JCB 525-50 RAF Loadall Service Manual (Supplement) – 9803/3675 - PDF DOWNLOAD

General Information Care & Safety Routine Maintenance R

Electrics

Service Manual (Supplement)

Hydraulics Transmission Brakes Steering

525-50 RAF

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WATERLOO PARK, UTTOXETER, ST14 5PA, ENGLAND Tel. 01889 - 590312 PRINTED IN ENGLAND Publication No. 9803/3675 Initial Issue

Engine

1 2 3 C E F G H K

Overall Contents i

i

Contents

Page

Section 1 General Information Introduction Care and Safety

1-1

Section 2 Care and Safety Safety Notices

1-1

Safety Warnings

2-1

Section 3 Routine Maintenance Service Schedules (Additional Items)

1-1

Category ‘C’ Safety System Oiling

2-1

Batteries Warning Symbols First Aid - Electrolyte Checking the Electrolyte Level

2-1 3-2 3-2

Section C Electrics Technical Data

1-1

Fuse Identification

1-2

Schematic Diagram

2-1

Load Moment Indicator Introduction Load Chart (Example Only) Calibration Diagnostic Fault Codes Testing Fault Location Chart

3-1 3-2 3-3 3-4 3-5 3 -11

Section E Hydraulics Schematic Diagram

9803/3675

2-1

Issue 1

Overall Contents ii

ii

Contents

Page

Section H Steering Circuit Description Steer Unit Operation Steer Mode Valve Operation

1-1 1-1

Steer Mode Valve Checking Solenoid Operation Removal Replacement

2-1 2-1 2-1

Section K Engine Technical Data

1-1

Machine Start-up Procedure

2-1

Category ‘C’ Safety System Introduction Operation Inlet Shutdown Valve Overspeed Spring Adjustment Replacing a Broken Tension Pin Webasto Water Heater Introduction Operation Heater Unit Fault Finding General Failure Symptoms Failure Symptoms After Switch-off Upon Failure Electrical Connections Heater Unit - Removal and Refitting Circulation Pump - Replacement Temperature Limiter - Replacement Temperature Sensor - Replacement Combustion Air Fan - Replacement Replacement of Burner, Flame Sensor and Glow Plug Burner Head - Replacement Heat Exchanger - Replacement Visual Inspection Electrical Component Testing

9803/3675

3-1 4-1 5-1 5-2

8-1 8-2 8-3 8-5 8-5 8-6 8-7 8-8 8-9 8 - 10 8 - 10 8 - 12 8 - 13 8 - 15 8 - 16 8 - 17 8 - 18

Issue 1

Section 1

General Information

Section 1

i

i

Contents Introduction Care and Safety

9803/3675

Page No. 1-1 1-1

Issue 1

Section 1

General Information Introduction

1-1

Section 1 1-1

This manual is a supplement to the JCB 525-50 Loadall Service Manual. The information covers the 525-50RAF machines with the following serial numbers: 881917, 881918 (winterised) 881982 to 882006 (standard machines).

Note: Only those areas of the machine which are different from the standard 525-50 Loadall are dealt with here. For all other information refer to Loadall Service Manual 9803/3620.

Unless specified otherwise, all references to ‘Service Manual’ in this supplement are to be taken as meaning Loadall Service Manual 9803/3620.

Read the standard Service Manual and this Supplement completely and carefully to familarise yourself with the machine before carrying out any servicing procedures.

Care and Safety Before carrying out any maintenance procedures on this machine, make sure you read the Care and Safety information in Section 2 of the Service Manual. The relevant information in that Section should be observed as well as any care and safety information contained in this supplement.

9803/3675

Issue 1

Section 2

Care & Safety

Section 2

i

i

Contents

9803/3675

Page No.

Safety Notices

1-1

Safety Warnings

2-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 1-1

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

! DANGER 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

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

INT-1-2-2

! CAUTION 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

! DANGER Study this Supplement and the Service Manual for the machine before carrying out any maintenance work on the machine. You must always understand and observe the relevant laws and regulations. If you are unsure about anything, ask your JCB Distributor.

9803/3675

Issue 1

Section 2

Care and Safety

2-1

Section 2 2-1

Before carrying out any maintenance procedures on this machine, make sure you read the Care and Safety information in Section 2 of the Service Manual. The relevant information in that Section should be observed as well as any care and safety information contained in this supplement.

Safety Warnings ! WARNING Working Beneath the Machine Make the machine safe before getting underneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake is engaged and the transmission is in neutral. Disconnect the battery. Chock all four wheels.

5-3-2-1

! WARNING If the engine safety system trips whilst the machine is being used in a hazardous area, DO NOT ATTEMPT TO RE-START until advice has been obtained from the person in authority and the cause of the shutdown found and corrected.

0088

! CAUTION If the engine has been running previously, it will not be possible to reset the engine safety shutdown system for a period of at least 30 seconds after shutdown due to the high engine inlet system vacuum. DO NOT attempt to push the operating lever to the start/reset position against this vacuum as use of excessive force will cause severe damage to the valve mechanism.

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Issue 1

Section 3

Routine Maintenance

Section 3

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Contents

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Page No.

Service Schedules (Additional Items)

1-1

Category ‘C’ Safety System - Oiling

2-1

Batteries - Warning Symbols - First Aid - Electrolyte - Checking the Electrolyte Level

3-1 3-2 3-2

Issue 1

Section 3 1-1

Routine Maintenance Service Schedules (Additional Items)

Operation

CATEGORY ‘C’ SAFETY SYSTEM Control Mechanism All Pivot Points Emergency Stop Overspeed Setting

WEBASTO HEATER SYSTEM System

9803/3675

Section 3

Daily 10 Hr

1-1

Weekly 2 Weekly 6 Monthly Yearly 50 100 500 1000 Hr Hr Hr Hr

2 Yearly 2000 Hr

Inspect

z

z

z

z

Oil

z

z

z

z

Test Check/Adjust

z

z

z

z

z

z

z

z

z

Inspect/Operate

Issue 1

Section 3 2-1

Section 3

Routine Maintenance Category ‘C’ Safety System

2-1

Oiling Lightly oil the shut-off valve spindle A and the pivot points B at the periods stated in the Service Schedules.

A B

397580

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Issue 1

Section 3

Routine Maintenance Batteries

3-1

Warning Symbols The following warning symbols may be found on the battery.

Symbol

Section 3 3-1

THIS MACHINE IS FITTED WITH A 24 VOLT ELECTRICAL SYSTEM WHICH IS POWERED BY TWO 12 VOLT BATTERIES WIRED IN SERIES.

! CAUTION

Meaning

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

Keep away from children.

INT- 3- 1-14

! WARNING

A289230

Shield eyes.

Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

INT-3-1-4

! DANGER

A289260

No smoking, no naked flames, no sparks.

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

INT-3-2-1/3

! CAUTION

A289280

Explosive Gas.

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

! WARNING

A289250

Battery acid.

A289240

Note operating instructions.

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames.

Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you.

A289270

Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.

When reconnecting, fit the positive (+) lead first.

Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.

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Issue 1

Section 3

Routine Maintenance

Section 3

Batteries

3-2

3-2

First Aid - Electrolyte Do the following if electrolyte: GETS INTO YOUR EYES

A

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

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

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

397432

5-3-4-3/1

Checking the Electrolyte Level 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.

1

B

Remove the rear grille A or open the battery box door B, as appropriate.

! WARNING 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 this happens you can get burned.

397370

5-2-2-4

2

Disconnect and remove battery.

! WARNING Do not top the battery up with acid. The electrolyte could boil out and burn you.

C

2-3-4-6

3

Remove covers C. 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.

4

Refit battery, close and lock the rear grille/battery box door.

A089660

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Issue 1

Section C

Electrics

Section C

i

i

Contents

Technical Data

1-1

Fuse Identification

1-2

Schematic Diagram

2-1

Load Moment Indicator Introduction Load Chart (Example Only) Calibration Diagnostic Fault Codes Testing Fault Location Diagram

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Page No.

3-1 3-2 3-3 3-4 3-5 3 - 11

Issue 1

Section C 1-1

Electrics Technical Data

Batteries Cold Crank amps for 1 minute to 1.4 VPC at -18°C (0°F) I.E.C. Reserve capacity (minutes) for 25 amp load

2 x 12 volts, negative earth

Alternator

Bosch 24V - 55A

Starter Motor

Bosch 24V LHS

Light Bulbs Headlights - dip Headlights - main Work lights Front side lights Stop/tail lights Turn indicators Warning lights Interior light Search light

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Section C 1-1

590 290

24V, 70 W 24V, 70 W 24V, 70 W Halogen 24V, 5 W 24V,21/5 W 24V, 21 W 24V, 1.2 W 24V, 10 W 24V, 70 W

Issue 1

Section C

Electrics

Section C

Technical Data

1-2

1-2

Fuse Identification The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the door. They are in three rows, labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.

Row A

Row B

Fuse 1

Circuit Brake lights

2

Panel warning lights, warning buzzer, instrument lights

3

4

Rating 7.5 5

L.H. sidelights, number plate light, trailer light (if fitted)

5

R.H. sidelights, number plate light, trailer light (if fitted)

5

Row C

Fuse 1

Circuit Junction box

Rating 5

Fuse 1

Circuit Spare

2

Engine shut-off switch (ESOS)

5

3

Dipped beam

15

4

Main beam

5

Rating -

2

Load Moment Indicator

3

3

Forward/reverse switch, transmission dump relay

7.5

15

4

Rear fog light

3

Working lights

7.5

5

Thermostart

15

6

Indicators

5

6

4WS

7.5

5

Rear wash/wipe switch 5

7

Parking brake circuit

5

7

Heated screen

25

6

Hazard warning lights

10

8

Heater

5

8

Headlight flasher

10

7

Interior light, beacon

5

9

Spare

-

9

Engine shutdown

5

8

Spare

-

9

Front wash/wipe switch, 7.5 horn

Fuse links

1 2 3 4 5

Circuit

Rating

Starter relay Tracker, Radio, Hazard lights, Wipers Lights relay Starter switch Not used

60 30 40 30 80

3 5

1 2

A

4

B S245110

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C Issue 1

Section C

Electrics

Section C

2-1

Schematics

2-1

Component Key (Sheet 1) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

28 29 30 31 32 33 34 35 36 36 37 38 39 40

Batteries (two in series) Starting aid Starter motor Neutral start relay Ignition switch Forward relay Forward solenoid Reverse relay Reverse solenoid Reverse light Forward/reverse switch Transmission dump relay Park brake light relay Reverse alarm mute relay Reverse alarm Park brake switch Park brake solenoid Cold start advance E.S.O.S. Load moment indicator (LMI) LMI transducer Heated screen switch Heated screen timer Heated screen relay Heated side screen Heated rear screen Hazard/steer mode indicator unit A Hazard flasher indicator light B Steer mode indicator light (see Sheet 2 for connections) Hazard switch Hazard flasher unit Indicator switch Left hand front indicator Left hand rear indicator Left hand trailer indicator Right hand trailer indicator Right hand rear indicator Right hand front indicator Fuel gauge Alternator Water temperature sender Fuel sender Instrument panel A Tachometer B Water temperature gauge C Fuel gauge D Hourmeter E Battery charge warning light F Hand brake on warning light G Water temperature warning light H Transmission oil temperature warning light J Engine oil pressure warning light K Transmission oil pressure warning light L Air filter blocked warning light M Brake fault warning light N 2-wheel steer indicator light P 4-wheel steer indicator light R Hazard warning indicator light S Main beam on indicator light T Panel illumination U Panel illumination V Turn signal indicator light

9803/3675

41 42 43 44 45 46 47 100 101 102

Water temperature switch Transmission oil temperature switch Engine oil pressure switch Transmission oil pressure switch Air filter blocked switch Brake pressure switch Warning buzzer Battery isolator switch Intervehicle start socket 24V to 12V convertor ....continued

Issue 1

200B

60A

9803/3675

C3 C2 C7 B6

106

A D

A6

E H

G

40

K

J M N P R S T

806

F

830

29 804

B

826B

803 803A

825B

106C

804A

805

458

404

405

403

404

406

401

407

408

409

412

806B

805B

200 200A

3

7 1

600BL

600G 600FP

600FP 600H 600AZ

805K

806L 806C 806E

39

41 42 43 44 45 46

600CE

600CK

600GL

600CF

600BU

600HH

600C

38

34 35 36

600LZ

600T

600BC

805E

600DX

31 32 33

26 600NZ

25 600NX

805C

1804B

1804A

600NY

600FF

600NS

600NJ

600NT

600JE

600

105A

600GN

600BN

600FR

600CD

600PA

600BT

600AD

600BS

600AC

600CV

15 105B

807

811C/811F

811

600FL 600EZ

Electrics Section C

2-2

Schematic 2-2

412

28

5

30A

40A

853-00004-1(2)

Issue 1

411

806

30

804

23

106F

464 803A

400

463

B

805

4

3

A

802

600DX

2

1

21

300

104

935

2

1

37

106E

323

106BN

7

6 4

24

001D

B2 001F

B7

3 1

102

8

17 9

105

937

20

2

10

974

13

106BL

12

16

106BP

C5 937C 936

8

001G

11

14

001H

4

122

852

1

401

934C

2 811A

8

3

967

106BM

811B

M

912A

808

812

9

810B

808

6 912A

7

912

934 934C

810

912

809

5

107N

107N

107A

809

4

107M

107A 107M

934A

934B

10

001J

001B

123

2

200J

200M

START PRE HEAT IGN OFF 003

003A

004

001

842

100

200C

003

934

101

810A

004

Section C

Sheet 1

600

406A

407

27

47

C

L

U V

830

22 837

A2 001

826B 825B 001

200B 200C

30A 200D

200D 106

200G

200G

200E

200E

9803/3675

68

837

75

200D 106N

96

855

832A

314

832

A3 833

894

836

94 868

106J

830

830D

830H

830J

830S

829E

829D

829G

829P

B3 835

837

834A 834B

A4

B5

303A

303J

863

B4

303A 303B

116

74 828D

828A

800

864

66

303B 303C

009D

B8 009A

106K

102F

4WS

600BM

102D

63

002L

71 808B

862

855B

835B

835A

837B

837A

834B

834A

103F

91 92

200L

B A5 106R

64 103J

814

303C

841

840

59

73

200H

A9

314

B1 103

839

67

002C

110J

110B

E

600W

110

825

D

70

009

C6

69

200R

200G

A 825A

824A

826 824

65

002

27 002H

57 101

62

002F

61

109F

60

109

CRAB 826A

2WS

109D

55 845

823

822

B

109C

819B

816E

F

200E

A1 C

002N

824B

56 820

819A

821

48

600BV

54

819

406A

109E

830 600BW

816

52 72

001L

001

53

200D

825B 816J

A

109B

109A

877

600H

600FP

600G

600AA

600PJ

600EH

600AP

600DY

600AJ

600CW

600AS

600P

600H

600G

600N

600BC

600AZ

600BC

600AZ

600AZ

600H

600AX

600FP

600BC

600G

600AU

600FP

600DW

600BM

600BH

600EB

600BK

600BD

600EF

600W

600B

600AK

600BG

600CC

600NP

58

001M

C9 108B

108A

816D

951

49

106AU

826B 163

406A

88 89

76 77 78 79 80 81 82 83 84 85 86 87

50 51

600

001C

001K

163A

Section C Electrics Section C

2-3

Schematic 2-3

Sheet 2

93

90

95 99

C4

98

97

001

A7

C8

106

200G

200E 853-00004-2

Issue 1

Section C

Electrics

Section C

2-4

Schematics

2-4

Component Key (Sheet 2) 27

48 49 50 51 52 53 54 55 56 57 58

59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

Hazard/steer mode indicator unit A Flasher indicator light (see Sheet 1 for connections) B Steer mode indicator light Shutdown relay Shutdown solenoid Left hand brake light Left hand trailer brake light Right hand trailer brake light Right hand brake light Brake light relay Brake light switch Proximity switch - front axle Proximity switch - rear axle Steer mode control unit A Crab steer relay B Four wheel/crab steer relay C Two wheel steer relay D Four wheel steer relay E 4WS/Crab selector F 2WS/4WS selector Steer mode selector switch AWS solenoid 4WS solenoid Crab steer solenoid 2WS solenoid Junction box Front washer pump Front wiper Front wash/wipe switch Ignition relay 2 Front horn Rear wiper Rear wash/wipe switch Rear washer pump Heater motor Heater switch Lights relay Left hand trailer light Left hand number plate light Left hand tail light Left hand side light Right hand trailer light Righft hand number plate light Right hand tail light Right hand side light Right hand dipped beam Left hand dipped beam Right hand main beam Left hand main beam Left hand fog light Right hand fog light Left hand front worklight Face level fan Interior light Beacon Headlight flasher switch Fog light switch Road lights switch Worklight switch Beacon Tracker

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Issue 1

Section C 3-1

Electrics

Section C

Load Moment Indicator

3-1

Introduction The machine is fitted with a Load Moment Indicator (LMI).

The load moment indicator warns the operator when the machine is nearing its maximum working limit (ie. when it could tip forward). Sensors measure the load exerted on the rear suspension and send signals to the indicator. These sensors take the form of the top locating pins B on the rear suspension cylinders.

Testing procedures described in this section should be carried out on level ground with the road wheels in the straight ahead position.

When the load carried by the forks is within the maximum working limit in terms of weight and boom extension, the green LEDs C on the display unit illuminate.

The three green LEDs illuminate progressively as the load increases and the amber LED D illuminates as the load nears the maximum working limit.

E D

100%

C G

A

All LEDs flash as the load continues to approach the maximum working limit.

If the load exceeds the maximum working limit, the red LED E illuminates and an audible warning sounds.

A363130

If a system fault is detected, various combinations of LEDs indicate a fault code. See Diagnostic Fault Codes.

LED G remains on whenever power is supplied to the display box.

9803/3675

Issue 1

Section C

Electrics

Section C

Load Moment Indicator

3-2

3-2

Load Chart (for example only)

A B

Y A B 0

1000

2000

3000

Z

9803/3675

4000

5000

X

A346470

Issue 1

Section C

Electrics Load Moment Indicator

3-3

Section C 3 -3

Calibration The LED indications described are in addition to the green power-on LED G at the bottom of the display, which remains on whenever power is supplied to the display unit.

1

Park the machine on firm level ground.

2

Turn the starter key to the OFF position. Press and hold display button A. Start the engine with button A held down. Hold the button for approximately 30 seconds after the engine has started. All display LEDs will illuminate during this time.

The display unit must be calibrated by setting the ‘100%’ point using a known load and boom extension.

! WARNING

Note: if the button is release during this time, the entire process must be repeated.

During the following procedure, do not raise the load more than 600mm above ground level otherwise the machine may be able to tip forward at a dangerous angle. Keep all personnel clear of the front and rear of the machine.

After approximately 30 seconds, the display will show the red LED E only and the alarm will emit short intermittent bleeps.

Elec 4-1

3

Release button A.

4

With the boom fully retracted, pick up a load between 1800 kg and 2000 kg. Use either pallet forks loaded with a test weight, or a bucket filled with a high density material.

5

Slowly extend the boom. Keep the load close to the ground until the machine is balanced about the front axle with the rear wheels off the ground.

Note: If the following actions are not completed within a five minute period, the display will automatically leave the calibration mode and the memory will revert to the previous settings. If the transducer signal is out of range, the display will indicate the appropriate error code. Calibration cannot continue until the fault is rectified.

E D

G

Press and release the display button A. The display will change to show the amber LED D and red LED E only.

7

Lower the load to the ground and measure the distance the boom is extended.

8

Refer to the correct load chart for the machine (this section).

9

Read up from the extension figure obtained at step 7 (example line X) to the tipping line AA.

10

Read horizontally (example line Y) to the maximum working limit line BB.

11

Read down to the horizontal axis to get the dimension for the boom extension (maximum working limit).

12

Draw a mark on the boom at the dimension obtained above. Raise and retract the boom to the mark drawn on the boom.

13

Press and release the display button. The display will revert to normal operation. The setting of the 100% position is now complete.

100%

A

A363130

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6

Issue 1

Section C

Electrics

Section C

Load Moment Indicator

3-4

3-4

Diagnostic Fault Codes When the system detects a fault, the audible alarm sounds for approximately 10 seconds and various combinations of lights on the display indicate a fault code.

The alarm cancels after 10 seconds and all the lights on the display flash as long as the fault remains. Press and release the display button A to show the fault for a further 10 seconds. When the fault clears, the display returns to normal.

If any of the fault codes are displayed, switch the starter key off and on again. Refer to the list of fault codes below if the fault does not clear.

Note: A new display box will not be calibrated. Always calibrate the system when fitting a new display box.

FAULT CODE

POSSIBLE CAUSE

REMEDY

Fault Code 1

Transducer not connected.

Check transducer connection.

Transducer signal fault

Faulty harness.

Check for trapped or damaged wires.

Faulty transducer.

Check for water ingress. Replace transducer.

Fault Code 2

System is incorrectly calibrated.

Re-calibrate system.

Calibration out of range

Transducer correctly.

Check mounting surfaces are clean and flat. Check mounting bolts are not bottoming-out.

Check tightness of transducer mounting bolts (70 Nm).

Fault Code 3

not

fixed

down

Faulty transducer.

Replace transducer.

System not calibrated.

Calibrate system.

The display box has detected an internal error.

Switch the starter key off and then on again. Replace the display box if the fault does not clear.

Low battery voltage

Do supply voltage test at display box. Check battery voltage.

Calibration required

Fault Code 4 Display unit faulty

Fault Code 5 Low battery voltage

9803/3675

Issue 1

Electrics

Section C

Section C

Load Moment Indicator

3-5

A

3-5

100%

TP1

TP2

TP3

TP4

TP5

RUN

BOSS

TEST 1

CHECK

TRANS

TEST 2 Power

A244691

J

E

H 1

2 2

1

S244690

9803/3675

Issue 1

Section C

Electrics Load Moment Indicator

3-6

Section C 3-6

Testing Introduction If the calibration procedure fails to rectify a problem, there are three main areas where faults can occur: the readout box, the transducer, and the machine electrical harness. The test box (892/00905) is designed to assist the service engineer to diagnose faults in the LMI system down to component level.

This unit should be used when the standard calibration procedure has been attempted and failed.

The test box contains five test points: TP 1 to TP 5 which allow currents in the circuits to be read as voltages by an AVO digital multimeter. The test points also allow continuity and open/short circuit tests to be made.

TP1 TP2 TP3 TP4 TP5

Earth Readout box supply Transducer supply Transducer output (Signal) Transducer output (voltage)

The test box also contains three switches: TEST 1/TEST 2, TRANS/BOSS, RUN/CHECK to change settings for the various tests.

The box is connected between the four-pin plug and socket which connects the readout box to the machine wiring harness behind the instrument panel in the cab.

Before carrying out the tests make sure that: (a) (b) (c) (d)

(e)

the machine is on level ground with the boom horizontal; the forks are fitted, with no load; the boom is fully retracted; two-wheel drive is engaged (if fitted) and the machine has been driven backwards and forwards several times with the wheels in the straight ahead position; the ignition switch is on, but the engine is not running.

Note: The readout display will be affected by extreme steer lock and axle angles.

Test point TP4 reads signal current in the transducer return wire and converts this to a voltage which can be read by the multimeter.

Service Procedure

Test point TP5 is a direct connection to the transducer return wire.

Remove the instrument panel and connect test box A as shown. The BOSS/TRANS switch should be set to the TRANS position for all tests on machines fitted with transducers.

The Black lead of the multimeter should be connected to TP1 (earth) when testing voltages.

Note: When returning equipment under warranty, the results of the following tests MUST be stated.

9803/3675

Issue 1

Section C

Electrics

Section C

Load Moment Indicator

3-7

3-7

Test 1: Supply Voltage and Fuse Test (V1)

1

RUN TRANS TEST 1

Measure the voltage between TP1 and TP2 Expected reading: Convertor voltage (11.0V to 15.0V).

C2

24/12v Convertor

974

001

+12v

Note: As an additional test, LED C should be illuminated when the display box is receiving a supply voltage.

TP2

600JE

0v TP1

Display Box

464

If the expected reading is not obtained, check the ignition is on, fuse C2, battery condition, test box connections and test harness. Rectify as required.

463

Test box settings:

Transducer V1 310864

Test 2: Transducer Supply Test (V2) Test box settings:

C2

Measure the voltage between TP1 and TP3 Expected reading: Convertor voltage (11.0V to 15.0V).

If the expected reading is not obtained, check the ignition is on, fuse C2, battery condition, test box connections and test harness. Rectify as required.

24/12v Convertor

974

001

1

RUN TRANS TEST 1

+12v

600JE

0v TP1

Display Box

If the expected reading is not obtained after the above checks, the display box should be renewed.

463

464

V2

Transducer 310874

9803/3675

Issue 1

Electrics

Section C 3-8

Section C

Load Moment Indicator

3-8

Test 3: Display Box Functional Test 1

Park the machine (unloaded) on level ground with the engine running. Apply the parking brake and place the forward/reverse lever in the neutral position.

2

The green LED G at the bottom of the display will illuminate to show that the indicator is receiving power.

3

Press the display button A and release.

4

All LEDs on the indicator will flash and the audible alarm will sound if the unit is functioning correctly.

100%

G A

A363130

9803/3675

Issue 1

Section C

Electrics

Section C

Load Moment Indicator

3-9

3-9

Test 4: Transducer Output Test (V3) (Transducer Fitted)

1

C2

RUN TRANS TEST 1

Measure the voltage between TP1 and TP4 Expected reading: 4.3V to 4.7V.

24/12v Convertor

974

001

Test box settings:

+12v

0v

600JE

TP1

Display Box

464

If Test 5 is successful, a transducer fault or incorrect transducer mounting should be suspected. Carry out Test 6 to test transducer output with the transducer removed from the axle.

463

If the expected reading is not obtained, carry out Test 5 to check for possible harness faults.

310880

Transducer V3

Test 5: Harness Wiring Continuity And Short Circuit Test Test box settings:

1

2

CHECK TRANS TEST 1

Disconnect the display box from the test box harness K, but leave the Test box harness connected to the machine wiring L. Disconnect the transducer harness from the machine wiring M. Turn OFF the ignition switch and check for continuity between the following points on the test box and the two pin connector E that was connected to the transducer. Remove the plastic pin retainer on the plug to access the connections.

If the expected readings are not obtained, check for damaged wiring and faulty connections.

If the expected readings are obtained, but the expected voltage reading from Test 4 above is not achieved, carry out Test 6 with the transducer removed from the axle.

Continuity Test 3

Switch the multimeter to the Ohms scale and measure the electrical resistance between: TP3 and pin 2 of connector M. TP5 and pin 1 of connector M. Expected reading: Less than 3 ohms.

Short Circuit Test

4

Measure the electrical resistance between: TP1 and TP5 TP1 and TP3 TP3 AND TP5 Expected reading: Open Circuit.

9803/3675

Issue 1

Section C

Electrics

Section C

Load Moment Indicator

3 - 10

3 - 10

Test 6: Transducer Output Test (V4) (Transducer Removed)

2

Reconnect the battery and turn the starter switch to on, but with the engine not running.

3

Reconnect the display box to the test harness.

4

24/12v Convertor

974

+12v

0v

600JE

TP1

Display Box

RUN TRANS TEST 1

464

Test box settings:

C2

463

Remove the transducer from the machine, reconnect to the machine harness and support under the machine.

001

1

Measure the voltage between TP1 and TP4 Expected reading: 4.48V to 4.52V. Transducer

If the transducer is not distorted, then V4 should be between 4.48V and 4.52V. If it is outside this range, but within 4.40V to 4.60V, it may still be OK providing that the conditions of Test 4 are achieved.

310890

V4

If the transducer passes this test, having failed Test 4, the apparent failure is probably due to uneven transducer mounting.

Check mounting surfaces are clean, flat and free from paint and rust etc. Refit the transducer to the machine and tighten the transducer fixing screw to 70Nm. Remove the test harness and reconnect electrical plugs.

Voltage Readings The following table may be used to record information in the event of an enquiry and must be submitted together with a warranty claim. If applicable any warranty parts must also be returned with any additional information such as: which lights are not illuminating, if system balancing is possible, or if display box function test is not successful.

V1 V2 V3 V4

12V Supply Transducer supply voltage Transducer output voltage (Fitted) Transducer output voltage (Removed)

Expected Readings V1

11.0V to 15.0V

V2

11.0V to 15.0V

V3

4.3V to 4.7V

V4

4.48V to 4.52V

Measured Readings

IMPORTANT: The system must always be re-calibrated after performing the above tests, and before operating the machine.

9803/3675

Issue 1

Electrics

Section C

Section C

Load Moment Indicator

3 - 11

3 - 11

Fault Location Diagram

System Not Working Correctly.

Yes

Do Supply and Fuse Test 1.

Record voltage V1.

Supply OK ?

Do Harness Wiring Continuity & Short Circuit Test 5.

Repair as required.

OK Now ?

Yes Done

No No

No

Is the transducer supply OK ?

No

Yes

Check ignition ON, fuse C2, battery condition, test box connections. Repair as required.

OK Now ?

Do Transducer Supply Test 2.

Record voltage V2.

OK Now ?

Yes

Done

Check for uneven mounting surfaces or bolts tightened correctly.

Yes Done

No

Check ignition ON, fuse C2, battery condition, test box connections. Repair as required.

Is the display box OK ?

No

Yes

Do Display Box Functional Test 3 and re-calibrate OK Now ?

Yes Done

No To next page ...

Replace display box.

Are the transducer output signals OK ?

Yes

No

Do Transducer Output Tests 4 & 6.

Record voltages V3, V4.

OK Now ?

Yes Done

No

9803/3675

Issue 1

Electrics

Section C

Section C

Load Moment Indicator

3 - 12

3 - 12

Fault Location Diagram (continued)

Fit new transducer and re-test

... From previous page

No Can the display box be re-calibrated

No

No Do transducer output test OK Now ?

Check transducers fixed securely ?

Yes Yes

Has frequent re-calibration been required ?

Suspect faulty display box.

Renew display box OK Now ?

Yes

Possible transducer slipping. Remove transducer, clean surfaces and re-torque bolts to 70Nm OK Now ?

Yes Done

Yes

Yes Done

Suspect faulty transducer

No

Check axle oscillates freely

9803/3675

Issue 1

Section E

Hydraulics

Section E

i

i

Contents

Schematic Diagram

9803/3675

Page No.

2-1

Issue 1

Section E

Hydraulics Schematic

2-1

Section E 2-1

Component Key C F LS P1 S S1 T X 1A 1B 1C 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 3 3A 3B 3C 5A 5B 5C 5D 5E 7 7A 10 11 12 13 14 15 16 17 17A 17B 17C 17D 17E 18 19 20 21 22 23

Cap Filter Load Sensing line Main pump Suction strainer Main pump suction line Tank Pressure test point Neutral circuit feed line Neutral circuit return line Steer circuit return line Valve block Main relief valve (M.R.V.) Auxiliary 2 spool Auxiliary 1 spool Lift spool Tilt spool Extension spool Auxiliary relief valve (A.R.V's) Auxiliary relief valve (A.R.V's) Load hold check valves (L.H.C.V's) Steer unit assembly Steer valve Shock valves (option) Relief valve Front steer ram Rear steer ram Steering compensation ram Brake packs Steering alignment valve Q Fit Carriage pin locking Q Fit Carriage manual diverter valve Lift ram check valve Lift ram Displacement ram Tilt ram Tilt ram check valve Extension ram check valve Extension ram Brake charge/priority valve Priority valve Distributor valve Pilot valve Relief valve Brake pressure switch Accumulator Brake valve Auxiliary 1 quick release couplings Auxiliary 2 quick release couplings Steer mode valve One-way restrictor

9803/3675

Issue 1

Hydraulics

Section E

Section E

Schematics

2-2

2-2

20

7

21

C T

10

F 7A

11

S

14

S1

13

P1 17 X 17A

12 1C T

15

EF 3

P

P 3C

F

17D T

F

LS

LS

16

17C

17E

17B 3A 23

A2

1B

23

1A

2

A1 X

18 2H

2H

2H

2G

2G

2G

3B 2A

3B

R

18 19

L 5C 5E 5B

2F

2E 2J

2D 2J

2J

5A

2B

2C 2J

5D

5D

2J B

22

A

5D

5D 397540

T

9803/3675

P

Issue 1

Section H

Steering

Section H

i

i

Contents

9803/3675

Page No.

Circuit Description Steer Unit Operation Steer Mode Valve Operation

1-1 1-1

Steer Mode Valve Checking Solenoid Operation Removal Replacement

2-1 2-1 2-1

Issue 1

Section H

Steering

Section H

Circuit Description

1-1

1-1

T

F S

S1 P1 17 X 17A

EF T

3

P

P 3C

T LS

LS 17C

3D

To brake circuits

3A

3B

3B

R

L 5C 5E 5A 5B A

B 22B

22

Z

Y

W

X

397541

22A T

9803/3675

P

Issue 1

Section H 1-2

Steering

Section H

Circuit Description

Note 1: The schematic shows priority valve 17A in the position it adopts during a turning operation.

Note 2: Port EF is connected to the main control valve block to provide lift end and auxiliary services.

Steer Unit Operation Neutral Whenever the steering wheel is stationary, irrespective of the position of the steered road wheels, steer unit 3 adopts the neutral position. The inner spool and sleeve are held in neutral by the centring springs. As the steer unit is ‘closed centre’ the flow from the pump is dead-ended by the unit.

This is sensed by the steering priority valve, whic directs flow to port EF. Turning Turning the steering wheel moves the inner spool a few degrees relative to the outer sleeve. This sends a pressure signal to relief valve 3C and, through the LS port, back to priority valve 17A which adopts the position shown on the schematic. Flow from priority valve 17A enters steer unit 3 via port P and non-return valve 3D. The relative movement between the inner spool and outer sleeve directs pressure oil through 6 of the 12 holes in the bottom of the outer sleeve. The metering unit is linked to the spools by a cross pin. As the steering is operated the oil is diverted by the inner spool to the stator. The rotor lobes pump the oil out via steer mode valve 22 to the appropriate steering ram(s), as described in Steer Mode Valve Operation and the required degree of turn is executed.

During a steering operation, oil returns to tank via steer unit 3, port T. When the ram(s) reach full stroke, the pump flow is dead ended, a higher pressure signal is felt at relief valve 2B which opens to route excess oil back to tank or to the control valve, as appropriate.

1-2

Steer Mode Valve Operation 2 Wheel Steer The steer mode valve directs the flow of oil from the steer unit to the appropriate axle(s) for the steer mode selected.

The valve is controlled by four solenoids which are energised according to the position of the steer mode selector switch in the cab (see the Electrical Schematic in Section C).

The solenoids energised for each mode are shown in the table below.

Mode Selected

Solenoid(s) Energised

2WS

W

4WS

X, Y

CRAB

X, Z

When 2 wheel steer is selected, solenoid W is energised and valve spool 22A is in the position opposite to that shown. In this state, oil flows through the steer mode valve, entering and leaving via ports P and T, according to the direction determined by steer unit 3. The position of spool 22B has no effect.

When either 4 wheel steer or crab steer is selected, solenoid X energises and spool 22A moves to the position where oil flows through the valve to spool 22B. Selection of 4 wheel steer energises solenoid Y; spool 22B is then in the position shown. Selection of crab steer energises solenoid Z; spool 22B is then in the position opposite to that shown.

Note: In the event of a power failure, e.g. fuse C6 blowing, the valve spools will remain in the state they are at the time.

Steer rams 5A and 5B, mounted on the front and rear axles respectively, provide the required turning moment.

Compensation ram 5C is included in the circuit in order to make up the difference in oil volume between the head side and rod side of the steering rams.

If it were not included, then, in 4 wheel steer and crab steer modes, pressure would be applied to the head side of one steer ram and the rod side of the other. As the volumes are unequal, this would result in unequal movement of the rams and, consequently, unequal movement of the wheels.

The inclusion of the compensation ram ensures that the flow is always head side to head side and rod side to rod side.

9803/3675

Issue 1

Section H

Steering

Section H 2-1

Steer Mode Valve

2-1

Checking Solenoid Operation

Removal

The solenoids operate according to the steer mode selected (see table below). 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.

1

Disconnect the hoses at A and B. Label the hoses and cap the ends to prevent the ingress of dirt.

2

Disconnect the electrical connection C to each of the solenoids. Label each connector before removal.

3

Unscrew retaining screws D and remove the valve.

Mode Selected

Solenoid(s) Energised

2WS

W

4WS

X, Y

Replacement

CRAB

X, Z

Replacement is the reverse of Removal.

If a solenoid is not energised proceed as follows until the reason is established: a

Check that fuse C6 is intact. If not, renew and then check that all steer mode solenoid combinations function correctly.

b

If the fuse is intact remove the electrical connector from the malfunctioning solenoid(s) and check that the 24V supply is present across the connector pins. If not, check the supply circuit.

c

Check the solenoid resistance which should measure a few ohms (if unsure 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.

Torque Settings Item D

Nm 28

X

A

B

C

P

lbf ft 21

V

W

kgf m 2.9

T

A B

Z Y

C

D

9803/3675

A292780

Issue 1

Section K

Engine

Section K

i

i

Contents Technical Data

1-1

Machine Start-up Procedure

2-1

Category ‘C’ Safety System Introduction Inlet System Exhaust System Control System Operation Inlet Shutdown Valve Overspeed Spring Adjustment Replacing a Broken Tension Pin Webasto Water Heater Introduction Operation Heater Unit Fault Finding General Failure Symptoms Failure Symptoms After Switch-off Upon Failure Electrical Connections Heater Unit - Removal and Refitting Circulation Pump - Replacement Temperature Limiter - Replacement Temperature Sensor - Replacement Combustion Air Fan - Replacement Replacement of Burner, Flame Sensor and Glow Plug Burner Head - Replacement Heat Exchanger - Replacement Visual Inspection Electrical Component Testing

9803/3675

Page No.

3-1 3-1 3-1 3-1 4-1 5-1 5-2

8-1 8-2 8-3 8-5 8-5 8-6 8-7 8-8 8-9 8 - 10 8 - 10 8 - 12 8 - 13 8 - 15 8 - 16 8 - 17 8 - 18

Issue 1

Section K 1-1

Engine Technical Data

Type:

JCB diesel engine, 4 cylinder, water cooled

Build Codes:

AR 50997 - naturally aspirated, low emission, 57.5kW (77 HP)

Bore (nominal)

103mm (4.055 in)

Stroke

127mm (5.000 in)

Swept Volume

4 litres (243 in3)

Compression Ratio

17.25:1

Induction System Air Cleaner Type

2 stage, dry element

Safety System

Category ‘C’

Section K 1-1

For further engine details see Engine Manual Publication No. 9806/2140.

*

9803/3675

Issue1

Section K

Section K

Engine Machine Start-up Procedure

2-1 1

The battery isolator must be on before attempting to start the engine.

2

The parking brake A 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 parking brake is engaged.

3

Put the Forward/Reverse lever B in neutral. The engine will not start unless the forward/reverse lever is in neutral.

4

Put the gear lever C in neutral.

5

Push the shutdown valve operating lever D to the start/reset position (down) and hold.

2-1

F

A

Note: If the engine has been running previously, it will not be possible to reset the engine safety shutdown system for a period of at least 30 seconds after shutdown due to the high engine inlet system vacuum. DO NOT attempt to push the operating lever to the start/reset position against this vacuum as use of excessive force will cause severe damage to the valve mechanism.

B

! WARNING

E

If the engine safety system trips whilst the machine is being used in a hazardous area, DO NOT ATTEMPT TO RE-START until advice has been obtained from the person in authority and the cause of the shutdown found and corrected.

C

0088

6

Fully depress the accelerator pedal E and hold it down.

Turn the starter switch to position HS and hold it there until the engine starts. Once the engine has started, release the starter key. The switch will return to position IGN. Ease off on the accelerator pedal to reduce engine speed.

S240311

If the outside temperature is low, say 0°C (32°F) or below, turn the starter switch key to the 'heat' position H for approximately 15 seconds to warm the engine induction manifold.

D

If the engine has not started after 20 seconds, release the starter key. Wait two minutes before attempting another start. This will allow the starter motor to cool down.

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores resulting in excessive oil consumption could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).

7

Once the engine has started, check that all the warning lights have gone off. Do not race the engine until the engine oil pressure low light F has gone out. Check that the audible alarm is silent.

9803/3675

397340

Note: If any warning lights fail to go off, or come on while the engine is running, stop the engine as soon as it is safe to do so.

8

Wait for a further seven seconds and then return the shutdown valve operating lever D to the neutral (mid) position.

9

If the engine will not start due to a flat battery, it can be started using the inter-vehicle start connector.

Issue 1

Section K

Section K

Engine Category ‘C’ Safety System

3-1

3-1

Introduction The Category ‘C’ Safety System has been designed to the Ministry of Defence PDCSS Specification 308. It shuts down the engine on detecting a coolant temperature of 105oC and/or engine overspeed.

The Safety System comprises the inlet system, the exhaust system and the control system.

Inlet System The main components of the inlet system are an inlet adaptor A, a shutdown valve B and a manual start/reset/emergency stop control C. Note:The valve operating gear is manufactured from stainless steel and must not be painted.

Exhaust System

C

The exhaust sytem consists of a spark arrestor D, a flexible exhaust E, silencer F and fume diluter G. 397340

Control System The operation of the inlet shutdown valve is controlled by a 24V dc solenoid valve H.

G

F

E

B A

H 393930 393930

9803/3675

Issue 1

Section K 4-1

Section K

Engine Category ‘C’ Safety System

4-1

Operation When reset/emergency stop lever is in the down position A, the cable mechanism causes the inlet shutdown valve to be held open to start the engine. The control cylinder is retained in the open position by an oil operated plunger B. The plunger holds the trip lever C until the pressurised oil feed from the engine is shut off by the remote solenoid operated valve allowing its release. This occurs if the system detects flammable gas or vehicle over temperature.

The trip lever overspeed spring D also allows the inlet shutdown valve to close with the plunger up. This occurs when an engine overspeed condition is detected.

E n

For emergency stop operation, reset/emergency stop lever is pulled up E, moving the cable in the direction of arrow E, tripping the roller over the plunger. Always ensure that the cable control is re-centred after use.

s

A

To reset the shutdown valve, push and hold down the reset/emergency stop lever in the 'reset' (down) position until maximum oil pressure is achieved (approximately seven seconds), then return the control to the neutral (mid) position.

397340

Note: If the engine has been running previously, it will not be possible to reset the engine safety shutdown system for a period of at least 30 seconds after shutdown due to the high engine inlet system vacuum. DO NOT attempt to push the operating lever to the start/reset position against this vacuum as use of excessive force will cause severe damage to the valve mechanism.

D C

B

s

A

397580

9803/3675

E n

397580

Issue 1

Section K

Section K

Engine Category ‘C’ Safety System

5-1

5-1

Inlet Shutdown Valve Overspeed Spring Adjustment The complete inlet system, from the air filter to the engine MUST be fully assembled before attempting to adjust the overspeed spring setting. An accurate setting cannot otherwise be achieved.

3

When the engine is fully warmed up, slacken locknut A, remove locking wire B and adjust the overspeed spring as follows: a

1

2

Fully warm up engine (some initial adjustment of the inlet shutdown valve may be necessary to enable the engine to run at a suitable speed, see item 3b below.

b If the existing setting gives shutdown below engine maximum rpm, turn the adjuster screw C one turn clockwise and recheck. Continue this with finer adjustments if necessary until the inlet shutdown valve gives shutdown at or just below maximum rpm.

Use the control arm to reset the valve.

Note: If the engine has been running previously, it will not be possible to reset the engine safety shutdown system for a period of at least 30 seconds after shutdown due to the high engine inlet system vacuum. DO NOT attempt to push the operating lever to the start/reset position against this vacuum as use of excessive force may result in breakage of the tension pin securing the inner assembly of the shutdown valve.

c

0088

If the existing setting does not give shutdown, turn adjuster screw C two or more turns anti-clockwise as necessary to give shutdown below maximum rpm and then adjust as above.

d Turn adjuster screw C one full turn clockwise.

! WARNING If the engine safety system trips whilst the machine is being used in a hazardous area, DO NOT ATTEMPT TO RE-START until advice has been obtained from the person in authority and the cause of the shutdown found and corrected.

Accelerate the engine to maximum rpm.

e

Rapidly accelerate the engine up to maximum rpm three or four times. If there is any tendency for the inlet shutdown valve to actuate, repeat steps a to d above.

4

Tighten locknut A and wire-lock (use new locking wire).

5

Check the emergency stop using lever.

A B C

397550

9803/3675

Issue 1

Section K

Section K

Engine Category ‘C’ Safety System

5-2

5-2

Inlet Shutdown Valve (continued) Replacing a Broken Tension Pin 1

Disconnect the inlet hose A from the inlet shutdown valve.

2

Remove the five button socket screws and washers B securing cover plate C.

3

Remove cover plate C to gain access to the inlet shutdown valve mechanism.

4

Ensure that all parts of the broken tension pin are removed. Foreign objects left in the inlet shutdown valve mechanism may cause further damage.

5

Fit a new tension pin D ensuring that the split in the pin is aligned with the arrow E.

6

Clean mating faces of cover plate and inlet shutdown valve from silicone sealant.

7

Apply a new thin film of silicone sealant, replace the cover plate and secure using the five button socket screws and plain washers.

8

If the inlet shutdown valve has been removed when fitting a new tension pin, a new gasket MUST be used.

C B

A 397560

9

Reconnect the inlet hose A to the inlet shutdown valve.

10

Check that the overspeed setting is correct and adjust if necessary (see Inlet Shutdown Valve - Overspeed Spring Adjustment).

D

E

393871

9803/3675

Issue 1

Section K

Section K

Engine Webasto Water Heater

8-1

8-1

Introduction Winterised machines are fitted with a fuel burning water heater to give efficient cold starting and to warm the operator’s cab by automatic preheating of the engine coolant, heating of the batteries and operation of the cab heater fan.

The system consists of a fuel-burning heater A, controlled by a digital timer in the cab (not shown), a heating element under each battery B and C, and the necessary hoses and fittings to circulate the warmed coolant.

The water is heated in the heater unit A and then flows via the outside battery heating element B, the inside battery heating element C and the stop valve D to the cab heater E. Return flow from the cab heater F returns to the heater unit.

The system is ‘teed’ into the normal heater circuit between the water pump G and the radiator H.

For operating details, refer to the Operator’s Handbook.

!DANGER DO NOT operate the water heater in a confined space such as a workshop or garage. The exhaust fumes may kill you or someone else.

8-4-2-4

!WARNING

Switch off the heater when the machine is being refuelled. There is a danger of fire or explosion.

D

At locations where combustible vapours or dust accumulation can form (e.g. in the vicinity of fuel, coal, saw-dust and grain depots and so forth) the heater must be switched off due to the danger of explosion.

to

bas

The heater must be inspected by a qualified person annually, preferably prior to the heating season commencing.

We

In the case of severe smoke development for an extended period of time, unusual combustion noises or fuel smell, the heater must be placed out of operation by removing the fuse and may only be re-started after it has been inspected by qualified personnel.

A

G H

F E B 397720

C

9803/3675

Issue 1

Section K 8-2

Section K

Engine Webasto Water Heater

8-2

Operation Switch-on

MO

B

When the Instant Heat push button A on the timer unit (in the cab) is operated, the Heater On indication B on the timer illuminates.

P

Circulation pump, glow plug, and combustion air fan are put into operation.

A

Heating Operation After approx. 50 seconds, combustion commences with the automatically controlled heating operation in full load for a maximum of 2 hours.

The vehicle's own heating blower starts to operate only after the heat carrier (coolant) has accumulated enough heat.

After reaching the preset temperature, heating performance precision control will take over in stages down to the lowest part load operation.

Control Operation If the coolant temperature rises up to the control idle threshold, the heater enters the control idle phase. The circulation pump, the vehicle's own blower, and the operating indicator remain in operation during the control idle period.

After the coolant has cooled down to the precoded reactivation temperature, the heater resumes operation.

If the water heater's water temperature is above the rated temperature but has not yet reached the threshold for control idle with the temperature dropping within 10 minutes back to rated temperature (after reaching it for the first time), the water heater reverts to the 9.1kW heating stage. Should the rated temperature be obtained after 10 minutes, there will be an automatic reactivation only up to 7.6kW. Switch-off When switching the heater off, the operation indicator on the timer/switch extinguishes. Combustion ends and run-down is initiated. Circulation pump and combustion air fan, however, continue operation to cool down the heater (rundown) and are automatically deactivated after about 90 seconds. A reactivation of the heater during run-down is permitted.

397610

After the fault has been removed, an error lockout condition exists. Reset by switching off the heater and switching on again.

In the case of overheating, the temperature limiter must be reset after the unit has cooled down.

!CAUTION To avoid damage to the component, do not attempt to reset the temperature by force whilst hot.

Fault Codes The following fault codes are displayed on the timer display after a Switch-off Upon Failure condition has occured.

F F F F F F F F F F F

01 02 03 04 05 06 07 08

No start (after 2 start attempts) Flame-out during operation (repeated > 5) Voltage too low or too high Premature flame detection Flame sensor open or short circuit Temperature sensor open or short circuit Dosing pump open or short circuit Fan motor open or short circuit or wrong speed of fan motor 09 Glow plug open or short circuit 10 Overheating 11 Circulation pump open or short circuit

After five short signals the following long flash pulses are counted:

In the event of a flame-out during operation, fuel is delivered foe a maximum of 90 seconds.

No start (after 2 start attempts) Flame-out during operation (repeated > 5) Voltage too low or too high Premature flame detection Flame sensor open or short circuit Temperature sensor open or short circuit Dosing pump open or short circuit Fan motor open or short circuit or wrong speed of fan motor 9x Glow plug open or short circuit 10x Overheating 11x Circulation pump open or short circuit

After switch-off by low volage protection (below 21 volts), for more than 20 seconds, the fuel supply is stopped.

For further details and remedial action, see Failure Symptoms After Switch-off Upon Failure.

Switch-off Upon Failure In the case of a no-flame condition, fuel is delivered for a maximum of 180 seconds.

9803/3675

1x 2x 3x 4x 5x 6x 7x 8x

Issue 1

Section K

Section K

Engine Webasto Water Heater

8-3

8-3

Heater Unit The water heater operates independently from the vehicle engine and is connected to the cooling system, the fuel system, and the electrical system of the vehicle.

The heater operates intermittently and is controlled by the temperature sensor.

Dependent on the deviation of the current coolant temperature from the rated value of the temperature sensor, combustion performance is continuously controlled within the range from 1.8 to 9.1 kW, for up to 2 hours after equipment activation.

Component Key 1 2 3 4 5 6 7 8 9 10 11

Combustion air fan Fuel connection Temperature sensor Temperature limiter Heat exchanger Coolant inlet Circulation pump Coolant outlet Exhaust outlet Combustion air inlet Control unit

The water heater consists of a combustion air fan, heat exchanger, burner insert with combustion tube and a circulation pump.

For control and monitoring, a control unit, flame sensor, glow plug, temperature sensor and temperature limiter are located inside the unit. A timer unit is mounted in the cab.

4 3 5 2

1 6

11

7 9

8

10

9803/3675

Issue 1

Section K 8-4

Section K

Engine Webasto Water Heater

8-4

Heater Unit (continued) 12 Control unit The control unit is the central controlling device for sequencing and monitoring the combustion operation.

13

Combustion air fan The combustion air fan delivers the air required for combustion from the combustion air inlet to the burner insert.

Temperature limiter 12 The overheat protection (bimetal) responds at a coolant temperature above 105oC to switch off the heater.

Temperature sensor 13

398910

14 15

The temperature sensor senses the coolant temperature in the heat exchanger as an electrical resistance. This signal is fed to the control unit for processing.

Heat exchanger 14 The heat exchanger transfers the heat provided by combustion to the coolant circuit.

Combustion tube 15

398920

The combustion of the fuel/air mixture takes place inside the combustion tube.

Burner insert 16

16 The burner insert is located within the combustion tube and distributes fuel across the burner cross-section.

Glow plug 17 The glow plug, located in the burner insert, ignites the fuel/air mixture at the start of heater operation.

Flame sensor 18

17

The flame sensor changes its electrical resistance dependent on its temperature. It monitors the flame operating condition throughout the heater operation and its signals are routed to the control unit.

398870A

18

Circulation pump 19 The circulation pump provides for circulation of the coolant in the vehicle and heater circuits. It is switched on and off by the control unit throughout the time of heater operation.

Dosing pump

19

The dosing pump (not shown) supplies fuel to the heater in response to signals from the control unit.

398930

9803/3675

Issue 1

Section K

Section K

Engine Webasto Water Heater

8-5

8-5

Fault Finding This section describes fault finding procedures for the Water Heater.

!CAUTION Fault finding requires profound knowledge about structure and theory of operation of heater components and may only be performed by skilled personnel.

Troubleshooting is normally limited to the isolation of defective components.

After correction of a failure, a functional test must be performed in the vehicle; before doing this, switch the heater off and on again.

General Failure Symptoms The following table lists possible, general failure symptoms.

Note: In many cases, the probable cause of failure may be the condition of the burner. Perform a visual inspection of the burner.

The following defects are not included in the trouble shooting procedures. Before troubleshooting, check for and eliminate these defects: corrosion on connector loose contact on connector wrong crimping on connector corrosion on electrical wiring and fuses corrosion on battery terminals Failure Symptom

Probable Cause

Heater switches off automatically

No combustion after start or repeat start Control unit goes to error lockout Switch heater off and on again

9803/3675

Remedy

Flame extinguishes during operation

If no-heating condition persists, carry out further rectification (see Failure Symptoms After Switch-off On Failure)

Heater overheats due to lack or loss of coolant

Replenish coolant After unit cools down, push the button of temperature limiter before continuing

Switch-off caused by temperature limiter

After unit cools down, push the button of temperature limiter before continuing. If fault still occurs, replace temperature limiter

Issue 1

Section K

Section K

Engine Webasto Water Heater

8-6

8-6

Failure Symptoms After Switch-off Upon Failure Fault codes are displayed on the timer display after a Switch-off Upon Failure condition has occured. After five short pulses, the following long flash pulses should be counted.

No of Flashes -

Failure Symptom

Probable Cause

Remedy

No function

Electrical wiring, fuses

Check fuses Check supply connections (see Pin Assignment) Replace control unit

Control unit defective 1

No start

Fuel system

Combustion air or exhaust duct Burner 2

Flame-out during operation

Fuel supply

Burner

Check fuel level Check fuel filter Bleed fuel system Check combustion air or exhaust duct for foreign matter and clean as required Clean or replace burner as necessary Check fuel level Check fuel filter Bleed fuel system Clean or replace burner as necessary

3

Low voltage

Power supplies

Check battery Check electrical connections

4

Flame sensor continuously hot

Flame sensor defective

Replace flame sensor

5

Flame sensor defective

Wiring

Check wiring for damage, open or short circuit Replace flame sensor

Flame sensor defective

6

Temperature sensor defective

Wiring Temperature sensor defective

7

Dosing pump or overheat defective

Coolant circuit

Wiring Dosing pump defective 8

Combustion air fan defective

Wiring Combustion air fan defective

9

Glow plug defective

Wiring Glow plug defective

9803/3675

Check wiring for damage, open or short circuit Replace temperature sensor

Check coolant level Bleed coolant circuit Reset temperature limiter Check wiring for damage, open or short circuit Replace dosing pump Check wiring for damage, open or short circuit Replace combustion air fan Check wiring for damage, open or short circuit Replace glow plug

Issue 1

Section K 8-7

Section K

Engine Webasto Water Heater

8-7

Electrical Connections Main Connector (X1) Pin Assignment 1 2 3 4 5 6 7 8 9 10 11 12

Glow plug + Temperature limiter + Flame sensor + Temperature sensor + Circulation pump + Combustion air fan + Combustion air fan Circulation pump Temperature sensor Flame sensor Temperature limiter Glow plug -

Main Connector (X1) Disconnecting Wires All connections from electrical components are joined in connector X1. Prior to removal of a component, the relevant electrical connections have to be disconnected.

Connectors X1 on heater and X12 on control unit must be disconnected and reconnected after making electrical connections.

1

Remove top cover from heater.

2

Using a suitable locally manufactured tool A, withdraw lock wedge B from connector using the hook end.

3

Use the screwdriver end to press down relevant locking tab C and, keeping tab depressed, withdraw cable(s) from connector.

B

Reconnecting Wires 1

Slide cable into relevant contact pocket until locked.

2

Using screwdriver end, insert lock wedge into connector and press in until locked.

3

Fit top cover.

9803/3675

A

Issue 1

Section K 8-8

Engine Webasto Water Heater

Section K 8-8

Heater Unit - Removal and Refitting Removal 1

Disconnect batteries.

2

Remove top cover.

3

Disconnect cable harness from heater unit connectors X1, and connectors X12 and X13 from control unit.

4

Disconnect fuel inlet and plug.

5

Loosen hose clamps and disconnect coolant hoses from heater unit.

6

Disconnect combustion air intake and exhaust outlet.

7

Remove three nuts and washetrs from heater mount and remove heater unit.

Refitting 1

Locate heater unit in position and secure with three nuts and washers.

2

Reconnect coolant hoses. Tighten hose clamps to 5Nm.

3

Refit fuel inlet connector on heater.

4

Refit coonections for combustion air inlet and exhaust outlet to heater.

5

Reconnect cable harness to heater unit connectors X1, and connectors X12 and X13 to control unit.

6

Refit top cover.

7

Reconnect batteries.

8

Bleed fuel supply system and coolant circuit.

9803/3675

Issue 1

Section K 8-9

Engine

Section K

Webasto Water Heater

8-9

Circulation Pump - Replacement Removal 1

Remove heater unit - see Heater Unit - Removal and Refitting.

2

Disconnect relevant electrical connections - see Electrical Connections.

3

Remove screws 1 and clamp 2.

4

Remove circulation pump 3.

5

Discard gasket 4.

4

3

Refitting 1

Apply acid free grease (e.g. Vaseline) to new gasket 4.

2

Fit pump 3 in position, securing with clamp 2 and screws 1. Tighten screws to 3Nm.

3

Remake electrical connections - see Electrical Connections.

4

Refit heater unit - see Heater Unit - Removal and Refitting.

9803/3675

2

1

Issue 1

Section K

Engine

Section K

Webasto Water Heater

8 - 10

8 - 10

2

1

3 5 4 6

9803/3675

Issue 1

Section K

Section K

Engine Webasto Water Heater

8 - 11

8 - 11

Temperature Limiter - Replacement

Temperature Sensor - Replacement

Removal

Removal

1

Remove heater unit - see Heater Unit - Removal and Refitting.

1

Remove heater unit - see Heater Unit - Removal and Refitting.

2

Disconnect relevant electrical connections - see Electrical Connections.

2

Disconnect relevant electrical connections - see Electrical Connections.

3

Remove clamp 1 and withdraw protective cap 2.

4

Using a suitable screwdriver, carefully lever off retaining clip and remove temperature limiter 3.

Note: Whenever the temerature limiter is removed, it must be renewed.

Refitting

!WARNING Escaping hot coolant may cause scalding.

3

Unscrew temperature sensor 5 and remove, together with O-ring 6.

4

Discard O-ring 6.

Refitting

!CAUTION

1

Apply acid free grease (e.g. Vaseline) to O-ring 6.

Incorrect installation of the temperature limiter will cause severe damage to the heat exchanger.

2

Screw temperature sensor 5, with O-ring 2, into heat exchanger 4. Tighten screws to 1.5Nm.

3

Remake electrical connections - see Electrical Connections.

4

Refit heater unit - see Heater Unit - Removal and Refitting.

1

Insert temperature limiter 3 into the heat exchanger 4 and press down retaining clip.

Note: Ensure that the retaining clip is heard to click fully in place. Only then is the temperature limiter in the proper installation position. If the clip does not audibly engage: clean the seat of the temperature limiter on the heat exchanger clean groove on heat exchanger ensure that locking cams are present on both sides of the spring. Renew temperature limiter if necessary.

2

Fit protective cap 2 in position, securing with clamp 1.

Tighten clamp to 1Nm.

3

Remake electrical connections - see Electrical Connections.

4

Refit heater unit - see Heater Unit - Removal and Refitting.

9803/3675

Issue 1

Section K

Section K

Engine Webasto Water Heater

8 - 12

8 - 12

Combustion Air Fan - Replacement Removal

Refitting

1

Remove heater unit - see Heater Unit - Removal and Refitting.

1

Locate profiled packing ring 3 carefully; do not squeeze.

2

Disconnect relevant electrical connections - see Electrical Connections.

2

Fit combustion air fan 2, together with packing ring 3 in position in burner head. Secure with screws 1.

Tighten screws to 3Nm.

3

Remove screws 1.

3

Refit control unit 4 to combustion air fan.

4

Pull combustion air fan 2 from burner head and remove, together with profiled packing ring 3 and control unit 4.

4

Remake electrical connections - see Electrical Connections.

5

Remove control unit 4 from combustion air fan.

5

Refit heater unit - see Heater Unit - Removal and Refitting.

6

Discard profiled packing ring.

1

3 2 4

9803/3675

Issue 1

Section K

Section K

Engine Webasto Water Heater

8 - 13

8 - 13

9 8

6 5

11

10

4 12 3

4

2

1 7

9803/3675

Issue 1

Section K 8 - 14

Section K

Engine Webasto Water Heater

8 - 14

Replacement of Burner, Flame Sensor and Glow Plug Removal

Refitting

1

Remove heater unit - see Heater Unit - Removal and Refitting.

1

Locate swirl ring 11 on burner 9.

2 2

Remove combustion air fan - see Combustion Air Fan Replacement.

Carefully and fully insert flame sensor 12 and glow plug 13 into burner 9 against stop and slide grommets 5 and 6 down slots in housing of combustion tube 7.

3

Remove screw 1 and washer 2.

3

Position burner 9 and grommet 8 in burner head 10.

4

Remove nuts 3 and withdraw bracket 4.

5

Withdraw grommets 5 and 6 from slots in housing of combustion tube 7.

6

Withdraw grommets 8 and burner 9 from burner head 10 and remove, together with swirl ring 11.

7

Pull flame sensor 12 and glow plug 13 from burner and remove.

8

Carry out visual inspection for damage of removed components - see Inspection and Testing.

9

!CAUTION When performing the following step, ensure that cables of flame sensor 12 and glow plug 13 are routed as shown below.

Discard profiled backing ring.

12 13

9803/3675

4

Slide insulation 14 onto bracket 4 and locate bracket in position.

5

Secure bracket 4, using nuts 3. Torque tighten nuts 3 to 3Nm.

6

Secure fuel line, using screw 1 and washer 2. Torque tighten screw 1 to 3Nm.

7

Refit combustion air fan - see Combustion Air Fan Replacement.

8

Remake electrical connections - see Electrical Connections.

9

Refit heater unit - see Heater Unit - Removal and Refitting.

Issue 1

Section K

Section K

Engine Webasto Water Heater

8 - 15

8 - 15

Burner Head - Replacement Removal

Refitting

1

Remove heater unit - see Heater Unit - Removal and Refitting.

1

Insert burner head 3 into heat exchanger 4, align as necessary and secure with V-clamp 2. Torque V-clamp attachment screw 1 to 3Nm.

2

Remove combustion air fan - see Combustion Air Fan - Replacement.

2

Remove burner, flame sensor and glow plug - see Replacement of Burner, Flame Sensor and Glow Plug.

Refit burner, flame sensor and glow plug - see Replacement of Burner, Flame Sensor and Glow Plug.

3

Refit combustion air fan - see Combustion Air Fan Replacement.

5

Refit heater unit - see Heater Unit - Removal and Refitting.

3

4

Remove attachment screw 1 and remove V-clamp 2.

5

Withdraw burner head 3 from heat exchanger 4 and remove.

4

2

1

3

9803/3675

Issue 1

Section K 8 - 16

Section K

Engine Webasto Water Heater

8 - 16

Heat Exchanger - Replacement Removal

Refitting

1

Remove heater unit - see Heater Unit - Removal and Refitting.

1

Clip connector housing onto heat exchanger and engage connector in connector housing - see Electrical Connections.

2

Remove circulation pump - see Circulation Pump Replacement.

2

Refit burner head - see Burner Head - Replacement.

3

Refit burner, flame sensor and glow plug - see Replacement of Burner, Flame Sensor and Glow Plug.

3

Remove combustion air fan - see Combustion Air Fan - Replacement.

4

Remove temperature limiter - see Temperature Limiter - Replacement.

4

Refit temperature limiter - see Temperature Limiter Replacement.

Remove temperature sensor - see Temperature Sensor - Replacement.

5

Refit temperature sensor - see Temperature Sensor Replacement.

6

Refit combustion air fan - see Combustion Air Fan Replacement.

5

6

Remove burner, flame sensor and glow plug - see Replacement of Burner, Flame Sensor and Glow Plug.

7

Remove burner head - see Burner Head Replacement.

7

Refit circulation pump - see Circulation Pump Replacement.

8

Remove connector and connector housing -see Electrical Connections.

8

Refit heater unit - see Heater Unit - Removal and Refitting.

9803/3675

Issue 1

Section K

Section K

Engine Webasto Water Heater

8 - 17

8 - 17

Visual Inspection Visual Inspection of Burner

1

The starting air bore 9 must not be clogged, otherwise there will be no start. If necessary, remove the glow plug and carefully remove any contamination from the bore with a 1.5mm diameter wire. Refit glow plug.

Rear Wall with Metal Evaporator

9

The pilot flame exit bore 10 must not be clogged, otherwise there will be no start.

2

If it is, the burner must be replaced.

Note: Cracks, delaminations as well as black or other discolourations of the evaporator do not cause a burner failure and should be disregarded.

Carbon deposits on the evaporator surface (except for the pilot flame bore) are usual and must not be removed. When the load changes from full load to part load and vice versa, the burner is normally self cleaning.

8 3

Combustion Chamber The combustion chamber 11 must not be damaged (e.g. dented). This would cause insufficient combustion or coking of the heater, in this event, the burner must be replaced.

The air bores 12 must not be coked. Coked air bores may cause no start or insufficient combustion. Remove any deposit by careful scraping.

7 1 2 3 4 5

4 6

5

Combustion tube O-ring Flame sensor Insulation Glow plug

6 7 8 9

Housing Screw Bracket Starting air bore

Burner assembly Check security of housing and combustion chamber.

O-ring 2 must be a tight fit around the fuel chamber edge and must seal completely.

The gap 13 between housing and combustion chamber should be equal around the entire circumference.

Insulation 4 must be present and in good condition.

10 2

11

12 13 9803/3675

Issue 1

Section K

Engine Webasto Water Heater

8 - 18

Section K 8 - 18

Electrical Component Testing Temperature Sensor During electrical testing of the temperature sensor using a digital multimeter, the following readings should be obtained: Resistance at 25oC Test current

990 to 1010Ω < 1mA

Glow Plug During electrical testing of the glow plug using a digital multimeter, the following readings should be obtained: Resistance at 25oC Test current

1.3 to 1.44Ω < 5mA

Flame Sensor During electrical testing of the flame sensor using a digital multimeter, the following readings should be obtained: Cold Test Resistance at 25oC Test current

990 to 1010Ω < 5mA

Hot Test Resistance at 800 to 1000oC Test current

990 to 1010Ω < 5mA

9803/3675

Issue 1