

Axle Hubs

55 and 70 Series Hubs

Axle Hub Swivels and Driveshafts

55 Series Hub Swivel and Driveshaft

Axle Integral Brakes

70 Series Integral Brakes (3 Piece Axles)(1)

Axle Drive Heads

80 Series Drive Heads (3 Piece Axles)(1)

Axle Drive Heads

55 and 80 Series Drive Heads (1 Piece Axles)(2)

(1) VAR = SD80 3 Piece Steer Drive Axle - Integral Brakes (2) VAR = SD55 1 Piece Steer Drive Axle

F4-2

F-04-11 Issue 01

F4-2

Section F4 - Transmission Rear Axles Specifications

Specifications Table 3. SD80 3 Piece Steer Drive Axle - Integral Brakes Designations Hubs

55 Series

Hub swivels and drive shafts

55 Series

Drive head

80 Series 3 piece

Brakes

70 Series Integral Brakes (3 Piece Axles)

Type

JCB spiral bevel input with epicyclic hub reduction

Brakes

Oil immersed multi-plate discs, located in centre section

Steering

Steer rams

Weight (dry, with no steer rams and without wheels)

TBA

Overall Gear Ratio

24.975 : 1

Crownwheel and Pinion Ratio

4.625 : 1

Hub Reduction

TBA Table 4. SD55 1 Piece Steer Drive Axle

Designations Hubs

55 Series

Hub swivels and drive shafts

55 Series

Drive head

55 Series 1 piece

Type

JCB spiral bevel input with epicyclic hub reduction

Steering

Steer rams

Weight (dry, with no steer rams and without wheels)

TBA

Overall Gear Ratio

23.625 : 1

Crownwheel and Pinion Ratio

TBA

Hub Reduction

TBA

F4-3

F-04-11 Issue 01

F4-3

F4-4

F-04-11 Issue 01

Pinion

Crownwheel

Differential unit

Drive shaft

Universal coupling

Reduction gear hub

Steer swivel trunnion bearings

Inboard oil-immersed multi-plate disc brakes

Note: Items A, B, C and D form the `drive head' part of the axle.

Yoke connection to propshaft

The axle is pivot mounted to the chassis.

The wheel hubs are connected to the halfshafts through universal joints which drive sun-and-planet gears inside the hubs.

The axle arms house the driveshafts. Specially shaped spider gears in the differential provide `torque proportioning'. This means that drive power will be kept on one wheel if the other is slipping.

The axle consists of a centre casing (drivehead) and two bolt on axle arms. The drivehead houses the differential gearing. The drivehead also houses two oil-immersed disc brake units.

The illustration shows a typical steer drive rear axle. K Fig 1. ( T F4-5).

Component Identification

SD80 3 Piece Steer Drive Axle Integral Brakes Brake actuating piston Hydraulic brake lines

M N

Component Identification

Section F4 - Transmission Rear Axles

Component Identification

F4-4

Section F4 - Transmission Rear Axles

Fig 1. SD80 3 Piece Steer Drive Axle - Integral Brakes

C021690

Component Identification

F4-5

F-04-11 Issue 01

F4-5

F4-6 Pinion Crownwheel Differential unit Drive shaft

B C D E

The axle has a single-piece casing which houses the differential and halfshafts.

Fig 2. SD55 1 Piece Steer Drive Axle

Yoke connection to propshaft

Component Identification

The illustration, shows a typical steer drive rear axle. K Fig 2. ( T F4-6).

The rear axle is pivot mounted to the chassis.

SD55 1 Piece Steer Drive Axle

Oil fill and level plug

Steer swivel trunnion bearings

H Axle pivot

Reduction gear hub

G J

Universal coupling

355950-C1

Section F4 - Transmission Rear Axles

Component Identification

F-04-11 Issue 01

F4-6

Section F4 - Transmission Rear Axles Removal and Replacement

Removal and Replacement SD80 3 Piece Steer Drive Axle - Integral Brakes

Park the machine and make it safe. Fit the boom maintenance strut. Obey the care and safety procedures. K Related Topics ( T F4-2)

Remove the bolt F securing the axle pivot pin G and drive out the pivot pin towards the front of the machine.

Lower the axle clear of the mounting yoke and withdraw from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Refit the road wheels and carry out the tightness checks. Refer to the Wheels and Tyres topic. K Related Topics ( T F4-2) Before driving the machine: – Bleed the brake system. K Related Topics ( T F4-2)

Removal

– Bleed the steering Topics ( T F4-2).

K Fig 3. ( T F4-8)

– Re-phase the Topics ( T F4-2)

Disconnect the propshaft coupling from the axle by unscrewing bolts A. Refer to the Propshafts topic. K Related Topics ( T F4-2)

– Grease the axle pivot. Refer to Section 3 Maintenance. K Related Topics ( T F4-2)

Disconnect and cap the hydraulic feed hoses B to the steer rams (one hose on each ram).

Slacken off the rear roadwheel retaining nuts then raise and support the rear end of the machine on axle stands or blocks positioned under the chassis. Remove the rear roadwheels. Refer to the Wheels and Tyres topic. K Related Topics ( T F4-2)

Remove the rear mud guards (if fitted).

Disconnect the brake hose C. Cap the open connections.

Support the axle on a trolley jack.

Undo the bolt D and remove the right side RAS ram pivot pin E. Repeat the procedure for the left side RAS ram pivot.

F4-7

system.

steering

system.

Item

Table 5. Torque Settings Nm kgf m

118

F-04-11 Issue 01

K Related K Related

lbf ft 87

F4-7

Section F4 - Transmission Rear Axles Removal and Replacement

C069110-C2

Fig 3. SD80 3 Piece Steer Drive Axle - Integral Brakes

F4-8

F-04-11 Issue 01

F4-8

Section F4 - Transmission Rear Axles Removal and Replacement

SD55 1 Piece Steer Drive Axle

– Refit the road wheels and carry out the tightness checks. Refer to the Wheels and Tyres topic. K Related Topics ( T F4-2)

Before driving the machine: – Bleed the steering Topics ( T F4-2). – Re-phase the Topics ( T F4-2)

steering

system.

K Related K Related

– Grease the axle pivot. Refer to Section 3 Maintenance. K Related Topics ( T F4-2)

Item

Table 6. Torque Settings Nm kgf m

118

GEN-1-1

Park the machine and make it safe. Fit the boom maintenance strut. Obey the care and safety procedures. K Related Topics ( T F4-2)

system.

lbf ft 87

Removal K Fig 4. ( T F4-10) 1

Disconnect the propshaft coupling from the axle by unscrewing bolts A. Refer to the Propshafts topic. K Related Topics ( T F4-2)

Disconnect and cap the hydraulic feed hoses B to the steer rams (one hose on each ram).

Remove the rear mud guards (if fitted).

Support the axle on a trolley jack.

Remove the bolt C securing the axle pivot pin D and drive out the pivot pin towards the front of the machine.

Lower the axle clear of the mounting yoke and withdraw from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

F4-9

F-04-11 Issue 01

F4-9

Section F4 - Transmission Rear Axles Removal and Replacement

C069110-C3

Fig 4. SD55 1 Piece Steer Drive Axle

F4-10

F-04-11 Issue 01

F4-10

Section F4 - Transmission Rear Axles Dismantle, Inspection and Assembly

Dismantle, Inspection and Assembly Make sure that you identify the axle sub-assemblies designations correctly. K Specifications ( T F4-3) The procedures for dismantling, inspection and assembly are described in the Transmissions Service Manual. K Related Topics ( T F4-2)

F4-11

F-04-11 Issue 01

F4-11

Section F4 - Transmission Rear Axles Dismantle, Inspection and Assembly

Page left intentionally blank

F4-12

F-04-11 Issue 01

F4-12

Section F5 - Transmission

PS750 Mk IV Gearbox SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes fault finding, test and service procedures. K Related Topics ( T F5-2) K Specifications ( T F5-3) K Gearbox ( T F5-3) K Hydraulic Pressure Test Points ( T F5-3) K Component Identification ( T F5-4) K Operation Overview ( T F5-5) K Start Up ( T F5-5) K Drive Select ( T F5-5) K â&#x20AC;&#x2DC;Manualâ&#x20AC;&#x2122; Gear Select ( T F5-5) K Park Brake ON ( T F5-5) K Transmission Dump ( T F5-5) K Drive Paths ( T F5-6) K Hydraulic Operation and Schematics ( T F5-8) K Electrical Operation and Schematics ( T F5-10) K Electrical Connectors ( T F5-20) K Fault Finding ( T F5-21) K Electronic Fault Codes ( T F5-21)

F5-1

F-05-25 issue 01

F5-1

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL

Stall Speed Combinations

ALL

ALL (Care and Safety)

ALL

Fluids Lubricants and Capacities

ALL

Transmission

Changing the Transmission Oil and Filter

(1)

Checking the Oil Level C

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Configuration

ALL

PS750 Mk 4 Gearbox

ALL

PS750 Mk 4 Pressure and Flow Tests

ALL

Flushing The Transmission Oil

ALL

Torque Converter Stall Tests

ALL

Powershift and SyncroShuttle Fault Finding

ALL

Engine

Removal and Replacement

(1) You must obey all of the relevant care and safety procedures.

F5-2

F-05-25 issue 01

F5-2

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Specifications

Specifications Gearbox Table 2. Oil Pressures bar

Converter Pressures (in neutral)

lbf/in2

1.53 - 4.1

22 - 58

Converter In at 50 0C

1000 rev/min 2000 rev/min

5.0 - 7.0

5.1 - 7.14

72 - 101

Converter Out at 50 0C

1000 rev/min

TBA

2000 rev/min

TBA

6.5

6.6

1000 rev/min

0.14 - 0.28

2.0 - 4.0

2000 rev/min

0.28 - 0.55

0.28 - 0.56

4.0 - 8.0

1000 rev/min

11 - 13

11.2 - 13.25

159 - 188

2000 rev/min

12 - 14.5

12.24 - 14.78

174 - 210

Converter Inlet Relief Pressure (max.)

1.5 - 4.0

kgf/cm2

Lubrication Pressure (in neutral) Oil at 50 0C Main Line Pressure (in neutral) Oil at 50 0C Clutch Pressure

All clutch pressures should be the same as mainline pressure to within 0.7 bar (10 lbf/in2) Table 3. Oil Flow Rates L/min

Flow Rates (in neutral) Cooler oil flow at 50 0C Pump oil flow at 50 C 0

US gal/min

UK gal/min

1000 rev/min

8 - 13

2.1 - 3.4

1.8 - 2.8

2000 rev/min

19 - 25

5.0 - 6.6

4.2 - 5.5

1000 rev/min

11 - 15

2.9 - 4.0

2.4 - 3.3

2000 rev/min

22.5 - 29.5

5.9 - 7.8

4.9 - 6.5

Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2).

Hydraulic Pressure Test Points For hydraulic pressure test point locations refer to PS750 Mk4 Gearbox - Hydraulic Testing. K Related Topics ( T F5-2)

F5-3

F-05-25 issue 01

F5-3

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Component Identification

Component Identification

C089330-C3

Fig 1. PS750 Mk4 Key

Key Bevel gearbox

Breather

Torque converter housing

Dipstick and oil filler tube

PS750 gearbox

Transmission oil cooler hoses

Gearbox solenoid control valves

Vibration damper

Oil filter

Park brake switch

Transmission oil pressure switch

Transmission oil cooler - liquid to liquid type

Drive to front axle

Transmission oil cooler - air blast type

Drive to rear axle

Dual Output Speed sensor (1)

Park brake disc

Park brake calliper bracket

Transmission mounting

F5-4

(1) Machines built before April 2010 have 2 single output speed sensors.

F-05-25 issue 01

F5-4

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Operation Overview

Operation Overview General For details of Hydraulic Operation, Fault Finding, Testing and other system components refer to the applicable topics in this section. K Related Topics ( T F5-2)

Start Up Electrical interlocks prevent the engine being started unless the transmission is set to neutral (N).

Drive Select Column switch controls the drive selection, forward, neutral or reverse (FNR). The switch energises the applicable relays which in turn energise the applicable gearbox control solenoids.

â&#x20AC;&#x2DC;Manualâ&#x20AC;&#x2122; Gear Select A rotating barrel switch controls selection of the gear ratios, 1,2,3 or 4. The switch energises the applicable relays which in turn energise the applicable gearbox control solenoids.

Park Brake ON When the park brake is on electrical switch sets the transmission to neutral even if F or R is selected. An audible warning sounds.

Transmission Dump A transmission `dump' switch on the hydraulic control lever de-selects the transmission drive when the switch is operated.

F5-5

F-05-25 issue 01

F5-5

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Operation Overview

Drive Paths

3rd GEAR FORWARD

Forward 1st GEAR FORWARD Clutches Engaged

Solenoids Energised

Forward Low Ratio

3022 (G2)

Layshaft

3029 (M2)

Clutches Engaged

Solenoids Energised

Forward Low Ratio

3022 (G2)

Mainshaft

3033 (M1)

A255490-C2

Fig 4. 4th GEAR FORWARD A255470-C2

Fig 2. 2nd GEAR FORWARD Clutches Engaged

Solenoids Energised

Forward High Ratio

3021 (G1)

Layshaft

3029 (M2)

Clutches Engaged

Solenoids Energised

Forward High Ratio

3021 (G1)

Mainshaft

3033 (M1)

Fig 5.

Fig 3.

F5-6

A265622-C2

A255480-C2

F-05-25 issue 01

F5-6

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Operation Overview Reverse

3rd GEAR REVERSE

1st GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse Low Ratio

3041 (L1)

Layshaft

3029 (M2)

Clutches Engaged

Solenoids Energised

Reverse Low Ratio

3041 (L1)

Mainshaft

3033 (M1)

A265650-C2

Fig 8. A255520-C2

Fig 6.

4th GEAR REVERSE

2nd GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse High Ratio

3040 (L2)

Layshaft

3029 (M2)

Clutches Engaged

Solenoids Energised

Reverse High Ratio

3040 (L2)

Mainshaft

3033 (M1)

Fig 9. Fig 7.

F5-7

A265661-C2

A265640-C2

F-05-25 issue 01

F5-7

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Oil pump J is directly driven by the engine via the torque converter. Oil from the pump J is fed through an internal passage via the filter Q to the pressure maintenance valve H, which maintains pressure to the solenoid valves T for clutch selection. Excess oil from the maintenance valve flows back through the casing to the torque converter A. Pressure in the converter is controlled by a relief valve G which dumps oil from the converter line back to the sump. Oil from the torque converter A flows out of the gearbox at position M to the external oil cooler R, returning at position K. The oil then flows through internal oilways providing lubrication for clutches and bearings before returning to the gearbox sump.

When a gear is selected via the control switch in the cab, 2 clutches are always engaged. By selecting different pairs of clutches different gear ratios are engaged. Note: All the clutches work on the same principle. For a full description of operation refer to the applicable gearbox topic in this section. K Related Topics ( T F5-2) When a gear is selected via the control switch in the cab, 2 clutches are always engaged. By selecting different pairs of clutches different gear ratios are engaged. The solenoids are electrically controlled using relays.

The torque converter A is a fluid coupling bolted to a drive plate which in turn is bolted to the engine driven bevel gearbox. As the engine starts to rotate, the converter gives smooth power take off gradually increasing the torque transmitted. This torque is transferred from the converter assembly to the clutch/gear assemblies via input shaft on the forward clutch assembly B. Forward clutch assembly B contains two hydraulically operated clutches; one clutch (B1) provides a forward low ratio drive and the other (B2) a forward high ratio drive. The clutches are controlled by a 3-position solenoid valve. When the applicable solenoid is energised, pressurised oil is directed to either the forward low (solenoid 3022) or forward high (solenoid 3021) clutch. The reverse clutch assembly C is similar to the forward clutch assembly. It contains two hydraulically operated clutches; one clutch (C1) provides a reverse low ratio drive and the other (C2) a reverse high ratio drive. Clutches are controlled by a 3 position solenoid valve. When the applicable solenoid is energised, pressurised oil is directed to either the reverse low (solenoid 3041) or reverse high (solenoid 3040) clutch. Both the mainshaft and the layshaft assemblies have a single clutch each. Both clutches are controlled by a 3 position solenoid valve. When energised solenoid 3029 directs pressurised oil to the layshaft clutch E1 and solenoid 3033 directs pressurised oil the mainshaft clutch D1.

F5-8

F-05-25 issue 01

F5-8

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM

4 3 2

Fig 10. Hydraulic Schematic

C089680

Hydraulic Operation and Schematics

F5-9

F-05-25 issue 01

F5-9

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics Introduction The 4-speed PS750 powershift gearbox is controlled using conventional relays. This section explains how the electrical system works when the following gearbox functions are operated: K Forward Gears ( T F5-11) K Reverse Gears ( T F5-14) K Neutral ( T F5-17) K Transmission Dump ( T F5-18) K Park Brake ON ( T F5-19)

F5-10

F-05-25 issue 01

F5-10

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Forward Gears

The table shows the electrical device status for all forward gears. K Table 4. ( T F5-13)

Key -006

Rear cab harness ground

-003

Panel harness ground A

-001

Chassis harness ground

1013

Column switch L/H

1068

Dump switch

1057

Park brake switch

2008

Drive relay

2009

Driveshaft relay

2017

Forward Hi/Lo relay

2018

Forward relay

2028

Park brake relay

2031

Reverse Hi/Lo relay

2032

Reverse relay

2048

Transmission dump relay

3021

Forward high solenoid

3022

Forward low solenoid

3029

Layshaft solenoid

3033

Mainshaft solenoid

3040

Reverse high solenoid

3041

Reverse low solenoid

7014

Diode gate - gearbox

8004

Panel harness to chassis harness connector A

8010

Panel harness to rear cab harness connector

8016

Transmission harness to chassis harness connector

9003

Fuse box C

The circuit is shown with 3rd gear forward selected. K Fig 11. ( T F5-12) The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page. K Electrical Connectors ( T F5-20) Note: The immobiliser connection is not shown for security reasons.

F5-11

F-05-25 issue 01

F5-11

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Fig 11. Electrical Schematic - 3rd Gear Forward Selected

F5-12

F-05-25 issue 01

C066560-C6

F5-12

F5-13

F-05-25 issue 01

7-4

FORWARD

14-13

4th GEAR

FORWARD

3rd GEAR

7-4

14-9

2nd GEAR

FORWARD

1-4

7-4

FORWARD

14-12

1st GEAR

1-4

Column Switch L/ Relay 2048 H 1013 Dump

Gearbox Function

6-9

8 7 9

Relay 2028 Park brake

3-5, 1-2

3 2

1-4

4-1

Table 4. Forward Gears Relay 2018 Relay 2032 Relay 2008 Forward Reverse Drive

3-7, 6

2-6, 1-5

Diode Gate - Gearbox 7014

8-10, 6-7

6-9

8-10, 6-7

6-9

8 7

8 7 9

8 7

8 7 9

6-9

8-10, 6-7

8 7 9

8 7

Relay 2017 Relay 2009 Forward Hi/ Driveshaft Lo

3021, 3033

3022, 3033

3021, 3029

3022, 3029

Gearbox Solenoids

Section F5 - Transmission

PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

F5-13

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Reverse Gears Key -006

Rear cab harness ground

-003

Panel harness ground A

-001

Chassis harness ground

1013

Column switch L/H

1068

Dump switch

1057

Park brake switch

2008

Drive relay

2009

Driveshaft relay

2017

Forward Hi/Lo relay

2018

Forward relay

2028

Park brake relay

2031

Reverse Hi/Lo relay

2032

Reverse relay

2048

Transmission dump relay

3021

Forward high solenoid

3022

Forward low solenoid

3029

Layshaft solenoid

3033

Mainshaft solenoid

3040

Reverse high solenoid

3041

Reverse low solenoid

7014

Diode gate - gearbox

8004

Panel harness to chassis harness connector A

8010

Panel harness to rear cab harness connector

8016

Transmission harness to chassis harness connector

9003

Fuse box C

The circuit is shown with 3rd gear reverse selected. K Fig 12. ( T F5-15) The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page. K Electrical Connectors ( T F5-20) Note: The immobiliser connection is not show for security reasons. The table shows the electrical device status for all reverse gears. K Table 5. ( T F5-16)

F5-14

F-05-25 issue 01

F5-14

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Fig 12. Electrical Schematic - 3rd Gear Reverse Selected

F5-15

F-05-25 issue 01

C066560-C3

F5-15

F5-16

14-12

7-10

1st GEAR

REVERSE

F-05-25 issue 01

7-10

REVERSE

14-13

4th GEAR

REVERSE

3rd GEAR

7-10

REVERSE

14-9

2nd GEAR

Column Switch 1013

Gearbox Function

1-4

Relay 2048 Dump

6-9

8 7 9

Relay 2028 Park brake

1-4

8-10, 6-7

8 7

3-5, 2-1

3 2

Table 5. Reverse Gears Relay 2018 Relay 2032 Relay 2008 Forward Reverse Drive

3-7, 6

2-6, 1-5

Diode Gate 7014

3-5, 1-2

1-4

3-5, 1-2

1-4

3 2

6-9

8-10, 6-7

8 7 9

8 7

Relay 2031 Relay 2009 Reverse Hi/ Driveshaft Lo

3040, 3033

3041, 3033

3040, 3029

3041, 3029

Gearbox Solenoids

Section F5 - Transmission

PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

F5-16

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Neutral Power is connected to the forward and reverse relays 2018 and 2032 via dump relay 2048 and park brake relay 2028. When the column switch 1013 is set to N both the forward relay 2018 and reverse relays 2032 are de-energised. There is no power supply to the gearbox solenoid relays A and no gearbox solenoids B are energised. There is no drive from the gearbox. The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page. K Electrical Connectors ( T F5-20) Gearbox Function NEUTRAL

Column Switch L/H 1013

Relay 2018 Forward

Relay 2032 Reverse

1-4

6-9

N 10 1

8 7 9

C066750

F5-17

F-05-25 issue 01

F5-17

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Transmission Dump Operation of the transmission dump switch (1068) energises relay 2048. There is no power supply to the common switch contacts of the forward and reverse relays 2018 and 2032. With the column switch in the F or R position the forward or reverse relay is energised, since the power supply is isolated at the relay common switch contacts there is no power supply to the gearbox solenoid relays A and no gearbox solenoids B are energised. There is no drive from the gearbox. The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page. K Electrical Connectors ( T F5-20) Gearbox Function

Relay 2048 Transmission Dump

Dump Switch 1068

TRANSMISSION DUMP

5-3, 1-2

1-2

5 1

3 2 4

C066760

F5-18

F-05-25 issue 01

F5-18

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Operation and Schematics

Park Brake ON When the park brake is set to the ON position the switch 1057 closes and energises relay 2028. There is no power supply to the common switch contacts of the forward and reverse relays 2018 and 2032 if the column switch 1013 is in the F or R position. There is no power supply to the gearbox solenoid relays A and no gearbox solenoids B are energised. There is no drive from the gearbox. The harness connector pin numbers are shown on the schematic. Harness connector details are shown on a separate page. K Electrical Connectors ( T F5-20) Gearbox Function

Relay 2028 Park Brake

Park Brake Switch 1057

PARK BRAKE ON

10-8, 6-7

1-3

10 6

8 7 9

C066770-C1

F5-19

F-05-25 issue 01

F5-19

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Electrical Connectors

Location

1013

Column Switch L/H

A cable and connector connects to the panel harness at the steering column below the steering wheel. K Operation Overview ( T F5-5).

1068

Transmission Dump Switch

The switch is fitted to the hydraulic control lever. A cable and connecter connects to the chassis harness below the hydraulic control lever. K Operation Overview ( T F5-5)

1057

Park Brake Switch

The switch is fitted to the park brake lever. A cable and connector connects to the rear cab harness at the park brake lever. K Operation Overview ( T F5-5)

2000

Relays

Refer to Section C - Fuses and Relays. K Related Topics ( T F5-2)

3021

Forward high solenoid

3022

Forward low solenoid

Located on the gearbox. K Forward Gears ( T F5-11)

3029

Layshaft solenoid

3033

Mainshaft solenoid

3040

Reverse high solenoid

3041

Reverse low solenoid

7014

Diode Gate - Gearbox

Connects to the panel harness below the left side instrument console.

8000

Harness interconnections

Refer to Section C - Electrical Harness SYSTEM. K Related Topics ( T F5-2)

9000

Fuse boxes

Refer to Section C - Fuses and Relays. K Related Topics ( T F5-2)

-000

Earth Points

Refer to Section C - Electrical Harness SYSTEM. K Related Topics ( T F5-2)

F5-20

Harness Connector

Located on the gearbox. K Reverse Gears ( T F5-14)

F-05-25 issue 01

F5-20

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Fault Finding

Fault Finding For related fault finding information refer to the Generic Fault Finding topics listed. K Related Topics ( T F5-2)

F5-21

F-05-25 issue 01

F5-21

Section F5 - Transmission PS750 Mk IV Gearbox SYSTEM Fault Finding

Page left intentionally blank

F5-22

F-05-25 issue 01

F5-22

Section F6 - Transmission

Torque Converter Operation Introduction This topic is intended to help you understand what the device does and how it works. K Related Topics ( T F6-2) K Component Identification ( T F6-3) K Descriptions ( T F6-4)

F6-1

F-50-04 issue 01

F6-1

Section F6 - Transmission Torque Converter Operation Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. General

File ID

Applications

AF-00-04

F6-2

F-50-04 issue 01

F6-2

Section F6 - Transmission Torque Converter Operation Component Identification

Component Identification K Fig 1. ( T F6-3) A

Impeller

Turbine

Reaction member

Drive plate (engine driven bevel gearbox)

Drive to gearbox input shaft

Spline location for reaction member

Direct drive from the engine to the gearbox oil pump

Direction of oil flow

Fig 1.

F6-3

F-50-04 issue 01

A401340-C3

F6-3

Section F6 - Transmission Torque Converter Operation Descriptions

Descriptions K Fig 1. ( T F6-3) The torque converter is similar to a fluid coupling, which utilises the centrifugal force exerted in the transmission oil to transmit power from the engine to the gearbox. It multiplies the torque from the engine and functions as a combined clutch and infinitely variable reduction gearbox. The torque converter is enclosed in a casing and consists of three basic parts, the impeller A, reaction member C, and turbine B. Impeller A is driven by the engine. Reaction member C does not rotate. Its hub engages with a splined tube on the gearbox oil pump and is held stationary. Turbine B is engaged with the splined end of the gearbox input shaft. The impeller A, driven by the engine, forms one set of shaped blades, it can be likened to a centrifugal pump imparting energy to the transmission oil. This energy is transferred to another set of shaped blades, which form the turbine B The turbine is connected to the gearbox and converts the energy back to a mechanical torque. When the impeller A is rotating faster than the turbine B, the fixed reaction member C causes some of the energy in the oil to be transferred back to the impeller A. This has the effect of multiplying the torque available. When the impeller A (input) is running much faster than the turbine B (output) there is a substantial circulation of transmission oil around the blades. The oil circulation is maximum when the turbine (output) is stalled, and is almost zero when the impeller and turbine speeds are equal i.e. the ratio is near 1:1. If the turbine (output) is stalled whilst the impeller (input) is revolving, all the power is dissipated as heat. Because of the absence of a direct mechanical connection between the engine and the gearbox therefore, the flexibility of the torque converter drive greatly reduces wear on the transmission, absorbing shocks and torsional vibration from the engine. The engine cannot be stalled due to overload, as the fluid coupling slips.

F6-4

F-50-04 issue 01

F6-4

Section F7 - Transmission

Gearbox Systems FAULT FINDING Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T F7-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T F7-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F7-2) K Electronic Fault Codes ( T F7-3) K Gearbox `Limp Modes' (Powershift Electronic Control) ( T F7-4) K Fault Finding ( T F7-5) K Machine drives but lacks power in all gears. Gearbox oil may also be overheating ( T F7-6) K Machine does not drive in any gear ( T F7-8) K Some gears fail to engage or lack power ( T F7-9) K Gearbox oil overheating ( T F7-10) K Noisy operation ( T F7-11) K Cannot engage 4 wheel drive (Spring ON clutch) ( T F7-12) K Cannot engage 2 wheel drive (Spring ON clutch) ( T F7-13) K Gearbox oil contaminated with water ( T F7-14) K Machine does not achieve maximum speed when travelling on the highway (Lock-up torque converter variants only) ( T F7-16) K Gear shifts fail to function normally or shifts occur at incorrect road speed ( T F7-17)

F7-1

F-52-01 issue 01

F7-1

Section F7 - Transmission Gearbox Systems FAULT FINDING Related Topics

File ID

Section 2 - Care and Safety

All files

(1)

Applications

AF-00-04

Section 3 - Routine Maintenance

All

Section F - Speed Sensor

All

(2)

Section M - Fault Code System

All

Section M - Transmission Devices

All

Section M - Servicemaster Tools

All

(3)

Generic Procedures Torque Converter Stall Tests

F-51-02

PS750 Mk4 Gearbox - Hydraulic Testing

F-51-04

PS760 Gearbox - Hydraulic Testing

F-51-04

SS700 Gearbox - Hydraulic Testing

F-51-06

Devices Cable Shift(4)

F-17-02

Flushing the Transmission Oil

F-51-01

(1) (2) (3) (4)

You must obey all of the relevant care and safety procedures. Machines with SD,SE,SF Engines Machines with SH, SL, DH Engines if fitted

F7-2

F-52-01 issue 01

F7-2

Section F7 - Transmission Gearbox Systems FAULT FINDING Electronic Fault Codes

Electronic Fault Codes Machines with an electronic instruments system will log some system faults as a fault code. These fault codes can be read with the correct diagnostics software tool, using a laptop computer connected to the machine CAN system. Refer to Section M - Fault Code SYSTEM. K Related Topics ( T F7-2)

F7-3

F-52-01 issue 01

F7-3

Section F7 - Transmission Gearbox Systems FAULT FINDING Gearbox `Limp Modes' (Powershift Electronic Control)

Gearbox `Limp Modes' (Powershift Electronic Control) When applicable the gearbox ECU provides restricted or modified gearbox operation if faults are detected by the ECU. Typical `Limp Mode' forms of operation are: Mode

Possible Reason

Limp Mode 1 (2 Beeps Internal `Setup Data' ECU at power-up) fault. Machine autoshifts at different road speeds than normal.

If on power-up the ECU detects an internal fault with its `Setup Data' it will revert to use of a default set of values.

Limp Mode 2 (1 Beep at power-up)

Error with ECU `Application Software'.

Machine remains in neutral at all times.

If on power-up the ECU detects an internal fault with its `core operating software' it will prevent operation of the gearbox.

Limp Mode 3 (Machine Error reading transmission will not autoshift) speed. Only 1st, 2nd, and 3rd gears available.

If the ECU does not detect any input from the speed sensor it will prevent selection of any gear above 3rd.

Limp Mode 4 (Repeating beeps until ECU power is reset)

Error reading transmission speed.

Machine holds a gear.

If the ECU detects an error with the speed sensor while operating it prevents autoshifting.

Note: On power-up the ECU will normally sound 3 beeps. These beeps can be masked by other audible warnings on start-up.

F7-4

F-52-01 issue 01

F7-4

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding

Fault Finding For related fault finding information refer to the Generic Fault Finding topics listed. K Related Topics ( T F7-2)

Tables The fault finding procedures are given in the form of tables. The tables are designed to identify possible causes by performing checks and where applicable, specific tests on the gearbox. Having identified a cause the suggested remedy is given. The tables are designed to identify causes through a process of elimination, starting with the simplest, most easily rectified faults. Gearbox faults may be caused by faulty electrical connectors or components as indicated in the fault finding tables.

F7-5

F-52-01 issue 01

F7-5

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Table 2. Machine drives but lacks power in all gears. Gearbox oil may also be overheating Fault Possible Cause Action Machine drives but lacks power in all gears. Gearbox oil may also be overheating.

Gearbox oil level low.

Check for leaks and top up oil level as required.

Gearbox oil contaminated or wrong grade.

Investigate the reason for the contamination and rectify as required. Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2)

Suction strainer restricted or blocked.

Remove the suction strainer and clean or renew as applicable. Refer to Section 3 - Routine Maintenance.

Pressure maintenance valve defective. Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Remove the pressure maintenance valve and inspect for signs of damage or excessive wear. Clean or renew as applicable. Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Remove the torque converter relief valve and inspect for signs of damage or excessive wear. Clean or renew as applicable. Oil cooler lines restricted or blocked. Internal blockage within the oil cooler matrix due to contamination.

Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Clear the restriction. Inspect the hose routing and renew the hoses or oil cooler matrix as applicable.

Faulty torque converter.

Carry out torque converter stall tests to confirm stall speeds are within specification. Refer to Torque Converter Stall Tests. K Related Topics ( T F7-2) Remove the gearbox and renew the torque converter. Note that the torque converter assembly is a non serviceable item.

F7-6

F-52-01 issue 01

F7-6

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault

Possible Cause Failure of oil pump assembly.

Action Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Remove the gearbox and inspect the oil pump for signs of damage or excessive wear. Renew oil pump as applicable.

Gearbox internal leakage fault.

Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Remove and dismantle the gearbox. Inspect all components for signs of damage or excessive wear. In particular, check the seals and renew as applicable.

F7-7

F-52-01 issue 01

F7-7

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault

Table 3. Machine does not drive in any gear Possible Cause

Machine does not drive in any gear. Gearbox oil level low. Park brake switch or transmission dump switch defective.

Action

Check for leaks and top up oil level as required. Check the function of the park brake switch and transmission dump switch. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact.

Gear selector column switch defective. Check the function of the gear selector column switch. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. Clutch solenoid wiring defective

Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact.

Low mainline oil pressure.

Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2)

Failure of oil pump assembly.

Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Remove the gearbox and inspect oil pump for signs of damage or excessive wear. Renew oil pump as applicable.

F7-8

F-52-01 issue 01

F7-8

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault

Table 4. Some gears fail to engage or lack power Possible Cause

Some gears fail to engage or lack power.

Action

Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact.

Solenoid coil faulty.

Check the solenoid for open or short circuits. Measure the solenoid coil resistance. Renew the solenoid coil.

Clutch operating oil pressure low.

Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2)

Failure of clutch assembly.

Check for clutch internal leakage. Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Check for clutch slippage. Carry out torque converter stall tests to confirm stall speeds are within specification. Refer to Torque Converter Stall Tests. K Related Topics ( T F7-2) Remove and dismantle gearbox. Inspect relevant clutch components for signs of damage or excessive wear. Renew as applicable.

F7-9

F-52-01 issue 01

F7-9

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault Gearbox oil overheating.

Table 5. Gearbox oil overheating Possible Cause

Action

Oil cooler heat exchanger matrix(1) clogged with dirt particles or chaff.

Clean the oil cooler matrix, refer to Section 3 - Routine Maintenance.

Gearbox oil contaminated or wrong grade.

Investigate the reason for the contamination and rectify as required. Drain the oil and flush the gearbox. K Related Topics ( T F7-2)

Suction strainer restricted or blocked.

Remove the suction strainer and clean or renew as applicable, refer to Section 3 - Routine Maintenance.

Oil cooler hoses kinked or trapped.

Clear the restriction. Inspect the hose routing and reroute or renew the hoses as applicable.

Machine being operated incorrectly i.e. Educate the operator. Incorrect gear ratio. Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2) Failure of oil pump assembly.

(1) Air blast oil coolers only. Some machines have liquid to liquid type coolers.

F7-10

F-52-01 issue 01

F7-10

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault Noisy operation.

F7-11

Table 6. Noisy operation Possible Cause

Action

Gearbox oil level low.

Check for leaks and top up oil level as required.

Gearbox oil contaminated or wrong grade.

Investigate the reason for the contamination and rectify as required. Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2)

Suction strainer restricted or blocked.

Remove the suction strainer and clean or renew as applicable, refer to Section 3 - Routine Maintenance.

Low lubrication oil pressure.

Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2)

Gearbox components damaged or excessively worn.

Remove and dismantle the gearbox. Inspect all components for signs of damage or excessive wear. In particular, check shaft seals and bearings. Renew as applicable.

F-52-01 issue 01

F7-11

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault

Table 7. Cannot engage 4 wheel drive (Spring ON clutch) Possible Cause

Cannot engage 4 wheel drive (Spring ON clutch).(1)

Action

4WD solenoid valve spool is sticking in Remove and inspect the solenoid valve the 2 wheel drive position due to cartridge. Clean the valve or renew as contamination. applicable. Solenoid coil permanently energised.

Check the function of the 4WD selector switch. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact.

Failure of clutch assembly.

Remove the 4WD clutch assembly. Inspect the clutch components for signs of damage or excessive wear. Renew as applicable.

(1) This type of clutch is engaged by spring force for 4 wheel drive, and disengaged by oil pressure for 2 wheel drive.

F7-12

F-52-01 issue 01

F7-12

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault

Table 8. Cannot engage 2 wheel drive (Spring ON clutch) Possible Cause

Cannot engage 2 wheel drive (Spring ON clutch).(1)

Action

Gearbox oil level low.

Check for leaks and top up oil level as required.

4WD selector switch defective.

Check the function of the 4WD selector switch. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact.

4WD solenoid valve is not being energised.

Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact.

Solenoid coil faulty.

Check the solenoid for open or short circuits. Measure the solenoid coil resistance. Renew the solenoid coil.

4WD solenoid valve spool is sticking in Remove and inspect the solenoid valve the 4 wheel drive position due to cartridge. Clean the valve or renew as contamination. applicable. Clutch operating oil pressure low.

Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2)

Failure of clutch assembly.

Check for clutch internal leakage. Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2). Remove the 4WD clutch assembly. Inspect the clutch components for signs of damage or excessive wear. Renew as applicable.

(1) This type of clutch is engaged by spring force for 4 wheel drive, and disengaged by oil pressure for 2 wheel drive.

F7-13

F-52-01 issue 01

F7-13

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault Gearbox oil contaminated with water. (1)

Table 9. Gearbox oil contaminated with water Possible Cause

Action

Water ingress during filling or topping- Drain the oil and flush the gearbox. up. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2) Missing or incorrect dipstick. Damaged Renew missing, incorrect or damaged filler tube. parts. Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2) Machine operated in deep water.

Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2)

Gearbox oil cooler faulty, gearbox oil contaminated with engine coolant.(2)

Remove and test oil cooler. K Related Topics ( T F7-2)

Gearbox casings damaged.

Inspect the gearbox casing. Renew missing or damaged parts. Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2)

Gearbox oil circuit pipework or hoses damaged.

Inspect the pipework and hoses. Renew missing or damaged parts. Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2)

Consequential Faults. (3) a Pressurisation of gearbox casing. Water in the oil combined with heat Dipstick blows out and oil escapes from from torque converter causes steam. dipstick tube.

Replace or renew the dipstick.

Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2) b Clutch failure due to friction lining Water ingress. separation.

c Badly worn or noisy bearings.

F7-14

Remove and dismantle gearbox. Inspect relevant clutch components for signs of damage or excessive wear. Renew as applicable.

Overheating transmission oil.

Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2)

Water ingress.

Remove and dismantle the gearbox. Inspect all components for signs of damage or excessive wear. Renew components as applicable.

Insufficient lubrication.

Drain the oil and flush the gearbox. Refer to Flushing the Transmission Oil. K Related Topics ( T F7-2)

F-52-01 issue 01

F7-14

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Fault

Possible Cause

Action Carry out oil pressure and flow tests. Refer to applicable gearbox Hydraulic Testing procedures. K Related Topics ( T F7-2).

(1) Carefully inspect the gearbox oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum permissible water content of the oil is 0.10%. If the gearbox oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before remedying, thoroughly investigate and rectify the cause of the water contamination. (2) Liquid to liquid oil coolers only. (3) Gearbox faults caused typically by water contamination and other factors related to the gearbox oil.

F7-15

F-52-01 issue 01

F7-15

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Table 10. Machine does not achieve maximum speed when travelling on the highway (Lock-up torque converter variants only) Fault Possible Cause Action Machine does not achieve maximum Operator error. speed when travelling on the highway (Lock-up torque converter variants only). Lock up torque converter solenoid not being energised.

Educate the operator. Ensure operator fully understands the characteristics of the lock up function. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact.

Lock up torque converter solenoid coil Check the solenoid for open or short faulty. circuits. Measure the solenoid coil resistance. Renew the solenoid coil. Engine or transmission speed sensor faulty.

Use the applicable JCB Diagnostics software to check the ECU inputs and outputs. Refer to Section M. K Related Topics ( T F7-2) Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. Renew the speed sensor. Refer to Section M - Devices Transmission.(1) K Related Topics ( T F7-2) Renew the speed sensor. Refer to Section F - Speed Sensor.(2) K Related Topics ( T F7-2)

Faulty lock up torque converter.

Remove the gearbox and renew the lock up torque converter. Note that the torque converter assembly is a non serviceable item.

(1) Machines with SH, SL, DH Engines (2) Machines with SD,SE or SF Engines

F7-16

F-52-01 issue 01

F7-16

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding Table 11. Gear shifts fail to function normally or shifts occur at incorrect road speed Fault Possible Cause Action Gear shift fails to function normally(1)

Cable shift mechanism faulty

Adjust or replace gear shift cables as necessary. Refer to the related Cable Shift topic. K Related Topics ( T F7-2)

Gear shifts fail to function normally Gear selector column switch faulty or shifts occur at incorrect road speed. (2)

Check the function of the gear selector column switch.

Fails to autoshift (3)

Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. Transmission speed sensor faulty.

Check the function of the speed sensor. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. Renew the speed sensor. Refer to Section M - Devices Transmission.(4) K Related Topics ( T F7-2) Renew the speed sensor. Refer to Section F - Speed Sensor.(5) K Related Topics ( T F7-2)

Gearbox electronic control unit (ECU) defective. (6)

Use the ECU Diagnostics software to check the ECU inputs and outputs. Refer to Section M - Servicemaster Tools. K Related Topics ( T F7-2) Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. Renew the ECU.(7)

(1) Sychroshuttle gearboxes only. (2) The simplest and best way to fault find the ECU controlled gearbox electrical system is by using the applicable JCB Diagnostics software and a laptop PC, refer to Section M. The diagnostics system enables the engineer to quickly identify faults with specific electrical circuits or devices. (3) Note that on 6 speed gearboxes, 4th, 5th and 6th gears utilise clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th gears fail to engage, check that the lower 3 gears function correctly before investigating a possible Shiftmaster fault, refer to `Fault Table - Some gears fail to engage or lack power'. (4) Machines with SH, SL, DH Engines (5) Machines with SD,SE or SF Engines (6) In response to certain faults the ECU will enter a `Limp Mode'. For a detailed description of the Limp Modes, refer to `Service Procedures - Powershift Gearbox, Electronic Control Unit'.

F7-17

F-52-01 issue 01

F7-17

Section F7 - Transmission Gearbox Systems FAULT FINDING Fault Finding (7) The ECU is inherently reliable. It is protected internally from electrical damage. It is housed in a rugged case for protection from mechanical damage and ingress of dirt and moisture. Faults with associated systems are more likely to be caused by wiring or other input and output device failure. Before renewing the ECU make sure beyond reasonable doubt that it is faulty.

F7-18

F-52-01 issue 01

F7-18

Section F8 - Transmission

Flushing the Transmission Oil Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T F8-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T F8-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T F8-2) K Procedure ( T F8-3)

F8-1

F-51-01 issue 01

F8-1

Section F8 - Transmission Flushing the Transmission Oil Related Topics

File ID All files

(1)

Section 3 - Maintenance

All

Generic Procedures Torque Converter Stall Tests

F-51-02

(1) You must obey all of the relevant care and safety procedures.

F8-2

F-51-01 issue 01

F8-2

Section F8 - Transmission Flushing the Transmission Oil Procedure

Procedure If the transmission oil has been contaminated with water or incorrect oil types, the transmission must be flushed to effectively remove the contaminated oil.

Allow the machine to cool then drain the transmission oil through the suction strainer aperture.

Test the oil for contamination. If the oil is still contaminated, repeat the flushing procedure from step 2.

If the oil is clean, refit the suction strainer, fit a new oil filter and refill the transmission with fresh JCB Special Transmission Fluid. Check the oil level, refer to Section 3 - Routine Maintenance. K Related Topics ( T F8-2)

Flush the transmission as follows: 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T F8-2)

Drain the oil from the powershift gearbox. Remove the suction strainer. Refer to Section 3 - Routine Maintenance. K Related Topics ( T F8-2)

Clean the suction strainer with a suitable solvent. Follow the solvent manufacturer's instructions on safety.

Refit the suction strainer.

Renew the oil filter. Refer to Section 3 - Routine Maintenance. K Related Topics ( T F8-2)

Note: The filter is remotely mounted on some machines. 6

If applicable, drain the oil from the bevel gearbox, refer to routine maintenance.

Fill the transmission with the correct new oil. Check the oil level, ensure that the filling procedure is strictly adhered to. Refer to Section 3 - Fluids, Lubricants and Capacities and Routine Maintenance. K Related Topics ( T F8-2)

Start the engine and run the machine until the normal operating temperature is reached (between 50 - 100 Â°C).

Stall the torque converter for 5 seconds. Refer to Torque Converter Stall Tests. K Related Topics ( T F8-2) DO NOT stall the torque converter for longer than 10 seconds or the transmission oil will overheat.

Continue running the engine under normal conditions for 5 minutes then repeat step 8. Continue this procedure for 30 minutes, if possible during machine operation.

F8-3

F-51-01 issue 01

F8-3

Section F8 - Transmission Flushing the Transmission Oil Procedure

Page left intentionally blank

F8-4

F-51-01 issue 01

F8-4

Section F9 - Transmission

Torque Converter Stall Tests Introduction This topic contains test procedures for a transmission system. For the stall values refer to Section 1 - Stall Figures.

K Related Topics ( T F9-2) K Transmission Technical Data Check List ( T F9-3) K Procedure ( T F9-5)

F9-1

F-51-02 issue 01

F9-1

Section F9 - Transmission Torque Converter Stall Tests Related Topics

File ID

Section 1 - Stall Figures Section 2 - Care and Safety

All All files

(1)

Section E - Hydraulic System Pressure Tests

All

Section K - Engine

All

Generic Procedures PS750 Gearbox - Hydraulic Testing

F-51-03

PS760 Gearbox - Hydraulic Testing(2)

F-51-04

SS700 Gearbox - Hydraulic Testing(2)

F-51-01

(1) You must obey all of the relevant care and safety procedures. (2) If fitted

F9-2

F-51-02 issue 01

F9-2

Section F9 - Transmission Torque Converter Stall Tests Transmission Technical Data Check List

Transmission Technical Data Check List To help with fault identification, record the test results in a check list. This section includes a blank check list to copy and use as required. K Fig 1. ( T F9-4) The check list will help the engineer to identify the cause of a gearbox fault, and if required, can be sent to the JCB Technical Service Team via e-mail.

F9-3

F-51-02 issue 01

F9-3

Section F9 - Transmission Torque Converter Stall Tests Transmission Technical Data Check List

Fig 1.

F9-4

F-51-02 issue 01

F9-4

Section F9 - Transmission Torque Converter Stall Tests Procedure

Procedure The purpose of the stall test is to check the performance of the transmission by `stalling' the torque converter. This is the point at which, due to torque applied by the engine the torque converter stops transmitting drive to the gearbox. The engine speed at which `stalling' occurs is compared to speeds recorded for a machine in normal condition. Abnormal stall speed results can be used to identify a possible faults as follows: – Poor engine performance

machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational. Do not disconnect the switch at the park brake. 3

Select 1st speed forward drive and open throttle fully. Record the engine speed from the tachometer.

Repeat the test in reverse drive.

Repeat the test with the machine in each configuration as described in the stall data tables. Refer to Section 1 - Stall Figures. K Related Topics ( T F9-2)

For machines with Powershift gearboxes repeat the test in 2nd and 3rd gears in both forward and reverse drive.

All recorded readings should be as specified. Refer to Section 1 Stall Figures. K Related Topics ( T F9-2)

– Faulty torque converter – Faulty gearbox hydraulic clutches – Faulty torque converter relief valve – Transmission hydraulic leaks – Faulty hydraulic system relief valves For normal stall speed values refer to Section 1 - Stall Figures. K Related Topics ( T F9-2) Note: DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat. Make sure that the oil level is correct and at normal operating temperature. Note: On machines fitted with a Variflow hydraulic pump make sure that the hydraulic oil temperature is above 50 o C. Also make sure that the valve block LSRV pressure and variflow pump Delta P pressure are set correctly. Refer to Section E - Variflow System Pressure Tests. K Related Topics ( T F9-2) Before completing the following test, remove the transmission dipstick. If there is any sign of smoke emitting from the dipstick tube STOP THE TEST IMMEDIATELY and dismantle the transmission for servicing. 1

Ensure that the engine and transmission are at normal working temperature (the transmission oil must be above 50°C). Run engine at maximum speed and check the engine speed is correct (High Idle/ Maximum Governed Speed), refer to Section K Engine. K Related Topics ( T F9-2)

Apply parking brake and footbrake firmly. If necessary, set the machine against a fixed obstruction.

Note: When fully engaged, the parkbrake electrically disconnects the transmission drive; this prevents the

F9-5

F-51-02 issue 01

F9-5

Section F9 - Transmission Torque Converter Stall Tests Procedure

Interpreting the Test Results If all the engine speeds are below the stated figures either the engine is losing power and should be serviced/ overhauled or the torque converter reaction member clutch is slipping. To check the engine, select Neutral, open throttle fully and operate a hydraulic service to 'blow off' the main relief valve. Engine speed should fall to slightly below the Maximum Governed Speed (Refer to Section K Engine). If engine speed is correct the torque converter reaction member clutch is slipping. If all the engine speeds are higher than the stated figures in all gears the torque converter safety relief valve may be faulty. Alternatively there may be internal oil leakage. If engine speeds are higher than the stated figures in some gears, check the transmission for clutch slippage or internal leakage. Look at the example below and see how the results can be used to isolate a suspect clutch. Stall Test Results - 4 Speed Powershift Gear

Clutches engaged Forward

Rev/min

Reverse

Rev/min

1st

T, Z

1990

W, Z

1980

2nd

U, Z

2060

V, Z

1975

3rd

T, Y

1985

W, Y

1990

In the example shown, we can see that the engine speed is abnormally high when 2nd gear forward drive is selected, indicating a slipping clutch, possibly U or Z. We can now use the results to determine which clutch is at fault. From the table we can see that there is no problem with clutch Z since it is engaged in other gears, the stall speeds for those gears are normal. This indicates that clutch U is slipping. Clutches may be slip for several reasons. Hydraulic leakage is possible and this can be confirmed by carrying out a pressure test. Refer to the applicable gearbox Pressure and Flow Tests procedures. K Related Topics ( T F9-2)

F9-6

F-51-02 issue 01

F9-6

Section F10 - Transmission

PS750 Mk IV Gearbox - Hydraulic Testing Introduction This topic contains test procedures for a hydraulic system. For the correct flow and pressure values refer to Specifications in the applicable system topic. K Related Topics ( T F10-2) K Transmission Technical Data Check List ( T F10-3) K Pressure and Flow Tests ( T F10-5) K Test Points ( T F10-5) K Mainline Pressure ( T F10-7) K Pump Flow (Machines with direct mount oil filter) ( T F10-7) K Converter In Pressure ( T F10-9) K Converter Relief (Safety Valve) Pressure ( T F10-9) K Bypassing the Converter Relief Valve ( T F10-11) K Converter Out Pressure and Oil Cooler Flow Rate ( T F10-13) K Lubrication Pressure ( T F10-13) K Isolating a Suspect Clutch ( T F10-15) K Individual Clutch Leakage Test ( T F10-16)

F10-1

F-51-03 issue 01

F10-1

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Related Topics

File ID

Section 2 - Care and Safety

All files

(1)

Generic Descriptions PS750 Mk IV Gearbox System

F-05-14

Description

460/15708(1)

Flow Test Adaptor

892/00229

Flow Meter

892/00253

Hydraulic Pressure Test Kit and Relevant Adaptors

892/00270

Load Valve

(1) (1) (1)

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

F10-2

F-51-03 issue 01

F10-2

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Transmission Technical Data Check List

Transmission Technical Data Check List To help with fault identification, record the test results in a check list. This section includes a blank check list to copy and use as required. K Fig 1. ( T F10-4) The check list will help the engineer to identify the cause of a gearbox fault, and if required, can be sent to the JCB Technical Service Team via e-mail.

F10-3

F-51-03 issue 01

F10-3

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Transmission Technical Data Check List

Fig 1.

F10-4

F-51-03 issue 01

F10-4

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Pressure and Flow Tests Before completing any of the transmission pressure/flow tests, make sure that the oil level is correct and at normal operating temperature (not less than 50Â°C). Refer to the transmission system topic (PS750 Mk IV Gearbox System) for pressure specifications. K Related Topics ( T F10-2)

Test Procedures: Pump Flow Mainline Pressure Converter in Pressure Converter Relief (Safety) Valve Pressure Converter Out Pressure and Oil Cooler Flow Rate

!MWARNING

Lubrication Pressure

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately. INT-3-1-10_2

Clutches:Isolating a Suspect Clutch Individual Clutch Leakage Test

Test Points Test Points: K Fig 2. ( T F10-6)

!MWARNING

Mainline pressure

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

Mainshaft clutch pressure

Converter inlet and converter relief valve pressure

Forward high ratio clutch pressure

Forward low ratio clutch pressure

Reverse high ratio clutch pressure

Reverse low ratio clutch pressure

Layshaft clutch pressure

2/4 wheel drive clutch pressure(1)

TRANS-1-2

!MWARNING Do not go underneath the machine with the engine running. Switch off the engine, apply the park brake and block both sides of all wheels before going underneath the machine. TRANS-2-1

!MWARNING

(1) Machines with selectable 2/4 wheel drive option

If a 4 wheel drive machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only one pair of wheels is raised, the machine could still drive through the other axle. TRANS-2-2_2

F10-5

F-51-03 issue 01

F10-5

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Fig 2. Pressure Test Points

F10-6

F-51-03 issue 01

C089360

F10-6

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Mainline Pressure

Pump Flow (Machines with direct mount oil filter)

K Fig 3. ( T F10-8) 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A. Start engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show the Main Line Pressure. A low reading can be caused by either a faulty pressure maintenance valve or a worn pump. A high or low reading may indicate a faulty pressure maintenance valve.

Repeat step 2, with engine running at 2000 rev/min note the gauge readings.

Stop engine and remove test gauge.

K Fig 3. ( T F10-8) 1

Stop the engine. Clean the area around the transmission oil filter R. Remove the filter and the adaptor fitted to the gearbox.

2 a

Fit one of the three alternative pump flow test adapters in place of oil filter R. K Service Tools ( T F10-2) The choice of adapter is best determined by the ease of installation and/or accessibility. Note that adapter type Z is fitted as standard on machines with a remote oil filter. Fit the chosen type as follows: Type X: Install item 1 in the gearbox casing. Fit item 2 and secure with item 3. Type Y: With the component parts assembled, install and secure with banjo bolt 2 screwed into the gearbox and tightened to a torque of 56 Nm (41 lbf ft, 5.7 kgf m). Type Z: With the component parts assembled, install and secure with fitting adapter 2 screwed into the gearbox, and tightened to a torque of 56 Nm (41 lbf ft, 5.7 kgf m).

b Connect flow meter W (892/00229) to the flow and return adapters (shown with arrows). 3

Start engine and run at 1000 rev/min. With the transmission in neutral the flowmeter will show the Pump Flow. A low reading indicates a worn pump or blocked suction strainer.

F10-7

Repeat step 3 and note gauge readings with engine running at 2000 rev/min.

Stop engine and remove test adapters. Replace the gearbox adaptor removed at step 1 and refit filter.

F-51-03 issue 01

F10-7

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Fig 3. Pump Flow Test

F10-8

F-51-03 issue 01

C089370

F10-8

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Converter In Pressure

Converter Relief (Safety Valve) Pressure

K Fig 4. ( T F10-10)

Note that the converter in pressure is affected by the transmission oil temperature, cooler circuit back pressure and torque converter relief valve operation. Before carrying out tests check the operation of the relief valve. K Converter Relief (Safety Valve) Pressure ( T F10-9)

The purpose of the torque converter relief valve is to protect the torque converter from excessive oil pressure. Excessive oil pressure can be generated when the transmission oil temperature is below 50Â°C and/or the engine is run at over 2000 rev/min. In this event the relief valve opens and returns oil directly to the transmission sump, bypassing the torque converter, cooler and clutch lubrication circuits, protecting against damage due to excessive pressure. For this reason it is essential that the transmission oil is above 50Â°C and the engine is run between idle and 1000 rev/min when testing the relief valve.

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test point C.

Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show Converter In Pressure. A low reading could indicate a worn pump, a worn pump would also be evident during a pump flow test. A high pressure together with low flow could be caused by a blocked oil cooler. Low pressure could be caused by a faulty pump or internal leakage.Stop engine and remove pressure test gauge.

Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test point C.

Fit a load valve P into the converter out line.

!MCAUTION Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT), before starting the following pressure test. Failure to do this could damage the pump. HYD-4-4_1

DO NOT allow the pressure to exceed 8.3 bar (120 lbf/in2) or damage to the converter seals will be caused. 3

Start the engine and run at 1000 rev/min. With the transmission in neutral, slowly screw down the load valve P whilst observing the gauge reading which should rise to the Converter Relief (Safety) Valve pressure setting.

Note: The gauge pressure will fall once the valve has opened. This is normal relief valve operation and does not indicate a fault. If necessary reset the load valve P and perform the test again, watching the pressure gauge carefully.

F10-9

If the converter relief valve opens at a pressure higher than specified then the valve is faulty. A low opening pressure indicates a leaking pump to casing seal or a faulty converter relief valve.

Stop engine, remove test gauges and load valve. Refit hoses to original position.

F-51-03 issue 01

F10-9

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Fig 4. Converter In, Converter Relief Valve Pressure Tests

F10-10

F-51-03 issue 01

C089380

F10-10

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Bypassing the Converter Relief Valve K Fig 5. ( T F10-12) During some powershift pressure and oil flow tests it is advisable to temporarily bypass the converter relief valve. If the relief valve opens during the following tests it will cause false results. Converter Out Pressure/Oil Cooler Flow Rate Converter in Pressure Lubrication Pressure Torque Converter Stall Test Important: Before bypassing the torque converter relief valve make sure that the mainline pressure is correct. Refer to `Mainline Pressure'. Make sure that the transmission oil filter is fitted. To temporarily bypass the relief valve (prevent the valve from opening) proceed as follows: 1

Stop the engine and undo the relief valve (shown at Z).

Carefully remove the spring N.

Obtain a suitable plug, drill and tap the centre and fit a locking bolt R as shown at Y.

Fit the plug assembly to the relief valve housing and hold the spool S on its seat by screwing in bolt R as shown at Y. Do not damage the spool and its seat.

Important: The torque converter can be damaged when the converter relief valve is bypassed. To avoid damage proceed as follows: Before starting the engine make sure that the transmission oil temperature is above 50 Â°C. Do not run the engine at more than 2000 rev/min for more than 1 minute. When testing is complete be sure to remove the plug assembly and refit the spring and cover/plug as shown at Z.

F10-11

F-51-03 issue 01

F10-11

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Fig 5. Bypassing the Converter Relief Valve

F10-12

F-51-03 issue 01

C089390

F10-12

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Converter Out Pressure and Oil Cooler Flow Rate K Fig 6. ( T F10-14) Note that the converter out pressure and oil cooler flow rate are affected by the torque converter relief valve operation. Before carrying out tests check the operation of the relief valve. K Converter Relief (Safety Valve) Pressure ( T F10-9) 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge and flowmeter into the converter out line as shown at C and K respectively.

Lubrication Pressure K Fig 6. ( T F10-14) Note that the lubrication pressure is affected by the torque converter relief valve operation and back pressure in the oil cooler circuit. Before carrying out tests check the operation of the relief valve. K Converter Relief (Safety Valve) Pressure ( T F10-9) 1

Stop engine, connect a suitable pressure gauge into the return line from the oil cooler to the transmission as shown at J.

Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will indicate the Lubrication Pressure which should be correct.

Repeat step 2 and note gauge readings with engine running at 2000 rev/min. If the pressure is high the oil cooler may be blocked. K Converter Out Pressure and Oil Cooler Flow Rate ( T F10-13)

Stop engine and remove pressure gauge.

Note: The flow meter may cause back pressure. If the torque converter relief valve is not by-passed, it may open and cause false readings. 2

Run the engine at 1000 rev/min with transmission in neutral. The pressure gauge indicates the Converter Out Pressure and the flowmeter indicates the Oil Cooler Flow Rate. Make sure that the readings are correct. A high pressure together with low flow could be caused by a blocked oil cooler. Low pressure could be caused by a faulty pump or internal leakage.

Repeat step 2, with engine running at 2000 rev/min note gauge readings.

Stop engine, remove test gauges and refit hoses to original position. Remember to remove the torque converter relief valve by-pass assembly and refit the relief valve, (ball, spring and cover/plug).

F10-13

F-51-03 issue 01

F10-13

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Fig 6. Converter Out, Lubrication Pressure Tests

F10-14

F-51-03 issue 01

C089400

F10-14

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Isolating a Suspect Clutch

By carrying out `Individual Clutch Leakage Tests', we can confirm that the forward high clutch is leaking. K Individual Clutch Leakage Test ( T F10-16)

K Fig 2. ( T F10-6) 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A (mainline pressure test point).

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.

Note: When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational. Alternatively, disconnect the switch at the park brake. 3

Start engine and run at 1000 rev/min, engage 1st gear forward. Record the pressure reading. Repeat the test for all gears in forward drive and record the pressure readings as shown in the following example:

Gear Ratio Clutch Select

Mainshaft or bar Layshaft Clutch

1st

Forward Low

Layshaft

9.65 140

2nd

Forward High Layshaft

8.62 125

3rd

Forward Low

Mainshaft

9.65 140

4th

Forward High Mainshaft

8.62 125

lbf/in2

Readings should not vary between clutches by more than 0.7 bar (10 lbf/in2). In the example shown, we can see that pressure is low when 2nd and 4th gear forward is selected, indicating clutch leakage. From the table we can see that the forward high clutch is used for selection of both 2nd and 4th gear forward. We know from the table that the mainshaft and layshaft clutches are working normally (1st and 3rd gear selection show normal operating pressure). So we can assume that the forward high clutch is leaking. Note: If necessary, repeat above test using reverse clutch ratios.

F10-15

F-51-03 issue 01

F10-15

Section F10 - Transmission PS750 Mk IV Gearbox - Hydraulic Testing Pressure and Flow Tests

Individual Clutch Leakage Test

In the following procedures the forward high clutch is tested, therefore in step 2 a pressure gauge is connected to the forward high clutch test point.

If after interchanging the gauges, the readings are different than at step 5, have the gauges calibrated and repeat the testing procedure.

When testing other suspect clutches connect a gauge to the relevant suspect clutch test point. K Test Points ( T F10-5) Because the forward high clutch is suspect, a gear must be selected that will use the forward high clutch, in this instance 2nd gear forward. 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A, mainline pressure test point.

Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector D forward high ratio clutch test point.

Remove the electrical connector from the layshaft clutch solenoid 3029. This will ensure that only the forward high clutch is energised when 2nd gear forward is selected.

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.

Fig 7.

C089760-C1

Start engine and run at 1000 rev/min, select 2nd gear forward. Note the pressure readings on both gauges, which should not vary by more than 0.7 bar (10 lbf/in2) If the difference on the gauges is greater than 0.7 bar (10 lbf/in2) do the following: a

Stop the engine and interchange the gauges.

b Start the engine and run at 1000 rev/min, select 2nd gear forward. If the difference on the gauges is still greater than 0.7 bar (10 lbf/in2) dismantle the forward high clutch for servicing.

F10-16

F-51-03 issue 01

F10-16

Section F11 - Transmission

Torque Converter Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. This topic includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F11-2) K Removal and Replacement ( T F11-3)

F11-1

F-07-06 issue 01

F11-1

Section F11 - Transmission Torque Converter Related Topics

File ID All files

(1)

Section K - Engine - Removal and Replacement Devices Torque Convertor Operation

F-50-04

PS750 MK4 Gearbox

F-09-10

PS760 Gearbox

F-09-11

SS700 Gearbox

F-16-04

Applications

AF-00-04

(1) You must obey all of the relevant care and safety procedures.

F11-2

F-07-06 issue 01

F11-2

Section F11 - Transmission Torque Converter Removal and Replacement

Removal and Replacement K Fig 1. ( T F11-4) Removal 1

Due to the configuration of the engine and transmission mounting system, it is advisable to remove the engine and transmission as a complete assembly. K Related Topics ( T F11-2)

Remove the gearbox. K Related Topics ( T F11-2)

Prise out the access panel A from the bevel gearbox torque converter housing.

Rotate the engine so as to gain access to one of four torque converter retaining bolts B.

Support the torque converter, undo and remove the four bolts B. Withdraw the torque converter.

Replacement Replacement is the reversal of the removal procedure. 1

Make sure that the drive plate C and torque converter mating faces are perfectly clean.

Should the drive plate C have been removed make sure that the mating faces are clean and free from burrs, before locating over the spigot on the drive flange. Fit the bolts E with JCB Threadlocker And Sealer.

Make sure that there are no burrs on the torque converter spigot D or to any of the mating faces adjacent to the drive plate C.

Locate the torque converter spigot D on the recess in the bevel box output shaft.

Set up a dial test indicator (DTI) as shown. Rotate the torque converter and measure the run out of the drive shaft. The run out must not exceed 0.38 mm (0.015 in).

Item

Table 2. Torque Settings Nm Kgf m

lbf ft

4.7

2.8

F11-3

F-07-06 issue 01

F11-3

Section F11 - Transmission Torque Converter Removal and Replacement

Fig 1. Torque Converter

F11-4

F-07-06 issue 01

C025040-C1

F11-4

Section F12 - Transmission

PS750 Mk IV Gearbox Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. This topic includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F12-2) K Specifications ( T F12-3) K Oil Pressure Switch - Removal and Replacement ( T F12-4) K Solenoid Control Valves - Removal and Replacement ( T F12-5) K 4 Wheel Drive Yoke and Oil Seal - Removal and Replacement ( T F12-7) K Gearbox Removal and Replacement ( T F12-8) K Gearbox Dismantle, Inspection and Assembly ( T F12-10)

F12-1

F-09-10 issue 01

F12-1

Section F12 - Transmission PS750 Mk IV Gearbox Related Topics

File ID

Section 2 - Care and Safety

All files

(1)

Section 3 - Maintenance

All files

Applications

AF-00-04

Section K - Engine - Removal and Replacement Generic Procedures PS750 Mk IV Gearbox - Hydraulic Testing

F-51-03

Section Titles

Topic Titles

Powershift Gearboxes

PS750 Mk 4 Gearbox

F12-2

F-09-10 issue 01

F12-2

Section F12 - Transmission PS750 Mk IV Gearbox Specifications

Specifications Designation

Table 3. PS750 4-Speed 2/4 Wheel Drive PS750 MkIV Powershift

Description

Full electro-hydraulic transmission unit with input, reverse, layshaft, and mainshaft drive clutch packs giving 4 forward and 4 reverse speeds. Electrically (relay) controlled gear selection. Permanent 4 wheel drive or selectable 2/4 wheel drive variants

Weight (dry)

2/4 wheel drive

215 kg (747 lb)

Permanent 4 wheel drive

TBA

Clutch Solenoid Current Draw

1.36 Amp maximum (at 68ยบF - 20ยบC)

Unit Identification

Fig 1.

C089090

The gearbox 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 replacements, always check the part number stamped on the gear, and the number of teeth.

F12-3

F-09-10 issue 01

F12-3

Section F12 - Transmission PS750 Mk IV Gearbox Oil Pressure Switch - Removal and Replacement

Oil Pressure Switch - Removal and Replacement Removal 1

Clean off all debris, dirt and grit from around the pressure switch A. There must be no ingress of debris, dirt or grit inside the gearbox.

Unscrew the pressure switch and discard the sealing washer C.

Cap the open port on the gearbox.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – The oil pressure switch is a non serviceable component. If it is faulty or damaged, it must be renewed. – Renew the sealing washer C. – Torque tighten the pressure switch to 16 Nm (11.8 lb ft).

Fig 2.

F12-4

F-09-10 issue 01

C089460

F12-4

Section F12 - Transmission PS750 Mk IV Gearbox Solenoid Control Valves - Removal and Replacement

Solenoid Control Valves - Removal and Replacement Gearbox Clutch Control Solenoid Valves

Removal

The following procedures are for one solenoid valve A. The procedure for valves B and C are the same.

Tag and disconnect the electrical harness connectors (if fitted) at the solenoid coils D and E. Record the position of the solenoid coil electrical connectors on the valve stem A.

Clean the area around the solenoid valves. Do not allow particles of grit to fall into the gearbox.

Remove the nut F, coil E, spacer G and coil D. Record the orientation of the spacer to ensure correct replacement.

Clean the area around the valve stem J and gearbox casing to prevent contamination of the gearbox.

Unscrew the valve stem A from the gearbox casing.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Inspect the ‘O’ ring seals H. If an ‘O’ ring is damaged replace it with a new one. – Put some clean oil on the ‘O’ ring seals H. – Use and extended socket to torque tighten the valve stem J to 25- 28 Nm (18.5 - 20.5 lb ft). – Install the spacer G the correct way round. – Put the solenoid coil electrical connectors in the correct position on the valve stem. – Torque tighten nut F to 6 Nm (4.4 lb ft). – Connect the electrical harness connectors at the solenoid coils in the correct positions.

Fig 3.

F12-5

C088930-C1

F-09-10 issue 01

F12-5

Section F12 - Transmission PS750 Mk IV Gearbox Solenoid Control Valves - Removal and Replacement

2/4WD Clutch Control Solenoid Valve (if fitted)

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Inspect the ‘O’ ring seals D. If an ‘O’ ring is damaged replace it with a new one. – Put some clean oil on the ‘O’ ring seals. – Torque tighten screws B to 6 Nm (4.4 lb ft).

Fig 4.

C088940

Removal 1

Tag and disconnect the electrical harness connector (if fitted) at the solenoid coil A.

Undo screws B.

Clean the area around the valve stem and gearbox casing to prevent contamination of the gearbox.

Remove the valve C from the gearbox casing.

F12-6

F-09-10 issue 01

F12-6

Section F12 - Transmission PS750 Mk IV Gearbox 4 Wheel Drive Yoke and Oil Seal - Removal and Replacement

4 Wheel Drive Yoke and Oil Seal - Removal and Replacement Removal 1

Bend back the stake nut locking ring F.

Clean the area around the yoke A. Do not allow particles of grit to fall into the gearbox

Using service tool 892/00812 hold the yoke A and at the same time undo the nut B. The nut is very tight, the help of an assistant will be required. Discard the nut.

Remove the yoke A.

Remove washer E.

If necessary remove the oil seal C. Do not damage the seal housing.

Replacement

Fig 5.

F12-7

Make sure that the oil seal interface D on the yoke is clean and free from wear or damage.

If necessary fit a new oil seal C.

Apply JCB HP grease to the lips of oil seal C.

Fit the yoke A.

Fit washer E.

Fit a NEW stake nut B. Torque tighten to 400 Nm (296 lbf ft).

Stake the nut to the shaft using a square ended staking tool, as shown at F.

C088910

F-09-10 issue 01

F12-7

Section F12 - Transmission PS750 Mk IV Gearbox Gearbox Removal and Replacement

Gearbox Removal and Replacement Important: No bolt is installed in hole X.

Support the gearbox with suitable lifting gear and undo the gearbox to torque converter housing bolts G.

Carefully withdraw the gearbox from the torque converter, keeping the assemblies square to each other.

Replacement Replacement is the opposite of the removal procedure. Before replacing the powershift gearbox check to see if pressure test points are fitted at the clutch pressure test points. Refer to the Test Procedures topic. K Related Topics ( T F12-2) 1

When assembling offer the gearbox square to the torque converter housing. Make sure that the dogs on the converter pump drive shaft engage with the recesses in the pump, also take care not to damage the oil seal. DO NOT use housing bolts or any other device to pull the assemblies together.

Remember to refit any cable tie locaters retained by the bolts G.

X Fig 6.

C089330-C2

Removal 1

Due to the configuration of the engine and transmission mounting system the powershift gearbox should be removed from the machine, together with the engine, bevel gearbox, torque converter and hydraulic pump as a complete assembly. K Related Topics ( T F12-2)

Support the engine and transmission assembly on a suitable frame A, then remove the engine lifting beam. K Fig 7. ( T F12-9). Make sure that the engine will be safely supported when the transmission components are removed.

Label and disconnect the external oil hoses and pipes, typically as follows: â&#x20AC;&#x201C; Oil cooler hoses B and C â&#x20AC;&#x201C; Bevel gearbox drain pipe D â&#x20AC;&#x201C; Remote oil filter pipes F (if fitted)

F12-8

F-09-10 issue 01

F12-8

Section F12 - Transmission PS750 Mk IV Gearbox Gearbox Removal and Replacement

Fig 7. Engine and Transmission

F12-9

F-09-10 issue 01

C089410

F12-9

Section F12 - Transmission PS750 Mk IV Gearbox Gearbox Dismantle, Inspection and Assembly

Gearbox Dismantle, Inspection and Assembly The procedures for dismantling, inspection and assembly are described in the Transmissions Service Manual. K Related Topics ( T F12-2)

F12-10

F-09-10 issue 01

F12-10

Section F13 - Transmission

Bevel Gearbox Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F13-2) K Removal and Replacement ( T F13-3) K Dismantle, Inspection and Assembly ( T F13-5)

F13-1

F-06-01 Issue 01

F13-1

Section F13 - Transmission Bevel Gearbox Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Hydraulic Pump

Removal and Replacement

Torque Converter

Removal and Replacement

PS750 Mk4 Gearbox

Removal and Replacement

PS760 Gearbox(2)

Removal and Replacement

SS700 Gearbox(2)

Removal and Replacement

Engine

Removal and Replacement

(1) You must obey all of the relevant care and safety procedures. (2) If fitted Table 2. Related Topics in Publication 9803/8610, Transmissions The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics. Sections

Section Titles

Topic Titles

Transfer Gearboxes

Bevel Gearbox

F13-2

F-06-01 Issue 01

F13-2

Section F13 - Transmission Bevel Gearbox Removal and Replacement

Removal and Replacement Removal 1

Due to the configuration of the engine and transmission mounting system, it is advisable to remove the engine and transmission as a complete assembly. K Related Topics ( T F13-2)

Remove the gearbox. K Related Topics ( T F13-2)

Remove the torque Topics ( T F13-2)

Remove the hydraulic pump. Refer to Section E Hydraulics. K Related Topics ( T F13-2)

Support the bevel gearbox with suitable lifting equipment and undo the flywheel housing bolts A on the engine. Withdraw the gearbox from the engine.

converter.

K Related

Replacement Replacement is the reversal of the removal procedure.

Item A

F13-3

Table 3. Torque Settings Nm Kgf m 70

7.1

lbf ft 51

F-06-01 Issue 01

F13-3

Section F13 - Transmission Bevel Gearbox Removal and Replacement

Fig 1. Bevel Gearbox

F13-4

F-06-01 Issue 01

C025050-C1

F13-4

Section F13 - Transmission Bevel Gearbox Dismantle, Inspection and Assembly

Dismantle, Inspection and Assembly The procedures for dismantling, inspection and assembly are described in the Transmissions Service Manual. K Related Topics ( T F13-2)

F13-5

F-06-01 Issue 01

F13-5

Section F13 - Transmission Bevel Gearbox Dismantle, Inspection and Assembly

Page left intentionally blank

F13-6

F-06-01 Issue 01

F13-6

Section F14 - Transmission

Transmission Oil Cooler - Liquid to Liquid Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F14-2) K Removal, Testing and Replacement ( T F14-3)

F14-1

F-08-04 Issue 01

F14-1

Section F14 - Transmission Transmission Oil Cooler - Liquid to Liquid Related Topics

File ID

Section 3 - Fluids, Lubricants and Capacities Section 3 - Checking the Transmission Oil Level Section 3 - Changing the Transmission Oil and Filter Section 3 - Changing the Coolant Section B - Engine Cover Section 2 - Care and Safety (1)

All files

Applications

AF-00-04

Generic Procedures Flushing the Transmission Oil

F-51-01

(1) You must obey all of the relevant care and safety procedures.

F14-2

F-08-04 Issue 01

F14-2

Section F14 - Transmission Transmission Oil Cooler - Liquid to Liquid Removal, Testing and Replacement

Removal, Testing and Replacement Removal

– Check the transmission Topics ( T F14-2)

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T F14-2)

– Refill the engine cooling system.

Access to the transmission oil cooler is made easier if the engine cover base is removed. K Related Topics ( T F14-2)

– Check the transmission Topics ( T F14-2)

Drain the engine Topics ( T F14-2)

coolant.

K Related

Disconnect the electrical oil temperature sensor C.

Disconnect the oil feed and return hoses D. Be aware that the oil may be hot.

Undo the water hose clips and retaining clips E. Withdraw the cooler F.

oil

level.

K Related

– Operate the machine, stop the engine and check for water/oil leaks at the cooler hose connections. oil

level.

K Related

– Check the engine coolant level. Important: If a faulty oil cooler has been renewed, the transmission may be contaminated with water. Carry out the flushing procedure. K Related Topics ( T F14-2) After 50 - 100 operating hours drain the transmission oil and check for signs of water contamination. There should be no contamination. Refill the transmission with fresh oil.

Testing The liquid/liquid cooler is a possible source of water contamination and should be tested for possible failure as follows: 1

Drain any remaining oil/water from the cooler.

Fit a blanking plug to the outlet of the cooler.

Connect an air supply to the transmission oil inlet.

Submerge the cooler in a tank of water and apply air pressure to test for leakage. If bubbles are visible there is a breakdown between the water and hydraulic circuits and the cooler must be renewed.

Note: Air test pressure must not exceed 6 bar (90 lbf/in2). 5

If the cooler is not damaged, it should be cleaned and dried ready for reassembly to the machine.

Replacement Replacing is the opposite of the removal procedure. During the replacement procedure do this work also:

F14-3

F-08-04 Issue 01

F14-3

Section F14 - Transmission Transmission Oil Cooler - Liquid to Liquid Removal, Testing and Replacement

Fig 1. Transmission Oil Cooler

F14-4

F-08-04 Issue 01

C067870-C3

F14-4

Section F15 - Transmission

Propshafts Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T F15-2) K Removal and Replacement ( T F15-3)

F15-1

F10-07 Issue 01

F15-1

Section F15 - Transmission Propshafts Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Routine Maintenance

ALL

(1) You must obey all of the relevant care and safety procedures.

F15-2

F10-07 Issue 01

F15-2

Section F15 - Transmission Propshafts Removal and Replacement

Removal and Replacement Important: When disconnecting propshafts the park brake will become ineffective or operate only on 2 wheels (depending on the machine variant). Before disconnecting any propshaft chock all 4 wheels.

Removal 1

Park the machine and make it safe. Fit the boom maintenance strut. Obey the care and safety procedures. K Related Topics ( T F15-2)

Remove the central access panels. K Related Topics ( T F15-2)

Put marks on both propshaft companion flanges and the sliding joints before removal to help during the replacement procedure.

!MWARNING When the driveshaft is disconnected the park brake will no longer function. The machine must be securely blocked to prevent any machine movement before disconnecting the driveshaft. TRANS-1-3

Fig 1.

C021520

Machines without RAS: a

Support the propshaft.

b Disconnect the propshaft coupling from the transmission by removing the nuts and bolts 2. c

Disconnect the propshaft coupling from the axle by removing the bolts 1 and straps A.

Machines with RAS: a

Support the auxiliary speed sensor plate 3.

b Support the propshaft 5. c

Disconnect the propshaft coupling from the transmission by removing the bolts 2.

d Remove the auxiliary speed sensor plates 3 from behind the parkbrake disc 4. e

F15-3

Disconnect the propshaft coupling from the axle by removing the bolts 1 and straps A.

F10-07 Issue 01

F15-3

Section F15 - Transmission Propshafts Removal and Replacement

C078870-C1

Fig 2.

Replacement

renewed, markings.

use

the

manufacturer's

alignment

Replacement is the opposite of the removal procedure.

– Apply JCB Threadlocker and Sealer to threads of all flange bolts.

During the replacement procedure do this work also:

– Retaining straps A stretch with use, therefore these straps must always be replaced with new ones.

– After lubricating sliding joints with JCB MPL Grease, align the shafts against identification marks previously made or, in the case of a shaft being

F15-4

– The propshaft must have both ends exactly on the same plane as shown at X. The yokes must not be at

F10-07 Issue 01

F15-4

Section F15 - Transmission Propshafts Removal and Replacement right angles as at Y or at an intermediate angle as at Z. â&#x20AC;&#x201C; Torque tighten the propshaft bolts and nuts. K Torque Settings ( T F15-5)

S189610-C1

Fig 3. Table 2. Torque Settings Nm

Item

F15-5

kgf m

lbf ft

Machines with Imperial Screws from Dec 2011

7.1

Metric and Imperial Screws

137

13.9

101

F10-07 Issue 01

F15-5

Section F15 - Transmission Propshafts Removal and Replacement

Page left intentionally blank

F15-6

F10-07 Issue 01

F15-6

Section G Brakes Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813-1800-2

Section G - Brakes

Notes:

G-0

9813-1800-2

G-0

Section G - Brakes Contents Page No. Applications Table ....................................................................................................... G0-1 Single Axle Service Brakes SYSTEM Introduction ............................................................................................. G1-1 Related Topics ........................................................................................ G1-2 Specifications ......................................................................................... G1-3 Operation Overview ................................................................................ G1-4 Fault Finding ........................................................................................... G1-7 Test Procedures .................................................................................... G1-11 Axle Breather (Braked Axles) - Inspection ............................................ G1-15 Bleeding ............................................................................................... G1-16 Dismantling and Assembly ................................................................... G1-17 Brake Light Switch - (Proximity Type) ................................................... G1-18 Brake Light Switch (Reed Type) ........................................................... G1-19 Twin Axle Service Brakes SYSTEM Introduction ............................................................................................. G2-1 Related Topics ........................................................................................ G2-3 Specifications (S1) .................................................................................. G2-4 Specifications (S2) .................................................................................. G2-5 Component Location .............................................................................. G2-6 Operation Overview ................................................................................ G2-7 Hydraulic Operation and Schematics ..................................................... G2-8 Fault Finding ........................................................................................... G2-9 Test Procedures .................................................................................... G2-13 Axle Breather (Braked Axles) - Inspection ............................................ G2-17 Bleeding ............................................................................................... G2-18 Dismantling and Assembly ................................................................... G2-19 Brake Light Switch (Proximity Type) ..................................................... G2-21 Brake Light Switch (Reed Type) ........................................................... G2-22 External Park Brake SYSTEM Introduction ............................................................................................. G3-1 Related Topics ........................................................................................ G3-2 Specifications ......................................................................................... G3-3 Operation Overview ................................................................................ G3-4 Test Procedures ...................................................................................... G3-5 Lever Adjustment .................................................................................... G3-6 Switch Adjustment .................................................................................. G3-8 Renewing the Brake Pads ...................................................................... G3-9 Renewing the Parkbrake Cable ............................................................ G3-11 Park Brake Calliper Introduction ............................................................................................. Related Topics ........................................................................................ Removal and Replacement .................................................................... Dismantle, Inspection and Assemble .....................................................

G4-1 G4-2 G4-3 G4-5

Park Brake Disc Introduction ............................................................................................. G5-1 Related Topics ........................................................................................ G5-2 Removal and Replacement .................................................................... G5-3

G-i

Section G - Brakes Contents Page No. Park Brake Switch Introduction ............................................................................................. G6-1 Related Topics ........................................................................................ G6-2 Removal and Replacement .................................................................... G6-3 Servo Exhauster Unit Introduction ............................................................................................. G7-1 Related Topics ........................................................................................ G7-2 Removal and Replacement .................................................................... G7-3 Servo Unit, Single Axle Brakes Introduction ............................................................................................. G8-1 Related Topics ........................................................................................ G8-2 Removal and Replacement .................................................................... G8-3 Servo Unit, Twin Axle Brakes Introduction ............................................................................................. G9-1 Related Topics ........................................................................................ G9-2 Removal and Replacement .................................................................... G9-3 Master Cylinder Introduction ........................................................................................... G10-1 Related Topics ...................................................................................... G10-2 Removal and Replacement .................................................................. G10-3

G-ii

Section G0 - Brakes Applications Table

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref Title

VARIANT

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

Single Axle Service Brakes SYSTEM

Twin Axle Service Brakes SYSTEM

External Park Brake SYSTEM

Park Brake Calliper

Park Brake Disc

Park Brake Switch

Servo Exhauster Unit

Servo Unit - Single Axle Brakes

z z z z z

Servo Unit - Twin Axle Brakes

G10

Master Cylinder

Machines with Single Axle Service Brakes System Machines with Twin Axle Service Brakes System

G0-1

9813/1800-2 (AG-00-08)

z z

z z z z

G0-1

Section G0 - Brakes Applications Table

Page left intentionally blank

G0-2

9813/1800-2 (AG-00-08)

G0-2

Section G1 - Brakes

Single Axle Service Brakes SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes fault finding, test and service procedures. K Related Topics ( T G1-2) K Specifications ( T G1-3) K Operation Overview ( T G1-4) K Fault Finding ( T G1-7) K Test Procedures ( T G1-11) K Brake Vacuum Test (if applicable) ( T G1-11) K Brake Piston Seal Leakage ( T G1-13) K Axle Breather (Braked Axles) - Inspection ( T G1-15) K Bleeding ( T G1-16) K Dismantling and Assembly ( T G1-17) K Brake Light Switch - (Proximity Type) ( T G1-18) K Adjustment ( T G1-18) K Brake Light Switch (Reed Type) ( T G1-19) K Operation ( T G1-19)

G1-1

G-01-11 Issue 01

G1-1

Section G1 - Brakes Single Axle Service Brakes SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

Machine Identification

ALL

Service Tools

ALL

ALL (Care and Safety)

Routine Maintenance

Checking the Foot Brake Fluid Level

Routine Maintenance

Transmission

Routine Maintenance

Fluids, Lubricants and Capacities

Master Cylinder

ALL

Servo Unit

ALL

(1)

ALL

Section Titles

Topic Titles

Axle Integral Brakes

55, 70 Series Integral Brakes

Table 3. Service Tools The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number

Description

892/00223(1)

Hand Pump and Relevant Adaptors/Hoses

892/00253(1)

Hydraulic Pressure Test Kit and Relevant Adaptors Vacuum Gauge â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Adaptor Vacuum Hoses

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

G1-2

G-01-11 Issue 01

G1-2

Section G1 - Brakes Single Axle Service Brakes SYSTEM Specifications

Specifications Table 4. Service Brakes: Type

Single circuit, oil-immersed multi-plate disc.

Actuation

Hydraulic Hydraulic, servo assisted (1)

Location

Front axle, centre mounted (2 brake packs).

Master Cylinder: Type

Master cylinder Master cylinder with remote servo unit. (1)

No. of Cylinders

Diameter

31.75 mm (1.25 in)

Stroke

39 mm (1.5 in)

Displacement Servo Unit:

Minimum - 2835 cc

(1)

Type

Vacuum assisted hydraulic valve.

Vacuum cylinder diameter

175 mm (6.9 in)

Hydraulic cylinder diameter

22.2 mm (0.9 in)

Brake vacuum pressure

0.8 - 1 bar negative (vacuum)

Minimum Oil Displacement

23.6 cc

Stroke

61 mm (2.4 in)

(1) Machines with turbo intercooled engines.

G1-3

G-01-11 Issue 01

G1-3

Section G1 - Brakes Single Axle Service Brakes SYSTEM Operation Overview

Operation Overview The front axle integral brake packs A are oil immersed, multi-disc types. The brake packs are actuated hydraulically by single foot pedal C and master cylinder D. On machines with servo assisted brakes, the assistance is provided by means of an engine driven vacuum pump E and remotely mounted servo unit F which is located on the front of the cab. A brake hydraulic fluid reservoir G is situated outside the cab, below the front windscreen.

An electrical switch J is fitted to the pedal assembly for operation of the rear facing brake lights. Auto 4 Wheel Braking: 4-wheel braking is achieved by engaging 4-wheel drive. In this way all 4 wheels are effectively braked via the machine transmission. With 2-wheel drive selected, pressing the brake pedal will automatically select 4-wheel drive. This gives increased braking effect. The transmission will switch back to 2wheel drive when the brake pedal is released.

Fig 1. Typical Single Axle Braking System

G1-4

G-01-11 Issue 01

C118680

G1-4

Section G1 - Brakes Single Axle Service Brakes SYSTEM Operation Overview

Hose and Pipework â&#x20AC;&#x201C; K Machines with Trailer Brakes ( T G1-5) â&#x20AC;&#x201C; K Machines without Trailer Brakes ( T G1-6)

Machines with Trailer Brakes

B D

F G

Fig 2. A

Servo Exhauster Unit

Master Cylinder

Servo Unit

Front Axle

T- Piece

Check Valve

Trailer brake valve

G1-5

G-01-11 Issue 01

C127850.eps

G1-5

Section G1 - Brakes Single Axle Service Brakes SYSTEM Operation Overview Machines without Trailer Brakes

D C

Fig 3. A

Servo Exhauster Unit

Master Cylinder

Servo Unit

Front Axle

G1-6

G-01-11 Issue 01

C127850-C1.eps

G1-6

Section G1 - Brakes Single Axle Service Brakes SYSTEM Fault Finding

Fault Finding Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. Fault(s) K Table 5. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side) ( T G1-7) K Table 6. Pedal travel excessive (but not touching floor) ( T G1-7) K Table 7. Pedal hard to operate ( T G1-8) K Table 8. Pedal touches floor under constant pressure - no fluid loss ( T G1-8) K Table 9. Pedal touches floor under constant pressure and fluid loss ( T G1-8) K Table 10. Poor braking (not pulling to one side) ( T G1-8) K Table 11. Brakes not releasing ( T G1-9) K Table 12. Poor braking when hot ( T G1-9) K Table 13. Excessive brake noise in operation ( T G1-10) K Table 14. Fluid loss when machine standing for instance - overnight ( T G1-10) Table 5. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side) Possible Cause Action 1

Master cylinder fault.

Check master cylinder to identify fault area, service as required. Refer to the Master Cylinder topic. K Related Topics ( T G1-2)

Friction/counter plate distortion.

Renew friction/counter plates - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G1-2)

Possible Cause 3

Table 6. Pedal travel excessive (but not touching floor) Action

Air in hydraulic system.

Check fluid reservoir level. Check for fluid/air leaks, rectify as required. Refer to Section 3 - Brakes. K Related Topics ( T G1-2) Bleed the brake system. K Bleeding ( T G1-16)

Leak in hydraulic system.

Check for fluid loss at master cylinder and brake piston, all pipes and fittings for loose connections. Rectify as required. K Brake Piston Seal Leakage ( T G1-13) Check fluid reservoir level. Check for fluid/air leaks, rectify as required. Refer to Section 3 - Brakes. K Related Topics ( T G1-2) Bleed the brake system. K Bleeding ( T G1-16)

Friction/counter plate distortion.

G1-7

See Item 2.

G-01-11 Issue 01

G1-7

Section G1 - Brakes Single Axle Service Brakes SYSTEM Fault Finding Table 7. Pedal hard to operate Action

Possible Cause 6

Tightness at pedal pivot.

Inspect pedal pivot. Free-off/lubricate.

Fluid contamination/seal damage.

Flush system and renew all hydraulic seals. Bleed the brake system. K Bleeding ( T G1-16)

Misaligned push rod/pedal.

Check and rectify as required.

Kinked or crushed brake pipes.

Vacuum failure due to low vacuum at source.

Inspect/service engine mounted exhauster unit as required.

Blocked/leaking vacuum pipe.

Check/renew vacuum pipe. K Brake Vacuum Test (if applicable) ( T G1-11)

Servo defect.(1)

Check/renew brake pipework. (1)

(1)

Renew servo unit. Refer to the applicable Servo Unit topic. K Related Topics ( T G1-2)

(1) Machines fitted with servo assisted brakes only.

Possible Cause

Table 8. Pedal touches floor under constant pressure - no fluid loss Action

Master cylinder fault.

See Item 1.

Friction/counter plate distortion.

See Item 2.

Air in hydraulic system.

See Item 3.

Possible Cause 16

Table 9. Pedal touches floor under constant pressure and fluid loss Action

External fluid leaks.

Check fluid reservoir level. Check for fluid/air leaks, rectify as required. Refer to Section 3 - Brakes. K Related Topics ( T G1-2) Bleed the brake system. K Bleeding ( T G1-16)

Internal fluid leaks.

Possible Cause

K Brake Piston Seal Leakage ( T G1-13) Table 10. Poor braking (not pulling to one side) Action

Friction plates worn beyond limits or distorted.

Renew friction/counter plates - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G1-2)

Master cylinder fault.

See Item 1.

Annular piston fault.

See Item 28.

Incorrect/low axle oil.

Fill axle with correct type of oil. Refer to Section 3 Transmission. K Related Topics ( T G1-2)

Vacuum failure.(1)

Inspect vacuum source/pipes, service as required. K Brake Vacuum Test (if applicable) ( T G1-11)

(1)

Machines fitted with servo assisted brakes only.

G1-8

G-01-11 Issue 01

G1-8

Section G1 - Brakes Single Axle Service Brakes SYSTEM Fault Finding Possible Cause

Table 11. Brakes not releasing Action

Brake pedal spring fault.

Fit a new spring.

Master cylinder fault (plunger stuck in bore).

See Item 1.

Blocked hole in master cylinder reservoir cap.

Fit a new reservoir cap.

Brake pedal free travel incorrect.

Adjust pedal free travel.

Fluid contamination/seal damage.

Flush system and renew hydraulic seals. Refill with clean fluid. Refer to Section 3 - Brakes. K Related Topics ( T G1-2) Bleed the brake system. K Bleeding ( T G1-16)

Annular brake piston(s) binding in axle.

– Check that correct brake fluid has been used (incorrect fluid could swell the annular brake piston seals). Refer to Section 3 - Fluids, Lubricants and Capacities. K Related Topics ( T G1-2) – Check if annular brake piston seals in good condition. Refer to the Transmission Service Manual. K Related Topics ( T G1-2) – Check that annular brake piston rotates freely in its housing with no seals fitted. Refer to the Transmission Service Manual. K Related Topics ( T G1-2) – Check that the annular brake piston seal retracts the piston approximately 0.5 mm (0.020 in). Refer to the Transmission Service Manual. K Related Topics ( T G1-2)

Kinked or crushed brake pipes.

Check and renew pipes as required.

Friction/counter plates not free on splines and/or dowels.

Check friction/counter plates for free movement, renew if required - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G1-2)

Possible Cause 31

Table 12. Poor braking when hot Action

Moisture in system vaporising when axle is hot.

Strip axle and clean annular piston to remove moisture. Refer to the Transmission Service Manual. K Related Topics ( T G1-2) Remove master cylinder and check for corrosion, service as required. Refer to the Master Cylinder topic. K Related Topics ( T G1-2) Flush system and renew hydraulic seals. Refill with clean fluid. Refer to Section 3 - Brakes. K Related Topics ( T G1-2) Bleed the brake system. K Bleeding ( T G1-16)

G1-9

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G1-9

Section G1 - Brakes Single Axle Service Brakes SYSTEM Fault Finding Possible Cause(1)

Table 13. Excessive brake noise in operation Action

Deterioration of axle oil or wrong type of axle oil.

Change axle oil. Refer to Section 3 - Transmission. K Related Topics ( T G1-2)

Axle oil loss.

Refill axle with correct oil and check for leaks. Refer to Section 3 - Transmission. K Related Topics ( T G1-2)

Friction plates worn beyond limits.

Renew friction/counter plates - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G1-2)

Friction/counter plates in poor condition.

Check for distortion or surface pitting and/or roughness of friction/counter plates (annular grooving of counter plates is acceptable). Refer to the Transmission Service Manual. K Related Topics ( T G1-2)

(1) Due to the metal to metal contact of oil immersed brakes, limited noise can be heard which is consistent with this type of design - this is normal.

Possible Cause(1)

Table 14. Fluid loss when machine standing for instance - overnight Action

Severe damage or slight cut/nick in the brake piston seal.

Test the brake piston seals for leakage. If necessary, strip axle and renew seal(s). K Brake Piston Seal Leakage ( T G1-13)

External leakage through brake pipe connections, etc. Check for and repair leaking connections.

(1) Confirm fault is as indicated by checking that the brake pedal does not touch the floor under constant pressure.

G1-10

G-01-11 Issue 01

G1-10

Section G1 - Brakes Single Axle Service Brakes SYSTEM Test Procedures

Test Procedures Brake Vacuum Test (if applicable)

b If there is little or no vacuum, check the vacuum hose connections for leaks. Check the security of the clips, then carry out step 7.

The procedure explains how to determine if the brake servo vacuum system is functioning correctly. The following test equipment is required, which can be obtained locally: – Vacuum gauge (range up to 1 bar) – `T' adaptor – Vacuum hose - 2 lengths X 75 mm (3 inch) long – Clips - worm drive

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Park the machine on firm level ground, apply the parking brake. Lower the loader to the ground, switch OFF the engine and remove the starter key.

Raise the engine cover, refer to Section 3Maintenance. K Related Topics ( T G1-2)

Working at the engine compartment, disconnect the brake vacuum line A at the brake vacuum pump and connect a vacuum gauge directly to the pump.

Run the engine at 1500 rev/min and note the reading on the vacuum gauge: a

If the vacuum is 625 mm mercury (Hg), carry out step 5.

b If there is little or no vacuum, renew the vacuum pump. 5

Remove the vacuum gauge from the pump port and reconnect it into the brake vacuum line A using a `T' adaptor B. Run the engine at 1500 rev/min and note the reading on the vacuum gauge: a

G1-11

Fig 4. 7

If the vacuum is 625 mm mercury (Hg), carry out step 7.

G-01-11 Issue 01

C007730

Switch OFF the engine and monitor the vacuum gauge reading: a

Check that after 60 seconds the vacuum remains above (holds) 500 mm mercury (Hg).

G1-11

Section G1 - Brakes Single Axle Service Brakes SYSTEM Test Procedures b Check that the vacuum is sufficient for 3 or 4 pedal operations. It is expected that the vacuum will decay slowly with each pedal operation. Note: The brake vacuum pump and brake servo unit are non-serviceable parts. If they are suspected as being faulty they must be renewed.

G1-12

G-01-11 Issue 01

G1-12

Section G1 - Brakes Single Axle Service Brakes SYSTEM Test Procedures

Brake Piston Seal Leakage The most common reason for internal piston seal leakage is a build-up of axle contamination as a result of excessive brake wear caused by extended service periods. Two types of internal leakage can occur within the axle or hub: â&#x20AC;&#x201C; Low Pressure Leaks - Seal damage, or scoring to seal component surfaces, caused by a build-up of metal particles. â&#x20AC;&#x201C; High Pressure Leaks - Mechanical leakage past a badly damaged or perished seal. Note: The low pressure leak test should be performed first. Low pressure leaks are difficult to find using a high pressure test - seals and other components can distort and form a seal under pressure.

Fig 5. 4

C022380

Test for a Low Pressure Leak: a

Install an adaptor fitted with a piece of clear tube to the brake piston port F.

The following procedures explain how to check for low or high pressure leaks without the need to dismantle the axle first. The test must only be done when the axle is COLD.

Front Axles

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK-1-4

!MWARNING

Do not drive the machine with any part of its brake system disconnected. When the following test has been completed reconnect all brake pipes and bleed the brake system using the recommended procedure.

Fig 6.

BRAK-2-1

C118690

Note: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine.

Disconnect and cap the brake piston feed pipe (or hose, as applicable) at port A.

Completely remove pipe B and plug port C.

b Fill the tube until approximately three quarters full with JCB Light Hydraulic Fluid.

Fill both brake piston housings with JCB Light Hydraulic Fluid through ports A and D.

Using a suitable pen, mark the level line of the brake fluid X on the tube.

d After approximately 1/2 hour, check if the level has dropped below the original marked line. If it has, check the brake piston seal for slight nicks, cuts or generally for wear.

G1-13

G-01-11 Issue 01

G1-13

Section G1 - Brakes Single Axle Service Brakes SYSTEM Test Procedures e 5

Repeat steps a to d at port E.

Test for a High Pressure Leak: a

Install a hand pump fitted with a 0 - 40 bar (0 - 600 lbf/in2) pressure gauge to brake piston port F.

Note: The hand pump must be filled with JCB Light Hydraulic Fluid. Do not exceed 69 bar (1000 lbf/in2).

Fig 7.

C118700

b Use the hand pump to generate a pressure in the brake piston housing. c

If the pressure falls off rapidly, or if no pressure reading can be obtained, the piston seal is severely damaged and needs replacing with a new one.

d Repeat steps a to c at port E. 6

Re-instate the brake system: Reconnect all brake pipes and bleed the brake system. K Bleeding ( T G1-16)

G1-14

G-01-11 Issue 01

G1-14

Section G1 - Brakes Single Axle Service Brakes SYSTEM Axle Breather (Braked Axles) - Inspection

Axle Breather (Braked Axles) - Inspection Breathers are fitted to axles to relieve pressure build up, due to braking and prolonged roading. If breathers are not kept clear, seal leakage and brake problems can result due to pressure build up. Most axles are fitted with long stem breather type A. Ensure there is adequate clearance around the breather and if it should be dislodged or removed, ensure it is refitted with hole C pointing outwards towards the wheel. The breather is always fitted on the opposite side to the crownwheel (in less turbulent oil) avoiding oil seepage. Plug B is fitted in the crownwheel side.

Fig 8.

G1-15

G-01-11 Issue 01

335302-1

G1-15

Section G1 - Brakes Single Axle Service Brakes SYSTEM Bleeding

Bleeding

!MWARNING Before proceeding with the bleeding procedure it is important to ensure that the park brake is engaged and that one pair of wheels is blocked on both sides. BRAK-1-2

Fill the reservoir with correct fluid (see Lubricants and Capacities, Section 3) and ensure that throughout the bleeding procedure the level is not allowed to fall below the MINIMUM mark.

!MWARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. BRAK-1-1

Fig 9. Front Axle

S107710-1

Bleed the brake system, in the appropriate sequence, as follows: a

Machines without servo brakes - Bleed at point A on the front axle.

b Machines with servo brakes - Bleed in turn at point B on the servo unit and point A on the front axle. 3

Attach a tube to the appropriate bleed screw, ensuring that the free end of the tube is immersed in fluid in a suitable container.

Open the bleed screw and apply one rapid full stroke of the brake pedal followed by three rapid short strokes from the halfway pedal position. After the third short stroke, allow the pedal to return quickly to its stop.

Continue bleeding normally until all air is dispelled, closing the bleed screw with the pedal fully depressed.

Top up reservoir to the full mark.

Fig 10. Servo Unit

G1-16

G-01-11 Issue 01

C118710

G1-16

Section G1 - Brakes Single Axle Service Brakes SYSTEM Dismantling and Assembly

Dismantling and Assembly

Fig 11.

C044220

The service brakes are located in the front axle, as shown at A. The procedures for dismantling and assembly are described in a separate publication, see Transmissions Service Manual (Publication No. 9803-8610) which includes procedures for the axle sub-assemblies. K Related Topics ( T G1-2)

G1-17

G-01-11 Issue 01

G1-17

Section G1 - Brakes Single Axle Service Brakes SYSTEM Brake Light Switch - (Proximity Type)

Brake Light Switch - (Proximity Type) Adjustment 1

Select the starter key switch to the ON position, do not start the engine.

Adjust the proximity sensor A to give a clearance of 2.0 to 3.0 mm (0.08 to 0.12 in) between the sensor face and the edge of the brake lever B. Torque tighten the locknuts C to 20 Nm (14.7 lbf ft).

Depress the brake pedal and check that the sensor operates (L.E.D. illuminates) when the brake pedal has travelled between 10 and 15 mm, and check that the sensor remains operated throughout the remaining brake travel.

Check that the brake lights come on when the brake pedal is depressed.

C029780

Fig 12.

G1-18

G-01-11 Issue 01

G1-18

Section G1 - Brakes Single Axle Service Brakes SYSTEM Brake Light Switch (Reed Type)

Brake Light Switch (Reed Type) Operation The brake light switch A is a reed type. It operates when the metal vane B moves between the switch faces C. The switch is not adjustable. If switch failure is suspected check all the associated wires and connectors for damage. Ensure that the vane B moves between the switch faces C when the brake pedal is pressed. If the switch has failed it must be renewed.

C089500

Fig 13.

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G1-19

Section G1 - Brakes Single Axle Service Brakes SYSTEM Brake Light Switch (Reed Type)

Page left intentionally blank

G1-20

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Section G2 - Brakes Twin Axle Service Brakes SYSTEM Introduction

Twin Axle Service Brakes SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes fault finding, test and service procedures. K Related Topics ( T G2-3) K Specifications (S1) ( T G2-4)(1) K Specifications (S2) ( T G2-5)(1) K Operation Overview ( T G2-7) K Hydraulic Operation and Schematics ( T G2-8) K Fault Finding ( T G2-9) K Test Procedures ( T G2-13) K Brake Vacuum Test ( T G2-13) K Brake Piston Seal Leakage ( T G2-15) K Axle Breather (Braked Axles) - Inspection ( T G2-17) K Bleeding ( T G2-18) K Dismantling and Assembly ( T G2-19) K Brake Light Switch (Proximity Type) ( T G2-21) K Adjustment ( T G2-21) K Brake Light Switch (Reed Type) ( T G2-22) (1) Specification variant. Make sure you refer to the correct procedure.

Specifications(1)

Table 1. Specification Variants Machine Model Application 507-42, 509-42, 51056, 512-56, 514-56, 535-125 HiViz, 535140 HiViz

K Specifications (S1) ( T G2-4)

K Specifications (S2) ( T G2-5)

G2-1

540-170, 550-170, 540140, 550-140, 540-200,

G-01-12 Issue 01

G2-1

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Introduction (1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

G2-2

G-01-12 Issue 01

G2-2

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Routine Maintenance

Checking the Foot Brake Fluid Level

Routine Maintenance

Transmission

Routine Maintenance

Fluids, Lubricants and Capacities

Master Cylinder

ALL

Servo Unit

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures. Table 3. Related Topics in Publication 9803/8610, Transmissions The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topics. Sections

Section Titles

Topic Titles

Axle Integral Brakes

70 Series Integral Brakes

Axle Hubs

80 Series Hub with Integral Brakes

Table 4. Service Tools The table lists the service tools you will need to do some of the procedures in this topic. Make sure you have the correct service tools BEFORE you start the procedures Tool Part Number

Description

892/00223(1)

Hand Pump and Relevant Adaptors/Hoses

892/00253(1)

Hydraulic Pressure Test Kit and Relevant Adaptors Vacuum Gauge "T" Adaptor Vacuum Hoses

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

G2-3

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G2-3

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Specifications (S1)

Specifications (S1) Table 5. Service Brakes: Type

Single circuit, oil-immersed multi-plate disc.

Actuation

Hydraulic, servo assisted (1)

Location

Front axle, centre mounted (2 brake packs). Rear axle, centre mounted (2 brake packs).

Master Cylinder: Type

Master cylinder with remote servo unit. (1)

No. of Cylinders

Diameter

38.1 mm (1.5 in)

Stroke

35 mm (1.3 in)

Displacement

39.5 cc/min

Servo Unit: (1) Type

Vacuum assisted hydraulic valve.

Vacuum cylinder diameter

201 mm (7.91in)

Hydraulic cylinder diameter

22.2 mm (0.875 in)

Brake vacuum pressure

0.8 - 1 bar negative (vacuum)

Oil Displacement

32 cc

Stroke

TBA

(1) Machines with turbo intercooled engines.

G2-4

G-01-12 Issue 01

G2-4

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Specifications (S2)

Specifications (S2) Table 6. Service Brakes: Type

Single circuit, oil-immersed multi-plate disc.

Actuation

Hydraulic, servo assisted (1)

Location

Front axle, centre mounted (2 brake packs). Rear axle, centre mounted (2 brake packs).

Master Cylinder: Type

Master cylinder with remote servo unit. (1)

No. of Cylinders

Diameter

41.28 mm (1.62 in)

Stroke

35 mm (1.3 in)

Displacement

42.81 cc/min

Servo Unit: (1) Type

Vacuum assisted hydraulic valve.

Vacuum cylinder diameter

201 mm (7.91in)

Hydraulic cylinder diameter

22.2 mm (0.875 in)

Brake vacuum pressure

0.8 - 1 bar negative (vacuum)

Oil Displacement

32 cc

Stroke

TBA

(1) Machines with turbo intercooled engines.

G2-5

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G2-5

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Component Location

Component Location Braking System

Table 7. Braking Components 507-42, 509-42, 510-56, 512-56, 514- 535-125 HiViz, 535-140 HiViz 56, 540-170, 540-140, 540-200

Servo Unit

Locations Key 1

Located under the RH rear of the chassis

Located under the Centre front of the chassis

G2-6

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G2-6

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Operation Overview

Operation Overview

IL LI O C

R DY H

ES GI L BCJ

D E

Fig 1.

C084650

The service brakes act on the front and rear axle half shafts of the machine. The brakes are oil immersed, multidisc types which are operated hydraulically by a single pedal E and master cylinder D arrangement. An exhauster (vacuum) unit B is fitted on the engine to power the servo unit A. The brake cylinder reservoir C is situated outside of the cab, below the front windscreen. Note: The location of Servo Unit A varies between machine models, refer to the component location table. K Component Location ( T G2-6)

G2-7

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G2-7

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Hydraulic Operation and Schematics

Hydraulic Operation and Schematics K Fig 2. ( T G2-8)

Key:

K Fig 2. ( T G2-8)

Fluid reservoir

Servo unit

Master cylinder

Front brake packs

Master cylinder (servo unit)

Rear brake packs

Key:

A B

D F

E Fig 2.

G2-8

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C084660

G2-8

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Fault Finding

Fault Finding Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. Fault(s) K Table 8. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side) ( T G2-9) K Table 9. Pedal travel excessive (but not touching floor) ( T G2-9) K Table 10. Pedal hard to operate ( T G2-10) K Table 11. Pedal touches floor under constant pressure - no fluid loss ( T G2-10) K Table 12. Pedal touches floor under constant pressure and fluid loss ( T G2-10) K Table 13. Poor braking (not pulling to one side) ( T G2-10) K Table 14. Brakes not releasing ( T G2-11) K Table 15. Poor braking when hot ( T G2-11) K Table 16. Excessive brake noise in operation ( T G2-12) K Table 17. Fluid loss when machine standing for instance - overnight ( T G2-12) Table 8. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side) Possible Cause Action 1

Master cylinder fault.

Check master cylinder to identify fault area, service as required. Refer to the Master Cylinder topic. K Related Topics ( T G2-3)

Friction/counter plate distortion

Renew friction/counter plates - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G2-3)

Possible Cause 3

Table 9. Pedal travel excessive (but not touching floor) Action

Air in hydraulic system

Check fluid reservoir level. Check for fluid/air leaks, rectify as required. Refer to Section 3 - Brakes. K Related Topics ( T G2-3) Bleed the brake system. K Bleeding ( T G2-18)

Leak in hydraulic system.

Check for fluid loss at master cylinder and brake piston, all pipes and fittings for loose connections. Rectify as required. K Brake Piston Seal Leakage ( T G2-15) Check fluid reservoir level. Check for fluid/air leaks, rectify as required. Refer to Section 3 - Brakes. K Related Topics ( T G2-3) Bleed the brake system. K Bleeding ( T G2-18)

Friction/counter plate distortion.

G2-9

See Item 2.

G-01-12 Issue 01

G2-9

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Fault Finding Table 10. Pedal hard to operate Action

Possible Cause 6

Tightness at pedal pivot.

Inspect pedal pivot. Free-off/lubricate.

Fluid contamination/seal damage.

Flush system and renew all hydraulic seals. Bleed the brake system. K Bleeding ( T G2-18)

Misaligned push rod/pedal.

Check and rectify as required.

Kinked or crushed brake pipes.

Vacuum failure due to low vacuum at source.

Inspect/service engine mounted exhauster unit as required.

Blocked/leaking vacuum pipe.

Check/renew vacuum pipe. K Brake Vacuum Test ( T G2-13)

Servo defect.(1)

Check/renew brake pipework. (1)

(1)

Renew servo unit. Refer to the applicable Servo Unit topic. K Related Topics ( T G2-3)

(1) Machines fitted with servo assisted brakes only.

Possible Cause

Table 11. Pedal touches floor under constant pressure - no fluid loss Action

Master cylinder fault.

See Item 1.

Friction/counter plate distortion.

See Item 2.

Air in hydraulic system.

See Item 3.

Possible Cause 16

Table 12. Pedal touches floor under constant pressure and fluid loss Action

External fluid leaks.

Check fluid reservoir level. Check for fluid/air leaks, rectify as required. Refer to Section 3 - Brakes. K Related Topics ( T G2-3) Bleed the brake system. K Bleeding ( T G2-18)

Internal fluid leaks.

Possible Cause

K Brake Piston Seal Leakage ( T G2-15) Table 13. Poor braking (not pulling to one side) Action

Friction plates worn beyond limits or distorted.

Renew friction/counter plates - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G2-3)

Master cylinder fault.

See Item 1.

Annular piston fault.

See Item 28.

Incorrect/low axle oil.

Fill axle with correct type of oil. Refer to Section 3 Transmission. K Related Topics ( T G2-3)

Vacuum failure.(1)

Inspect vacuum source/pipes, service as required. K Brake Vacuum Test ( T G2-13)

(1)

Machines fitted with servo assisted brakes only.

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G2-10

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Fault Finding Table 14. Brakes not releasing Action

Possible Cause 23

Brake pedal spring fault.

Fit a new spring.

Master cylinder fault (plunger stuck in bore).

See Item 1.

Blocked hole in master cylinder reservoir cap.

Fit a new reservoir cap.

Brake pedal free travel incorrect.

Adjust pedal free travel.

Fluid contamination/seal damage.

Flush system and renew hydraulic seals. Refill with clean fluid. Refer to Section 3 - Brakes. K Related Topics ( T G2-3) Bleed the brake system. K Bleeding ( T G2-18)

Annular brake piston(s) binding in axle

– Check that correct brake fluid has been used (incorrect fluid could swell the annular brake piston seals). Refer to Section 3 - Fluids, Lubricants and Capacities. K Related Topics ( T G2-3) – Check if annular brake piston seals in good condition. Refer to the Transmission Service Manual. K Related Topics ( T G2-3) – Check that annular brake piston rotates freely in its housing with no seals fitted. Refer to the Transmission Service Manual. K Related Topics ( T G2-3) – Check that the annular brake piston seal retracts the piston approximately 0.5 mm (0.020 in). Refer to the Transmission Service Manual. K Related Topics ( T G2-3)

Kinked or crushed brake pipes.

Check and renew pipes as required.

Friction/counter plates not free on splines and/or dowels.

Check friction/counter plates for free movement, renew if required - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G2-3)

Possible Cause 31

Table 15. Poor braking when hot Action

Moisture in system vaporising when axle is hot.

Strip axle and clean annular piston to remove moisture. Refer to the Transmission Service Manual. K Related Topics ( T G2-3) Remove master cylinder and check for corrosion, service as required. Refer to the Master Cylinder topic. K Related Topics ( T G2-3) Flush system and renew hydraulic seals. Refill with clean fluid. Refer to Section 3 - Brakes. K Related Topics ( T G2-3) Bleed the brake system. K Bleeding ( T G2-18)

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G2-11

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Fault Finding Possible Cause(1)

Table 16. Excessive brake noise in operation Action

Deterioration of axle oil or wrong type of axle oil.

Change axle oil. Refer to Section 3 - Transmission. K Related Topics ( T G2-3)

Axle oil loss.

Refill axle with correct oil and check for leaks. Refer to Section 3 - Transmission. K Related Topics ( T G2-3)

Friction plates worn beyond limits.

Renew friction/counter plates - Both sides of relevant axle. Refer to the Transmission Service Manual. K Related Topics ( T G2-3)

Friction/counter plates in poor condition.

(1) Due to the metal to metal contact of oil immersed brakes, limited noise can be heard which is consistent with this type of design - this is normal.

Possible Cause(1)

Table 17. Fluid loss when machine standing for instance - overnight Action

Severe damage or slight cut/nick in the brake piston seal.

Test the brake piston seals for leakage. If necessary, strip axle and renew seal(s). K Brake Piston Seal Leakage ( T G2-15)

External leakage through brake pipe connections, etc. Check for and repair leaking connections.

(1) Confirm fault is as indicated by checking that the brake pedal does not touch the floor under constant pressure.

G2-12

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G2-12

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Test Procedures

Test Procedures Brake Vacuum Test

b If there is little or no vacuum, check the vacuum hose connections for leaks. Check the security of the clips, then carry out step 7.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Park the machine on firm level ground, apply the parking brake. Lower the loader to the ground, switch OFF the engine and remove the starter key.

Raise the engine cover, refer to Section 3Maintenance.

Working at the engine compartment, disconnect the brake vacuum line A at the brake vacuum pump and connect a vacuum gauge directly to the pump.

Run the engine at 1500 rev/min and note the reading on the vacuum gauge: a

If the vacuum is 625 mm mercury (Hg), carry out step 5.

b If there is little or no vacuum, renew the vacuum pump. 5

Remove the vacuum gauge from the pump port and reconnect it into the brake vacuum line A using a `T' adaptor B. Run the engine at 1500 rev/min and note the reading on the vacuum gauge: a

G2-13

Fig 3. 7

If the vacuum is 625 mm mercury (Hg), carry out step 7.

G-01-12 Issue 01

C007730

Switch OFF the engine and monitor the vacuum gauge reading: a

Check that after 60 seconds the vacuum remains above (holds) 500 mm mercury (Hg).

G2-13

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Test Procedures b Check that the vacuum is sufficient for 3 or 4 pedal operations. It is expected that the vacuum will decay slowly with each pedal operation. Note: The brake vacuum pump and brake servo unit are non-serviceable parts. If they are suspected as being faulty they must be renewed.

G2-14

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G2-14

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Test Procedures

Fig 4. 4

C022380

Test for a Low Pressure Leak: a

Install an adaptor fitted with a piece of clear tube to the brake piston port F.

The following procedures explain how to check for low or high pressure leaks without the need to dismantle the axle first. The test must only be done when the axle is COLD. The procedure is for one axle. The procedure for both axles is the same.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK-1-4

!MWARNING

Fig 5.

BRAK-2-1

C118690

Note: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine.

Disconnect and cap the brake piston feed pipe (or hose, as applicable) at port A.

Completely remove pipe B and plug port C.

b Fill the tube until approximately three quarters full with JCB Light Hydraulic Fluid.

Fill both brake piston housings with JCB Light Hydraulic Fluid through ports A and D.

Using a suitable pen, mark the level line of the brake fluid X on the tube.

d After approximately 1/2 hour, check if the level has dropped below the original marked line. If it has, check the brake piston seal for slight nicks, cuts or generally for wear.

G2-15

G-01-12 Issue 01

G2-15

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Test Procedures e 5

Repeat steps a to d at port E.

Test for a High Pressure Leak: a

Install a hand pump fitted with a 0 - 40 bar (0 - 600 lbf/in2) pressure gauge to brake piston port F.

Note: The hand pump must be filled with JCB Light Hydraulic Fluid. Do not exceed 69 bar (1000 lbf/in2).

Fig 6.

C118700

b Use the hand pump to generate a pressure in the brake piston housing. c

If the pressure falls off rapidly, or if no pressure reading can be obtained, the piston seal is severely damaged and needs replacing with a new one.

d Repeat steps a to c at port E. 6

Re-instate the brake system: Reconnect all brake pipes and bleed the brake system. K Bleeding ( T G2-18) Alternately, proceed to rear axle, if applicable.

G2-16

G-01-12 Issue 01

G2-16

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Axle Breather (Braked Axles) - Inspection

Fig 7.

G2-17

G-01-12 Issue 01

335302-1

G2-17

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Bleeding

Bleeding

!MWARNING Before proceeding with the bleeding procedure it is important to ensure that the park brake is engaged and that one pair of wheels is blocked on both sides. BRAK-1-2

Fill the reservoir with correct fluid (see Lubricants and Capacities, Section 3) and ensure that throughout the bleeding procedure the level is not allowed to fall below the MINIMUM mark.

!MWARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. Fig 8. Servo Unit

BRAK-1-1

A311790-C1

Bleed the brake system, in the appropriate sequence, as follows: Bleed in turn at point B on the servo unit, point A on the front axle and rear axle (first left side, then right side).

Attach a tube to the appropriate bleed screw, ensuring that the free end of the tube is immersed in fluid in a suitable container.

Continue bleeding normally until all air is dispelled, closing the bleed screw with the pedal fully depressed.

Top up reservoir to the full mark.

G2-18

G-01-12 Issue 01

S107710-1

G2-18

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Dismantling and Assembly

Dismantling and Assembly Integral Brake Systems

Fig 10.

C044220

The service brakes are located in the front and rear axles, as shown at A. The procedures for dismantling and assembly are described in a separate publication, see Transmissions Service Manual which includes procedures for the axle sub-assemblies. K Related Topics ( T G2-3)

G2-19

G-01-12 Issue 01

G2-19

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Dismantling and Assembly

Hub Brakes

Fig 11.

C021820-C1

On some machine variants the service brakes are located in the rear axle hubs as shown at B. The procedures for dismantling and assembly are described in a separate publication, see Transmissions Service Manual which includes procedures for the axle sub-assemblies. K Related Topics ( T G2-3)

G2-20

G-01-12 Issue 01

G2-20

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Brake Light Switch (Proximity Type)

Brake Light Switch (Proximity Type) Adjustment 1

Select the starter key switch to the ON position, do not start the engine.

Adjust the proximity sensor A to give a clearance of 2.0 to 3.0 mm (0.08 to 0.12 in) between the sensor face and the edge of the brake lever B. Torque tighten the locknuts C to 20 Nm (14.7 lbf ft).

Check that the brake lights come on when the brake pedal is depressed.

C029780

Fig 12.

G2-21

G-01-12 Issue 01

G2-21

Section G2 - Brakes Twin Axle Service Brakes SYSTEM Brake Light Switch (Reed Type)

C089500

Fig 13.

G2-22

G-01-12 Issue 01

G2-22

Section G3 - Brakes

External Park Brake SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes fault finding, test and service procedures. K Related Topics ( T G3-2) K Specifications ( T G3-3) K Operation Overview ( T G3-4) K Test Procedures ( T G3-5) K Lever Adjustment ( T G3-6) K Switch Adjustment ( T G3-8) K Renewing the Brake Pads ( T G3-9) K Renewing the Parkbrake Cable ( T G3-11)

G3-1

G-02-10 Issue 01

G3-1

Section G3 - Brakes External Park Brake SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Park Brake Calliper

ALL

Park Brake Disc

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

G3-2

G-02-10 Issue 01

G3-2

Section G3 - Brakes External Park Brake SYSTEM Specifications

Specifications

Park Brake: Independent cable operated parking brake in the drive to the front axle. Type

Disc brake, manually adjusted calliper.

Actuation

Cable operated.

Location

Mounted on the gearbox.

Disc diameter

279.4 mm (11 in)

G3-3

G-02-10 Issue 01

G3-3

Section G3 - Brakes External Park Brake SYSTEM Operation Overview

Operation Overview

Fig 1.

C084690-C3

The park brake is Independent of the service brakes. It operates on the drive to the front axle by means of a disc mounted on the gearbox output shaft A. When the operator moves the park brake lever to the vertical position, the cable pulls the calliper reaction lever C and pressure is applied to the calliper mounted brake pads B to hold the brake disc D. The lever has a simple system for adjustment of the cable when necessary. An electrical switch senses if the park brake lever is set to the brake ON or brake OFF position. The switch controls operator warnings and transmission interlocks.

G3-4

G-02-10 Issue 01

G3-4

Section G3 - Brakes External Park Brake SYSTEM Test Procedures

Test Procedures

!MWARNING

Before testing the park brake make sure the area around the machine is clear of people. 2-2-4-5

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T G3-2)

Fully apply the parking brake A.

Start the engine and raise the attachments to the appropriate travelling position.

Select fourth gear B.

Push down hard on foot brake pedal C.

Select forward drive B.

If the machine moved during this test, adjust the parking brake and repeat the test. K Lever Adjustment ( T G3-6)

If you have any queries concerning this test procedure or parking brake adjustment, consult your local JCB distributor.

!MWARNING Do not use a machine with a faulty park brake. 3-2-3-10_2

!MWARNING Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake. 3-2-3-11

!MWARNING If the machine starts to move during the following test, immediately apply the foot brake and reduce the engine speed.

12 9

RPM x 100

2-2-5-1

Test the parking brake as follows: 7

Move the parking brake lever fractionally forward until the warning light D is just extinguished.

Slowly release the foot brake pedal C.

If the machine has not moved, use the accelerator pedal to gradually increase the engine speed to 1500 RPM. The machine should not move.

Do not do this test for longer than 20 seconds.

Reduce the engine speed to idle and select neutral B.

Return the park brake lever A to the fully on position from its partially applied position.

Lower attachments and stop the engine.

G3-5

G-02-10 Issue 01

535

Fig 2.

530

C022290

G3-5

Section G3 - Brakes External Park Brake SYSTEM Lever Adjustment

Lever Adjustment

!MCAUTION The park brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced. Whenever the park brake has been used in an emergency, always renew both brake pads. 4-2-1-1_2

!MWARNING Before adjusting the park brake, make sure that the machine is on level ground. Put blocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. 2-3-2-4

Fig 3.

!MWARNING

A347580A-5

Over adjustment of the park brake could result in the park brake not fully releasing. 0011

Note: Before attempting to adjust the park brake after an emergency stop remove and inspect the brake friction components. Renew components if necessary.

Lever Adjustment The parking brake should be fully engaged when the lever is vertical. The parking brake indicator light should illuminate when the brake is engaged with the forward and reverse lever away from neutral (starter switch at IGN). 1

Disengage the parking brake (lever horizontal).

Pull and turn handle grip A clockwise, half a turn.

Test the parking Procedures ( T G3-5)

brake.

K Test

If the brake fails the test, repeat steps 1, 2 and 3. If there is no more adjustment and pin B is at the end of its travel adjust the cable at the calliper. K Lever Adjustment ( T G3-6)

G3-6

G-02-10 Issue 01

G3-6

Section G3 - Brakes External Park Brake SYSTEM Lever Adjustment

Cable Adjustment Adjust the cable at the calliper if there is insufficient adjustment at the parking brake lever.

Note: If a new cable is being fitted, position the threaded section of the cable with approximately four threads visible below the bottom adjusting nut. 5

Make sure there is adequate freedom of movement of operating lever H to ensure a positive brake application, and that the lever returns to the rest position when the parking brake is released. The total clearance between the brake pad to brake disc should be 0.5 to 0.75 mm (0.02 to 0.3 in).

Test the parking Procedures ( T G3-5)

If there is no adjustment at the lever or the calliper, change the brake pads. K Renewing the Brake Pads ( T G3-9) Always renew a worn or damaged cable. 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T G3-2)

Disengage the parking brake (lever horizontal).

Turn hand grip E anti-clockwise to centre the pin F in its slot.

Release the two locknuts at G and adjust the cable length as required.

G3-7

K Test

Make final adjustments at the park brake lever if the brake fails the test. K Lever Adjustment ( T G3-6)

Fig 5.

Fig 4.

brake.

C118730

C022470

G-02-10 Issue 01

G3-7

Section G3 - Brakes External Park Brake SYSTEM Switch Adjustment

Switch Adjustment The park brake switch A is a reed type. It operates when the metal vane B moves between the switch faces C. The switch is not adjustable. If switch failure is suspected check all the associated wires and connectors for damage. Ensure that the vane B moves between the switch faces C when the park brake is operated. If the switch has failed it must be renewed.

Fig 6.

G3-8

C030040

G-02-10 Issue 01

G3-8

Section G3 - Brakes External Park Brake SYSTEM Renewing the Brake Pads

Renewing the Brake Pads Pad Inspection

K Fig 7. ( T G3-10)

!MWARNING

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

Oil on the brake disc will reduce brake effectiveness. Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer's safety instructions. If the pads are oily, new ones must be fitted.

Installation and mounting of the park brake caliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available. 0010

2-3-2-3_3

The minimum thickness of the friction material on either pad is 1mm (0.04 in), but it is recommended new pads are fitted as pads worn to this limit may not be able to be adjusted.

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn.

Renew the cable if worn or damaged.

!MWARNING Before working on the park brake, park on level ground and put blocks on each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. BRAK-8-8

Pad Replacement

!MWARNING Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work. 13-3-1-3

Fit the pad 2 to the lever side of the calliper. Position the pad inside housing 3. Locate the plastic clip in the centre of the rotor 4 into the hole X, and press the pad into place.

Make sure the plastic anti-rattle pad Y is correctly located. Fit the pad 1 to the carrier side of the calliper. Add a small amount of silicone sealant to the back outer edge of the backing plate to hold the pad in place within the housing.

Replace the calliper. K Related Topics ( T G3-2)

Pad Removal 1

Remove the parking brake calliper from the axle mounting bracket, refer to the Parkbrake Calliper topic. K Related Topics ( T G3-2)

Press carrier side pad 1 into housing 3 and remove. Ensure any residual silicone used for pad retention during assembly is removed.

Carefully lever pad 2 from the rotor inside the housing using a flat blade screwdriver. Take care to prevent damage to the plastic clip in the centre of the rotor 4 (there is no need to remove the rotor from the calliper).

G3-9

Note: If there is insufficient adjustment after fitting new pads change the brake cable.

G-02-10 Issue 01

G3-9

Section G3 - Brakes External Park Brake SYSTEM Renewing the Brake Pads

4 Fig 7. Brake Pads

G3-10

C119010

G-02-10 Issue 01

G3-10

Section G3 - Brakes External Park Brake SYSTEM Renewing the Parkbrake Cable

Renewing the Parkbrake Cable

Uncouple the park brake switch electrical connector 2.

Undo the lever fixing bolts 3 and withdraw the lever assembly together with the cable E.

Measure and record dimension X.

Undo the 2 buffer bracket fixing bolts F.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T G3-2)

Release the parking brake lever 1 (lever horizontal).

Fig 8.

A396181-C3

Working at the park brake caliper, disconnect clevis A, note which of the three holes on the actuating lever B is used.

Remove clip or loosen locknut C as applicable. Disconnect the cable from the bracket D. Note the cable routing to the underside of the cab.

Working at the park brake lever, undo the gaiter fixings and pull up the gaiter (not shown).

G3-11

G-02-10 Issue 01

Fig 9.

C118740

G3-11

Section G3 - Brakes External Park Brake SYSTEM Renewing the Parkbrake Cable 10

Withdraw the cable sideways from the lever, disengaging the cable nipple from the clevis H. Remove the buffer assembly J from the cable.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Be sure to route the cable correctly. – Ensure that the locknut G is screwed fully down. Adjust sleeve K to allow cable location to the lever assembly. – Apply JCB Threadlocker to the buffer bracket fixing bolts F. – Ensure that the buffer bracket assembly J is located correctly. Torque tighten the bolts F. – Adjust the sleeve K and locknut G until dimension X is achieved (recorded during removal) Note: if a new cable is fitted make sure dimension X is 15mm (0.6 in). – Tighten the locknut G. – Ensure that the cable clevis A is connected at the correct hole in the caliper actuating lever B. – Ensure that the actuating lever B is not being pulled by the cable when the parking brake lever is in the OFF (horizontal) position. If necessary adjust sleeve K until the actuating lever is allowed to return fully to its OFF position. – Adjust the cable. K Lever Adjustment ( T G3-6)

Item F

G3-12

Table 2. Torque Settings Nm kgf m 3

0.3

lbf ft 2.2

G-02-10 Issue 01

G3-12

Section G4 - Brakes

Park Brake Calliper Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G4-2) K Removal and Replacement ( T G4-3) K Removal ( T G4-3) K Replacement ( T G4-3) K Torque Figures ( T G4-4) K Dismantle, Inspection and Assemble ( T G4-5) K Dismantle ( T G4-5) K Inspection ( T G4-7) K Assemble ( T G4-7)

G4-1

G-03-04 Issue 01

G4-1

Section G4 - Brakes Park Brake Calliper Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Park Brake SYSTEM

Parkbrake Cable

Parkbrake Disc

Removal and Replacement

(1) You must obey all of the relevant care and safety procedures.

G4-2

G-03-04 Issue 01

G4-2

Section G4 - Brakes Park Brake Calliper Removal and Replacement

Removal and Replacement

!MWARNING

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

D E B

C119030

Fig 1.

BRAK-8-8

!MWARNING

Replacement

Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work.

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Locate the calliper on the brake disc. Fit new mounting bolts B with hardened washers and torque tighten. K Table 2. Torque Settings ( T G4-3).

13-3-1-3

Removal Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T G4-2)

– Attach the cable to the mounting bracket and secure in place with clip A. – Refit the clevis C and pin D into the relevant hole in the operating lever E.

Release the parking brake lever (lever horizontal).

Remove pin D and disconnect clevis C, note which of the three holes on the lever E is used.

– Make sure there is adequate freedom of movement of operating lever E to ensure a positive brake application, and that the lever returns to the rest position when the parking brake is released.

Remove clip A and disconnect the cable from the bracket.

– Adjust the park brake cable. Never unscrew the clevis to adjust the cable. K Related Topics ( T G4-2)

Support the calliper and remove the two mounting bolts and hardened washers B. Lift the calliper clear of the brake disc.

Item

Table 2. Torque Settings Nm kgf m

lbf ft

255

188

Note: Do not remove transmission mounting bracket F unless it needs to be renewed.

G4-3

G-03-04 Issue 01

G4-3

Section G4 - Brakes Park Brake Calliper Removal and Replacement

Torque Figures

Fig 2.

A396540-C

Where appropriate, the grade of bolt is indicated in parenthesis e.g. (10.9). Refer also to relevant dismantling and assembly procedures.

Item

Table 3. Torque Settings Nm Kgf m

166

122 (grade 12.9)

13 - 16

1.3 - 1.6

9 - 12

255

188 (grade 10.9)

(1)

lbf ft

(1) Always use new bolts.

G4-4

G-03-04 Issue 01

G4-4

Section G4 - Brakes Park Brake Calliper Dismantle, Inspection and Assemble

Dismantle, Inspection and Assemble

!MWARNING

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so. Installation and mounting of the park brake caliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available. 0010

Remove the rotor seal 14 followed by bearing ring 15. Note that the rotor seal may be located on the rotor shaft or may have been left in the calliper housing 16.

Note: Shaft seal 17 will not need to be renewed unless excessively worn or damaged. If removal is necessary, press the seal out from inside the housing using a suitable spacer block and bench press. Clean out any remains of the seal after removal. Component Key K Fig 3. ( T G4-6)

!MWARNING Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work. 13-3-1-3

Dismantle K Fig 3. ( T G4-6). The numerical sequence shown on the illustration is intended as a guide to dismantling. 1

Remove the calliper and brake pads. K Removal and Replacement ( T G4-3)

Hold lever 6 against the tension of the spring and remove the screw 3, and washers 4 and 5.

Note the position of lever 6 relative to the splines of the rotor shaft 8. Mark the end of the shaft and lever 6 to aid assembly. Remove lever 6 and spring 7.

Push out rotor 8 and remove ball spacer 9 and ball bearings 10. Take care not to lose the ball bearings.

Push out mounting bushes 11 and remove dust seals 12 and `O' rings 13.

G4-5

Carrier side pad

Lever side pad

Screw

Washer

Lever

Spring

Rotor

Ball spacer

Ball bearings

Mounting bushes

Dust seals

`O' Rings

Rotor Seal

Bearing ring

Housing

Shaft seal

G-03-04 Issue 01

G4-5

Section G4 - Brakes Park Brake Calliper Dismantle, Inspection and Assemble

Fig 3. Park Brake Calliper

G4-6

G-03-04 Issue 01

C047760

G4-6

Section G4 - Brakes Park Brake Calliper Dismantle, Inspection and Assemble

Inspection 1

Clean and dry all parts. Check all parts are free from excessive wear, damage or corrosion. Light scores or stains should be removed. Renew corroded or deeply scored parts.

Check rotor 8 for damage or distortion. Renew if necessary. Always renew both brake pads if the parking brake has been used in an emergency.Check the ball pockets in housing 16 for signs of scoring, pitting, damage or corrosion. Renew the housing if damaged. Check spring 7 is not broken or distorted. Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn. K Related Topics ( T G4-2)

Fit lever 6. Align the lever to the mark made during dismantling.

Hold the lever against the tension of the spring and fit washers 4 and 5 Fit screw 3 and torque tighten. K Table 4. Torque Settings ( T G4-7).

Fit the brake pads. K Related Topics ( T G4-2)

Lubricate the dust seals 12 and bushes 11 with silicone grease. Fit the dust seals to the housing and insert mounting bushes. Make sure that the dust seals locate in their location grooves on the bushes 11 and housing 16. Fit new `O' rings 13 and lubricate. Wipe off any excess grease.

Before fitting the calliper, ensure the lever rotates smoothly and that the lever side pad 2 returns to the off position when the lever is released.

Refit the brake calliper. Replacement ( T G4-3)

Refit and adjust the park brake cable. K Related Topics ( T G4-2)

Assemble K Fig 3. ( T G4-6). The numerical sequence shown on the illustration is intended as a guide to assembling. Before assembly make sure all parts are clean and serviceable. 1

Fit a new shaft seal 17 if removed. Install the seal as shown. Press the seal into the housing using a suitable spacer block and bench press.

Coat the shaft, outer diameter and ball pockets of rotor 8 and the ball pockets of housing 16 with silicone grease.

Insert the three ball bearings 10 into the pockets in the housing 16. Insert ball spacer 9.

Coat the bearing ring 15 with silicone grease and fit the ring to the inner diameter on rotor seal 14. Assemble the rotor seal to the rotor 8.

Slide rotor 8 through the casting and seat the ball pockets against the bearings.

Position spring 7 over the shaft of rotor 8. Insert the large diameter end of the spring into hole X in the face of the housing.

Locate the small diameter end of spring 7 around the outside edge of lever 6 as shown at Y.

G4-7

C004120

Fig 4.

Item 3

G-03-04 Issue 01

K Removal

Table 4. Torque Settings Nm kgf m 13 - 16

1.3 - 1.6

and

lbf ft 9 - 12

G4-7

Section G4 - Brakes Park Brake Calliper Dismantle, Inspection and Assemble

Page left intentionally blank

G4-8

G-03-04 Issue 01

G4-8

Section G5 - Brakes

Park Brake Disc Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G5-2) K Removal and Replacement ( T G5-3)

G5-1

G-04-05 Issue 01

G5-1

Section G5 - Brakes Park Brake Disc Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Propshafts

ALL

Park Brake Caliper

ALL

External Parkbrake System

Specifications

Description

Flange Spanner - park brake disc

992/04800(1)

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

G5-2

G-04-05 Issue 01

G5-2

Section G5 - Brakes Park Brake Disc Removal and Replacement

Removal and Replacement Removal 1

Remove the park Topics ( T G5-2)

brake

calliper.

K Related

Remove the drive shaft at the park brake disc. K Related Topics ( T G5-2)

Clean the brake disc and gearbox adjacent to the brake disc. Do not allow particles of grit to fall into the gearbox when the brake disc is removed.

While holding brake disc A with service tool T1 unscrew output shaft nut B.

Discard the nut B.

Lift off the brake disc. If necessary use a soft face hammer to help remove the disc. DO NOT use a steel hammer, damage can occur to the output shaft bearings E.

Inspection â&#x20AC;&#x201C; Inspect the thickness of the parkbrake disc. The minimum thickness is specified in the parkbrake system topic - Section G - External Parkbrake System. K Related Topics ( T G5-2) â&#x20AC;&#x201C; Inspect the condition of the disc. If disc is deeply pitted or scored replace with a new one.

Replacement 1

Make sure that the oil seal interface D on the brake disc is clean and free from wear or damage.

Apply JCB HP grease to the lips of oil seal C.

Fit the brake disc on to the output shaft F.

Hold the brake disc with service tool T1.

Fit a NEW stake nut B. Progressively torque tighten to 300 Nm (221 lbf ft).

Stake nut B into the slot in the shaft.

G5-3

C067210

Fig 1.

G-04-05 Issue 01

G5-3

Section G5 - Brakes Park Brake Disc Removal and Replacement

Page left intentionally blank

G5-4

G-04-05 Issue 01

G5-4

Section G6 - Brakes

Park Brake Switch Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G6-2) K Removal and Replacement ( T G6-3)

G6-1

G-05-02 Issue 01

G6-1

Section G6 - Brakes Park Brake Switch Related Topics

Topic Titles

Applications

ALL (Care and Safety)

Sub Titles ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

G6-2

G-05-02 Issue 01

G6-2

Section G6 - Brakes Park Brake Switch Removal and Replacement

Removal and Replacement Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T G6-2)

Put chocks under the wheels. Release the park brake.

Remove the rubber gaiter A.

Disconnect the electrical connector C from the switch connector D.

Hold the switch B and remove screw E.

Remove the switch B.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; To align the switch correctly, engage the switch location dowel F with hole in the mounting bracket G.

C047230-C1.eps

Fig 1.

G6-3

G-05-02 Issue 01

G6-3

Section G6 - Brakes Park Brake Switch Removal and Replacement

Page left intentionally blank

G6-4

G-05-02 Issue 01

G6-4

Section G7 - Brakes

Servo Exhauster Unit Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G7-2) K Removal and Replacement ( T G7-3)

G7-1

G-07-01 Issue 1

G7-1

Section G7 - Brakes Servo Exhauster Unit Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Service Brake SYSTEM

Brake Vacuum Test

Cooling Pack

Removal and Replacement

ALL ALL

(1)

(1) You must obey all of the relevant care and safety procedures.

G7-2

G-07-01 Issue 1

G7-2

Section G7 - Brakes Servo Exhauster Unit Removal and Replacement

Removal and Replacement If the brake performance is poor and the brake servo vacuum is suspected, carry out the brake vacuum test before renewing the servo exhauster unit. For the test procedure refer to the Service Brake System topic. K Related Topics ( T G7-2)

!MWARNING

– Ensure the servo exhauster unit flange and engine mating face are clean. Fit a new gasket E. – Carefully align the gear G so that the gear teeth engage with the drive gear in the engine. – Torque tighten screws D. K Table 2. Torque Settings ( T G7-4) – On completion test the brakes.

Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T G7-2)

Disconnect the battery.

Raise the engine cover.

Note: Access to the servo exhauster unit is limited. If necessary remove the machine cooling pack to gain sufficient access. K Related Topics ( T G7-2) 4

K Fig 1. ( T G7-4) Working in the engine compartment, undo the clip and release the brake vacuum hose A from the pipe stub B. Disconnect the oil feed hose C. Blank off the open ends of the hoses to prevent ingress of dirt. Tie the hoses out of the way.

Undo the two screws D and carefully withdraw the servo exhauster unit from the engine. Discard the gasket E.

Replacement Note: The servo exhauster unit is a non-serviceable part. If it is suspected as being faulty it must be renewed as a complete assembly. Important: The special adaptor F is fitted with an oil feed restrictor orifice (3 mm diameter). Check to make sure that the orifice is not blocked before fitting the servo exhauster unit. Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

G7-3

G-07-01 Issue 1

G7-3

Section G7 - Brakes Servo Exhauster Unit Removal and Replacement

Fig 1.

Item

Table 2. Torque Settings Nm kgf m lbf ft

43 - 51

G7-4

4.4 - 5.2

C033440

32 - 38

G-07-01 Issue 1

G7-4

Section G8 - Brakes

Servo Unit, Single Axle Brakes Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G8-2) K Removal and Replacement ( T G8-3)

G8-1

G-08-02 Issue 01

G8-1

Section G8 - Brakes Servo Unit, Single Axle Brakes Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Routine Maintenance

Checking the Foot Brake Fluid Level

Service Brake SYSTEM

Bleeding

ALL ALL

(1)

(1) You must obey all of the relevant care and safety procedures.

G8-2

G-08-02 Issue 01

G8-2

Section G8 - Brakes Servo Unit, Single Axle Brakes Removal and Replacement

Removal and Replacement Removal

C128160.eps

Fig 1. 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T G8-2)

Disconnect servo vacuum hose A.

Disconnect and blank off master cylinder output pipe B. Plug the cylinder port.

Replacement Replacement is the opposite of the removal procedure.

Disconnect cylinder output hose C. Blank off the hose and plug the cylinder port.

Loosen the three securing nuts/bolts D and slide the servo unit G out of its mounting bracket E.

During the replacement procedure do this work also: – Check the brake Topics ( T G8-2)

fluid

level.

K Related

– Make sure to install the washers F (if fitted). – Bleed the brake Topics ( T G8-2)

system.

K Related

Note: Make sure to retain the washers F (if fitted).

G8-3

G-08-02 Issue 01

G8-3

Section G8 - Brakes Servo Unit, Single Axle Brakes Removal and Replacement

Page left intentionally blank

G8-4

G-08-02 Issue 01

G8-4

Section G9 - Brakes

Servo Unit, Twin Axle Brakes Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G9-2) K Removal and Replacement ( T G9-3)

G9-1

G-09-03 Issue 01

G9-1

Section G9 - Brakes Servo Unit, Twin Axle Brakes Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Routine Maintenance

Checking the Foot Brake Fluid Level

Service Brake SYSTEM

Bleeding

(1) You must obey all of the relevant care and safety procedures.

G9-2

G-09-03 Issue 01

G9-2

Section G9 - Brakes Servo Unit, Twin Axle Brakes Removal and Replacement

Removal and Replacement Removal

â&#x20AC;&#x201C; Check the brake Topics ( T G9-2)

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T G9-2)

â&#x20AC;&#x201C; Bleed the brake Topics ( T G9-2)

Disconnect servo vacuum hose A.

Fig 1.

fluid

level.

system.

K Related K Related

A311830-1-C1.eps

Disconnect and blank off master cylinder hose B. Plug the cylinder port.

Disconnect cylinder output hose C. Blank off the hose and plug the cylinder port.

Disconnect servo breather hose D.

Remove the three securing nuts E and lift the servo unit complete with the rear mounting bracket F, from it's front mounting bracket.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

G9-3

G-09-03 Issue 01

G9-3

Section G9 - Brakes Servo Unit, Twin Axle Brakes Removal and Replacement

Page left intentionally blank

G9-4

G-09-03 Issue 01

G9-4

Section G10 - Brakes

Master Cylinder Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G10-2) K Removal and Replacement ( T G10-3)

G10-1

G-10-02 Issue 02

G10-1

Section G10 - Brakes Master Cylinder Related Topics

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Routine Maintenance

Checking the Foot Brake Fluid Level

Service Brake SYSTEM

Bleeding Brake Light Switch

(1) You must obey all of the relevant care and safety procedures.

G10-2

G-10-02 Issue 02

G10-2

Section G10 - Brakes Master Cylinder Removal and Replacement

Removal and Replacement 1

Vent the hydraulic pressure, see Section 2 - General procedures. K Related Topics ( T G10-2)

On machines with Power Brake Systems vent the brake system pressure, see Section 2 - General procedures. K Related Topics ( T G10-2)

Remove the retaining clip 1.

Remove clevis pin 2 to disconnect the master cylinder operating rod 4 from the brake pedal lever bracket 3.

Get access to the master cylinder hydraulic connections which are located behind the cab front cover 8.

Disconnect plastic feed pipe 9 from the brake fluid reservoir and either blank off the pipe or drain the reservoir.

Disconnect the master cylinder output hose (or pipe, as applicable) 10. Plug the cylinder port and blank off the hose (or pipe) to prevent ingress of dirt.

4 5

C130180-C1.eps

Fig 1. Single Axle Braking System - Master Cylinder

3 1 2 4

8 C130180.eps

Fig 2. Twin Axle Braking System - Master Cylinder

Removal

Note: The master cylinder is not serviceable and must be renewed if faulty.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels.

Fig 3.

C118800-C2.eps

BRAK-1-4

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures. K Related Topics ( T G10-2)

Note: Machines with Twin Axle service brakes have 3 master cylinder securing bolts and machines with Single Axle service brakes have 2 securing bolts. 9

G10-3

G-10-02 Issue 02

Support the master cylinder 7.

G10-3

Section G10 - Brakes Master Cylinder Removal and Replacement 10

Remove nuts 5 and bolts 6 and remove master cylinder 7 from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Once the master cylinder is installed and the pipework connected check the brake fluid reservoir (see Section 3 - Checking the Brake Fluid Level) and then bleed the brake system. K Related Topics ( T G10-2). â&#x20AC;&#x201C; Check the operation of the brake light switch. Adjust if necessary. K Related Topics ( T G10-2)

G10-4

G-10-02 Issue 02

G10-4

Section H Steering Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813-1800-2

Section K - Engine

Notes:

K-0

9813-1800-2

K-0

Section H - Steering Contents Page No. Applications Table ....................................................................................................... H0-1 Steering SYSTEM Introduction ............................................................................................. H1-1 Related Topics ........................................................................................ H1-2 Specifications ......................................................................................... H1-3 Component Location .............................................................................. H1-5 Operation Overview ................................................................................ H1-6 Hydraulic Operation and Schematics ..................................................... H1-8 Fault Finding ......................................................................................... H1-13 Test Procedures .................................................................................... H1-19 Re-phasing the Road Wheels ............................................................... H1-25 Bleeding the System ............................................................................. H1-26 Proximity Switch - Setting ..................................................................... H1-28 Hydraulic Steering Unit H-02-07 Introduction ............................................................................................. H2-1 Related Topics ........................................................................................ H2-2 Hydraulic Operation and Schematics ..................................................... H2-3 Removal and Replacement (S1) ............................................................ H2-5 Removal and Replacement (S2) ............................................................ H2-7 Removal and Replacement (S3) ............................................................ H2-9 Removal and Replacement (S4) .......................................................... H2-11 Priority Valve Introduction ............................................................................................. H3-1 Related Topics ........................................................................................ H3-2 Removal and Replacement .................................................................... H3-3 Manual Steer Mode SYSTEM Introduction ............................................................................................. H4-1 Related Topics ........................................................................................ H4-2 Component Location .............................................................................. H4-3 Operation Overview ................................................................................ H4-4 Hydraulic Operation and Schematics ..................................................... H4-5 Electrical Operation and Schematics - Indicated System (if fitted) ....... H4-11 Fault Finding ......................................................................................... H4-13 Test Procedures .................................................................................... H4-14 Manual Steer Mode Valve Introduction ............................................................................................. Related Topics ........................................................................................ Removal and Replacement (P1) ............................................................ Removal and Replacement (P2) ............................................................ Dismantle and Assemble ........................................................................

H5-1 H5-2 H5-3 H5-5 H5-7

Steer Rams Introduction ............................................................................................. Related Topics ........................................................................................ Removal and Replacement .................................................................... Dismantle and Assemble ........................................................................

H6-1 H6-2 H6-3 H6-4

Steering Column Introduction ............................................................................................. H7-1

H-i

Section H - Steering Contents Page No. Related Topics ........................................................................................ H7-2 Removal and Replacement .................................................................... H7-3

H-ii

Section H0 - Steering Applications Table

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref Title

Steering SYSTEM

Hydraulic Steering Unit

Priority Valve

Manual Steer Mode SYSTEM

Manual Steer Mode Valve

Steer Rams

Steering Column

H0-1

VARIANT

9813/1800-2 (AH-00-08)

506-36 5CD 507-42 5CE 510-56 5CG 509-42 5CF 512-56 5CH 514-56 5CJ

z z z

z z z z

H0-1

Section H0 - Steering Applications Table

Page left intentionally blank

H0-2

9813/1800-2 (AH-00-08)

H0-2

Section H1 - Steering

Steering SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T H1-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T H1-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H1-2) K Specifications ( T H1-3) K Steering Pump ( T H1-4) K Hydraulic Steering Unit ( T H1-3) K Priority Valve ( T H1-4) K Component Location ( T H1-5) K Operation Overview ( T H1-6) K Hydraulic Operation and Schematics ( T H1-8) K Gearpump Machines ( T H1-8) K Variflow Machines ( T H1-12) K Fault Finding ( T H1-13) K Tables ( T H1-13) K Diagnostic `Blink' Codes ( T H1-18) K Test Procedures ( T H1-19) K Checking for Internal Hydraulic Leakage ( T H1-19) K Hydraulic Pressure Tests ( T H1-23) K Auto Steer Mode Valve (if fitted) - Checking Solenoid Operation ( T H1-24) K Re-phasing the Road Wheels ( T H1-25) K Bleeding the System ( T H1-26) K Proximity Switch - Setting ( T H1-28)

H1-1

H-01-11 Issue 01

H1-1

Section H1 - Steering Steering SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Hydraulic System

Wheel Alignment

Applications

ALL

Systems and Schematics

Schematics

Main Pump

Specifications

Hydraulic Control Valve

Specifications

Main Pump

Pressure and Flow Tests - Steering Section

Wheels and Tyres

Tyres and Tyre pressures

Hydraulic Steering Unit

ALL

Priority Valve

ALL

Manual Steer Mode System

ALL

Auto Steer Mode System

ALL

Power Track Rod

ALL

Steering Column

ALL

Steer Proximity Switches

Adjustment

Loadall Monitoring System

ALL

Fault Code System

ALL

Steer Mode Devices

ALL

ALL ALL

(1)

Checking the Hydraulic Fluid Level

Description

892/01268(1)

Digital Pressure Gauge

892/01271(1)

Hose for Pressure Gauge

892/00253

Hydraulic Pressure Test Kit and Relevant Adaptors

(1)

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

H1-2

H-01-11 Issue 01

H1-2

H1-3

195 - 200 bar (199 - 204 kgf/ cm2, 2830 2900 lbf/in2)

250 bar (254 kgf/cm2, 3626 lbf/in2)

Relief Valve Operating Pressure (at 1500 revs/min)

Shock Valve Operating Pressure - if fitted

160 cc/rev

Volumetric Displacement Gerotor 1:

Volumetric Displacement Gerotor 2:

Rexroth Bosch LAGC 160

531-70, 535-95, 536-60, 541-70, 533-105, 53670, 526-56

Machines

Model

Hydraulic Steer Unit

Steer unit with load sensing, complete with integral relief valve and shock valves.

Hydraulic Steering Unit

H-01-11 Issue 01

235 bar (239 kgf/cm2, 3408 lbf/in2)

175 bar (178.4 kgf/cm2, 2538 lbf/in2)

160 cc/rev

Eaton 160cc

235 - 242 bar (239 - 247 kgf/ cm2, 3408 3509 lbf/in2)

175 - 182 bar (178 - 185 kgf/ cm2, 2538 2640 lbf/in2)

285 cc/rev

125 cc/rev

Eaton SXB

531-70, 535-95, 550-80 536-60, 541-70, 533-105, 53670, 526-56

255 bar (260 kgf/cm2, 3700 lbf/in2)

195 - 200 bar (199 - 204 kgf/ cm2, 2830 2900 lbf/in2)

95 cc/rev (2 : 1 ratio)

TBA

250 bar (254 kgf/cm2, 3626 lbf/in2)

190 bar (193 kgf/cm2, 2755 lbf/in2)

160 cc/rev

Eaton 4037424-78

506-36, 507-42, 535-125 HiViz, 509-42, 510-56, 535-140 HiViz 512-56, 514-56

Table 3. Hydraulic Steer Unit

Specifications

250 bar (254 kgf/cm2, 3626 lbf/in2)

190 bar (193 kgf/cm2, 2755 lbf/in2)

200 cc/rev

Eaton 4017255-78

540-140

255 bar (260 kgf/cm2, 3700 lbf/in2)

195 bar (199 kgf/cm2, 2830 lbf/in2)

95 cc/rev

Eaton 2633341-002

540-170

Section H1 - Steering Steering SYSTEM Specifications

H1-3

Section H1 - Steering Steering SYSTEM Specifications

Steering Pump Type

Table 4. Steering Pump Gear pump/Variflow pump The steering pump specifications are part of the main hydraulic pump specifications. K Related Topics ( T H1-2)

Priority Valve Gearpump Machines Standby Pressure:

7 bar (7.1 kgf/cm2, 102 lbf/in2)

Variflow Pump Machines The priority valve is part of the main hydraulic control valve. Refer to the Control Valve Topics for specifications. K Related Topics ( T H1-2)

H1-4

H-01-11 Issue 01

H1-4

Section H1 - Steering Steering SYSTEM Component Location

Component Location Priority Valve

Electro Servo (Agri excluding Extra) Machines

Gearpump Machines

The priority valve is an integral part of the control valve block priority inlet section A. For more details refer to the hydraulic system topic. K Related Topics ( T H1-2)

The priority valve is mounted on the side of the gearpump

Fig 1.

A263820-C3

C089420

Fig 3.

Variflow Machines Electro Servo (Agri Xtra) Machines The priority valve is an integral part of the control valve block priority inlet section A. For more details refer to the hydraulic system topic. K Related Topics ( T H1-2)

Fig 2.

H1-5

C049170-C1

H-01-11 Issue 01

H1-5

Section H1 - Steering Steering SYSTEM Operation Overview

Operation Overview When the steering wheel is turned, a pressure signal (demand) is generated in the load sense line from the steer unit to the priority valve. The priority valve B then directs oil from the hydraulic pump A to the steer unit C, which in turn directs the flow to the steer rams F on the axles.

Illustrations: K Machine with Power Track Rods ( T H1-6) K Machine with Steer Rams ( T H1-7) The main components of the steering system are the priority valve B, load sensing steer unit C, steer mode control valve D (if fitted), and double acting steer rams F or power track rods E as applicable. The priority valve B is mounted: â&#x20AC;&#x201C; On Gearpump Machines - on the side of the gearpump.

When the steering lock is achieved, the pressure signal in the load sense line ceases. The priority valve then directs the oil from the hydraulic pump into the main hydraulic system for operation of the hydraulic services. The maximum steering system pressure is set by a relief valve housed inside the steer unit C.

â&#x20AC;&#x201C; On Variflow Machines - in the control valve.

Fig 4. Machine with Power Track Rods

H1-6

H-01-11 Issue 01

A311952-C2

H1-6

Section H1 - Steering Steering SYSTEM Operation Overview

Fig 5. Machine with Steer Rams

H1-7

H-01-11 Issue 01

A311951-1

H1-7

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics

Hydraulic Operation and Schematics For illustration purposes a typical hydraulic circuit is shown. For specific details of the circuit refer to the applicable hydraulic schematic in the Hydraulics Section. K Related Topics ( T H1-2)

Gearpump Machines

Machines with Steer Rams This diagram shows the complete steer circuit. For diagrams of the different steer modes refer to the steer mode system topic. K Related Topics ( T H1-2) Component Key: 1

Hydraulic Pump

Priority Valve

Steer Unit

Relief Valve

Non-return Valve

Steer Mode Control Valve

Steer Rams - Front Axle

Steer Rams - Rear Axle

Hydraulic Tank

Fig 6.

H1-8

H-01-11 Issue 01

C025380-C2

H1-8

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics Machines with Power Track Rods

This diagram shows the complete steer circuit. For diagrams of the different steer modes refer to the steer mode system topic. K Related Topics ( T H1-2) Component Key: 1

Hydraulic Pump

Priority Valve

Steer Unit

Steering System Relief Valve

Shock Valves

Steer Mode Control Valve

Power Track Rod - Front Axle

Power Track Rod - Rear Axle

Hydraulic Tank

Steering Pressure Test Point

Fig 7.

H1-9

H-01-11 Issue 01

C049350-C3

H1-9

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics Priority Valve Operation Neutral

Fig 8. Gearpump type valve shown

A308141-C3.eps

Note: The illustration is for the purpose of explanation only and is not necessarily an accurate pictorial representation of the valve. The priority valve supplies hydraulic oil to the steering circuit on demand. When the steering is not being operated, flow to the steering circuit is dead ended by the `closed centre' steering unit 2, and no pressure signal (demand) is generated in the load sense line LS. Pressure from the pump outlet at A is directed through orifice B and orifice D, onto the end of the priority valve spool C. This creates a large pressure difference across the spool, causing it to move up against the force of the spring. This allows the full pump flow to be directed through port EF back to tank or joins with the main flow to the control valve. See Section E- Hydraulic Schematics. K Related Topics ( T H1-2)

H1-10

H-01-11 Issue 01

H1-10

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics Turning

Fig 9. Gearpump type valve shown

A313610-C3.eps

When the steering wheel is turned, a pressure signal (demand) is generated in the load sense line LS from the steering unit 2. Pressure is then applied to the spring end of the priority valve spool C. This reduces the pressure difference across the spool, causing it to move down under spring force. This allows some of the pump outlet flow at A to be directed through port P to the steering unit 2, which in turn directs the flow to the corresponding steer rams to turn the wheels. The excess flow goes through port EF back to tank or joins with the main flow to the control valve. See Section EHydraulic Schematics. K Related Topics ( T H1-2) When the steering reaches the required position, the pressure signal in the load sense line LS from the steering unit ceases, restoring the pressure difference across the spool C. The spool moves back up, allowing the full pump flow to be directed through port EF back to tank or joins with the main flow to the control valve. The maximum steering system pressure is set by a relief valve housed inside the steering unit 2.

H1-11

H-01-11 Issue 01

H1-11

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics

Variflow Machines This diagram shows the complete steer circuit. For diagrams of the different steer modes refer to the steer mode system topic. K Related Topics ( T H1-2) Component Key: Hydraulic Pump

Control Valve Block - Priority Inlet Section

Priority Valve

Steer Unit(1)

Steering System Relief Valve

Shock Valves

Steer Mode Control Valve

Power Track Rod - Front Axle

Power Track Rod - Rear Axle

Hydraulic Tank

Pump Output Pressure Test Point

Load Sense Pressure Test Point M

DLS 0.8

(1) A dual gerotor unit is fitted to 550-80 machines. Refer to the applicable Hydraulic Steer Unit topic for details.

8 BAR

LIFT

X T

Fig 10.

H1-12

H-01-11 Issue 01

C089430

H1-12

Section H1 - Steering Steering SYSTEM Fault Finding

Fault Finding The purpose of this section is to help you trace faults to a faulty unit (valve, actuator, ram, solenoid, proximity switch, etc.). Once you have located the fault, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the steering section. To help identify circuits, switches, valves, rams etc. mentioned in the fault finding procedures, refer also to the electrical schematic diagrams in Section C- Electrical Schematics or the hydraulic schematic diagrams in Section E- Hydraulic Schematics as applicable. K Related Topics ( T H1-2) 1

Before you begin fault finding, read the Safety information at the beginning of this manual.

Make any relevant electrical checks before moving on to the hydraulics.

Make simple checks before say, stripping a major component.

Make sure that the hydraulic fluid is at correct working temperature (50 Â°C, 122 Â°F).

Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.

Replace any seals such as 'O' rings before reassembling hydraulic components.

H1-13

Tables Fault Descriptions: K Table 5. Steering wheel difficult to turn. ( T H1-14) K Table 6. Steering wheel turns on its own. ( T H1-14) K Table 7. Machine will not turn when the steering wheel turned. ( T H1-15) K Table 9. Steering fails to respond to selected mode (solenoid operated mode valve only) ( T H1-17) K Table 8. Steering `drifts' out of phase during operation. ( T H1-16)

H-01-11 Issue 01

H1-13

Section H1 - Steering Steering SYSTEM Fault Finding Possible Cause

Table 5. Steering wheel difficult to turn. Action

Tyres not inflated to correct pressure.

Inflate tyres to correct pressure.

Insufficient hydraulic fluid.

Check for leaks and top up the hydraulic tank as required. Refer to Section 3 - Hydraulics. K Related Topics ( T H1-2)

Leaks in the relevant hoses or component connections.

Check hoses and connections for leaks.

Air in the hydraulic system.

Bleed system - bleed the load sense line. K Bleeding the System ( T H1-26)

Low pump flow.

Check pump flow, if required service or replace pump. K Test Procedures ( T H1-19)

Steer relief valve set incorrectly.

Check pressure setting of steer unit relief valve, adjust as required. K Test Procedures ( T H1-19)

Worn or damaged parts in the steer control valve.

Remove and inspect.

Priority valve not operating correctly.

– Check if the priority valve is sticking (contamination) rectify as required. – Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.

Steer mode valve not operating correctly (if fitted)

– Check if spools sticking, rectify as required. Refer to the Steer Mode Valve topic. – Check if solenoids operating, replace solenoids as required. K Auto Steer Mode Valve (if fitted) Checking Solenoid Operation ( T H1-24)

Mechanical failure.

Possible Cause

Check for damaged axle components, such as rams, track rods, linkages, etc. Table 6. Steering wheel turns on its own. Action

Dirt in the steer control unit (causing sleeves to stick open) Clean and inspect unit. Refer to the Steer Unit topic. K Related Topics ( T H1-2) Steer control valve centring springs damaged, broken or missing.

Check steer unit. Refer to the Steer Unit topic. K Related Topics ( T H1-2)

Steer control valve - position of rotor to shaft slot incorrect.

Correct as required. Refer to the Steer Unit topic. K Related Topics ( T H1-2)

H1-14

H-01-11 Issue 01

H1-14

Section H1 - Steering Steering SYSTEM Fault Finding Possible Cause

Table 7. Machine will not turn when the steering wheel turned. Action

Insufficient hydraulic fluid.

Check for leaks and top up the hydraulic tank as required. Refer to Section 3 - Hydraulics. K Related Topics ( T H1-2)

Leaks in the relevant hoses or component connections.

Check hoses and connections for leaks.

Air in the hydraulic system.

Bleed system - bleed the load sense line. K Bleeding the System ( T H1-26)

Low pump flow.

Check pump flow, if required service or replace pump. K Test Procedures ( T H1-19)

Steer relief valve set incorrectly.

Check pressure setting of steer unit relief valve, adjust as required. K Test Procedures ( T H1-19)

Worn or damaged parts in the steer control valve.

Remove and inspect.

Priority valve not operating correctly.

– Check if the priority valve is sticking (contamination) rectify as required. K Steer Priority Valve Cleaning ( T H1-22) – Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.

Steer mode valve not operating correctly (if fitted)

– Check if spools sticking, rectify as required. K Machines with Manual Steer Mode Valve (Option) ( T H1-27) – Check if solenoids operating, replace solenoids as required. K Auto Steer Mode Valve (if fitted) Checking Solenoid Operation ( T H1-24)

Mechanical failure.

Check for damaged axle components, such as rams, track rods, linkages, etc.

Steer column splined shaft not fully engaged in steer valve. Check shaft engagement. Refer to the Steer Unit topic. K Related Topics ( T H1-2) Power track rod/Steer Ram failure.

H1-15

Check power track rod/Steer Ram for signs of damage, leaks etc. Refer to the Power Track Rod/Steer Ram topic. K Related Topics ( T H1-2)

H-01-11 Issue 01

H1-15

Section H1 - Steering Steering SYSTEM Fault Finding Action

Table 8. Steering `drifts' out of phase during operation. Yes

Does steering go out of phase in less than four hours of continuous use?

Does steering go out of phase by a small amount and drift Go to 3 no further when changing steer modes?

Go to 4

Ensure operator changes steer mode at low engine speed Done and observes 5 second delay between modes (see Operator's Handbook), OK now?

Ensure power track-rod piston is centralised and wheel tracking is correct. Adjust alignment of steer proximity switches to optimise accuracy.

Bleed steering system to remove air. OK now? K Bleeding the System ( T H1-26)

Done

Go to 5

Possible leakage through anti-cavitation valve (if fitted). Replace Steer Unit. Refer to Steer Unit topic. K Related Topics ( T H1-2)

Done

Go to 6

Check both front and rear power track rods for internal Done leakage. K Checking for Internal Hydraulic Leakage ( T H1-19) Check the seal installation is correct, check the seal damage, scoring or bore ovality. Re-seal or renew faulty unit(s). OK now?

Go to 7

Strip steer mode valve and inspect spool for scoring or damage. Renew valve if required. OK now? Refer to the Steer Valve Manual/Auto topic. K Related Topics ( T H1-2)

Done

Go to 8

Check for contamination in the hydraulic system.

Filter the hydraulic system. It is likely that one of the Refer to Section 3 preceeding tests was not Hydraulics. K Related conclusive. Go to 1. Topics ( T H1-2)

H1-16

Go to 2.

H-01-11 Issue 01

Ensure system is rephased after four hours of continuous use (see Operator's Handbook).

H1-16

Section H1 - Steering Steering SYSTEM Fault Finding Table 9. Steering fails to respond to selected mode (solenoid operated mode valve only) Possible Cause Action Electrical failure.

Check relevant electrical connectors, if problem still persists, do a wiring continuity check on relevant circuits.

Note: The steer mode ECU will generate a blink code for some fault conditions, K Diagnostic `Blink' Codes ( T H1-18) Selector switch faulty.

Check selector switch, replace as required.

Proximity switches not operating correctly.

Check operation of proximity switches, adjust or replace switches as required. K Proximity Switch Setting ( T H1-28)

Steer mode relay not operating correctly

Renew relay. Refer to the Section 3 - Fuses and Relays topic. K Related Topics ( T H1-2)

Steer mode valve not operating correctly.

â&#x20AC;&#x201C; Check if spools sticking, rectify as required. Refer to the Steer Valve Manual/Auto topic. K Related Topics ( T H1-2) â&#x20AC;&#x201C; Check if solenoids operating in accordance with mode selected. K Auto Steer Mode Valve (if fitted) Checking Solenoid Operation ( T H1-24)

Leaks in the relevant hoses or component connections.

Check hoses and connections for leaks.

ECU failure.

The ECU is normally a reliable component and failure is unlikely. Before renewing the ECU make sure that all relevant electrical connections and components are functioning correctly(1).

(1) Do not connect a test meter directly to the pins on the ECU.

H1-17

H-01-11 Issue 01

H1-17

Section H1 - Steering Steering SYSTEM Fault Finding

Diagnostic `Blink' Codes

Note: Machines with an electronic instruments system will log an error code, see Section M - Loadall Monitoring SYSTEM. K Related Topics ( T H1-2)

Machines with SD/SE/SF engines Auto Steer Mode machines are fitted with a solenoid actuated steer mode valve incorporate an electronic control unit (ECU). The ECU has the facility to detect faults with the valve electrical system. These faults are indicated using the 2WS indicator light A in the instrument panel. The blink code sequence consists of the light being switched ON for approximately one second followed by a number of flashes (the code). The sequence is repeated until the fault is cleared.

Machines with SH/SL/DH Engines The steer mode system is controlled by the Hydraulic Control ECU. Any faults will be displayed as codes on the right hand cluster. Refer to Section M - Fault Code System. K Related Topics ( T H1-2)

A C044330-C5.eps

Fig 11. Blink Code Cause

Action

1 flash

`C' solenoid coil or circuit fault (open or short circuit).

Check coil and related harness wires and connectors. See Electrical Connections.

2 flashes

`D' solenoid coil or circuit fault (open or short circuit).

Check coil and related harness wires and connectors. See Electrical Connections.

3 flashes

Relay / diode or circuit fault (open or short circuit).

Check related relay and related harness wires and connectors. See Electrical Connections.

H1-18

H-01-11 Issue 01

H1-18

Section H1 - Steering Steering SYSTEM Test Procedures

Test Procedures Checking for Internal Hydraulic Leakage If hydraulic leaks occur at the steer mode valve or power track rods the steering system will go progressively out of phase, the more the steering is operated the further the front and rear wheels will `drift' out of phase.

bore. Dismantle and inspect the power track rod. K Related Topics ( T H1-2) If the track rod has not moved it can be assumed there is internal leakage at the steer mode valve.

Note: Some drifting out of phase is normal over time and the system must be routinely re-phased. K Re-phasing the Road Wheels ( T H1-25). If the system goes out of phase over short periods of time it is probable that there is hydraulic leakage. External leakage is obvious and may occur at track rod seals, relevant hoses, pipes and adaptors. Internal leakage can occur across power track rod piston seals or within the steer mode valve. When identifying internal leakage proceed as follows; For 4WS mode faults both front and rear track rods and the steer mode valve must be investigated individually for possible leakage. For 2WS mode faults it is possible to identify if internal leakage is at the rear power track rod, or steer mode valve without first removing and dismantling components. Proceed as follows: 1

Stop the engine and remove the starter key. Disconnect the hydraulic hoses A at the rear power track rod. Fit an isolating ball valve B at each port on the track rod and then reconnect the hoses.

Open the ball valves. Start the engine and bleed the system. K Bleeding the System ( T H1-26)

Set the machine in 2-wheel steer mode and then close the ball valves B. Measure the length of one side of the track rod C and record the value.

Drive the machine, in a circle, in one direction, several times. Stop the machine and re-measure the track rod length. Compare the measurements.

Fig 12. Typical Power Track Rod

714810-C3.jpg

If the track rod has moved then it can be assumed that there is internal leakage across the piston seals in the power track rod. This may be due to defective or incorrectly installed seals, or a defective cylinder

H1-19

H-01-11 Issue 01

H1-19

Section H1 - Steering Steering SYSTEM Test Procedures

Gearpump Machines

Refer to the Priority Valve topic. K Related Topics ( T H1-2)

Hydraulic Pressure Tests Standby Pressure 1

Park the machine and make it safe. Obey the care and safety procedures. Vent the Hydraulic pressure. Refer to Section 2 - General Procedures. K Related Topics ( T H1-2)

Turn the steering wheel to the left and to the right several times to vent system pressure.

Fig 13. Typical Pump

A313800-2.jpg

GEN-4-1_1

Disconnect hose D and install a 0 - 70 bar (0 - 1000 lbf/in2) pressure test gauge (892/01268) into the valve port. Position the open end of hose D into a clean container in order to collect any oil drainage.

Disconnect hose A from load sensing port adaptor B and blank off hose A. Do not cap the load sensing port adaptor B.

Set the steering to neutral, i.e. do not turn the steering wheel, and start the engine. Gradually increase the engine speed to 1000 rpm while checking the maximum pressure gauge reading which should be 5.9 to 8.7 bar (86 to 126 lbf/in2). If the pressure is outside the limits try cleaning the Priority Valve priority valve. K Steer Cleaning ( T H1-22) If cleaning the valve does not rectify, check the steering pump section flow rate and pressure, see Section E Hydraulics. K Related Topics ( T H1-2) If the hydraulic pump flow and pressure tests are satisfactory, then the priority valve must be renewed.

H1-20

H-01-11 Issue 01

H1-20

Section H1 - Steering Steering SYSTEM Test Procedures Steering Pressure

Park the machine and make it safe. Obey the care and safety procedures. Vent the Hydraulic pressure. Refer to Section 2 - General Procedures. K Related Topics ( T H1-2)

Turn the steering wheel to the left and to the right several times to vent system pressure.

Using an allen key, adjust the valve screw D until the correct pressure is shown on the gauge.

Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure gauge (part no. 892/00279) to test point A located on the priority valve B.

Fig 15.

C119040.jpg

Note: The pressure adjusting screw D can be accessed through a cut-out at the base of the steering column after first removing the panels. It may be necessary to remove the hydraulic steer unit if access is restricted. 7

Fig 14.

A326070-C2

Run the engine at 1500 rpm and turn the steering wheel to full lock. Hold the wheel on full lock and check the gauge reading. This should be equal to the relief valve operating pressure. K Specifications ( T H1-3)

If necessary, adjust the pressure setting by removing plug C on the hydraulic steer unit.

H1-21

Refit the plug C.

H-01-11 Issue 01

H1-21

Section H1 - Steering Steering SYSTEM Test Procedures Steer Priority Valve - Cleaning The priority valve spool and spring may be removed for cleaning with the pump in-situ. 1

Park the machine and make it safe. Obey the care and safety procedures. Vent the Hydraulic pressure. Refer to Section 2 - General Procedures. K Related Topics ( T H1-2)

Turn the steering wheel to the left and to the right several times to vent system pressure.

!MWARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. Fig 16. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Disconnect hose A from the load sensing port. Blank off the hose to prevent loss of fluid.

Unscrew adaptor B and extract the priority valve spring. Remove the blanking plug C and extract the priority valve spool. Take care not to damage the bore of the valve.

Clean these components paying particular attention to the orifices at each end of the spool. Dry off and lubricate with clean hydraulic fluid.

Refit the priority valve spool making sure that the spring seat end of the spool faces towards the LS port. Refit blanking plug C and torque tighten.

Refit the priority valve spring and adaptor B and torque tighten.

Reconnect the hose to the load sensing port, and bleed the load sense line as described below:

A313800-2.jpg

Item

Table 10. Torque settings Nm Kgf m

100 - 105

10.2 - 10.7

74 - 77

75 - 81

7.6 - 8.3

55 - 60

lbf ft

Start the engine, loosen the connection on the valve, then turn and hold the steering wheel fully in either direction. When bubble free oil seeps from the joint, tighten the connection.

H1-22

H-01-11 Issue 01

H1-22

Section H1 - Steering Steering SYSTEM Test Procedures

Variflow Machines Hydraulic Pressure Tests Standby and Steering Pressure The steer circuit pressure is integrated with operation of the variflow pump and the main hydraulic system pressures. See Section E - Hydraulics. K Related Topics ( T H1-2)

H1-23

H-01-11 Issue 01

H1-23

Section H1 - Steering Steering SYSTEM Test Procedures

Auto Steer Mode Valve (if fitted) Checking Solenoid Operation Note: Machines may be fitted with different types of steer mode solenoid valve. The solenoids operate according to the steer mode that is selected. Mode:

Solenoid(s) Energised:

2 Wheel Steer

4 Wheel Steer

B, C

Crab Steer

B, D

Operation (energisation) of a solenoid can be easily detected by placing a steel object (e.g. screwdriver blade) close to the outer casing. A magnetic attraction of the steel object towards the solenoid indicates energisation.

Fig 17. Steer Mode Solenoid Valve

C044170-C3.jpg

If a solenoid is not energising carry out the following checks: 1

Check the fuse is intact. If not, renew and then check that all steer mode solenoid combinations function correctly.

If the fuse is intact remove the electrical connector from the malfunctioning solenoid(s) and check that the 12V supply is present across the connector pins. If not, check the supply circuit.

Check the solenoid coil resistance which should measure a few ohms (if unsure of the value compare with a known good solenoid). Renew the solenoid if the reading indicates a short circuit (zero ohms) or open circuit (infinite resistance). If a reading somewhere between the two is obtained, reverse the two instrument probes and repeat for a valid check.

Note: The electrical connectors at the steer mode valve solenoids are identical. Before uncoupling any of the connectors be sure to label them A, B, C or D as applicable. If is suspected that the connectors have been fitted to the wrong solenoids see the electrical connection data for wire number identification. Refer to the Auto Steer Mode SYSTEM topic for electrical connectors. K Related Topics ( T H1-2)

H1-24

H-01-11 Issue 01

H1-24

Section H1 - Steering Steering SYSTEM Re-phasing the Road Wheels

Re-phasing the Road Wheels The re- phasing procedure is given in the routine maintenance section. Refer to Section 3 - Routine Maintenance. K Related Topics ( T H1-2)

H1-25

H-01-11 Issue 01

H1-25

Section H1 - Steering Steering SYSTEM Bleeding the System

Bleeding the System Machines with Auto Steer Mode Valve

Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows:

b Turn steering wheel to full left lock.

With the engine running, the following procedure must be carried out in the correct order that is laid down. You must not alter the order of selections and operations. 1

c 8

Turn steering wheel to full right lock.

Select 4 Wheel Steer. a

Turn steering wheel to left, until the front and rear wheels are fully locked.

Select 2 Wheel Steer. a

Turn steering wheel to left, until front wheels are fully locked to the left.

b Turn steering wheel to right, until front wheels are fully locked to the right. 2

Select 4 Wheel Steer. a

Turn steering wheel to left, until front wheels are fully locked to the left.

Select 2 Wheel Steer. a

Turn steering wheel to full right lock.

b Turn steering wheel to full left lock. c 4

Select 4 Wheel Steer. a

Turn steering wheel to full right lock.

Turn steering wheel to left, until the front wheels are fully locked to the left.

Select 2 Wheel Steer. a

Turn steering wheel to full right lock.

b Turn steering wheel to full left lock. c 6

Select 4 Wheel Steer. a

Turn steering wheel to full right lock.

Turn steering wheel to left, until front wheels are fully locked to the left.

Select 2 Wheel Steer.

H1-26

H-01-11 Issue 01

H1-26

Section H1 - Steering Steering SYSTEM Bleeding the System

Machines with Manual Steer Mode Valve (Option)

b Turn steering wheel to full left lock.

Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows: This procedure must be carried out in the correct order that is laid down. You must not alter the order of selections and operations. 1

Start the Engine.

Select 2 Wheel Steer. a

Turn steering wheel to full right lock.

d Turn steering wheel to left until front wheels are in the straight ahead position. 9

b Turn steering wheel to right until front wheels are in the straight ahead position. 4

Turn steering wheel to full right lock.

b Turn steering wheel to full left lock.

Turn steering wheel to left until front wheels are in the straight ahead position.

Turn steering wheel to left, until front wheels are fully locked to the left.

Select 2 Wheel Steer. a

Select 4 Wheel Steer. a

Select 4 Wheel Steer.

b Turn steering wheel to right until front wheels are in the straight ahead position.

b Turn steering wheel to right, until front wheels are fully locked to the right. c

Turn steering wheel to full right lock.

d Turn steering wheel to left until front wheels are in the straight ahead position.

Turn steering wheel to left, until front wheels are fully locked to the left.

Turn steering wheel to full right lock.

Select 4 Wheel Steer. Turn steering wheel to left, until the front and rear wheels are fully locked.

Turn steering wheel to full right lock.

Stop the engine and top up the hydraulic tank as required.

b Turn steering wheel to full left lock. c

Turn steering wheel to full right lock.

d Turn steering wheel to left until front wheels are in the straight ahead position. 5

Select 4 Wheel Steer. a

Turn steering wheel to left, until the front wheels are fully locked to the left.

b Turn steering wheel to right until front wheels are in the straight ahead position. 6

Select 2 Wheel Steer.

H1-27

H-01-11 Issue 01

H1-27

Section H1 - Steering Steering SYSTEM Proximity Switch - Setting

Proximity Switch - Setting Note: These are fitted to machines with Auto Steer Mode System or Manual (Indicated) Steer Mode System. Refer to Section H - Steer Proximity Switches (if fitted) K Related Topics ( T H1-2)

H1-28

H-01-11 Issue 01

H1-28

Section H2 - Steering Hydraulic Steering Unit H-02-07 Introduction

Hydraulic Steering Unit H-02-07 Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H2-2) K Hydraulic Operation and Schematics ( T H2-3) K Removal and Replacement (S1) ( T H2-5)(1) K Removal and Replacement (S2) ( T H2-7)(1) K Removal and Replacement (S3) ( T H2-9)(1) K Removal and Replacement (S4) ( T H2-11)(1) (1) Specification variant. Make sure you refer to the correct specification.

Procedures, Specifications(1)

Table 1. Procedure and Specification Variants Machine Model Application 531-70, 535-95, 506-36, 507-42, 540-170, 550526-56, 527-58 536-60, 541-70, 509-42, 510-56, 170, 540-140, 533-105, 536512-56, 514-56 550-140, 53570 125 HiViz, 535140 HiViz, 540200

K Removal and Replacement (S1) ( T H2-5)

z z

K Removal and Replacement (S2) ( T H2-7)

K Removal and Replacement (S3) ( T H2-9)

K Removal and Replacement (S4) ( T H2-11)

(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

H2-1

H-02-07 Issue 01

H2-1

Section H2 - Steering Hydraulic Steering Unit H-02-07 Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Hydraulic System

Checking the Hydraulic Fluid Level

Steering System

Bleeding The System

Steering System

Test Procedures

Description

60057(1)

Spring Installation Tool

(1) Eaton Hydraulics Part Number

H2-2

H-02-07 Issue 01

H2-2

Section H2 - Steering Hydraulic Steering Unit H-02-07 Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Item

K Fig 1. ( T H2-4)

Hydraulic Steering Unit

Shock Valves (if fitted)

Check Valve

Left Feed/Return Port

Right Feed/Return Port

Valve inlet

Return Line

Steer Valve

Load Sense Port

Steering System Relief Valve

H2-3

H-02-07 Issue 01

H2-3

Section H2 - Steering Hydraulic Steering Unit H-02-07 Hydraulic Operation and Schematics

C D

K E

Fig 1.

H2-4

H-02-07 Issue 01

C066920-C2

H2-4

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S1)

Removal and Replacement (S1)

A268450-1

Fig 2.

Removal

Replacement

Park the machine and make it safe. Obey the care and safety procedures. Vent the Hydraulic Pressure. Refer to Section 2 - Care and Safety. K Related Topics ( T H2-2) Turn the steering wheel to the left and to the right several times to vent system pressure. Ensure that the steering wheel is in the straight ahead position. Gain access to the steer unit. Remove the front panel 1 from the cab.

Withdraw steering unit A.

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Torque tighten fixing bolts C. K Table 4. Torque Settings ( T H2-6). – Make sure that the hoses are refitted in the correct positions. – If the hydraulic adaptors have been removed make sure to torque tighten. K Fig 4. ( T H2-6) K Torque Settings ( T H2-6) Note: The steering unit is spring loaded to the neutral position (i.e. straight ahead). Make sure the steering wheel is in the straight ahead position when re-connecting splined shaft B. – Before driving the machine, bleed the steering system. Refer to the Steering System topic. K Related Topics ( T H2-2)

1 Fig 3. 4

C082290-C1

Disconnect the hydraulic hoses to steering unit A, labelling them to aid reconnection. Cap the open hoses and ports to prevent contamination.

Mark the orientation of steering unit A to splined shaft B.

Remove bolts C (4 off) from inside the cab. At the same time have an assistant support steering unit A beneath the machine.

H2-5

– If a new steering unit has been fitted then the system relief valve must be tested for correct pressure setting. Refer to the Steering System topic. K Related Topics ( T H2-2) – Check the hydraulic fluid level. Refer to Section 3 Hydraulic System. K Related Topics ( T H2-2)

H-02-07 Issue 01

H2-5

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S1)

E D D

D C106200-C1

Fig 4.

Item

Table 4. Torque Settings Nm kgf m

lbf ft

4.6

4.9

35.5

1.4

10.3

H2-6

H-02-07 Issue 01

H2-6

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S2)

Removal and Replacement (S2) E

D D

A C082250

Fig 5.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Vent the Hydraulic Pressure.Refer to Section 2 - Care and Safety. K Related Topics ( T H2-2)

Turn the steering wheel to the left and to the right several times to vent system pressure. Ensure that the steering wheel is in the straight ahead position.

Gain access to the steer unit. Remove the front panel 1 from the cab.

Label and disconnect the hydraulic hoses D and E at steering unit A. Plug the ports and hoses to prevent the ingress of dirt and excessive loss of hydraulic oil.

Note: On 510-56, 512-56 and 514-56 machines hoses D have 90Â° end fittings. 5

Mark the orientation of steering unit A to splined shaft B.

Remove bolts C (4 off) from inside the cab. At the same time have an assistant support steering unit A beneath the machine.

Withdraw steering unit A.

1 Fig 6.

H2-7

C082290-C1

H-02-07 Issue 01

H2-7

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S2)

Replacement

Replacement is the opposite of the removal procedure.

During the replacement procedure do this work also: – Torque tighten fixing Settings ( T H2-6).

bolts

K Torque

Make sure that the hoses are refitted in the correct positions. If the hydraulic adaptors have been removed make sure to torque tighten. K Fig 7. ( T H2-8), and K Torque Settings ( T H2-6) – Make sure that the hoses are refitted in the correct positions.

Note: The steering unit is spring loaded to the neutral position (i.e. straight ahead). Make sure the steering wheel is in the straight ahead position when re-connecting splined shaft B. – Before driving the machine, bleed the steering system. Refer to the Steering System topic. K Related Topics ( T H2-2)

Fig 7.

C106180-C2

Item

Table 5. Torque Settings Nm kgf m

lbf ft

4.6

2.2

16.2

7.8

56.7

H2-8

H-02-07 Issue 01

H2-8

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S3)

Removal and Replacement (S3)

A268450-1

Fig 8.

Removal 1

Remove bolts C (4 off) from inside the cab. At the same time have an assistant support steering unit A beneath the machine.

Withdraw steering unit A.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Gain access to the steer unit. Remove the front panel 1 from the cab.

– Torque tighten fixing Settings ( T H2-6).

bolts

K Torque

Make sure that the hoses are refitted in the correct positions. If the hydraulic adaptors have been removed make sure to torque tighten. K Fig 7. ( T H2-8), and K Fig 12. ( T H2-10) K Fig 11. ( T H2-10) K Torque Settings ( T H2-6)

1 C082290-C1

Note: The steering unit is spring loaded to the neutral position (i.e. straight ahead). Make sure the steering wheel is in the straight ahead position when re-connecting splined shaft B.

Disconnect the hydraulic hoses to steering unit A, labelling them to aid reconnection. Plug the ports and hoses to prevent the ingress of dirt and excessive loss of hydraulic oil.

– Before driving the machine, bleed the steering system. Refer to the Steering System topic. K Related Topics ( T H2-2)

Mark the orientation of steering unit A to splined shaft B.

Fig 9.

H2-9

H-02-07 Issue 01

H2-9

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S3)

G F

D F

F E

C106200

Fig 12. 535-125 HiViz and 535-140 HiViz Machines

Item Fig 10. 540-140 and 550-140 machines

C106180

Table 6. Torque Settings Nm kgf m

lbf ft

4.6

7.8

56.7

2.2

16.2

4.9

35.5

1.4

10.3

D D

D C106190

Fig 11. 540-170, 550-170 and 540-200 machines

H2-10

H-02-07 Issue 01

H2-10

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S4)

Removal and Replacement (S4)

A268450-1

Fig 13.

Removal

Replacement

Withdraw steering unit A.

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Torque tighten fixing bolts C. K Table 4. Torque Settings ( T H2-6). – Make sure that the hoses are refitted in the correct positions. – If the hydraulic adaptors have been removed make sure to torque tighten. K Fig 15. ( T H2-12) K Torque Settings ( T H2-6) Note: The steering unit is spring loaded to the neutral position (i.e. straight ahead). Make sure the steering wheel is in the straight ahead position when re-connecting splined shaft B. – Before driving the machine, bleed the steering system. Refer to the Steering System topic. K Related Topics ( T H2-2)

1 Fig 14. 4

C082290-C1

Disconnect the hydraulic hoses to steering unit A, labelling them to aid reconnection. Cap the open hoses and ports to prevent contamination.

Mark the orientation of steering unit A to splined shaft B. Remove bolts C (4 off) from inside the cab. At the same time have an assistant support steering unit A beneath the machine.

H2-11

Item

Table 7. Torque Settings Nm kgf m

lbf ft

4.6

7.8

56.8

H-02-07 Issue 01

H2-11

Section H2 - Steering Hydraulic Steering Unit H-02-07 Removal and Replacement (S4) Item

kgf m

lbf ft

2.2

16.2

E D D

D Fig 15.

H2-12

C106210

H-02-07 Issue 01

H2-12

Section H3 - Steering

Priority Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H3-2) K Removal and Replacement ( T H3-3) K Gearpump Machines ( T H3-3) K 550-80 and Agri Machines (Excluding Xtra) ( T H3-4) K Agri Xtra Machines ( T H3-5)

H3-1

H-03-07 Issue 01

H3-1

Section H3 - Steering Priority Valve Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Hydraulic System

Checking the Hydraulic Fluid Level

Hydraulic Control Valve

ALL

Steering System

ALL

(1) You must obey all of the relevant care and safety procedures.

H3-2

H-03-07 Issue 01

H3-2

Section H3 - Steering Priority Valve Removal and Replacement

Removal and Replacement Gearpump Machines

– Lightly grease and fit new `O' rings between the mounting faces.

The priority valve assembly is not serviceable beyond the removal of foreign matter. For instructions on cleaning the valve refer to the Steering System topic. K Related Topics ( T H3-2)

– Torque tighten socket head screws D evenly and Torque Settings progressively. K Table 2. ( T H3-3).

A faulty unit must be replaced.

– Check the hydraulic fluid level. Refer to Section 3 Hydraulic System. K Related Topics ( T H3-2)

Removal 1

– Before driving the machine, bleed the steering system. Refer to the Steering System topic. K Related Topics ( T H3-2)

Park the machine and make it safe. Obey the care and safety procedures. Vent the Hydraulic Pressure. Refer to Section 2 - Care and Safety. K Related Topics ( T H3-2)

Turn the steering wheel to the left and to the right several times to vent system pressure. Ensure that the steering wheel is in the straight ahead position.

D A

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Disconnect hoses A, B and C. Blank off the hoses to prevent loss of fluid and ingress of dirt.

Remove the three socket head screws D and lift the priority valve assembly away from the pump.

Fig 1. Typical Pump

Item

Table 2. Torque Settings Nm kgf m

30 +/- 4

3 +/- 0.4

A313800-C3

lbf ft 22 +/- 3

Remove and discard all `O' ring seals between the mounting faces of the priority valve assembly and the pump.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

H3-3

H-03-07 Issue 01

H3-3

Section H3 - Steering Priority Valve Removal and Replacement

550-80 and Agri Machines (Excluding Xtra) The priority valve is part of the control valve block priority inlet section A. For dismantling and assembling procedures refer to the hydraulic valve block topic. K Related Topics ( T H3-2)

Fig 2.

H3-4

C089420

H-03-07 Issue 01

H3-4

Section H3 - Steering Priority Valve Removal and Replacement

Agri Xtra Machines The priority valve is part of the control valve block priority inlet section A. For dismantling and assembling procedures refer to the hydraulic valve block topic. K Related Topics ( T H3-2)

Fig 3.

H3-5

C049170

H-03-07 Issue 01

H3-5

Section H3 - Steering Priority Valve Removal and Replacement

Page left intentionally blank

H3-6

H-03-07 Issue 01

H3-6

Section H4 - Steering

Manual Steer Mode SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T H4-2). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T H4-2) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H4-2) K Component Location ( T H4-3) K Operation Overview ( T H4-4) K Hydraulic Operation and Schematics ( T H4-5) K Fault Finding ( T H4-13) K Test Procedures ( T H4-14)

H4-1

H-01-15 Issue 01

H4-1

Section H4 - Steering Manual Steer Mode SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Hydraulic System

Wheel Alignment

Main Pump

E F

ALL (1)

ALL Checking the Hydraulic Fluid Level Specifications Pressure and Flow Tests - Steering Section

Wheels and Tyres

Tyres and Tyre pressures

Hydraulic Steer Unit

ALL

Priority Valve

ALL

(1) You must obey all of the relevant care and safety procedures.

H4-2

H-01-15 Issue 01

H4-2

Section H4 - Steering Manual Steer Mode SYSTEM Component Location

Component Location Item

Key

Item

Steer Mode Selection Lever

Steer Mode Unit Cable

Steer Mode Selection Unit

Steer Mode Valve

Key

2 1

Fig 1.

H4-3

H-01-15 Issue 01

C084910-C1.eps

H4-3

Section H4 - Steering Manual Steer Mode SYSTEM Operation Overview

Operation Overview Three steering modes are available: – 2-Wheel Steer (front axle only) – 4-Wheel Steer – Crab Steer In 2-wheel steer mode only the front wheels are steered. In 4-wheel steer mode both axles are steered, giving a smaller turning circle. The crab steer mode allows the machine to be driven diagonally.

H4-4

H-01-15 Issue 01

H4-4

Section H4 - Steering Manual Steer Mode SYSTEM Hydraulic Operation and Schematics

Hydraulic Operation and Schematics Machines with Power Track Rods Operation - 2-Wheel Steer Selected F

K Fig 2. ( T H4-5). With the spool of steer mode control valve V in the 2-wheel steer position there is a hydraulic connection between the steer unit S and the front power track rod F. (Steer mode control valve ports T and P are internally connected). The oil feed to the rear axle power track rod R is blocked by the spool assembly and the axle is held in the straight ahead position by the locked-up hydraulic oil in the track rod ram. When the steering wheel is turned, only the front power track rod F is operated by the steering unit S. If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction.

Fig 2. Typical Machine - Right turn shown

H4-5

H-01-15 Issue 01

C093190

H4-5

Section H4 - Steering Manual Steer Mode SYSTEM Hydraulic Operation and Schematics Operation - 4-Wheel Steer Selected K Fig 3. ( T H4-6). With the spool of steer mode valve V in the 4-wheel steer position there is a hydraulic connection between the steer unit S and the front and rear axle power track rods F and R. (Steer mode control valve ports T and B are internally connected, also ports A and P). When the steering wheel is turned (right turn shown), oil is fed to the rear power track rod R and the displaced oil is fed to the front power track rod F via the valve spool. The front power track rod turns the wheels in the opposite direction to the rear wheels and displaced oil returns to tank. If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction.

Fig 3. Typical Machine - Right turn shown

H4-6

H-01-15 Issue 01

C093191

H4-6

Section H4 - Steering Manual Steer Mode SYSTEM Hydraulic Operation and Schematics Operation - Crab Steer Selected K Fig 4. ( T H4-7). With the spool of steer mode valve V in the crab steer position there is a hydraulic connection between the steer unit S and the front and rear axle power track rods F and R. (Steer mode valve ports T and A are internally connected, also ports B and P). When the steering wheel is turned (right turn shown), oil is fed to the rear power track rod R and the displaced oil is fed to the front power track rod F via the valve spool. The front power track rod turns the wheels in the same direction as the rear wheels, causing the machine to crab to the right. Displaced oil returns to tank. If the steering wheel is turned to the left, the oil flow is reversed and the machine will crab in the opposite direction.

Fig 4. Typical Machine - Right turn shown

H4-7

H-01-15 Issue 01

C093192

H4-7

Section H4 - Steering Manual Steer Mode SYSTEM Hydraulic Operation and Schematics

Machines with Steer Rams Operation - 2-Wheel Steer Selected With the spool of steer mode control valve D in the 2-wheel steer position there is a hydraulic connection between the steer unit C and the front steer rams F1, F2. (Steer mode control valve ports T and P are internally connected.) The oil feed to the rear axle steer rams F3, F4 is blocked by the spool assembly and the axle is held in the straight ahead position by the locked-up hydraulic oil in the rams. When the steering wheel is turned, only the front axle rams F1, F2 are operated by the steering unit C. If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction.

803740-0

Fig 5. Typical Machine Installation

H4-8

H-01-15 Issue 01

H4-8

Section H4 - Steering Manual Steer Mode SYSTEM Hydraulic Operation and Schematics Operation - 4-Wheel Steer Selected With the spool of steer mode valve D in the 4-wheel steer position there is a hydraulic connection between the steer unit C and the front and rear axle steer rams F1 to F4. (Steer mode control valve ports T and B are internally connected, also ports A and P.) When the steering wheel is turned (right turn shown), oil is fed to the rear rams F3, F4 and the displaced oil is fed to the front rams F1, F2 via the spool assembly. The front rams turn the wheels in the opposite direction to the rear wheels and displaced oil returns to tank. If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction.

803750-1

Fig 6. Typical Machine Installation

H4-9

H-01-15 Issue 01

H4-9

Section H4 - Steering Manual Steer Mode SYSTEM Hydraulic Operation and Schematics Operation - Crab Steer Selected With the spool of steer mode valve D in the crab steer position there is a hydraulic connection between the steer unit C and the front and rear axle steer rams F1 to F4. (Steer mode valve ports T and A are internally connected, also ports B and P.) When the steering wheel is turned (right turn shown), oil is fed to the rear rams F3, F4 and the displaced oil is fed to the front rams F1, F2 via the spool assembly. The front rams turn the wheels in the same direction as the rear wheels, causing the machine to crab to the right. Displaced oil returns to tank. If the steering wheel is turned to the left, the oil flow is reversed and the machine will crab in the opposite direction.

803730-1

Fig 7. Typical Machine Installation

H4-10

H-01-15 Issue 01

H4-10

Section H4 - Steering Manual Steer Mode SYSTEM Electrical Operation and Schematics - Indicated System (if fitted)

Electrical Operation and Schematics - Indicated System (if fitted) The schematic diagrams show an overview of the system. For machine specific schematics refer to Section C Schematics. K Related Topics ( T H4-2) Note: This topic refers to electrical systems and devices. For details refer to Section M-Applications. K Related Topics ( T H4-2) 526-56 machines have indicator lights F and R. When both the lights are ON the front and rear wheels are in the straight ahead position. The wheels must be set to the straight ahead position before changing the steer mode. If the indicator lights do not work correctly re-phase the road wheels before fault finding the electrical system. K Related Topics ( T H4-2) K Fig 8. ( T H4-12) A

Front axle proximity switch

Rear axle proximity switch

Wheel align indicator light relay

Drive Control ECU(1)

Indicator light unit

Indicator light - front wheels straight ahead

Fuse Box

Indicator light - rear wheels straight ahead

(1) For details of the Drive Control ECU - refer to Section F - Dual Control System. When the front and rear wheels are in the straight ahead position the axle proximity switches A and B connect power to the F and R indicator lights. When the transmission is set to neutral (N) the ECU D energises relay C. The relay connects the F and R lights to earth and the lights come ON.

H4-11

H-01-15 Issue 01

H4-11

Section H4 - Steering Manual Steer Mode SYSTEM Electrical Operation and Schematics - Indicated System (if fitted)

B REAR AXLE PROXIMITY SWITCH

A FRONT AXLE PROXIMITY SWITCH

E WHEEL ALIGN INDICATOR LIGHTS

WHEEL ALIGN INDICATOR LIGHTS RELAY

C ECU

D IGN

Fig 8.

H4-12

H-01-15 Issue 01

C118820

H4-12

Section H4 - Steering Manual Steer Mode SYSTEM Fault Finding

Fault Finding Refer to the Steering SYSTEM topic for fault finding information. K Related Topics ( T H4-2)

H4-13

H-01-15 Issue 01

H4-13

Section H4 - Steering Manual Steer Mode SYSTEM Test Procedures

Test Procedures Refer to the Steering SYSTEM topic for test procedures. K Related Topics ( T H4-2)

H4-14

H-01-15 Issue 01

H4-14

Section H5 - Steering Manual Steer Mode Valve Introduction

Manual Steer Mode Valve Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H5-2) K Removal and Replacement (P1) ( T H5-3)(1) K Removal and Replacement (P2) ( T H5-5)(1) K Dismantle and Assemble ( T H5-7) K Dismantle ( T H5-7) K Assemble ( T H5-8) (1) Specification variant. Make sure you refer to the correct specification.

Procedures, Specifications(1)

Table 1. Procedure and Specification Variants Machine Model Application All excluding 527-58

527-58

K Removal and Replacement (P1) ( T H5-3)

K Removal and Replacement (P2) ( T H5-5)

(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

H5-1

H-04-10 Issue 02

H5-1

Section H5 - Steering Manual Steer Mode Valve Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Hydraulic System

Checking the Hydraulic Fluid Level

Steering System

ALL

Manual Steer Mode System

ALL

(1) You must obey all of the relevant care and safety procedures.

H5-2

H-04-10 Issue 02

H5-2

Section H5 - Steering Manual Steer Mode Valve Removal and Replacement (P1)

Removal and Replacement (P1) Removal 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures. Vent the Hydraulic Pressure. Refer to Section 2 Care and Safety. K Related Topics ( T H5-2)

Turn the steering wheel to the left and to the right several times to vent system pressure. Ensure that the steering wheel is in the straight ahead position.

Remove the nuts and bolts 2 securing the steer mode valve 3 to the chassis.

Remove the steer mode selector control handle 4 (located inside the cab).

C118840-C1.eps

Fig 1.

C084910-C2.eps

Disconnect and cap the four hydraulic hoses from the steer mode valve. Label hoses for identification.

H5-3

H-04-10 Issue 02

Fig 2.

C118850-C1.eps

H5-3

Section H5 - Steering Manual Steer Mode Valve Removal and Replacement (P1)

8 3 C083250-C1.eps

Fig 3.

Note: Before removing the steer mode valve assembly from the machine, observe the routing of the operating cable. 6

Remove the nuts 5 securing the steer mode selector unit 6 to the cab.

The steer mode selector unit, operating cable and valve can now be removed from the machine as a complete assembly.

Note: Make sure to keep the two washers 8 to the rear of the valve block 3 which may fall out when screws 2 are removed. Note: Make sure to retain the spacer plate 1.

system.

K Related

– Make sure that the two washers 8 are fitted between the valve block 3, spacer 1 and the chassis sideplate 7. – Check the hydraulic Topics ( T H5-2)

H5-4

fluid

level.

K Related

H-04-10 Issue 02

H5-4

Section H5 - Steering Manual Steer Mode Valve Removal and Replacement (P2)

Removal and Replacement (P2) Removal 1

Park the machine and make it safe. Fit the boom safety strut. Obey the care and safety procedures K Related Topics ( T H5-2)

Remove the chassis undershield. Refer to Section 3 - Access Panels. K Related Topics ( T H5-2)

Put a label on the hydraulic hoses to aid replacement.

Disconnect and cap the four hydraulic hoses A from the steer mode valve B.

Remove the nuts and bolts C securing the steer mode valve B to the chassis.

Remove the steer mode selector control handle F (located inside the cab).

Fig 5.

C067610-C2

A B

C A

Fig 4.

H5-5

C094910-C5.eps

Fig 6.

H-04-10 Issue 02

C067540-C2

H5-5

Section H5 - Steering Manual Steer Mode Valve Removal and Replacement (P2) 7

Remove the nuts E securing the steer mode selector unit D to the cab. The steer mode selector unit, operating cable and valve can now be removed from the machine as a complete assembly.

Item

Table 3. Torque Settings Nm kgf m

lbf ft

2.4

17.7

4.9

35.5

2.7

Note: Before removing the steer mode valve assembly from the machine, observe the routing of the operating cable.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Make sure that the hoses are fitted in the correct position. – If the hydraulic adaptors G and H have been removed make sure to torque tighten. K Fig 7. ( T H5-6) K Table 3. Torque Settings ( T H5-6) – Torque tighten the securing bolts C and nuts. K Table 3. Torque Settings ( T H5-6) – Bleed the steering Topics ( T H5-2) – Check the hydraulic Topics ( T H5-2)

system. fluid

level.

K Related K Related

G Fig 7.

H5-6

C094910-C4.eps

H-04-10 Issue 02

H5-6

Section H5 - Steering Manual Steer Mode Valve Dismantle and Assemble

Dismantle and Assemble

805030-1

Fig 8.

Dismantle

Remove screws G from endcap H.

Remove the steer mode valve assembly from the machine. K Removal ( T H5-3)

Remove screws A from endcap B.

Undo locknut J. Rotating the locknut and endcap H counter-clockwise (so that the parts travel away from the valve) until they disengage the operating cable thread.

Undo locknut C. Rotating the locknut and endcap B counter-clockwise (so that the parts travel away from the valve) until they disengage the operating cable thread.

Disengage operating cable E from the steer mode selector K

Undo locknut D and disconnect operating cable E from valve adaptor F.

H5-7

H-04-10 Issue 02

H5-7

Section H5 - Steering Manual Steer Mode Valve Dismantle and Assemble

Assemble Assembly is the opposite of the Dismantling procedure. During the assembly procedure do this work also: â&#x20AC;&#x201C; Before connecting the operating cable to the valve, set locknut D as shown. K Fig 9. ( T H5-8) In this position the locknut can be used as a guide as to how far to wind the operating cable into valve adaptor F.

Fig 9.

805040-1

Apply JCB Threadlocker and Sealer to screws A and G.

H5-8

H-04-10 Issue 02

H5-8

Section H6 - Steering

Steer Rams Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H6-2) K Removal and Replacement ( T H6-3) K Removal ( T H6-3) K Replacement ( T H6-3) K Dismantle and Assemble ( T H6-4)

H6-1

H-05-03 Issue 01

H6-1

Section H6 - Steering Steer Rams Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Routine Maintenance

ALL

Ram Dismantle and Assemble

ALL

Steering System

ALL

(1) You must obey all of the relevant care and safety procedures.

H6-2

H-05-03 Issue 01

H6-2

Section H6 - Steering Steer Rams Removal and Replacement

Removal and Replacement

337510-C1

Fig 1.

Removal

Blank off the hoses and plug the ram ports to prevent loss of fluid and ingress of dirt.

Carry out the general safety procedures detailed under Section 2 - General Procedures. K Related Topics ( T H6-2)

!MWARNING

Remove screws B and pins C at each end of the ram and lift the ram clear.

Replacement

Before commencing work clean the area around the axle and steer ram. The following procedure applies to each of the steering rams on the front and rear axles: 1

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: Torque tighten the screws B. K Table 2. Torque Settings ( T H6-3) Before driving the machine, bleed the steering system. K Related Topics ( T H6-2)

Item B

Table 2. Torque Settings Nm kgf m 56

5.7

lbf ft 41

Disconnect the three hoses A. Label each hose before disconnecting to ensure correct replacement.

H6-3

H-05-03 Issue 01

H6-3

Section H6 - Steering Steer Rams Dismantle and Assemble

Dismantle and Assemble Refer to Section E - Rams, Dismantle and Assemble, Typical Ram.

H6-4

H-05-03 Issue 01

H6-4

Section H7 - Steering

Steering Column Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H7-2) K Removal and Replacement ( T H7-3) K Steering Wheel ( T H7-3) K Steering Column Switches ( T H7-4) K Steering Column ( T H7-6)

H7-1

H-06-05 Issue 01

H7-1

Section H7 - Steering Steering Column Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

H7-2

H-06-05 Issue 01

H7-2

Section H7 - Steering Steering Column Removal and Replacement

Removal and Replacement Steering Wheel

â&#x20AC;&#x201C; If key D becomes damaged during the removal procedure, replace with a new key.

Removal

â&#x20AC;&#x201C; Make sure that the steering wheel lines up with the marks created when removing.

Mark the position of the steering wheel E on the splined shaft F.

Prise the steering wheel centre cap A from the wheel E.

â&#x20AC;&#x201C; If removed replace the foam collar H - attach the adhesive lined side to the column trim panel G before installing the steering wheel E.

Remove the steering wheel securing nut B.

Retrieve the washer C.

Pull the steering wheel E off the splined shaft F.

Make sure to retain key D.

Remove the foam collar H (if fitted).

C D E Fig 2.

C127910.eps

F Fig 1.

770320-C2.eps

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

H7-3

H-06-05 Issue 01

H7-3

Section H7 - Steering Steering Column Removal and Replacement

Steering Column Switches K Fig 3. ( T H7-4), K Fig 5. ( T H7-5)

K Fig 4. ( T H7-4)

and

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T H7-2)

Remove the Wheel ( T H7-3)

Remove the two screws on the top of the steering column upper surround G.

steering

wheel.

K Steering

Remove the two button head screws J, remove the steering column lower surround.

Remove the two button head screws H and remove the steering column upper surround.

Remove the steering column switch retaining plate screw K.

Lift off the switch retaining plate L if fitted.

Remove the switch covers M.

Disconnect the harness connectors at Q.

Unscrew the retaining screw R from the switch collar N.

00:00:05

C118870-C1.eps

Fig 3.

K L

Q R Fig 4.

H7-4

H-06-05 Issue 01

C118880-C1.eps

H7-4

Section H7 - Steering Steering Column Removal and Replacement 11

Pull the column switches P away from the column.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Make sure that the transmission lever securing bolt S has 2 washers installed as shown.

Fig 5.

H7-5

C118890

H-06-05 Issue 01

H7-5

Section H7 - Steering Steering Column Removal and Replacement

Steering Column

Note: There are two types of steering column. Type X is tilt adjustable and type Y is tilt and height adjustable. The removal and replacement procedures are the same for both types.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T H7-2)

Remove the steering wheel and steering column surround. K Steering Wheel ( T H7-3)

Remove the column switches. K Steering Column Switches ( T H7-4)

Important: The electrical connectors A and B are the same. Record the position of the connectors. 4

Disconnect the electrical connectors A and B.

Put aligning marks on the steering shaft D and column E.

Remove clips F and pins G.

Hold the steering column assembly and remove the lever lock C (if fitted)

Lift the column assembly clear of the cab.

H D E C

Replacement

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Align the marks on the steering shaft and steering column (step 5). – Engage the steering shaft splines H with the steer valve internal spline.

– Put electrical connectors A and B in their correct positions. Fig 6.

H7-6

H-06-05 Issue 01

C045420-C1.eps

H7-6

Section K Engine Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813-1800-2

Section K - Engine

Notes:

K-0

9813-1800-2

K-0

Section K - Engine Contents Page No. Applications Table ....................................................................................................... K0-1 Engine Start/Stop SYSTEM Introduction ............................................................................................. Related Topics ........................................................................................ Operation Overview ................................................................................ Electrical Operation and Schematics ...................................................... Fault Finding ...........................................................................................

K1-1 K1-2 K1-3 K1-4 K1-5

Cold Start Heater SYSTEM Introduction ............................................................................................. Related Topics ........................................................................................ Operation Overview ................................................................................ Electrical Operation and Schematics ...................................................... Fault Finding ...........................................................................................

K2-1 K2-2 K2-3 K2-4 K2-5

Starter Motor (K-04-05) Introduction ............................................................................................. K3-1 Related Topics ........................................................................................ K3-2 Removal, Inspection and Replacement .................................................. K3-3 Cooling Pack (K-02-15) Introduction ............................................................................................. Related Topics ........................................................................................ Removal and Replacement .................................................................... Dismantle and Assemble ........................................................................

K4-1 K4-2 K4-3 K4-7

Coolant Expansion Tank (K-05-06) Introduction ............................................................................................. K5-1 Related Topics ........................................................................................ K5-2 Removal and Replacement .................................................................... K5-3 Throttle Position Sensor (TPS) (K-07-12) Introduction ............................................................................................. Related Topics ........................................................................................ Operation Overview ................................................................................ Removal and Replacement ....................................................................

K6-1 K6-2 K6-3 K6-4

Air Cleaner Housing Introduction ............................................................................................. K7-1 Related Topics ........................................................................................ K7-2 Removal and Replacement .................................................................... K7-3 Exhaust Silencer (K-06-10) Introduction ............................................................................................. K8-1 Related Topics ........................................................................................ K8-2 Removal and Replacement .................................................................... K8-3 Fuel Cooler Matrix Introduction ............................................................................................. K9-1 Related Topics ........................................................................................ K9-2 Removal and Replacement .................................................................... K9-3

K-i

Section K - Engine Contents Page No. JCB EcoMax (SH, SL and DH) Introduction ........................................................................................... K10-1 Related Topics ...................................................................................... K10-2 Specifications ....................................................................................... K10-3 Removal and Replacement .................................................................. K10-4 Separating the Engine and Bevel Box .................................................. K10-9

K-ii

Section K0 - Engine Applications Table

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref Title

Engine Start/Stop SYSTEM

Cold Start Heater SYSTEM

Starter Motor

Cooling Pack (SH,SL,DH)

Coolant Expansion Tank

Throttle Position Sensor (TPS) (K-07-21)

Air Cleaner Housing

Exhaust Silencer

Fuel Cooler Matrix

K10

JCB EcoMax

VARIANT

55kW (SL) 81kW (SH)

506-36 5CD 507-42 5CE 509-42 5CF

510-56 5CG 512-56 5CH 514-56 5CJ

z z z

z z z z z

z z z

93kW (SH) 108kW (DH)

K0-1

9813/1800-2 (AK-00-08)

K0-1

Section K0 - Engine Applications Table

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K0-2

9813/1800-2 (AK-00-08)

K0-2

Section K1 - Engine

Engine Start/Stop SYSTEM Introduction This topic contains information about a machine SYSTEM. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not related devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K1-2) K Operation Overview ( T K1-3) K Electrical Operation and Schematics ( T K1-4) K Fault Finding ( T K1-5)

K1-1

K-08-13 Issue 01

K1-1

Section K1 - Engine Engine Start/Stop SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Applications

ALL

(1) You must obey all of the relevant care and safety procedures.

K1-2

K-08-13 Issue 01

K1-2

Section K1 - Engine Engine Start/Stop SYSTEM Operation Overview

Operation Overview Before the engine will start the transmission must be set to N (neutral).

the fuel injectors 3 as required and there is fuel supply to the engine.

The engine is started with an electric starter motor 5. Electrical solenoid 4 moves the starter pinion gear into mesh with the engine flywheel ring gear before closing switch contacts to energise the motor. The solenoid is energised when the machine starter switch 2 is set to position III.

While the engine is running an output from the alternator sends a signal to the Right Hand Cluster display hour meter 1. The meter increments the time units. When the starter switch 2 is set to position O the engine ECU de-energises the injectors 3 and there is no fuel supply to the engine. The engine stops.

When the engine has started the starter switch 2 is released it moves to position I. The engine ECU energises

2 2

4 5 Fig 1.

K1-3

K-08-13 Issue 01

C119910

K1-3

Section K1 - Engine Engine Start/Stop SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics The schematic diagrams show a typical system. For machine specific schematics refer to Section C, Schematics. K Related Topics ( T K1-2) This topic refers to electrical systems and devices. For details refer to Section M-Applications. K Related Topics ( T K1-2) The schematic is shown with the ignition switch 1 set to position III and the transmission set to N. A signal will be sent between the Transmission ECU and Engine ECU 9 via the CANbus to tell the Engine ECU that the transmission is in Neutral. For details of Neutral Start relay and other electrical devices refer to Section M Applications. K Related Topics ( T K1-2) The engine ECU 9 is providing power to the Engine Compartment Fusebox 5 to energise the start relay 6 fuel pump relay 7, starter motor 2 and fuel pump 8.

Key

Device

Ignition switch

Starter motor

Primary fuse

RHC/LMS Display

Engine Compartment Fusebox

Start Signal Relay

Fuel Pump Relay

Fuel Pump

Engine ECU

Alternator

Battery

Charge D+ W

ECU 4

M 2 +VE

-VE

3 4 5 6

6 M

7 8

ECU

+VE

Fig 2. Electrical Schematic - Engine Start

K1-4

K-08-13 Issue 01

-VE C119930

K1-4

Section K1 - Engine Engine Start/Stop SYSTEM Fault Finding

Fault Finding If there are faults with the system or any of the components a Fault Code will be displayed on the Right Hand Cluster. For details of fault codes and diagnostics refer to Section M - Applications. K Related Topics ( T K1-2)

K1-5

K-08-13 Issue 01

K1-5

Section K1 - Engine Engine Start/Stop SYSTEM Fault Finding

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K1-6

K-08-13 Issue 01

K1-6

Section K2 - Engine

Cold Start Heater SYSTEM Introduction This topic contains information about a machine SYSTEM. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not related devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K2-2) K Operation Overview ( T K2-3) K Electrical Operation and Schematics ( T K2-4) K Fault Finding ( T K2-5)

K2-1

K-03-13 Issue 01

K2-1

Section K2 - Engine Cold Start Heater SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Applications

ALL

(1) You must obey all of the relevant care and safety procedures.

K2-2

K-03-13 Issue 01

K2-2

Section K2 - Engine Cold Start Heater SYSTEM Operation Overview

Operation Overview The system aids engine starting by heating the air in the induction manifold 5 via electrical `grid heater' 6. Operation of the system is fully automatic and is controlled by the engine ECU. The power to the grid heater is supplied by a primary fuse 4 through the link harness 8 to relay 3. The relay when energised supplies power to the heater 7 via the power lead 6.

Starter key set to the ON position

Warning light 2 illuminated - grid heater ON - engine not ready to start

After a preset `pre-heat' time the warning light 2 extinguishes - engine ready to start (1)

Starter key turned to engage starter motor and start the engine - grid heater on

Engine started - starter motor disengaged - grid heater OFF (2)

The relay 3 is located at the side of the Coolant Expansion Tank 1. The relay is energised by a feed from the engine compartment fusebox, with the engine ECU proving an earth for the relay. The heating sequence is as follows:

(1) The `pre-heat' stage can not be repeated unless the starter key is first set to the OFF position. (2) If the engine stalls and is restarted without turning the starter key to OFF, the grid heater will come on while the starter motor is engaged.

Fig 1.

K2-3

K-03-13 Issue 01

C119890-C1.jpg

K2-3

Section K2 - Engine Cold Start Heater SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics The schematic diagrams show a typical system. For machine specific schematics refer to Section C, Schematics. K Related Topics ( T K2-2) This topic refers to electrical systems and devices. For details refer to Section M-Applications. K Related Topics ( T K2-2)

Key 1

Primary Fuse Link

Engine Compartment Fuse

Cold Start Relay

Grid Heater Element

Engine ECU

FUSE

2 5

+VE

-VE

Fig 2.

K2-4

K-03-13 Issue 01

C119900

K2-4

Section K2 - Engine Cold Start Heater SYSTEM Fault Finding

K2-5

K-03-13 Issue 01

K2-5

Section K2 - Engine Cold Start Heater SYSTEM Fault Finding

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K2-6

K-03-13 Issue 01

K2-6

Section K3 - Engine

Starter Motor (K-04-05) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K3-2) K Removal, Inspection and Replacement ( T K3-3) K Removal ( T K3-3) K Inspection ( T K3-3) K Replacement ( T K3-3)

K3-1

K-04-05 Issue 01

K3-1

Section K3 - Engine Starter Motor (K-04-05) Related Topics

Topic Titles

ALL (Care and Safety)

Sub Titles ALL

(1)

(1) You must obey all of the relevant care and safety procedures.

K3-2

K-04-05 Issue 01

K3-2

Section K3 - Engine Starter Motor (K-04-05) Removal, Inspection and Replacement

Removal, Inspection and Replacement

1 2

3 C122140

Fig 1.

Removal

Replacement

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Park the machine and make it safe. Install the boom safety strut. Obey the care and safety procedures. K Related Topics ( T K3-2)

Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started. 2

Disconnect the negative (-) cable followed by the positive (+) cable from the battery terminals.

If fitted, remove the protective cover from the starter motor solenoid electrical terminals (not shown).

Remove nut 2 and disconnect the positive electrical cables from the terminal post. Label the cables to ensure they are refitted in the correct positions on assembly.

Disconnect the electrical harness connector at position 1 on the starter motor.

Remove nut 3 (if fitted) and disconnect the negative cables from the terminal post.

Undo the three bolts 4 and withdraw the starter motor from the flywheel housing.

– Ensure that the flywheel housing and starter motor mating faces are clean. – Smear the drive pinion splines with JCB MPL Grease before assembly. – Torque tighten bolts 4. – Be sure to reconnect the electrical leads to the starter motor in the correct positions. Torque tighten the nuts 2 and 3.

Item

Table 2. Torque Settings Nm kgf m

lbf ft

1.5

1.2

43-51

4.3-5.2

32-38

Inspection 1

Check the drive pinion splines for damage and excessive wear.

K3-3

K-04-05 Issue 01

K3-3

Section K3 - Engine Starter Motor (K-04-05) Removal, Inspection and Replacement

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K3-4

K-04-05 Issue 01

K3-4

Section K4 - Engine

Cooling Pack (K-02-15) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K4-2) K Removal and Replacement ( T K4-3) K Dismantle and Assemble ( T K4-7)

K4-1

K-02-15 Issue 01

K4-1

Section K4 - Engine Cooling Pack (K-02-15) Related Topics

Topic Titles

Sub Titles

ALL (Care and Safety)

Access Panels

ALL

Engine

Engine, Changing the Coolant

Hydraulic System

Checking the Hydraulic Fluid Level

Transmission

Checking the Transmission Oil Level

Cab Air Conditioning SYSTEM(2)

Refrigerant Charging and Discharging

Air Conditioning Condenser - Cooling Pack Mounted

Removal and Replacement

Engine Cover

ALL

Cooling Fan Motor

Removal and Replacement

Hydraulic Oil Cooler

Removal and Replacement

Transmission Oil Cooler - Air Blast

Removal and Replacement

Fuel Cooler

Removal and Replacement

ALL

(1)

(1) You must obey all of the relevant care and safety procedures. (2) If fitted

K4-2

K-02-15 Issue 01

K4-2

Section K4 - Engine Cooling Pack (K-02-15) Removal and Replacement

Removal and Replacement The engine cooling pack is designed as a sub assembly which can include the following components depending on machine variant/specification. Refer to the applicable topics for details of removal and replacement procedures: – Transmission Oil Cooler - Refer to Section F Transmission Oil Cooler - Air Blast. K Related Topics ( T K4-2) – Hydraulic Oil Cooler - Refer to Section E - Hydraulic Oil Cooler. K Related Topics ( T K4-2) – Fuel Cooler - Refer to Section K - Fuel Cooler. K Related Topics ( T K4-2) – Air Conditioning Condenser - Refer to Section B - Air Conditioning Condenser - Cooling Pack Mounted. K Related Topics ( T K4-2) K Fig 1. ( T K4-4)

Although it is possible to remove individual components it is quicker and easier to remove the complete sub assembly, particularly if access is necessary for engine overhaul or removal and replacement for example.

Removal Park the machine and make it safe. Obey the care and safety procedures. See Section 2 - General Procedures. K Related Topics ( T K4-2) Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started. Before trying to remove the cooling pack let the engine and hydraulic system cool. 1

Remove the engine cover and side pod assembly, see Section B - Engine Cover. K Related Topics ( T K4-2)

Put a label on the fuel lines, hoses and electrical connectors to help identification when replacing.

Disconnect the fuel lines and electrical connector at the sedimentor 2 or undo the sedimentor bolts and fuel line clips and tie the assembly safely out of the way.

Drain the engine coolant by disconnecting the radiator bottom hose at 15.

Disconnect the radiator top hose at 11.

Disconnect the fan motor electrical connections (if fitted):

Air Cleaner Box/Fuse Box Support Bolts

Fuel sedimentor and Pump

Air to air intercooler matrix(1)

Hydraulic oil cooler matrix (if fitted)(1)

Fixing points

Hydraulic hoses - Fan Motor/Oil Cooler

Solenoid valve - reversible fan (if fitted)

Fan Speed Sensor

Proportional Fan Speed Control Solenoid

Engine coolant radiator matrix

Radiator top hose connection

Intercooler inlet hose connection

13a

Fixed Speed Cooling fan and hydraulic motor assembly (55KW Engines)

13b

Variable Speed Cooling fan and hydraulic motor assembly (81, 93 and 108 KW Engines)

81, 93 and 108 KW Machines

Intercooler outlet hose connection

Radiator bottom hose connection

Disconnect the electrical connectors at the fan motor direction control valve 7 (if fitted), control solenoid 9 and speed sensor 8.

(1)

(1) The engine coolant radiator, transmission oil cooler and air to air intercooler matrix are all integral. If any part of the assembly has failed the complete unit must be renewed.

K4-3

K-02-15 Issue 01

Disconnect transmission cooler hoses at the chassis. Cap all open hoses and pipes.

K4-3

Section K4 - Engine Cooling Pack (K-02-15) Removal and Replacement

1 5

5 2

4 6 6 6 5 6

6 6 6

7 12 8

13a

14 13b

15 Fig 1.

K4-4

K-02-15 Issue 01

C122200

K4-4

Section K4 - Engine Cooling Pack (K-02-15) Removal and Replacement 8

Disconnect the hydraulic hoses 6 at the chassis. Cap all open hoses and pipes.

Note: On 527-56 machines the fan motor hydraulic hoses 17 are connected to the bulkhead plate 16 as shown.

17 16 Fig 2.

C122200-C2.eps

Disconnect intercooler hoses at positions 12 and 14.

Support the cooling pack assembly, unscrew bolts from positions 1 and 5 and carefully lift the assembly away from the machine.

K4-5

K-02-15 Issue 01

K4-5

Section K4 - Engine Cooling Pack (K-02-15) Removal and Replacement

Replacement

Fig 3.

C128950.jpg

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also. – Torque tighten the clamps X. K Table 2. Torque Settings ( T K4-6) – After replacement fill the engine cooling system with the correct coolant. See Section 3 - Engine. K Related Topics ( T K4-2) – Operate the engine and do a check of the fan motor speed. – Do a check of the hydraulic fluid level. See Section 3 - Hydraulics. K Related Topics ( T K4-2) – Do a check of the transmission oil level and top up as necessary. See Section 3 - Transmission. K Related Topics ( T K4-2)

Item

Table 2. Torque Settings Nm kgf m

5.5

K4-6

0.5

lbf ft 4

K-02-15 Issue 01

K4-6

Section K4 - Engine Cooling Pack (K-02-15) Dismantle and Assemble

Dismantle and Assemble With the cooling pack removed from the machine dismantle components as necessary. – Transmission Oil Cooler - Refer to Section F Transmission Oil Cooler - Air Blast. K Related Topics ( T K4-2) – Cooling fan motor - Refer to Section E - Fan Motor. K Related Topics ( T K4-2) – Hydraulic Oil Cooler - Refer to Section E - Hydraulic Oil Cooler. K Related Topics ( T K4-2) – Fuel Cooler - Refer to Section K - Fuel Cooler. K Related Topics ( T K4-2) – Air Conditioning Condenser - Refer to Section B - Air Conditioning Condenser - Cooling Pack Mounted. K Related Topics ( T K4-2)

K4-7

K-02-15 Issue 01

K4-7

Section K4 - Engine Cooling Pack (K-02-15) Dismantle and Assemble

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K4-8

K-02-15 Issue 01

K4-8

Section K5 - Engine

Coolant Expansion Tank (K-05-06) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K5-2) K Removal and Replacement ( T K5-3) K Removal ( T K5-3) K Replacement ( T K5-4)

K5-1

K-05-06 Issue 01

K5-1

Section K5 - Engine Coolant Expansion Tank (K-05-06) Related Topics

Topic Titles

Applications

ALL (Care and Safety)

Engine

Sub Titles ALL ALL

(1)

Changing the Coolant

(1) You must obey all of the relevant care and safety procedures.

K5-2

K-05-06 Issue 01

K5-2

Section K5 - Engine Coolant Expansion Tank (K-05-06) Removal and Replacement

Removal and Replacement

2 1 4

5 C119500

Fig 1.

Removal

Remove expansion tank cover 3.

Disconnect the coolant level sensor electrical connector (if fitted).

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T K5-2)

Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started.

Unscrew the hose clips 1 and disconnect the hoses 2 from the expansion tank.

Support the expansion tank 4.

If the engine is hot let it cool for one hour.

Remove the expansion tank 4 from the bracket 6.

Open the engine cover.

Drain the engine coolant. Refer to Section 3 Routine Maintenance. K Related Topics ( T K5-2)

Remove bolts 5.

K5-3

K-05-06 Issue 01

K5-3

Section K5 - Engine Coolant Expansion Tank (K-05-06) Removal and Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: – Apply JCB Locking Fluid Medium Strength to the bolts 5. – Torque tighten the bolts 5. K Table 2. Torque Settings ( T K5-4) – Fill the engine cooling system with the correct type of coolant. Refer to Section 3 - Routine Maintenance. K Related Topics ( T K5-2) – When the replacement procedure is complete start the engine and check for coolant leaks.

Item 5

K5-4

Table 2. Torque Settings Nm kgf m 10

lbf ft 7.3

K-05-06 Issue 01

K5-4

Section K6 - Engine

Throttle Position Sensor (TPS) (K-07-12) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K6-2) K Operation Overview ( T K6-3) K Removal and Replacement ( T K6-4) K Replacement ( T K6-4) K Replacement ( T K6-4)

K6-1

K-07-12 Issue 01

K6-1

Section K6 - Engine Throttle Position Sensor (TPS) (K-07-12) Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

K6-2

K-07-12 Issue 01

K6-2

Section K6 - Engine Throttle Position Sensor (TPS) (K-07-12) Operation Overview

Operation Overview 1

Fig 1.

C122180

The throttle pedal sensor (TPS) transmits the movement from the pedal into an electrical signal for interpretation by the Engine ECU, Variflow Pump ECU or Hydraulic control ECU. The the movement of the throttle pedal B is transmitted from the footplate to the roller D and the swing arm C on the Throttle Position Sensor (TPS) unit A. A variable resistor within the TPS unit A changes the voltage output in relation to the position of the pedal. K Fig 1. ( T K6-3)

Fig 2. Throttle Pedal Movement

Pedal Position

C122180-C1

Table 2. TPS Output Voltage output

K Fig 2. ( T K6-3) 1

Signal 1 = 0V Signal 2 = 5V

Signal 1 = 2.0V Signal 2 = 3.0V

Signal 1 = 5.0V Signal 2 = 0V

Two signals are output from the unit, a track 1 signal and a track 2 signal. One signal varies the voltage by the angle below the foot pedal pad. The other signal varies the voltage by the angle above the foot pedal pad. Both signals will always add up to 5v, for example K Table 2. TPS Output ( T K6-3)

K6-3

K-07-12 Issue 01

K6-3

Section K6 - Engine Throttle Position Sensor (TPS) (K-07-12) Removal and Replacement

Removal and Replacement Removal

C122170-C1.eps

Fig 3. 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T K6-2)

Make sure that the engine cannot be started.

Remove the floor mat from the cab.

Working below the cab, disconnect the electrical connector E from the chassis harness.

Slowly remove the pedal assembly A from inside the cab making sure to pull the connector E through the hole in the floor F.

Replacement

Remove the socket head bolts B.

Make sure to retain the spacer plate C (if fitted).

Remove the nut D to release the clip and connector E from the floor.

K6-4

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Apply JCB Threadlocker and Sealer to the threads of the bolts B.

K-07-12 Issue 01

K6-4

Section K7 - Engine

Air Cleaner Housing Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K7-2) K Removal and Replacement ( T K7-3) K Removal ( T K7-3) K Replacement ( T K7-4)

K7-1

K-03-14 Issue 01

K7-1

Section K7 - Engine Air Cleaner Housing Related Topics

Topic Titles

Applications

ALL (Care and Safety)

Access Panels

Sub Titles ALL ALL

(1)

Engine Cover

(1) You must obey all of the relevant care and safety procedures.

K7-2

K-03-14 Issue 01

K7-2

Section K7 - Engine Air Cleaner Housing Removal and Replacement

Removal and Replacement

2 2

11 10

10 C122220-C4.eps

Fig 1.

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T K7-2)

K7-3

Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started. 2

K-03-14 Issue 01

If the engine is hot let it cool for one hour.

K7-3

Section K7 - Engine Air Cleaner Housing Removal and Replacement 3

Open the engine cover. Refer to Section 3 - Access Panels. K Related Topics ( T K7-2)

Disconnect the Vacuum Switch/TMAF electrical connectors 2.

Disconnect the hose 5 from the air cleaner housing 4 to the filter minder 6 (if fitted)

Remove the bolts 1, 7 and 8.

Slacken the clip 11 and disconnect the hose 9 from the air cleaner housing 3.

Disconnect the scavenge hose 11 from air cleaner housing.

Remove the air cleaner housing 3 and support bracket from the machine.

Remove the bolts 10 and remove the air cleaner housing 3 from the support bracket.

K7-4

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Inspect the housing seals and replace as necessary.

K-03-14 Issue 01

K7-4

Section K8 - Engine

Exhaust Silencer (K-06-10) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K8-2) K Removal and Replacement ( T K8-3) K Removal ( T K8-3) K Replacement ( T K8-4)

K8-1

K-06-10 Issue 01

K8-1

Section K8 - Engine Exhaust Silencer (K-06-10) Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Description

332/E9711(1)

Exhaust Fitting Clamp

(1) Tool available from JCB Service, refer to Section 1 - Service Tools

K8-2

K-06-10 Issue 01

K8-2

Section K8 - Engine Exhaust Silencer (K-06-10) Removal and Replacement

Removal and Replacement

5 7

4 3

1 1

C119490-C3

Fig 1.

Removal

Remove the screws 4.

Park the machine and make it safe. Obey the care and safety procedures. Let the engine cool. K Related Topics ( T K8-2)

Remove the cover 5.

Remove the inlet nuts 8.

Open the engine cover.

Support the silencer 3.

Remove the exhaust jacket (not shown).

Remove the nuts 2.

Fit clamp 6 (service tool) to the flexible section of the exhaust pipe.

Lift off the silencer 3.

Note: The clamp 6 is designed to protect the flexible section of the exhaust pipe so that it can be re-fitted correctly. New silencers are supplied with a clamp fitted.

K8-3

Note: Make sure to remove all traces of gasket 7. 11

K-06-10 Issue 01

Examine the rubber mounts 1. If they are defective replace them with new ones.

K8-3

Section K8 - Engine Exhaust Silencer (K-06-10) Removal and Replacement

Replacement Note: Do not use a defective silencer. If the silencer is defective replace it with a new one. Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Use a new gasket 7. â&#x20AC;&#x201C; Remove clamp 6 before starting the engine. Note: New silencers are supplied with a clamp 6 fitted.

K8-4

K-06-10 Issue 01

K8-4

Section K9 - Engine

Fuel Cooler Matrix Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K9-2) K Removal and Replacement ( T K9-3) K Removal ( T K9-3) K Replacement ( T K9-4)

K9-1

K-09-00 Issue 01

K9-1

Section K9 - Engine Fuel Cooler Matrix Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Access Panels

Engine Cover

Engine

Fuel System

ALL ALL

(1)

(1) You must obey all of the relevant care and safety procedures.

K9-2

K-09-00 Issue 01

K9-2

Section K9 - Engine Fuel Cooler Matrix Removal and Replacement

Removal and Replacement

C119880

Fig 1.

Removal

Remove nuts B.

Remove the fuel cooler matrix from the machine.

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T K9-2)

Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started. 2

If the engine is hot let it cool for one hour.

Open the engine cover. Refer to Section 3 - Access Panels. K Related Topics ( T K9-2)

Disconnect the fuel hoses from the matrix C at the quick release couplings A.

Support the matrix C.

K9-3

K-09-00 Issue 01

K9-3

Section K9 - Engine Fuel Cooler Matrix Removal and Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Bleed the fuel system. Refer to Section 3 - Routine Maintenance. K Related Topics ( T K9-2) â&#x20AC;&#x201C; When the replacement procedure is complete start the engine and check for fuel leaks.

K9-4

K-09-00 Issue 01

K9-4

Section K10 - Engine

JCB EcoMax (SH, SL and DH) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T K10-2) K Specifications ( T K10-3) K Removal and Replacement ( T K10-4) K Separating the Engine and Bevel Box ( T K10-9)

K10-1

K-01-12 Issue 01

K10-1

Section K10 - Engine JCB EcoMax (SH, SL and DH) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Fuel

Acceptable and Unacceptable Fuels

Service Tools

ALL (Care and Safety)

Brakes

Adjusting the Parking Brake

Engine

Changing the Coolant

Transmission

Checking the Transmission Oil Level

Chassis Panels

ALL

Cab Air Conditioning SYSTEM

ALL

Main Pump - Gearpump

ALL

Main Pump - Variflow

ALL

Propshafts

ALL

Cableshift

ALL

External Park Brake SYSTEM

ALL

Internal Park Brake SYSTEM

ALL

Cooling Pack (SH, SL, DH)

ALL

Coolant Expansion Tank

ALL

Exhaust Silencer

ALL

Air Cleaner Housing

ALL

ALL ALL

(1)

(1) You must obey all of the relevant care and safety procedures. Table 2. Related Topics in Publication 9806/4300, T4i Engine Service Manual The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Sections

Section Titles

Topic Titles

ALL

K10-2

K-01-12 Issue 01

K10-2

K10-3 1, 3, 4, 2 - Number 1 cylinder at 1, 3, 4, 2 - Number 1 cylinder at 1, 3, 4, 2 - Number 1 cylinder at 1, 3, 4, 2 - Number 1 cylinder at crankshaft pulley end crankshaft pulley end crankshaft pulley end crankshaft pulley end 4.40 litres (268.5 in3) 16.9 : 1 Fixed Geometry Clockwise 4 per cylinder

Inlet: 0.15 to 0.20 mm (0.006 to Inlet: 0.15 to 0.20 mm (0.006 to Inlet: 0.15 to 0.20 mm (0.006 to Inlet: 0.15 to 0.20 mm (0.006 to 0.008 in) 0.008 in) 0.008 in) 0.008 in)

Firing Order

Displacement

Compression ratio

Turbo

Direction of rotation (viewed from crankshaft pulley end)

K-01-12 Issue 01

Valves

Valve tip clearances (measured cold)

1.6 to 6.5 bar (23 to 91 lb in2)

1.6 to 6.5 bar (23 to 91 lb in2) 850 rpm

Lubricating oil pressure (1)

Idle speed

JCB Engine Service Manual

(1) Engine at normal operating temperature and maximum revs.

9806/4300, T4i Engine Service Manual

Recommended fuel specifications

2370 rpm

Refer to Section 1 - Fuel K Related Topics ( T K10-2)

High Idle (Maximum Governed Speed)

850 rpm

Exhaust: 0.43 to 0.50 mm (0.017 to 0.020 in)

4 per cylinder

Clockwise

Variable Geometry (VGT)

16.9 : 1

4.40 litres (268.5 in3)

Diesel 4 stroke

TBA

850 rpm

1.6 to 6.5 bar (23 to 91 lb in2)

Exhaust: 0.43 to 0.50 mm (0.017 to 0.020 in)

4 per cylinder

Clockwise

Variable Geometry (VGT)

16.9 : 1

4.40 litres (268.5 in3)

Diesel 4 stroke

135 mm (5.31 in)

TBA

1.6 to 6.5 bar (23 to 91 lb in2)

Exhaust: 0.43 to 0.50 mm (0.017 to 0.020 in)

4 per cylinder

Clockwise

Variable Geometry (VGT)

16.7:1 +/- 0.5

4.765 litres (290 in3)

Diesel 4 stroke

In line

Diesel 4 stroke

132 mm (5.196 in) In line

Cycle

In line

132 mm (5.196 in)

106 mm (4.17 in)

132 mm (5.196 in)

103 mm (4.05 in)

In line

103 mm (4.05 in)

108kW (145Hp) 496 kg (1091 lb)

Cylinder arrangement

103 mm (4.05 in)

Nominal bore size

93kW (125Hp) 496.5 kg (1094 lb)

Stroke

Number of cylinders

81kW (109Hp) 496.5 kg (1094 lb)

55kW (74Hp) 492.5 kg (1085 lb)

Weight (dry)

Engine Designation Code

Electronic common rail fuel injection. Turbocharged with intercooler with Exhaust Gas Recirculation System (EGR)

Identification Plate. For details refer to Section 1 Machine Identification.

Type

Note: The engine designation code (SH, SL or DH) and power rating (kW) can be found on the Engine

Specifications

Section K10 - Engine

JCB EcoMax (SH, SL and DH) Specifications

K10-3

Section K10 - Engine JCB EcoMax (SH, SL and DH) Removal and Replacement

Removal and Replacement Introduction

All Machines

The engine and gearbox must be removed from the machine as a complete unit. The total weight of the engine and gearbox assembly is approximately 1000 kg.

Remove the engine cover and side pod, see Section B - Chassis Panels. K Related Topics ( T K10-2)

Remove the cooling pack. Refer to the applicable Cooling Pack topic. K Related Topics ( T K10-2)

Remove the coolant expansion tank. Refer to the Coolant Expansion Tank topic. K Related Topics ( T K10-2)

Disconnect the following electrical connectors at the points shown: K Fig 1. ( T K10-5)

A suitable overhead crane and lifting frame will be required to safely lift and manoeuvre the assembly in and out of the machine chassis. The following procedures describe removing and replacing the engine and gearbox as a complete unit. Before separating the engine and bevel the Engine and Bevel box. K Separating Box ( T K10-9)

Removal

Note: The following procedures are for a typical engine and gearbox installation. There will be some procedural differences dependant on machine variant. Before attempting to remove the engine and gearbox ensure that all the necessary components have either been removed, or safely disconnected.

b Starter motor electrical connections 4. c

Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started.

Alternator 3.

Cold start heater electrical cables at the relay 13 (if fitted).

g Air conditioning binary switch 11(if fitted) h Air conditioning compressor 6 (if fitted)

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Machines with Air Conditioning K Fig 1. ( T K10-5)

Lambda sensor 12 (if fitted)

Transmission oil temperature sensor 16.

Transmission speed sensor. PS750 - item 5

Discharge the air conditioning system and disconnect the pipes 10 at the compressor. See Section B - Cab Air Conditioning SYSTEM. K Related Topics ( T K10-2)

PS760 - items 2 l

Fan motor solenoids 14 and speed sensor 15 (if fitted)

d Intake air sensor 9 and air cleaner vacuum switch 8.

!MWARNING

The engine ECU machine electrical harness connector 7. Make sure that the open connectors on the harness and ECU are capped. DO NOT touch the connector pins on the ECU.

Disconnect the engine electrical harness connector 1 from the pod harness connector.

m Disconnect the gearbox harness connection from the chassis harness connector. 5

If necessary remove the air cleaner housing assembly to improve access. Refer to the Air Cleaner Housing topic. K Related Topics ( T K10-2)

4-3-4-1_2

K10-4

K-01-12 Issue 01

K10-4

Section K10 - Engine JCB EcoMax (SH, SL and DH) Removal and Replacement

5 7

6 11

10 9 12 13

10 15

16 Fig 1. Electrical Connections

K10-5

K-01-12 Issue 01

C122240-C1

K10-5

Section K10 - Engine JCB EcoMax (SH, SL and DH) Removal and Replacement Note: When disconnecting pipes and hoses make sure to cap the open ports to prevent the ingress of dirt.

Undo the transmission oil cooler pipe fixing on the chassis (not shown).

K Fig 2. ( T K10-7)

Disconnect the transmission breather pipes (not shown).

Disconnect the following fuel connections at the points shown: K Fig 2. ( T K10-7)

Disconnect the cableshift connectors (if fitted). Refer to Section F - Cableshift topic. K Related Topics ( T K10-2)

Make sure that all the relevant hoses pipes and wiring have been disconnected and tied away from the transmission assembly.

Attach a specially fabricated lifting frame to engine and transmission assembly. Using suitable lifting equipment take the weight of the engine and transmission assembly (approx. 1000 kg). Refer to Section 1 Service Tools. K Related Topics ( T K10-2)

n Fuel leak-off pipe 19. o Fuel pipe 18 at the fuel filter (from the lift pump). 7

Disconnect the following coolant hoses at the points shown: K Fig 2. ( T K10-7) a

Top hose21.

b Bottom hose 24. 8

Disconnect the following induction hoses at the points shown: K Fig 2. ( T K10-7) a

Important: Do not attempt to lift the engine and gearbox assembly using the engine lifting brackets. The brackets are designed to lift the engine only.

Intercooler inlet 22.

b Intercooler outlet 23. c 9

Note: The lifting frame is designed specifically to lift the side mounted engine, bevel box and Powershift gearbox as a complete assembly.

Turbo inlet 20.

Disconnect the brake servo vacuum hoses 17 from the exhauster unit. Remove the exhaust silencer/DOC/POC assembly. Refer to the Exhaust Silencer or Diesel Oxidation Catalyst/Particulate Oxidation Catalyst topics as applicable. K Related Topics ( T K10-2) Disconnect the parking brake cable 27 at the brake calliper or gearbox as applicable. See Section G Park Brake SYSTEM. K Related Topics ( T K10-2)

Disconnect the front and rear propshafts at the gearbox. 29. K Related Topics ( T K10-2)

Drain the hydraulic tank.

Label and disconnect the pipe and hose connections to the hydraulic pump 25. See Section E - Main Pump. K Related Topics ( T K10-2)

Disconnect the gearbox hydraulic remote filter hoses 31 (if fitted)

K10-6

Important: The lifting frame is not to be used to lift the engine on its own, any other part of the machine or for any other lifting duty or use. 21

Place suitable engine support stands 32 under the engine and gearbox. DO NOT place support stands under the engine sump.

Undo and remove the three transmission mounting bolts and nuts 26 and 28. Make sure that the assembly is safely supported by the lifting equipment and then remove the stands.

Lower and withdraw the assembly from the machine.

K-01-12 Issue 01

K10-6

Section K10 - Engine JCB EcoMax (SH, SL and DH) Removal and Replacement

21 22 18

19 28 24

26 27

27 32

29 32 30

31 Fig 2.

K10-7

K-01-12 Issue 01

C122240

K10-7

Section K10 - Engine JCB EcoMax (SH, SL and DH) Removal and Replacement

Replacement Replacement is a opposite of the removal procedure. During the replacement procedure do this work also: – Fill the engine with the correct coolant. See Section 3 - Fluids, Lubricants and Capacities. K Related Topics ( T K10-2) – Check the transmission oil level. See Section 3 Gearbox. K Related Topics ( T K10-2) – Check the hydraulic oil level. See Section 3 Hydraulics. K Related Topics ( T K10-2) – Recharge the Air Conditioning system. Refer to Section B - Cab Air Conditioning SYSTEM. K Related Topics ( T K10-2) – Bleed the fuel system. See Section 3 - Fuel System. K Related Topics ( T K10-2) – Torque tighten the propshaft bolts 30. Refer to Section F Propshafts. K Related Topics ( T K10-2) – Torque tighten the mounting nuts and bolts 26 and 28. K Table 3. Torque Settings ( T K10-8) – Adjust the parking brake. See Section G-Parking Brake SYSTEM. K Related Topics ( T K10-2)

Item

Table 3. Torque Settings Nm kgf m

lbf ft

205

20.9

151.2

690

70.4

508.9

K10-8

K-01-12 Issue 01

K10-8

Section K10 - Engine JCB EcoMax (SH, SL and DH) Separating the Engine and Bevel Box

Separating the Engine and Bevel Box Note: The following procedures are for a typical engine and gearbox installation. There will be some procedural differences dependant on machine variant. Before attempting to remove the engine and gearbox ensure that all the necessary components have either been removed, or safely disconnected.

Dismantling The engine, bevel box and transmission should be removed from the machine as one complete unit before carrying out the following procedure. K Removal ( T K10-4) Note: For lifting brackets and spreader bar refer to Section 1 - Service Tools. K Related Topics ( T K10-2) 1

A A

Using appropriate lifting equipment attached to the engine lifting brackets, support the weight of the engine. The equipment must be capable of lifting 600 kg (1320 lb). Check the lifting brackets for damage and security before the engine is lifted. The correct torque for the lifting bracket setscrews is 44 Nm (33 lbf ft).

Note: The lifting equipment must be arranged so that it provides a vertical lift directly above each of the two lifting brackets, as shown at A, ensuring that there is a clearance between the hooks and the rocker cover to avoid damage to the engine. Never use a single bracket to raise an engine.

Fig 3. 2

T062740-C1

Remove bell housing bolts C.

Note: The bolts C are sized to suit their positions. Bell housing bolts must be replaced in the same positions.

K10-9

K-01-12 Issue 01

K10-9

Section K10 - Engine JCB EcoMax (SH, SL and DH) Separating the Engine and Bevel Box

C118670

Fig 5.

C Fig 4.

Item C118660

Carefully draw the engine away from the transmission. Be careful not to put any side force on the transmission input shaft. Lift the engine clear of the machine.

Place the engine on a suitable stand.

Table 4. Torque Settings Nm kgf m

lbf ft

7.1

67 - 72

6.8 - 7.3

49 - 53

Assembly Assembly is opposite of the dismantle procedure. During the assembly procedure do this work also: – If the damper E has been removed, clean the mating faces with a clean, dry cloth. The damper can be fitted in any position as it is balanced individually. – Apply JCB Activator and JCB Threadlocker and Sealer to the 6 bolts D. – Torque tighten the 6 bolts D. K Table 4. Torque Settings ( T K10-10) – Apply locking fluid and torque tighten bolts C, making sure the bolts are fitted in the correct position, as marked during removal. K Table 4. Torque Settings ( T K10-10)

K10-10

K-01-12 Issue 01

K10-10

Section M Electronic Network Service Manual - 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Network

Publication No.

9813/1800-2

Section M - Data Systems

Notes:

M-0

9813/1800-2

M-0

Section M - Electronic Control Systems Contents Page No. Applications Table ....................................................................................................... M0-1 CANbus SYSTEM Introduction ............................................................................................. Related Topics ........................................................................................ Operation Overview ................................................................................ Electrical and Electronic Systems ..........................................................

M1-5 M1-6 M1-7 M1-8

Sub Section Intentionally Blank .................................................................................. M2-1 Fault Code SYSTEM Introduction ............................................................................................. M3-3 Related Topics ........................................................................................ M3-5 Operation Overview ................................................................................ M3-6 General ‘D’ Codes ................................................................................ M3-12 Transmission ‘T’ Codes ........................................................................ M3-17 Powertrain ‘P’ Codes ............................................................................ M3-38 Constant Auxiliary ECU ‘A’ Codes ........................................................ M3-39 HVCS ‘H’ Codes ................................................................................... M3-40 Machine Control ECU ‘L’ Codes ........................................................... M3-41 Cab Area ‘B’ Codes .............................................................................. M3-55 Chassis ‘C’ Codes ................................................................................ M3-59 CANbus ‘U’ Codes ................................................................................ M3-63 RAS “S” Codes ..................................................................................... M3-66 Electronic Engine SE Engine ECU Codes ............................................ M3-80 Electronic Engine SH/SL/DH Engine ECU Codes ................................ M3-90 Servicemaster SYSTEM Introduction ............................................................................................. Why Use ServiceMaster? ....................................................................... What is Servicemaster? .......................................................................... How to Set-up Servicemaster .................................................................

M4-1 M4-2 M4-3 M4-5

Servicemaster Tool Set Introduction ............................................................................................. Related Topics ........................................................................................ Tool Suite ................................................................................................ Diagnostics Connector ........................................................................... Servicemaster Machine Selection ..........................................................

M5-1 M5-2 M5-3 M5-4 M5-5

JCB EcoMax (SH,SL,DH) Engine Set Up Tool User Guide (M-05-21) Introduction ............................................................................................. M6-1 Related Topics ........................................................................................ M6-2 User Guide ............................................................................................. M6-3 JCB EcoMax (SH,SL,DH) Engine Diagnostics Tool User Guide (M-05-20) Introduction ............................................................................................. M7-1 Related Topics ........................................................................................ M7-2 User Guide ............................................................................................. M7-3 Cluster (LMS) Setup Tool - User Guide Introduction ............................................................................................. M8-1 Related Topics ........................................................................................ M8-2

M-i

Section M - Electronic Control Systems Contents Page No. Loadall Cluster (LMS) Setup - User Guide ............................................. M8-3 Loadall Datalogger Tool - User Guide (M-05-12) Introduction ............................................................................................. M9-1 Related Topics ........................................................................................ M9-2 Loadall Datalogger - User Guide ............................................................ M9-3 Machine Diagnostic Tool User Guide (M-05-25) Introduction ........................................................................................... M10-1 Related Topics ...................................................................................... M10-2 Loadall Machine Diagnostics - User Guide .......................................... M10-3 Immobiliser Setup Tool (M-05-15) Introduction ........................................................................................... M11-1 Related Topics ...................................................................................... M11-2 User Guide ........................................................................................... M11-3 Immobiliser Diagnostics Tool (M-05-17) Introduction ........................................................................................... M12-1 Related Topics ...................................................................................... M12-2 User Guide ........................................................................................... M12-3 Pulse Width Modulation Theory Introduction ........................................................................................... M13-1 Related Topics ...................................................................................... M13-2 Operation Overview .............................................................................. M13-3 Electronic Control Unit Theory Introduction ........................................................................................... M14-1 Related Topics ...................................................................................... M14-2 Operation Overview .............................................................................. M14-3 Sub Section Intentionally Blank ................................................................................ M15-1 Sub Section Intentionally Blank ................................................................................ M16-1 Devices Introduction ........................................................................................... M17-1 Electronic Controllers Introduction ........................................................................................... M18-1 Related Topics ...................................................................................... M18-3 LMS ECU .............................................................................................. M18-4 Immobiliser ECU ................................................................................. M18-13 Livelink ECU (S1) ............................................................................... M18-19 Livelink ECU (S2) ............................................................................... M18-25 RAS ECU ............................................................................................ M18-31 Brake System Devices Introduction ........................................................................................... M19-1 Related Topics ...................................................................................... M19-3 Park Brake Switch ................................................................................ M19-4 Footbrake Operated Switch ................................................................ M19-13

M-ii

Section M - Electronic Control Systems Contents Page No. Footbrake Pressure Transducer (S1) ................................................. M19-20 Footbrake Pressure Transducer (S2) ................................................. M19-24 Charge Pressure Transducer ............................................................. M19-28 Transmission Disconnect (Footbrake Dump) Switch .......................... M19-33 Sub Section Intentionally Blank ................................................................................ M20-1 Engine and Fuel System Devices Introduction ........................................................................................... M21-1 Related Topics ...................................................................................... M21-4 Fuel Level Sender ................................................................................ M21-5 Coolant Temperature Switch .............................................................. M21-10 Vacuum Switch ................................................................................... M21-11 Fuel Lift Pump .................................................................................... M21-15 WIF Sensor ......................................................................................... M21-20 TMAF Sensor ..................................................................................... M21-25 Inlet Manifold Heater/Cold Start Relay ............................................... M21-29 Alternator ............................................................................................ M21-33 Throttle Position Sensor (TPS) ........................................................... M21-37 Engine Compartment Fuse/Relay Box ............................................... M21-41 Power Hold Relay ............................................................................... M21-45 Engine ECU ........................................................................................ M21-48 Start Signal Relay ............................................................................... M21-51 Fuel Lift Pump Relay .......................................................................... M21-54 Exhaust Gas Re circulation (EGR) Actuator ....................................... M21-57 Variable Geometry Turbo (VGT) Actuator ........................................... M21-59 General Control Devices Introduction ........................................................................................... M22-1 Related Topics ...................................................................................... M22-3 Ignition Switch ...................................................................................... M22-4 Info Operator Switch ........................................................................... M22-11 Neutral Start Relay ............................................................................. M22-17 Centre Cluster Warning Panel ............................................................ M22-18 Operator Present Switch .................................................................... M22-26 Direction Indicators/Turn Signal Lamps .............................................. M22-33 Trailer Turn Signal Lamp Circuit ......................................................... M22-42 Hazard Lamps .................................................................................... M22-47 Joystick (Thumbwheel and Button Type) ............................................ M22-53 Joystick (Button Type) ........................................................................ M22-64 Right Hand Column Switch ................................................................. M22-69 Sub Section Intentionally Blank ................................................................................ M23-1 Sub Section Intentionally Blank ................................................................................ M24-1 Sub Section Intentionally Blank ................................................................................ M25-1 Sub Section Intentionally Blank ................................................................................ M26-1

M-iii

Section M - Electronic Control Systems Contents Page No. Stabiliser and Sway Devices Introduction ........................................................................................... M27-1 Related Topics ...................................................................................... M27-3 Stabiliser Deployed Sensor .................................................................. M27-4 Stabiliser Isolation Solenoid (S1) ........................................................ M27-12 Stabiliser Isolation Solenoid (S2) ........................................................ M27-16 Stabiliser Isolation Switch ................................................................... M27-19 Stabiliser, Sway Relay ........................................................................ M27-26 Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) .............. M27-27 Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S2) .............. M27-33 Sway Direction Solenoid (S1) ............................................................. M27-34 Sway Direction Solenoid (S2) ............................................................. M27-41 Sway Switch (S1) ............................................................................... M27-42 Sway Switch (S2) ............................................................................... M27-48 Sub Section Intentionally Blank ................................................................................ M28-1 Sub Section Intentionally Blank ................................................................................ M29-1 Harness Interconnections Introduction ........................................................................................... M30-1 Related Topics ...................................................................................... M30-3 Harness Interconnections ..................................................................... M30-4 Device Ground Points Introduction ........................................................................................... M31-1 Related Topics ...................................................................................... M31-2 Ground Points ....................................................................................... M31-3

M-iv

Section M0 - Electronic Control Systems Applications Table

Note: For full details of machine identification refer to Section 1 - Machine Identification.

Machine models Topic Ref

Title

Variant

CANbus SYSTEM

Blank

Fault Code SYSTEM

Servicemaster SYSTEM

Servicemaster Tool Set

JCB EcoMax (SH,SL,SH) Engine Set Up Tool

JCB EcoMax (SH,SL,SH) Engine Diagnostic Tool

Cluster (LMS) Set Up Tool

Datalogger Tool User Guide

M10

Machine Diagnostics Tool

M11

Immobiliser Set Up Tool User Guide

M12

Immobiliser Diagnostics User Guide

M13

Pulse Width Modulation Theory

M14

Electronic Control Unit Theory

M15

Blank

M16

Blank

M17

Devices

M18

Electronic Controllers LMS ECU Immobiliser ECU Livelink ECU

506-36 5CD

z z z z z

z z z z z z z

z z z z z

z z z z z z z z z

z z z

Brake System Devices Park Brake Switch Footbrake Operated Switch

M0-1

9813/1800-2 (AM-00-08)

510-56 5CG 512-56 5CH 514-56 5CJ

RAS ECU M19

507-42 5CE 509-42 5CF

M0-1

Section M0 - Electronic Control Systems Applications Table Machine models Topic Ref

Title

Variant

506-36 5CD

507-42 5CE 509-42 5CF

510-56 5CG 512-56 5CH 514-56 5CJ

Footbrake Pressure Transducer Charge Pressure Transducer Transmission Disconnect (Footbrake Dump) Switch M20

Blank

M21

M22

81, 93 and 108 kW engines

General Control Devices Ignition Switch Info Operator Switch Neutral Start Relay Centre Cluster Warning Panel

z z z z z z z z z z z z z z z z z

z z z z z

Operator Present Switch

M0-2

9813/1800-2 (AM-00-08)

M0-2

Section M0 - Electronic Control Systems Applications Table Machine models Topic Ref

Title

Variant

506-36 5CD

507-42 5CE 509-42 5CF

510-56 5CG 512-56 5CH 514-56 5CJ

Direction Indicator/Turn Signal Lamps Trailer Turn Signal Lamp Circuit Hazard Lamps Joystick (Thumbwheel and Button Type) Joystick (Button Type) Right Hand Column Switch M23

Blank

M24

Blank

M25

Blank

M26

Blank

M27

Stabiliser and Sway Devices

z z

Stabiliser Deployed Sensor Stabiliser Isolation Solenoid (S1)

z z

z z z

z z

Blank

M29

Blank

M30

Device Harness Interconnections

M31

Device Ground Points

M0-3

9813/1800-2 (AM-00-08)

M0-3

Section M0 - Electronic Control Systems Applications Table

Page left intentionally blank

M0-4

9813/1800-2 (AM-00-08)

M0-4

Section M1 - Electronic Control Systems

CANbus SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T M1-6). Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T M1-6) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M1-6) K Operation Overview ( T M1-7) K CANbus Communications System ( T M1-7) K Electrical and Electronic Systems ( T M1-8)

M1-5

M-01-08 issue 01

M1-5

Section M1 - Electronic Control Systems CANbus SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

RAS SYSTEM

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

M1-6

M-01-08 issue 01

M1-6

Section M1 - Electronic Control Systems CANbus SYSTEM Operation Overview

Operation Overview Modern machines use electronic control units (ECU’s) to control machine systems such as hydraulics, transmission and engine. In much the same way as office computers can be ‘networked’ to communicate with each other the machine ECU’s can be ‘networked’. Some advantages of networking are: – Improved more intelligent control systems – More comprehensive instrumentation

and

reliable

in-cab

– Service software tools can be used for fault finding and machine control set up. The engine ECU can communicate with other machine ECU’s using a CANbus network system.

CANbus Communications System C

Controller

Area

Network

An electronic communications system that connects all the machine ECU’s to one pair of data wires called the CANbus. Coded data is sent to and from the ECU’s on the CANbus. By connecting Servicemaster diagnostic software to the CANbus, data is seen and decoded for use by a service engineer. Note: The CANbus system shown is for illustration purposes. Some components may be machine/variant specific. Refer to the applicable Electrical Schematics and Harness Drawings in Section C. K Related Topics ( T M1-6)

MPHkm/h

X 6

Fig 1. CANbus Communication Devices X

CANbus wires

Diagnostics Socket

RAS ECU (if fitted)

Immobiliser ECU (if fitted)

LMS ECU

EGR Valve

VGT Unit

Engine ECU

M1-7

M-01-08 issue 01

C122380-C1

Livelink ECU

M1-7

Section M1 - Electronic Control Systems CANbus SYSTEM Electrical and Electronic Systems

Electrical and Electronic Systems For details about electrical and electronic systems refer to Section C - Harness System/Electrical Schematics.

K Fig 2. ( T M1-9)

Table 2. Refer to:

Item

Device

CANbus Terminating Resistor

LMS ECU

K LMS ECU ( T M18-4)

RAS ECU

Refer to Section B - RAS SYSTEM. K Related Topics ( T M1-6)

Immobiliser ECU

K Immobiliser ECU ( T M18-13)

Diagnostic Socket

Used for connecting the machine to Servicemaster. Refer to the Servicemaster topics. K Servicemaster SYSTEM ( T M4-1)

Engine ECU (Grey Connector)

Refer to Tier 4 Engine Service Manual

EGR Actuator

Refer to Tier 4 Engine Service Manual

VGT Actuator

Refer to Tier 4 Engine Service Manual

Engine ECU (Black Connector)

Refer to Tier 4 Engine Service Manual

M1-8

M-01-08 issue 01

M1-8

M1-9

scr

2 15

Fig 2.

ECU

12 3

ECU

RAS

13 5

ECU

scr

C122390-C1

Section M1 - Electronic Control Systems CANbus SYSTEM

Electrical and Electronic Systems

M-01-08 issue 01

M1-9

Section M1 - Electronic Control Systems CANbus SYSTEM Electrical and Electronic Systems

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Section M2 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

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Section M3 - Electronic Control Systems

Fault Code SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. K Related Topics ( T M3-5) Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. K Related Topics ( T M3-5) This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T M3-5) K Operation Overview ( T M3-6) K Fault Code Display (S1) ( T M3-7)(1) K Fault Code Display (S2) ( T M3-9)(1) K General ‘D’ Codes ( T M3-12) K Transmission ‘T’ Codes ( T M3-17) K Powertrain ‘P’ Codes ( T M3-38) K Constant Auxiliary ECU ‘A’ Codes ( T M3-39) K HVCS ‘H’ Codes ( T M3-40) K Machine Control ECU ‘L’ Codes ( T M3-41) K Cab Area ‘B’ Codes ( T M3-55) K Chassis ‘C’ Codes ( T M3-59) K CANbus ‘U’ Codes ( T M3-63) K RAS “S” Codes ( T M3-66) K Electronic Engine SE Engine ECU Codes ( T M3-80) K Electronic Engine SH/SL/DH Engine ECU Codes ( T M3-90) (1) System variant. Make sure you refer to the correct procedure.

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M3-4 SH,SL,DH

Table 1. System Variants

z z

506-36, 507-42, 509-42, 510-56, 512-56, 514-56

531-70, 531-T70, 535-95, 535T95, 536-60, 536-T60, 541-70, 541-T70, 533-105, 536-70, 536T70, 550-80, 540-170, 550-170, 540-140, 550-140, 535-125 HiViz, 535-140 HiViz, 540-200, 526-56, 527-58

Machine Model Application

(1) The table lists procedure variants and the applicable machine models. Use the table to make sure you refer to the correct information.

K Fault Code Display (S2) ( T M3-9)

SD,SE,SF

K Fault Code Display (S1) ( T M3-7) SH,SL

Engine

Procedures(1)

Section M3 - Electronic Control Systems Fault Code SYSTEM Introduction

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Section M3 - Electronic Control Systems Fault Code SYSTEM Related Topics

Topic Titles

Sub Titles

Applications

ALL

Machine Identification

ALL

ALL (Care and Safety)

ALL

(1)

(1) You must obey all of the relevant care and safety procedures. Table 3. Related Topics in Publication 9806/4300, T4i Engine Service Manual The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Sections

Section Titles

Topic Titles

Electronic Data Systems

ALL

Table 4. Related Topics in Publication 9803/8610, Transmissions The table lists topics in another manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Sections

Section Titles

Topic Titles

TBA

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Section M3 - Electronic Control Systems Fault Code SYSTEM Operation Overview

Operation Overview There are many different variants of machine specification, where a specific model, transmission, engine or axle type is specified refer to Section 1 - Machine Identification to assist in identifying the applicable variant. K Related Topics ( T M3-5) The fault code display and procedure for accessing the codes varies according to the engine that is fitted to the machine. Refer to the System Variant table for details. K Table 1. System Variants ( T M3-4) â&#x20AC;&#x201C; K Fault Code Display (S1) ( T M3-7) â&#x20AC;&#x201C; K Fault Code Display (S2) ( T M3-9) All possible fault codes are contained in this section for the Loadall range of machines. Some codes will be machine model or variant specific. Only cross reference to codes shown on the display or fault code log.

Fault Code Abbreviations Abbreviation

Table 5. Description

EEPROM

Electronically Erasable Programmable Read-Only Memory

STB

Short Circuit to Battery

STG

Short Circuit to Ground/Earth

OORL

Out of Range - Low

OORH

Out of Range - High

Open

Open Circuit

Short

Short Circuit

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Section M3 - Electronic Control Systems Fault Code SYSTEM Operation Overview

Fault Code Display (S1)

Depending on the machine specification fault codes recorded by the engine ECU can be accessed and displayed in several ways:

Blink

2 second delay 7

CAN Enabled Display

Blink

2 second delay

Blink

The machine may be equipped with a CAN enabled display. Such a display will be capable of displaying all recorded codes, for example E127. All logged codes will be displayed. The operator may also have a facility to erase the fault code log. See the applicable machine documentation for further information.

The light will be ON for approximately 1 second and OFF for approximately 0.5 seconds. There is an OFF time of approximately 2 seconds between error code digits.

Malfunction Indicator Light (MIL)

Refer to the applicable system topic for details about the related blink codes.

When a blink code is displayed the MIL light can also come on. K Malfunction Indicator Light (MIL) ( T M3-7)

CANbus Connected Computer

Amber/Red light. The MIL light comes on to show that a system error has been detected. – Red light. The light comes ON (and a continuous audible alarm sounds) to indicate faults that may result in serious damage to the machine or make the machine dangerous to operate. This is known as a ‘STOP NOW’ fault. – Amber light. The light comes ON (and a audible alarm sounds for one second) to indicate faults that may result in reduced machine performance but are not dangerous. They are unlikely to damage the machine. This is known as a ‘SERVICE’ fault. When the MIL light comes on other applicable system warning can come on. These lights can show a blink code. K Blink Codes ( T M3-7)

Error codes logged can be accessed via a suitable laptop computer running the applicable diagnostics software. The computer must be connected to the machine CANbus socket using a data link adapter (DLA). Once connected all recorded codes can be displayed, for example E127. The engineer also has a facility to erase the fault code log.

Fault Code Log The monitoring system electronic control unit (ECU) incorporates a ‘data logging’ feature for recording fault codes. The log enters the fault code together with the current time and date. The fault code log can be read on the LCD. Alternatively use the JCB diagnostics tool. Reading the Fault Code Log on the LCD The machine graphical user interface (GUI) is one of two types:

Blink Codes

– When centre LCD panel is present it is used to display the fault code log. Fig 1. (X M3-8)

Some machine systems are equipped with a dedicated indicator light. If there is a system fault the light can display fault codes as a series of blinks. For example code E127 can be displayed as a series of blinks as follows:

M3-7

– When centre LCD panel is not present the fault code log is displayed on LMS LCD panel. Fig 2. (X M3-8) 1

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Operate the info button 4 with quick presses (less than 2 seconds) until the ‘time until next service’ is displayed.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Operation Overview 2

Operate the info button 4 with a long press (20 seconds or more). The ‘Service’ menu is selected.

Press the UP 3 or Down 2 buttons adjacent to the applicable LCD until ‘Fault List’ is displayed.

Operate the info button with a quick press (less than 2 seconds) to display the fault list. Press the UP 3 or Down 2 buttons to scroll through the fault list on the applicable LCD.

The faults are listed in the order they were logged.The duration of the fault and time are logged too. The list contains a maximum of 30 fault logs.

Fig 1. Centre Panel (CANbus Enabled)

C049480

Fig 2. Monitoring System Display Panel

C049470

Reading the Fault Code Log with JCB Servicemaster Use JCB Servicemaster and a laptop computer connected to machine CANbus to see the codes. The diagnostics tool will also enable fault finding options.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Operation Overview

Fault Code Display (S2)

‘OPERATOR’ faults. Warnings remain active until the operator acknowledges the warning with the info key.

A fault codes will be displayed on the Right Hand Cluster.

The active fault screen is shown at E. Do a short Press of the info button to display the fault code log screen F. Do a long press of the info button to return to display D.

The procedure for navigating between screens is described in the Screen Navigation section. K Screen Navigation ( T M3-10) The colour of the screen will change according to the severity of the fault displayed: – Critical Fault: The display screen is Red, the buzzer will sound, an Icon representing area of machine affected and a fault code will display to indicate faults that may result in serious damage to the machine or make the machine dangerous to operate. This is known as a ‘Critical’ fault. The operator must stop the machine. Critical faults remain active until the critical fault is no longer there, otherwise it cannot be cancelled or acknowledged. The active fault screen is shown at A. After 2 seconds screen B is displayed. Screens A and B will display alternately every 2 seconds. Press the info button to display the fault code log screen C.

C127760-C4.jpg

Fig 4. Service/Operator Fault Warning Displays

C127760-C3.jpg

Fig 3. Critical Fault Warning Displays

– Service/Operator Fault: The display screen is Amber, the buzzer will sound for 1 second, an Icon representing area of machine affected and a fault code is displayed. This indicates faults that may result in reduced machine performance but are not dangerous. They are unlikely to damage the machine. These are known as ‘SERVICE’ or

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Section M3 - Electronic Control Systems Fault Code SYSTEM Operation Overview Screen Navigation

Fig 5.

C D

C119740-C5

Navigation of the different screens shown on the LCD display A is done using 3 buttons. The Up B and Down C arrows on the right hand console and the info button D located as shown. The info button is used to perform two different actions: – Short Press - Press the info button for less than two seconds. Allows the operator to cycle through the main screens. – Long Press - Press the info button for longer than twenty seconds. Allows the operator to enter the displayed screen. – Arrow Buttons - Press to scroll vertically within the selected screen. They are also used to adjust screens, such as the time etc.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Operation Overview Fault Code Log The monitoring system electronic control unit (ECU) incorporates a â&#x20AC;&#x2DC;data loggingâ&#x20AC;&#x2122; feature for recording fault codes. The log enters the fault code together with the current time and date. The fault code log can be read on the LCD. Alternatively use the JCB diagnostics tool. Reading the Fault Code Log with Servicemaster Error codes logged can be accessed via a suitable laptop computer running the applicable diagnostics software. The computer must be connected to the machine CANbus socket using a data link adapter (DLA). Once connected all recorded codes can be displayed. The engineer also has a facility to erase the fault code log. Refer to Section M - Servicemaster SYSTEM. K Related Topics ( T M3-5) Reading the Fault Code Log on the LCD 1

Operate the info button with quick presses (less than 2 seconds) until the machine status screen A is displayed.

Press the UP or Down buttons to scroll through the fault list B on the screen. Fig 6. RHC Fault Code Log

M3-11

Key

K Fig 6. ( T M3-11)

Machine Status Screen

C127760-C5.jpg

Fault Code Log Screen

Fault Code

Time of Fault Occurrence

Date of Fault Occurrence

Engine Hours at which Fault Occurred

How Many Times Fault Was Recorded.

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Section M3 - Electronic Control Systems Fault Code SYSTEM General ‘D’ Codes

General ‘D’ Codes Fault Code

Description

Warning Displays

D001

Air filter blocked

Continuous buzzer activated. MIL lamp activated (Red). Air filter blocked warning lamp activated.

D001

D002

Water in fuel detected

On start-up sequence Message displayed on LCD.

WIF

With engine running - MIL lamp activated (RED). Message displayed on LCD. Continuous buzzer activated.

D002

With engine running - MIL lamp activated (RED). Message displayed on LCD. Continuous buzzer activated.

D003

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Water in fuel - operator fault

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Description

Warning Displays

D004

Coolant over temperature

Continuous buzzer activated. MIL lamp activated (Red). Over temperature warning lamp activated. Message displayed on LCD(1)

D004

D006

Transmission oil over temperature

Continuous buzzer activated. MIL lamp activated (Red). Over temperature warning lamp activated. Message displayed on LCD

D006

D010

Coolant level low

Fault Logged

D011

Engine oil level low when engine started

Fault Logged

D012

Engine oil pressure low

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MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

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D012

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Section M3 - Electronic Control Systems Fault Code SYSTEM General â&#x20AC;&#x2DC;Dâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

D014

Transmission oil pressure low

MIL lamp activated (RED). Message displayed on LCD. Continuous buzzer activated. Transmission oil pressure warning lamp activated.

D014

D079

CANbus communication MIL lamp activated. Message failure between LMS displayed on LCD. ECU and Engine ECU (SE Engine only)

D079

D106

Alternator excitation open circuit

Fault Logged

D107

Engine RPM open circuit

Fault Logged

D108

Ground speed sensor open circuit

Fault Logged

D115

Transmission oil pressure output open circuit

Fault Logged

D117

Fuel level sensor open circuit

Fault Logged

D118

Coolant temperature sensor signal open circuit

MIL lamp activated (amber). D118 Message displayed on LCD. Buzzer activated for 1 second. Coolant temperature gauge falls to minimum reading.

D119

Water in fuel sensor open circuit

MIL lamp activated (Amber). D119 Message displayed on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM General â&#x20AC;&#x2DC;Dâ&#x20AC;&#x2122; Codes Fault Code

Description

D128

Reversing fan output open circuit

Fault Logged

D205

Alternator not charging

Fault Logged

D215

Transmission oil pressure output short circuit

Fault Logged

D217

Fuel level sensor short circuit

Fault Logged

D218

Coolant temperature sensor signal short circuit

Fault Logged

D219

Water in fuel sensor short circuit

Fault Logged

D228

Reversing fan output short circuit

Fault Logged

D229

Brake Pressure Supply Out Of Range Low

D229

D230

Brake Pressure Supply Out Of Range High

D229

D230

Brake Pressure Supply Out Of Range High

D230

D231

Brake Pressure Supply Low

D231

D232

Brake Pressure Option Fault

D232

D300

CANbus communication fault

Fault Logged

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Warning Displays

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Section M3 - Electronic Control Systems Fault Code SYSTEM General â&#x20AC;&#x2DC;Dâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

Severity

RAS diagnostic LED blink code

RAS system fault warning

MIL lamp activated (Amber). Buzzer activated for 1 second. The RAS fault LED flashes a fault code. Refer to Section B, RAS SYSTEM. Fault logged.

RAS diagnostic LED blink code

RAS system critical fault MIL lamp activated (Red). Continuous buzzer activated. The RAS fault LED flashes a fault code. Refer to Section B, RAS SYSTEM. Fault logged.

RAS diagnostic LED blink code

Control valve spool switch critical fault

Z000

Error logs erased

Z111

Error logs full

Fault Logged

Z200

Vehicle serviced

Fault Logged

MIL lamp activated (Red). Continuous buzzer activated. Hydraulic isolation lamp activated. The RAS fault LED flashes a fault code. Refer to Section B, RAS SYSTEM. Fault logged.

Fault Logged

(1) The engine coolant warning light in the cluster in front of the steering wheel is activated by a switch in the temperature sender unit. A buzzer is also activated. These warning devices are not controlled by the systems ECU.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission ‘T’ Codes

Transmission ‘T’ Codes Fault Code

Description

Warning Displays

T000

Column switch neutral out of range error

MIL lamp activated T000 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T001

Column switch forward out of range error

MIL lamp activated T001 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T002

Column switch reverse out of range error

MIL lamp activated T002 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T003

Column switch short circuit

MIL lamp activated (Red). T003 Message displayed on LCD. Continuous buzzer activated

T004

Column switch open circuit

MIL lamp activated (Red). T004 Message displayed on LCD. Continuous buzzer activated

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Description

Warning Displays

T005

Joystick F/N/R switch short circuit

MIL lamp activated T005 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T006

Joystick F/N/R switch open circuit

MIL lamp activated T006 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T007

Joystick CANbus fault

MIL lamp activated T007 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T008

Joystick F/N/R neutral fault

MIL lamp activated T008 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T009

Joystick F/N/R forward fault

MIL lamp activated T009 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T010

Joystick F/N/R reverse fault

MIL lamp activated T010 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Description

Warning Displays

T011

Pump forward solenoid (high side) - short circuit to battery

MIL lamp activated (Red). T011 Message displayed on LCD. Continuous buzzer activated

T012

Pump forward solenoid (high side) - short circuit to ground

MIL lamp activated (Red). T012 Message displayed on LCD. Continuous buzzer activated

T013

Pump forward solenoid (high side) - open circuit

MIL lamp activated (Red). T013 Message displayed on LCD. Continuous buzzer activated

T014

Pump forward solenoid (low side) - short circuit to battery

MIL lamp activated (Red). T014 Message displayed on LCD. Continuous buzzer activated

T015

Pump forward solenoid (low side) - short circuit to ground

MIL lamp activated (Red). T015 Message displayed on LCD. Continuous buzzer activated

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T016

Pump forward solenoid (low side) - open circuit

MIL lamp activated (Red). T016 Message displayed on LCD. Continuous buzzer activated

T017

Pump reverse solenoid (high side) - short circuit to battery

MIL lamp activated (Red). T017 Message displayed on LCD. Continuous buzzer activated

T018

Pump reverse solenoid (high side) - short circuit to ground

MIL lamp activated (Red). T018 Message displayed on LCD. Continuous buzzer activated

T019

Pump reverse solenoid (high side) - open circuit

MIL lamp activated (Red). T019 Message displayed on LCD. Continuous buzzer activated

T020

Pump reverse solenoid (low side) - short circuit to battery

MIL lamp activated (Red). T020 Message displayed on LCD. Continuous buzzer activated

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T021

Pump reverse solenoid (low side) - short circuit to ground

MIL lamp activated (Red). T021 Message displayed on LCD. Continuous buzzer activated

T022

Pump reverse solenoid (low side) - open circuit

MIL lamp activated (Red). T022 Message displayed on LCD. Continuous buzzer activated

T023

Motor control solenoid (high side) - short circuit to battery

MIL lamp activated T023 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T024

Motor control solenoid (high side) - short circuit to ground

MIL lamp activated T024 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T025

Motor control solenoid (high side) - open circuit

MIL lamp activated T025 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T026

Motor control solenoid (low side) - short circuit to battery

MIL lamp activated T026 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T027

Motor control solenoid (low side) - short circuit to ground

MIL lamp activated T027 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T028

Motor control solenoid (low side) - open circuit

MIL lamp activated T028 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T029

Low speed solenoid (high side) - short circuit to battery

MIL lamp activated T029 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T030

Low speed solenoid (high side) - short circuit to ground

MIL lamp activated T030 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T031

Low speed solenoid (high side) - open circuit

MIL lamp activated T031 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T032

Low speed solenoid (low side) MIL lamp activated T032 - short circuit to battery (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T033

Low speed solenoid (low side) MIL lamp activated T033 - short circuit to ground (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T034

Low speed solenoid (low side) MIL lamp activated T034 - open circuit (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T035

Vari-inch dial 1 - short circuit to MIL lamp activated T035 ground (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T036

Vari-inch dial 1 - short circuit to MIL lamp activated T036 battery (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T037

Vari-inch dial 2 - short circuit to MIL lamp activated T037 ground (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Warning Displays

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T038

Vari-inch dial 2 - short circuit to MIL lamp activated T038 battery (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T039

Vari-inch dial signal mismatch MIL lamp activated T039 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T040

Park brake switch - open circuit

MIL lamp activated T040 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T041

Park brake switch - short circuit

MIL lamp activated T041 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T042

Transmission temperature MIL lamp activated sensor out of range error - low (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T042

T746

Transmission temperature sensor out of range error high

T746

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Warning Displays

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T044

Steer valve A - short circuit to MIL lamp activated (Red). T044 battery Message displayed on LCD. Continuous buzzer activated

T045

Steer valve A - short circuit to MIL lamp activated (Red). T045 ground Message displayed on LCD. Continuous buzzer activated

T046

Steer valve A - open circuit

MIL lamp activated (Red). T046 Message displayed on LCD. Continuous buzzer activated

T047

Steer valve B- short circuit to battery

MIL lamp activated (Red). T047 Message displayed on LCD. Continuous buzzer activated

T048

Steer valve B - short circuit to MIL lamp activated (Red). T048 ground Message displayed on LCD. Continuous buzzer activated

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Warning Displays

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T049

Steer valve B - open circuit

MIL lamp activated (Red). T049 Message displayed on LCD. Continuous buzzer activated

T050

Steer valve C - short circuit to MIL lamp activated (Red). T050 battery Message displayed on LCD. Continuous buzzer activated

T051

Steer valve C - short circuit to MIL lamp activated (Red). T051 ground Message displayed on LCD. Continuous buzzer activated

T052

Steer valve C- open circuit

T053

Steer valve D - short circuit to MIL lamp activated (Red). T053 battery Message displayed on LCD. Continuous buzzer activated

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MIL lamp activated (Red). T052 Message displayed on LCD. Continuous buzzer activated

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T054

Steer valve D - short circuit to MIL lamp activated (Red). T054 ground Message displayed on LCD. Continuous buzzer activated

T055

Steer valve D - open circuit

MIL lamp activated (Red). T055 Message displayed on LCD. Continuous buzzer activated

T056

Steer mode switch - short circuit

MIL lamp activated T056 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T057

Steer mode switch - open circuit

MIL lamp activated T057 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T058

Left turn output - short circuit to battery

MIL lamp activated T058 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Warning Displays

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T059

Left turn output - short circuit to ground

MIL lamp activated T059 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T060

Left turn output - open circuit

MIL lamp activated T060 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T061

Right turn output - short circuit MIL lamp activated T061 to battery (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T062

Right turn output - short circuit MIL lamp activated T062 to ground (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T063

Right turn output - open circuit MIL lamp activated T063 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T064

Neutral start - short circuit to battery

MIL lamp activated (Red). T064 Message displayed on LCD. Continuous buzzer activated

T065

Neutral start - short circuit to ground

MIL lamp activated T066 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T066

Neutral start - open circuit

MIL lamp activated T066 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T067

Brake lights - short circuit to battery

MIL lamp activated T067 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T068

Brake lights - short circuit to ground

MIL lamp activated T068 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-29

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M3-29

Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T069

Brake lights - open circuit

MIL lamp activated T069 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T070

Footbrake switch (Normally closed) out of range error

MIL lamp activated T070 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T071

Footbrake switch (Normally open) out of range error

MIL lamp activated T071 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T072

Footbrake switch - open circuit MIL lamp activated T072 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T073

Footbrake switch - short circuit MIL lamp activated T07 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-30

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Severity

M3-30

Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T074

Reverse alarm - short circuit to MIL lamp activated (Red). T074 battery Message displayed on LCD. Continuous buzzer activated

T075

Reverse alarm - short circuit to MIL lamp activated T075 ground (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T076

Reverse alarm - open circuit

MIL lamp activated T076 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T077

Ground speed sensor out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T077

T078

Ground speed sensor out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T078

M3-31

Warning Displays

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M3-31

Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T079

Ground speed invalid

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T079

T080

Secondary ground speed lost MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T080

T081

Ground speed signal disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T081

T082

Secondary ground speed invalid

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T082

T083

Vari-inch LED - short circuit to MIL lamp activated (Red). T083 battery Message displayed on LCD. Continuous buzzer activated

T084

Vari-inch LED - short circuit to MIL lamp activated T084 ground (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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M3-32

Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T085

Vari-inch LED - open circuit

MIL lamp activated T085 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T086

Switch supply - short circuit to MIL lamp activated (Red). T086 battery Message displayed on LCD. Continuous buzzer activated

T087

Switch supply - short circuit to MIL lamp activated T087 ground (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T088

Switch supply - open circuit

MIL lamp activated T088 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T089

Application checksum failure

MIL lamp activated (Red). T089 Message displayed on LCD. Continuous buzzer activated

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M3-33

Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

Warning Displays

T091

Constant data checksum failure

MIL lamp activated T091 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T310 (SE engine)

CAN data unavailable - engine percent load at current speed.

Fault Logged

T311 (SE engine)

CAN data unavailable - torque convertor lockup disable

Fault Logged

T312 (SE engine)

CAN data unavailable - engine speed

Fault Logged

T730

T Solenoid electrical fault - HS MIL lamp activated T730 output fault (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T731

W Solenoid electrical fault HS output fault

T732

U Solenoid electrical fault - HS MIL lamp activated T732 output fault (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T733

V Solenoid electrical fault - HS MIL lamp activated T733 output fault (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-34

Severity

MIL lamp activated T731 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T734

X Solenoid electrical fault - HS MIL lamp activated T734 output fault (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T735

Y Solenoid electrical fault - HS MIL lamp activated T735 output fault (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T736

LUC Solenoid electrical fault - MIL lamp activated HS output fault (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T736

T737

Neutral start electrical fault HS output fault

Fault Logged

T738

Reverse lamp electrical fault HS output fault

Fault Logged

T739

Z solenoid electrical fault - HS MIL lamp activated output fault (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T739

T740

4WD solenoid fault - HS output fault

T740

T741

Transmission warning lamp electrical fault - LS output fault

M3-35

Warning Displays

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

Severity

Fault Logged

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T742

ECU buffered speed electrical fault - LS output fault

Fault Logged

T743

Low oil pressure lamp electrical fault - LS output fault

Fault Logged

T744

Kickdown / pressure electrical fault - LS output fault

Fault Logged

T745

Transmission ECU status - no setup file blank ECU, default data in use

Fault Logged

T746

Transmission oil temperature too high

T747

Transmission oil pressure low. MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

T7467

T748

Gear selector logical error invalid gear selection

Fault Logged

T749

Column switch electrical fault invalid FNR lever switch pattern

Fault Logged

T750

Joystick lever electrical fault invalid joystick lever switch pattern

Fault Logged

T751

Handbrake switch fault invalid logic 00 or 11 ECU inputs detected.

T752

Footbrake pressure switch fault - invalid logic 00 or 11 ECU inputs detected.

M3-36

Warning Displays

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

Severity

T746

T751

Fault Logged

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Section M3 - Electronic Control Systems Fault Code SYSTEM Transmission â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; Codes Fault Code

Description

T800

Transmission speed signal open circuit

T801

Engine speed signal open circuit

MIL lamp activated T801 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T900

Transmission speed signal voltage above normal

MIL lamp activated T900 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T901

Engine speed signal voltage above normal

MIL lamp activated T901 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T950

Transmission speed signal voltage below normal

MIL lamp activated T950 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

T951

Engine speed signal voltage below normal

MIL lamp activated T951 (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-37

Warning Displays

Severity Fault Logged

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M3-37

Section M3 - Electronic Control Systems Fault Code SYSTEM Powertrain ‘P’ Codes

Powertrain ‘P’ Codes Should faults occur related to the transmission 0711 ECU, IFM ECU, Engine ECU or the electrical devices connected to it the ECU generates fault codes and stores them in its memory. By using the JCB Servicemaster Diagnostics Tool these codes can be read using a laptop computer connected to the ECU. The system will also display ‘real time’ data for faults active with the engine running.

The ‘P’ fault code will display a 5 digit code followed by a suffix of 2 digits: ‘P1234-56’ The third digit of the code (in the above example = 2) refers to which system is affected. K Table 6. P Code Definitions ( T M3-38)

Depending on the machine installation fault codes may be displayed using one or more display systems. K Operation Overview ( T M3-6). Table 6. P Code Definitions Third Digit

System

Powertrain Component Affected

Fuel and Air Metering

Engine

Fuel and Air Metering (Injector Circuit Malfunction Only)

Engine

Ignition System or Misfire

Engine

Auxiliary Emission Control System

Engine

Vehicle Speed Control and Idle Control System

Engine/Transmission

Computer Output Circuit

Engine/Transmission

Transmission

For details of ‘P’ fault codes refer to the applicable service manual: – 9806/4300 T4i Engine Service Manual. K Related Topics ( T M3-5) – 9803/8610 Transmissions K Related Topics ( T M3-5)

M3-38

Service

Manual.

M-03-06 issue 01

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Section M3 - Electronic Control Systems Fault Code SYSTEM Constant Auxiliary ECU ‘A’ Codes

Constant Auxiliary ECU ‘A’ Codes Fault Code

Description

Warning Displays

A XXX

Constant auxiliary fault

Message displayed on LCD.

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Severity AXXX

M3-39

Section M3 - Electronic Control Systems Fault Code SYSTEM HVCS ‘H’ Codes

HVCS ‘H’ Codes Fault Code

Description

Warning Displays

H _ TBA

HVCS fault

MIL lamp activated H___ (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-40

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Severity

M3-40

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU ‘L’ Codes

Machine Control ECU ‘L’ Codes Fault Code Description

Warning Displays

L000

10° Proximity switch - open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L001

10° Proximity switch - short circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L002

10° Proximity switch - supply open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L003

10° Proximity switch - supply short circuit to ground

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L004

10° Proximity switch - supply short circuit to battery

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L005

Boom retracted proximity switch open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L006

Boom retracted proximity switch short circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L007

Boom retracted proximity switch supply open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L008

Boom retracted proximity switch supply short circuit to ground

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L009

Boom retracted proximity switch supply short circuit to battery

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L010

45° Proximity switch - open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L011

45° Proximity switch - short circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L012

45° Proximity switch - supply open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

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M3-41

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU ‘L’ Codes Fault Code Description

Warning Displays

L013

45° Proximity switch - supply short circuit to ground

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L014

45° Proximity switch - supply short circuit to battery

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L015

Boom lower transducer - out of range MIL lamp activated (Red). Message displayed on error - low LCD. Continuous buzzer activated

L016

Boom lower transducer - out of range MIL lamp activated (Red). Message displayed on error - high LCD. Continuous buzzer activated

L017

Fork tilt switch - out of range error low

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L018

Fork tilt switch - out of range error high

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L019

Lower/tilt switch - supply open circuit MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L020

Lower/tilt switch - supply short circuit MIL lamp activated (Red). Message displayed on to ground LCD. Continuous buzzer activated

L021

Lower/tilt switch - supply short circuit MIL lamp activated (Red). Message displayed on to battery LCD. Continuous buzzer activated

L022

Load Moment Indicator (LMI) fault

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L023

SRS switch - short circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L024

80% Solenoid - open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L025

80% Solenoid - short circuit to ground

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L026

80% Solenoid - short circuit to battery MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

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M3-42

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L027

100% Solenoid - open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L028

100% Solenoid - short circuit to ground

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L029

100% Solenoid - short circuit to battery

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L030

Accumulator solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L031

Accumulator solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L032

Accumulator solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L033

Drain solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L034

Drain solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L035

Drain solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L036

Boom extend solenoid - open circuit MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L037

Boom extend solenoid - short circuit MIL lamp activated (Amber). Message displayed on to ground LCD. Buzzer activated for 1 second.

L038

Boom extend solenoid - short circuit MIL lamp activated (Amber). Message displayed on to battery LCD. Buzzer activated for 1 second.

L039

Boom retract solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L040

Boom retract solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-43

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M3-43

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU ‘L’ Codes Fault Code Description

Warning Displays

L041

Boom retract solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L042

Boom extend/retract solenoid return MIL lamp activated (Amber). Message displayed on - open circuit LCD. Buzzer activated for 1 second.

L043

Boom extend/retract solenoid return MIL lamp activated (Amber). Message displayed on - short circuit to ground LCD. Buzzer activated for 1 second.

L044

Boom extend/retract solenoid return MIL lamp activated (Amber). Message displayed on - short circuit to battery LCD. Buzzer activated for 1 second.

L045

Auxiliary ‘A’ solenoid - open circuit

L046

Auxiliary ‘A’ solenoid - short circuit to MIL lamp activated (Amber). Message displayed on ground LCD. Buzzer activated for 1 second.

L047

Auxiliary ‘A’ solenoid - short circuit to MIL lamp activated (Amber). Message displayed on battery LCD. Buzzer activated for 1 second.

L048

Auxiliary ‘B’ solenoid - open circuit

L049

Auxiliary ‘B’ solenoid - short circuit to MIL lamp activated (Amber). Message displayed on ground LCD. Buzzer activated for 1 second.

L050

Auxiliary ‘B’ solenoid - short circuit to MIL lamp activated (Amber). Message displayed on battery LCD. Buzzer activated for 1 second.

L051

Auxiliary ‘A’/’B’ solenoid return - open MIL lamp activated (Amber). Message displayed on circuit LCD. Buzzer activated for 1 second.

L052

Auxiliary ‘A’/’B’ solenoid return - short MIL lamp activated (Amber). Message displayed on circuit to ground LCD. Buzzer activated for 1 second.

L053

Auxiliary ‘A’/’B’ solenoid return - short MIL lamp activated (Amber). Message displayed on circuit to battery LCD. Buzzer activated for 1 second.

L054

Auxiliary changeover solenoid - open MIL lamp activated (Amber). Message displayed on circuit (Hitch/Aux) LCD. Buzzer activated for 1 second.

M3-44

Severity

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M-03-06 issue 01

M3-44

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU ‘L’ Codes Fault Code Description

Warning Displays

L055

Auxiliary changeover solenoid - short MIL lamp activated (Amber). Message displayed on circuit to ground (Hitch/Aux) LCD. Buzzer activated for 1 second.

L056

Auxiliary changeover solenoid - short MIL lamp activated (Amber). Message displayed on circuit to battery (Hitch/Aux) LCD. Buzzer activated for 1 second.

L057

Boom extend/retract thumbwheel out MIL lamp activated (Amber). Message displayed on of range error - low LCD. Buzzer activated for 1 second.

L058

Boom extend/retract thumbwheel out MIL lamp activated (Amber). Message displayed on of range error - high LCD. Buzzer activated for 1 second.

L059

Column F/N/R switch - ‘Neutral’ position open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L060

Column F/N/R switch - ‘Neutral’ position short circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L061

Auxiliary thumbwheel out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L062

Auxiliary thumbwheel out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L063

Joystick hydraulic lock (isolation) switch - open circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L064

Joystick hydraulic lock (isolation) switch - short circuit

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L065

Neutral start relay - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L066

Neutral start relay - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L067

Neutral start relay - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L068

Joystick/control lever F/N/R switch supply - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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M3-45

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L069

Joystick/control lever F/N/R switch supply - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L070

Joystick/control lever F/N/R switch supply - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L071

CANbus fault

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L072

EEPROM fault

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L073

Lower transducer disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L074

Tilt transducer disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L075

Boom angle sensor disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L076

Boom angle sensor 1 out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L077

Boom angle sensor 1 out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L078

Boom angle sensor 2 out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L079

Boom angle sensor 2 out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L080

Lift pressure transducer out of range MIL lamp activated (Amber). Message displayed on error - low LCD. Buzzer activated for 1 second.

L081

Lift pressure transducer out of range MIL lamp activated (Amber). Message displayed on error - high LCD. Buzzer activated for 1 second.

L082

Raise solenoid - open circuit

M3-46

Severity

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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M3-46

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L083

Raise solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L084

Raise solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L085

Lower solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L086

Lower solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L087

Lower solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L088

Crowd solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L089

Crowd solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L090

Crowd solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L091

Dump solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L092

Dump solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L093

Dump solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L094

Throttle extend - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L095

Throttle extend - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L096

Throttle extend - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-47

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M3-47

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L097

Throttle retract - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L098

Throttle retract - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L099

Throttle retract - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L100

Throttle relay - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L101

Throttle relay - short circuit to ground MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L102

Throttle relay - short circuit to battery MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L103

Hydraulic shut off solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L104

Hydraulic shut off solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L105

Hydraulic shut off solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L106

Raise / lower solenoid return - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L107

Raise / lower solenoid return - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L108

Raise / lower solenoid return - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L109

Crowd / dump solenoid return - open MIL lamp activated (Amber). Message displayed on circuit LCD. Buzzer activated for 1 second.

L110

Crowd / dump solenoid return - short MIL lamp activated (Amber). Message displayed on circuit to ground LCD. Buzzer activated for 1 second.

M3-48

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M3-48

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L111

Crowd / dump solenoid return - short MIL lamp activated (Amber). Message displayed on circuit to battery LCD. Buzzer activated for 1 second.

L112

Tilt lock switch - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L113

Tilt lock switch - short circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L114

Throttle position feedback - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L115

Throttle position feedback - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L116

SRS pressure switch - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L117

SRS pressure switch - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L118

SRS pressure switch - disagreement MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L119

Throttle dial sensor 1 - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L120

Throttle dial sensor 1 - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L121

Throttle dial sensor 2 - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L122

Throttle dial sensor 2 - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L123

Throttle dial sensor - disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L124

Boom movement when joystick is at neutral (valve spool fault)

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-49

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Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L125

Boom movement when load moment MIL lamp activated (Amber). Message displayed on is more than 115% (valve spool fault) LCD. Buzzer activated for 1 second.

L126

Throttle not able to achieve position

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L127

Hydraulic stop switch - short circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L128

Hydraulic stop switch - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L129

Speed sensor - out of range error high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L130

Speed sensor - out of range error low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L131

Speed sensor - disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L132

Chassis angle sensor disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L133

Chassis angle sensor 1 - out of range MIL lamp activated (Amber). Message displayed on error - low LCD. Buzzer activated for 1 second.

L134

Chassis angle sensor 1 - out of range MIL lamp activated (Amber). Message displayed on error - high LCD. Buzzer activated for 1 second.

L135

Chassis angle sensor 2 - out of range MIL lamp activated (Amber). Message displayed on error - low LCD. Buzzer activated for 1 second.

L136

Chassis angle sensor 2 - out of range MIL lamp activated (Amber). Message displayed on error - high LCD. Buzzer activated for 1 second.

L137

Sway switch - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L138

Sway switch - short circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-50

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Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L139

Stabiliser isolation switch - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L140

Stabiliser isolation switch - short circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L141

Lift/lower spool neutral disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L142

Lift/lower spool - out of range error low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L143

Lift/lower spool - out of range error high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L144

Extend/retract spool neutral disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L145

Extend/retract spool - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L146

Extend/retract spool - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L147

Crowd/dump spool neutral disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L148

Crowd/dump spool - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L149

Crowd/dump spool - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L150

Aux A/B spool neutral - disagreement MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L151

Aux A/B spool - out of range error low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L152

Aux A/B spool - out of range error high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L153

Left stabiliser spool neutral disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L154

Left stabiliser spool - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L155

Left stabiliser spool - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L156

Right stabiliser spool neutral disagreement

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L157

Right stabiliser spool - out of range error - low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L158

Right stabiliser spool - out of range error - high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L159

Ext Aux 2B sw - out of range error

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L160

Aux A AUx B sw - out of range error MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L161

Ret Aux 2A sw - out of range error

L162

Sway isolation solenoid - open circuit MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L163

Sway isolation solenoid - short circuit MIL lamp activated (Amber). Message displayed on to ground LCD. Buzzer activated for 1 second.

L164

Sway isolation solenoid - short circuit MIL lamp activated (Amber). Message displayed on to battery LCD. Buzzer activated for 1 second.

L165

Switch supply - open circuit

L166

Switch supply - short circuit to ground MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-52

Severity

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M-03-06 issue 01

M3-52

Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L167

Switch supply - short circuit to battery MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L168

Transmission dump - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L169

Transmission dump - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L170

Transmission dump - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L171

Stabiliser isolation solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L172

Stabiliser isolation solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L173

Stabiliser isolation solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L174

Sway right solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L175

Sway right solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L176

Sway right solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L177

Sway left solenoid - open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L178

Sway left solenoid - short circuit to ground

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L179

Sway left solenoid - short circuit to battery

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

L180

Sway/stabiliser isolation return relay MIL lamp activated (Amber). Message displayed on - open circuit LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Machine Control ECU â&#x20AC;&#x2DC;Lâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Displays

L181

Sway/stabiliser isolation return relay MIL lamp activated (Amber). Message displayed on - short circuit to ground LCD. Buzzer activated for 1 second.

L182

Sway/stabiliser isolation return relay MIL lamp activated (Amber). Message displayed on - short circuit to battery LCD. Buzzer activated for 1 second.

L183

Motion cut out valve LS - open circuit MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L184

Motion cut out valve LS - short circuit MIL lamp activated (Red). Message displayed on to battery LCD. Continuous buzzer activated

L185

Engine start with immobiliser on

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

L186

Left stabiliser deployed sensor disagreement

Fault logged

L187

Right stabiliser deployed sensor disagreement

Fault logged

M3-54

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Section M3 - Electronic Control Systems Fault Code SYSTEM Cab Area ‘B’ Codes

Cab Area ‘B’ Codes Note: Faults that are classed as ‘Trivial’ severity will not be displayed on the RHC. These can only be read using Servicemaster. Fault Code Description

Warning Display Colour

Severity

B104C-67

LLMI Calibration tip point

Amber

Operator

B104D-67

LLMI Calibration travel point

Amber

Operator

B104E-54

LLMI Calibration Required

Amber

Operator

B104F-49

LLMI LED’s connection error

Amber

Operator

B1050-29

LLMI calibration error

Amber

Operator

B1051-46

LLMI EEPROM Store Error

Amber

Operator

B1052-46

LLMI EEPROM Read Error

Amber

Operator

B1053-0

LLMI Valve Application Error

Amber

Operator

B1054-87

LLMI CAN No Response Error

Amber

Operator

B1055-16

LLMI Low Voltage Error

Amber

Operator

B1056-17

LLMI High Voltage Error

Amber

Operator

B1057-47

LLMI PIC Comms Error

Amber

Operator

B1058-24

LLMI Override Mode Error

Amber

Operator

B1059-62

LLMI Cross Checking Error

Amber

Operator

B1500-64

SRS Switch Short Circuit

Amber

Operator

B1501-1C

SRS Switch Out Of Range Error

Amber

Operator

B1502-13

Hydraulic Isolation Switch Open Circuit

Amber

Operator

B1503-64

Hydraulic Isolation Switch Short Circuit

Amber

Operator

B1504-1C

Hydraulic Isolation Switch Out Of Range Error

Amber

Operator

B150D-13

Column Forward/Neutral/Reverse Switch Open Circuit

Amber

Operator

B150E-64

Column Forward/Neutral/Reverse Switch Short Circuit

Amber

Operator

B150F-64

Steer Mode Proximity Switch/Sensor Disagreement

Amber

Operator

B1510-18

Steer Mode Proximity Switch/ Sensor 1 - Out Of Range Low

Amber

Operator

B1511-17

Steer Mode Proximity Switch/Sensor 1 - Out Of Range High

Amber

Operator

B1512-18

Steer Mode Proximity Switch/Sensor 2 - Out Of Range Low

Amber

Operator

B1513-17

Steer Mode Proximity Switch/Sensor 2 - Out Of Range High

Amber

Operator

B1514-64

Forward/Neutral/Reverse Transmission Monitor Rationality Fault

Amber

Operator

B1515-13

Brake Light Switch Open Circuit

Amber

Operator

B1516-64

Brake Light Switch Short Circuit

Amber

Operator

B1517-1C

Brake Light Switch Out Of Range

Amber

Operator

B1518-13

Parkbrake Switch Open Circuit

Amber

Operator

B1519-64

Parkbrake Switch Short Circuit

Amber

Operator

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Section M3 - Electronic Control Systems Fault Code SYSTEM Cab Area ‘B’ Codes Fault Code Description

Warning Display Colour

Severity

B151A-1C

Amber

Operator

Parkbrake Switch Out Of Range

B151B-13

2WD Switch Open Circuit

Amber

Operator

B151C-64

2WD Switch Short Circuit

Amber

Operator

B151D-1C

2WD Switch Out Of Range

Amber

Operator

B151E-13

Drive Control Shutdown Open Circuit

Amber

Operator

B151F-11

Drive Control Shutdown Short to Ground

Amber

Operator

B1520-12

Drive Control Shutdown Short to Battery

Amber

Operator

B1521-1C

Footbrake Dump Switch Out of Range

Amber

Operator

B1522-13

Auto Trans Switch Open Circuit

Amber

Operator

B1523-64

Auto Trans Switch Short Circuit

Amber

Operator

B1524-1C

Auto Trans Switch Out Of Range

Amber

Operator

B1525-13

Operator Present Seat Switch Open Circuit

Amber

Operator

B1526-64

Operator Present Seat Switch Short Circuit

Amber

Operator

B1527-13

Neutral Start Relay Open Circuit

Amber

Operator

B1528-11

Neutral Start Relay Short to Ground

Amber

Operator

B1529-12

Neutral Start Relay Short to Battery

Amber

Operator

B152A-13

Brake Lamp Open Circuit

Amber

Operator

B152B-11

Brake Lamp Short to Ground

Amber

Operator

B152C-12

Brake Lamp Short to Battery

Amber

Operator

B152D-13

Reverse Lamp Open Circuit

Amber

Operator

B152E-11

Reverse Lamp Short to Ground

Amber

Operator

B152F-12

Reverse Lamp Short to Battery

Amber

Operator

B1530-18

Footbrake Pressure Switch Out of Range Low

Amber

Operator

B1531-17

Footbrake Pressure Switch Out of Range High

Amber

Operator

B1532-18

5V Sensor Supply Short to Ground

Amber

Operator

B1533-17

5V Sensor Supply Short to Battery

Amber

Operator

B1534-13

Tilt Lock Switch Open Circuit

Amber

Operator

B1535-64

Tilt Lock Switch Short Circuit

Amber

Operator

B1536-1C

Tilt Lock Switch Out of Range

Amber

Operator

B1537-64

Constant Auxiliary Set Switch Disagreement

Amber

Operator

B1539-13

Constant Auxiliary Enable Switch Open Circuit

Amber

Operator

B153A-64

Constant Auxiliary Enable Switch Short Circuit

Amber

Operator

B153B-1C

Constant Auxiliary Enable Switch Out of Range

Amber

Operator

B153C-13

Joystick Forward/Neutral/Reverse Open Circuit

Amber

Operator

B153D-64

Joystick Forward/Neutral/Reverse Short Circuit

Amber

Operator

B153E-21

Low Fuel Level (Operator Level)

Amber

Operator

B153F-13

Fuel Level Sensor Open Circuit

Amber

Operator

B1540-68

Low Fuel Level (Service Level)

Amber

Service

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Section M3 - Electronic Control Systems Fault Code SYSTEM Cab Area â&#x20AC;&#x2DC;Bâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Display Colour

Severity

B1541-68

Amber

Operator

Engine Oil Low When Engine Started

B1542-68

Air Filter Blocked

Amber

Operator

B1543-4B

Coolant Temperature High (Critical Level)

Red

Critical

B1544-14

Coolant Temperature Sensor Short Circuit

Amber

Operator

B1545-13

Coolant Temperature Sensor Open Circuit

Amber

Operator

B1546-68

Coolant Temperature Sensor High (Operator Level)

Amber

Operator

B1547-68

Coolant Level Low, Engine Running

Amber

Operator

B1548-21

Coolant Level Low, Engine Not Started

Amber

Operator

B1549-21

Ambient Temperature Sensor Out of Range Low

Amber

Service

B154A-68

Service Interval Elapsed

Amber

Service

B154B-12

Left Direction Indicator - Short to Battery

Amber

Operator

B154C-11

Left Direction Indicator - Short to Ground

Amber

Operator

B154D-13

Left Direction Indicator - Bulb Out/Open Circuit

Amber

Operator

B154E-12

Right Direction Indicator - Short to Battery

Amber

Operator

B154F-11

Right Direction Indicator - Short to Ground

Amber

Operator

B1550-13

Right Direction Indicator - Bulb Out/Open Circuit

Amber

Operator

B1551-13

Right Trailer Indicator - Bulb Out/Open Circuit

Amber

Operator

B1552-13

Left Trailer Indicator - Bulb Out/Open Circuit

Amber

Operator

B1553-13

Alternator Open Circuit

Amber

Operator

B1554-21

Alternator not Charging

Amber

Operator

B1555-68

Error Logs Full

No Display

Trivial

B1556-68

Error Logs Erased

No Display

Trivial

B1557-68

Vehicle Serviced

No Display

Trivial

B1558-12

Reversing Fan Output Short to Battery

Amber

Operator

B1559-11

Reversing Fan Output Short to Ground

Amber

Operator

B155A-13

Reversing Fan Output Open Circuit

Amber

Operator

B155B-12

Trailer Indicator LED Output Short to Battery

Amber

Operator

B155C-11

Trailer Indicator LED Output Short to Ground

Amber

Operator

B155D-13

Trailer Indicator LED Output Open Circuit

Amber

Operator

B155E-12

Proportional Fan Output Short to Battery

Amber

Operator

B155F-11

Proportional Fan Output Short to Ground

Amber

Operator

B1560-13

Proportional Fan Output Open Circuit

Amber

Operator

B1561-02

HVAC Switch Out of Range

Amber

Operator

B1562-12

HVAC Fan Output Short to Battery

Amber

Operator

B1563-11

HVAC Fan Output Short to Ground

Amber

Operator

B1564-13

HVAC Fan Output Open Circuit

Amber

Operator

B1565-12

A/C Output Short to Battery

Amber

Operator

B1566-11

A/C Output Short to Ground

Amber

Operator

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Section M3 - Electronic Control Systems Fault Code SYSTEM Cab Area ‘B’ Codes Fault Code Description

Warning Display Colour

Severity

B1567-13

Amber

Operator

A/C Output Open Circuit

B1568-12

Wading Output Short to Battery

No Display

Trivial

B1569-11

Wading Output Short to Ground

No Display

Trivial

B156A-13

Wading Output Open Circuit

No Display

Trivial

M3-58

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Section M3 - Electronic Control Systems Fault Code SYSTEM Chassis ‘C’ Codes

Chassis ‘C’ Codes Note: Faults that are classed as ‘Trivial’ severity will not be displayed on the RHC. These can only be read using Servicemaster. Fault Code Description

Warning Display Colour

Severity

C1019-38

LLMI Transducer 1 PWM signal error

Amber

Operator

C101A-29

LLMI Transducer 1 range error

Amber

Operator

C101B-38

LLMI Transducer 2 PWM signal error

Amber

Operator

C101C-29

LLMI Transducer 2 range error

Amber

Operator

C1500-13

boom retracted switch open

Amber

Operator

C1501-64

boom retracted switch short

Amber

Operator

C1502-1C

boom retracted switch OOR

Amber

Operator

C1503-07

boom retracted switch stuck

Amber

Operator

C1504-62

Load Moment Indicator disagreement fault

Amber

Operator

C1505-13

Accumulator Solenoid Open

Amber

Operator

C1506-11

Accumulator Solenoid STG

Amber

Operator

C1507-12

Accumulator Solenoid STB

Amber

Operator

C1508-13

Drain Solenoid Open

Amber

Operator

C1509-11

Drain Solenoid STG

Amber

Operator

C150A-12

Drain Solenoid STB

Amber

Operator

C150B-13

Extend Solenoid Open

Amber

Operator

C150C-11

Extend Solenoid STG

Amber

Operator

C150D-12

Extend Solenoid STB

Amber

Operator

C150E-13

Retract Solenoid Open

Amber

Operator

C150F-11

Retract Solenoid STG

Amber

Operator

C1510-12

Retract Solenoid STB

Amber

Operator

C1511-13

Extend/Retract Solenoid Return Open

Amber

Operator

C1512-11

Extend/Retract Solenoid Return STG

Amber

Operator

C1513-12

Extend/Retract Solenoid Return STB

Amber

Operator

C1514-13

Auxiliary A Solenoid Open

Amber

Operator

C1515-11

Auxiliary A Solenoid STG

Amber

Operator

C1516-12

Auxiliary A Solenoid STB

Amber

Operator

C1517-13

Auxiliary B Solenoid Open

Amber

Operator

C1518-11

Auxiliary B Solenoid STG

Amber

Operator

C1519-12

Auxiliary B Solenoid STB

Amber

Operator

C151A-13

Auxiliary Changeover Solenoid Open

Amber

Operator

C151B-11

Auxiliary Changeover Solenoid STG

Amber

Operator

C151C-12

Auxiliary Changeover Solenoid STB

Amber

Operator

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Section M3 - Electronic Control Systems Fault Code SYSTEM Chassis â&#x20AC;&#x2DC;Câ&#x20AC;&#x2122; Codes Fault Code Description

Warning Display Colour

Severity

C151D-46

Amber

Operator

EEPROM Fault

C151E-62

Boom Angle Sensor Disagreement

Amber

Operator

C151F-23

Boom Angle Sensor 1 OORL

Amber

Operator

C1520-24

Boom Angle Sensor 1 OORH

Amber

Operator

C1521-23

Boom Angle Sensor 2 OORL

Amber

Operator

C1522-24

Boom Angle Sensor 2 OORH

Amber

Operator

C1523-13

hyd isolate solenoid Open

Amber

Operator

C1524-11

hyd isolate solenoid STG

Amber

Operator

C1525-12

hyd isolate solenoid STB

Amber

Operator

C1526-23

SRS pressure switch OORL

Amber

Operator

C1527-24

SRS pressure switch OORH

Amber

Operator

C1528-62

SRS pressure switch disagreement

Amber

Operator

C1529-62

Chassis Angle Sensor Disagreement

Amber

Operator

C152A-23

Chassis Angle Sensor 1 OORL

Amber

Operator

C152B-24

Chassis Angle Sensor 1 OORH

Amber

Operator

C152C-23

Chassis Angle Sensor 2 OORL

Amber

Operator

C152D-24

Chassis Angle Sensor 2 OORH

Amber

Operator

C1564-23

front steer alignment sensor 1 OORL

Amber

Operator

C1565-24

front steer alignment sensor 1 OORH

Amber

Operator

C1566-23

front steer alignment sensor 2 OORL

Amber

Operator

C1567-24

front steer alignment sensor 2 OORH

Amber

Operator

C1568-23

rear steer alignment sensor 1 OORL

Amber

Operator

C1569-24

rear steer alignment sensor 1 OORH

Amber

Operator

C156A-23

rear steer alignment sensor 2 OORL

Amber

Operator

C156B-24

rear steer alignment sensor 2 OORH

Amber

Operator

C156C-13

Steer A Solenoid Open

Amber

Operator

C156D-11

Steer A Solenoid STG

Amber

Operator

C156E-12

Steer A Solenoid STB

Amber

Operator

C156F-13

Steer B Solenoid Open

Amber

Operator

C1570-11

Steer B Solenoid STG

Amber

Operator

C1571-12

Steer B Solenoid STB

Amber

Operator

C1572-13

Steer C Solenoid Open

Amber

Operator

C1573-11

Steer C Solenoid STG

Amber

Operator

C1574-12

Steer C Solenoid STB

Amber

Operator

C1575-13

Steer D Solenoid Open

Amber

Operator

C1576-11

Steer D Solenoid STG

Amber

Operator

C1577-12

Steer D Solenoid STB

Amber

Operator

C1578-13

Drain / Accumulator Solenoid Return Open

Amber

Operator

M3-60

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Section M3 - Electronic Control Systems Fault Code SYSTEM Chassis ‘C’ Codes Fault Code Description

Warning Display Colour

Severity

C1579-11

Amber

Operator

Drain / Accumulator Solenoid Return STG

C157A-12

Drain / Accumulator Solenoid Return STB

Amber

Operator

C157B-13

Steer Solenoid Return Open

Amber

Operator

C157C-11

Steer Solenoid Return STG

Amber

Operator

C157D-12

Steer Solenoid Return STB

Amber

Operator

C157E-11

5V supply STG

Amber

Operator

C157F-12

5V supply STB

Amber

Operator

C1582-87

ECU pairing fault

Amber

Operator

C1585-22

hydraulic temp high

Amber

Operator

C1586-21

brake charge pressure low

Amber

Operator

C1587-16

brake charge pressure OORL

Amber

Operator

C1588-17

brake charge pressure OORH

Amber

Operator

C1589-23

“brake charge pressure low, engine running”

Red

Critical

C158A-13

pump control solenoid Open

Amber

Operator

C158B-11

pump control solenoid STG

Amber

Operator

C158C-12

pump control solenoid STB

Amber

Operator

C158D-13

pump control Solenoid Return Open

Amber

Operator

C158E-18

pump control Solenoid Return STG

Amber

Operator

C158F-19

pump control Solenoid Return STB

Amber

Operator

C1590-1B

hydraulic temp OORH

Amber

Operator

C1591-1A

hydraulic temp OORL

Amber

Operator

C1592-13

Auxiliary A/B Solenoid Return Open

Amber

Operator

C1593-18

Auxiliary A/B Solenoid Return STG

Amber

Operator

C1594-19

Auxiliary A/B Solenoid Return STB

Amber

Operator

C1595-13

raise Solenoid Open

Amber

Operator

C1596-11

raise Solenoid STG

Amber

Operator

C1597-12

raise Solenoid STB

Amber

Operator

C1598-13

lower Solenoid Open

Amber

Operator

C1599-11

lower Solenoid STG

Amber

Operator

C159A-12

lower Solenoid STB

Amber

Operator

C159B-13

crowd Solenoid Open

Amber

Operator

C159C-11

crowd Solenoid STG

Amber

Operator

C159D-12

crowd Solenoid STB

Amber

Operator

C159E-13

dump Solenoid Open

Amber

Operator

C159F-11

dump Solenoid STG

Amber

Operator

C15A0-12

dump Solenoid STB

Amber

Operator

C15A1-13

raise/lower Solenoid Return Open

Amber

Operator

C15A2-18

raise/lower Solenoid Return STG

Amber

Operator

M3-61

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M3-61

Section M3 - Electronic Control Systems Fault Code SYSTEM Chassis ‘C’ Codes Fault Code Description

Warning Display Colour

Severity

C15A3-19

raise/lower Solenoid Return STB

Amber

Operator

C15A4-13

crowd/dump Solenoid Return Open

Amber

Operator

C15A5-18

crowd/dump Solenoid Return STG

Amber

Operator

C15A6-19

crowd/dump Solenoid Return STB

Amber

Operator

C15A7-64

emergency stop switch short

Amber

Operator

M3-62

M-03-06 issue 01

M3-62

Section M3 - Electronic Control Systems Fault Code SYSTEM CANbus ‘U’ Codes

CANbus ‘U’ Codes Note: Faults that are classed as ‘Trivial’ severity will not be displayed on the RHC. These can only be read using Servicemaster. Fault Code Description

Warning Display Colour

Severity

U0001-00

General CAN fault

No Display

Trivial

U0001-00

J1939 Information

No Display

Trivial

U0073-00

CAN communication error: CAN bus confirmed off

No Display

Trivial

U0100-00

CAN communication error: ECU confirmed absent (#0)

No Display

Trivial

U010A-88

CAN communication error: EGR communications

No Display

Trivial

U010C-88

CAN communication error: VGT communications error

No Display

Trivial

U0121-00

CAN communication error with ABS

No Display

Trivial

U0401-00

CAN communication error: checksum error

No Display

Trivial

U0401-00

CAN communication error: message frozen

No Display

Trivial

U0401-00

CAN communication error: message intermittent

No Display

Trivial

U0401-00

CAN communication error: out of range

No Display

Trivial

U0401-00

CAN communication error: timeout

No Display

Trivial

U040B-00

CAN communication error: EGR calibration

No Display

Trivial

U040B-00

CAN communication error: EGR obstruction

No Display

Trivial

U040B-4B

CAN communication error: EGR overtemperature

Amber

Operator

U040B-96

CAN communication error: EGR hardware

No Display

Trivial

U040B-97

CAN communication error: EGR obstruction

Amber

Operator

U040B-98

CAN communication error: EGR overtemperature

Amber

Operator

U040D-00

CAN communication error: VGT end-of-line learnt position

No Display

Trivial

U040D-00

CAN communication error: VGT spanlearn

No Display

Trivial

U040D-54

CAN communication error: VGT spanlearn

Amber

Operator

U040D-96

CAN communication error: VGT hardware

Amber

Operator

U040D-97

CAN communication error: VGT obstruction

No Display

Trivial

U040D-98

CAN communication error: VGT overtemperature

Amber

Operator

U040D-9A

CAN communication error: VGT position

No Display

Trivial

U1500-88

LMI CAN fault

Red

Critical

U1500-88

Load Moment Indicator Can Fault

No Display

Trivial

U1501-88

Engine Can Fault

Red

Critical

U1501-88

Engine CAN fault

Red

Critical

U1502-88

Transmission Can Fault

Red

Critical

U1502-88

Transmission CAN fault

Red

Critical

U1503-88

Joystick Can Fault

Red

Critical

U1503-88

Joystick CAN fault

Red

Critical

M3-63

M-03-06 issue 01

M3-63

Section M3 - Electronic Control Systems Fault Code SYSTEM CANbus â&#x20AC;&#x2DC;Uâ&#x20AC;&#x2122; Codes Fault Code Description

Warning Display Colour

Severity

U1504-88

Hydraulics controller Can Fault

Red

Critical

U1505-88

Machine Controller Can Fault

Red

Critical

U1506-88

Telematics Can Fault

Red

Critical

U1507-88

Immobilizer Can Fault

Red

Critical

U1900-16

LiveLink - Vehicle Battery Voltage Below Normal

Amber

Operator

U1901-16

LiveLink - Internal Voltage Below Normal

Amber

Operator

U1902-18

LiveLink - Telematics Output for Relay 0 Current Below Normal or Open Circuit

Amber

Operator

U1903-18

LiveLink - Telematics Output for Relay 1 Current Below Normal or Open Circuit

Amber

Operator

U1904-85

LiveLink - ECU Above Temperature Threshold

Amber

Operator

U1905-84

LiveLink - ECU Below Temperature Threshold

Amber

Operator

U1906-96

LiveLink - Accelerometer Internal Failure

Amber

Operator

U1907-09

LiveLink - Modem Jammed

No Display

Trivial

U1908-09

LiveLink - GPS Antenna Not OK

No Display

Trivial

U1909-96

LiveLink - No Comms with GPS Module

No Display

Trivial

U190A-09

LiveLink - SIM Card Failure

Amber

Operator

U190B-96

LiveLink - No Comms with GSM Module

No Display

Trivial

U190C-86

LiveLink - GSM Network Registration Failure

No Display

Trivial

U1910 -16

Relay 1 Failure - no voltage detected when relay on

No Display

Trivial

U1910 -17

Relay 1 Failure - voltage detected when relay off

No Display

Trivial

U1911 -16

Relay 2 Failure - no voltage detected when relay on

No Display

Trivial

U1911 -17

Relay 2 Failure - voltage detected when relay off

No Display

Trivial

U1912 -16

Relay 3 Failure - no voltage detected when relay on

No Display

Trivial

U1912 -17

Relay 3 Failure - voltage detected when relay off

No Display

Trivial

U1913 -84

Supply Voltage Below Normal

Amber

Operator

U1913 -85

Supply Voltage Above Normal (?32V)

Amber

Operator

U1914 -96

Immobiliser Lockout

Amber

Operator

U1915 -56

Transponder Key - Invalid Key Detected

Amber

Operator

U1915 -9

Transponder Key - Antenna Fault

Amber

Operator

U1915 -96

Transponder Key - No Transponder Detected in Key

Amber

Operator

U1916 -56

Keypad - Invalid Keypad Code Entered

Amber

Operator

U1916 -85

Key / Keypad Code - Memory Full

Amber

Operator

U1917 -2f

Engine - Communications Fault

Amber

Operator

U1917 -4

Engine - Error State

Amber

Operator

U1917 -87

Engine - No Communication

Amber

Operator

U1917 -9

Engine - Engine ECU Lockout

Amber

Operator

U1917 -96

Engine - Disarm Failure

Amber

Operator

M3-64

M-03-06 issue 01

M3-64

Section M3 - Electronic Control Systems Fault Code SYSTEM CANbus ‘U’ Codes Fault Code Description

Warning Display Colour

Severity

U1918 -96

Immobiliser Internal Fault

Amber

Operator

U3FFF-00

Radiator Out Temperature (ROT) global fault (alternative coolant temp sensor)

No Display

Trivial

U3FFF-00

Wide Range Air Fuel

No Display

Trivial

U3FFF-13

Wide Range Air Fuel

No Display

Trivial

U3FFF-13

Wide Range Air Fuel open circuit

No Display

Trivial

U3FFF-23

Wide Range Air Fuel

No Display

Trivial

U3FFF-24

Wide Range Air Fuel

No Display

Trivial

U3FFF-64

Wide Range Air Fuel

No Display

Trivial

M3-65

M-03-06 issue 01

M3-65

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS “S” Codes

RAS “S” Codes Fault Code

Description

Warning Displays

S000

Forward/Neutral/ Reverse switch open circuit

MIL lamp activated (Red). Continuous buzzer activated

S001

Forward/Neutral/ Reverse switch short circuit

S002

Brake switch fault - short MIL lamp activated (Amber). S002 circuit Message displayed on LCD. Buzzer activated for 1 second.

S003

Brake switch fault - open MIL lamp activated (Amber). S003 circuit Message displayed on LCD. Buzzer activated for 1 second.

S004

Sway switch open circuit MIL lamp activated (Red). Continuous buzzer activated

S004

S005

Sway switch short circuit

Fault Logged

M3-66

Severity S000

Fault Logged

M-03-06 issue 01

M3-66

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

Warning Displays

S006

Left stabiliser switch open circuit

MIL lamp activated (Amber). S006 Message displayed on LCD. Buzzer activated for 1 second.

S007

Left stabiliser switch short circuit

MIL lamp activated (Amber). S007 Message displayed on LCD. Buzzer activated for 1 second.

S008

Right stabiliser switch open circuit

MIL lamp activated (Red). Continuous buzzer activated

S009

Right stabiliser switch short circuit

S010

Transmission speed sensor open circuit

MIL lamp activated (Amber). S010 Message displayed on LCD. Buzzer activated for 1 second.

S011

Transmission speed sensor short circuit to ground

MIL lamp activated (Amber). S011 Message displayed on LCD. Buzzer activated for 1 second.

M3-67

Severity

S008

Fault Logged

M-03-06 issue 01

M3-67

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

Warning Displays

S012

Transmission speed sensor fault (disagreement with calc value)

MIL lamp activated (Amber). S012 Message displayed on LCD. Buzzer activated for 1 second.

S013

Foot brake relay open circuit

MIL lamp activated (Red). Continuous buzzer activated

S014

Foot brake relay short circuit to ground

Fault Logged

S015

Foot brake relay short circuit to battery

Fault Logged

S016

Control valve output 1 open circuit

MIL lamp activated (Amber). S016 Message displayed on LCD. Buzzer activated for 1 second.

S017

Control valve output 1 short circuit to ground

MIL lamp activated (Amber). S017 Message displayed on LCD. Buzzer activated for 1 second.

S018

Control valve output 1 short circuit to battery

MIL lamp activated (Amber). S018 Message displayed on LCD. Buzzer activated for 1 second.

M3-68

M-03-06 issue 01

Severity

S013

M3-68

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

Warning Displays

S019

Control valve output 2 open circuit

MIL lamp activated (Red). Continuous buzzer activated

S020

Control valve output 2 short circuit to ground

Fault Logged

S021

Control valve output 2 short circuit to battery

Fault Logged

S022

Sway switch power open MIL lamp activated (Amber). S022 circuit Message displayed on LCD. Buzzer activated for 1 second.

S023

Sway switch power short MIL lamp activated (Amber). S023 circuit to ground Message displayed on LCD. Buzzer activated for 1 second.

S024

Sway switch power short MIL lamp activated (Amber). S024 circuit to battery Message displayed on LCD. Buzzer activated for 1 second.

S025

Left stabiliser switch power open circuit

M3-69

MIL lamp activated (Red). Continuous buzzer activated

M-03-06 issue 01

Severity S019

S025

M3-69

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

S026

Left stabiliser switch power short circuit to ground

Fault Logged

S027

Left stabiliser switch power short circuit to battery

Fault Logged

S028

Right stabiliser switch power open circuit

MIL lamp activated (Amber). S028 Message displayed on LCD. Buzzer activated for 1 second.

S029

Right stabiliser switch power short circuit to ground

MIL lamp activated (Amber). S029 Message displayed on LCD. Buzzer activated for 1 second.

S030

Right stabiliser switch power short circuit to battery

MIL lamp activated (Amber). S030 Message displayed on LCD. Buzzer activated for 1 second.

S031

Boom raise isolation MIL lamp activated (Red). ground relay open circuit Continuous buzzer activated

S031

S032

Boom raise isolation ground relay short circuit to ground

Fault Logged

S033

Boom raise isolation ground relay short circuit to battery

Fault Logged

M3-70

Warning Displays

M-03-06 issue 01

Severity

M3-70

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

Warning Displays

S034

Diagnostic LED open circuit

MIL lamp activated (Amber). S034 Message displayed on LCD. Buzzer activated for 1 second.

S035

Diagnostic LED short circuit to ground

MIL lamp activated (Amber). S035 Message displayed on LCD. Buzzer activated for 1 second.

S036

Diagnostic LED short circuit to battery

MIL lamp activated (Amber). S036 Message displayed on LCD. Buzzer activated for 1 second.

S037

Foot brake switch open circuit

MIL lamp activated (Red). Continuous buzzer activated

S038

Foot brake switch short circuit

S039

Foot brake switch power MIL lamp activated (Amber). S039 open circuit Message displayed on LCD. Buzzer activated for 1 second.

M3-71

Severity

S037

Fault Logged

M-03-06 issue 01

M3-71

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS “S” Codes Fault Code

Description

S040

Foot brake switch power MIL lamp activated (Amber). S040 short circuit to ground Message displayed on LCD. Buzzer activated for 1 second.

S041

Foot brake switch power MIL lamp activated (Amber). S041 short circuit to battery Message displayed on LCD. Buzzer activated for 1 second.

S042

Hydraulic inloader valve open circuit

MIL lamp activated (Red). Continuous buzzer activated

S042

S043

Hydraulic inloader valve short circuit to ground

MIL lamp activated (Red). Continuous buzzer activated

S043

S044

Hydraulic inloader valve short circuit to battery

S045

40° proximity switch open circuit

M3-72

Warning Displays

Severity

Fault Logged MIL lamp activated (Amber). S045 Message displayed on LCD. Buzzer activated for 1 second.

M-03-06 issue 01

M3-72

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS “S” Codes Fault Code

Description

Warning Displays

S046

40° proximity switch short circuit

MIL lamp activated (Amber). S046 Message displayed on LCD. Buzzer activated for 1 second.

S047

60° proximity switch open circuit

MIL lamp activated (Red). Continuous buzzer activated

S048

60° proximity switch short circuit

S049

Boom extend switch open circuit

MIL lamp activated (Amber). S049 Message displayed on LCD. Buzzer activated for 1 second.

S050

Boom extend switch short circuit

MIL lamp activated (Amber). S050 Message displayed on LCD. Buzzer activated for 1 second.

S051

Left stabiliser transducer MIL lamp activated (Red). fault Continuous buzzer activated

M3-73

Severity

S047

Fault Logged

M-03-06 issue 01

S051

M3-73

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS “S” Codes Fault Code

Description

Warning Displays

S052

Right stabiliser transducer fault

MIL lamp activated (Amber). S052 Message displayed on LCD. Buzzer activated for 1 second.

S053

40° proximity switch power open circuit

MIL lamp activated (Red). Continuous buzzer activated

S053

S054

40° proximity switch power short circuit to ground

MIL lamp activated (Red). Continuous buzzer activated

S054

S055

40° proximity switch power short circuit to battery

S056

60° proximity switch power open circuit

MIL lamp activated (Amber). S056 Message displayed on LCD. Buzzer activated for 1 second.

S057

60° proximity switch power short circuit to ground

MIL lamp activated (Amber). S057 Message displayed on LCD. Buzzer activated for 1 second.

M3-74

Severity

Fault Logged

M-03-06 issue 01

M3-74

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS “S” Codes Fault Code

Description

Warning Displays

S058

60° proximity switch power short circuit to battery

MIL lamp activated (Amber). S058 Message displayed on LCD. Buzzer activated for 1 second.

S059

Boom extend proximity MIL lamp activated (Red). switch power open circuit Continuous buzzer activated

S059

S060

Boom extend proximity MIL lamp activated (Red). switch power short circuit Continuous buzzer activated to ground

S060

S061

Boom extend proximity switch power short circuit to battery

Fault Logged

S062

Hydraulic isolation valve MIL lamp activated (Amber). S062 open circuit Message displayed on LCD. Buzzer activated for 1 second.

S063

Hydraulic isolation valve MIL lamp activated (Amber). S063 short circuit to ground Message displayed on LCD. Buzzer activated for 1 second.

M3-75

M-03-06 issue 01

Severity

M3-75

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

S064

Hydraulic isolation valve MIL lamp activated (Amber). S064 short circuit to battery Message displayed on LCD. Buzzer activated for 1 second.

S065

Boom raise isolation valve open circuit

MIL lamp activated (Red). Continuous buzzer activated

S065

S066

Boom raise isolation valve short circuit to ground

MIL lamp activated (Red). Continuous buzzer activated

S066

S067

Boom raise isolation valve short circuit to battery

S068

Hydraulic isolation MIL lamp activated (Amber). S068 ground relay open circuit Message displayed on LCD. Buzzer activated for 1 second.

S069

Hydraulic isolation MIL lamp activated (Amber). S069 ground relay short circuit Message displayed on LCD. to ground Buzzer activated for 1 second.

M3-76

Warning Displays

Severity

Fault Logged

M-03-06 issue 01

M3-76

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

S070

Hydraulic isolation MIL lamp activated (Amber). S070 ground relay short circuit Message displayed on LCD. to battery Buzzer activated for 1 second.

S071

Gear select open circuit

S072

Gear select short circuit

S073

Parkbrake relay ground open circuit

MIL lamp activated (Amber). S073 Message displayed on LCD. Buzzer activated for 1 second.

S074

Parkbrake relay ground short circuit

MIL lamp activated (Amber). S074 Message displayed on LCD. Buzzer activated for 1 second.

S075

Parkbrake switch ground MIL lamp activated (Red). open circuit Continuous buzzer activated

S075

S076

Parkbrake switch ground short circuit

Fault Logged

M3-77

Warning Displays

MIL lamp activated (Red). Continuous buzzer activated

Severity

S071

Fault Logged

M-03-06 issue 01

M3-77

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

Warning Displays

S077

Forward/Neutral/ Reverse supervisory fault

MIL lamp activated (Amber). S077 Message displayed on LCD. Buzzer activated for 1 second.

S078

CAN fault

MIL lamp activated (Amber). S078 Message displayed on LCD. Buzzer activated for 1 second.

S079

EEPROM fault

MIL lamp activated (Amber). S079 Message displayed on LCD. Buzzer activated for 1 second.

S080

Sway lever neutral fault

S080 MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

S081

Left stabiliser neutral fault

MIL lamp activated (Amber). S081 Message displayed on LCD. Buzzer activated for 1 second.

S082

Right stabiliser neutral fault

MIL lamp activated (Amber). S082 Message displayed on LCD. Buzzer activated for 1 second.

M3-78

M-03-06 issue 01

Severity

M3-78

Section M3 - Electronic Control Systems Fault Code SYSTEM RAS â&#x20AC;&#x153;Sâ&#x20AC;? Codes Fault Code

Description

S083

Left stabiliser transducer MIL lamp activated (Amber). S083 out of range (high) fault Message displayed on LCD. Buzzer activated for 1 second.

S084

Left stabiliser transducer MIL lamp activated (Amber). S084 out of range (low) fault Message displayed on LCD. Buzzer activated for 1 second.

S085

Right stabiliser transducer out of range (high) fault

MIL lamp activated (Amber). S085 Message displayed on LCD. Buzzer activated for 1 second.

S086

Right stabiliser transducer out of range (low) fault

MIL lamp activated (Amber). S086 Message displayed on LCD. Buzzer activated for 1 second.

M3-79

Warning Displays

M-03-06 issue 01

Severity

M3-79

Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes

Electronic Engine SE Engine ECU Codes Should faults occur related to the engine ECU or the electrical devices connected to it the ECU generates fault codes and stores them in its memory. By using the JCB Engine Tool diagnostics these codes can be read using a laptop computer connected to the ECU. The system will

also display ‘real time’ data for faults active with the engine running. Depending on the machine installation fault codes may be displayed using one or more display systems. K Operation Overview ( T M3-6).

Fault Code

Description

Warning Displays

E001

Engine control module (ECU) fault

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

E002

Engine speed (crankshaft) sensor data erratic, intermittent or incorrect.

Fault Logged

E008

Inlet manifold air pressure sensor fault – voltage above normal or shorted high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E009

Inlet manifold air pressure sensor fault – voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E010

Throttle pedal position sensor fault - MIL lamp activated (Red). Message displayed on voltage above normal or shorted high LCD. Continuous buzzer activated

E011

Throttle pedal position sensor fault voltage below normal or shorted low

E012

Hand throttle position sensor fault Fault Logged voltage above normal or shorted high

E013

Hand throttle position sensor fault voltage below normal or shorted low

E014

Engine oil pressure sensor fault MIL lamp activated (Red). Message displayed on voltage above normal or shorted high LCD. Continuous buzzer activated

E015

Engine oil pressure sensor fault voltage below normal or shorted low

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

E017

Engine coolant temperature sensor fault – voltage above normal or shorted high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E018

Engine coolant temperature sensor fault – voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M3-80

Severity

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

Fault Logged

M-03-06 issue 01

M3-80

Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

E023

Inlet manifold air temperature sensor MIL lamp activated (Amber). Message displayed fault – voltage above normal or on LCD. Buzzer activated for 1 second. shorted high

E024

Inlet manifold air temperature sensor MIL lamp activated (Amber). Message displayed fault – voltage below normal or on LCD. Buzzer activated for 1 second. shorted low

E027

Sensor supply voltage 3 (+5V) – voltage above or below normal or shorted to a high or low source.

E036

Sensor supply voltage 3 (+5V) - data MIL lamp activated (Amber). Message displayed erratic, intermittent or incorrect. on LCD. Buzzer activated for 1 second.

E040

Machine speed sensor fault - data erratic, intermittent or incorrect.

Fault Logged

E041

Machine speed sensor circuit fault data abnormal rate of change.

Fault Logged

E047

Fuel temperature sensor fault – MIL lamp activated (Amber). Message displayed voltage above normal or shorted high on LCD. Buzzer activated for 1 second.

E048

Fuel temperature sensor fault - root cause not known

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E049

Fuel temperature sensor fault – voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E051

High pressure fuel solenoid valve number 1 fault – voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E052

High pressure fuel solenoid valve MIL lamp activated (Amber). Message displayed number 1 fault – voltage above on LCD. Buzzer activated for 1 second. normal or shorted high, current below normal or open circuit.

E068

Engine control module (ECU) internal MIL lamp activated (Amber). Message displayed temperature sensor – voltage above on LCD. Buzzer activated for 1 second. normal or shorted high

E069

Engine control module (ECU) internal MIL lamp activated (Amber). Message displayed temperature sensor – voltage below on LCD. Buzzer activated for 1 second. normal or shorted low

E076

Injector solenoid valve fault, cylinder MIL lamp activated (Amber). Message displayed 1 – current above normal or grounded on LCD. Buzzer activated for 1 second. circuit

M3-81

Warning Displays

Severity

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M-03-06 issue 01

M3-81

Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

E078

Injector solenoid valve fault, cylinder MIL lamp activated (Amber). Message displayed 3 – current above normal or grounded on LCD. Buzzer activated for 1 second. circuit

E080

Injector solenoid valve fault, cylinder MIL lamp activated (Amber). Message displayed 2 – current above normal or grounded on LCD. Buzzer activated for 1 second. circuit

E082

Injector solenoid valve fault, cylinder MIL lamp activated (Amber). Message displayed 4 – current above normal or grounded on LCD. Buzzer activated for 1 second. circuit

E083

Injector solenoid valve fault, cylinder 1 – current below normal or open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E085

Injector solenoid valve fault, cylinder 3 – current below normal or open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E089

Injector solenoid valve fault, cylinder 2 – current below normal or open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E090

Injector solenoid valve fault, cylinder 4 – current below normal or open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E091

Engine control module (ECU) calibration memory - fault condition exists.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E095

Sensor supply voltage 1 (+5V) voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E096

Fuel injection pump control valve (IMV) – voltage above normal or shorted high

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E097

Fuel injection pump control valve (IMV) – voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E104

Fuel pump control module idle fault – Fault Logged data erratic, intermittent or incorrect.

E113

Sensor supply voltage 2 - voltage above normal or shorted high

E114

Sensor supply voltage 1 (+5V) MIL lamp activated (Amber). Message displayed voltage above normal or shorted high on LCD. Buzzer activated for 1 second.

M3-82

Warning Displays

Severity

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

M-03-06 issue 01

M3-82

Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

E119

Water in fuel detected – data valid but MIL lamp activated (Amber). Message displayed above normal operating range. on LCD. Buzzer activated for 1 second.

E122

Water in fuel indicator fault – voltage MIL lamp activated (Amber). Message displayed above normal or shorted high on LCD. Buzzer activated for 1 second.

E126

Inlet manifold air pressure sensor fault – data erratic, intermittent or incorrect.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E127

Power supply fault – data erratic, intermittent or incorrect.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E129

Battery voltage fault – data valid but below normal operating range.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E130

Battery voltage fault – data valid but above normal operating range.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E133

Fuel pump delivery pressure - data valid but above normal operating range.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E134

Injector metering rail #1 pressure MIL lamp activated (Amber). Message displayed voltage above normal or shorted high on LCD. Buzzer activated for 1 second.

E135

Injector metering rail pressure voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E159

Cylinder power imbalance – data erratic, intermittent or incorrect

Fault Logged

E172

Engine coolant temperature sensor fault - data erratic, intermittent or incorrect.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E183

Injector metering rail #1 pressure data erratic, intermittent or incorrect.

Fault Logged

E202

Minimum drive pulse drift (injector #2) Fault Logged - mechanical system not responding or out of adjustment.

E203

Minimum drive pulse drift (injector #1) Fault Logged - mechanical system not responding or out of adjustment.

E204

Minimum drive pulse drift (injector #3) Fault Logged - mechanical system not responding or out of adjustment.

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Warning Displays

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Severity

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Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

E205

Minimum drive pulse drift (injector #0) Fault Logged - mechanical system not responding or out of adjustment.

E700

High pressure fuel pump delivery pressure - data valid but below normal operating range.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E701

High fuel pressure solenoid valve 1 fault - data erratic, intermittent or incorrect.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E702

High pressure fuel pump delivery pressure - data valid but below normal operating range.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E703

High pressure fuel pump delivery pressure - fault condition exists.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E704

Engine knock sensor - fault condition Fault Logged exists.

E708

Engine control module main relay Fault Logged fault â&#x20AC;&#x201C; relay not responding correctly.

E709

Engine coolant temperature sensor - MIL lamp activated (Red). Message displayed on fault condition exists. LCD. Continuous buzzer activated

E710

Intake air heater (relay enable #1) fault - voltage above normal or shorted high

Fault Logged

E711

Intake air heater (relay enable #1) fault - voltage below normal or shorted low

Fault Logged

E712

Intake air heater (relay enable #1) fault - current below normal or open circuit

Fault Logged

E713

Intake air heater (relay enable #1) fault - current above normal or grounded circuit

Fault Logged

E714

Cruise control set speed- mechanical Fault Logged system not responding or out of adjustment

E715

Boost pressure validity â&#x20AC;&#x201C; fault condition exists.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E716

Throttle pedal position sensor fault data erratic, intermittent or incorrect.

MIL lamp activated (Red). Message displayed on LCD. Continuous buzzer activated

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Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

Warning Displays

E717

Injector metering rail #1 pressure fault condition exists.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E718

Engine position (camshaft) sensor fault – data erratic, intermittent or incorrect.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E719

Engine speed (crankshaft) sensor fault – data erratic, intermittent or incorrect.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E720

Engine speed (crankshaft) sensor fault – abnormal rate of change.

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E722

Auxiliary output #1 (temperature gauge/lamp) fault - voltage below normal or shorted low

Fault Logged

E723

Auxiliary output #1 (temperature gauge/lamp) fault - current below normal or open circuit

Fault Logged

E724

Auxiliary output #1 (temperature gauge/lamp) fault - current above normal or grounded circuit

Fault Logged

E725

Wiring harness resistance too high or Fault Logged too low, cylinder 4

E726

Wiring harness resistance too high or Fault Logged too low, cylinder 2

E727

Wiring harness resistance too high or Fault Logged too low, cylinder 1

E728

Wiring harness resistance too high or Fault Logged too low, cylinder 3

E729

Engine injector bank 1 fault – voltage MIL lamp activated (Red). Message displayed on above normal or shorted high. LCD. Continuous buzzer activated

E730

Engine injector bank 2 fault – voltage MIL lamp activated (Red). Message displayed on above normal or shorted high LCD. Continuous buzzer activated

E731

High fuel pressure solenoid valve #1 MIL lamp activated (Amber). Message displayed fault - data valid but above normal on LCD. Buzzer activated for 1 second. operational range.

E732

High fuel pressure solenoid valve #1 MIL lamp activated (Amber). Message displayed fault - data valid but below normal on LCD. Buzzer activated for 1 second. operational range.

E733

Maintenance lamp - voltage below normal or shorted low

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Severity

Fault Logged

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Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

Warning Displays

E734

Maintenance lamp - current below normal or open circuit.

Fault Logged

E735

Maintenance lamp - current above normal or grounded circuit.

Fault Logged

E736

Engine injector bank 1 fault - voltage MIL lamp activated (Red). Message displayed on below normal or shorted low. LCD. Continuous buzzer activated

E737

Engine injector bank 2 fault - voltage MIL lamp activated (Red). Message displayed on below normal or shorted low. LCD. Continuous buzzer activated

E738

Hand throttle position sensor fault data erratic, intermittent or incorrect.

Fault Logged

E746

Auxiliary output #2 (oil pressure gauge/lamp) fault - voltage below normal or shorted low

Fault Logged

E747

Engine gaseous fuel correction factor MIL lamp activated (Amber). Message displayed - out of calibration on LCD. Buzzer activated for 1 second.

E748

Engine gaseous fuel correction factor MIL lamp activated (Amber). Message displayed - data erratic, intermittent or incorrect. on LCD. Buzzer activated for 1 second.

E749

Auxiliary output #2 (oil pressure gauge/lamp) fault - current below normal or open circuit

Fault Logged

E750

Auxiliary output #2 (oil pressure gauge/lamp) fault - current above normal or grounded circuit

Fault Logged

E751

Malfunction indicator lamp - voltage above normal or shorted high

Fault Logged

E752

Maintenance lamp - voltage above normal or shorted high

Fault Logged

E753

Engine electric fuel lift pump fault MIL lamp activated (Amber). Message displayed voltage above normal or shorted high on LCD. Buzzer activated for 1 second.

E755

Engine position sensor fault Fault Logged mechanical system not responding or out of adjustment.

E756

Machine speed sensor fault - voltage Fault Logged below normal or shorted low.

E757

ECU power output supply #2 - current MIL lamp activated (Amber). Message displayed below normal or open circuit. on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

E758

ECU power output supply #2 - current MIL lamp activated (Amber). Message displayed above normal or grounded circuit. on LCD. Buzzer activated for 1 second.

E759

Engine speed sensor fault Fault Logged mechanical system not responding or out of adjustment.

E760

Engine electric fuel lift pump fault voltage below normal or shorted low

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E761

Engine electric fuel lift pump fault current below normal or open circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E762

Engine electric fuel lift pump fault current above normal or grounded circuit

MIL lamp activated (Amber). Message displayed on LCD. Buzzer activated for 1 second.

E763

Intake manifold temperature sensor - Fault Logged fault condition exists.

E773

Malfunction indicator lamp - current above normal or grounded circuit.

Fault Logged

E774

Injector metering rail #1 pressure out of calibration

Fault Logged

E775

Sensor supply voltage 1 (+5V) - data MIL lamp activated (Amber). Message displayed erratic, intermittent or incorrect on LCD. Buzzer activated for 1 second.

E776

Engine fuel injection pump fuel control valve (IMV) - current below normal or open circuit.

Fault Logged

E777

Engine fuel injection pump fuel control valve (IMV) - current above normal or grounded circuit.

Fault Logged

E778

Engine fuel injection pump fuel control valve (IMV) - data valid but above normal operating range.

Fault Logged

E779

Engine fuel injection pump fuel control valve (IMV) - data valid but below normal operating range.

Fault Logged

E780

Engine fuel injection pump fuel control valve (IMV) - fault condition exists.

Fault Logged

E781

Sensor supply voltage 3 (+5V) - data MIL lamp activated (Amber). Message displayed erratic, intermittent or incorrect on LCD. Buzzer activated for 1 second.

E782

Malfunction indicator lamp - voltage below normal or shorted low.

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Warning Displays

Severity

Fault Logged

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Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

Warning Displays

E783

Malfunction indicator lamp - current below normal or open circuit.

Fault Logged

E784

Intake manifold temperature sensor fault - abnormal rate of change.

Fault Logged

E785

Machine speed sensor fault - current Fault Logged below normal or open circuit.

E786

Intake air heater (relay enable #2) fault - voltage below normal or shorted low

Fault Logged

E787

Intake air heater (relay enable #2) fault - current below normal or open circuit

Fault Logged

E788

Intake air heater (relay enable #2) fault - current above normal or grounded circuit

Fault Logged

E789

Machine speed sensor fault - current Fault Logged above normal or grounded circuit.

E790

Machine speed sensor fault Fault Logged mechanical system not responding or out of adjustment.

E791

Machine speed sensor fault - voltage Fault Logged above normal or shorted high.

E792

Auxiliary output #1 (temperature gauge/lamp) fault - voltage above normal or shorted high

Fault Logged

E793

Auxiliary output #2 (oil pressure gauge/lamp) fault - voltage above normal or shorted high

Fault Logged

E794

Intake air heater (relay enable #2) fault - voltage above normal or shorted high

Fault Logged

E795

Sensor supply voltage 2 - data erratic, MIL lamp activated (Amber). Message displayed intermittent or incorrect. on LCD. Buzzer activated for 1 second.

E796

ECU power output supply #2 - voltage MIL lamp activated (Amber). Message displayed below normal or shorted low. on LCD. Buzzer activated for 1 second.

E797

ECU power output supply #1 - voltage MIL lamp activated (Amber). Message displayed below normal or shorted low. on LCD. Buzzer activated for 1 second.

E798

ECU power output supply #1 - current MIL lamp activated (Amber). Message displayed below normal or open circuit. on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SE Engine ECU Codes Fault Code

Description

E799

ECU power output supply #1 - current MIL lamp activated (Amber). Message displayed above normal or grounded circuit. on LCD. Buzzer activated for 1 second.

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Section M3 - Electronic Control Systems Fault Code SYSTEM Electronic Engine SH/SL/DH Engine ECU Codes

Electronic Engine SH/SL/DH Engine ECU Codes Refer to Powertrain ‘P’ Codes. K Powertrain ‘P’ Codes ( T M3-38)

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Section M4 - Electronic Control Systems

Servicemaster SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Refer to the applications table. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Why Use ServiceMaster? ( T M4-2) K Fault Finding ( T M4-2) K Identify Poor Maintenance ( T M4-2) K Access Machine Set-up Data ( T M4-2) K Re-Programming ECUs ( T M4-2) K Summary ( T M4-2) K What is Servicemaster? ( T M4-3) K Introduction ( T M4-3) K CANbus Communications System ( T M4-3) K Servicemaster Structure ( T M4-3) K How to Set-up Servicemaster ( T M4-5) K New Installation of JCB ServiceMaster DVD ( T M4-6) K New Installation of JCB ServiceMaster WebUpdate ( T M4-9) K Authorising JCB WebUpdate Downloads ( T M4-12) K Using JCB WebUpdate to Download Updates ( T M4-13) K JCB ServiceMaster ( T M4-14) K ServiceMaster Front End ( T M4-14) K Selecting Service Tool Applications ( T M4-15) K Start Servicemaster ( T M4-16) K Load the DLA Laptop Driver Software ( T M4-17) K Configure the DLA Type and Communications Port ( T M4-18) K Check the DLA Firmware File ( T M4-19) K Connect Servicemaster to the Machine CANbus ( T M4-21)

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Section M4 - Electronic Control Systems Servicemaster SYSTEM Why Use ServiceMaster?

Why Use ServiceMaster? JCB machines use the latest developments in electronic management of machine systems. This means that machine systems such as service hydraulics, engine, transmission and steering are controlled using electronic control units (ECUs). The ECUs process inputs from electrical sensors and then output signals to electrical actuators on the applicable devices. The ECUs are also connected to the machine CANbus electronic communication system.

Re-Programming ECUs The ECU's use pre-loaded data to compute responses to inputs from sensors. If an ECU is replaced the correct data files must be programmed (`flashed') into the ECU memory. New data files may also be issued by JCB Service to improve machine operation. This will also require the ECU to be re-programmed.

Fault Finding

This can only be done with ServiceMaster.

Faults with ECU controlled systems can be difficult or impossible to trace using traditional methods.

Summary

In addition to the primary function of machine control the ECUs are also able to detect possible faults with sensors and actuators. The faults are `logged' using a code system. Use ServiceMaster to see and understand these codes. In addition ServiceMaster has direct links to relevant onscreen help information about relevant devices. This information is designed to help you identify, test, and if applicable, remove and replace devices.

With the latest ServiceMaster software loaded on your laptop and you can: – Fault find – For fast, effective fault finding. – Check maintenance standards – See if the machine has been abused. – View and change machine set-up data – This can only be done with ServiceMaster. – Flash ECUs with the correct data files – This can only be done with ServiceMaster.

Identify Poor Maintenance System faults that are present, or have happened in the past can be seen. This is not only useful when fault finding but can also identify poor standards of maintenance. For example a log showing a history of water in fuel detected. Use ServiceMaster to see and understand these logs.

Access Machine Set-up Data Machine parameters such as tyre sizes, gear shift points and engine injector calibration codes are all stored and used by the relevant control ECU's. During the life of the machine it will be necessary to change some of these parameters. Without the correct data the machine will not operate correctly. This can only be done with ServiceMaster.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM What is Servicemaster?

What is Servicemaster? Introduction JCB Servicemaster is software for use with Microsoft Windows and a laptop personal computer. The laptop computer is connected to the machine ‘diagnostic socket' using special cables and an adaptor. Use ServiceMaster software to: – Display data from machine ECUs – Change data stored in ECUs

CANbus Communications System C

Controller

Area

Network

Servicemaster software communicates with the machine ECUs using the CAN. Fig 1. CAN is an electronic communications system that connects compatible machine ECUs to one pair of data wires called the CANbus. Coded data is sent to and from the ECUs on the CANbus. By connecting Servicemaster software to the CANbus this data is seen and decoded for use by an engineer.

T063980

Tool Sets Tool sets are different for each machine range. A typical tool set includes:

Servicemaster Structure Servicemaster software is supplied via DVD and updated via internet. A selector window is used to choose the correct software tool set for each machine range.

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Vehicle Set-up tool

Diagnostics tool

Flash Programmer tool

Data Logger tool

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Section M4 - Electronic Control Systems Servicemaster SYSTEM What is Servicemaster?

Service History Each tool is specific to the chosen machine range. The tool icons are `shortcuts' to the tool software files. Detailed information about how to use the tools is given in the applicable machine documentation.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

How to Set-up Servicemaster Note: The procedures that follow describe how to set-up Servicemaster for USB compatible equipment. There are other procedures and options. These are described in detail in the Servicemaster help files contained on the JCB Service Information DVD.

Run the service master WebUpdate.

Start Servicemaster.

Load the DLA laptop driver software.

Before you set-up Servicemaster make sure you have:

Configure the DLA type and communications port.

– A Microsoft Windows compatible laptop computer with a DVD drive and/or a USB port A

Make sure that the DLA flash memory contains the latest firmware file.

Note: Servicemaster is compatible with Windows 98, 2000, ME, XP, Vista, and 7 (32 bit and 64bit).

Connect Servicemaster to the machine CANbus.

– The latest Servicemaster software B (DVD and internet connection for web updates). – A JCB compatible data link adaptor (DLA) C. – The correct connection cables D.

K New Installation of JCB ServiceMaster DVD ( T M4-6) K New Installation of JCB ServiceMaster WebUpdate ( T M4-9) K Start Servicemaster ( T M4-16)

Important: DO NOT connect any cables at the laptop, DLA or machine now.

K Load the DLA Laptop Driver Software ( T M4-17) K Configure the DLA Type and Communications Port ( T M4-18) K Check the DLA Firmware File ( T M4-19) K Connect Servicemaster to the Machine CANbus ( T M4-21)

Fig 2.

T063421

To set-up Servicemaster for the first time: 1

Install Servicemaster from the DVD.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

New Installation of JCB ServiceMaster DVD This topic covers the new installation ServiceMaster on a new laptop / PC.

JCB

Once you have put the CD into your computer, open “My Computer” and select the CD Drive (D:).

Double clicking on this will explore the contents of the CD. Please double click on the “Set-up.exe” application. Fig 4.

T0640010-1

Note: The version number will depend on when the CD was obtained. 4

A popup box will now appear to allow you to select a language. Once selected, click “OK”

Fig 5.

Fig 3. 3

T0640010-11

Fig 6.

This will start the set-up application, click on “Install V10.0.3”.

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T040010-2

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T040010-3

On the next screen, click “Next”.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Fig 7. 6

T040010-5

The next screen requires you to put in your username and organization. Once inserted, click next.

Fig 8.

Fig 9. 8

The next screen shows you where ServiceMaster will be installed to on your computer. Click next to begin the install.

T040010-6

Fig 10. 7

On the next screen, please choose â&#x20AC;&#x153;Completeâ&#x20AC;? to do the full install to your laptop.

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T040010-7

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T040010-7

During the install you may get a number of errors indicating language files for TransLink haven't been found. Please click Ignore, these files will be installed later via WebUpdate.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Fig 13.

Fig 11. 10

To6020-10

The two shortcuts will be placed on the desktop

Once the install has finished, you will get the following popup box.

Fig 14. Fig 12. 11

T040010-9

T040010-10

T040010-8

Once you have clicked OK, the following screen will appear. Clicking Finish on this will take you to the JCB portal, please see Fresh Installation of JCB WebUpdate for the next steps.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

New Installation of JCB ServiceMaster WebUpdate This topic covers the fresh installation of JCB WebUpdate on a new laptop / PC. 1

Once you have ServiceMaster installed on your laptop you will need to keep it updated. This is done via JCB Webupdate. The following steps are a guide to downloading and installing JCB WebUpdate.

JCB WebUpdate is installed using the following web address: www.business.jcb.com.

This link brings up the following page:

Fig 15.

T064000-3

Fig 16.

If you do not already have a User ID and Password then please click Get Support and apply for an account with access to JDS and Serviceparts Pro.

Once logged in you will find a link on the left hand tool bar called â&#x20AC;&#x153;JDSâ&#x20AC;?, click this.

Clicking this will bring up a popup with the following screen:

Fig 17. 7

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T064000-2

T064000-4

From this screen, click on the SM WebUpdate link on the left hand tool bar. This will bring up the following screen:

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Fig 20. Fig 18. 8

T064000-11

The download will now begin. When the download is finished, the installer will automatically run.

Within the orange text there is a “click here” link. Click this to begin the download of JCB WebUpdate.

Fig 21. Fig 19. 9

T064000-1

T064000-9

Please click “Run” when the above popup appears. This will begin the download. Due to the firewall on the computer you may get the following popup, if this occurs, click “Run”.

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T064000-8

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JCB WebUpdate has now finished installing and the following icon should appear on your desktop:

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Fig 22. 12

T064000-10

Please follow the instruction in the Authorising JCB WebUpdate downloads to authorise your downloads.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Authorising JCB WebUpdate Downloads This topic covers the authorisation process needed to access downloads via JCB WebUpdate on a laptop / PC. 1

After the installation you will need to authorise the download to ensure that you get future updates.

This is accessed from the webupdate section of JDS (see instruction within Fresh Installation of JCB WebUpdate to get to the following page).

Fig 23. 3

T04000-6

This now completes the authorisation step of JCB WebUpdate.

To perform a ServiceMaster Update, please run WebUpdate either by using your desktop icon or from within the help menu within ServiceMaster.

The program will check for updates and inform you if you have any to download.

T064000-11

On this page you will either have a red or orange box dependant on the download privileges attached to your name (red for pre release, orange for full release only). Clicking on this box will begin the authorisation process.

Fig 24. 5

Fig 25.

Fig 26.

T064000-7

From here you can either click “Details” to see which files have been changed, added or removed.

Clicking on the “Download” button will start the download of the updates.

Once downloaded, WebUpdate will ask you if you want to install the updates. You can either choose to install the updates immediately or at a later date.

T039990

After the system has authorised the download it will ask you if you wish to perform the download. Please click “Download”

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Using JCB WebUpdate to Download Updates This topic covers the download of ServiceMaster updates via JCB WebUpdate on a laptop / PC.

Fig 27.

To perform a ServiceMaster Update, please run WebUpdate either by using your desktop icon or from within the help menu within ServiceMaster.

The program will check for updates and inform you if you have any to download.

Fig 28. 3

From here you can either click “Details” to see which files have been changed, added or removed.

Clicking on the “Download” button will start the download of the updates.

Fig 29. 5

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T064020-1

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T064020-2

Once downloaded, WebUpdate will ask you if you want to install the updates. You can either choose to install the updates immediately or at a later date.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

JCB ServiceMaster JCB ServiceMaster is an application allowing engineers to diagnose/set-up the various electronic control units within the JCB product range. The tools comprises of a Front End GUI allowing the user to select the machine which they wish to work on as well as a number of various tools which allow: programming of electronic control units, the diagnosing of electronic issues, the set-up of various options and checking the service history of the machine.

Once the user has clicked on the applicable machine type they will be able to select the tool they require from a list of the tools available for that machine range. Below are screen-shots showing the difference between 2 machine types tool set.

JCB ServiceMaster is updated on a monthly basis by incorporating WebUpdate. This is a program which works alongside ServiceMaster to let the user know and allow them to download an update as and when it becomes available to them

ServiceMaster Front End The start-up page of ServiceMaster is known as the front end. This is a GUI allowing the user to easily and quickly navigate to the machine they are working on to ensure that they have the applicable tools for that machine.

Fig 30.

T063980

The front end is split into 3 main sections (denoted by the tabs in the black bar), Construction machines, Agricultural machines and other applications. Within the construction and agricultural tabs are the applicable machine ranges, i.e. Backhoe Loaders in construction and Fastrac in agricultural.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Selecting Service Tool Applications When you have navigated to the correct machine type via the front end, you will be greeted with the relevant tools for that particular machine. These tools are accessed by a single click on the icon of the tool you require. There are 5 main tools within ServiceMaster, these are: Set-up

Parameter settings, Option/ Attachment control Alternative Language Support Model/Serial Number Identification

Vehicle Set-up

As well as the tools stated above there are also 3rd party tools for some of the machine range which will need to be installed. These tools are denoted by the following symbol:

To install these applications you need to take the following steps: – On the front end, click the other tab – Click on general – Click onto “extra applications”

Data Logging

Running Data Collection, Operating Data, Statistics, Device Error Log Recording.

– Choose the relevant tool which you require to be installed and run the installer. Once the installer has been run, the icon should have changed within the machine tool page. e.g. the above icon has now become:

Data Logger Service History Engine Hour records, Service Dealership Codes.

Service History Flashloader

Reprogramming and Software update/Revision capability.

Diagnostics

ECU I/O testing and diagnostics.

Flashloader

Diagnostics

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Start Servicemaster 1

Double click on the Servicemaster icon. (The icon is found on the desktop or in the `Start' menu `Programs' - 'JCB'.)

Fig 31. 2

The Servicemaster window will open. Fig 33.

Fig 32. 3

T064020-

T063980

Double click the desired machine group.

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Load the DLA Laptop Driver Software To use Servicemaster for the first time you must load the DLA driver software. You will not have to do the procedure again. Important: DO NOT connect the DLA or cables at the laptop or machine now. 1

Start the Servicemaster software on your laptop computer. K Start Servicemaster ( T M4-16).

Click the ‘Other’ tab.

Click on the ‘General’ icon.

Click on the ‘DLA' icon. K Fig 34. ( T M4-17).

Fig 35.

Fig 36.

T064020-11

Note: Drivers are also available for computers with serial ports (no USB) and other versions of Microsoft Windows. If your laptop does not have a USB port, double click on the correct driver icon. 6

T06020-5

Fig 34. 5

Double click on K Fig 36. ( T M4-17)

M4-17

the

The driver installer window will open. Follow the onscreen installation instructions to complete the installation.

USB

driver

icon.

M-04-04 issue 01

M4-17

Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Configure the DLA Type and Communications Port To use Servicemaster for the first time you must make sure that the correct DLA and laptop port is selected to communicate with the DLA. You will not have to do the procedure again. 1

Start the Servicemaster software on your laptop computer.

Click the ‘Other’ tab.

Click on the ‘General’ icon.

Click on the ‘DLA' icon.

Double click the COM Port icon. Fig 38.

Co47220-C1

Note: Older DLAs and laptop computers may not be compatible with USB ports. Choose the `Parallel/Serial DLA' device in the DLA screen.

Fig 37. 6

T06020-8

The DLA window will open. Select the `USB/Serial DLA' device and then click `Apply'.

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M-04-04 issue 01

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Check the DLA Firmware File The DLA has software embedded in its own flash memory. This file must be replaced with a new one when new firmware is released. You will only have to Check the DLA firmware file version if you receive a new Servicemaster version or use a different DLA. 1

Make sure that the DLA is connected to the laptop computer. K Connect the 'USB PC Cable' A to the DLA and a free port on your laptop computer. ( T M4-21) Start the Servicemaster software on your laptop computer. K Start Servicemaster ( T M4-16)

Click the ‘Other’ tab.

Click on the ‘General’ icon.

Click on the ‘DLA' icon.

Double click on the USB DLA Flash Loader icon. K Fig 39. ( T M4-19)

Fig 39.

Fig 40. 8

C048070.jpg

Check for a new firmware file: Click on the browse button A and locate the file stored within the JCB_Servicemaster directory on your laptop hard drive. a

Click the `Open' button. The selected file appears in the `Firmware File Name' field together with its release date and application version, for example 2.01.K Fig 42. ( T M4-20)

T06020-9

Note: Older DLAs and laptop computers may not be compatible with USB ports. Double click the `Flash loader for Serial/Parallel DLA' icon. 7

The device flash update tool window opens. The details of the firmware in the DLA are displayed including the application version, for example 1.04.

M4-19

M-04-04 issue 01

Fig 41.

M4-19

Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Fig 42. 9

C048070-C3.jpg

Load a new firmware file: If the firmware in the DLA is not up to date, load the new file. Click the `Start' button A and follow the on-screen instructions.

M4-20

M-04-04 issue 01

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

Connect Servicemaster to the Machine CANbus To use Servicemaster connect your laptop computer to the machine CANbus. Connection is made using Data Link Adaptor (DLA) C and the applicable cables.

Make sure the machine ignition system is OFF.

Connect the 'USB PC Cable' A to the DLA and a free port on your laptop computer.

Note: Connect the USB cable directly to the laptop computer. DO NOT connect the cable via a USB hub. Note: Older DLAs and laptop computers may not be compatible with USB ports. Use the serial PC cable B to connect the DLA to the laptop serial port.

Fig 44.

Connect the 'Machine Cable' D to the DLA. The 'Machine Cable' has a 15-way D-type connector on one end and a 9-way CAN connector on the other. Plug the 15-way connector into the DLA and tighten the thumb-screws.

Connect the 9-way CAN connector into the machines' Diagnostics Connector A as follows:

C032140-C1.eps

Fig 43.

Table 1. Component Key USB PC Cable 718/20235

Serial PC Cable

USB DLA

728/26500

Machine Cable

718/20237

A405350-C4.jpg

Position the CAN connector B to align the centre pin location tab C with the diagnostics connector A.

b Couple the connectors. Turn the locking ring D clockwise to secure the connectors.

718/20236

Kit 892/01174 (includes items A,B,C and D)

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M-04-04 issue 01

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Section M4 - Electronic Control Systems Servicemaster SYSTEM How to Set-up Servicemaster

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M-04-04 issue 01

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Section M5 - Electronic Control Systems

Servicemaster Tool Set Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M5-2) K Tool Suite ( T M5-3) K Diagnostics Connector ( T M5-4) K Servicemaster Machine Selection ( T M5-5)

M5-1

M-04-09 issue 01

M5-1

Section M5 - Electronic Control Systems Servicemaster Tool Set Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Servicemaster Tool User Guides

Servicemaster SYSTEM

ALL (1)

ALL ALL

(1) You must obey all of the relevant care and safety procedures.

M5-2

M-04-09 issue 01

M5-2

Section M5 - Electronic Control Systems Servicemaster Tool Set Tool Suite

Tool Suite Note: All tools available for the Loadall range of machines are included in this section. Tool applicability depends on Tool

Machine Application

JCB EcoMax Engine Setup

Machines with SH,SL and DH Engines

Configure the engine ECU to match the engine parameters.

JCB Loadall LMS Setup

All machines

Configure the LMS display ECU to match machine parameters.

JCB Loadall Machine Diagnostics T4i

All Machines

Comprehensive diagnostic information about machine related sensors, actuators and ECUs.

Loadall Immobiliser Setup

Machines with Immobiliser

Immobiliser Diagnostics

Machines with Immobiliser

M5-3

Icon

machine model/variant. Refer to the tool user guide topics for details of tool use. Description

View immobiliser operating parameters in real time. Applicable for key system and keypad system immobilisers.

M-04-09 issue 01

M5-3

Section M5 - Electronic Control Systems Servicemaster Tool Set Diagnostics Connector

Diagnostics Connector Note: Refer to the Servicemaster SYSTEM topic for the connection procedure. K Related Topics ( T M5-2)

D C B

E F

A J H

A Fig 1. Diagnostic Socket Location

M5-4

C118990

M-04-09 issue 01

M5-4

Section M5 - Electronic Control Systems Servicemaster Tool Set Servicemaster Machine Selection

Servicemaster Machine Selection 1

Open servicemaster as detailed in Servicemaster SYSTEM. K Related Topics ( T M5-2)

Click on the “Construction” tab 1 or “Agricultural” tab 2.

Click on the “Telescopic Handlers” icon 3.

Fig 3.

Fig 2. 4

C126750-C1

C126750

Select the applicable machine model: a

2007 - (Machines built before 2007)

b 2007 + (Machines built after 2007)

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M-04-09 issue 01

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Section M5 - Electronic Control Systems Servicemaster Tool Set Servicemaster Machine Selection

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M-04-09 issue 01

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Section M6 - Electronic Control Systems

JCB EcoMax (SH,SL,DH) Engine Set Up Tool User Guide (M-05-21) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M6-2) K User Guide ( T M6-3)

M6-1

M-05-21 issue 01

M6-1

Section M6 - Electronic Control Systems JCB EcoMax (SH,SL,DH) Engine Set Up Tool User Guide (M-05-21) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Servicemaster SYSTEM

Servicemaster Tool Set

ALL (1)

ALL ALL

Section Titles

Topic Titles

Electronic Data Systems

Servicemaster

M6-2

M-05-21 issue 01

M6-2

Section M6 - Electronic Control Systems JCB EcoMax (SH,SL,DH) Engine Set Up Tool User Guide (M-05-21) User Guide

User Guide For the Engine Setup tool user guide refer to the JCB Ecomax Engine Service Manual publication number 9806/4300. K Related Topics ( T M6-2)

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M-05-21 issue 01

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Section M6 - Electronic Control Systems JCB EcoMax (SH,SL,DH) Engine Set Up Tool User Guide (M-05-21) User Guide

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M-05-21 issue 01

M6-4

Section M7 - Electronic Control Systems

JCB EcoMax (SH,SL,DH) Engine Diagnostics Tool User Guide (M-05-20) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M7-2)

M7-1

M-05-20 issue 01

M7-1

Section M7 - Electronic Control Systems JCB EcoMax (SH,SL,DH) Engine Diagnostics Tool User Guide (M-05-20) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL (Care and Safety)

Servicemaster SYSTEM

Servicemaster Tool Set

ALL (1)

ALL ALL

Section Titles

Topic Titles

Electronic Data Systems

Servicemaster

M7-2

M-05-20 issue 01

M7-2

Section M7 - Electronic Control Systems JCB EcoMax (SH,SL,DH) Engine Diagnostics Tool User Guide (M-05-20) User Guide

User Guide For the Engine diagnostics tool user guide refer to the JCB Ecomax Engine Service Manual publication number 9806/4300. K Related Topics ( T M7-2)

M7-3

M-05-20 issue 01

M7-3

Section M7 - Electronic Control Systems JCB EcoMax (SH,SL,DH) Engine Diagnostics Tool User Guide (M-05-20) User Guide

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M-05-20 issue 01

M7-4

Section M8 - Electronic Control Systems

Cluster (LMS) Setup Tool - User Guide Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M8-2) K Loadall Cluster (LMS) Setup - User Guide ( T M8-3)

M8-1

M-05-11 issue 01

M8-1

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL

ALL (Care and Safety)(1)

ALL

Servicemaster SYSTEM

ALL

(1) You must obey all of the relevant care and safety procedures.

M8-2

M-05-11 issue 01

M8-2

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Loadall Cluster (LMS) Setup - User Guide

C032980

Introduction

Care and Safety

The Loadall LMS Setup software tool is part of the JCB Service Master software suite. The software is designed to allow software updates and to configure the Electronic Instrument cluster to match machine parameters. Note: This software guide is universal and some functions may not be available on particular machine variants.

!MWARNING Be sure to read and follow any on screen instructions. Failure to follow correct procedure could result in death or injury. 2-4-5-5

This software is intended for use on IBM Compatible Personal Computers (PCs) running Windows 9x, Windows2000 and WindowsXP operating systems but is not compatible with either earlier versions of Windows 3.x. Ideally the computer should be a laptop type.

M8-3

M-05-11 issue 01

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Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Installing The Loadall LMS Setup tool is fully integrated within JCB Service Master. To use the setup program you must install JCB Service Master onto a suitable laptop computer. For full instructions on how to install JCB Service Master software see Section M - Servicemaster SYSTEM for servicemaster installation details. K Related Topics ( T M8-2)

M8-4

M-05-11 issue 01

M8-4

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Connection To use the setup program your laptop computer must be connected to the machine CANbus. See Section M Servicemaster SYSTEM for servicemaster installation details. K Related Topics ( T M8-2)

M8-5

M-05-11 issue 01

M8-5

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Starting Loadall LMS Setup 1

Open servicemaster as detailed in Servicemaster SYSTEM. K Related Topics ( T M8-2)

Click on the “Construction” tab 1 or “Agricultural” tab 2.

Click on the “Telescopic Handlers” icon 3.

Fig 2. 5

Fig 1. 4

C126750-C1

Make sure that the correct DLA is selected in the chooser. Click on `Other'. Select “General” then “DLA”. The DLA Chooser window opens. Check the button to match to the Current Device. Click `Apply'. K Fig 3. ( T M8-6)

C126750

Select the applicable machine model: a

2007 - (Machines built before 2007)

b 2007 + (Machines built after 2007) Fig 3. 6

C033110

Start the setup tool running by clicking on the Loadall Cluster Setup icon. K Fig 4. ( T M8-6)

Fig 4.

M8-6

M-05-11 issue 01

M8-6

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide 7

The Loadall LMS Setup tool will then open up displaying the build option window (circled) K Fig 5. ( T M8-7).

Fig 5. 8

P008380

Enable the connection between the PC/Laptop by pressing the “Connect” button. K Fig 6. ( T M8-7)

Fig 6.

M8-7

C075510-C2

M-05-11 issue 01

M8-7

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Navigating within Loadall LMS Setup

Menu Bar - File Menu

Navigation is designed to be via a mouse. On Laptop PCs this may take the form of a small joystick or touch sensitive pad and some buttons, usually located near to the keyboard.

K Fig 7. ( T M8-8)

As with most Windows based programs, it is possible to navigate the cluster setup software using the keyboard by pressing certain combinations of keys. Note: This can be particularly useful for certain Laptop computers where the mouse/joystick can be oversensitive. Try out the following, it may come in useful one day. There are two main methods of navigation described below; Fig 7. – Pressing the ALT key will cause the File option on the Menu Bar to be highlighted. You can then use the arrow keys to navigate the menus. – Notice that all the menu items on the Menu Bar have a letter that is underlined (e.g. the 'F' in File). Holding down the ALT key and pressing the required letter key will activate that option (i.e. either open the menu or execute a function). For example, if you wish to open the Preferences Dialogue this can be done by pressing ALT + O (to open the Options menu) then ALT + P (to execute the Preferences option).

M8-8

C075530-C1

– Connect: to connect the PC/laptop to the instrument cluster to enable communication. – Disconnect: to disconnect the PC/laptop and the instrument cluster and cease communication. – Read: to read the existing configuration of the instrument cluster. – Write: used to update the instrument cluster configuration. – Exit: to close down the program. On exiting the program communications with both ECU and DLA are shut down.

M-05-11 issue 01

M8-8

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Menu Bar - Utilities Menu

Fig 8.

C075540-C1

â&#x20AC;&#x201C; Select Language: - to select the language of the setup program. K Fig 9. ( T M8-9)

Fig 10.

C075570

â&#x20AC;&#x201C; Controller Status: to show that the ECU is online.When the ECU is online the machine codes are displayed. This diagram shows the actual settings read from a test machine.K Fig 10. ( T M8-9)

Fig 9.

M8-9

C075550

M-05-11 issue 01

M8-9

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Menu Bar - Help Menu K Fig 11. ( T M8-10)

Fig 11.

C075580-C1

– Help: opens the help program. K Fig 12. ( T M8-10) – About: Opens a window showing the version number of the installed copy of the software. K Fig 13. ( T M8-10)

Fig 12.

Fig 13.

M8-10

C095060

C087950-C13

M-05-11 issue 01

M8-10

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Build Options K Fig 14. ( T M8-11) This screen is used to configure the instrument cluster ECU machine build options. The options available will vary depending on machine model selected.

Click on the relevant check boxes to inform the ECU that the machine has that option fitted.

Click “Next” to be taken to the Powertrain Screen.

Powertrain Options K Fig 15. ( T M8-11) This screen is used to configure the instrument cluster ECU powertrain options. The options available will vary depending on machine model selected.

Fig 14.

P008380

Configure Electronic Instrument Cluster Build Options 1

Click “Connect” to begin communication with the ECU.

Using the “Model” Drop down menu select the machine model.

Note: Agri Machines built before October 2010 will have the suffix ‘EH’ (Electro Hydraulic) 3

Enter the machine VIN number into the VIN box.

The available build options will be represented with white check boxes next to the text.

M8-11

Fig 15.

C075520-C3

Configure Electronic Instrument Cluster Powertrain Options 1

Using the “Tyre Type and Manufacturer” drop down menu select the tyres that are fitted to the machine.

Type the wheel circumference size into the “Wheel Circumference” box.

Using the “Axle Ratio” drop down box select the axle ratio of the machine.

M-05-11 issue 01

M8-11

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide 4

Select the engine type by clicking on the check button next to the engine type fitted:

Hydraulic Options K Fig 16. ( T M8-12)

Mechanical - For Mechanical F. I. Engines Electronic - For Electronic F. I. Engines 5

Select the transmission type by clicking on the check button next to the transmission type fitted.

Make sure the ‘Transmission Output Gear Teeth’ setting is set to ‘Standard Machine (47 Teeth)’.

Click “Next” to be taken to the Hydraulic Screen.

This screen is used to configure the instrument cluster ECU hydraulic options. The options available will vary depending on machine model selected.

Fig 16.

C087940-C5

Configure Electronic Instrument Cluster Hydraulic Options 1

The available hydraulic build options will be represented with white check boxes next to the text.

Click on the relevant check boxes to inform the ECU that the machine has that option fitted.

Note: Machines from the serial number in the table below must have the EURO LCS check box selected unless they are Australian or New Zealand build machines.

Model

M8-12

Table 2. Serial Number Range

540-170

1522578

541-Agri

1522566

M-05-11 issue 01

M8-12

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide Model

Serial Number Range

541-Construction

1522566

535-125

1522579

535-95 Agri

1522569

535-95 Construction

1522588

531-Agri

1522570

531-Construction

1522574

536

1522577

535-140

1522591

535-105

1522615

526-56

1448231

Service Options K Fig 17. ( T M8-13) This screen is used to configure the instrument cluster ECU service interval options. The options available will vary depending on machine model selected.

Click “Next” to be taken to the Service Hours Screen.

Fig 17.

C087940-C2

Configure Electronic Instrument Cluster Service Options

M8-13

Using the “Service Hours Schedule” drop down menu select the applicable service interval for the machine.

Click “Next” to be taken to the Languages Screen.

M-05-11 issue 01

M8-13

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Language Options K Fig 18. ( T M8-14) This screen is used to configure the instrument cluster ECU language options. The options available will vary depending on machine model selected.

Fig 18.

C087940-C3

Configure Electronic Instrument Cluster Language Options 1

Using the â&#x20AC;&#x153;Countryâ&#x20AC;? drop down menu select the applicable language for the machine.

The settings can now be written the machine electronic instrument cluster ECU. K Write ( T M8-15)

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M-05-11 issue 01

M8-14

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Write The User can program the machine Electronic Instrument Cluster connected using the write function. Several programming checks are made to ensure all required values are made (Model Type, Languages etc.) to ensure the data written will not make any invalid conditions in the vehicle system. Press the “Write” button K Fig 19. ( T M8-15) or select “Write” from the “File” menu K Fig 20. ( T M8-15). Fig 22.

Fig 19.

Fig 20.

C075530-C1

C075520-C1

C075530-C1

If the “Write” function is disabled make sure the communication connection is enabled by pressing the “Connect” button K Fig 21. ( T M8-15) or select “Connect” from the “File” Menu. K Fig 22. ( T M8-15)

Fig 21.

M8-15

C075510-C2

M-05-11 issue 01

M8-15

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Read On occasion it may be necessary for the software and setup information to be read back from the ECU to check settings or preload current settings ready for updating because of new options being fitted to the vehicle. Press the “Read” button K Fig 23. ( T M8-16) or select “Read” from the “File” menu. K Fig 24. ( T M8-16)

Fig 23.

C075510-C1

Fig 25.

Fig 24.

C075510-C4

C075530-C1

The progress of the read operation is shown in the status window. When the data has been read from the ECU the data is stored back into the data entry boxes on the options screen. K Fig 25. ( T M8-16)

M8-16

M-05-11 issue 01

M8-16

Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

Connection Problems In general, whenever there are problems communicating with the DLA there will be an error message displayed.The following section although not exhaustive attempts to identify the more common ECU communication problems. The setup program must use the authorised Data Link Adaptor (DLA) contained in the Electronic Service Tool Kit. The latest versions of both the hardware and software can be obtained through authorised suppliers. Servicemaster software has been designed to run on the Windows 9.X, Windows 2000 and Windows XP operating systems. A number of reasons can generate software problems and assistance from an Information Technology engineer is advised. In particular, laptop PCs can suffer serial communications conflicts where the PC hardware does not allow the software access to the communication ports. In the majority of cases conflicts are caused by either software already running on the PC, or by certain 'driver' files not releasing the COM port(s). An error is generated K Fig 26. ( T M8-17) when no communications can be established with the DLA and the ECU usually through a hardware problem. Another source could be related to resistance of the two data communication wires making up the machine’s harness for the ECU’s CAN connection to the Deutsch 9 way round diagnostic connector.

Fig 26.

– DLA Drivers. The DLA and PC are programmed with software ‘drivers’ which handle communications. Ensure the latest drivers are installed on the PC and DLA (contained in the latest version of Service Master). – PC Power Management. Previous experiences have shown that some laptops’ Power Management software can disrupt the COM ports. Turning off the power management software may resolve the problem. – IR Drivers. If the PC has an InfraRed (IR) communications port then disabling the driver may help. – Modem Drivers. Modem drivers could cause communication conflicts and temporary disabling to establish if the software is conflicting with the port may establish this source. If the aforementioned information fails to resolve the situation then the following contacts may be able to provide further assistance; – Information Technology (IT) engineer. – Authorised machine dealer or agent. – Machine OEM. The Original Equipment Manufacturer (OEM) will make the relevant enquires.

C075620

Note: The ECU must be powered for communications to work, i.e. the machine ignition must be ON (but the engine need not be running). If a problem is experienced it can take one of three forms, a constant failure to establish communications, drop out during communications or intermittent communication connection. Contributory factors to communication errors could be related to the following items:

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M-05-11 issue 01

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Section M8 - Electronic Control Systems Cluster (LMS) Setup Tool - User Guide Loadall Cluster (LMS) Setup - User Guide

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M-05-11 issue 01

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Section M9 - Electronic Control Systems

Loadall Datalogger Tool - User Guide (M-05-12) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M9-2) K Loadall Datalogger - User Guide ( T M9-3)

M9-1

M-05-12 issue 01

M9-1

Section M9 - Electronic Control Systems Loadall Datalogger Tool - User Guide (M-05-12) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL

ALL (Care and Safety)(1)

ALL

Servicemaster SYSTEM

ALL

(1) You must obey all of the relevant care and safety procedures.

M9-2

M-05-12 issue 01

M9-2

Section M9 - Electronic Control Systems Loadall Datalogger Tool - User Guide (M-05-12) Loadall Datalogger - User Guide

Loadall Datalogger - User Guide Introduction The datalogger tool is used to retrieve stored error codes from the machine ECU’s. The tool will also allow the codes to be printed out and the fault memory cleared. New data logger tool 14 that will have the function of removing front screen errors from Production Build. E.g. – low fuel count. K Fig 1. ( T M9-3). DataLogger will also have the ability to log: – When the LLMI has been in the RED – When the machine has been tripped ‘Less than 800Kgs on rear axle’ – LLMC override button has been used. – Capture a 2 minute log when above has been logged.

P008450

Fig 1.

M9-3

M-05-12 issue 01

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Section M9 - Electronic Control Systems Loadall Datalogger Tool - User Guide (M-05-12) Loadall Datalogger - User Guide

Reading Machine Data 1

Connect the laptop to the machine CANbus.

Click on the ‘File’ menu and select ‘Read Data’.

Fig 2. 3

C105690

To clear the error log select ‘Reset’ and “Reset Error Log’.

Fig 5.

105710

The stored machine error logs will appear in the error log tab.

Fig 3. 4

C105700

To print the log file select ‘File’ and ‘Print’.

Fig 4.

M9-4

C105690

M-05-12 issue 01

M9-4

Section M10 - Electronic Control Systems

Machine Diagnostic Tool User Guide (M-05-25) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M10-2) K Loadall Machine Diagnostics - User Guide ( T M10-3)

M10-1

M-05-25 issue 01

M10-1

Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL

ALL (Care and Safety)(1)

ALL

Servicemaster SYSTEM

ALL

Servicemaster Tool Set

ALL

IFM Transmission Diagnostic Tool User Guide ALL

(1) You must obey all of the relevant care and safety procedures.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Loadall Machine Diagnostics - User Guide This tool set is for machines with JCB SH, SL, DH Ecomax engines with PS764 and PS750 transmissions. For transmission diagnostics for machines with JCB SH, SL, DH Ecomax engines and PS766 transmission refer to the IFM Transmission Diagnostic Tool User Guide. K Related Topics ( T M10-2) Note: For full details of machine/engine and transmission identification refer to Section 1 - Machine Identification.

Care and Safety

!MWARNING Be sure to read and follow any on screen instructions. Failure to follow correct procedure could result in death or injury. 2-4-5-5

Machine Applications The diagnostics software is not applicable to all machine variants. The diagnostics software contains more than one diagnostics tool. The different tools are selected by clicking on the applicable tab. Use the table to select the correct tool.

Machine System Tab Machine Applications Hydraulics ECU

Agri, Agri Plus, Agri Super. Nov. 2009 on

Powershift Transmission

Machines with PS764 and PS750 transmission

Hydraulic Pump Control

Machines with Variflow Hydraulic Pump

Rear Axle Stabilisation For Machines with Manplatform System Vehicle Can

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To view the status of all machine ECUâ&#x20AC;&#x2122;s

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Installing The Loadall Machine Diagnostics tool is fully integrated within JCB Service Master 4. To use the program you must install JCB Service Master 4 onto a suitable laptop computer. For full instructions on how to install JCB Service Master software see Section M - Servicemaster SYSTEM for servicemaster installation details. K Related Topics ( T M10-2)

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Connection To use the program your laptop computer must be connected to the machine CANbus. See Section M Servicemaster SYSTEM for servicemaster installation details. K Related Topics ( T M10-2)

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Starting Loadall Machine Diagnostics 1

Open servicemaster as detailed in Servicemaster SYSTEM. K Related Topics ( T M10-2)

Click on the “Construction” tab 1 or “Agricultural” tab 2.

Click on the “Telescopic Handlers” icon 3.

Fig 2. 5

Fig 1. 4

C126750-C1

C126750

Select the applicable machine model: a

2007 - (Machines built before 2007)

b 2007 + (Machines built after 2007) Fig 3. 6

C033110

Start the dignostic tool running by clicking on the Loadall Machine Diagnostics icon. K Fig 4. ( T M10-6)

Fig 4.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide 7

The Loadall Machine Diagnostic tool will then open up displaying the main window. K Fig 5. ( T M10-7).

Fig 7.

Fig 5. 8

C128600-C3.jpg

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Enable the connection between the PC/Laptop by pressing the “Start Diagnostics” button K Fig 6. ( T M10-7) or select “Start Diagnostics” from the “File” Menu. K Fig 7. ( T M10-7)

Fig 6.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Navigating within Loadall Machine Diagnostics

Menu Bar - File Menu

Navigation is designed to be via a mouse. On Laptop PCs this may take the form of a small joystick or touch sensitive pad and some buttons, usually located near to the keyboard. As with most Windows based programs, it is possible to navigate the cluster setup software using the keyboard by pressing certain combinations of keys. Note: This can be particularly useful for certain Laptop computers where the mouse/joystick can be oversensitive. Try out the following, it may come in useful one day. There are two main methods of navigation described below; – Pressing the ALT key will cause the File option on the Menu Bar to be highlighted. You can then use the arrow keys to navigate the menus. – Notice that all the menu items on the Menu Bar have a letter that is underlined (e.g. the 'F' in File). Holding down the ALT key and pressing the required letter key will activate that option (i.e. either open the menu or execute a function). For example, if you wish to open the Preferences Dialogue this can be done by pressing ALT + O (to open the Options menu) then ALT + P (to execute the Preferences option).

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Fig 8.

C128600-C4.jpg

– Exit: to close down the program. On exiting the program communications with both ECU and DLA are shut down.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Menu Bar - Options Menu

Fig 10.

Fig 9.

C075550

C128600-C5.jpg

– Start Diagnostics: to connect the PC/laptop to the ECU to enable communication and the tracking of machine sensors and actuators. – Stop Diagnostics: to disconnect the PC/laptop and the ECU and cease communication. – Controller Status: to show that the ECU is online.When the ECU is online the machine codes are displayed. This diagram shows the actual settings read from a test machine.K Fig 11. ( T M10-9)

Fig 11.

C075570

– Preferences: - to select the language of the machine diagnostic program. K Fig 10. ( T M10-9) – Unlock. Refer to the Unlock Procedure. K Unlock Procedure ( T M10-10)

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide Unlock Procedure To access the ECU a new access code must be requested. This can only be requested from Loadall Technical Service, and the following procedure must be followed.

Fig 13. 8

Fig 12.

C128440.jpg

Set up can then be completed.

C128600-C5.jpg

Select unlock. K Fig 12. ( T M10-10).

This will produce a security unlock screen displaying a `Challenge Value'. K Fig 13. ( T M10-10).

No further connection - set up can be made until the engineer either emails this value or contacts JCB Service.

JCB Service will apply your `Challenge Code' and through a special Dongle Tool and set up exe file, JCB Service will then receive a `Response Value'.

This value will be passed back to the dealer / engineer to use this into the unlock screen.

When all numbers / letters have been completed the ECU will self unlock.

Set up can then be completed.

Note: This is a ONE OFF response code only so if the dealer / engineer types this incorrect they will need to restart the complete procedure again.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Menu Bar - Help Menu

Menu Bar - Data Capture

Fig 16.

C128600-C8.jpg

– Capture Open Diagrams: allows the current display to be saved. Fig 14.

C128600-C6.jpg

– Stop: Stop the capture operation.

– Help: opens the help program. – About: Opens a window showing the version number of the installed copy of the software. K Fig 15. ( T M10-11)

Fig 15.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

LED Status Key Displays a key for the colour status of the LEDs shown on the diagnostics pages. The LED's change colour dependant on the electrical signal.

Fig 17. LED Colour

Electrical signal status

Dark Green

Input/Output OFF

Light Green

Input/Output ON

Blue

Open circuit

Red

Short to ground

Magenta

Short to battery

Grey

No data

C128600-C10.jpg

Status bar There are 3 items of interest displayed on the Status Bar, which is located along the bottom of the Diagnostics main window.

Fig 18.

C128600-C9.jpg

CAN Communications: Two small LEDs indicate data being transmitted (red) and received (green) over the CAN communications link. These LEDs can be seen to be flashing rapidly as data is transported. This can be another useful aid to determining the state of any established communications. Connection Status: Indicates if the diagnostics software is connected, connecting or not connected to the ECU. Data Identification: When the mouse pointer is put on a data field or â&#x20AC;&#x2DC;LEDâ&#x20AC;&#x2122; in the diagnostics page its description is shown in the status bar at C.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Hydraulics ECU Diagnostic Pages

Pages

Information on the diagnostic pages is constantly updated in real-time. The status of the ECU electrical inputs and outputs is displayed using:

K Hydraulics ECU Power Supply ( T M10-14) K Engine Speed ( T M10-15) K Extend/Retract/Auxiliaries ( T M10-16)

– Simulated LED's. The LED's change colour depending on the status of the inputs and outputs. – Numerical values i.e. Volts, PWM output, Current. Switches

K Raise/Lower ( T M10-16) K Crowd/Dump ( T M10-17) K Smooth Ride System ( T M10-17) K Second Auxiliary ( T M10-18)

The status of each of the switch inputs to the ECU is shown. Where there are two switch inputs ‘NO’ (Normally Open) and ‘NC’ (Normally closed) both inputs are shown. The status is displayed using the simulated LED's.

K Constant Auxiliary ( T M10-18) K Hydraulic Isolation ( T M10-19) K Tilt Isolation ( T M10-19) K Load Control ( T M10-20) K Auto Steer Mode Control ( T M10-21)

Variable Inputs The voltage of the variable inputs is shown on this page. The voltages can be observed during operation and their values compared to expected readings.

For details of the electrical operation refer the relevant system topic.

Digital Outputs The status of the digital outputs from ECU are displayed using the simulated LED's. Valve Outputs The status of the digital outputs from the ECU to the hydraulic solenoid valves is displayed using the simulated LED's. The current value of the solenoid outputs can be monitored to make sure they both meet specifications.

Diagnostic Procedure Important: Use of the diagnostics pages requires operation of the relevant machine system at the same time. If necessary get the help of an assistant. In the event of a system fault the applicable diagnostic page can be used to check the operation of all the relevant electronic and electrical devices. Operate the system and view the diagnostics page to see if the system devices respond as expected. For example; there is no voltage change shown when the servo control lever is operated in the relevant axis. This may indicate a fault with the servo lever or its wire interconnection.

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Fig 19. Hydraulics ECU Power Supply

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Fig 20. Engine Speed

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Fig 21. Extend/Retract/Auxiliaries

Fig 22. Raise/Lower

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Fig 23. Crowd/Dump

Fig 24. Smooth Ride System

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Fig 25. Second Auxiliary

Fig 26. Constant Auxiliary

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Fig 27. Hydraulic Isolation

Fig 28. Tilt Isolation

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Fig 29. Load Control

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Fig 30. Auto Steer Mode Control

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

LLMI/LLMC ECU Diagnostic Pages

Pages

Information on the diagnostic pages is constantly updated in real-time. The status of the ECU electrical inputs and outputs is displayed using:

K System Diagram ( T M10-23) K LED Health ( T M10-24) K Active Fault Codes ( T M10-25)

– Simulated LED's. The LED's change colour depending on the status of the inputs and outputs. – Numerical values i.e. Volts, PWM output, Current.

K Calibration Settings ( T M10-26) K Calibration Status ( T M10-27) For details of the electrical operation refer the relevant system topic.

The following is a brief explanation of each feature. Switches The status of each of the switch inputs to the ECU is shown. Where there are two switch inputs ‘NO’ (Normally Open) and ‘NC’ (Normally closed) both inputs are shown. The status is displayed using the simulated LED's. Variable Inputs The voltage of the variable inputs is shown on this page. The voltages can be observed during operation and their values compared to expected readings. Digital Outputs The status of the digital outputs from ECU are displayed using the simulated LED's. Valve Outputs The status of the digital outputs from the ECU to the hydraulic solenoid valves is displayed using the simulated LED's. The current value of the solenoid outputs can be monitored to make sure they meet specifications.

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Fig 31. System Diagram

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Fig 32. LED Health

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Fig 33. Active Fault Codes

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Fig 34. Calibration Settings

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Fig 35. Calibration Status

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Powershift Transmission Diagnostic Pages

Pages K System Status ( T M10-29)

Information on the diagnostic pages is constantly updated in real-time. The status of the ECU electrical inputs and outputs is displayed using:

For details of the electrical operation refer the relevant system topic.

– Simulated LED's. The LED's change colour depending on the status of the inputs and outputs. – Numerical values i.e. Volts, PWM output, Current. The following is a brief explanation of each feature. Switches The status of each of the switch inputs to the ECU is shown. Where there are two switch inputs ‘NO’ (Normally Open) and ‘NC’ (Normally closed) both inputs are shown. The status is displayed using the simulated LED's. Variable Inputs The voltage of the variable inputs is shown on this page. The voltages can be observed during operation and their values compared to expected readings. Digital Outputs The status of the digital outputs from ECU are displayed using the simulated LED's. Valve Outputs The status of the digital outputs from the ECU to the hydraulic solenoid valves is displayed using the simulated LED's. The current value of the solenoid outputs can be monitored to make sure they meet specifications.

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Fig 36. System Status

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Variflow Hydraulic Pump Control Diagnostic Pages

Pages K System Status ( T M10-31)

Information on the diagnostic pages is constantly updated in real-time. The status of the ECU electrical inputs and outputs is displayed using:

For details of the electrical operation refer the relevant system topic.

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Fig 37. System Status

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Rear Axle Stabilisation (RAS) Diagnostic Pages Information on the diagnostic pages is constantly updated in real-time. The status of the ECU electrical inputs and outputs is displayed using: – Simulated LED's. The LED's change colour depending on the status of the inputs and outputs. – Numerical values i.e. Volts, PWM output, Current.

Switches The status of each of the switch inputs to the ECU is shown. Where there are two switch inputs ‘NO’ (Normally Open) and ‘NC’ (Normally closed) both inputs are shown. The ECU switch power output status is shown in the third column as ‘COM’. The status is displayed using the simulated LED's. K Fig 38. ( T M10-33)

Transmission

RAS Mode The current mode of the RAS system is displayed.

Pages K RAS System Status ( T M10-33) For details of the electrical operation refer the relevant system topic.

The status of the transmission gear and direction inputs to the ECU are shown using the simulated LED's. K Fig 38. ( T M10-33). The output shaft and vehicle speed readings can also be monitored to make sure they correspond.

Ignition Switch The ignition switch input to the ECU status is shown using the simulated LED's. K Fig 38. ( T M10-33) The battery voltage is also displayed to make sure it meets specifications.

Digital Outputs The status of the digital outputs from ECU are displayed using the simulated LED's. K Fig 38. ( T M10-33).

Valve Outputs The status of the digital outputs from the ECU to the LS (low side) and HS (high side) of the hydraulic solenoid valves is displayed using the simulated LED's. K Fig 38. ( T M10-33). The current value of the solenoid outputs can be monitored to make sure they both meet specifications.

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Fig 38. RAS System Status

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Vehicle Can - Diagnostic Pages

Pages

Information on the diagnostic page is constantly updated in real-time. Each ECU connected to the CANbus is shown. Data is displayed in the fields on the page when CAN messages are transmitted.

K Vehicle Can - Machines with PS760 Transmission and Variflow Hydraulic Pump ( T M10-34) K Vehicle Can - Machines with PS760/PS750 Transmission and Gearpump Hydraulic Pump ( T M10-35)

Fig 39. Vehicle Can - Machines with PS760 Transmission and Variflow Hydraulic Pump

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Fig 40. Vehicle Can - Machines with PS760/PS750 Transmission and Gearpump Hydraulic Pump

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Section M10 - Electronic Control Systems Machine Diagnostic Tool User Guide (M-05-25) Loadall Machine Diagnostics - User Guide

Connection Problems

DLA (contained in the latest version of Service Master).

In general, whenever there are problems communicating with the DLA there will be an error message displayed.The following section although not exhaustive attempts to identify the more common ECU communication problems.

– PC Power Management. Previous experiences have shown that some laptops’ Power Management software can disrupt the COM ports. Turning off the power management software may resolve the problem.

The setup program must use the authorised Data Link Adaptor (DLA) contained in the Electronic Service Tool Kit. The latest versions of both the hardware and software can be obtained through authorised suppliers.

– IR Drivers. If the PC has an InfraRed (IR) communications port then disabling the driver may help.

A number of reasons can generate software problems and assistance from an Information Technology engineer is advised. In particular, laptop PCs can suffer serial communications conflicts where the PC hardware does not allow the software access to the communication ports. In the majority of cases conflicts are caused by either software already running on the PC, or by certain 'driver' files not releasing the COM port(s). An error is generated K Fig 41. ( T M10-36) when no communications can be established with the DLA and the ECU usually through a hardware problem. Another source could be related to resistance of the two data communication wires making up the machine’s harness for the ECU’s CAN connection to the Deutsch 9 way round diagnostic connector.

Fig 41.

– Modem Drivers. Modem drivers could cause communication conflicts and temporary disabling to establish if the software is conflicting with the port may establish this source. If the aforementioned information fails to resolve the situation then the following contacts may be able to provide further assistance; – Information Technology (IT) engineer. – Authorised machine dealer or agent. – Machine OEM. The Original Equipment Manufacturer (OEM) will make the relevant enquires.

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Section M11 - Electronic Control Systems

Immobiliser Setup Tool (M-05-15) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M11-2) K User Guide ( T M11-3) K Introduction ( T M11-3) K Installing Immobiliser Setup ( T M11-3) K Connecting Immobiliser Setup ( T M11-3) K Starting Immobiliser Setup ( T M11-3) K Using the Immobiliser Setup Tool ( T M11-4)

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Section M11 - Electronic Control Systems Immobiliser Setup Tool (M-05-15) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL

ALL (Care and Safety)(1)

ALL

Servicemaster SYSTEM

ALL

Servicemaster Tool Set

(1) You must obey all of the relevant care and safety procedures.

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Section M11 - Electronic Control Systems Immobiliser Setup Tool (M-05-15) User Guide

User Guide Introduction

Installing Immobiliser Setup

This tool is provided to setup/amend the immobiliser. Situations which may require the immobiliser settings to be changed may be:

The setup tool is fully integrated within JCB Service Master. To use the setup tool you must install JCB ServiceMaster onto a suitable laptop computer. See Section M - Servicemaster SYSTEM for servicemaster installation details. K Related Topics ( T M11-2)

– Transfer of machine ownership. – Replacement of immobiliser system components. – Loss of keys/codes to deactivate the immobiliser. This tool is used to perform the following actions: – Obtain an unlock ‘Response Code’ for security authorisation to re-configure the immobiliser. (The ‘Response Code’ is only available via JCB Tech Web.) – Configure a new immobiliser. (Change from ‘Factory Mode’ to key system or keypad system mode as applicable.) – Configure new immobiliser keys. (Key systems only.)

For full instructions on how to install JCB ServiceMaster software please refer to the documentation which accompanies JCB ServiceMaster.

Connecting Immobiliser Setup To use the setup tool the DLA and your laptop computer must be connected to the machine diagnostics connector Refer to the Servicemaster SYSTEM and Servicemaster Tools Set topics.

Starting Immobiliser Setup

– Configure new immobiliser codes. (Keypad systems only.)

Turn ON the machine ignition.

– Delete existing keys/codes.

Start JCB ServiceMaster on the laptop computer and select the correct machine range. Refer to Servicemaster Tools Set topic.

Start the diagnostics tool running by clicking on the Immobiliser Setup icon.

Fig 1.

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Section M11 - Electronic Control Systems Immobiliser Setup Tool (M-05-15) User Guide

Using the Immobiliser Setup Tool To use the immobiliser set up tool click on the “Help Menu” and select “Help”. The Help file will display and details the procedures to unlock and use the tool.

Fig 2.

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Section M12 - Electronic Control Systems

Immobiliser Diagnostics Tool (M-05-17) Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M12-2) K User Guide ( T M12-3) K Introduction ( T M12-3) K Installing Immobiliser Diagnostics ( T M12-3) K Connecting Immobiliser Diagnostics ( T M12-3) K Starting Immobiliser Diagnostics ( T M12-3) K Using the Immobiliser Diagnostics Tool ( T M12-4)

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Section M12 - Electronic Control Systems Immobiliser Diagnostics Tool (M-05-17) Related Topics

Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL

ALL (Care and Safety)(1)

ALL

Servicemaster SYSTEM

ALL

Servicemaster Tools Set

(1) You must obey all of the relevant care and safety procedures.

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Section M12 - Electronic Control Systems Immobiliser Diagnostics Tool (M-05-17) User Guide

User Guide Introduction

Installing Immobiliser Diagnostics

The immobiliser diagnostics tool has the following status windows:

The diagnostics tool is fully integrated within JCB Service Master. To use the setup tool you must install JCB ServiceMaster onto a suitable laptop computer. See Section M - Servicemaster SYSTEM for servicemaster installation details. K Related Topics ( T M12-2)

– System Diagram. – Active Fault Codes.

– Status of the immobiliser internal switches.

For full instructions on how to install JCB ServiceMaster software please refer to the documentation which accompanies JCB ServiceMaster.

– Status of devices connected to the immobiliser ECU. (includes key antenna and keypad devices).

Connecting Immobiliser Diagnostics

This tool is used to show the following:

– View active fault codes.

To use the diagnostics tool the DLA and your laptop computer must be connected to the machine diagnostics connector Refer to the Servicemaster SYSTEM and Servicemaster Tools Set topics.

Starting Immobiliser Diagnostics 1

Turn ON the machine ignition.

Start JCB ServiceMaster on the laptop computer and select the correct machine range. Refer to Servicemaster Tools Set topic.

Start the diagnostics tool running by clicking on the Immobiliser Diagnostics icon.

Fig 1.

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Section M12 - Electronic Control Systems Immobiliser Diagnostics Tool (M-05-17) User Guide

Using the Immobiliser Diagnostics Tool To use the immobiliser diagnostics tool click on the ‘Help Menu’ and select ‘Help’. The Help file will display and details the procedures for use of the tool.

Fig 2.

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Section M13 - Electronic Control Systems

Pulse Width Modulation Theory Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M13-2) K Operation Overview ( T M13-3)

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Topic Titles

Sub Titles

Applications

ALL

Service Tools

ALL

ALL (Care and Safety)(1)

ALL

Electronic Control Unit Theory

ALL

(1) You must obey all of the relevant care and safety procedures.

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M-06-06 issue 01

M13-2

Section M13 - Electronic Control Systems Pulse Width Modulation Theory Operation Overview

Operation Overview The machines use an electronic control unit (ECU) to provide a current signal output to operate proportional solenoid valves for some machine operations. Note that the ECU is a non serviceable part and is NOT programmable. For information on the ECU operation please refer to the relevant topic - Electronic Control Unit Theory. K Related Topics ( T M13-2) Ohms law states that, the amount of current flow in a circuit is determined by the voltage, and the resistance. A 12v circuit with a resistance of 6 ohms, would draw a current of 2 amps. This would be the case for a standard solenoid, which is either on or off. Once the voltage is applied to the circuit, it is present 100% of the time. This would be known as a 100% duty cycle. Therefore the circuit will draw 2 amps constantly.

It is easier, more economical, and more reliable to change the duty cycle of the circuit, especially using today's computer - controller technology. The duty cycle is the amount of time a component is switched on compared to the time it is switched off. If a solenoid is on for three seconds, then off for one second, on for three, off for one etc. this would be a 75% duty cycle. The graph A although unstable would give a current rating of 1.5 amps. To stabilise the current in the circuit, the frequency would need to be increased. If the time scale on the graph A was one second, the frequency would be 4Hz (Hertz (cycles per second)). The graph B shows the same duty cycle, but at a higher frequency of 32 Hz. Note that the proportional solenoids can operate at a frequency of 250 Hz.

A 3

Current

Time 75% Duty cycle

ON 1 cycle 3

Voltage

Current Time

Fig 1. A proportional solenoid requires differing amounts of current, depending on its condition. As the coil has a fixed resistance, changing the current rating can be done in either of two ways, 1

Having lots of different resistors switched in and out of the circuit at different times to change the current flowing.

To change the duty cycle of the solenoid.

M13-3

M-06-06 issue 01

Fig 2.

M13-3

Section M13 - Electronic Control Systems Pulse Width Modulation Theory Operation Overview

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M13-4

M-06-06 issue 01

M13-4

Section M14 - Electronic Control Systems

Electronic Control Unit Theory Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T M14-2) K Operation Overview ( T M14-3)

M14-1

M-06-05 issue 01

M14-1

Section M14 - Electronic Control Systems Electronic Control Unit Theory Related Topics

Topic Titles

Applications

Sub Titles ALL

ALL (Care and Safety)

(1)

ALL

LSP Variflow Flowshare Hydraulic SYSTEM

ALL

PS766 Gearbox SYSTEM

ALL

Drive Control ECU - Dual Control SYSTEM

ALL

Auto Steer Mode SYSTEM

ALL

Stop and Start SYSTEM (Electronic F.I. Engines)

ALL

Pulse Width Modulation Theory

ALL

Loadall Monitoring SYSTEM

ALL

Servicemaster SYSTEM

ALL

(1) You must obey all of the relevant care and safety procedures.

M14-2

M-06-05 issue 01

M14-2

Section M14 - Electronic Control Systems Electronic Control Unit Theory Operation Overview

Operation Overview The machines use an electronic control unit (ECU) to control machine operations. The ECU uses analog and digital signals from machine sensors, switches etc. and uses this data to supply a feed or a ground connection for other machine devices. The machines can have one or more ECUâ&#x20AC;&#x2122;s depending on the model variant. For information on each ECU refer to the correct topic.

Switch (lights etc.)

ECU

12v

Input

The machine ECUâ&#x20AC;&#x2122;s can be connected to JCB Servicemaster diagnostic software to check ECU version and operation. K Related Topics ( T M14-2)

ECU Inputs

Digital inputs (i.e. On-Off switch type inputs): Digital type inputs are on-off type inputs (i.e. switches) and can be Low side inputs or High side inputs. Low side inputs are inputs that provide a ground to the ECU. High side inputs are inputs that provide a positive feed to the ECU. Low side input: The low side input is the most frequently used input on an electrical system. The low side input can be in the form of rocker switches or pressure switches.

Analogue inputs (i.e. sensor type inputs): Analogue inputs are sensor type inputs that provide a varying type input to the ECU, this input could be a voltage, resistance or frequency type input.

ECU

Input

Thumbwheel position switch

Sensor ref voltage 5v

Sensor ref 0 voltage

Switch (rocker, pressure etc.)

ECU

C007180GB-C1

Fig 2.

There are two main types of input, Digital and Analogue.

Thumbwheel input (Potentiometer type input)

12v

Fig 3.

Fig 1.

C007190GB-C1

C007170GB-C1

High side input: The high side input is used on circuits that require a positive feed when the ignition is switched off, e.g. sidelights or hazard lights.

M14-3

M-06-05 issue 01

M14-3

Section M14 - Electronic Control Systems Electronic Control Unit Theory Operation Overview

ECU Outputs There are three main types of outputs. Low side output, High side output and Modulated output. 1

Low side output: In the Low side output circuit the solenoid or relay which is being driven already has a positive feed available, the ECU then provides the ground side of the circuit.

Solenoid or relay coil

ECU

Fig 4.

Fig 6.

C007240GB-C1

C007220GB-C1

High side output: In the High side output circuit the solenoid or relay which is being driven already has a ground available, the ECU provides the positive side of the circuit.

Solenoid or relay coil

ECU

Output

12v

Fig 5. 3

Output

12v

Output

Proportional solenoid

ECU

C007230GB-C1

Modulated outputs: In the Modulated Output circuit the ECU provides a PWM (Pulse Width Modulation) signal to a proportional valve. As the ECU varies the duty cycle of the signal the proportional valve will select more or less depending on the change in duty cycle. Pulse Width Modulation Theory. K Related Topics ( T M14-2)

M14-4

M-06-05 issue 01

M14-4

Section M15 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M15-1

M-07 issue 01

M15-1

Section M15 - Electronic Control Systems Sub Section Intentionally Blank

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M15-2

M-07 issue 01

M15-2

Section M16 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M16-1

M-08 issue 01

M16-1

Section M16 - Electronic Control Systems Sub Section Intentionally Blank

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M16-2

M-08 issue 01

M16-2

Section M17 - Electronic Control Systems

Devices Introduction Electrical and electronic systems comprise control devices connected by electrical wiring or CAN systems. Faulty devices, wires and connectors can cause fault codes to be logged. Refer to the Fault Codes SYSTEM topic. The following topics describe relevant electronic and electrical control devices together with their wiring. The information is useful when fault finding. Note: Some devices are specific to some machine variants. Refer to the correct device when fault finding. Use the table at the front of each device topic. For information about the main machine systems refer to the applicable system topic in the relevant section of this publication.

M17-1

M-09-00 issue 01

M17-1

Section M17 - Electronic Control Systems Devices Introduction

Page left intentionally blank

M17-2

M-09-00 issue 01

M17-2

Section M18 - Electronic Control Systems

Electronic Controllers Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T M18-3) K LMS ECU ( T M18-4) K Location ( T M18-4) K Wires and Connectors ( T M18-5) K Removal and Replacement Guide ( T M18-9) K Test Procedures ( T M18-9) K Service Hours Reset ( T M18-10) K Immobiliser ECU ( T M18-13) K Location ( T M18-13) K Wires and Connectors ( T M18-14) K Removal and Replacement Guide ( T M18-17) K Test Procedures ( T M18-18) K Livelink ECU (S1) ( T M18-19)(1) K Location ( T M18-19) K Wires and Connectors ( T M18-20) K Removal and Replacement Guide ( T M18-23) K Test Procedures ( T M18-24) K Livelink ECU (S2) ( T M18-25)(1) K Location ( T M18-25) K Wires and Connectors ( T M18-25) K Removal and Replacement Guide ( T M18-29) K Test Procedures ( T M18-30) K RAS ECU ( T M18-31) (1) System variant. Make sure you refer to the correct procedure.

M18-1

M-10-02 issue 01

M18-1

Section M18 - Electronic Control Systems Electronic Controllers Introduction Table 1. System Variants Machine Model Application

Systems(1) K Livelink ECU (S1) ( T M18-19)

Machines up to 30/1/2013

K Livelink ECU (S2) ( T M18-25)

Machines from 30/1/2013

(1) The table lists system variants and the applicable machine models. Use the table to make sure you refer to the correct information.

M18-2

M-10-02 issue 01

M18-2

Section M18 - Electronic Control Systems Electronic Controllers Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Cab

ALL

RAS ECU

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Servicemaster System

ALL

Servicemaster Tools

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

M18-3

M-10-02 issue 01

M18-3

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU

LMS ECU Location

1 3

Fig 1.

Item

Table 3. Description

Analog fuel level gauge

Analog engine coolant temperature gauge

Analog tachometer

LCD panel

Up and Down user control buttons

C123370

If the ECU receives electronic fault codes or electrical signals to be interpreted as faults the ECU activates visual and, when applicable, audible warnings. Fault codes are also logged by the ECU. Refer to the Fault Code SYSTEM topic. K Related Topics ( T M18-3)

Fault Code Display

The LMS ECU is located in the RH side of the instrument panel. The LMS ECU is an integral part of the RH switch panel 6. The integral ECU controls the information shown on the LCD panel 4, the tachometer 3 and fuel level and temperature gauges (1 and 2).

The ECU monitors data from electrical and electronic devices on the machine. Data is received via dedicated wires and from the machine CANbus, depending on the type of device. The ECU processes the data and controls devices in the graphical user interface (GUI) such as the engine coolant temperature gauge, system status indicator lamps and engine tachometer. The LMS ECU also monitors machine usage in the form of engine run hours and service events.

M18-4

M-10-02 issue 01

M18-4

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU

Wires and Connectors The RH cluster is connected to the panel harness.

C122930

Fig 2. The tables show how the monitoring system ECU’s respond to inputs from connected devices.

connectors are viewed from the front. DO NOT TOUCH the pins on the ECU’s.

Note: Some of the warning and indicator light signals are sent through the CANBus system and do not have a dedicated input.

Note: All machine options are included - some machines will not be fitted with these options and the harness pin will be blank.

Important: The connector pin numbers are for the harness connectors, NOT the pins on the ECU’s. The

Note: Some machine variants will use different inputs/ outputs on the connector pin, these are also shown.

Table 4. Connector J1 Type

Refer to device:

Not Used

Alternator Excitation

Input

K Alternator ( T M21-33)

Alternator Output

Input

K Alternator ( T M21-33)

Not Used

Fuel Level Sender

Analog Input

Transmission Oil Pressure Sensor Input

Refer to Section F - Transmission

Coolant Level Switch

Input

TBA

Air Filter Vacuum Switch

Input

K Vacuum Switch ( T M21-11)

Pin Number

Connected to:

1 2

M18-5

M-10-02 issue 01

K Fuel Level Sender ( T M21-5)

M18-5

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU Pin Number

Connected to:

Type

Refer to device:

Not Used

Engine Oil Pressure Sender

Input

Refer to Tier 4 Engine Service Manual

Power

+12V Battery

K LMS ECU Power and Earths ( T M18-8)

Earth

K LMS ECU Power and Earths ( T M18-8)

CANbus High

CANbus

K CANbus SYSTEM ( T M1-5)

CANbus Low

CANbus

K CANbus SYSTEM ( T M1-5)

CANbus SCR

CANbus

K CANbus SYSTEM ( T M1-5)

Not Used

Power

+12V Battery

K LMS ECU Power and Earths ( T M18-8)

Wake Up (Side Lights)

Input

TBA

Pin Number

Connected to:

Table 5. Connector J2 Type

Refer to device:

Water In Fuel Sensor

Input

K WIF Sensor ( T M21-20)

Not Used

Forward Drive (L/H Column Switch)

Input

Refer to Section F - Transmission

Not Used

Neutral Drive (L/H Column Switch) Input

Refer to Section F - Transmission

Reverse Drive (L/H Column Switch)

Input

Refer to Section F - Transmission

Not Used

Left Stabiliser

Input

K Stabiliser Deployed Sensor ( T M27-4)

Transmission Oil Temperature

Input

Refer to Section F - Transmission

Not Used

Right Stabiliser

Input

K Stabiliser Deployed Sensor ( T M27-4)

Transmission Speed Sensor

Input

Refer to Section F - Transmission

Centre warning display panel transmission oil pressure LED

Input

K Centre Cluster Warning Panel ( T M22-18)

M18-6

M-10-02 issue 01

M18-6

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU Pin Number

Connected to:

Type

Refer to device:

RAS Isolation Relays

Output

Refer to Section B - RAS SYSTEM. K Related Topics ( T M18-3)

Centre warning display panel Warning Buzzer

Output

K Centre Cluster Warning Panel ( T M22-18)

RAS ECU

TBA

Refer to Section B - RAS SYSTEM. K Related Topics ( T M18-3)

Info Button

Input

K Info Operator Switch ( T M22-11)

Sensor Earth

Earth

K LMS ECU Power and Earths ( T M18-8)

Not Used

M18-7

M-10-02 issue 01

M18-7

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU LMS ECU Power and Earths

CONNECTOR J1 FUSEBOX FUSEBOX

12 11 19 CONNECTOR J2 ECU

LMS ECU C123380

Fig 3. Table 6. Harness Connector J1 Connectors

Pins

P003

Details 12

Fusebox C - Refer to Section C - Fuses and Relays. K Related Topics ( T M18-3)

P001 P039

M18-8

19 16

Fusebox A - Refer to Section C - Fuses and Relays. K Related Topics ( T M18-3) Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M18-3)

M-10-02 issue 01

M18-8

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU

Removal and Replacement Guide

1 2

6 1

6 5

4 C123390

Fig 4.

Removal

Test Procedures

Disconnect the battery.

Remove the radio 5 (if fitted).

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Do not use a multimeter at the pins on the ECU. Only use the meter at the pins on the harness connectors.

Without the use of sophisticated electronic test equipment it is not possible to test the ECU. If the ECU is returned under warranty it will be tested at the factory to confirm possible faults.

Note: Do not touch the connector pins 3 on the RH cluster ECU. 3

Remove the three screws1 that hold the RH switch panel 4 in place, label and disconnect all connections and remove the panel.

Replacement Replacement of the LMS ECU is the reverse of the removal procedure noting the following: – The LMS ECU is an integral part of the RH switch panel. – If the LMS ECU is to be replaced with a new one, the switches 6 must be transferred to the new switch panel. Label the switches to ensure they are installed in the correct locations. – Before operating the machine, ensure the LMS ECU is configured correctly. Use the correct Servicemaster setup tool. K Related Topics ( T M18-3)

M18-9

M-10-02 issue 01

M18-9

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU

Service Hours Reset Introduction The Time Until Service display 1 is the difference between the next service interval and the current engine hours. In the example, the Time Until Service is 314.6 hours (1500 hours - 1185.4 hours). Note: When the display is set to the Time Until Service screen, the Service symbol 1A comes on. This value can be reset using either: â&#x20AC;&#x201C; The machine LCD Display. K Using the Machine LCD Display ( T M18-11) â&#x20AC;&#x201C; Servicemaster 2. Servicemaster ( T M18-12)

Fig 5.

M18-10

K Using

JCB

432711-C1

M-10-02 issue 01

M18-10

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU Using the Machine LCD Display You can use the instrument panel and related controls to reset the Service Hours. It is not necessary to connect a laptop computer to complete this task.

To reset the service hours, use the digital display A and the left or right arrow button. K Using the Machine LCD Display ( T M18-11)

432711-9

Fig 6. Procedure 1

Make the machine safe with the boom lowered.

Make sure that the park brake is engaged, then Switch ON the ignition.

Quickly push then release the Information button. Repeat as necessary until the Service Hours (the open book symbol 1) is shown.

Fig 7.

M18-11

M-10-02 issue 01

432711-14

M18-11

Section M18 - Electronic Control Systems Electronic Controllers LMS ECU 4

Push then hold the Information button for 20 seconds. Release the information button.

If necessary, use the left or right arrow button to change the screen from FLT LST to SRV RST.

Push then hold the Information button for one second to go into the RESET screen. Release the information button.

Push then hold the Information button for three seconds to reset the service hours (The word RESET flashes once). Release the information button.

Push then hold the Information button for one second to exit the RESET screen. Release the information button.

Use the left or right arrow buttons to move to EXIT.

Quickly push then release the Information button to go to the normal operation mode.

M18-12

Using JCB Servicemaster Refer to Section M - Servicemaster Tools. K Related Topics ( T M18-3)

M-10-02 issue 01

M18-12

Section M18 - Electronic Control Systems Electronic Controllers Immobiliser ECU

Immobiliser ECU Location

Fig 8.

Item

Table 7. Description

Immobiliser ECU

M18-13

C123240

The Immobiliser ECU is located within the instrument trim panel.

M-10-02 issue 01

M18-13

Section M18 - Electronic Control Systems Electronic Controllers Immobiliser ECU

Wires and Connectors

Immobiliser Transponder Antenna/ Keypad are connected to the ECU through connector B.

The Immobiliser ECU is connected to the panel harness.

6 B

C123250

Fig 9. Table 8. Connector A (Black) Type

Pin Number

Connected to:

LH Column Switch pin 7

TBA

Power

12V Battery

K Immobiliser ECU Power and Earth Connections ( T M18-16)

Power

12V Battery

K Immobiliser ECU Power and Earth Connections ( T M18-16)

M18-14

M-10-02 issue 01

Refer to device:

M18-14

Section M18 - Electronic Control Systems Electronic Controllers Immobiliser ECU Pin Number

Connected to:

Type

Refer to device:

Not Used

Power

12V Battery

K Immobiliser ECU Power and Earth Connections ( T M18-16)

Power

12V Battery

K Immobiliser ECU Power and Earth Connections ( T M18-16)

CANbus High

CANbus

K CANbus SYSTEM (M-0107) ( T M1-9)

CANbus Low

CANbus

K CANbus SYSTEM (M-0107) ( T M1-9)

Not Used

Earth

K Device Ground Points ( T M31-1)

M18-15

M-10-02 issue 01

M18-15

Section M18 - Electronic Control Systems Electronic Controllers Immobiliser ECU Immobiliser ECU Power and Earth Connections FUSEBOX

CONNECTOR A 12

FUSEBOX

8 CONNECTOR B ECU

IMMOBILISER ECU C123260-C1

Fig 10. Table 9. Harness Connector A Connectors

Pins

P003

P039

M18-16

Details 12 Fusebox C - Refer to Section C - Fuses and Relays. K Related Topics ( T M18-3) 3

Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M18-3)

M-10-02 issue 01

M18-16

Section M18 - Electronic Control Systems Electronic Controllers Immobiliser ECU

Removal and Replacement Guide

2 3

1 5

C123240-C1

Fig 11.

Removal 1

Park the machine and make it safe with the boom raised. Refer to Section 2 - General Procedures. K Related Topics ( T M18-3)

Remove the applicable trim panels/instrument panels to get access to the ECU. Refer to Section B - Cab. K Related Topics ( T M18-3)

Disconnect the battery.

Support the ECU 1 and remove the mounting bolts 3, nuts 5 and washers 4.

Remove the ECU from the machine.

Replacement Replacement is the reverse of the removal procedure noting the following:

Note: Do not touch the connector pins on the ECU.

– Before operating the machine, ensure the ECU is configured correctly. Use the correct Servicemaster setup tool. K Related Topics ( T M18-3)

– Make sure to replace the washers 4 in the positions shown.

Disconnect the electrical connectors from the ECU connectors 2.

M18-17

– Torque tighten the nuts 5 to 10Nm.

M-10-02 issue 01

M18-17

Section M18 - Electronic Control Systems Electronic Controllers Immobiliser ECU

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Do not use a multimeter at the pins on the ECU. Only use the meter at the pins on the harness connectors.

Without the use of sophisticated electronic test equipment it is not possible to test the ECU. If the ECU is returned under warranty it will be tested at the factory to confirm possible faults.

M18-18

M-10-02 issue 01

M18-18

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S1)

Livelink ECU (S1) Location

Fig 12.

Item

Table 10. Description

Livelink ECU

C123210

The Livelink ECU is located within the instrument trim panel.

M18-19

M-10-02 issue 01

M18-19

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S1)

Wires and Connectors The Livelink ECU is connected to the LiveLink harness.

C123220

Fig 13.

Pin Number

Connected to:

Table 11. Connector C Type

SCR

CANbus Screen

K CANbus SYSTEM (M-0107) ( T M1-9)

CANbus Low

CANbus

K CANbus SYSTEM (M-0107) ( T M1-9)

Not Used

Power

12V Battery

K Livelink ECU Power and Earth Connections ( T M18-22)

Not Used

Power

12V Battery

K Livelink ECU Power and Earth Connections ( T M18-22)

Earth

K Livelink ECU Power and Earth Connections ( T M18-22)

M18-20

M-10-02 issue 01

Refer to device:

M18-20

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S1) Pin Number

Connected to:

Not Used

CANbus High

CANbus

K CANbus SYSTEM (M-0107) ( T M1-9)

Not Used

M18-21

Type

M-10-02 issue 01

Refer to device:

M18-21

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S1) Livelink ECU Power and Earth Connections

CONNECTOR C 9

8 CONNECTOR D

ECU 2

Fig 14.

C123230-C1

Table 12. Harness Connector LL001 Connectors

Pins

LL001

LL04

Details 8

9 Primary Fuse + (Located at the battery terminal)

LL05

Primary Fuse - (Located at the battery terminal)

LL03

Ignition supply from Chassis connector.

i033

K i033 - Panel Harness/LiveLink Harness ( T M30-39)

P002

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M18-3)

M18-22

M-10-02 issue 01

M18-22

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S1)

Removal and Replacement Guide

1 2

C123210-C1

Fig 15.

Removal

Disconnect the electrical connectors from the ECU connectors 2.

Park the machine and make it safe with the boom raised. Refer to Section 2 - General Procedures. K Related Topics ( T M18-3)

Support the ECU 3 and remove the mounting nuts 1.

Remove the ECU from the machine.

Remove the applicable trim panels/instrument panels to get access to the ECU. Refer to Section B - Cab. K Related Topics ( T M18-3)

Replacement

Disconnect the battery.

Replacement is the reverse of the removal procedure noting the following:

Note: Do not touch the connector pins on the ECU.

M18-23

M-10-02 issue 01

M18-23

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S1) â&#x20AC;&#x201C; Before operating the machine, ensure the ECU is configured correctly. Use the correct Servicemaster setup tool. K Related Topics ( T M18-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Do not use a multimeter at the pins on the ECU. Only use the meter at the pins on the harness connectors.

Without the use of sophisticated electronic test equipment it is not possible to test the ECU. If the ECU is returned under warranty it will be tested at the factory to confirm possible faults.

M18-24

M-10-02 issue 01

M18-24

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S2)

Livelink ECU (S2) Location

Fig 16.

Item

Table 13. Description

Livelink ECU

C130350-C1.jpg

The Livelink ECU is located on the right front of the cab.

Wires and Connectors The Livelink ECU is connected to the LiveLink harness.

M18-25

M-10-02 issue 01

M18-25

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S2)

C123220

Fig 17.

Pin Number

Connected to:

Table 14. Connector C Type

SCR

CANbus Screen

K CANbus SYSTEM (M-0107) ( T M1-9)

CANbus Low

CANbus

K CANbus SYSTEM (M-0107) ( T M1-9)

Not Used

Power

12V Battery

K Livelink ECU Power and Earth Connections ( T M18-22)

Not Used

M18-26

M-10-02 issue 01

Refer to device:

M18-26

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S2) Pin Number

Connected to:

Type

Refer to device:

Power

12V Battery

K Livelink ECU Power and Earth Connections ( T M18-22)

Earth

K Livelink ECU Power and Earth Connections ( T M18-22)

Not Used

CANbus High

CANbus

K CANbus SYSTEM (M-0107) ( T M1-9)

Not Used

M18-27

M-10-02 issue 01

M18-27

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S2) Livelink ECU Power and Earth Connections

CONNECTOR C 9

8 CONNECTOR D

ECU 2

Fig 18.

C123230-C1

Table 15. Harness Connector LL001 Connectors

Pins

LL001

LL04

Details 8

9 Primary Fuse + (Located at the battery terminal)

LL05

Primary Fuse - (Located at the battery terminal)

LL03

Ignition supply from Chassis connector.

i033

K i033 - Panel Harness/LiveLink Harness ( T M30-39)

P002

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M18-3)

M18-28

M-10-02 issue 01

M18-28

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S2)

Removal and Replacement Guide

C130350.jpg

Fig 19.

Removal

Support the ECU 3 and remove the mounting screws 1.

Remove the ECU from the machine.

If necessary remove the ECU 3 from the bracket 5 by removing nuts 4.

Park the machine and make it safe. Refer to Section 2 General Procedures. K Related Topics ( T M18-3)

Remove the applicable trim panels/instrument panels to get access to the ECU. Refer to Section B - Cab. K Related Topics ( T M18-3)

Replacement

Disconnect the battery.

Replacement is the opposite of the removal procedure.

Note: Do not touch the connector pins on the ECU. 4

During the procedure do this work also:

Disconnect the electrical connectors from the ECU connectors 2.

M18-29

M-10-02 issue 01

M18-29

Section M18 - Electronic Control Systems Electronic Controllers Livelink ECU (S2) â&#x20AC;&#x201C; Before operating the machine, ensure the ECU is configured correctly. Use the correct Servicemaster setup tool. K Related Topics ( T M18-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Do not use a multimeter at the pins on the ECU. Only use the meter at the pins on the harness connectors.

Without the use of sophisticated electronic test equipment it is not possible to test the ECU. If the ECU is returned under warranty it will be tested at the factory to confirm possible faults.

M18-30

M-10-02 issue 01

M18-30

Section M18 - Electronic Control Systems Electronic Controllers RAS ECU

RAS ECU Refer to Section Topics ( T M18-3)

M18-31

RAS

ECU.

K Related

M-10-02 issue 01

M18-31

Section M18 - Electronic Control Systems Electronic Controllers RAS ECU

Page left intentionally blank

M18-32

M-10-02 issue 01

M18-32

Section M19 - Electronic Control Systems

Brake System Devices Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T M19-3) K Park Brake Switch ( T M19-4) K Location ( T M19-4) K Wires and Connectors ( T M19-5) K Removal and Replacement Guide ( T M19-12) K Test Procedures ( T M19-12) K Footbrake Operated Switch ( T M19-13) K Location ( T M19-13) K Wires and Connectors ( T M19-14) K Removal and Replacement Guide ( T M19-19) K Test Procedures ( T M19-19) K Footbrake Pressure Transducer (S1) ( T M19-20)(1) K Location ( T M19-20) K Wires and Connectors ( T M19-21) K Removal and Replacement Guide ( T M19-22) K Test Procedures ( T M19-23) K Footbrake Pressure Transducer (S2) ( T M19-24)(1) K Location ( T M19-24) K Wires and Connectors ( T M19-25) K Removal and Replacement Guide ( T M19-27) K Test Procedures ( T M19-27) K Charge Pressure Transducer ( T M19-28) K Location ( T M19-28) K Wires and Connectors ( T M19-29) K Removal and Replacement Guide ( T M19-31) K Test Procedures ( T M19-32) K Transmission Disconnect (Footbrake Dump) Switch ( T M19-33) K Location ( T M19-33) K Wires and Connectors ( T M19-34)

M19-1

M-11-01 issue 01

M19-1

Section M19 - Electronic Control Systems Brake System Devices Introduction K Removal and Replacement Guide ( T M19-37) K Test Procedures ( T M19-37) (1) Procedure variant. Make sure you refer to the correct procedure.

Systems(1)

Table 1. System Variants Machine Model Application 526-56, 531-70, 541-70, 536-60, 536-70, 535-95

K Footbrake Pressure Transducer (S1) ( T M19-20) K Footbrake Pressure Transducer (S2) ( T M19-24)

550-80

(1) The table lists system variants and the applicable machine models. Use the table to make sure you refer to the correct information.

M19-2

M-11-01 issue 01

M19-2

Section M19 - Electronic Control Systems Brake System Devices Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Routine Maintenance

Checking the brake fluid level

Routine Maintenance

Fluids, lubricants and capacities

RAS SYSTEM

ALL

CAB

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Transmission Dump - Brake Pedal

ALL

Service Brake SYSTEM

ALL

Park Brake SYSTEM

ALL

Power Brake SYSTEM

ALL

Charge Valve

ALL

(1) You must obey all of the relevant care and safety procedures.

M19-3

M-11-01 issue 01

M19-3

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch

Park Brake Switch Location

2 3

3 1 2

Fig 1.

Item

Table 3. Description

Park brake lever

Park brake switch trigger plate

Park brake switch

C123400-C2.eps

The switch operates by means of a trigger plate 2 attached to the lever arm 1. The switch outputs change according to the presence of the trigger plate.

The park brake switch 3 is located on the park brake lever 1.

M19-4

M-11-01 issue 01

M19-4

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch

Wires and Connectors – K 526-56 Machines ( T M19-6) – K 506-36 Machines ( T M19-7) – K 507-42, 509-42, Machines ( T M19-9)

510-56,

512-56,

514-56

– K Xtra/Super Machines ( T M19-10) – K Other Machines ( T M19-11)

Fig 2.

M19-5

M-11-01 issue 01

C123400-C1

M19-5

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch 526-56 Machines The Park brake switch is connected to the rear cab harness.

1 2

A 3K3R

J1-15

ECU

33K

1 3

1 2

A 3K3R

J1-15

ECU

33K

C123550

Fig 3. Item

Item 1

Fuse

Hydraulic ECU

Parkbrake Switch

Resistor

Table 4. Harness Connector RC02L Connectors

Pins

Details

RC02

i019

K i019 - Panel Harness/Rear Cab Harness ( T M30-26)

Fusebox B - Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

P03 i016

C060A

C060B C060A

Resistor Park Brake 5K6 1

C060B

K i016 - Panel Harness/Chassis Harness ( T M30-22) Resistor Park Brake 33K Resistor Park Brake 5K6

Resistor Park Brake 33K

C045

Hydraulic Control ECU Connector J1 K Hydraulic Control ECU 3626 ( T M20-13)

C060C

Resistor Park Brake 12K

C060C

Resistor Park Brake 12K

C049

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

M19-6

M-11-01 issue 01

M19-6

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch 506-36 Machines The Park brake switch is connected to the Rear Cab Harness

5 2 4

7 9

4 7

4 2

6 10

1 2 14

9 7

5 2 4

7 9

4 7

4 2

6 10

9 7 10

1 2

14 3

6 C126420

Fig 4. Item

Item 1

Fuse

Reverse Drive Relay

Transmission Dump Relay

LH Column Switch

Parkbrake Relay

Parkbrake Switch

Forward Drive Relay

M19-7

M-11-01 issue 01

M19-7

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch Table 5. Harness Connector AL Connectors

Pins

Details 2

i027

P101

K i025 - RAS Panel Harness/Panel Harness (RAS Interface 1) ( T M30-32)

P103

K i025 - RAS Panel Harness/Panel Harness (RAS Interface 1) ( T M30-32)

P103

K i025 - RAS Panel Harness/Panel Harness (RAS Interface 1) ( T M30-32)

P101

K i025 - RAS Panel Harness/Panel Harness (RAS Interface 1) ( T M30-32)

P018-10

Parkbrake Relay. Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

M19-8

Rear Cab Earth Point - Refer to Section C - Harness System. K Related Topics ( T M19-3) K i027 - Panel Harness/Rear Cab Harness ( T M30-34)

M-11-01 issue 01

M19-8

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch 507-42, 509-42, 510-56, 512-56, 514-56 Machines The Park brake switch is connected to the RAS Panel Harness

J2-24

J1-32

J1-20

ECU

J2-24

J1-32

J1-20

ECU

C126430

Fig 5. Item

Item 1

Parkbrake Switch

RAS ECU

Table 6. Harness Connector PA005 Connectors

Pins

PA005

PA006

PA007

M19-9

Details 3 RAS ECU Connector J1. K RAS ECU ( T M18-31) 24

RAS ECU Connector J2. K RAS ECU ( T M18-31)

M-11-01 issue 01

M19-9

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch Xtra/Super Machines The Park brake switch is connected to the chassis harness.

1 2

A 3K3R

33K

J1-15

J5-7 1K8R

ECU

1 3

1 2

A 5K6R

33K

J1-15

J5-7 1K8R

ECU

C123550-C1

Fig 6. Item

Item 1

Fuse

Hydraulic ECU

Parkbrake Switch

Resistor

Table 7. Harness Connector P104 Connectors

Pins

P104

Details 2

P003

3 6

Fusebox C - Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

P104A

Resistor Park Brake 33K

P104A

Resistor Park Brake 33K

P104B

Resistor Park Brake 5K6R

P104B

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

Resistor Park Brake 5K6R

C045

Hydraulic Control ECU Connector J1 K Hydraulic Control ECU 3626 ( T M20-13)

P104C

Resistor Park Brake 1K8R

P104C

Resistor Park Brake 1K8R

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C049

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

M19-10

M-11-01 issue 01

M19-10

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch Other Machines The Park brake switch is connected to the rear cab harness.

1 2

A 5K6

J5-4

ECU

33K

J5-7 1K8R

1 3

1 2

A 5K6

J5-4

33K

A 2

ECU

J5-7 1K8R

C123550-C2

Fig 7. Item

Item 1

Fuse

Hydraulic ECU

Parkbrake Switch

Resistor

Table 8. Harness Connector AL Connectors

Pins

Details

i019

K i019 - Panel Harness/Rear Cab Harness ( T M30-26)

Fusebox C - Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

P003 P109

Resistor Park Brake 33K

P109

Resistor Park Brake 33K

P110

Resistor Park Brake 5K6

P110

Resistor Park Brake 5K6

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C017

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

P111

Resistor Park Brake 1K8

P111

Resistor Park Brake 1K8

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C017

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

M19-11

M-11-01 issue 01

M19-11

Section M19 - Electronic Control Systems Brake System Devices Park Brake Switch

Removal and Replacement Guide

Fig 8.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

C047230

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M19-3)

Put chocks under the wheels. Release the park brake.

Remove the rubber gaiter A.

Disconnect the electrical connector C from the switch connector D.

Hold the switch B and remove screw E.

Remove the switch B.

M19-12

M-11-01 issue 01

M19-12

Section M19 - Electronic Control Systems Brake System Devices Footbrake Operated Switch

Footbrake Operated Switch Location

Fig 9.

Item

Table 9. Description

Footbrake Pedal Arm

Footbrake Switch

C123450

The footbrake switch 1 is located on the footbrake pedal arm 2.

M19-13

M-11-01 issue 01

M19-13

Section M19 - Electronic Control Systems Brake System Devices Footbrake Operated Switch

Wires and Connectors

– K 526-56 Machines ( T M19-15)

The footbrake switch is connected to the panel harness.

– K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M19-16) – K Xtra/Super Machines ( T M19-17) – K Other Machines ( T M19-18)

Fig 10.

M19-14

M-11-01 issue 01

C123460

M19-14

Section M19 - Electronic Control Systems Brake System Devices Footbrake Operated Switch 526-56 Machines

1 2

A A A

J1-4 10K

J5-14

5K360R

J5-7

ECU

1K300

2 1

1 2

A A A

J1-15

10K

J5-14

10K

J5-7

ECU

1K300

2 1

C123470-C1

Fig 11. Item

Item 1

Footbrake Switch

Hydraulic ECU

Resistor

Table 10. Harness Connector P32 Connectors

Pins

P32

Details

P32A

Resistor Footbrake 10K

P32A

Resistor Footbrake 10K

P32B

Resistor Footbrake 1K300

P32B

Resistor Footbrake 1K300

P01/C01

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C049

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

P32C

Resistor Footbrake 5K360

P01/C01

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C049

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

P32C

Resistor Footbrake 5K360

P01/C01

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C046

Hydraulic Control ECU Connector J1 K Hydraulic Control ECU 3626 ( T M20-13)

M19-15

M-11-01 issue 01

M19-15

Section M19 - Electronic Control Systems Brake System Devices Footbrake Operated Switch 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

J2-11

J2-35

J2-34

ECU

J2-11

J2-35

J2-34

ECU

C123470-C2

Fig 12. Item

Item 1

Footbrake Switch

RAS ECU

Table 11. Harness Connector P066 Connectors

Pins

P066

P107

M19-16

Details RAS ECU Connector J2 - Refer to Section B - RAS SYSTEM. K Related Topics ( T M19-3)

M-11-01 issue 01

M19-16

Section M19 - Electronic Control Systems Brake System Devices Footbrake Operated Switch Xtra/Super Machines

10k

J5-4

1 2

J5-14

5k360R J5-7

ECU

1k300R

10k

1 2

J5-14 J5-4

5k360R J5-7

ECU

1k300R

C123470

Fig 13. Item

Item 1

Footbrake Switch

Hydraulic ECU

Resistor

Table 12. Harness Connector P050 Connectors

Pins

P050

Details

P050B

Resistor Footbrake 5K360R

P050B

Resistor Footbrake 5K360R

P050A

Resistor Footbrake 1K300R

P050A

Resistor Footbrake 1K300R

P039/C015

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C049

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

P039/C015

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C046

Hydraulic Control ECU Connector J1 K Hydraulic Control ECU 3626 ( T M20-13)

P050C

Resistor Footbrake 10K

P050C

Resistor Footbrake 10K

P039/C015

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C049

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

M19-17

M-11-01 issue 01

M19-17

Section M19 - Electronic Control Systems Brake System Devices Footbrake Operated Switch Other Machines

10k

J5-4

1 2

J5-14

5k360R J5-7

ECU

1k300R

10k

1 2

J5-14 J5-4

5k360R J5-7

ECU

1k300R

C123470

Fig 14. Item

Item 1

Footbrake Switch

Hydraulic ECU

Resistor

Table 13. Harness Connector P050 Connectors

Pins

P050

Details

P092

Resistor Footbrake 5K360R

P092

Resistor Footbrake 5K360R

P091

Resistor Footbrake 1K300R

P091

Resistor Footbrake 1K300R

P039/C015

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C049

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

P039/C015

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C013

Hydraulic Control ECU Connector J1 K Hydraulic Control ECU 3626 ( T M20-13)

P090

Resistor Footbrake 10K

P090

Resistor Footbrake 10K

P039/C015

K i016 - Panel Harness/Chassis Harness ( T M30-22)

C017

Hydraulic Control ECU Connector J5 K Hydraulic Control ECU 3626 ( T M20-13)

M19-18

M-11-01 issue 01

M19-18

Section M19 - Electronic Control Systems Brake System Devices Footbrake Operated Switch

Removal and Replacement Guide

C123490

Fig 15.

Removal

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M19-3)

Press the brake pedal.

Disconnect the electrical connector 1 from the panel harness.

Hold the switch 4 and remove screw 3.

Remove the switch 4 from the bracket 2.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Replacement Replacement is the opposite of the removal procedure.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

M19-19

M-11-01 issue 01

M19-19

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S1)

Footbrake Pressure Transducer (S1) Location The footbrake pressure Transducer 1 is located in the power brake circuit.

Fig 16.

M19-20

M-11-01 issue 01

C123430

M19-20

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S1)

Wires and Connectors The Footbrake Pressure Transducer is connected to the Chassis harness. A

2 3 4

ECU

V 3 12

4 5.0 4.5 0.9 0.5 0 C123410

Fig 17.

250

C123440

Fig 18. Item A

Fuse

Transmission 0711 ECU

Pressure Transducer

Pin 3 - Switch output - brake pedal operated

Pin 4 - proportional output - brake pedal pressure

Volts

Pressure (bar)

Table 14. Harness Connector C018 Connectors

Pins

C018

C003

Details 2

P002

M19-21

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M19-3)

i016 P069

K i016 - Panel Harness/Chassis Harness ( T M30-22) Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

Transmission ECU 0711 Connector A K Transmission ECU 0711 ( T M20-38)

M-11-01 issue 01

M19-21

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S1)

Removal and Replacement Guide

C123430

Fig 19.

Removal

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels.

Vent the braking system pressure. Refer to Section 2 General Procedures. K Related Topics ( T M19-3)

Remove the transducer 1 from the circuit.

Replacement

BRAK-1-4

Replacement is the opposite of the removal procedure.

During the replacement procedure do this work also:

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T M19-3) Vent the hydraulic system pressure. Refer to Section 2 General Procedures. K Related Topics ( T M19-3)

M19-22

â&#x20AC;&#x201C; Torque tighten the transducer 1 to 18-20 Nm. â&#x20AC;&#x201C; Replace any O Ring Seals.

M-11-01 issue 01

M19-22

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S1)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M19-23

M-11-01 issue 01

M19-23

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S2)

Footbrake Pressure Transducer (S2) Location The Footbrake Pressure Transducer 2 is located on the brake servo 1.

2 Fig 20.

M19-24

C130190-C1.eps

M-11-01 issue 01

M19-24

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S2)

Wires and Connectors The Footbrake Pressure Transducer is connected to the Chassis harness. A

– K Machines with Gearpump Parallel Hydraulic System ( T M19-26)

2 3

– K Machines with Electro Servo Hydraulic System (excluding 526-56) ( T M19-26)

ECU

– K 526-56 Machines ( T M19-26) B

V 3 12

4 5.0 4.5

0.9 0.5 0

250 Fig 22.

C123440-C1.eps

Item

Fig 21.

M19-25

C123410

Fuse

Transmission 0711 ECU

Pressure Transducer

Pin 3 - Switch output - brake pedal operated

Pin 4 - proportional output - brake pedal pressure

Volts

Pressure (bar)

M-11-01 issue 01

M19-25

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S2) Machines with Gearpump Parallel Hydraulic System Table 15. Harness Connector C027 Connectors

Pins

C027

C010

Details 2

4 Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M19-3)

i016

P002

P069

K i016 - Panel Harness/Chassis Harness ( T M30-22) Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

Transmission ECU 0711 Connector A K Transmission ECU 0711 ( T M20-38)

Machines with Electro Servo Hydraulic System (excluding 526-56) Table 16. Harness Connector C018 Connectors

Pins

C018

C003

Details 2

4 Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M19-3)

i016

P002

P069

K i016 - Panel Harness/Chassis Harness ( T M30-22) Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

Transmission ECU 0711 Connector A K Transmission ECU 0711 ( T M20-38)

526-56 Machines Table 17. Harness Connector C011 Connectors

Pins

C011

C010

Details 2

P02

M19-26

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M19-3)

i016 P74A

K i016 - Panel Harness/Chassis Harness ( T M30-22) Fusebox A- Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

Transmission ECU 0711 Connector A K Transmission ECU 0711 ( T M20-38)

M-11-01 issue 01

M19-26

Section M19 - Electronic Control Systems Brake System Devices Footbrake Pressure Transducer (S2)

Removal and Replacement Guide During the replacement procedure do this work also:

– Torque tighten the transducer 3 to 18-20 Nm. – Replace any O Ring Seals. – Check the brake fluid level. Top up if necessary. Refer to Section 3 - Routine Maintenance. K Related Topics ( T M19-3) – Bleed the brake system. Refer to the brake system topic. K Related Topics ( T M19-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

3 2 Fig 23.

C130190-C2.eps

Removal

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T M19-3)

Vent the hydraulic system pressure. Refer to Section 2 General Procedures. K Related Topics ( T M19-3)

Get access to the brake servo 1.

Disconnect the chassis harness electrical connector from the sensor electrical connector 2.

Unscrew the sensor 3 from the servo unit.

Replacement Replacement is the opposite of the removal procedure.

M19-27

M-11-01 issue 01

M19-27

Section M19 - Electronic Control Systems Brake System Devices Charge Pressure Transducer

Charge Pressure Transducer Location The charge pressure transducer 1 is located in the Charge valve 2.

Fig 24.

M19-28

M-11-01 issue 01

C111320-C2

M19-28

Section M19 - Electronic Control Systems Brake System Devices Charge Pressure Transducer

Wires and Connectors The Charge Pressure Transducer is connected to the Chassis harness. A

2 3 4

ECU

V 3

5.0 4.5 4

Fig 25.

C123410

0.9 0.5 0

250

X C123420

Fig 26. Item

M19-29

Fuse

Transmission 0711 ECU

Pressure Transducer

Pin 3 - Switch output - Charge pressure Low Warning

Pin 4 - proportional output - Charge Pressure Display

Volts

Pressure (bar)

M-11-01 issue 01

M19-29

Section M19 - Electronic Control Systems Brake System Devices Charge Pressure Transducer Table 18. Harness Connector C075 Connectors

Pins

C075

C003

Details 2

P002

M19-30

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M19-3)

i016 P069

K i016 - Panel Harness/Chassis Harness ( T M30-22) Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M19-3)

Transmission ECU 0711 Connector A K Transmission ECU 0711 ( T M20-38)

M-11-01 issue 01

M19-30

Section M19 - Electronic Control Systems Brake System Devices Charge Pressure Transducer

Removal and Replacement Guide

C111320-C2

Fig 27.

Removal

Remove the transducer 1 from the charge valve 2.

Replacement

!MWARNING

Replacement is the opposite of the removal procedure.

Before working on the brake system make sure the machine is on level ground and chock all four wheels.

â&#x20AC;&#x201C; Torque tighten the transducer 1 to 35-39 Nm.

BRAK-1-4

To aid access remove the charge valve from the machine. Refer to Section G - Charge Valve. K Related Topics ( T M19-3)

M19-31

During the replacement procedure do this work also:

â&#x20AC;&#x201C; Replace any O Ring Seals.

M-11-01 issue 01

M19-31

Section M19 - Electronic Control Systems Brake System Devices Charge Pressure Transducer

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M19-32

M-11-01 issue 01

M19-32

Section M19 - Electronic Control Systems Brake System Devices Transmission Disconnect (Footbrake Dump) Switch

Transmission Disconnect (Footbrake Dump) Switch Location The transmission disconnect switch is located in the RH switch panel.

Fig 28.

C123500

Table 19. Position 1

Off

M19-33

M-11-01 issue 01

M19-33

Section M19 - Electronic Control Systems Brake System Devices Transmission Disconnect (Footbrake Dump) Switch

Wires and Connectors The transmission disconnect switch is connected to the Panel harness.

10 3 2 1 8

9 6 5 4 7

10 3 2 1 8

Fig 29.

M19-34

M-11-01 issue 01

9 6 5 4 7 C123510

M19-34

Section M19 - Electronic Control Systems Brake System Devices Transmission Disconnect (Footbrake Dump) Switch

ECU

B-11

A-8

8 1

2 3

5 6

1K300R

5K360R

ECU

B-11

A-8

8 1

2 3

5 6

1K300R

5K360R

Fig 30.

C123520

Item 1

Transmission 0711 ECU

Disconnect Switch

Resistor

– K 526-56 Machines ( T M19-36) – K Other Machines ( T M19-36)

M19-35

M-11-01 issue 01

M19-35

Section M19 - Electronic Control Systems Brake System Devices Transmission Disconnect (Footbrake Dump) Switch 526-56 Machines Table 20. Harness Connector P67 Connectors

Pins

P067

Details 2

P67B

P67C

Footbrake Dump Resistor 1K300R

Footbrake Dump Resistor 5K360R

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P74B

Transmission ECU 0711 connector B, refer to K Transmission ECU 0711 ( T M20-38)

Transmission ECU 0711 connector A, refer to K Transmission ECU 0711 ( T M20-38)

SRS Switch

P74A

P52

Other Machines Table 21. Harness Connector P019 Connectors

Pins

P019

P070

Details 2

Transmission ECU 0711 connector B, refer to K Transmission ECU 0711 ( T M20-38)

P019

P069

Transmission ECU 0711 connector A, refer to K Transmission ECU 0711 ( T M20-38)

P019A

Footbrake Dump Resistor 1K300R

P019A

Footbrake Dump Resistor 1K300R

Footbrake Dump Resistor 10K

P019C

Footbrake Dump Resistor 10K

P019B

Footbrake Dump Resistor 5K360R

P019B

Footbrake Dump Resistor 5K360R

Transmission ECU 0711 connector B, refer to K Transmission ECU 0711 ( T M20-38)

P070

M19-36

M-11-01 issue 01

M19-36

Section M19 - Electronic Control Systems Brake System Devices Transmission Disconnect (Footbrake Dump) Switch

Removal and Replacement Guide

1 3

10 3 2 1 8

9 6 5 4 7

2 C123530

Fig 31.

Removal

Replacement Replacement is the opposite of the removal procedure.

!MWARNING

Test Procedures

Before working on the brake system make sure the machine is on level ground and chock all four wheels.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

BRAK-1-4

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M19-3)

Disconnect the battery.

Remove the switch panel. Refer to Section B - Cab. K Related Topics ( T M19-3)

Make a note of switch orientation to aid replacement.

If multiple switches are to be removed make sure to label the switch harness connectors to aid identification.

Lift the panel away from the trim sufficiently to allow the harness connector 3 to be disconnected from the switch 2.

Disconnect the harness connector 3.

Press the tabs 1 and push the switch 2 from the panel.

M19-37

M-11-01 issue 01

M19-37

Section M19 - Electronic Control Systems Brake System Devices Transmission Disconnect (Footbrake Dump) Switch

Page left intentionally blank

M19-38

M-11-01 issue 01

M19-38

Section M20 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M20-1

M-12 issue 01

M20-1

Section M20 - Electronic Control Systems Sub Section Intentionally Blank

Page left intentionally blank

M20-2

M-12 issue 01

M20-2

Section M21 - Electronic Control Systems

Engine and Fuel System Devices Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

K Related Topics ( T M21-4) K Fuel Level Sender ( T M21-5) K Location ( T M21-5) K Description ( T M21-6) K Wires and Connectors ( T M21-7) K Removal and Replacement Guide ( T M21-9) K Test Procedures ( T M21-9) K Coolant Temperature Switch ( T M21-10) K Vacuum Switch ( T M21-11) K Location ( T M21-11) K Description ( T M21-11) K Wires and Connectors ( T M21-12) K Removal and Replacement Guide ( T M21-14) K Test Procedures ( T M21-14) K Fuel Lift Pump ( T M21-15) K Location ( T M21-15) K Wires and Connectors ( T M21-16) K Removal and Replacement Guide ( T M21-9) K Test Procedures ( T M21-19) K WIF Sensor ( T M21-20) K Location ( T M21-20) K Description ( T M21-20) K Wires and Connectors ( T M21-21) K Removal and Replacement Guide ( T M21-24) K Test Procedures ( T M21-24) K TMAF Sensor ( T M21-25) K Location ( T M21-25) K Wires and Connectors ( T M21-26) K Removal and Replacement Guide ( T M21-28)

M21-1

M-13-01 issue 01

M21-1

Section M21 - Electronic Control Systems Engine and Fuel System Devices Introduction K Test Procedures ( T M21-28) K Inlet Manifold Heater/Cold Start Relay ( T M21-29) K Location ( T M21-29) K Wires and Connectors ( T M21-30) K Removal and Replacement Guide ( T M21-32) K Test Procedures ( T M21-32) K Alternator ( T M21-33) K Location ( T M21-33) K Description ( T M21-33) K Wires and Connectors ( T M21-34) K Removal and Replacement Guide ( T M21-36) K Test Procedures ( T M21-36) K Throttle Position Sensor (TPS) ( T M21-37) K Location ( T M21-37) K Wires and Connectors ( T M21-38) K Removal and Replacement Guide ( T M21-40) K Test Procedures ( T M21-40) K Engine Compartment Fuse/Relay Box ( T M21-41) K Location ( T M21-41) K Wires and Connectors ( T M21-42) K Removal and Replacement ( T M21-44) K Test Procedures ( T M21-44) K Power Hold Relay ( T M21-45) K Location ( T M21-45) K Description ( T M21-46) K Test Procedures ( T M21-47) K Engine ECU ( T M21-48) K Location ( T M21-48) K Description ( T M21-48) K Wires and Connectors - ECU Power Supply ( T M21-49) K Removal and Replacement Guide ( T M21-50) K Test Procedures ( T M21-50) K Start Signal Relay ( T M21-51) K Location ( T M21-51) K Description ( T M21-52) K Wires and Connectors ( T M21-53) K Test Procedures ( T M21-53) K Fuel Lift Pump Relay ( T M21-54) K Location ( T M21-54)

M21-2

M-13-01 issue 01

M21-2

Section M21 - Electronic Control Systems Engine and Fuel System Devices Introduction K Description ( T M21-55) K Wires and Connectors ( T M21-56) K Test Procedures ( T M21-56) K Exhaust Gas Re circulation (EGR) Actuator ( T M21-57) K Location ( T M21-57) K Description ( T M21-57) K Wires and Connectors - EGR Actuator Power Supply ( T M21-58) K Removal and Replacement Guide ( T M21-58) K Test Procedures ( T M21-58) K Variable Geometry Turbo (VGT) Actuator ( T M21-59) K Location ( T M21-59) K Description ( T M21-59) K Wires and Connectors - VGT Actuator Power Supply ( T M21-60) K Removal and Replacement Guide ( T M21-60) K Test Procedures ( T M21-60)

M21-3

M-13-01 issue 01

M21-3

Section M21 - Electronic Control Systems Engine and Fuel System Devices Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Fuel Tank

Fuel Sender Unit

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Alternator

ALL

Throttle Position Sensor

ALL

Section Titles

Topic Titles

Electronic Data Systems

Servicemaster

M21-4

M-13-01 issue 01

M21-4

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Level Sender

Fuel Level Sender Location All Machines Excluding 526-56 The fuel level sender 2 is located in the top of the fuel tank 1.

C098110-C2.eps

Fig 1.

M21-5

M-13-01 issue 01

M21-5

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Level Sender 526-56 The fuel level sender 2 is located in the top of the fuel tank 1.

2 1

9 8

7 6

Fig 2.

C075050-C1

Description

K Fig 3. ( T M21-6)

The fuel level sender generates an analogue signal. The float A moves up or down as the fuel quantity in the tank changes. As the float moves it closes the switch at the position of the float. Each position has a different resistance value which informs the ECU of the float position.

Fig 3.

C130520.eps

Table 3. Fuel level sender resistance values Float Position Sender Resistance (Ohms) 0 (empty)

110

130

150

170

9 (Full)

190

M21-6

M-13-01 issue 01

M21-6

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Level Sender

Wires and Connectors – K Agri/Xtra/Super/Plus Machines ( T M21-7) – K 531-70, 541-70, 539-95, 533-105, 536-70, 540140, 535-125 HiViz, 535-140 HiViz SLC/DLC Machines ( T M21-7) – K 526-56 Machines ( T M21-8) – K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M21-8)

ECU 2 1 C117780-C10

Fig 4. Item

Item 1

RHC/LMS ECU

Fuel Level Sender

Agri/Xtra/Super/Plus Machines

Harness Connector C031 Connectors

Pins

C031

Details 2

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P072

RHC ECU J2 K RHC ECU ( T M20-5)

C003

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

531-70, 541-70, 539-95, 533-105, 536-70, 540-140, 535-125 HiViz, 535-140 HiViz SLC/DLC Machines

Harness Connector C035 Connectors

Pins

C035

i016 P072 C010

M21-7

Details 2 18

K i016 - Panel Harness/Chassis Harness ( T M30-22)

RHC ECU J2 K RHC ECU ( T M20-5) Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

M-13-01 issue 01

M21-7

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Level Sender 526-56 Machines

Harness Connector C035 Connectors

Pins

C035

Details 2

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P15

RHC ECU J2 K RHC ECU ( T M20-5)

C010

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

Harness Connector C010 Connectors

Pins

C010

i028

K i028 - Panel Harness/Chassis Harness ( T M30-35)

P055

LMS ECU J1 K LMS ECU ( T M18-4)

C008

M21-8

Details 2

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

M-13-01 issue 01

M21-8

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Level Sender

Removal and Replacement Guide For fuel sender unit removal and replacement refer to Section B - Fuel Tank. K Related Topics ( T M21-4)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-9

M-13-01 issue 01

M21-9

Section M21 - Electronic Control Systems Engine and Fuel System Devices Coolant Temperature Switch

Coolant Temperature Switch For details of the Coolant Temperature Switch Refer to T4i Engine Service Manual - Publication Number: 9806/ 4300 K Related Topics ( T M21-4)

M21-10

M-13-01 issue 01

M21-10

Section M21 - Electronic Control Systems Engine and Fuel System Devices Vacuum Switch

Vacuum Switch Location The air filter vacuum switch 1 is located in the rear of the air filter housing in the engine compartment.

Fig 5.

C118240

Description If the air flow to the engine induction system is restricted by a blocked air filter element for example, the air pressure inside the air filter housing is reduced. When the air pressure inside the air filter housing is below a pre-set value the air filter vacuum switch contacts close. The digital signal is transmitted to the RHC ECU.

M21-11

M-13-01 issue 01

M21-11

Section M21 - Electronic Control Systems Engine and Fuel System Devices Vacuum Switch

Wires and Connectors â&#x20AC;&#x201C; K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M21-12) â&#x20AC;&#x201C; K Other Machines ( T M21-13)

506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

ECU J2 2

C117780-C14

Fig 6. Item

Item 1

LMS ECU

Vacuum Switch

Harness Connector E006 Connectors

Pins

E006

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

C008

Details

i028

K i028 - Panel Harness/Chassis Harness ( T M30-35)

P055

LMS ECU J1 K LMS ECU ( T M18-4)

M21-12

M-13-01 issue 01

M21-12

Section M21 - Electronic Control Systems Engine and Fuel System Devices Vacuum Switch Other Machines

ECU J2 2

C117780-C14

Fig 7. Item

Item 1

RHC ECU

Vacuum Switch

Harness Connector E006 Connectors

Pins

E006

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

C003

Details

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P072

RHC ECU J2 K RHC ECU ( T M20-5)

M21-13

M-13-01 issue 01

M21-13

Section M21 - Electronic Control Systems Engine and Fuel System Devices Vacuum Switch

Removal and Replacement Guide

interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM. 2

Fig 8.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

C123670

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M21-4)

Disconnect the battery.

Disconnect the electrical harness connector 2 at the vacuum switch.

Unscrew and remove the vacuum switch 1 from the air filter housing.

Replacement Replacement is the opposite of the removal procedure noting the following: â&#x20AC;&#x201C; Apply JCB locking fluid - high strength to the threads of the vacuum switch. â&#x20AC;&#x201C; Torque tighten the Vacuum switch to 1.75 Nm.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control

M21-14

M-13-01 issue 01

M21-14

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump

Fuel Lift Pump Location

1 2

Fig 9.

C123680

The fuel lift pump 1 is integral with the pre-filter/water separator 2. The unit is located on the engine cooling pack 3.

M21-15

M-13-01 issue 01

M21-15

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump

Wires and Connectors

Fig 10.

C123680-C6

The fuel lift pump is connected to the Engine Pod Harness. – K 526-56 Machines ( T M21-17) – K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M21-17) – K Other Machines ( T M21-18)

M21-16

M-13-01 issue 01

M21-16

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump

4 5 6

7 8

ECU

1 3 2

+VE

C123690

Fig 11. Item

K Fig 11. ( T M21-17)

Item

K Fig 11. ( T M21-17)

Ignition Switch

Power Hold Relay

Secondary Fuse

Engine Compartment Fuse/Relay Box

Engine Compartment Fuse

Fuel Lift Pump

Start Signal Relay

Engine ECU

Fuel Lift Pump Relay

526-56 Machines

Harness Connector E003 Connectors

Pins

E003

Details 2

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C010

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

E001

Engine Fuse/Relay box - Refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

Harness Connector E003 Connectors

Pins

E003

i004

M21-17

Details 2 17

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

M-13-01 issue 01

M21-17

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump C008 E001

1 L

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4) Engine Fuse/Relay box - Refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

Other Machines

Harness Connector E003 Connectors

Pins

E003

Details 2

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C003

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

E001

M21-18

Engine Fuse/Relay box - Refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

M-13-01 issue 01

M21-18

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump

Removal and Replacement Guide

Disconnect the Lift Pump harness connector 1 from the pod harness connector.

If the fuel lift pump is faulty the fuel pre filter/separator assembly must be replaced.

Disconnect the Water In Fuel sensor harness connector 3 from the pod harness connector.

Put a label on the fuel pipes to aid reconnection.

Disconnect the fuel pipes from the quick release connectors 4.

Support the fuel pre filter/separator and remove the securing bolts 2.

Remove the fuel pre filter/separator from the machine.

1 2

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Make sure to locate the electrical connectors 1 and 2 and harness correctly to make sure that the harness does not contact the air cooler.

2 4 4

Fig 12.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

C123680-C5

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M21-4)

Disconnect the battery.

M21-19

M-13-01 issue 01

M21-19

Section M21 - Electronic Control Systems Engine and Fuel System Devices WIF Sensor

WIF Sensor Location The water in fuel sensor is Integral with the pre-filter/water separator assembly 2. The unit is located on the engine

cooling pack 4. The sensor consists of an electronic module 1 mounted to pre-filter/water separator body and probe 3 at the separator bowl.

3 Fig 13.

C123680-C3

Description The water in fuel sensor detects presence of water above a pre-determined level in the pre-filter/water separator bowl. Its electrical resistance range changes when sensor probe is submerged in water.

M21-20

M-13-01 issue 01

M21-20

Section M21 - Electronic Control Systems Engine and Fuel System Devices WIF Sensor

Wires and Connectors The WIF sensor is connected to the engine pod harness. – K 526-56 Machines ( T M21-23) – K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M21-23) – K Other Machines ( T M21-23)

B C

Fig 14.

M21-21

C123680-C7

M-13-01 issue 01

M21-21

Section M21 - Electronic Control Systems Engine and Fuel System Devices WIF Sensor

3 4 5 6

ECU

7 8

B C

5 7

-VE

+VE

3 4 5 6

ECU

7 8

B C

5 7

-VE

+VE

Fig 15.

C124210

Item 1

Ignition Switch

Fuse

Engine Compartment Fuse

Start Signal Relay

Engine Compartment Fuse/Relay Box

Engine ECU

WIF Switch

M21-22

M-13-01 issue 01

M21-22

Section M21 - Electronic Control Systems Engine and Fuel System Devices WIF Sensor 526-56 Machines

Harness Connector E002 Connectors

Pins

E002

E001

E004

Details B

C Engine Fuse/Relay box - Refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

Engine ECU

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C010

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

Harness Connector E002 Connectors

Pins

E002

E001

E004

Details B

C Engine Fuse/Relay box - Refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

Engine ECU Connector Grey - Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C008

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

Other Machines

Harness Connector E002 Connectors

Pins

E002

E001

E004

Details B

C Fuse/Relay Pod Box

Engine ECU Connector Grey - Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C003

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

M21-23

M-13-01 issue 01

M21-23

Section M21 - Electronic Control Systems Engine and Fuel System Devices WIF Sensor

Removal and Replacement Guide If the WIF sensor is faulty the fuel pre filter/separator assembly must be replaced. Refer to the Fuel Lift Pump for Removal and Replacement Procedures. K Fuel Lift Pump ( T M21-15)

Replacement Replacement is the opposite of the removal procedure.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-24

M-13-01 issue 01

M21-24

Section M21 - Electronic Control Systems Engine and Fuel System Devices TMAF Sensor

TMAF Sensor Location

areas on the TMAF - area 2 senses the air flow and area 3 senses the air temperature.

The TMAF sensor 1 is located in the rear of the air filter housing in the engine compartment. There are two sensor

Fig 16.

M21-25

M-13-01 issue 01

C123770-C1

M21-25

Section M21 - Electronic Control Systems Engine and Fuel System Devices TMAF Sensor

Wires and Connectors The TMAF sensor is connected to the engine pod harness.

6 5 4 3 2 1

1 2 3 4 5 6

Fig 17. Pin Number

Function

1/F

Not Used

2/E

Inlet Air Temperature Output

3/D

Air Flow Output

4/C

Earth

5/B

Power

6/A

Not Used

M21-26

M-13-01 issue 01

C123740

M21-26

Section M21 - Electronic Control Systems Engine and Fuel System Devices TMAF Sensor

5 4 2

ECU

X 9201 6577 Z 4274 2086 0

0 13

250

700

Y C123760

Fig 18. Item

Item A

Engine ECU

kg/h Air flow rate

TMAF Sensor

Pin 3 air flow output

Hz Output

Harness Connector E008 Connectors

Pins

E008

E004

M21-27

Details Engine ECU Connector Grey - Refer to T4i Engine Service Manual Publication Number: 9806/4300 K Related Topics ( T M21-4)

M-13-01 issue 01

M21-27

Section M21 - Electronic Control Systems Engine and Fuel System Devices TMAF Sensor

Removal and Replacement Guide

C123770

Fig 19.

Removal

Replacement

Note: The temperature sensor area 3 in the TMAF unit 1 may be hot. Do not touch this area.

Replacement of the TMAF sensor is the opposite of the removal procedure.

Note: Do not touch the temperature sensor area 3, air flow sensor area 2 or connector pins.

Test Procedures

Note: Do not use a TMAF sensor which has been dropped or damaged. Replace with a new one. 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M21-4)

Disconnect the battery.

Disconnect the electrical harness connector 4 at the TMAF sensor 1.

Remove the screws 5 and 6.

Remove the TMAF sensor 1 from the air filter housing.

M21-28

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M-13-01 issue 01

M21-28

Section M21 - Electronic Control Systems Engine and Fuel System Devices Inlet Manifold Heater/Cold Start Relay

Inlet Manifold Heater/Cold Start Relay Location

Fig 20.

C123640

The Inlet Manifold Heater/Cold Start relay 1 is located to the side of the coolant expansion tank 2.

M21-29

M-13-01 issue 01

M21-29

Section M21 - Electronic Control Systems Engine and Fuel System Devices Inlet Manifold Heater/Cold Start Relay

Wires and Connectors

A ECU 3

4 C123650

Fig 21. Item

Item A

Power Cable to Grid Heater

Grid Heater

Power Cable from Primary Fuse

Engine ECU

Engine Compartment Fuse Box

Primary Fuse

Relay

M21-30

M-13-01 issue 01

M21-30

Section M21 - Electronic Control Systems Engine and Fuel System Devices Inlet Manifold Heater/Cold Start Relay Harness Connector E020 Connectors

Pins

E020

E001

E004

M21-31

Details 2 Engine Fuse/Relay box - Refer to Section C - Fuses and Relays. K Related Topics ( T M21-4) 48

Engine ECU Connector Grey - Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

M-13-01 issue 01

M21-31

Section M21 - Electronic Control Systems Engine and Fuel System Devices Inlet Manifold Heater/Cold Start Relay

Removal and Replacement Guide

1 2

4 2 3

C123640-C1

Fig 22.

Removal

Replacement

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M21-4)

Replacement is the opposite of the removal procedure.

Disconnect the battery.

Disconnect the pod harness connector from the relay connector 3.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Disconnect the power lead connectors 2 from the relay.

Remove the nuts 1 and remove the relay 4 from the machine.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-32

Test Procedures

M-13-01 issue 01

M21-32

Section M21 - Electronic Control Systems Engine and Fuel System Devices Alternator

Alternator Location The alternator 1 is located on the engine driven by the engine Front End Accessory Drive belt (FEAD).

Fig 23.

C118250-C1

Description The alternator is a three phase generator having a rotating field winding and static power windings. Output is controlled by a solid state regulator and rectifier. The regulator varies the field current in accordance with electrical demand. The rectifier converts the AC output from the alternator to a DC supply for the machine battery. Both the regulator and rectifier are integral parts of the alternator. When the starter switch is set to ON the RH cluster ECU sends an output to the W terminal. This output creates a magnetic field and supplements the residual magnetism in the rotor poles and ensures that the alternator starts to function on engine start up. The L terminal is connected to the RH cluster ECU which monitors the voltage output from the alternator.

M21-33

M-13-01 issue 01

M21-33

Section M21 - Electronic Control Systems Engine and Fuel System Devices Alternator

Wires and Connectors

Note: For details of the internal circuits of the alternator refer to Section C - Alternator (C-04-02). K Related Topics ( T M21-4)

– K 526-56 Machines ( T M21-34) – K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M21-35) – K Other Machines ( T M21-35)

L 2

ECU J2

ECU J1

C123630

Fig 24. Item

Item 1

RHC/LMS ECU

Battery

526-56 Machines

Harness Connector Alternator Connectors

Pins

Details

i009

i016

P14 P15 -

M21-34

B K i009 - Chassis Harness/Starter Motor Harness ( T M30-15)

K i016 - Panel Harness/Chassis Harness ( T M30-22)

RHC ECU J1 K RHC ECU ( T M20-5)

RHC ECU J2 K RHC ECU ( T M20-5) +

Vehicle Battery

M-13-01 issue 01

M21-34

Section M21 - Electronic Control Systems Engine and Fuel System Devices Alternator 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

Harness Connector Alternator Connectors

Pins L

Details W

i009

2/B 1/A

K i009 - Chassis Harness/Starter Motor Harness ( T M30-15)

i028

K i028 - Panel Harness/Chassis Harness ( T M30-35)

P055

LMS ECU J1 K LMS ECU ( T M18-4)

P052

Centre Cluster Warning Panel K Centre Cluster Warning Panel ( T M22-18)

Vehicle Battery

Other Machines

Harness Connector Alternator Connectors

Pins

Details

i009

i016

P071 P072 -

M21-35

B K i009 - Chassis Harness/Starter Motor Harness ( T M30-15)

K i016 - Panel Harness/Chassis Harness ( T M30-22)

RHC ECU J1 K RHC ECU ( T M20-5)

RHC ECU J2 K RHC ECU ( T M20-5) +

Vehicle Battery

M-13-01 issue 01

M21-35

Section M21 - Electronic Control Systems Engine and Fuel System Devices Alternator

Removal and Replacement Guide Note: For details of the Removal and Replacement of the alternator refer to Section C - Alternator (C-04-02). K Related Topics ( T M21-4)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-36

M-13-01 issue 01

M21-36

Section M21 - Electronic Control Systems Engine and Fuel System Devices Throttle Position Sensor (TPS)

Throttle Position Sensor (TPS) Location The TPS 1 is located on the Throttle Pedal Assembly 2. For TPS operation details refer to Section K - TPS. K Related Topics ( T M21-4)

2 1

Fig 25.

M21-37

C122180-C2

M-13-01 issue 01

M21-37

Section M21 - Electronic Control Systems Engine and Fuel System Devices Throttle Position Sensor (TPS)

Wires and Connectors The TPS is connected to the Chassis harness.

5 4

2 3

1 2 3

6 5 4

C122180-C3

Fig 26. Fig 27. 1

Item

TPS

Engine ECU (Grey Connector)

3 4

ECU

B A C124140

M21-38

M-13-01 issue 01

M21-38

Section M21 - Electronic Control Systems Engine and Fuel System Devices Throttle Position Sensor (TPS) Harness Connector C056 Connectors

Pins

C056

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

E004

Engine ECU Connector Grey - Refer to T4i Engine Service Manual Publication Number: 9806/4300 K Related Topics ( T M21-4)

M21-39

Details

M-13-01 issue 01

M21-39

Section M21 - Electronic Control Systems Engine and Fuel System Devices Throttle Position Sensor (TPS)

Removal and Replacement Guide For TPS removal and replacement refer to Section KTPS. K Related Topics ( T M21-4)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-40

M-13-01 issue 01

M21-40

Section M21 - Electronic Control Systems Engine and Fuel System Devices Engine Compartment Fuse/Relay Box

Engine Compartment Fuse/Relay Box Location

Fig 28.

C122220-C1

The engine compartment fuse and relay box 1 is located next to the air cleaner in the engine compartment. The fuse and relay circuit board 2 is located inside the fuse and relay box. For fuse and relay locations and identification refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

M21-41

M-13-01 issue 01

M21-41

Section M21 - Electronic Control Systems Engine and Fuel System Devices Engine Compartment Fuse/Relay Box

Wires and Connectors The Fuse and Relay box is connected to the Engine Pod Harness

K L N

M21-42

M-13-01 issue 01

X G

B A

Fig 29.

D P

F E

U T

C122220-C3

M21-42

Section M21 - Electronic Control Systems Engine and Fuel System Devices Engine Compartment Fuse/Relay Box P

K1 D

F1 E

F14

F15

F11

F16

F12

K3 L

F17

X M

K2 B

F3 N

Fig 30. Electrical Schematic Table 4. Fuse No.

Circuit

Power Hold Relay

Starter Inhibit

Fuel Pump

Power Hold Relay

Fuel Pump

Starter Solenoid

Fuel Pump ECU - 40

Spare

ECU - 49

ECU - 53

F10

HC-Doser / Spare

F11

Lambda Sensor / Spare

M21-43

Fuse No.

Circuit

F12

WF Sensor

F13

Empty / Spare

F14

Engine Power Supply

F15

Engine Power Supply

F16

Engine ECU - 60

F17

Engine ECU - 57

M-13-01 issue 01

C126440

M21-43

Section M21 - Electronic Control Systems Engine and Fuel System Devices Engine Compartment Fuse/Relay Box

Removal and Replacement

5 6

4 1

1 C122220-C1

Fig 31.

Removal

Replacement

Replacement is the opposite of the removal procedure.

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. K Related Topics ( T M21-4)

Important: Switch OFF the engine before working in the engine compartment. Remove key or isolate battery to prevent the engine from being started. 2

If the engine is hot let it cool for one hour.

Open the engine cover. Refer to Section 3 - Access Panels. K Related Topics ( T M21-4)

Disconnect the electrical connector 4 from the fuse and relay box assembly 3.

Remove the securing screws and remove the fuse and relay box lid 2.

Support the fuse and relay box assembly and remove the securing screws 1.

Remove the fuse and relay box assembly 3 from the machine.

Remove the securing screws 5 from the circuit board.

Remove the circuit board 6 from the fuse and relay box assembly 3.

M21-44

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M-13-01 issue 01

M21-44

Section M21 - Electronic Control Systems Engine and Fuel System Devices Power Hold Relay

Power Hold Relay Location For the power hold relay location and identification refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

M21-45

M-13-01 issue 01

M21-45

Section M21 - Electronic Control Systems Engine and Fuel System Devices Power Hold Relay

Description

fuse/relay box are connected to the machine battery via a primary fuse 1.

When the starter switch is set to position I there is an input at the machine side of the engine ECU 5. The ECU responds by energising the power hold relay 3. The relay contacts close and fused power supplies 4 from the engine

When the starter switch is set to OFF the engine ECU deenergises the power hold relay after a pre-set period of time. This ensures that the engine systems power down in the correct sequence.

4 2 1 3 ECU

Fig 32.

C125100

Item 1

Primary fuse

Fuse - engine fuse/relay box

Power hold relay - engine fuse/relay box

Fuses - engine fuse/relay box

Engine ECU (internal power hold switch)

M21-46

M-13-01 issue 01

M21-46

Section M21 - Electronic Control Systems Engine and Fuel System Devices Power Hold Relay

Wires and Connectors

K L

X G

B A

D P

F E

U T

Fig 33. Harness Connector E001

C122220-C3

Harness Connector E001 Connectors

Pins

E001

Details

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C005

Primary fuse - battery

C005

Primary fuse - battery

i004

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

E001

Harness connector - engine fuse/relay box. K Engine Compartment Fuse/Relay Box ( T M21-41)

E004

Harness connector - engine fuse/relay box. K Engine Compartment Fuse/Relay Box ( T M21-41)

Harness connector - engine ECU (grey). K Engine ECU ( T M21-48)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-47

M-13-01 issue 01

M21-47

Section M21 - Electronic Control Systems Engine and Fuel System Devices Engine ECU

Engine ECU Location The engine ECU 1 is located on the LH side of the engine.

Fig 34.

C125650

Description For details about the engine ECU Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

M21-48

M-13-01 issue 01

M21-48

Section M21 - Electronic Control Systems Engine and Fuel System Devices Engine ECU

Wires and Connectors - ECU Power Supply Note: This information shows the wires and connectors for the power supply to the machine ECU. For details about other wires and connectors Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

The engine ECU has two harness connectors, the machine harness connector 2 and the engine harness connector 3. For details of the engine harness connector refer to the applicable engine documentation. Important: Do not touch the connector pins 1 on the engine ECU. Do not use a multi-meter on the engine ECU connector pins, only use a multi-meter on the harness connector pins.

The engine ECU power supply is controlled by the power hold relay. K Power Hold Relay ( T M21-45)

1 62

3 C125650-C1

Fig 35. Harness Connector E004 Table 5. Engine ECU Power Supply Harness Connector E004 Connectors

Pins

E004

Harness connector - engine ECU (grey). K Engine ECU ( T M21-48)

E001

Harness connector - engine fuse/relay box. K Engine Compartment Fuse/ Relay Box ( T M21-41)

M21-49

Details

M-13-01 issue 01

M21-49

Section M21 - Electronic Control Systems Engine and Fuel System Devices Engine ECU

Removal and Replacement Guide For removal and replacement procedures Refer to T4i Engine Service Manual - Publication Number: 9806/ 4300 K Related Topics ( T M21-4)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Rectify as required.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-50

M-13-01 issue 01

M21-50

Section M21 - Electronic Control Systems Engine and Fuel System Devices Start Signal Relay

Start Signal Relay Location For the start signal relay location and identification refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

M21-51

M-13-01 issue 01

M21-51

Section M21 - Electronic Control Systems Engine and Fuel System Devices Start Signal Relay

Description

When the engine ECU 9 receives an input from the starter switch or immobiliser (if fitted) the ECU responds by energising the starter relay.

When the power hold relay 6 energises, power is connected to the start Signal relay 5.

2 3

4 5 6

7 8

5 ECU

6 3

2 7 +VE

Fig 36.

C125230-C1

Item 1

Ignition Switch

Secondary Fuse

Engine Compartment Fuse

Start Signal Relay

Fuel Lift Pump Relay

Power Hold Relay

Engine Compartment Fuse/Relay Box

Starter Motor

Engine ECU

M21-52

M-13-01 issue 01

M21-52

Section M21 - Electronic Control Systems Engine and Fuel System Devices Start Signal Relay

Wires and Connectors

K L

X G

B A

D P

W V

F E

U T

Fig 37. Harness Connector E001

C122220-C3

Harness Connector E001 Connectors

Pins Details

E001

Harness connector - engine fuse/relay box. K Engine Compartment Fuse/Relay Box ( T M21-41)

E004

Harness connector - engine ECU (grey). K Engine ECU ( T M21-48)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-53

M-13-01 issue 01

M21-53

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump Relay

Fuel Lift Pump Relay Location For the fuel lift pump relay location and identification refer to Section C - Fuses and Relays. K Related Topics ( T M21-4)

M21-54

M-13-01 issue 01

M21-54

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump Relay

Description When the power hold relay 6 energises, power is connected to the fuel lift pump relay 5. The relay energises by means of a low side output from the engine ECU 9.

4 5 6

7 8

M 8

ECU

1 3 2

+VE

Fig 38.

C123690

Item 1

Ignition Switch

Secondary Fuse

Engine Compartment Fuse

Start Signal Relay

Fuel Lift Pump Relay

Power Hold Relay

Engine Compartment Fuse/Relay Box

Fuel Lift Pump

Engine ECU

M21-55

M-13-01 issue 01

M21-55

Section M21 - Electronic Control Systems Engine and Fuel System Devices Fuel Lift Pump Relay

Wires and Connectors

K L

X G

B A

D P

F E

U T

C122220-C3

Fig 39. Harness Connector E001 Harness Connector E001 Connectors

Pins

E001

E004 E003

Details M

Harness connector - engine fuse/relay box. K Engine Compartment Fuse/Relay Box ( T M21-41)

Harness connector - engine ECU (grey). K Engine ECU ( T M21-48)

Harness Connector Fuel lift pump. K Fuel Lift Pump ( T M21-15)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M21-56

M-13-01 issue 01

M21-56

Section M21 - Electronic Control Systems Engine and Fuel System Devices Exhaust Gas Re circulation (EGR) Actuator

Exhaust Gas Re circulation (EGR) Actuator Location

Engine Service Manual - Publication Number: 9806/ 4300 K Related Topics ( T M21-4)

The EGR actuator 1 is part of the EGR valve 2 which is mounted on the engine exhaust manifold. Refer to T4i

2 Fig 40.

C125680

Description For a description of the EGR valve and actuator, Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

M21-57

M-13-01 issue 01

M21-57

Section M21 - Electronic Control Systems Engine and Fuel System Devices Exhaust Gas Re circulation (EGR) Actuator

Wires and Connectors - EGR Actuator Power Supply The EGR actuator power supply is controlled by the power hold relay. K Power Hold Relay ( T M21-45)

Note: This information shows the wires and connectors for the power supply to the EGR actuator. For details about other wires and connectors refer to the applicable engine documentation.

C125680-C1

Fig 41. Harness Connector CE008 Harness connector CE008 Connectors

Pins

CE008

Harness connector - EGR actuator. Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

Details

i022

Harness interconnector. K i022 - Engine Pod Harness/Engine Harness ( T M30-29)

E001

Harness connector - engine compartment fuse/relay box. K Engine Compartment Fuse/ Relay Box ( T M21-41)

i004

Harness interconnector. K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C003

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

Removal and Replacement Guide

For removal and replacement procedures Refer to T4i Engine Service Manual - Publication Number: 9806/ 4300 K Related Topics ( T M21-4)

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Rectify as required.

M21-58

M-13-01 issue 01

M21-58

Section M21 - Electronic Control Systems Engine and Fuel System Devices Variable Geometry Turbo (VGT) Actuator

Variable Geometry Turbo (VGT) Actuator Location The VGT actuator 1 is part of the turbocharger 2. Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

2 Fig 42.

C125690

Description For a description of the VGT actuator, Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

M21-59

M-13-01 issue 01

M21-59

Section M21 - Electronic Control Systems Engine and Fuel System Devices Variable Geometry Turbo (VGT) Actuator

Wires and Connectors - VGT Actuator Power Supply The engine ECU power supply is controlled by the power hold relay. K Power Hold Relay ( T M21-45)

Note: This information shows the wires and connectors for the power supply to the EGR actuator. For details about other wires and connectors refer to the applicable engine documentation.

C125690-C1

Fig 43. Harness Connector CE033 Harness connector CE033 Connectors

Pins

Details

CE006

Harness connector - EGR actuator. Refer to T4i Engine Service Manual - Publication Number: 9806/4300 K Related Topics ( T M21-4)

i022

Harness interconnector. K i022 - Engine Pod Harness/Engine Harness ( T M30-29)

E001

Harness connector - engine compartment fuse/relay box. K Engine Compartment Fuse/ Relay Box ( T M21-41)

i004

Harness interconnector. K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

C003

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M21-4)

Removal and Replacement Guide

For removal and replacement procedures Refer to T4i Engine Service Manual - Publication Number: 9806/ 4300 K Related Topics ( T M21-4)

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Test Procedures 1

Ensure that the EGR valve calibration is correct. Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required.

M21-60

M-13-01 issue 01

M21-60

Section M22 - Electronic Control Systems

General Control Devices Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T M22-3) K Ignition Switch ( T M22-4) K Location ( T M22-4) K Wires and Connectors ( T M22-5) K Removal and Replacement Guide ( T M22-10) K Test Procedures ( T M22-10) K Info Operator Switch ( T M22-11) K Location ( T M22-11) K Wires and Connectors ( T M22-12) K Removal and Replacement Guide ( T M22-16) K Test Procedures ( T M22-16) K Neutral Start Relay ( T M22-17) K Centre Cluster Warning Panel ( T M22-18) K Location ( T M22-18) K Wires and Connectors ( T M22-19) K Removal and Replacement Guide ( T M22-25) K Test Procedures ( T M22-25) K Operator Present Switch ( T M22-26) K Location ( T M22-26) K Wires and Connectors ( T M22-27) K Removal and Replacement Guide ( T M22-31) K Test Procedures ( T M22-32) K Direction Indicators/Turn Signal Lamps ( T M22-33) K Location ( T M22-33) K Wires and Connectors ( T M22-34) K Removal and Replacement Guide ( T M22-40) K Test Procedures ( T M22-41) K Trailer Turn Signal Lamp Circuit ( T M22-42) K Location ( T M22-42)

M22-1

M-14-01 issue 01

M22-1

Section M22 - Electronic Control Systems General Control Devices Introduction K Wires and Connectors ( T M22-43) K Removal and Replacement Guide ( T M22-46) K Test Procedures ( T M22-46) K Hazard Lamps ( T M22-47) K Location ( T M22-47) K Wires and Connectors ( T M22-48) K Removal and Replacement Guide ( T M22-52) K Test Procedures ( T M22-52) K Joystick (Thumbwheel and Button Type) ( T M22-53)(1) K Location ( T M22-53) K Wires and Connectors ( T M22-54) K Removal and Replacement Guide ( T M22-63) K Test Procedures ( T M22-63) K Joystick (Button Type) ( T M22-64)(1) K Location ( T M22-64) K Wires and Connectors ( T M22-65) K Removal and Replacement Guide ( T M22-68) K Test Procedures ( T M22-68) K Right Hand Column Switch ( T M22-69) K Location ( T M22-69) K Wires and Connectors ( T M22-70) K Removal and Replacement Guide ( T M22-73) K Test Procedures ( T M22-73) (1) System variant. Make sure you refer to the correct procedure. Table 1. System Variants Systems(1) Variants K Joystick (Thumbwheel and Button Type) ( T M22-53)

Agri, Agri Plus, Agri Super

K Joystick (Button Type) ( T M22-64)

Machines with Gearpump/Parallel Hydraulic System and Single Lever Control

(1) The table lists system variants and the applicable machine models. Use the table to make sure you refer to the correct information.

M22-2

M-14-01 issue 01

M22-2

Section M22 - Electronic Control Systems General Control Devices Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Cab

Instrument Panels

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Electro Servo Control Lever

ALL

Steering Column

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

M22-3

M-14-01 issue 01

M22-3

Section M22 - Electronic Control Systems General Control Devices Ignition Switch

Ignition Switch Location The Ignition switch 1 is located in the RH console.

Fig 1.

M22-4

M-14-01 issue 01

C123890

M22-4

Section M22 - Electronic Control Systems General Control Devices Ignition Switch

Wires and Connectors

– K 526-56 Machines ( T M22-8)

The ignition switch is connected to the Panel Harness.

– K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M22-8) – K Other Machines ( T M22-9)

8 7

6 5

10 1 2 3

2 2 1 4 3

Fig 2.

M22-5

M-14-01 issue 01

8 9 5 6

C123900

M22-5

Section M22 - Electronic Control Systems General Control Devices Ignition Switch

ECU 1 4 1

3 4 5 6

7 8

9 10

ECU 6

8 39

11 -VE

+VE

Fig 3. Ignition Switch in position 0 (off)

C123930

Item

Item Secondary Fuse

Engine Compartment Fuse/Relay Box

Primary Fuse

Transmission 0711 ECU

Secondary Fuse Box

Starter Motor

Ignition Switch

Engine ECU Grey Connector

Neutral Start Relay

Secondary Fuse Box

Start Signal Relay

M22-6

M-14-01 issue 01

M22-6

Section M22 - Electronic Control Systems General Control Devices Ignition Switch

ECU 1 N

4 1

3 4 5 6

7 8

9 10

ECU 6

8 39

11 -VE

+VE

Fig 4. Ignition Switch in position III (Starter)

C123930-C1

Item

Item Secondary Fuse

Engine Compartment Fuse/Relay Box

Primary Fuse

Transmission 0711 ECU

Secondary Fuse Box

Starter Motor

Ignition Switch

Engine ECU Grey Connector

Neutral Start Relay

Secondary Fuse Box

Start Signal Relay

M22-7

M-14-01 issue 01

M22-7

Section M22 - Electronic Control Systems General Control Devices Ignition Switch 526-56 Machines Table 3. Harness Connector 1 Connectors

Pins

P13

P06 P71

Details 2

Neutral Start Relay. K Neutral Start Relay ( T M22-17)

Primary Fuse 2 Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Table 4. Harness Connector 2 Connectors

Pins

Details

P12

P03

Fusebox B - Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines Table 5. Harness Connector 1 Connectors

Pins

P059

P004 P062

Details 4 -

Fusebox D- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Primary Fuse A&B Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3) Table 6.

Harness Connector 2 Connectors

Pins

P060

P003

P002 P004

M22-8

Details 6

15 3

Fusebox C- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Fusebox D- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

M-14-01 issue 01

M22-8

Section M22 - Electronic Control Systems General Control Devices Ignition Switch Other Machines Table 7. Harness Connector 1 Connectors

Pins

P043

P004 P045

Details 2

Fusebox D- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Primary Fuse Blue Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Table 8. Harness Connector 2 Connectors

Pins

P12

P001 P003(1) P002 P004

Details 6

Fusebox A- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Fusebox C - Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

3(1)

Fusebox D- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

(1) 540-170 machines only

M22-9

M-14-01 issue 01

M22-9

Section M22 - Electronic Control Systems General Control Devices Ignition Switch

Removal and Replacement Guide

2 3 Fig 5.

4 C123500-C8

Removal 1

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M22-3)

Disconnect the battery.

Remove the switch panel 1. Refer to Section B Cab. K Related Topics ( T M22-3)

Lift the panel away from the trim sufficiently to allow the harness connectors 2 to be disconnected from the switch 3.

Disconnect the harness connectors 2.

Release the ignition switch retaining clips 4 and push the switch 3 out from the rear of the panel.

Replacement Replacement is the opposite of the removal procedure.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M22-10

M-14-01 issue 01

M22-10

Section M22 - Electronic Control Systems General Control Devices Info Operator Switch

Info Operator Switch Location The info operator switch is located in the RH switch panel.

Fig 6.

C123500-C2

Table 9. Position 1

Off

ON (Push then release to move to next screen)

M22-11

M-14-01 issue 01

M22-11

Section M22 - Electronic Control Systems General Control Devices Info Operator Switch

Wires and Connectors

– K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M22-14)

The info switch is connected to the panel harness.

– K 526-56 Machines ( T M22-14) – K 540-170 Machines ( T M22-14) – K Other Machines ( T M22-15)

10 3 2 1 8

9 6 5 4 7

10 3 2 1 8

Fig 7.

M22-12

M-14-01 issue 01

9 6 5 4 7 C123510

M22-12

Section M22 - Electronic Control Systems General Control Devices Info Operator Switch

2 3

5 6

ECU

J2-6

2 3

5 6

ECU

J2-6

Fig 8.

C123940

Item 1

Fuse

Info Switch

LMS/RHC ECU

M22-13

M-14-01 issue 01

M22-13

Section M22 - Electronic Control Systems General Control Devices Info Operator Switch 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines Table 10. Harness Connector P043 Connectors

Pins

P063

P002

P039

P056

Details 2

2 18

Fusebox B - Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

LMS Connector J2. K LMS ECU ( T M18-4)

526-56 Machines Table 11. Harness Connector P046 Connectors

Pins

P063

P015

P03

P04 P036

Details 2

4 4

RHC Connector J2. K RHC ECU ( T M20-5)

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Fusebox C- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

540-170 Machines Table 12. Harness Connector P053 Connectors

Pins

P063

P002

P044

P052

M22-14

Details 2

2 3

Fusebox B - Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

RHC Connector J2. K RHC ECU ( T M20-5)

M-14-01 issue 01

M22-14

Section M22 - Electronic Control Systems General Control Devices Info Operator Switch Other Machines Table 13. Harness Connector P063 Connectors

Pins

Details

P063

P001

P002

P030

P072

M22-15

12 1

Fusebox A- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

RHC Connector J2. K RHC ECU ( T M20-5)

M-14-01 issue 01

M22-15

Section M22 - Electronic Control Systems General Control Devices Info Operator Switch

Removal and Replacement Guide

1 3

10 3 2 1 8

9 6 5 4 7

C123530

Fig 9.

Removal

Test Procedures

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M22-3)

Disconnect the battery.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Remove the switch panel. Refer to Section B - Cab. K Related Topics ( T M22-3)

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Make a note of switch orientation to aid replacement.

If multiple switches are to be removed make sure to label the switch harness connectors to aid identification.

Lift the panel away from the trim sufficiently to allow the harness connector 3 to be disconnected from the switch 2.

Disconnect the harness connector 3.

Press the tabs 1 and push the switch 2 from the panel.

Replacement Replacement is the opposite of the removal procedure.

M22-16

M-14-01 issue 01

M22-16

Section M22 - Electronic Control Systems General Control Devices Neutral Start Relay

Neutral Start Relay For relay details refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

M22-17

M-14-01 issue 01

M22-17

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel

Centre Cluster Warning Panel Location The centre cluster warning panel 2 is located in the centre console. The cluster displays warning lights 1.

Fig 10.

M22-18

C123860

M-14-01 issue 01

M22-18

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel

Wires and Connectors

â&#x20AC;&#x201C; K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M22-20)

The centre cluster warning light panel is connected to the Panel Harness.

â&#x20AC;&#x201C; K Other Machines ( T M22-22)

Fig 11.

M22-19

M-14-01 issue 01

C123860-C1

M22-19

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

14 18

12 11 1 4 3 13

2 6

2 16

17 8 9

3 +VE

-VE

Fig 12.

C123870-C1

Item 1

Fuse

Buzzer

Centre Cluster Warning Panel

M22-20

M-14-01 issue 01

M22-20

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel Table 14. Pin Number

Connected to:

Type

Refer to device:

Not Used

Turn Signal Lamps/Hazard Lamps Input

K Direction Indicators/Turn Signal Lamps ( T M22-33), K Hazard Lamps ( T M22-47)

Main Beam

Input

K Right Hand Column Switch ( T M22-69)

Not Used

Air Filter Vacuum Switch

Input

K Vacuum Switch ( T M21-11)

Engine Oil Pressure

Input

Refer to T4i Engine Service Manual Publication Number: 9806/4300 K Related Topics ( T M22-3)

Not Used

Alternator L Terminal (Charging)

Input

K Alternator ( T M21-33)

Earth

Panel Earth Point. Refer to Section C Harness System. K Related Topics ( T M22-3)

Not Used

Parkbrake Switch

Input

K Park Brake Switch ( T M19-4)

Transmission Oil Temperature

input

K Oil Temperature Sender PS750/ SS700 ( T M31-61)

LMS ECU Warning Buzzer Request

Input

LMS ECU Connector J1 K LMS ECU ( T M18-4)

LMS ECU transmission oil pressure LED Request

Input

LMS ECU Connector J1 K LMS ECU ( T M18-4)

Coolant Level Sensor

TBA

Water In Fuel Sensor

K WIF Sensor ( T M21-20)

Power

12V Battery

Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

M22-21

M-14-01 issue 01

M22-21

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel Other Machines

14 18 12

11 1 4 3 13 10

2 6 19 5

2 16

17 8 9

3 +VE

-VE

Fig 13.

C123870

Item 1

Fuse

Buzzer

Centre Cluster Warning Panel

M22-22

M-14-01 issue 01

M22-22

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel Table 15. Pin Number

Connected to:

Type

Illumination

Input

Main Beam

Input

Turn Signal Lamps/Hazard Lamps Input

K Direction Indicators/Turn Signal Lamps ( T M22-33), K Hazard Lamps ( T M22-47)

RHC ECU - Trailer Direction Indicators

Input

K RHC ECU ( T M20-5)

Not Used

Worklights

Input

Worklights

Input

Boom Worklights

Input

Not Used

Earth

Panel Earth Point. Refer to Section C Harness System. K Related Topics ( T M22-3)

Fog Light Switch

Input

RHC ECU - Master Warning Indicator

Input

Immobiliser Warning Light

Input

Parkbrake Switch

Input

K Park Brake Switch ( T M19-4)

Not Used

Transmission Oil Pressure Switch Input

K Oil Pressure Switch PS750/ SS700 ( T M31-52), K Oil Pressure Switch PS760 ( T M31-57)

Not Used

Power

12V Battery

Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

M22-23

M-14-01 issue 01

Refer to device:

K Right Hand Column Switch ( T M22-69)

K RHC ECU ( T M20-5)

M22-23

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel Centre Cluster Power and Earth Connections – K 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines ( T M22-24) – K 526-56 Machines ( T M22-24) – K 540-170 Machines ( T M22-24) – K Other Machines ( T M22-24)

506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines Table 16. Harness Connector P052 Connectors

Pins

P052

P001 P039

Details 20 16

Fusebox A- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3) Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

526-56 Machines Table 17. Harness Connector P020 Connectors

Pins

P020

P05 P36

Details 20 16

Fusebox D - Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3) Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

540-170 Machines Table 18. Harness Connector P040 Connectors

Pins

P020

P003 P044

Details 20 18

Fusebox C- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3) Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

Other Machines Table 19. Harness Connector P040 Connectors

Pins

P020

P003 P030

M22-24

Details 20 4

Fusebox C- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3) Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

M-14-01 issue 01

M22-24

Section M22 - Electronic Control Systems General Control Devices Centre Cluster Warning Panel

Removal and Replacement Guide For Removal and Replacement procedures refer to Section B - Cab. K Related Topics ( T M22-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M22-25

M-14-01 issue 01

M22-25

Section M22 - Electronic Control Systems General Control Devices Operator Present Switch

Operator Present Switch Location The operator present switch 1 is located in the seat base 2.

Fig 14.

C126760

Note: USA specification machines do not use the Operator Present Switch. Some machines will be fitted with a linking plug to bypass this switch.

M22-26

M-14-01 issue 01

M22-26

Section M22 - Electronic Control Systems General Control Devices Operator Present Switch

Wires and Connectors

â&#x20AC;&#x201C; K Machines without Fans ( T M22-27)

The operator present switch is connected to the rear cab harness.

â&#x20AC;&#x201C; K Machines with Fans ( T M22-29)

Roof Roof

Air Air

Conditioning Conditioning

Machines without Roof Air Conditioning Fans

3 2 1 6 5 4

C126760-C1

Fig 15.

A-12

A-10

2 3

ECU

-VE

+VE

Fig 16.

Item

Table 20. Key K Fig 16. ( T M22-27)

Fuse

Operator Present Switch

Transmission ECU 0711

C126770

Table 21. Operator Present Switch - Pin Outs Item K Fig 15. ( T M22-27) 1

Common Power

Channel 1 Supply

Channel 2 Supply

Channel 1 Signal

Channel 2 Signal

Common Earth

M22-27

M-14-01 issue 01

M22-27

Section M22 - Electronic Control Systems General Control Devices Operator Present Switch Table 22. Harness Connector AM K Fig 15. ( T M22-27) Connectors

Pins

Details

i019

AF P003 P069

M22-28

6 K i019 - Panel Harness/Rear Cab Harness ( T M30-26) 9

Rear Cab Earth Point Refer to Section C - Harness System. K Related Topics ( T M22-3) Fusebox C - Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Transmission ECU 0711 Connector A. K Transmission ECU 0711 ( T M20-38)

M-14-01 issue 01

M22-28

Section M22 - Electronic Control Systems General Control Devices Operator Present Switch Machines with Roof Air Conditioning Fans

C126760-C3

Fig 17.

A-12

A-10

ECU

C B

-VE

+VE

Fig 18.

Item

Table 23. Key K Fig 18. ( T M22-29)

Fuse

Operator Present Switch

TransmissionECU 0711

C126770-C1

Table 24. Operator Present Switch - Pin Outs Item K Fig 17. ( T M22-29) 1

Common Power

Earth

Channel 1 Signal

Channel 2 Signal

M22-29

M-14-01 issue 01

M22-29

Section M22 - Electronic Control Systems General Control Devices Operator Present Switch Table 25. Harness Connector RC01 K Fig 17. ( T M22-29) Connectors

Pins

i019

RC06 P003 P069

M22-30

Details 2

K i019 - Panel Harness/Rear Cab Harness ( T M30-26) Rear Cab Earth Point Refer to Section C - Harness System. K Related Topics ( T M22-3)

Fusebox C - Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3) 10

Transmission ECU 0711 Connector A. K Transmission ECU 0711 ( T M20-38)

M-14-01 issue 01

M22-30

Section M22 - Electronic Control Systems General Control Devices Operator Present Switch

Removal and Replacement Guide

4 3 5

6 7

9 Fig 19.

8 C126760-C2

Note: This procedure is the same for the upper switch 2 and the lower switch 1 unless otherwise stated.

Note: Make sure to keep hands away from the seat suspension mechanism.

Removal

Remove the seat cushion 7 from the seat base assembly 6.

Disconnect the operator present switch electrical connector 8 from the rear cab harness (lower proximity switch assembly 1 only - the upper proximity switch 2 has no electrical connector.)

Cut and discard the cable ties 5 securing the operator switch electrical cable 4 to the seat base assembly 6.

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M22-3)

Disconnect the battery.

Remove the seat suspension cover 9.

M22-31

M-14-01 issue 01

M22-31

Section M22 - Electronic Control Systems General Control Devices Operator Present Switch 7

Remove the switch mounting screws 3.

Remove the switch 1 or 2 from the seat base assembly 6.

Replacement Replacement is the opposite of the removal procedure.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M22-32

M-14-01 issue 01

M22-32

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps

Direction Indicators/Turn Signal Lamps Note: The turn signal lamps are not ECU controlled on 540-170, 550-170, 506-36, 507-42, 509-42, 510-56, 51256 and 514-56 machines. Therefore this section is not applicable to these machines. Note: The colour and position of the turn signal units may vary according to territory.

Location The turn signal lamps are located in the front and rear light clusters. They are controlled by the RH Column Switch. K Right Hand Column Switch ( T M22-69)

Fig 20.

C123980

Item 1

Rear Indicator Light Unit

Front Indicator and Headlamp Unit

M22-33

M-14-01 issue 01

M22-33

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps

Wires and Connectors

Note: 550-80 machines have additional link harnesses for the light units. Refer to Section C - Harness System.

The turn signal lamp units are connected to the machine harnesses as follows:

– K 526-56 Machines ( T M22-38) – K Other Machines ( T M22-38)

– Front LH Headlamp - Panel harness – Front RH Headlamp - Chassis Harness – LH and RH rear lights - Chassis Harness

1 2 3

6 5 4

3 2 1

4 5 6

1 2 3

6 5 4

3 2 1

4 5 6

Fig 21.

M22-34

M-14-01 issue 01

C123980-C1

M22-34

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps

6 10

7 6

RHF

RHR

J2-20

J2-4

ECU

14 11

J1-17

J2-10

3 2

4 1 2

4 5 2 1

LHF 5

LHR

+VE

C123970-C3

Fig 22. RH Indicators Enabled Item

K Fig 22. ( T M22-35)

Item

K Fig 22. ( T M22-35)

Fuse

Trailer Lights Direction Relay

RH Column Switch

Diode

LMS/RHC ECU

Centre Warning Cluster

M22-35

M-14-01 issue 01

-VE

M22-35

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps Item

K Fig 22. ( T M22-35)

LHF

Left Hand Front Light Connector

LHR

Left Hand Rear Light Connector

RHF

Right Hand Front Light Connector

RHR

Right Hand Rear Light Connector

M22-36

M-14-01 issue 01

M22-36

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps

6 10

7 6

RHF

RHR

J2-20

J2-4

ECU

14 11

J1-17

J2-10

3 2

4 1 2

4 5 2 1

LHF 5

LHR

+VE

C123970-C4

Fig 23. LH Indicators Enabled Item

K Fig 23. ( T M22-37)

Item

K Fig 23. ( T M22-37)

Fuse

Trailer Lights Direction Relay

RH Column Switch

Diode

LMS/RHC ECU

Centre Warning Cluster

M22-37

M-14-01 issue 01

-VE

M22-37

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps Item

K Fig 23. ( T M22-37)

LHF

Left Hand Front Light Connector

LHR

Left Hand Rear Light Connector

RHF

Right Hand Front Light Connector

RHR

Right Hand Rear Light Connector

526-56 Machines Table 26. Harness Connector RH Front Connectors

Pins

RHF

C010

Details 6 1

Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P15

RHC Connector J2. K RHC ECU ( T M20-5) Table 27.

Harness Connector LH Front Connectors

Pins

LHF

P036 P15

Details 6 3

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3) RHC Connector J2. K RHC ECU ( T M20-5) Table 28.

Harness Connector RH Rear Connectors

Pins

RHR

C010

Details 6 1

Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P15

RHC Connector J2. K RHC ECU ( T M20-5) Table 29.

Harness Connector LH Rear Connectors

Pins

LHR

C010

Details 6 1

Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P15

RHC Connector J2. K RHC ECU ( T M20-5)

Other Machines Table 30. Harness Connector RH Front Connectors

Pins

RHF

M22-38

Details 6

M-14-01 issue 01

M22-38

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps C003

Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P072

RHC Connector J2. K RHC ECU ( T M20-5) Table 31.

Harness Connector LH Front Connectors

Pins

LHF

P035 P072

Details 6 1

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3) RHC Connector J2. K RHC ECU ( T M20-5) Table 32.

Harness Connector RH Rear Connectors

Pins

RHR

C003

Details 6 1

Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P072

RHC Connector J2. K RHC ECU ( T M20-5) Table 33.

Harness Connector LH Rear Connectors

Pins

LHR

C003

Details 6 1

Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P072

RHC Connector J2. K RHC ECU ( T M20-5)

M22-39

M-14-01 issue 01

M22-39

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps

Removal and Replacement Guide Front Indicator/Headlamp Unit

3 1 4

1 4

Fig 24.

C123990

Removal

Replacement

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M22-3)

Replacement is the opposite of the removal procedure.

Disconnect the harness connector from the lamp unit electrical connector 1.

Support the lamp unit 3.

Remove the nut 4.

Remove the lamp unit 3 from the mounting arm 2.

M22-40

M-14-01 issue 01

M22-40

Section M22 - Electronic Control Systems General Control Devices Direction Indicators/Turn Signal Lamps Rear Indicator Lamp Unit

C124000

Fig 25. Removal

Test Procedures

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M22-3)

Disconnect the harness connector from the lamp unit electrical connector 4.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Support the lamp unit 3.

Remove the securing nuts 1 and washers 2.

Remove the lamp unit 3 from the mounting bracket 5.

Replacement Replacement is the opposite of the removal procedure.

M22-41

M-14-01 issue 01

M22-41

Section M22 - Electronic Control Systems General Control Devices Trailer Turn Signal Lamp Circuit

Trailer Turn Signal Lamp Circuit Note: The turn signal lamps are not ECU controlled on 540-170, 550-170,506-36, 507-42, 509-42, 510-56, 51256 and 514-56 machines. Therefore this section is not applicable to these machines. For details of the Trailer Turn Signal relay refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Location The trailer socket 1 has terminals to operate the turn signal lamps on a trailer or connected device. The RHC ECU and associated circuits â&#x20AC;&#x153;auto Senseâ&#x20AC;? when a remote set of turn signals are plugged into the trailer socket. The trailer socket is located on the rear of the machine.

Fig 26.

M22-42

M-14-01 issue 01

C124020

M22-42

Section M22 - Electronic Control Systems General Control Devices Trailer Turn Signal Lamp Circuit

Wires and Connectors

â&#x20AC;&#x201C; K 526-56 Machines ( T M22-45) â&#x20AC;&#x201C; K Other Machines ( T M22-45)

The trailer socket is connected to the Chassis harness.

3 2 1

1 2 3 4

5 6 7 8

8 7 6 5

Fig 27.

M22-43

M-14-01 issue 01

C124020-C1

M22-43

Section M22 - Electronic Control Systems General Control Devices Trailer Turn Signal Lamp Circuit

LH 10

J2-4

J2-20

ECU

J2-10 11

J1-17

3 2

J1-14

J1-16

4 1

RH 5

6 10

2 7

6 9

2 1

7 +VE

-VE

Fig 28. Item

K Fig 28. ( T M22-44)

Fuse

RH Column Switch

LMS/RHC ECU

Trailer Lights Direction Relay

Trailer Socket

Centre Warning Cluster

Diode

Left Hand Turn Signal Connectors

Right Hand Turn Signal Connectors

M22-44

M-14-01 issue 01

C123970-C1

M22-44

Section M22 - Electronic Control Systems General Control Devices Trailer Turn Signal Lamp Circuit 526-56 Machines Table 34. Harness Connector C019 Connectors

Pins

C019

C010

Details 3

4 Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P14

RHC Connector J1. K RHC ECU ( T M20-5)

Other Machines Table 35. Harness Connector C043 Connectors

Pins

C043

C003

Details 3

4 Chassis Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

i016

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P071

RHC Connector J1. K RHC ECU ( T M20-5)

M22-45

M-14-01 issue 01

M22-45

Section M22 - Electronic Control Systems General Control Devices Trailer Turn Signal Lamp Circuit

Removal and Replacement Guide

3 4

2 3

C124030

Fig 29.

Removal

Test Procedures

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M22-3)

Disconnect the harness connector from the trailer socket electrical connector 2.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Support the trailer socket 1.

Remove the nuts 3.

Remove the trailer socket 1 and pull the electrical connector 2 through the hole 4.

Replacement Replacement is the opposite of the removal procedure.

M22-46

M-14-01 issue 01

M22-46

Section M22 - Electronic Control Systems General Control Devices Hazard Lamps

Hazard Lamps Note: The turn signal lamps are not ECU controlled on 540-170, 550-170, 506-36, 507-42, 509-42, 510-56, 51256 and 514-56 machines. Therefore this section is not applicable to these machines.

Location The hazard lamps use the turn signal lamps which are located in the front and rear light clusters. K Direction Indicators/Turn Signal Lamps ( T M22-33) The circuit is controlled by a Hazard Lamp operator switch. The Hazard Lamp switch is located in the RH switch panel.

Fig 30.

C123500-C3

Table 36. Position 1

Off

M22-47

M-14-01 issue 01

M22-47

Section M22 - Electronic Control Systems General Control Devices Hazard Lamps

Wires and Connectors

â&#x20AC;&#x201C; K 526-56 Machines ( T M22-51) â&#x20AC;&#x201C; K Other Machines ( T M22-51)

The Hazard Lamp switch is connected to the panel harness.

10 3 2 1 8

9 6 5 4 7

10 3 2 1 8

Fig 31.

M22-48

M-14-01 issue 01

9 6 5 4 7 C123510

M22-48

Section M22 - Electronic Control Systems General Control Devices Hazard Lamps

5 2

RHF

RHR

1 2

J2-20 3

ECU

4 20

5 J1-13

J2-10

6 2 1

5 3

LHF

LHR +VE

-VE C123970-C5

Fig 32. Hazard Lamps - Off Item

K Fig 32. ( T M22-49)

Item

K Fig 32. ( T M22-49)

Fuse

LHF

Left Hand Front Light Connector

Hazard Switch

LHR

Left Hand Rear Light Connector

LMS/RHC ECU

RHF

Right Hand Front Light Connector

Centre Cluster Warning Light Panel

RHR

Right Hand Rear Light Connector

Diode

M22-49

M-14-01 issue 01

M22-49

Section M22 - Electronic Control Systems General Control Devices Hazard Lamps

5 2

RHF

RHR

1 2

J2-20 3

ECU

4 20

5 J1-13

J2-10

6 2 1

5 3

LHF

LHR +VE

-VE C123970-C6

Fig 33. Hazard Lamps - On Item

K Fig 33. ( T M22-50)

Item

K Fig 33. ( T M22-50)

Fuse

LHF

Left Hand Front Light Connector

Hazard Switch

LHR

Left Hand Rear Light Connector

LMS/RHC ECU

RHF

Right Hand Front Light Connector

Centre Cluster Warning Light Panel

RHR

Right Hand Rear Light Connector

Diode

M22-50

M-14-01 issue 01

M22-50

Section M22 - Electronic Control Systems General Control Devices Hazard Lamps 526-56 Machines Table 37. Harness Connector P59 Connectors

Pins

P59

Details 2

3 8

8 3

P59

P30A

Diode

P30B

Diode

P20

K Centre Cluster Warning Panel ( T M22-18)

P04

Fusebox C- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

P14

RHC Connector J1. K RHC ECU ( T M20-5)

20 13

P36

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

Other Machines Table 38. Harness Connector P020 Connectors

Pins

P020

P031

P032

P040

P003

P071

P030

M22-51

Details 2

Diode

K Centre Cluster Warning Panel ( T M22-18)

Fusebox C- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

RHC Connector J1. K RHC ECU ( T M20-5)

20 13 1

Panel Earth Point. Refer to Section C - Harness System. K Related Topics ( T M22-3)

M-14-01 issue 01

M22-51

Section M22 - Electronic Control Systems General Control Devices Hazard Lamps

Removal and Replacement Guide

1 3

10 3 2 1 8

9 6 5 4 7

C123530

Fig 34.

Removal

Test Procedures

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M22-3)

Disconnect the battery.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Remove the switch panel. Refer to Section B - Cab. K Related Topics ( T M22-3)

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Make a note of switch orientation to aid replacement.

If multiple switches are to be removed make sure to label the switch harness connectors to aid identification.

Lift the panel away from the trim sufficiently to allow the harness connector 3 to be disconnected from the switch 2.

Disconnect the harness connector 3.

Press the tabs 1 and push the switch 2 from the panel.

Replacement Replacement is the opposite of the removal procedure.

M22-52

M-14-01 issue 01

M22-52

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type)

Joystick (Thumbwheel and Button Type) Location The joystick thumbwheels and buttons are located on the Joystick handle assembly.

4 5

7 8

1 6 2 3

Fig 35.

C123790

Item 1

Forward/Neutral/Reverse Direction Switch (F/N/R)

Joystick Handle Assembly

Joystick Powerbase ECU

Gear Down (-) Button (if fitted)

Extend/Retract Thumbwheel

Constant Aux/Aux 1/2 Selection

Gear Up (+) Button (if fitted)

Auxiliary Thumbwheel

M22-53

M-14-01 issue 01

M22-53

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type)

Wires and Connectors

Machines with Cab Mounted Joystick

– K Machines with Joystick ( T M22-54)

Cab

Mounted

– K Machines with Joystick ( T M22-57)

Pod

Mounted

The Joystick handle assembly is connected to: – Connector 1 - the powerbase ECU. – Connector 2 - the Armrest harness.

– K 529-56 Machines ( T M22-60)

12 11 10 9 8 7 1 2 3 4 5 6

1 2 3 4 5 6 121110 9 8 7 1 Fig 36.

M22-54

M-14-01 issue 01

C123800

M22-54

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type)

4.3V 0.7V

0.7V 4.3V

1 2 3 4 5 6

12 11 10 9 8 7

4.3V

12 0.7V

ECU F

3 4

N 9

ECU 2

J5-8

J5-17

3 Fig 37.

C123810

Item 1

Connector 1

Connector 2

Joystick Handle Assembly

Joystick Powerbase ECU

Hydraulic Control ECU

M22-55

M-14-01 issue 01

M22-55

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type) Table 39. Harness Connector 1 Connectors

Pins

Details

Joystick Powerbase ECU Connector K Joystick Powerbase ECU ( T M20-67)

Table 40. Harness Connector 2 Connectors

Pins

i005

K i005 - Chassis Harness/Control Pod/Armrest Harness ( T M30-11)

C049

Hydraulic Control ECU connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

M22-56

Details

M-14-01 issue 01

M22-56

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type) Machines with Pod Mounted Joystick

â&#x20AC;&#x201C; Connector 1 - the powerbase ECU. â&#x20AC;&#x201C; Connector 2 - the Joystick harness.

The Joystick handle assembly is connected to:

12 11 10 9 8 7 1 2 3 4 5 6

1 2 3 4 5 6 121110 9 8 7 1 Fig 38.

M22-57

M-14-01 issue 01

C123800

M22-57

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type)

4.3V 0.7V

0.7V 4.3V

1 2 3 4 5 6

12 11 10 9 8 7

4.3V

12 0.7V

ECU F

3 4

N 9

J5-17

ECU

3 C123810-C2

Fig 39. Item

Item 1

Connector 1

Joystick Powerbase ECU

Connector 2

Hydraulic Control ECU

Joystick Handle Assembly

Table 41. Harness Connector 1 Connectors

Pins

M22-58

Details

M-14-01 issue 01

Joystick Powerbase ECU Connector K Joystick Powerbase ECU ( T M20-67)

M22-58

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type) Table 42. Harness Connector 2 Connectors

Pins

i005

K i005 - Chassis Harness/Control Pod/Armrest Harness ( T M30-11)

C049

Hydraulic Control ECU connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

M22-59

Details

M-14-01 issue 01

M22-59

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type) 529-56 Machines

â&#x20AC;&#x201C; Connector 1 - the powerbase ECU. â&#x20AC;&#x201C; Connector 2 - the Chassis harness.

The Joystick handle assembly is connected to:

12 11 10 9 8 7 1 2 3 4 5 6

1 2 3 4 5 6 121110 9 8 7 1 Fig 40.

M22-60

M-14-01 issue 01

C123800

M22-60

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type)

4.3V 0.7V

0.7V 4.3V

1 2 3 4 5 6

12 11 10 9 8 7

4.3V

12 0.7V

ECU F

3 4

N 9

J5-17

ECU

3 C123810-C2

Fig 41. Table 43. Harness Connector 1 Connectors

Pins

M22-61

Details

M-14-01 issue 01

Joystick Powerbase ECU Connector K Joystick Powerbase ECU ( T M20-67)

M22-61

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type) Table 44. Harness Connector 2 Connectors

Pins

C049

M22-62

Details Hydraulic Control ECU connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

M-14-01 issue 01

M22-62

Section M22 - Electronic Control Systems General Control Devices Joystick (Thumbwheel and Button Type)

Removal and Replacement Guide

The Joystick handle assembly and powerbase ECU must be removed from the machine to get access to the electrical connectors.

Replacement

For removal and replacement details of the joystick refer to Section E - Electro Servo Control Lever. K Related Topics ( T M22-3)

Test Procedures

Unscrew the lever top 1 from the powerbase 3.

Replacement is the opposite of the removal procedure.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth.

The Handle assembly can then be removed from the powerbase ECU. K Remove the Powerbase from the Joystick Handle ( T M22-63)

Remove the Powerbase from the Joystick Handle

Rectify as required.

1 2

4 5 Fig 42.

C123190-C3

Removal 1

Slacken the locknut 2.

Cut any cable ties and discard.

Disconnect the handle assembly electrical connector 5 from the powerbase ECU connector 4.

M22-63

M-14-01 issue 01

M22-63

Section M22 - Electronic Control Systems General Control Devices Joystick (Button Type)

Joystick (Button Type) Location The joystick buttons 2 and 3 are located on the Joystick handle 1 assembly.

Note: Machines with two auxiliary circuits have a 6 button lever. Machines with a single auxiliary circuit have a 4 button lever.

Fig 43.

M22-64

C122150-C1

M-14-01 issue 01

M22-64

Section M22 - Electronic Control Systems General Control Devices Joystick (Button Type)

Wires and Connectors

3 2 1 7 6 5 4 11 10 9 8 14 13 12

10 11

12 13 14

Fig 44. Key

K Fig 45. ( T M22-66)

Fuse

Joystick

0711 Transmission ECU

Hydraulic Control ECU

R1-R9

Resistors

Transmission Dump Switch

Extend Button

Aux 2 Button (if fitted)

Aux 1 Button

Retract Button

Aux 2 Button (if fitted)

M22-65

M-14-01 issue 01

C122150-C3.eps

M22-65

Section M22 - Electronic Control Systems General Control Devices Joystick (Button Type) 1

J2-14

ECU

C 6

SSLC1

J2-17

SSLC2

J2-16

J5-14

SSLC4

ECU

E 2

J2-15 SSLC3

4 7

G 12

2 +VE

Fig 45.

M22-66

M-14-01 issue 01

C128730.eps

M22-66

M22-67

M-14-01 issue 01

P002

P070

i016

C017

17 14

C014

i030

SLC 13

Table 45.

SLC 13

SLC14

SLC7

SLC8

SLC10

SLC11

SLC10

SLC2

Pins

Connectors

Harness Connector SLC2 13

Transmission ECU (07 11)Connector J2. K Transmission ECU 0711 ( T M20-38)

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

K i016 - Panel Harness/Chassis Harness ( T M30-22)

Hydraulic Control ECU connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

Hydraulic Control ECU connector J2. K Hydraulic Control ECU 3626 ( T M20-13)

K i030 - Chassis Harness/Valve Block Harness ( T M30-37)

Resistor R7 909 Ohm

Resistor R8 1K43 Ohm

Resistor R1 909 Ohm

Resistor R2 1K43 Ohm

Resistor R4 909 Ohm

Resistor R5 1K43 Ohm

Details

Section M22 - Electronic Control Systems General Control Devices Joystick (Button Type)

M22-67

Section M22 - Electronic Control Systems General Control Devices Joystick (Button Type)

Removal and Replacement Guide For removal and replacement details of the joystick refer to Section E - Parallel Single Lever Control Lever. K Related Topics ( T M22-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M22-68

M-14-01 issue 01

M22-68

Section M22 - Electronic Control Systems General Control Devices Right Hand Column Switch

Right Hand Column Switch Note: This switch is not ECU controlled on 506-36, 50742, 509-42, 510-56, 512-56 and 514-56 machines. Therefore this section is not applicable to these machines.

Location The RH column switch 1 is located on the steering column trim.

Fig 46.

M22-69

M-14-01 issue 01

C123950

M22-69

Section M22 - Electronic Control Systems General Control Devices Right Hand Column Switch

Wires and Connectors

â&#x20AC;&#x201C; K 526-56 Machines ( T M22-72) â&#x20AC;&#x201C; K Other Machines ( T M22-15)

The RH Column switch is connected to the Panel harness.

11 14 10 13 9 12 8

7 3 6 2 5 1 4

Fig 47.

M22-70

M-14-01 issue 01

7 11 14 3 6 10 2 13 5 9 12 1 4 8

C123960

M22-70

Section M22 - Electronic Control Systems General Control Devices Right Hand Column Switch

6 10

7 6

RHF

RHR

J2-20

J2-4

ECU

14 11

J1-17

J2-10

3 2

4 1 2

4 5 2 1

LHF 5

LHR

+VE

6 Fig 48. RH Column Switch - Direction Indicator Controls

Item

K Fig 48. ( T M22-71)

Item

K Fig 48. ( T M22-71)

Fuse

Trailer Lights Direction Relay

RH Column Switch

Diode

LMS/RHC ECU

Centre Warning Cluster

M22-71

M-14-01 issue 01

-VE

C123970

M22-71

Section M22 - Electronic Control Systems General Control Devices Right Hand Column Switch Item

K Fig 48. ( T M22-71)

LHF

Left Hand Front Light Connector

LHR

Left Hand Rear Light Connector

RHF

Right Hand Front Light Connector

RHR

Right Hand Rear Light Connector

526-56 Machines Table 46. Harness Connector P17 Connectors

Pins

P17

P15

P14

Details 11

14 RHC Connector J2. K RHC ECU ( T M20-5)

P02

RHC Connector J1. K RHC ECU ( T M20-5) 2

Fusebox A- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

Other Machines Table 47. Harness Connector P038 Connectors

Pins

P038

P072

P071 P001

M22-72

Details 11

14 RHC Connector J2. K RHC ECU ( T M20-5)

RHC Connector J1. K RHC ECU ( T M20-5) 12

Fusebox A- Refer to Section C - Fuses and Relays. K Related Topics ( T M22-3)

M-14-01 issue 01

M22-72

Section M22 - Electronic Control Systems General Control Devices Right Hand Column Switch

Removal and Replacement Guide For Removal and Replacement procedures refer to Section H Steering Column. K Related Topics ( T M22-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M22-73

M-14-01 issue 01

M22-73

Section M22 - Electronic Control Systems General Control Devices Right Hand Column Switch

Page left intentionally blank

M22-74

M-14-01 issue 01

M22-74

Section M23 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M23-1

M-16 issue 01

M23-1

Section M23 - Electronic Control Systems Sub Section Intentionally Blank

Page left intentionally blank

M23-2

M-16 issue 01

M23-2

Section M24 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M24-1

M-16 issue 01

M24-1

Section M24 - Electronic Control Systems Sub Section Intentionally Blank

Page left intentionally blank

M24-2

M-16 issue 01

M24-2

Section M25 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M25-1

M-17 issue 01

M25-1

Section M25 - Electronic Control Systems Sub Section Intentionally Blank

Page left intentionally blank

M25-2

M-17 issue 01

M25-2

Section M26 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M26-1

M-18 issue 01

M26-1

Section M26 - Electronic Control Systems Sub Section Intentionally Blank

Page left intentionally blank

M26-2

M-18 issue 01

M26-2

Section M27 - Electronic Control Systems

Stabiliser and Sway Devices Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics. K Related Topics ( T M27-3) K Stabiliser Deployed Sensor ( T M27-4) K Stabiliser Isolation Solenoid (S1) ( T M27-12)(1) K Stabiliser Isolation Solenoid (S2) ( T M27-16)(1) K Stabiliser, Sway Relay ( T M27-26) K Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) ( T M27-27)(1) K Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S2) ( T M27-33)(1) K Sway Direction Solenoid (S1) ( T M27-34)(1) K Sway Direction Solenoid (S2) ( T M27-41)(1) K Sway Switch (S1) ( T M27-42)(1) K Sway Switch (S2) ( T M27-48)(1) (1) System variant. Make sure you refer to the correct procedure.

M27-1

M-19-10 issue 01

M27-1

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Introduction Table 1. Specification Variants - Stabilisers Specifications

Machine Model Application

(1)

531-70, 541-70, 536-60, 536-70, 535- 506-36, 507-42, 509-42, 510-56, 51295, 550-80, 533-105, 540-170, 550- 56, 514-56 170, 540-140, 550-140, 535-125 HiViz, 535-140 HiViz K Stabiliser Isolation Solenoid (S1) ( T M27-12)

z z

K Stabiliser Isolation Solenoid (S2) ( T M27-16) K Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) ( T M27-27)

z z

K Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S2) ( T M27-33) K Sway Direction Solenoid (S1) ( T M27-34)

z z

K Sway Direction Solenoid (S2) ( T M27-41) K Sway Switch (S1) ( T M27-42)

z z

K Sway Switch (S2) ( T M27-48)

(1) The table lists specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

M27-2

M-19-10 issue 01

M27-2

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Related Topics

Topic Titles

Sub Titles

Applications

ALL (Care and Safety)

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

Control Valve

ALL

ALL (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

M27-3

M-19-10 issue 01

M27-3

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor

Stabiliser Deployed Sensor Location The stabiliser deployed sensors 1 are located on the stabiliser legs.

Fig 1.

M27-4

M-19-10 issue 01

C124690

M27-4

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor

Wires and Connectors

â&#x20AC;&#x201C; K 510-56, 512-56, 514-56 Machines ( T M27-6) â&#x20AC;&#x201C; K Other Machines ( T M27-8)

The Stabiliser Deployed sensors are connected to the Stabiliser Harness.

3 4

2 1

2 3 1 4

Fig 2.

M27-5

M-19-10 issue 01

C124620

M27-5

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor 510-56, 512-56, 514-56 Machines

J2-9

ECU

0/12V

J2-12

J2-19

0-5V

J1-22 J2-30

ECU LH

0/12V

J2-18 J2-29

0-5V

4 1

V 12

4.5 4 0.9 0.5 0

250

Fig 3.

250

X C124630-C1

Item A

Fuse

LMS ECU

RAS ECU

LH Stabiliser Deployed Sensor

RH Stabiliser Deployed Sensor

Stabiliser On/Off output pin 3

Stabiliser Proportional Output pin 4

Output - V

Pressure - Bar

M27-6

M-19-10 issue 01

M27-6

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor Harness Connector RL002 LH Stabiliser Connectors

Pins

RL002

i031

K i031 - Chassis Harness/Front Chassis/Stabiliser Harness ( T M30-38)

i028

K i028 - Panel Harness/Chassis Harness ( T M30-35)

P056

P001

Details

LMS ECU Connector J2. K LMS ECU ( T M18-4)

P107

Fusebox A - Refer to Section C - Fuses and Relays. K Related Topics ( T M27-3) 18

RAS ECU Connector J2. K RAS ECU ( T M18-31)

Harness Connector RL001 RH Stabiliser Connectors

Pins

RL001

i031

K i031 - Chassis Harness/Front Chassis/Stabiliser Harness ( T M30-38)

i028

K i028 - Panel Harness/Chassis Harness ( T M30-35)

P056

P001

Details

12 8

Fusebox A - Refer to Section C - Fuses and Relays. K Related Topics ( T M27-3)

P106 P107

M27-7

LMS ECU Connector J2. K LMS ECU ( T M18-4) 22

RAS ECU Connector J1. K RAS ECU ( T M18-31) RAS ECU Connector J2. K RAS ECU ( T M18-31)

M-19-10 issue 01

M27-7

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor Other Machines

J2-14

ECU

0/12V

J2-13

0-5V

J3-10 J5-7

J1-10

0/12V

0-5V

ECU

V 12

4.5 4 0.9 0.5 0

250

Fig 4.

250

X C124630

Item A

Fuse

RHC ECU

Hydraulic Control ECU

LH Stabiliser Deployed Sensor

RH Stabiliser Deployed Sensor

Stabiliser On/Off output pin 3

Stabiliser Proportional Output pin 4

Output - V

Pressure - Bar

M27-8

M-19-10 issue 01

M27-8

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor Harness Connector SH002 LH Stabiliser Connectors

Pins

SH002

I008

I016 C017

Details

K i016 - Panel Harness/Chassis Harness ( T M30-22)

P002

K i008 - Chassis Harness/Stabiliser Harness ( T M30-14) Hydraulic Control ECU Connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

P072

Fusebox B - Refer to Section C - Fuses and Relays. K Related Topics ( T M27-3) 15

C015

RHC ECU Connector J2. K RHC ECU ( T M20-5) 10

Hydraulic Control ECU Connector J3. K Hydraulic Control ECU 3626 ( T M20-13)

Harness Connector SH003 RH Stabiliser Connectors

Pins

SH003

I008

I016 C017 P002 P072 C013

M27-9

Details K i008 - Chassis Harness/Stabiliser Harness ( T M30-14) K i016 - Panel Harness/Chassis Harness ( T M30-22)

Hydraulic Control ECU Connector J5. K Hydraulic Control ECU 3626 ( T M20-13) 18

Fusebox B - Refer to Section C - Fuses and Relays. K Related Topics ( T M27-3) 16

RHC ECU Connector J2. K RHC ECU ( T M20-5) 10

Hydraulic Control ECU Connector J1. K Hydraulic Control ECU 3626 ( T M20-13)

M-19-10 issue 01

M27-9

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor

Removal and Replacement Guide

3 Fig 5.

Removal

Note: The illustration and procedure describes removal of one stabiliser deployed sensor. The procedure for the second sensor is identical. 1

Lower the boom and carriage to the ground.

Lower the stabilisers as far as the ground. Do not allow them to support the machine.

M27-10

M-19-10 issue 01

5 C124690-C1

Park the machine and make it safe. Vent the hydraulic pressure. Obey the care and safety procedures. K Related Topics ( T M27-3)

M27-10

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Deployed Sensor

Remove the bolts 2 and cover bracket 1.

Disconnect the harness connector 3 from the sensor 4.

Remove the sensor 4 and washer 5 from the ram.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure so this work also: â&#x20AC;&#x201C; Torque tighten the stabiliser deployed sensor 4 to 3539 Nm. â&#x20AC;&#x201C; Fit a new washer 5. â&#x20AC;&#x201C; Check the hydraulic Topics ( T M27-3)

fluid

level.

K Related

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M27-11

M-19-10 issue 01

M27-11

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Solenoid (S1)

Stabiliser Isolation Solenoid (S1) Location

Fig 6. 1

C118020

Stabiliser Isolation Solenoid

Description The solenoid is controlled by the Hydraulic Control ECU. The stabiliser isolation switch in the cab also operates this solenoid. The supply to the stabilisers is prevented by de-energising the solenoid.

M27-12

M-19-10 issue 01

M27-12

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Solenoid (S1)

Wires and Connectors

C118020-C1

Fig 7. Connector Pins

ECU -

+ 1 2

Fig 8. Wiring Schematic

M27-13

M-19-10 issue 01

C117780-C6

M27-13

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Solenoid (S1) Item

Item 1

Hydraulic Control ECU

Stabiliser Isolation Solenoid

Harness Connector C066 Connectors

Pins

C066

C015

C014

M27-14

Details 2 Hydraulic Control ECU Connector J3. K Hydraulic Control ECU 3626 ( T M20-13) 18

Hydraulic Control ECU Connector J2. K Hydraulic Control ECU 3626 ( T M20-13)

M-19-10 issue 01

M27-14

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Solenoid (S1)

Removal and Replacement Guide The Solenoid is a non serviceable component. If it is faulty the solenoid must be replaced. Refer to Section E Control Valve. K Related Topics ( T M27-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M27-15

M-19-10 issue 01

M27-15

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Solenoid (S2)

Stabiliser Isolation Solenoid (S2) Location

Fig 9. 1

C065760-C4

Stabiliser/Sway Isolation Solenoid

Description The solenoid is controlled by the RAS ECU. The stabiliser isolation switch in the cab also operates this solenoid. The supply to the stabilisers is prevented by de-energising the solenoid.

M27-16

M-19-10 issue 01

M27-16

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Solenoid (S2)

Wires and Connectors

C065760-C5

Fig 10. Connector Pins

ECU -

+ 1 2

C117780-C6

Fig 11. Wiring Schematic Item

Item 1

RAS ECU

Stabiliser Isolation Solenoid

Harness Connector C029 Connectors

Pins

C029

i028

P107

P101

M27-17

Details K i028 - Panel Harness/Chassis Harness ( T M30-35) RAS ECU Connector J2. K RAS ECU ( T M18-31) 9

K Stabiliser, Sway Relay ( T M27-26)

M-19-10 issue 01

M27-17

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Solenoid (S2)

Removal and Replacement Guide The Solenoid is a non serviceable component. If it is faulty the solenoid must be replaced. Refer to Section E Control Valve. K Related Topics ( T M27-3)

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M27-18

M-19-10 issue 01

M27-18

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Switch

Stabiliser Isolation Switch Location The Stabiliser Isolation switch is located in the RH switch panel.

Fig 12.

C124050-C1

Table 3. Position 1

Off

M27-19

M-19-10 issue 01

M27-19

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Switch

Wires and Connectors The Stabiliser Isolation switch is connected to the panel harness.

10 3 2 1 8

9 6 5 4 7

10 3 2 1 8

Fig 13.

M27-20

M-19-10 issue 01

9 6 5 4 7 C123510

M27-20

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Switch 506-36, 507-42, 509-42, 510-56, 512-56, 514-56 Machines

ECU

J2-21

2 3

ECU

J2-21

2 3

C124500-C1

Fig 14. Item

Item 1

M27-21

Stabiliser Isolation Switch

RAS ECU

Fuse

M-19-10 issue 01

M27-21

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Switch Table 4. Harness Connector P034 Connectors

Pins

P036

P107

Details 3

P002

P039

P004

M27-22

2 14

RAS ECU Connector J2. K RAS ECU ( T M18-31)

Fusebox D- Refer to Section C - Fuses and Relays. K Related Topics ( T M27-3)

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M27-3)

Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

12 3

M-19-10 issue 01

M27-22

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Switch Other Machines

8 1

J3-16

1K300

ECU

J5-14

2 3 4 5 6

5.360K

10K

8 1

J3-16

1K300

J5-14

ECU

3 4 5 6

5.360K

10K

Fig 15.

C124120

Item 1

Stabiliser Isolation Switch

Hydraulic Control ECU

Fuse

Resistor

M27-23

M-19-10 issue 01

M27-23

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Switch Table 5. Harness Connector P036 Connectors

Pins

P036

Details 2

P081

Resistor 1K300R

P081

Resistor 1K300R

P082

Resistor 5K360R

P082

Resistor 5K360R

P083

Resistor 10K

P083

Resistor 10K

K i016 - Panel Harness/Chassis Harness ( T M30-22)

Hydraulic Control ECU Connector J3. K Hydraulic Control ECU 3626 ( T M20-13)

Hydraulic Control ECU Connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

P030

Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

P002

Fusebox B- Refer to Section C - Fuses and Relays. K Related Topics ( T M27-3)

i016

C015 C017

M27-24

14 1 12

M-19-10 issue 01

M27-24

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser Isolation Switch

Removal and Replacement Guide

1 3

10 3 2 1 8

9 6 5 4 7

C123530

Fig 16.

Removal

Test Procedures

Park the machine and make it safe. Obey the care and safety procedures. K Related Topics ( T M27-3)

Disconnect the battery.

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Remove the switch panel. Refer to Section B - Cab. K Related Topics ( T M27-3)

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Make a note of switch orientation to aid replacement.

If multiple switches are to be removed make sure to label the switch harness connectors to aid identification.

Lift the panel away from the trim sufficiently to allow the harness connector 3 to be disconnected from the switch 2.

Disconnect the harness connector 3.

Press the tabs 1 and push the switch 2 from the panel.

Replacement Replacement is the opposite of the removal procedure.

M27-25

M-19-10 issue 01

M27-25

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Stabiliser, Sway Relay

Stabiliser, Sway Relay For relay details refer to Section C - Fuses and Relays. K Related Topics ( T M27-3)

M27-26

M-19-10 issue 01

M27-26

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1)

Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) Location

Fig 17. 1

C118040

Sway Isolation Solenoid

Description The engine cooling fan hydraulic oil supply is also used to operate the sway system when fitted. When the solenoid is energised the hydraulic fan supply is switched over to supply the relevant sway direction solenoid. When the solenoid is not energised the hydraulic supply goes to the fan and the sway system is isolated. The sway proximity switch/boom angle sensor detect the boom angle, if the boom is above 10ยบ the ECU/Relay prevent the sway solenoids from being energised.

M27-27

M-19-10 issue 01

M27-27

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1)

Wires and Connectors

Fig 18. Connector Pins

M27-28

M-19-10 issue 01

C118060

M27-28

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) All Machines excluding 540-140, 535-125 HiViz and 535-140 HiViz 8 1

7 2

3 4

6 1

3 5

Fig 19. Wiring Schematic

C118050

Item 1

Sway Switch

Sway Relay

Sway Isolation Solenoid

Sway Isolation Proximity Switch

Fuse

M27-29

M-19-10 issue 01

M27-29

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) Harness Connector AC Connectors

Pins

i010

K i010 - Chassis Harness/Sway Harness ( T M30-16)

i020

K i020 - Sway Chassis Link Harness/Sway Panel Link Harness ( T M30-27)

P005

1,3

P003

Details

K Sway Switch (S1) ( T M27-42) 1

Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

540-140, 535-125 HiViz and 535-140 HiViz

ECU -

+ 1 2

C117920-C2

Fig 20. Wiring Schematic Item

Item 1

Hydraulic Control ECU

Sway Isolation Solenoid

Harness Connector AC Connectors

Pins

i010

C015

C010

M27-30

Details K i010 - Chassis Harness/Sway Harness ( T M30-16) Hydraulic Control ECU Connector J3. K Hydraulic Control ECU 3626 ( T M20-13) 1

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

M-19-10 issue 01

M27-30

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1)

Removal and Replacement Guide

1 2

C118080

Fig 21.

Removal

Pull the coil 3 from the valve stem 4.

Disconnect the battery.

Remove the valve stem 4 and O ring 5 from the valve block 6.

Label and connector.

Inspect the stem 4 for signs of wear, nicks scratches etc.

Remove the nut 1 and O ring 2.

M27-31

disconnect

the

electrical

harness

M-19-10 issue 01

M27-31

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) Replacement Replacement of the solenoid is the reverse of the removal procedure noting the following: – Ensure that the solenoid is installed the correct way round as shown. – Renew all O-rings. – Lightly lubricate all parts with clean hydraulic fluid before assembling. – Apply a small quantity of JCB Threadlocker and Sealer to the threads in the knurled nut 1 before fitting. – Ensure that the harness connectors are connected to the correct solenoids.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M27-32

M-19-10 issue 01

M27-32

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S2)

Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S2) Refer to the Stabiliser Isolation Solenoid S1. K Stabiliser Isolation Solenoid (S2) ( T M27-16)

M27-33

M-19-10 issue 01

M27-33

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S1)

Sway Direction Solenoid (S1) Location

B A

Fig 22. A

Sway Right Solenoid

Sway Left Solenoid

C118040-C1

Description Operation of the sway switch energises the solenoids A or B in the sway/fan changeover valve. The solenoids control the direction of the supply to the correct side of the sway ram.

M27-34

M-19-10 issue 01

M27-34

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S1)

Wires and Connectors

Fig 23. Connector Pins

M27-35

M-19-10 issue 01

C118060-C1

M27-35

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S1) All Machines excluding 540-140, 535-125 HiViz and 535-140 HiViz

8 1

7 1

3 4

6 2

3 5

Fig 24. Wiring Schematic

C118050-C1

Item 1

Sway Relay

Sway Switch

Sway Direction Solenoid A

Sway Direction Solenoid B

Fuse

M27-36

M-19-10 issue 01

M27-36

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S1) Harness Connector AB Connectors

Pins

i010

K i010 - Chassis Harness/Sway Harness ( T M30-16)

i020

K i020 - Sway Chassis Link Harness/Sway Panel Link Harness ( T M30-27)

P005

P003

Details

K Sway Switch (S1) ( T M27-42) 1

Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

Harness Connector AD Connectors

Pins

i010

K i010 - Chassis Harness/Sway Harness ( T M30-16)

i020

K i020 - Sway Chassis Link Harness/Sway Panel Link Harness ( T M30-27)

P005

P003

Details

K Sway Switch (S1) ( T M27-42) 1

Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

540-140, 535-125 HiViz and 535-140 HiViz

ECU

+ 1 3

Fig 25. Wiring Schematic

C117920-C3

Item 1

Hydraulic Control ECU

Sway Direction Solenoid A

Sway Direction Solenoid B

M27-37

M-19-10 issue 01

M27-37

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S1) Harness Connector AB Connectors

Pins

i010

K i010 - Chassis Harness/Sway Harness ( T M30-16)

C013

13 1

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

C010

Details

Hydraulic Control ECU Connector J1. K Hydraulic Control ECU 3626 ( T M20-13)

Harness Connector AD Connectors

Pins

i010

K i010 - Chassis Harness/Sway Harness ( T M30-16)

C016

13 1

Chassis Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

C010

M27-38

Details

Hydraulic Control ECU Connector J4. K Hydraulic Control ECU 3626 ( T M20-13)

M-19-10 issue 01

M27-38

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S1)

Removal and Replacement Guide

1 2

C118080

Fig 26.

Removal

Pull the coil 3 from the valve stem 4.

Disconnect the battery.

Remove the valve stem 4 and O ring 5 from the valve block 6.

Label and connector.

Inspect the stem 4 for signs of wear, nicks scratches etc.

Remove the nut 1 and O ring 2.

M27-39

disconnect

the

electrical

harness

M-19-10 issue 01

M27-39

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S1) Replacement Replacement of the solenoid is the reverse of the removal procedure noting the following: – Ensure that the solenoid is installed the correct way round as shown. – Renew all O-rings. – Lightly lubricate all parts with clean hydraulic fluid before assembling. – Apply a small quantity of JCB Threadlocker and Sealer to the threads in the knurled nut 1 before fitting. – Ensure that the harness connectors are connected to the correct solenoids.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

M27-40

M-19-10 issue 01

M27-40

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Direction Solenoid (S2)

Sway Direction Solenoid (S2) On these machines the Sway System is hydraulically controlled from the Parallel Control Valve Block. Refer to Section E- Control Valve. K Related Topics ( T M27-3)

M27-41

M-19-10 issue 01

M27-41

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Switch (S1)

Sway Switch (S1) Location

Fig 27. 1

Sway Left

Sway Right

Off

C118200

Description The sway switch is a 3 position momentary switch. When the switch is pushed and held in position 1 or 2 the applicable sway direction solenoid is energised.

M27-42

M-19-10 issue 01

M27-42

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Switch (S1)

Wires and Connectors

10 3 2 1 8

9 6 5 4 7

10 3 2 1 8

Fig 28. Connector Pins

M27-43

M-19-10 issue 01

9 6 5 4 7 C118210

M27-43

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Switch (S1) All Machines excluding 540-140, 535-125 HiViz and 535-140 HiViz 8 1

7 2

3 4

1 5

6 2

+ 7 3

4 -

C118050-C2

Fig 29. Wiring Schematic Item

Item 1

Sway Relay

Sway Switch

Sway Direction Solenoid A

Sway Direction Solenoid B

Sway Isolation Solenoid

Sway Isolation Proximity Switch

M27-44

M-19-10 issue 01

Fuse

M27-44

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Switch (S1) Harness Connector P005 Connectors

Pins

P005

i020

Details 3

i010

P004 AD

K i020 - Sway Chassis Link Harness/Sway Panel Link Harness ( T M30-27)

K i010 - Chassis Harness/Sway Harness ( T M30-16)

K Sway/Fan Selector Solenoid (Sway Isolation Solenoid)(S1) ( T M27-27)

K Stabiliser, Sway Relay ( T M27-26)

K Sway Direction Solenoid (S1) ( T M27-34)

2 1

540-140, 535-125 HiViz and 535-140 HiViz

8 1

7 2

3 4

56R

6 2

120R

ECU 2 3 2

332R

Fig 30. Wiring Schematic

M27-45

M-19-10 issue 01

C117920-C4

M27-45

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Switch (S1) Item

K Fig 30. ( T M27-45)

Item

K Fig 30. ( T M27-45)

Sway Switch

Hydraulic Control ECU

Resistor

Harness Connector P060 Connectors

Pins

P060

P096

Details 2

K Connector Pins ( T M27-43)

56R Resistor

Hydraulic Control ECU Connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

K Sway Switch (S1) ( T M27-42)

Panel Earth Point - Refer to Section C - Harness System. K Related Topics ( T M27-3)

P096

C017

P060

P030

P098

332R Resistor

P098

332R Resistor

C017

Hydraulic Control ECU Connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

P097

120R Resistor

P097

120R Resistor

C017

Hydraulic Control ECU Connector J5. K Hydraulic Control ECU 3626 ( T M20-13)

M27-46

M-19-10 issue 01

M27-46

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Switch (S1)

Removal and Replacement Guide

1 3

10 3 2 1 8

9 6 5 4 7

2 C118220

Fig 31.

Removal

Disconnect the battery.

Remove the switch panel.

Make a note of switch orientation to aid replacement.

If multiple switches are to be removed make sure to label the switch harness connectors to aid identification.

Lift the panel away from the trim sufficiently to allow the harness connector 3 to be disconnected from the switch 2.

Disconnect the harness connector 3.

Press the tabs 1 and push the switch 2 from the panel.

Test the applicable wires and connectors for continuity, shorts to battery and shorts to earth. Rectify as required.

Replacement Replacement of the solenoid is the reverse of the removal procedure.

Test Procedures 1

Use the applicable Servicemaster diagnostics tool to identify faults. Ensure that the applicable control interface operates correctly. Rectify as required. Refer to Servicemaster SYSTEM.

M27-47

M-19-10 issue 01

M27-47

Section M27 - Electronic Control Systems Stabiliser and Sway Devices Sway Switch (S2)

Sway Switch (S2) On these machines the Sway System is hydraulically controlled from the Parallel Control Valve Block. Refer to Section E- Control Valve. K Related Topics ( T M27-3)

M27-48

M-19-10 issue 01

M27-48

Section M28 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M28-1

M-20 issue 01

M28-1

Section M28 - Electronic Control Systems Sub Section Intentionally Blank

Page left intentionally blank

M28-2

M-20 issue 01

M28-2

Section M29 - Electronic Control Systems

Sub Section Intentionally Blank This sub section does not apply to the machine group covered by this publication.

M29-1

M-21 issue 01

M29-1

Section M29 - Electronic Control Systems Sub Section Intentionally Blank

Page left intentionally blank

M29-2

M-21 issue 01

M29-2

Section M30 - Electronic Control Systems

Harness Interconnections Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

K Related Topics ( T M30-3) K Harness Interconnections ( T M30-4) K Index of Connectors ( T M30-5) K i001 - Chassis Harness/Boom Harness ( T M30-7) K i002 - Chassis Harness/Boom Harness ( T M30-8) K i003 - Chassis Harness/Boom Harness ( T M30-9) K i004 - Chassis Harness/Engine Pod Harness ( T M30-10) K i005 - Chassis Harness/Control Pod/Armrest Harness ( T M30-11) K i006 - Chassis Harness/SRS Harness ( T M30-12) K i007 - Chassis Harness/Stabiliser Harness ( T M30-13) K i008 - Chassis Harness/Stabiliser Harness ( T M30-14) K i009 - Chassis Harness/Starter Motor Harness ( T M30-15) K i010 - Chassis Harness/Sway Harness ( T M30-16) K i011 - Chassis Harness/Towing Link Harness ( T M30-17) K i012 - Chassis Harness/Transmission Harness ( T M30-18) K i013 - Chassis Harness/Valve Block Harness ( T M30-19) K i014 - Chassis Harness/Valve Block Harness ( T M30-20) K i015 - Panel Harness/Auxiliary Harness (Sway Panel Link Harness Connector) ( T M30-21) K i016 - Panel Harness/Chassis Harness ( T M30-22) K i017 - Panel Harness/Hitch Switch Harness ( T M30-24) K i018 - Panel Harness/Radio Harness ( T M30-25) K i019 - Panel Harness/Rear Cab Harness ( T M30-26) K i020 - Sway Chassis Link Harness/Sway Panel Link Harness ( T M30-27) K i021 - Towing Link Harness/Rear Lamp Harness ( T M30-28) K i022 - Engine Pod Harness/Engine Harness ( T M30-29) K i023 - Chassis Harness/Rear Lamp Harness ( T M30-30) K i024 - RAS Panel Harness/RAS Chassis Harness ( T M30-31) K i025 - RAS Panel Harness/Panel Harness (RAS Interface 1) ( T M30-32) K i026 - RAS Panel Harness/Panel Harness (RAS Interface 2) ( T M30-33)

M30-1

M-50-01 issue 01

M30-1

Section M30 - Electronic Control Systems Harness Interconnections Introduction K i027 - Panel Harness/Rear Cab Harness ( T M30-34) K i028 - Panel Harness/Chassis Harness ( T M30-35) K i029 - RH Headlamp Harness/Chassis Harness ( T M30-36) K i030 - Chassis Harness/Valve Block Harness ( T M30-37) K i031 - Chassis Harness/Front Chassis/Stabiliser Harness ( T M30-38) K i033 - Panel Harness/LiveLink Harness ( T M30-39) K i038 - Transmission Input Speed Sensor Link Harness ( T M30-40)

M30-2

M-50-01 issue 01

M30-2

Section M30 - Electronic Control Systems Harness Interconnections Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Fuses and Relays

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

(1) You must obey all of the relevant care and safety procedures.

M30-3

M-50-01 issue 01

M30-3

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

Harness Interconnections Introduction Machine electrical harnesses are connected together at specific points. These points are referred to as â&#x20AC;&#x2DC;Interconnectionsâ&#x20AC;&#x2122;. To aid in identifying and locating the connectors, each one is listed in turn on the index and further information is available on the connector page shown. K Table 2. Harness Interconnectors ( T M30-5)

M30-4

M-50-01 issue 01

M30-4

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

Index of Connectors Table 2. Harness Interconnectors Pins

ID number

Description

i001

Chassis Harness/Boom Harness

K i001 - Chassis Harness/Boom Harness ( T M30-7)

i002

Chassis Harness/Boom Harness

K i002 - Chassis Harness/Boom Harness ( T M30-8)

i003

Chassis Harness/Boom Harness

K i003 - Chassis Harness/Boom Harness ( T M30-9)

i004

Chassis Harness/Engine Pod Harness

K i004 - Chassis Harness/Engine Pod Harness ( T M30-10)

i005

Chassis Harness/Control Pod/Armrest Harness

K i005 - Chassis Harness/Control Pod/Armrest Harness ( T M30-11)

i006

Chassis Harness/SRS Harness

K i006 - Chassis Harness/SRS Harness ( T M30-12)

i007

Chassis Harness/Stabiliser Harness

K i007 - Chassis Harness/Stabiliser Harness ( T M30-13)

i008

Chassis Harness/Stabiliser Harness

K i008 - Chassis Harness/Stabiliser Harness ( T M30-14)

i009

Chassis Harness/Starter Motor Harness

K i009 - Chassis Harness/Starter Motor Harness ( T M30-15)

i010

Chassis Harness/Sway Harness

K i010 - Chassis Harness/Sway Harness ( T M30-16)

i011

Chassis Harness/Towing Link Harness

K i011 - Chassis Harness/Towing Link Harness ( T M30-17)

i012

Chassis Harness/Transmission Harness

K i012 - Chassis Harness/ Transmission Harness ( T M30-18)

i013

Chassis Harness/Valve Block Harness

K i013 - Chassis Harness/Valve Block Harness ( T M30-19)

i014

Chassis Harness/Valve Block Harness

K i014 - Chassis Harness/Valve Block Harness ( T M30-20)

i015

Panel Harness/Auxiliary Harness (Sway Panel Link Harness Connector)

K i015 - Panel Harness/Auxiliary Harness (Sway Panel Link Harness Connector) ( T M30-21)

i016

Panel Harness/Chassis Harness

K i016 - Panel Harness/Chassis Harness ( T M30-22)

i017

Panel Harness/Hitch Switch Harness

K i017 - Panel Harness/Hitch Switch Harness ( T M30-24)

i018

Panel Harness/Radio Harness

K i018 - Panel Harness/Radio Harness ( T M30-25)

i019

Panel Harness/Rear Cab Harness

K i019 - Panel Harness/Rear Cab Harness ( T M30-26)

M30-5

M-50-01 issue 01

Refer to:

M30-5

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections ID number

Description

i020

Sway Chassis Link Harness/Sway Panel Link Harness 6

K i020 - Sway Chassis Link Harness/ Sway Panel Link Harness ( T M30-27)

i021

Towing Link Harness/Rear Lamp Harness

K i021 - Towing Link Harness/Rear Lamp Harness ( T M30-28)

i022

Engine Pod Harness/Engine Harness

K i022 - Engine Pod Harness/Engine Harness ( T M30-29)

i023

Chassis Harness/Rear Lights Harness

K i023 - Chassis Harness/Rear Lamp Harness ( T M30-30)

i024

RAS Panel Harness/RAS Chassis Harness

K i024 - RAS Panel Harness/RAS Chassis Harness ( T M30-31)

i025

RAS Panel Harness/Panel Harness (RAS Interface 1) 14

K i025 - RAS Panel Harness/Panel Harness (RAS Interface 1) ( T M30-32)

i026

RAS Panel Harness/Panel Harness (RAS Interface 2) 10

K i026 - RAS Panel Harness/Panel Harness (RAS Interface 2) ( T M30-33)

i027

Panel Harness/Rear Cab Harness

K i027 - Panel Harness/Rear Cab Harness ( T M30-34)

i028

Panel Harness/Chassis Harness

K i028 - Panel Harness/Chassis Harness ( T M30-35)

i029

RH Headlamp Harness/Chassis Harness

K i029 - RH Headlamp Harness/ Chassis Harness ( T M30-36)

i030

Chassis Harness/Valve Block Harness

K i030 - Chassis Harness/Valve Block Harness ( T M30-37)

i031

Chassis Harness/Front Chassis/Stabiliser

K i031 - Chassis Harness/Front Chassis/Stabiliser Harness ( T M30-38)

i033

Panel Harness/LiveLink Harness

K i033 - Panel Harness/LiveLink Harness ( T M30-39)

i038

Transmission Input Speed Sensor Link Harness

K i038 - Transmission Input Speed Sensor Link Harness ( T M30-40)

M30-6

Pins

M-50-01 issue 01

Refer to:

M30-6

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i001 - Chassis Harness/Boom Harness Pin Numbers

Fig 1.

C122550

Location At the time of publication some of the applicable descriptions, specifications and procedures were not available. When information becomes available it will be included in a future issue of this publication. Refer to the latest publication issue.

M30-7

M-50-01 issue 01

M30-7

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i002 - Chassis Harness/Boom Harness Pin Numbers

Fig 2.

C122560

M30-8

M-50-01 issue 01

M30-8

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i003 - Chassis Harness/Boom Harness

Location

Pin Numbers

Fig 3.

C122570

Fig 4.

C130220.jpg

Interconnect i003 is located on the inside of the rear right chassis side plate 1.

M30-9

M-50-01 issue 01

M30-9

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i004 - Chassis Harness/Engine Pod Harness

Location

Pin Numbers

6 19

29 27 28 15 26

13 25

Fig 6.

2 3 12

19 8

C122840-C3

Interconnect i004 is adjacent to the park brake disc 1.

20 21

10 22 11

Fig 5.

M30-10

25 13

2 9

C122580

M-50-01 issue 01

M30-10

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i005 - Chassis Harness/Control Pod/ Armrest Harness Pin Numbers

1 21 22 23

10 11 12 24

20 9 3 4 13 25

8 2 1 5 14

31 19 7 6 15 26

30 18 17 16

i005

Fig 8.

30 29 28

18 17 16 27

31 19 7 6 15 26

8 2 1 5 14

Fig 7.

20 9 3 4 13 24

C130210.eps

21 10 11 12

22 23

C122590

Location Interconnect i005 is located to the rear or the armrest/ control pod 1.

M30-11

M-50-01 issue 01

M30-11

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i006 - Chassis Harness/SRS Harness Pin Numbers

Fig 9.

C122600

M30-12

M-50-01 issue 01

M30-12

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i007 - Chassis Harness/Stabiliser Harness Pin Numbers

Fig 10.

C122610

M30-13

M-50-01 issue 01

M30-13

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i008 - Chassis Harness/Stabiliser Harness Pin Numbers

4 Fig 11.

C122620

M30-14

M-50-01 issue 01

M30-14

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i009 - Chassis Harness/Starter Motor Harness Pin Numbers

C Fig 12.

C122630

M30-15

M-50-01 issue 01

M30-15

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i010 - Chassis Harness/Sway Harness Pin Numbers

Fig 13.

C122640

M30-16

M-50-01 issue 01

M30-16

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i011 - Chassis Harness/Towing Link Harness Pin Numbers

C Fig 14.

C122650

M30-17

M-50-01 issue 01

M30-17

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i012 - Chassis Harness/Transmission Harness

Location

Pin Numbers

W H

J A

F S R

E Q

K L B

C D

N O

Fig 16.

K L M

B C

J A

D O

E Q

Fig 15.

M30-18

W H

Interconnect i012 is adjacent to the park brake disc 1.

V U

G F

C122840-C2

T S

C122660

M-50-01 issue 01

M30-18

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i013 - Chassis Harness/Valve Block Harness Pin Numbers

9 10 11 12

12 11 10

Fig 17.

C122670

M30-19

M-50-01 issue 01

M30-19

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i014 - Chassis Harness/Valve Block Harness Pin Numbers

1 2 3 4

6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

10 9 8 7

5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

Fig 18.

C122680

M30-20

M-50-01 issue 01

M30-20

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i015 - Panel Harness/Auxiliary Harness (Sway Panel Link Harness Connector) Pin Numbers

Fig 19.

C122690

M30-21

M-50-01 issue 01

M30-21

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i016 - Panel Harness/Chassis Harness Pin Numbers

13 19

25 31

37 43

49 55

61 67

73 79

2 8 3 9

14 20 15 21

26 32 27 33

38 44 39 45

50 56 51 57

62 68 63 69

74 80 75 81

4 10

16 22

28 34

40 46

52 58

64 70

76 82

5 11 6 12

17 23 18 24

29 35 30 36

41 47 42 48

53 59 54 60

65 71 66 72

77 83 78 84

79 73

67 61

55 49

43 37

31 25

19 13

7 1

80 74 81 75

68 62 69 63

56 50 57 51

44 38 45 39

32 26 33 27

20 14 21 15

8 2 9 3

82 76

70 64

58 52

46 40

34 28

22 16

10 4

83 77 84 78

71 65 72 66

59 53 60 54

47 41 48 42

35 29 36 30

23 17 24 18

11 5 12 6

Fig 20.

M30-22

1 7

M-50-01 issue 01

C122700

M30-22

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections Location

Fig 21.

C122850-C1

Remove the cab front cover 1 to get access to the connector.

M30-23

M-50-01 issue 01

M30-23

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i017 - Panel Harness/Hitch Switch Harness Pin Numbers

Fig 22.

4 C122710

M30-24

M-50-01 issue 01

M30-24

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i018 - Panel Harness/Radio Harness Pin Numbers

Fig 23.

C122730

M30-25

M-50-01 issue 01

M30-25

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i019 - Panel Harness/Rear Cab Harness Pin Numbers

10 9 8 7

5 4 3 2 1

20 19 18 17 16 15 14 13 12 11

1 2 3 4

6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

Fig 24.

C122740

M30-26

M-50-01 issue 01

M30-26

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i020 - Sway Chassis Link Harness/Sway Panel Link Harness Pin Numbers

Fig 25.

4 C122750

M30-27

M-50-01 issue 01

M30-27

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i021 - Towing Link Harness/Rear Lamp Harness Pin Numbers

Fig 26.

C122760

M30-28

M-50-01 issue 01

M30-28

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i022 - Engine Pod Harness/Engine Harness

Location

Pin Numbers

F G

B H

M L

B K

i022

H Fig 28.

Fig 27.

M30-29

C122820

C122720

M-50-01 issue 01

M30-29

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i023 - Chassis Harness/Rear Lamp Harness Pin Numbers

Fig 29.

C122860

M30-30

M-50-01 issue 01

M30-30

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i024 - RAS Panel Harness/RAS Chassis Harness Pin Numbers

2 6

Fig 30.

M30-31

At the time of publication some of the applicable descriptions, specifications and procedures were not available. When information becomes available it will be included in a future issue of this publication. Refer to the latest publication issue.

Location

C122870

M-50-01 issue 01

M30-31

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i025 - RAS Panel Harness/Panel Harness (RAS Interface 1) Pin Numbers

2 6

Fig 31.

M30-32

Location

C122880

M-50-01 issue 01

M30-32

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i026 - RAS Panel Harness/Panel Harness (RAS Interface 2) Pin Numbers

3 7

2 6

1 5

5 8

6 9

Fig 32.

7 10

C122890

M30-33

M-50-01 issue 01

M30-33

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i027 - Panel Harness/Rear Cab Harness Pin Numbers

Fig 34.

Fig 33.

C130250.jpg

C122900

Location Interconnect i027 is located at the rear of the cab behind the operator seat 1.

M30-34

M-50-01 issue 01

M30-34

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i028 - Panel Harness/Chassis Harness Pin Numbers

10 11 12 13 14

15 16 17 18 19 20 21

22 23 24 25 26 27 28

29 30 31 32 33 34 35

36 37 38 39 40 41 42

43 44 45 46 47 48 49

50 51 52 53 54 55 56

57 58 59 60 61 62 63

64 65 66 67 68 69 70

14 13 12 11 10

28 27 26 25 24 23 22

21 20 19 18 17 16 15

42 41 40 39 38 37 36

35 34 33 32 31 30 29

56 55 54 53 52 51 50

49 48 47 46 45 44 43

70 69 68 67 66 65 64

63 62 61 60 59 58 57

Fig 35.

C122910

M30-35

M-50-01 issue 01

M30-35

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i029 - RH Headlamp Harness/Chassis Harness Pin Numbers

Fig 36.

C122560

M30-36

M-50-01 issue 01

M30-36

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i030 - Chassis Harness/Valve Block Harness

Pin Numbers

Fig 37.

M30-37

C122870

M-50-01 issue 01

M30-37

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i031 - Chassis Harness/Front Chassis/ Stabiliser Harness Pin Numbers

2 6

Fig 38.

M30-38

Location

C122870

M-50-01 issue 01

M30-38

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i033 - Panel Harness/LiveLink Harness Pin Numbers

Fig 39.

C122690

M30-39

M-50-01 issue 01

M30-39

Section M30 - Electronic Control Systems Harness Interconnections Harness Interconnections

i038 - Transmission Input Speed Sensor Link Harness Pin Numbers

Fig 40.

C122690

M30-40

M-50-01 issue 01

M30-40

Section M31 - Electronic Control Systems

Device Ground Points Introduction This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the applications table. Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.

K Related Topics ( T M31-2) K Ground Points ( T M31-3)

M31-1

M-51-01 issue 01

M31-1

Section M31 - Electronic Control Systems Device Ground Points Related Topics

Topic Titles

Sub Titles

Applications

ALL

ALL (Care and Safety)(1)

ALL

Electrical Harness SYSTEM

ALL

Electrical Schematics

ALL

(1) You must obey all of the relevant care and safety procedures.

M31-2

M-51-01 issue 01

M31-2

Section M31 - Electronic Control Systems Device Ground Points Ground Points

Ground Points For machine Ground points refer to Section C - Harness System. K Related Topics ( T M31-2)

M31-3

M-51-01 issue 01

M31-3

Section M31 - Electronic Control Systems Device Ground Points Ground Points

Page left intentionally blank

M31-4

M-51-01 issue 01

M31-4