JCB 8250 Fastrac Tractor Service Manual - 9803/8040-6 - PDF DOWNLOAD by www.heydownloads.com

Service Manual JCB 8250 Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-6

World Class Customer Support Copyright Â© 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section 1 General Information Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-2

Section 1 - General Information

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9803/8040-2

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Section 1 - General Information Contents Page No. Identifying the Machine Serial Numbers ........................................................................................ 1 - 1 Serial Number Plate ........................................................................... 1 - 1 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... Introduction ......................................................................................... Zinc Plated Fasteners (golden finish) ................................................. Dacromet Fasteners (mottled silver finish) ......................................... Hydraulic Connections ............................................................................. 'O' Ring Face Seal System ................................................................. 'Torque Stop' Hose System ................................................................

1-3 1-3 1-4 1-5 1-6 1-6 1-9

Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 10

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Section 1 - General Information Contents

1 - ii

Page No.

1 - ii

Section 1 - General Information Identifying the Machine Serial Numbers

Identifying the Machine Serial Numbers Serial Number Plate

Unit Identification

Each machine has a serial number plate located at X. The 17 digit Vehicle Identification Number (VIN), and the serial numbers of the engine and transmission are stamped on the plate.

The serial number of each major unit is also stamped on the unit itself as shown below. If a major unit is replaced by a new one, the serial number on the 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. Engine

Gearbox

Front axle

Rear axle

Fig 1.

Typical Vehicle Identification No. (VIN)

Fig 2. A

Manufacturing code

Machine range FT = Fastrac

Engine type

Transmission type

Vehicle max. speed

(gearbox & axle combination)

Fig 3.

40 = 40 kph 50 = 50 kph 65 = 65 kph F

1-1

Serial number

9803/8040-2

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Section 1 - General Information Identifying the Machine Serial Numbers

N Fig 4.

Fig 5.

Fig 6.

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9803/8040-2

1-2

Section 1 - General Information

Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Some external fasteners on Fastrac machines are assembled 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. The two types of fasteners can be readily identified by colour and part number suffix as follows: Fastener Type

Colour

Part Number

Zinc and Yellow

Golden finish

Z (e.g. 1315/3712Z)

Dacromet

Mottled silver finish

D (e.g. 1315/3712D)

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 fasteners. A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a Zinc and Yellow plated bolt. 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 and engine joint seams or internal applications. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

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9803/8040-2

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

Zinc Plated Fasteners (golden finish)

Metric - All Internal Hexagon Headed Cap Screws

Use the values on these pages only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

Diameter

Torque Settings

kgf m

lbf ft

0.2

1.5

0.6

4.5

1.1

1.9

4.7

M10

9.3

M12

159

16.2

117

M16

395

292

M18

550

406

770

568

1332 136

Metric Grade 8.8 Bolts Size

Torque Settings Nm

Diameter (mm) M5

(5)

kgf m lbf ft

Hexagon (A/F) mm 8

0.7

(6)

1.2

M20

(8)

3.0

M24

M10

(10)

5.7

M12

(12)

M16

(16)

244

180

M18

(18)

350

258

M20

(20)

476

352

M24

(24)

822

607

M30

(30)

1633 166

1205

M36

(36)

2854 291

2105

Metric Grade 10.9 Bolts Size

Torque Settings Nm

1-4

983

Verbus Ripp Bolts

Fig 7. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

kgf m lbf ft

Diameter (mm)

Hexagon (A/F) mm

(6)

1.6

(8)

M10

(10)

M12

(12)

137

101

M16

(16)

343

253

M20

(20)

657

485

M24

(24)

1157 118

853

9803/8040-2

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

Dacromet Fasteners (mottled silver finish)

Metric Grade 12.9 Bolts

Use the values on these pages only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process. Do not lubricate Metric Grade 8.8 Bolts

Bolt size

Torque Settings

Dia.

kgf m lbf ft

M6 x 1.0

1.5

M8 x 1.25

4.1

M10 x 1.5

8.2

M12 x 1.75

133

13.6

M14 x 2

225

166

Bolt size

Torque Settings

M16 x 2

350

35.7

258

Dia.

kgf m lbf ft

M18 x 2.5

463

342

M6 x 1.0

0.9

M20 x 2.5

654

482

M8 x 1.25

22.5

2.3

M24 x 3

1125 115

830

M30 x 3.5

2247 229

1657

M10 x 1.5

47.5

4.8

M12 x 1.75

8.2

M14 x 2

133

13.6

M16 x 2

200

20.4

148

M18 x 2.5

278

28.4

205

M20 x 2.5

392

289

M24 x 3

675

498

M30 x 3.5

1348 138

994

Metric Grade 10.9 Bolts Bolt size

Torque Settings

Dia.

kgf m lbf ft

M6 x 1.0

13.5

1.4

M8 x 1.25

3.6

M10 x 1.5

62.5

6.4

M12 x 1.75

115

11.7

M14 x 2

175

17.9

129

M16 x 2

300

30.6

221

M18 x 2.5

395

291

M20 x 2.5

559

412

M24 x 3

962

710

M30 x 3.5

1920 196

1-5

1416

9803/8040-2

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Section 1 - General Information Standard 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 1. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-6

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

SAE Tube Size

Thread Size

kgf m

lbf ft

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

9803/8040-2

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

Fig 8. Hoses 8-B screwed into adaptors 8-A seal onto an `O' ring 8-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-7

Note: Dimension 8-D will vary depending upon the torque applied.

Table 3. BSP Hose - Torque Settings Hexagon (A/F) mm

1/8

14.0

14.0 - 16.00

1.4 - 1.6

10.3 - 11.8

1/4

19.0

24.0 - 27.0

2.4 - 2.7

17.7 - 19.9

3/8

22.0

33.0 - 40.0

3.4 - 4.1

24.3 - 29.5

1/2

27.0

44.0 - 50.0

4.5 - 5.1

32.4 - 36.9

5/8

30.0

58.0 - 65.0

5.9 - 6.6

42.8 - 47.9

3/4

32.0

84.0 - 92.0

8.6 - 9.4

61.9 - 67.8

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

9803/8040-2

kgf m

lbf ft

1-7

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

1-8

in.

kgf m

lbf ft

1/8

20.0

2.1

15.0

1/4

34.0

3.4

25.0

3/8

75.0

7.6

55.0

1/2

102.0

10.3

75.0

5/8

122.0

12.4

90.0

3/4

183.0

18.7

135.0

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

9803/8040-2

1-8

Section 1 - General Information Standard Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 9. `Torque Stop' Hoses 9-B screwed into adaptors 9-A seal onto an 'O' ring 9-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 9-D, which acts as a physical stop. Note: Minimum dimension 9-E fixed by shoulder 9-D.

Table 5. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F)

1-9

in.

kgf m

lbf ft

1/8

14.0

1.4

10.0

1/4

19.0

27.0

2.7

20.0

3/8

22.0

40.0

4.1

30.0

1/2

27.0

55.0

5.6

40.0

5/8

30.0

65.0

6.6

48.0

3/4

32.0

95.0

9.7

70.0

38.0

120.0

12.2

89.0

1 1/4

50.0

189.0

19.3

140.0

1 1/2

55.0

244.0

24.9

180.0

9803/8040-2

1-9

Section 1 - General Information Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_3

Table 6. Type

Description

Part No.

Quantity

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.

4101/0651

50 ml

JCB Threadlocker and Sealer

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

– 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

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9803/8040-2

1 - 10

Section 2 Care and Safety Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-3

Section 2 - Care and Safety

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9803/8040-2

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Section 2 - Care and Safety Contents Page No. Safety Check List Introduction .............................................................................................. 2 - 1 Safety First .............................................................................................. 2 - 2 Safety - Yours and Others .................................................................. 2 - 2 General Safety ................................................................................... 2 - 2 Operating Safety ..................................................................................... 2 - 4 Maintenance Safety ................................................................................. 2 - 9

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Section 2 - Care and Safety Contents

2 - ii

Page No.

2 - ii

Section 2 - Care and Safety

Safety Check List Introduction T1-006

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

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

9803/8040-1

2-1

Section 2 - Care and Safety Safety Check List Safety First

Safety First As well as the warnings in this chapter, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices.

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.

General Safety

!MWARNING

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

!MWARNING 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

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

T1-007

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

BE ALERT

!MWARNING

BE SAFE

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

2-2

9803/8040-1

2-2

Section 2 - Care and Safety Safety Check List Safety First

!MWARNING

!MDANGER

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

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

8-1-2-4

!MWARNING

!MWARNING Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury. Switch off and do not use your mobile phone when refuelling the machine.

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

INT-3-3-9

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

!MWARNING Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1-1-6

!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

2-3

9803/8040-1

2-3

Section 2 - Care and Safety Safety Check List Operating Safety

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.

If the machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/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-2-1-2_2

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

!MWARNING Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

INT-2-1-9_4

!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

!MWARNING

INT-2-1-5

!MWARNING Engine The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6_1

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

!MWARNING 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. Get out of the cab into fresh air.

!MWARNING 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

INT-2-1-10

2-4

9803/8040-1

2-4

Section 2 - Care and Safety Safety Check List Operating Safety

!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.

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-2-2-5

!MWARNING

INT-2-1-1

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. INT-2-2-6

!MWARNING 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-2-2-9_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. INT-2-2-8

!MDANGER

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

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. INT-2-2-10

!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 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. INT-2-1-14

!MWARNING 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

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

2-5

9803/8040-1

2-5

Section 2 - Care and Safety Safety Check List Operating Safety

!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.

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

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.

INT-2-1-3

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

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.

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 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.

!MWARNING

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use selfcontained breathing apparatus. INT-3-2-7_2

!MWARNING Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened. INT-2-1-12

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

2-4-5-2_1

!MWARNING

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

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

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

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Section 2 - Care and Safety Safety Check List Operating Safety

!MWARNING

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

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

13-3-2-5

!MWARNING

13-1-1-13_1

!MCAUTION

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

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

13-2-1-2

13-2-2-8

!MWARNING

!MCAUTION

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

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

13-2-2-1_1

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

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

13-2-2-13

!MWARNING

13-1-1-5_2

!MWARNING When driving the machine on the road, use the accelerator pedal and not the hand throttle to control the engine speed. Always set the hand throttle to 'idle' before using the accelerator pedal. 13-2-1-8_1

!MWARNING When driving the machine on the road with an implement or trailer connected to the machine, the transport locks must be engaged to prevent unintentional operation of electronic linkage, front and rear PTO or external hydraulics. 13-2-4-13

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Section 2 - Care and Safety Safety Check List Operating Safety

!MCAUTION

!MWARNING

Electronic Control Unit The electronic control unit under the passenger's seat is protected by a cover. Do not use the machine with the cover removed.

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

0103

13-2-3-6

!MWARNING When operating PTO equipment, always observe the following safety precautions: Follow the instructions in the implement Operator Manual. Rotating equipment is dangerous. Do not wear loose fitting clothing when working close to rotating shafts. Always disengage the PTO, stop the engine and wait until the equipment stops, before: 1

Leaving the cab

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

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

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

!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

!MDANGER Leaving the machine in gear will not prevent it running away. Do not leave the driving seat under any circumstances unless the park brake is on. 13-2-1-10

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

13-2-1-6

!MWARNING

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

13-2-2-2

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

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Section 2 - Care and Safety Safety Check List Maintenance Safety

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.

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.

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. INT-3-1-3_2

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

0125

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

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

!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

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

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

!MCAUTION

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

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

INT-3-1-10_2

!MWARNING

!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 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.

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

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

!MWARNING

INT-3-1-6

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

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

2 - 10

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. INT-3-2-11

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions.

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.

GEN-1-9

!MCAUTION

INT-3-3-8_2

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

!MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: – Damaged hose ends – Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses

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

– Embedded armouring in outer covers – Displaced end fittings. INT-3-3-2

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

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

Thoroughly wash contaminated detergent and water.

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

5-3-1-9

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area

with

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Section 2 - Care and Safety Safety Check List Maintenance Safety DO NOT BURN FLUOROELASTOMERIC MATERIALS.

!MWARNING

If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately.

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

INT-3-3-5_2

!MWARNING

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

Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. 0094

GEN-1-12

!MWARNING

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

!MWARNING

INT-3-1-17

Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements. If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine. Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable no more than 0.6 metres (2 feet) from the part being welded. INT-3-1-15_2

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

!MWARNING 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

!MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock 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

!MWARNING Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine. INT-3-1-16

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING

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

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

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

0091

!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.

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

13-3-2-16

13-1-1-15

!MWARNING

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

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

!MWARNING

GEN-1-19

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

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

!MCAUTION 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

Stop the engine and block all four wheels.

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

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

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

BRAK-8-3_1

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Section 2 - Care and Safety Safety Check List Maintenance Safety

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

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Section 3 Maintenance Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

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Section 3 - Maintenance

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Section 3 - Maintenance Contents Page No. Routine Maintenance Service Requirements ............................................................................. 3 - 1 Introduction ......................................................................................... 3 - 1 Owner/Operator Support .................................................................... 3 - 1 Service/Maintenance Agreements ..................................................... 3 - 1 Initial Service and Inspection (100 Hours) .......................................... 3 - 1 Obtaining Replacement Parts ............................................................. 3 - 2 Health and Safety .................................................................................... 3 - 3 Lubricants ........................................................................................... 3 - 3 Battery ................................................................................................ 3 - 5 First Aid - Electrolyte .......................................................................... 3 - 5 Service Schedules ................................................................................... 3 - 7 How to Use the Service Schedules .................................................... 3 - 7 Service Schedule Tables .................................................................... 3 - 8 Fluids, Lubricants and Capacities .......................................................... 3 - 14 Coolant Mixtures .............................................................................. 3 - 15 Cleaning the Machine ............................................................................ 3 - 16 Checking for Damage ............................................................................ 3 - 17 Seats and Seat Belts ............................................................................. 3 - 18 Seats ................................................................................................ 3 - 18 Checking the Seat Belt Condition and Security ................................ 3 - 18 Checking the ROPS Structure ............................................................... 3 - 19 Bonnet ................................................................................................... 3 - 20 Opening the Bonnet ......................................................................... 3 - 20 Closing the Bonnet ........................................................................... 3 - 20 Greasing ................................................................................................ 3 - 21 General Information .......................................................................... 3 - 21 Propshafts and Rear PTO Drive Shaft .............................................. 3 - 22 Front 3-Point Linkage (Optional) ...................................................... 3 - 23 Front Axle Steering Swivels .............................................................. 3 - 24 Steering Column Universal Joints .................................................... 3 - 25 Rear Suspension Cylinder Pivots ..................................................... 3 - 26 Hydraulic Lift and 3-Point Linkage .................................................... 3 - 27 Pick-up Hitch .................................................................................... 3 - 28 Automatic Trailer Coupling (if fitted) ................................................. 3 - 29 Air Conditioning and Heater .................................................................. 3 - 30 Air Conditioning Filters ..................................................................... 3 - 30 Cleaning the Heater Filter ................................................................ 3 - 32 Adjusting the Compressor Belt ......................................................... 3 - 33 Brakes ................................................................................................... 3 - 34 Checking the Foot Brake Fluid Level ............................................... 3 - 34 Checking the Trailer Air Tank ........................................................... 3 - 35 Checking and Renewing Foot Brake Pads ....................................... 3 - 36 Checking the Park Brake Pads ........................................................ 3 - 38 Renewing the Park Brake Pads ....................................................... 3 - 38 Electrical System ................................................................................... 3 - 40 Battery .............................................................................................. 3 - 40 Jump-starting the Engine ................................................................. 3 - 41 Fuses ................................................................................................ 3 - 43 Relay Identification ........................................................................... 3 - 45 Checking the Beam Alignment ......................................................... 3 - 47

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Section 3 - Maintenance Contents Contents Page No. Engine ................................................................................................... 3 - 48 Changing the Air Filter Elements ...................................................... 3 - 48 Checking the Oil Level ..................................................................... 3 - 50 Changing the Oil and Filter ............................................................... 3 - 51 Checking the Crankcase Breather Tube .......................................... 3 - 53 Cooling System ..................................................................................... 3 - 54 Checking the Coolant Level ............................................................. 3 - 54 Changing the Coolant Filter .............................................................. 3 - 55 Draining and Refilling the Coolant .................................................... 3 - 56 Cleaning the Radiator and Coolers .................................................. 3 - 58 Fan Belt ............................................................................................ 3 - 59 Fuel System ........................................................................................... 3 - 61 Types of Fuel .................................................................................... 3 - 61 Filling the Tank ................................................................................. 3 - 62 Draining the Fuel Filter ..................................................................... 3 - 63 Changing the Fuel Filter Elements ................................................... 3 - 64 Hydraulic System ................................................................................... 3 - 65 Checking the Fluid Level .................................................................. 3 - 65 Changing the Filter Element ............................................................. 3 - 66 Changing the Hydraulic Fluid and Cleaning the Suction Strainers ... 3 - 68 Emptying the Hydraulic Coupling Drain Reservoirs ......................... 3 - 70 Transmission ......................................................................................... 3 - 71 Checking the Transmission Oil Level ............................................... 3 - 71 Changing the Transmission Oil Filter ............................................... 3 - 72 Changing the Transmission Oil and Strainer .................................... 3 - 73 Checking the Clutch Fluid Level ....................................................... 3 - 74 Axles ...................................................................................................... 3 - 75 Front Axle ......................................................................................... 3 - 75 Rear Axle and PTO .......................................................................... 3 - 78 Tyres and Wheels .................................................................................. 3 - 81 General ............................................................................................. 3 - 81 Wheel and Tyre Replacement .......................................................... 3 - 81 Checking Wheel Nut Torques ........................................................... 3 - 81 Tyre Inflation ..................................................................................... 3 - 82 Checking and Adjusting the Front Wheel Alignment ........................ 3 - 83 Fender Adjustment ........................................................................... 3 - 84 Power Take-off (PTO) ............................................................................ 3 - 85 Front PTO ......................................................................................... 3 - 85 Rear PTO ......................................................................................... 3 - 86 Windscreen Washer .............................................................................. 3 - 87 Checking Fluid Level ........................................................................ 3 - 87 Automatic Trailer Coupling (Optional) ................................................... 3 - 88 Checking for Wear ............................................................................ 3 - 88

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Section 3 - Maintenance

Routine Maintenance Service Requirements Introduction T3-002

Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals.

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

Giving your name, address and telephone number.

This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency.

Quoting your machine model and serial number.

Date of purchase and hours of work.

It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently.

Nature of the problem.

JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine.

Service/Maintenance Agreements

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

Owner/Operator Support JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your

3-1

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

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

Initial Service and Inspection (100 Hours) T3-005

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

9803-8040-6

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Section 3 - Maintenance Routine Maintenance Service Requirements

Obtaining Replacement Parts T3-004_2

We recommend you fit only JCB Genuine Parts. A Parts Book will help you identify parts and order them from your JCB distributor. Your dealer will need to know the exact model, build and serial number of your machine. See Identifying Your Machine in INTRODUCTION section. The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

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Section 3 - Maintenance Routine Maintenance Health and Safety

Health and Safety T3-001_3

Lubricants

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.

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.

Handling New Oil

Hygiene

There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

JCB lubricants are not a health risk when used properly for their intended purposes.

Used Oil

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation. 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.

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: a

Storage

Wash your skin thoroughly with soap and water.

b Using a nail brush will help.

Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

Use special hand cleansers to help clean dirty hands.

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

Waste Disposal

!MCAUTION

Avoid skin contact with oil soaked clothing.

It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.

Don't keep oily rags in pockets.

Wash dirty clothing before re-use.

Throw away oil-soaked shoes.

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.

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Section 3 - Maintenance Routine Maintenance Health and Safety First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice. Skin In the case of excessive skin contact, wash with soap and water.

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

Fires

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

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Section 3 - Maintenance Routine Maintenance Health and Safety

Battery

Warning Symbols

!MWARNING

The following warning symbols may be found on the battery.

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

Symbol

Meaning Keep away from children.

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.

Shield eyes.

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

No smoking, no naked flames, no sparks.

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.

Explosive Gas.

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

First Aid - Electrolyte

Battery acid.

Do the following if electrolyte:

GETS INTO YOUR EYES Note operating instructions.

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.

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

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

INT-3-1-14

5-3-4-3_1

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Section 3 - Maintenance Routine Maintenance Health and Safety

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

!MCAUTION 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

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Section 3 - Maintenance Routine Maintenance Service Schedules

Service Schedules 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.

!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 firm level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery and block the wheels when you are working beneath the machine. If you do not take these precautions you could be killed or injured. 9-3-1-1

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, see Instruments in Operation Section. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. If the machine is operating in ambient temperatures below -18째C [0째F] or above 38째C [100째F], change engine oil and filter, air and fuel filters at shorter intervals. Shorter maintenance intervals are also required if the machine is operated in a dusty environment or if frequent stops are made. Calendar equivalents: 10 Hours = Daily 50 Hours = Weekly 250 Hours = Three Months 500 Hours = Six Months 1000 Hours = Yearly 2000 Hours = 2 Years 4000 Hours = 4 Years

How to Use the Service Schedules T3-012_2

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.

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Section 3 - Maintenance Routine Maintenance Service Schedules

Service Schedule Tables Pre-start Cold Checks, Service Points and Fluid Levels

Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

4000 5000 Hr Hr

ENGINE Oil level Oil and Filter

- Check

Air Cleaner Outer Element

- Change

(3)

Air Cleaner Inner Element

- Change

Air Cleaner Hose and Clamp Security

- Check

Air Compressor Mountings

- Check

(4)

Air Compressor Discharge Lines

(4)

- Check

Fuel Filter

- Drain

Fuel Filter

- Change

Coolant Level

- Check

Coolant Antifreeze and Coolant Additive Concentration(4)

- Check

Coolant

- Change

Coolant Filter

- Change

Fan Belt Condition

- Check

Fan Hub (4)

- Check

Fan Belt Tensioner (4)

- Check

Vibration Damper (4)

- Check

Valve Clearances (4)

- Check and Adjust

Crankcase Breather Tube

- Check

Air Conditioning Compressor Belt Tension and Condition

- Check

Engine Mounting Bolts for Tightness(4)

- Check

Fuel Injection Pump Mounting Bolts for Tightness(4)

- Check

Radiator and Coolers

- Clean

Charge Air Cooler Hose and Clamp Security

- Check

Charge Air Cooler

- Check

Turbocharger(4)

- Check

3-8

- Change

(2)

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Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Engine

Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

4000 5000 Hr Hr

- Steam Clean

TRANSMISSION, AXLES AND STEERING Transmission Oil Level

- Check

- Change

Transmission Oil(5) Transmission Strainer

- Change

(4)

Transmission Filter

- Change

Clutch Fluid Level

- Check

Axle Oil Level (incl. Hubs)

(6)

Axle Oil (incl. Hubs)

(7)

Tyre Pressures/Condition Oil Cooler and Pipework Front PTO Gearbox Oil Level

- Check - Change - Check

- Check and Clean

- Check

- Security/ Grease

Steer Axle Pivots

- Grease

Steering Column Universal Joints

- Grease

Front PTO Gearbox Oil Front PTO Gearbox Oil Filter Propellor Shafts

- Change - Clean

Steering Axle Wheel Alignment

- Check

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

- Check

Wheel Nut Security

- Check

HYDRAULICS Oil Level Oil(4)

- Sample/ Change

Oil Filter

- Change

Hydraulic System

- Check for Leaks

Hydraulic Lift and 3 Point Linkage, Front and Rear

- Grease

Rear 3 Point Linkage Cross-shaft Oil level

- Check

Ram Piston Rods Condition

- Check

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Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Hydraulic Oil Cooler and Pipework

Operation 10 Hr 50 Hr

100 Hr(1)

- Check and Clean

Hydraulic Oil Strainer

- Clean

Hydraulic Coupling Drain Reservoir

- Empty

Security of Front Weight

500 Hr

1000 Hr

2000 Hr

- Check

- Drain

4000 5000 Hr Hr

BRAKES Air System Tank Air System Drier Canister

(4)

- Change

Trailer Brake Control Line Air Filter(4)

- Clean

Brake System Fluid Level

- Check

Brake System Fluid Park Brake

- Change - Check and Adjust

Park Brake Pad Condition and Security

- Check

Service Brake Pad Condition and Security

- Check

Calliper Bolt Torque(4)

- Check

Pipework Security

- Check

ELECTRICS Battery Electrolyte Level (if applicable)

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

Battery Charge Condition(4)

- Check

Headlamp Alignment

- Check

BODY AND FRAMEWORK Bonnet Hinges

- Lubricate

Seat Belt Condition and Security

- Check

Air Conditioning Condensor

- Clean

ROPS Structure(4)

- Check

Cab Air Intake Filter (standard type only)(8)

- Clean

Door Locks

- Check

Windscreen Washer Fluid Level

- Check

Condition of Paintwork

- Check

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Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Machine Generally Automatic Trailer Coupling (if fitted)

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

- Grease

Operation 10 Hr 50 Hr - Check and Clean

4000 5000 Hr Hr

SUSPENSION Cylinder Pivots Panhard Rod Condition and Torque Tightness(4)

- Check

Control Arms Condition and Torque Tightness(4)

- Check

`V' Link Condition and Torque Tightness(4)

- Check

Accumulator Pressure(4)

Gas Spring Pressure(4)

- Check

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Applies only if recommended oil is available. If this is not available, this job should be carried out every 250 hours. See Fluids, Lubricants and Capacities for suitable alternative oil. (3) If operating in dusty working environments, change more frequently. (4) Jobs which should only be done by a specialist. (5) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (6) Check for leaks every 50 hours, check level if leaking. (7) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted. (8) Heavy duty carbon type filters must be changed at 250 hour intervals.

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Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and and Final Inspection

Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

ENGINE Idle Speed(2)

- Check

Maximum No Load Speed(2)

- Check

Exhaust System Security(2)

- Check

Cooling System for Leaks

- Check

Fuel System for Leaks and Contamination

- Check

Lubrication System for Leaks

- Check

Stop Control

- Check

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

- Check

Oil Leakage

- Check

Transmission Lubrication Pressure

(2)

4WD/PTO Supply Pressure

(2)

Differential Lock Pressure Relief Valve

(2)

- Check

Neutral Start Operation

- Check

PTO Selection and Operation

- Check

Selection of Transmission Modes and Ranges

- Check

Steering Operation

- Check

Steering Pressure Relief Valve

(2)

- Check

HYDRAULICS Maximum System Pressure(2)

- Check and Adjust

Operation All Services

- Check

System for Oil Leakage

- Check

Oil Cooler and Pipework for Damage or Leakage

- Check

BRAKES Foot Brake - Operation

- Check

Park Brake - Operation

- Check

Air System Warning Lights

- Check

ABS(2)

- System Test

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Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and and Final Inspection

Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

ELECTRICS Starter Motor Alternator - Output

- Check (2)

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

- Check - Check

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

- Download and Rectify

EMS Datalog(2)

- Download and Rectify

- Check

Circuit Pressure(2)

- Check

Rear Axle to Chassis Clearance(2)

- Check

Ride Height and Corrector Valve Operation(2)

- Check

Brake Light Switch Input to ABS ECU using computer diagnostic tool(2) SUSPENSION

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

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities 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). Whilst 15W/40 oil is

ITEM

CAPACITY

recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at temperatures below -5ºC (23ºF). Continued use of low viscosity oils can decrease engine life and will require different service intervals. K Service Schedules ( T 3-7)

Table 1. FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Litres UK Gal Fuel Tank

577

127

Diesel Oil

ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

5.3

JCB Engine Oil EP 15W/40 (-20 to +40 deg C)

API CH-4 or ACEA E3/ B3A3, SAE15W/40(1)

Engine (Coolant)

7.7

JCB High Performance Antifreeze & Inhibitor/ Water K Coolant Mixtures ( T 3-15)

ASTM D6210

Transmission

16.5

JCB V-Tronic Transmission Fluid

ZF TE-ML06, B and C

Rear 3 Point Linkage Cross-shaft

0.2

0.04

JCB V-Tronic Transmission Fluid

ZF TE-ML06, B and C

Clutch

0.5

0.1

JCB V-Tronic Clutch Fluid

Pentosin CHF 11S

JCB HD90 Gear Oil

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

- Axle Beam

3.5

- Hubs (each)

0.9 JCB HD90 Gear Oil

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

JCB Brake Fluid Dot 4

SAE J1703 DOT 4

JCB Hydraulic Fluid HP46

ISO VG46

Front Axle

Rear Axle - Axle Beam

12.3

- Hubs (each)

1.5

Brake System - Front - Rear Hydraulic System(2)

0.75

0.2

0.75

0.20

180

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

ISO VG32

(Below 38ºC,100ºF) Grease Points

Front PTO Gearbox (optional)

1.5

JCB HP Grease

Lithium complex NLGI No.2 consistency including extreme pressure additives

JCB HP Universal ATF

ZF TE-MIL 09,11,12,14

(1) If API CH-4 or ACEA E3/B3A3 engine oil AT SAE 15W/40 is not available, the engine oil must be changed at 250 hours, using the following alternative oils: For -20ºC to +40ºC: JCB Engine Oil HP15W/40 or for -25ºC to +30 ºC: JCB Engine Oil HP10W/30. (2) The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank

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Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities

Coolant Mixtures T3-009_3

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

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

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).

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Section 3 - Maintenance Routine Maintenance Cleaning the Machine

Cleaning the Machine

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

Clean the machine using water and/or steam. Pay particular attention to the underside. Do not allow mud to build up on the engine and transmission. Make sure that the radiator grille is not clogged up. Excessive power washing can cause damage to seals, bearings and electrical connections. Do not direct high power water jets at oil seals, universal joints or electrical components and wiring. Take special care to avoid directing high power water jets at the electrical connections to the front and rear axle ABS sensors.

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Section 3 - Maintenance Routine Maintenance Checking for Damage

Checking for Damage 1

Inspect steelwork for damage. Note damaged paintwork and repair.

Make sure all pivot pins are correctly in place and secured by their locking devices.

Ensure that the steps and handrails are undamaged and secure.

Check for broken or cracked window glass. Replace damaged items.

Check all lamp lenses for damage.

Inspect the tyres for damage and penetration by sharp objects.

Check that all safety decals are in place and undamaged. Fit new decals where necessary.

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Section 3 - Maintenance Routine Maintenance Seats and Seat Belts

Seats and Seat Belts Seats

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

Make sure that the seat mounting bolts are tight.

!MWARNING

Keep the seat slide runners lightly greased. Check driver's seat for correct operation, ensuring that it can be moved and locked into all positions and can be raised and lowered. If any parts are faulty, repairs should be done by a JCB dealer. Keep the upholstery clean, using a commercially available upholstery or plastic cleaner. Test first for compatibility on a small concealed area of the seat. During cleaning, the upholstery should not be soaked through.

Take care with the backrest frame. It may jerk forward and cause injury. 13-3-2-9

Checking the Seat Belt Condition and Security

!MWARNING

T3-008

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.

Fig 1.

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Section 3 - Maintenance Routine Maintenance Checking the ROPS Structure

Checking the ROPS Structure

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

Check the structure for damage. Check that the four mounting bolts are installed and undamaged. Check that torque tightness of nuts A and B is 365 Nm (270 lbf ft). Tighten them to the correct torque if necessary.

Fig 2.

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3 - 19

Section 3 - Maintenance Routine Maintenance Bonnet

Bonnet Opening the Bonnet

!MWARNING Engine The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.

Closing the Bonnet 1

To fit the side panels, locate the front edge of the panel and then push the rear edge of the panel firmly into position.

Pull the bonnet down by means of the cable, push the bonnet down, make sure it is locked in place.

INT-2-1-6_1

Engage the park brake, put the transmission in neutral, stop the engine. Remove the starter key.

To remove the side panels, pull at the rear edge of the panel and lift out the panel from its location at the front.

Fig 3. 2

Release the latch by pulling up handle A. The bonnet will automatically open and be supported on gas struts.

Note: If you need the bonnet open further than the limit of the gas struts, disconnect the gas struts, raise the bonnet and fit a suitable size bolt through the hinge lever mechanism to prevent the bonnet inadvertently closing.

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3 - 20

Section 3 - Maintenance Routine Maintenance Greasing

Greasing General Information Read and understand Lubricants - Health and Safety, before greasing. 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 Schedules for the recommended frequencies. Note: If working in muddy conditions the propshafts and PTO driveshafts must be greased daily. Note: The machine must always be greased after pressure-washing or steam cleaning. Extra care must be taken to ensure that propshaft universal joints and splines are greased regularly Greasing should be done with a grease gun. Normally, two strokes of the gun should be enough. Stop greasing when fresh grease appears at the joint. Use only JCB HP Grease. In the following illustrations the grease points are numbered. Count them off as you grease them. Refit the grease point dust caps after greasing.

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Section 3 - Maintenance Routine Maintenance Greasing

Propshafts and Rear PTO Drive Shaft

Front axle propshaft

!MWARNING

Grease points 5 to 6

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

Note: When greasing the universal joints, you must ensure that grease appears at all four bearing caps. If grease does not appear at any cap, move the shaft from side to side and then re-grease. Wipe away all excess grease.

Fig 5.

3 Fig 4.

Fig 6.

Rear PTO drive shaft Grease points 1 to 2

Rear axle propshaft Grease points 3 to 4

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Section 3 - Maintenance Routine Maintenance Greasing

Front 3-Point Linkage (Optional)

!MWARNING You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged. Block all four wheels before getting under the machine. 2-3-2-1

.K General Information ( T 3-21) Grease at points 1 to 6.

Fig 7.

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Section 3 - Maintenance Routine Maintenance Greasing

Front Axle Steering Swivels

.K General Information ( T 3-21) Grease points 1 to 4.

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

Note: After initial greasing, turn the wheels from lock to lock, then grease again to ensure full penetration.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Fig 8.

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3 - 24

Section 3 - Maintenance Routine Maintenance Greasing

Steering Column Universal Joints

.K General Information ( T 3-21) Note: It may be necessary to turn the steering wheel to put the grease nipples in an accessible position.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Grease at point 1 from underneath the machine. Grease at points 2 to 4 from under the bonnet.

Fig 9.

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Section 3 - Maintenance Routine Maintenance Greasing

Rear Suspension Cylinder Pivots

.K General Information ( T 3-21) Grease points 1 to 4.

3 +

Fig 10.

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Section 3 - Maintenance Routine Maintenance Greasing

Hydraulic Lift and 3-Point Linkage

.K General Information ( T 3-21)

!MWARNING

Hydraulic lift rams

You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the park brake is engaged.

Grease points 1 to 4.

Three point linkage lift rods Grease at nipples 5 to 10 (lift collars A and B to access nipples 9 and 10).

Block all four wheels before getting under the machine. 2-3-2-1

5 6 9 A

7 8 10 B 2

Fig 11.

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Section 3 - Maintenance Routine Maintenance Greasing

Pick-up Hitch

.K General Information ( T 3-21)

Cross-Shafts

Grease points 1 to 4.

Block all four wheels before getting under the machine. 2-3-2-1

Fig 12.

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Section 3 - Maintenance Routine Maintenance Greasing

Automatic Trailer Coupling (if fitted) .K General Information ( T 3-21) Note: Whenever the coupling has been pressure-washed it must always be greased. Make sure the coupling is in the open position, i.e. the coupling pin is up and the hand lever A is in its highest position. Grease at points 1 and 2. Operate lever A several times so that the grease is distributed throughout the bearing.

!MCAUTION Keep your hands out of the funnel or you may be injured by the coupling pin as it is forced down by its spring. 13-2-2-17

Grease again and operate the hand lever again. If driving without a trailer attached, close the coupling to prevent dirt accumulation. Fig 13.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater

Air Conditioning and Heater Air Conditioning Filters

If the filter is undamaged, pull foam pre-cleaner E out of the filter casing, wash it in low suds detergent and blow dry with compressed air at a maximum pressure of 5.5 bar (80 lbf/in2). Use the same compressed air to blow dirt out of filter D in the opposite direction to the arrows marked on the filter.

Check and clean the filter sealing face on the cab body.

Refit the pre-cleaner and fit the filter into the cab aperture using two screws C. Refit the closing panel B.

Cleaning the Standard Air Conditioning Filter

Fig 14. Note: The air conditioning system contains environmentally safe R-134A refrigerant. Do not use test equipment or gauges that have contacted R12 refrigerant or the system will be damaged. Note: For crop spraying applications or very dusty conditions, a heavy duty carbon filter can be used in place of the standard filter. Carbon filters must not be cleaned. Keep a log of the hours used and change at 250 hour intervals.

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Unscrew the two quarter-turn fasteners A and remove closing panel B. Remove the two screws C and pull out the filter D. Check condition of filter and renew if split or worn.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater Changing the Heavy Duty Carbon Filter Note: Carbon filters must not be cleaned. Keep a log of the hours used and change at 250 hour intervals.

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Fig 16. 2

The new filter is supplied with a separate foam seal K that has a self-adhesive face covered by protective film. Clean the contact face of the new filter L, peel off the protective film from the foam seal and press the foam seal, self-adhesive face downwards, into position on the filter.

Check and clean the seal contact face on the cab body.

Fit the filter into the cab aperture using two screws H. Refit the closing panel G.

Fig 15. 1

Unscrew the two quarter-turn fasteners F and remove closing panel G. Remove the two screws H and pull out the filter J.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater

Cleaning the Heater Filter

!MCAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Pull out the fastener A and remove grille panel B.

Lift out filter C and check for splits or tears. Renew filter if damaged.

If the filter is undamaged, use compressed air at a maximum pressure of 5.5 bar (80 lbf/in2) to blow dirt out of the filter in the opposite direction to the air flow when the filter is installed.

Refit the filter into the cab aperture.

Refit the grille panel, making sure that the tongue D engages in slot E.

Fig 17.

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Section 3 - Maintenance Routine Maintenance Air Conditioning and Heater

Adjusting the Compressor Belt

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

!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

Stop the engine.

Open the bonnet.

Loosen fasteners A and B.

Fig 18. 4

Position the compressor so that there is 10 mm (0.4 in) slack on the longest run of the belt.

Retighten fasteners A and B.

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Section 3 - Maintenance Routine Maintenance Brakes

Brakes Checking the Foot Brake Fluid Level

!MWARNING If the brake fluid warning light comes on, check the brake fluid level immediately. 13-3-1-2_1

!MWARNING Faulty brakes can kill. If you have to top up the brake reservoir frequently, get the brake system checked by your JCB Dealer. Do not use the machine until the fault has been put right. 2-3-2-5_1

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

Unlock and turn handle A, lift the access door B and engage the support stay.

Check the fluid level in the three reservoirs C, D and E. The fluid level should be between the two lines F and G moulded into the side of each reservoir. If necessary, add fluid as follows.

Note: If the level has fallen below the lower mark G, the system must be checked by your JCB distributor. 3

Add the specified brake fluid. Clean the area around the filler cap J. Remove the cap and carefully pour in the recommended fluid until it reaches the correct level. Avoid spilling it. Wipe up any spillage. Do not allow dirt to enter the reservoir. Fit the cap securely.

Fig 19.

Note: Do not use ordinary hydraulic fluid.

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Section 3 - Maintenance Routine Maintenance Brakes

Checking the Trailer Air Tank 1

Charge the air system by starting the engine. Wait for the tank warning lights to go out. Stop the engine, apply the park brake.

Grip `keyring' fitting K at the bottom of tank L and pull sideways until all water is expelled. The amount of water released is a guide to the functioning of the air dryer. If purging of water takes much longer than about 5 seconds, or if oil is present, the system must be checked by your JCB distributor.

Fig 20.

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Section 3 - Maintenance Routine Maintenance Brakes

Checking and Renewing Foot Brake Pads

B D B

E C

E Fig 21. 1

!MWARNING

Prepare the Machine. Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground. Jack up the machine and support it on axle stands. Remove the wheels.

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

Note: Disc brakes are fitted to all four wheels, with two callipers per wheel. The illustration shows a typical calliper.

!MWARNING

Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work.

Oil on the brake disc will reduce brake effectiveness. Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer's safety instructions. If the pads are oily, new ones must be fitted.

13-3-1-3

Tap out two pad locating pins B and C in direction of the arrow. Collect pin D and clip E which will become loose as pins B and C are removed.

With a suitable lever, force the worn pads back against the pistons. Remove the pads. Force both pistons fully back, taking care not to damage the seals.

2-3-2-3_3

Check the thickness of all the friction pads A and the condition of each disc Y. If the friction material is 3 mm (0.12 in) or less on any of the pads, fit a new set. If the surface of the disc is badly warped or pitted, you must consult your JCB distributor.

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Section 3 - Maintenance Routine Maintenance Brakes 5

Ensure that the seals are not leaking and that both pistons move freely in the calliper. If not in perfect condition, the calliper must be repaired by your JCB distributor.

Slide in the new pads and fit locating pin B making sure that the pin passes through the holes in both pads and through the hooked end of clip E. Fit pins C, D and clip E as shown at Z, making sure that clip E is fitted over pin C and behind pin D.

Refit the wheels and tighten the wheel nuts, K Checking Wheel Nut Torques ( T 3-81).

Before driving the machine, start the engine, wait for air pressure to rise and pump the brake pedal until the brakes are felt to engage at the middle of the pedal travel range.

Try to avoid heavy braking for the first 50 hours of operation after fitting new pads.

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Section 3 - Maintenance Routine Maintenance Brakes

!MWARNING

Checking the Park Brake Pads

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

2-3-2-3_3

!MWARNING

!MWARNING Before checking the park brake, park on level ground. Put blocks each side of all four wheels. Ensure that all three air tank warning lights are out. Release the park brake, then stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

Check the disc condition If the surface of the disc is badly warped, pitted or showing signs of overheating, the disc must be renewed. Contact your JCB dealer.

Renewing the Park Brake Pads

!MWARNING

13-3-1-4_1

Before checking the park brake, park on level ground. Put blocks each side of all four wheels. Ensure that all three air tank warning lights are out. Release the park brake, then stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. 13-3-1-4_1

!MWARNING Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work. 13-3-1-3

!MWARNING The actuator contains a large spring which can exert a force of up to 1134 kgf (2500 lbf) and cause injury if suddenly released. When working on or near the actuator, carefully follow all service instructions. Fig 22. 1

13-3-1_11_1

Check the Pad Condition. Measure pad thickness A. If the thickness of the friction material is 3 mm (0.12 in) or less, the pads must be renewed by your JCB distributor.

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Section 3 - Maintenance Routine Maintenance Brakes

!MWARNING

b Remove split pins C. Fully support the complete brake assembly until guide pins E are replaced at step c. From caliper D remove guide pins E. Withdraw the pads F as they become detached from the guide pins, followed by spring plate G.

2-3-2-3_3

Slacken locknuts X and remove pin from clevis Y. Apply brake, causing rod Z to draw back into the actuator. Turn clevis Y through 90Â°. Remove plastic cap and insert a 1/4 in hexagon allen key at B. Turn it clockwise to back the pads right away from the disc. Do not turn the key further than necessary to allow space for the new pads.

Check the pad thickness and the disc condition. K Checking the Park Brake Pads ( T 3-38) 3

Fit the new pads in the following order: a

Insert top guide pin E just enough to support the brake caliper.

b Fit the thicker pad and push in the top guide pin through the thinner pad as it is inserted from the underside of disc. c

Fit bottom guide pin. Secure guide pins E with split pins C.

d Release brake, reconnect clevis and tighten locknuts. 4

Adjust the brake using the allen key. Support the weight of the brake with one hand and turn the allen key anti-clockwise until the pads are tight on the disc. From this position, turn the allen key half a turn clockwise.

Test the park brake

Fig 23.

Drive the machine for a short distance of 300-400m. If the brake disc is getting hot, turn the allen key clockwise slightly, If the brake is rattling slightly, turn the allen key anti-clockwise slightly. The adjustment should never be less than a 1/4 turn or more than 3/4 of a turn from tight.

Remove the old pads as follows:

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Section 3 - Maintenance Routine Maintenance Electrical System

Electrical System Battery

Fig 24.

Checking the Electrolyte Level

Note: If battery charging is required, the battery cables should be disconnected before charging.

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.

Note: The two batteries fitted to the machine are connected in parallel. When fitting the cables, ensure that they are connected as shown on the illustration.

!MWARNING Do not top the battery up with acid. The electrolyte could boil out and burn you. 2-3-4-6

Apply the park brake and stop the engine. Remove the battery access panel A.

Prize out covers B. Look at the level in each cell. The electrolyte should be 6 mm (0.25 in) above the plates. Top up if necessary with distilled water or de-ionized water.

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Section 3 - Maintenance Routine Maintenance Electrical System

Jump-starting the Engine

!MWARNING

Note: The procedure below should be used if the batteries have become discharged. It is not possible to tow-start or push-start the Fastrac due to the design of the transmission.

Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery fully charged.

Note: The following procedure relates to machines equipped with two batteries connected in parallel.

Do not try to charge a frozen battery or jump-start and run the engine, the battery could explode. Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels. When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This prevents any chance of sparks near the battery. Set all the machine switches to their OFF positions before connecting the external power supply. Even with the starter switch set to off some circuits will be energised when the external power supply is connected. Do not connect the booster (slave) supply directly across the starter motor. Doing this by-passes the neutral gear safety switch. If the machine is in gear, it may 'runaway' and kill or injure bystanders. Use only sound jump leads with securely attached connectors. Connect one jump lead at a time. The machine has a negative earth electrical system. Check which battery terminal is positive (+) before making any connections.

Engage the park brake. The park brake should have been engaged when the machine was last parked. But if it is not already engaged, engage it now.

Set all switches in the cab to Off.

Note: Although the JCB Fastrac has two batteries, they are connected in parallel to give 12 Volts. Use a booster supply of 12 Volts (not 24 Volts). 3

Remove panel A to gain access to the batteries and open the bonnet to gain access to the earth connection, K Fig 25. ( T 3-42).

!MWARNING Keep metal watch straps, and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metalwork. If this happens, you can be burned. Make sure that the fuel filler cap is tightly fitted. Make sure that all spilt fuel is cleaned away from the battery area. 2-2-4-2

Keep metal watch straps and jewellery away from the jump lead connectors and the battery terminals - an accidental short could cause serious burns and damage equipment. Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system.

Connect the booster cables as follows: a

Connect the positive booster cable to the positive (+) terminal on the front battery of the machine.

b Connect the other end of this cable to the positive (+) terminal of the booster supply.

If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply. 4-2-2-3_1

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Section 3 - Maintenance Routine Maintenance Electrical System

Fig 25. d Connect the other end of this cable to the negative (-) terminal on the booster supply. 5

Do the Pre-Start Checks. See Before Starting the Engine (Operation Section).

Start the Engine. See (Operation Section).

Disconnect the Booster Cables. a

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the

Engine

Disconnect the negative (-) booster cable from the earth connection B. Then disconnect it from the booster supply.

b Disconnect the positive (+) booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.

Fig 26. c

Starting

Connect the negative (-) booster cable to the earth connection B on the engine. The connections on the machine must be free from paint and dirt. Do not use any other part of the machine for an earth.

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Section 3 - Maintenance Routine Maintenance Electrical System

Fuses

If a fuse blows, find out why and rectify the fault before fitting a new one.

The electrical circuits are protected by fuses. The main fuse block A contains 27 fuses, A1 to A9, B1 to B9 and C1 to C9. It is located, together with fuses E, F, G, H and W, behind panel K. To gain access to these fuses, remove screws L and remove panel K. When refitting the panel, ensure that locating tab X is inserted correctly before fitting screws L. There are also six lighting circuit fuses D1 - D6 behind a panel to the left of the steering column. K Fig 28. ( T 3-44) Also one engine-mounted fuse. K Fig 29. ( T 3-44)

Fig 27.

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Fuse Circuit No

Fuse Rating (Amps)

Start inhibit, Limp home mode

Brake lights

Rear wash/wipe, Seat heating and suspension

Front wash/wipe, Horn

Electronic engine

Electronic draft control (ignition supply)

7.5

ECU 1

Electronic spool valves

Air conditioning unit and compressor

Radio/cassette memory, Interior lights, Beacon socket.

7.5

Hazard warning lamps

Front work lights

Rear work lights

Headlamp flasher

Radio/cassette power supply

7.5

Auxiliary socket

Cigar lighter

Electronic draft control, Instrument cluster, ECU 1 (battery supply)

Reverse lights

Direction indicators

7.5

ISO 11786 Socket (12V ignition)

Instrument cluster, Switch illumination, Fuse C5, Brake lights relay

7.5

Radar

Diagnostic connector,

3-pin power socket

3-pin power socket, relay switched socket and terminal posts

Air drier

ABS trailer socket

Tractor ABS

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Section 3 - Maintenance Routine Maintenance Electrical System F4

Tractor ABS

Heated screen LH

Heated screen RH

Heated mirrors

Mirror adjustment

Heated rear screen

Transmission control actuator

CVT display ECU

7.5

CVT display ECU

Maintained 12v supply

Engine power

CVT display ECU (ignition supply)

Transmission management EST (ignition supply)

8.5v sensor supply

J10

Transmission management EST (battery 40 supply

Maxifuse - feed to side and headlight switch

Main beam

Dipped beam

Rear Fog lights

LH Side lights

7.5

RH Side lights

7.5

Auxiliary lights switching

Engine-mounted Fuses To gain access to the engine-mounted fuse K, pull off the plastic cover. The fuse is retained by two nuts. Fuse Circuit No

Fuse Rating (Amps)

100

Manifold Heaters

D1 D2 D3 D4 D5 D6

Fig 29.

Fig 28.

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Section 3 - Maintenance Routine Maintenance Electrical System

Relay Identification

Fig 30. The following relays are located under a panel behind the seats. R1

Maintained 12 Volts

Air conditioning compressor clutch

Intermittent wipe

Neutral solenoid

Start inhibit 1

Brake lights

Reverse lights

R9 R11

The following relays are located under a panel near the steering column. R8

Warning buzzer

Single trailer turn

R10

Rear fog lights

R11

Intermittent wipe

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R10 Fig 31.

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Section 3 - Maintenance Routine Maintenance Electrical System

Fig 32. The following relays are located near the main fuse panel R12

Work lights

R13

Ignition

R14

Heated screen

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Section 3 - Maintenance Routine Maintenance Electrical System

Checking the Beam Alignment

fitted mark a second horizontal line YY on the wall approximately 1.3 m above XX.

Park the machine on level ground so that the front headlights A are 2.00 m from a wall.

Measure the distance Z from the ground to the centre of the front headlights A. Subtract 25 to 30 mm from this distance and mark a horizontal line XX on the wall at this height. When the auxiliary headlights B are

When the headlights are switched on to dipped beam, the horizontal tops of the light beams should be in line with the horizontal lines X - X and Y - Y on the wall.

To adjust the beam, slightly slacken nut C or D, reposition the light and then tighten the nut.

Y Y

1.3m A

X X

2.0m

Fig 33.

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Section 3 - Maintenance Routine Maintenance Engine

Engine Changing the Air Filter Elements Note: In a dusty working environment, the outer element may have to be renewed more frequently than the service schedule recommendation. A new inner element must be fitted at latest, every third time the outer element is changed. As a reminder, mark the inner element with a felt tip pen each time you change only the outer element. DO NOT attempt to wash or clean elements - they must be renewed.

!MCAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates. 2-3-3-1

Turn the front wheels onto full left lock and stop the engine. Remove the starter key.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Open the bonnet.

If changing the inner element disconnect the filter induction hose A to prevent dust getting into the engine. Cover the hose to prevent rain and dirt getting into the engine.

Release the clips B and remove cover C.

Pull out the outer element D. Take care not to tap or knock the element as you remove it.

If the inner element E is to be changed, lift up pulls G and remove inner element E.

Clean the inside of canister F, and cover C.

Carefully insert the new elements into the canister. Make sure that the tongue Y on the inner element engages in the slot inside the canister F.

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Fig 34.

3 - 48

Section 3 - Maintenance Routine Maintenance Engine

C022920

Fig 35. 9

Connect induction hose A. Fit cover C onto the canister. Secure the clips B. Make sure the air filter blocked switch connector K is fitted. Check all hoses for condition and tightness.

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Section 3 - Maintenance Routine Maintenance Engine

Checking the Oil Level

Check the Oil Level

!MCAUTION

Make sure that the dipstick Y is fully in before removing it.

Never operate the engine with the oil level below the low mark or above the high mark, otherwise engine damage or poor engine performance can occur.

Check that the oil level is between the two marks on the dipstick.

13-3-2-13

Prepare the Machine Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground. Turn the front wheels to full left hand lock.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Stop the Engine Remove the starter key. Before checking the oil level, wait at least 15 minutes to allow the oil to drain down into the sump.

Locate the dipstick Y below the cab left hand door. Fig 37. 5

Add oil if necessary If oil is needed, open the bonnet and add only the recommended oil at filler Z, K Fluids, Lubricants and Capacities ( T 3-14). Make sure that the dipstick and filler cap are refitted.

Fig 36.

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Section 3 - Maintenance Routine Maintenance Engine

Changing the Oil and Filter 1

Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil. Park the machine on firm ground and turn the front wheels to full right hand lock.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

3-3-1-1

!MCAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug.

13-3-1-15

!MWARNING

Fig 38.

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.

Remove both drain plugs C and D and the sealing washers. Make sure the sealing washers and mating surfaces are not damaged. Let the oil drain out, then clean and refit the drain plugs and the sealing washers.

Open the bonnet.

!MCAUTION

INT-3-2-3

Stop the Engine. Disconnect the battery to prevent the engine being started. Chock all four wheels before getting under the machine.

The oil filter canister will contain some oil which could spill out when you remove the canister. MD-3-2-1

Place a container that can hold at least 30 litres beneath the engine to catch the oil.

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Section 3 - Maintenance Routine Maintenance Engine Wipe off any spilt oil. Check for leaks. Make sure the filler cap is correctly refitted. 11

Connect the battery and run the engine for a few minutes to allow the oil to circulate.

!MCAUTION If the oil pressure low light does not go out within 15 seconds of the engine starting, stop the engine immediately to avoid engine damage. Do not start the engine until the fault has been rectified. 0200

Stop the engine, remove the starter key and check for leaks. Before checking the oil level, wait at least 15 minutes to allow the oil to drain down into the sump. Recheck the oil level and top up if required.

Dispose of the drained oil as required by local environmental regulations.

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Fig 39. 6

Unscrew the filter F.

Clean the filter head G, especially on its sealing face.

Note: The old seal can stick to the filter head. Ensure that it is removed. 8

Add clean engine lubricating oil to the new filter. Allow enough time for the oil to pass through the filter element.

Smear the seal H on the new filter with oil. Screw in the new filter, hand-tight only. Do not overtighten the filter as this could damage the treads.

Fill the engine to the upper mark on the dipstick with new oil through the filler K Checking the Oil Level ( T 3-50). K Fluids, Lubricants and Capacities ( T 3-14) for recommended oil grades.

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Section 3 - Maintenance Routine Maintenance Engine

Checking the Crankcase Breather Tube

Prepare the Machine Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground.

Stop the Engine. Disconnect the battery to prevent the engine being started. Chock all four wheels before getting under the machine.

Check the breather tube B for sludge, debris or ice that could be blocking the tube. Make sure it is clear.

Note: In icy conditions, check the breather tube more frequently.

Fig 40.

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Section 3 - Maintenance Routine Maintenance Cooling System

Cooling System Checking the Coolant Level

marked `COLD MIN'. Do not overfill. K Coolant Mixtures ( T 3-15)

!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 checking the coolant level or checking the system.

Note: Check the quality of the antifreeze mixture every year before the cold weather starts. Change it every two years. 6

Make sure it is tight.

9-3-3-1_1

Prepare the Machine

Refit the Filler Cap

Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground. Turn the front wheels to full left hand lock.

Check for Leaks Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and check for leaks.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Stop the Engine Remove the starter key.

Open the Bonnet

Check the Level Visually check that the level of the coolant is up to the line marked `COLD MIN' but below the line marked `HOT MAX'. If the level is low, then continue with steps 5 to 7.

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

Fig 41.

Top-up the Expansion Tank Remove filler cap A and add pre-mixed water/ antifreeze solution until the level is up to the line

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Section 3 - Maintenance Routine Maintenance Cooling System

!MWARNING

Changing the Coolant Filter

When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Stop the Engine. Remove the starter key

Open the Bonnet

Remove filler cap. Level ( T 3-54).

Turn the shut-off valve to the off position by rotating the knob B from vertical to horizontal.

Unscrew and discard the coolant filter C.

Smear the seal on the new filter with a thin film of oil.

K Checking the Coolant

!MCAUTION Do not allow oil to get into the filter. Oil will damage the coolant additive. 13-3-2-11

Screw in the new filter until the seal touches the filter head, then tighten by an additional 1/2 to 3/4 of a turn. Do not overtighten the filter as this could damage the threads. 8

Turn the shut-off valve to the ON position by rotating the knob B from horizontal to vertical.

!MCAUTION The shut-off valve must be in the ON position to avoid damage to the engine. 13-3-2-12

Fig 42. 1

Refit the Filler Cap. Make sure it is tight.

Check for Leaks

Park the machine on firm, level ground. Apply the park brake. Lower any mounted implements to the ground. Turn the front wheels to full left hand lock.

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Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and check for leaks.

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Section 3 - Maintenance Routine Maintenance Cooling System

Draining and Refilling the Coolant

Open the bonnet. Carefully loosen the filler cap. Let any pressure escape. Remove the cap.

!MCAUTION Keep your face away from the drain hole when removing the drain plug. 2-3-3-4

Place a container that can hold at least 25 litres beneath the radiator to catch the coolant.

Remove drain plug B and disconnect hose C. Let the coolant drain out.

Check for damaged hoses and loose or damaged hose clips. Check the radiator for damage and build up of dirt. Clean and repair as required.

Clean and refit drain plug B and hose C.

Prepare a mixture of 23 litres of water and 0.5 kg of sodium carbonate (or a commercially available alternative).

3-3-1-1

!MCAUTION This solution contains no antifreeze. Do not allow the cooling system to freeze during the cleaning operation. 13-3-2-17

Fill the system slowly with the mixture to prevent air locks. Wait 2 to 3 minutes to allow air to be vented then top up to the level marked `COLD MIN'. DO not fit the filler cap at this stage

Note: Make sure the heater control is in the hot position before running the engine. This will ensure that the coolant mixture circulates through the entire cooling system.

Fig 43.

3 - 56

Run the engine for 5 minutes at the normal running temperature.

Stop the engine and allow to cool.

Drain the cooling system, checking that the coolant is not dirty. If it is dirty, repeat the flushing process, (steps 6 to 10) until the coolant is clean.

Refill the system slowly to prevent air locks, using pre-mixed water/antifreeze solution K Coolant Mixtures ( T 3-15).

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Section 3 - Maintenance Routine Maintenance Cooling System

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

Note: A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point. 12

Wait for 2 to 3 minutes to allow air to be vented then top up the expansion tank and fit the filler cap. K Checking the Coolant Level ( T 3-54).

Run the engine and raise the coolant to working temperature. Stop the engine. Check for leaks.

Dispose of the drained coolant as required by local environmental regulations.

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Section 3 - Maintenance Routine Maintenance Cooling System

Cleaning the Radiator and Coolers

Brush off all debris from tubes and fins on both sides of condensor A, cooler stack B, transmission oil cooler C, radiator D and from the front of charge air cooler E.

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

!MWARNING

Check for cracks, holes or other damage.

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

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

If any damage is found, contact your JCB dealer.

Reposition the coolers and the condensor.

Close the bonnet.

If the tubes or fins become clogged, the radiator and coolers will be less efficient. 1

Stop the engine.

2-3-3-5

Open the bonnet.

Pull forward air conditioning condensor A and allow it to rest against the retaining strap.

Lift and pull forward the cooler stack B. This comprises the hydraulic oil cooler, the fuel cooler and the cooler for the front PTO (if fitted).

Fig 44.

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Section 3 - Maintenance Routine Maintenance Cooling System

Fan Belt 1

Stop the engine.

Open the bonnet.

!MWARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

!MWARNING Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure. 0094

Inspect the belt for damage.

Fig 45.

Cracks across the belt width A are acceptable.

Cracks across the belt which intersect those in the direction of the belt length B are not acceptable. Renew the belt if oily or if it has unacceptable cracks or if it is frayed or has pieces of material missing as at C or D. Damage can be caused by: a

Renew the Belt (if damaged or oily) a

Slacken the tension of the air conditioning compressor belt and lift the belt clear of the fan the Compressor pulley, K Adjusting Belt ( T 3-33)

b If the machine is fitted with a front PTO, disconnect the drive shaft as follows to allow the fan belt to be removed and replaced:

Incorrect tension

b lncorrect size or length c

Pulley misalignment

d Incorrect installation e

Severe operating environment

Oil or grease on the belt

Note: The belt tension is automatically maintained by the tensioner K. K Fig 47. ( T 3-60)

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Section 3 - Maintenance Routine Maintenance Cooling System f

Fit the new belt over the pulleys as shown and allow the tensioner to return to its normal position.

g If the front PTO drive shaft has been disconnected, refit spacer plate F and screws E Tighten screws E to 85 Nm. h Refit the compressor belt and adjust the tension K Adjusting the Compressor Belt ( T 3-33).

Fig 46.

Remove the ring of socket head screws E.

Remove spacer plate F so that the fan belt can pass between flexible coupling G and shaft H.

Release the belt tension as follows: Using a suitable square drive inserted into the square hole in the belt tensioner J, lever the tensioner roller K in the direction of the arrow to allow the belt to be lifted clear. Do not use excessive force or the tensioner will be damaged.

Fig 47.

Note: The belt tensioner is spring-loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. d Before fitting the new fan belt, check that the rollers and the fan pulley rotate smoothly and that there is no play in the bearings. e

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Make sure that all pulley grooves are free from debris and belt rubber build-up so that the belt will seat properly.

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Section 3 - Maintenance Routine Maintenance Fuel System

Fuel System Types of Fuel

– ASTM D975-91 Class 1-1DA. T3-007_2

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

– JP7, MIL T38219 XF63. – NATO F63.

Sulphur Content

Recommended Fuel Specification

!MCAUTION

– EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4. – BS2869 Class A2. – ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA. – JIS K2204 (1992) Grades 1, 2, 3, and Special Grade 3. Note: Where low sulphur/low aromatic fuels are used it is important that lubricity additives are used. The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. They have not been tested or approved by the engine manufacturer. They should be added by your fuel supplier who should understand the concentration level necessary. 1

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%).

!MCAUTION

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

High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently. Table 2. Percentage of sulphur in Oil Change Interval the fuel (%) Less than 0.5

Normal

0.5 to 1.0

0.75 of normal

More than 1.0

0.50 of normal

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

Low Temperature Fuels

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

Acceptable Fuel Specification

!MCAUTION The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also affect the engine performance.

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

Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels Fuel resources such as Rape Methyl Ester and Soybean Methyl ester, collectively known as Fatty Acid Methyl

GEN-9-3

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Section 3 - Maintenance Routine Maintenance Fuel System Esters are being used as alternatives and extenders for mineral oil. Fatty Acid Methyl Esters must conform to certain standards to be of acceptable quality, just as mineral oils do at present. Consult your JCB distributor for advice about the use of Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.

Petrol

!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

Filling the Tank At the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel.

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Section 3 - Maintenance Routine Maintenance Fuel System

Draining the Fuel Filter 1

Turn the front wheels onto full left lock and stop the engine. Remove the starter key.

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

!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

Open the bonnet.

Position a suitable container underneath the filter valve A. Unscrew valve A by approximately 31/2 turns until the valve drops down by 25 mm. and draining occurs. Close the valve when clear fuel, free from water is visible. Do not overtighten or the threads may be damaged.

Dispose of the drained liquid as required by local environmental regulations.

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Fig 48.

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Section 3 - Maintenance Routine Maintenance Fuel System

Changing the Fuel Filter Elements 1

Lightly lubricate the seals of the new element with clean fuel. To assist bleeding, fill with fuel before fitting. Tighten the element hand-tight only. Check for leaks.

Bleed the fuel system as follows:

Turn the front wheels onto full left lock and stop the engine. Remove the starter key.

!MWARNING

b Turn the starter switch to position 0, wait 10 seconds and then turn back to position 1 to allow the fuel pump to run again for 30 seconds.

Block all four wheels before getting under the machine.

2-3-2-1

!MWARNING

Turn the starter switch to position 1 and allow the fuel pump to run for 30 seconds.

Repeat step b twice more before attempting to start the engine

Run the engine and ensure that there are no fuel leaks.

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

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Open the bonnet.

Disconnect the electrical connection from the water in fuel sensor B and unscrew the sensor with `O' ring from the bottom of the element. Retain the sensor for fitting to the new element.

Unscrew the element C.

Note: Fuel will run from the element. 5

Lightly lubricate the seals of the new element with clean fuel. To assist bleeding, fill with fuel before fitting. Tighten the element hand-tight only. Fit the water in fuel sensor B (removed from old element). Connect the electrical connection. Check for leaks. .

Unscrew the element D.

D C

Note: Fuel will run from the element.

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Fig 49.

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Hydraulic System Checking the Fluid Level

!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. 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

!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

Prepare the Machine. Park the machine on level ground. Apply the park brake. Lower the rear linkage to the ground. Stop the engine. Remove the starter key.

Check the Level. Fluid should be visible in the sight gauge B. If the fluid is cloudy, water or air has entered the system. Water or air in the system could damage the hydraulic pump. Contact your JCB distributor if the fluid is cloudy.

Fig 50.

Add Oil If fluid is not visible in the sight gauge, add recommended fluid at tank cap C.

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Changing the Filter Element

Fig 51. 1

Park the machine on level ground. Apply the park brake. Lower the rear linkage to the ground. Stop the engine. Remove the starter key. Wash off all dirt from around the tank cap C and element cover plate E.

g Clean the magnets L. 3

Fit the new element as follows: a

Remove the element as follows: a

Remove tank cap C.

b Remove nuts D, cover plate E and 'O' ring F. c

Remove the element assembly G and 'O' ring H.

d Remove the nut and spring assembly J. Remove the element K from its spindle. e

Remove and discard the paper insert Y from metal outer element K.

Clean the metal outer element K.

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Fit a new paper insert Y into metal outer element K.

b Assemble the refurbished element K on to the spindle, using a new seal M. Ensure that the top lip of the seal locates in the groove inside the filter head N. Fit and tighten the nut and spring assembly J. c

Fit the element assembly G using a new 'O' ring H.

d Refit cover plate E and nuts D using a new 'O' ring F.

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Section 3 - Maintenance Routine Maintenance Hydraulic System e

3 - 67

Tighten nuts D to 7 Nm (5 lbf ft) and top up the fluid level, K Checking the Fluid Level ( T 3-65).

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Changing the Hydraulic Fluid and Cleaning the Suction Strainers

!MCAUTION

Fig 52.

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

Park the machine on firm, level ground. Lower the attachments, stop the engine and remove the starter key. Disconnect the battery, chock the wheels.

Place a container that can hold at least 120 litres (26.4 UK gal; 31.7 US gal) beneath drain plug B. Remove the plug B and allow the oil to drain. Refit the drain plug.

!MCAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Fig 53. 3

Remove the strainers as follows: a

Disconnect and remove hoses C and D.

b Unscrew strainers E and F. 4

Clean the strainers with a suitable solvent. Follow the solvent manufacturer's instructions on safety.

Refit the strainers, using JCB Activator and JCB Threadlocker and Sealer on the threads.

Refit hoses C and D.

Fill the tank with the recommended hydraulic fluid.

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Section 3 - Maintenance Routine Maintenance Hydraulic System

Emptying the Hydraulic Coupling Drain Reservoirs Drain the front and rear reservoirs as follows:

Fig 55. 4

Fig 54. 1

Position a suitable container beneath the reservoir C.

Remove the cap D and allow the hydraulic oil to drain into the container.

Dispose of the drained oil as required by local environmental regulations.

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Repeat the procedure at reservoir E.

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Section 3 - Maintenance Routine Maintenance Transmission

Transmission Checking the Transmission Oil Level 1

Park the machine on firm, level ground. Engage the park brake. Lower the equipment. Stop the engine.

Check that oil is at the top mark on dipstick A. Add recommended oil, if necessary, at filler B. K Fluids, Lubricants and Capacities ( T 3-14) for recommended oil. After topping up, run the engine for 1 minute, then stop the engine and allow to stand for 2 minutes before re-checking the level.

Note: Do not overfill as this would cause oil to be forced past the oil seals and out of the gearbox.

Fig 56.

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Section 3 - Maintenance Routine Maintenance Transmission

Changing the Transmission Oil Filter Note: If the transmission oil filter warning light comes on when the engine is running and the oil is warm, change the filter element before the time shown in the service schedule. 1

Prepare the Machine. Park the machine on firm, level ground.

Remove the element. a

Position a small container to catch the oil when the bowl is removed.

b Unscrew bowl A and take out the element B. 3

Fit the new element (do not wash the old one). a

Clean the filter head C.

b Make sure that seals D are in position and apply a film of oil to the seals. Fit the new element into the bowl and screw the bowl onto the filter head. 4

Tighten the bowl to 40 Nm.

Check the Oil Level and top up if required.

Check for Oil Leaks a

Run the engine for a few moments to circulate the oil. Check that the transmission oil warning light has gone out. If the light stays on, contact your JCB Distributor.

b Stop the engine and check for leaks around the filter.

Fig 57.

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Section 3 - Maintenance Routine Maintenance Transmission

Changing the Transmission Oil and Strainer 1

Prepare the Machine. Park the machine on firm, level ground.

Stop the Engine. Disconnect the battery to prevent the engine being started. Chock all four wheels before getting under the machine.

Place a container that can hold at least 75 litres (16.5 UK gal) beneath the transmission to catch the oil.

Remove drain plug A and the Ò' ring. Make sure the Ò' ring and mating surface are not damaged. Let the oil drain out, then clean and refit the drain plug and the Ò' ring.

Remove screws B and cover plate C. Pull out the strainer D.

Fit a new strainer D. Refit cover C and its 'O' ring. Fit screws B.

Fill the transmission with the specified oil. K Checking the Transmission Oil Level ( T 3-71)

Fig 58.

Fig 59.

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Section 3 - Maintenance Routine Maintenance Transmission

Checking the Clutch Fluid Level

!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

Check the fluid level in the reservoir A. The fluid level should be between the two lines B and C moulded into the side of the reservoir. If necessary, add fluid as in Step 2.

E A

Note: If the level has fallen below the lower mark C, the system must be checked by your JCB distributor.

Add the specified fluid. Clean the area around the filler cap E. Remove the cap and carefully pour in the recommended fluid until it reaches the correct level. Avoid spilling it. Wipe up any spillage. Do not allow dirt to enter the reservoir. Fit the cap securely.

Note: Do not use ordinary hydraulic fluid. Fig 60.

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Section 3 - Maintenance Routine Maintenance Axles

Axles Front Axle Checking the Axle Beam Oil Level 1

Prepare the Machine Park the machine on firm, level ground.

!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

Check/Add Oil a

Fig 61.

Clean the area around the fill/level plug A, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole.

b Add recommended oil, if necessary. K Fluids, Lubricants and Capacities ( T 3-14) for recommended oil. c

3 - 75

Clean the plug and sealing washer before refitting.

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Section 3 - Maintenance Routine Maintenance Axles Checking the Hub Oil Levels Check each hub separately.

!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

Prepare the Machine Park the machine on firm, level ground with the oil level plug B for one hub in the position shown. Engage the park brake. Stop the engine and remove the starter key.

Check/Add Oil a

Clean the area around the fill/level plug B, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole.

b Add recommended oil, if necessary. K Fluids, Lubricants and Capacities ( T 3-14) for recommended oil. c 3

Clean the plug before refitting.

Repeat steps 1 and 2 for the other hub.

DRAIN OIL LEVEL

Fig 62.

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Section 3 - Maintenance Routine Maintenance Axles Changing the Oil 1

Position level/drain plug C in both of the hubs at the bottom.

Note: Depending on the phasing of the hubs, it may not be possible to position both hub level/drain plugs at the bottom at the same time. In this case, do Step 2 at one hub, then rotate the axle and drain the other hub.

Fig 64. 2

!MCAUTION

OIL LEVEL

DRAIN

Place containers beneath the two hub level/drain plugs C and the axle beam drain plug D. Remove the plugs and allow the oil to drain

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

Fig 63.

3 - 77

Clean and refit plugs C and D.

Fill both hubs and the axle beam separately, K Checking the Axle Beam Oil Level ( T 3-75) and K Checking the Hub Oil Levels ( T 3-76).

9803-8040-6

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Section 3 - Maintenance Routine Maintenance Axles

Rear Axle and PTO

Check hub oil level Clean the area around the level plug A, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. If the level is low proceed to step 3. Otherwise, clean and refit the level plug.

Checking the Oil Level

Add oil until it runs from the hole, K Fluids, Lubricants and Capacities ( T 3-14) for recommended oil. Clean the plug before refitting Note: Do not overfill as this would cause oil to be forced past the oil seals and out of the axle. 4

!MCAUTION

Add oil

Repeat steps 1 to 3 for the other rear hub.

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

Note: Although the same oil is used right through the rear axle, it is necessary to check the level at both hubs and the axle beam. 1

Prepare the machine Park the machine on firm, level ground with the oil level plug A for one hub in the position shown. Engage the park brake. Stop the engine and remove the starter key.

Fig 65.

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Section 3 - Maintenance Routine Maintenance Axles

Fig 66. 5

Check axle beam oil Level Clean the area around the level plug B, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. If the level is low proceed to step 6. Otherwise, clean and refit the level plug.

Add Oil Clean the area around the filler plug C, then remove the plug and its sealing washer. Add oil until it runs from the level plug hole B. K Fluids, Lubricants and Capacities ( T 3-14) for recommended oil. Clean both plugs before refitting.

Note: Do not overfill as this would cause oil to be forced past the oil seals and out of the axle.

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Section 3 - Maintenance Routine Maintenance Axles Changing the Oil

Fig 67. 1

Position level/drain plug D in both of the hubs at the bottom.

Fig 68. 2

Place containers beneath the two hub level/drain plugs D and the axle beam drain plug E. Remove the plugs and allow the oil to drain.

!MCAUTION

3-3-1-1

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

3 - 80

Clean and refit plugs D and E.

Fill both hubs and the axle beam separately, see K Checking the Oil Level ( T 3-78).

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Section 3 - Maintenance Routine Maintenance Tyres and Wheels

Tyres and Wheels General

necessary to have the speed limiter adjusted (consult your JCB Dealer).

The versatility of the JCB Fastrac dictates a range of tyre types which may be operated at differing loads and widely differing speeds. Agricultural type tyres are designated according to both their load carrying ability and their ability to operate at certain speeds.

Wheel and Tyre Replacement If a replacement wheel or tyre is needed, call in a qualified tyre mechanic. Make sure he is aware of the following warning and notes:

Generally, the speed at which a given tyre can operate depends upon inflation pressure and the load carried. The table in the Specification section gives the load carrying capacity per tyre at varying pressures and speeds. All tyres supplied as original equipment may be operated over the full speed range of the vehicle provided the pressure is correct and their loading is no higher than that given in the table.

!MWARNING When ordering tyres, you must specify not only the tyre size but also the speed designation. The correct tyres for the machine are shown in the Tyre Pressures, Speeds and Loads table. On no account should you use tyres of other designations without first gaining approval from the machine manufacturer. 13-3-1-8_2

!MWARNING Running tyres outside recommended guidelines may result in failure of the tyres which at high speeds may endanger life. BE WARNED. 13-3-1-6

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

Note: The front and rear tyres fitted to this model of tractor are not the same size. If replacement wheels or tyres are fitted, always make sure that the correct matching front/ rear sizes are fitted K Table 3. Permitted Tyre Size Combinations ( T 3-81) Note: To reduce the possibility of vibration, wheels and tyres with a rim diameter bigger than 30 inches must be assembled with the wheel high spot and the tyre low spot correctly aligned within a tolerance of +/- 7.5 degrees. Table 3. Permitted Tyre Size Combinations Front Tyre Size Rear Tyre Size

13-3-2-5

!MWARNING

540/65 R34

650/65 R38

540/65 R38

710/70 R38

Checking Wheel Nut Torques

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

Every day, before starting work, check that the wheel nuts are tight.

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

Wheel Nut Torque Setting

13-3-1-7_1

Note: If tyres are fitted that are a different size from those previously fitted, ensure that the road speed display is programmed to show the correct speeds for the new tyres (see Instruments in Operation section). It may also be

3 - 81

Item

lbf ft

Front and rear wheels

500

370

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Section 3 - Maintenance Routine Maintenance Tyres and Wheels

Tyre Inflation

!MWARNING An exploding tyre can kill, inflated tyres can explode if overheated. Do not cut or weld the rims. Use a tyre/ wheel specialist for all repair work. 2-3-2-7

These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic. If a replacement tyre is required, K Wheel and Tyre Replacement ( T 3-81). The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job. 1

Prepare the Wheel. Before you add air to the tyre, make sure it is correctly fitted on the machine or installed in a tyre inflation cage.

Prepare the Equipment.

Fig 69.

Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 lbf/in2) above the recommended tyre pressure. See Tyre Pressures, Speeds and Loads (Specification section) for recommended tyres and pressures for your machine. Use an air hose fitted with a self-locking air chuck and remote shut-off valve. 3

Add the Air. Make sure that the air hose is correctly connected to the tyre valve. Clear other people from the area. Stand behind the tread of the tyre while adding the air. Inflate the tyre to the recommended pressure. Do not over-inflate.

!MCAUTION The high speed capability of the Fastrac dictates that water ballasting of the tyres is not recommended. 13-3-1-12

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Section 3 - Maintenance Routine Maintenance Tyres and Wheels

Checking and Adjusting the Front Wheel Alignment

Fig 70.

!MWARNING

Note: The use of a ball joint splitter will make this job easier.

!MCAUTION Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

Position the wheels so that the toe-in measurements are mid-way between the limits given K Checking the Alignment ( T 3-83).

Slacken locking nut/bolt G and screw the track rod end E in or out of the track rod as required, ensuring that the taper of the track rod end E aligns with the taper of the steering arm F.

Refit the track rod end and firmly tighten nut D and nut/bolt G. Re-check the toe-in. If correct, tighten nut D to 250 Nm (184 lbf ft) and nut/bolt G by means of the nut to 70-90 Nm (52-66 lbf ft).

Checking the Alignment 1

Measure the distance A between the leading edge of the front wheel rims at hub height.

Measure the corresponding distance B at the trailing edge.

Distance A should be less than distance B by 0 to 5 mm (0 to 0.2 in). If this is incorrect, proceed to step 2.

Adjusting the Alignment 1

Remove split pin C and nut D. Disconnect the adjustable track rod end E from the steering arm F.

Note: The adjustable end of the track rod may be at either the left or right hand side of the machine, depending upon which way round the track rod has been fitted.

3 - 83

Note: Orientate clamp H as illustrated, i.e. so that nut/bolt G is horizontal on the underside of the track rod. 5

9803-8040-6

Align nut D with the split pin hole by tightening to the next castellation. Fit the split pin C.

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Section 3 - Maintenance Routine Maintenance Tyres and Wheels

Fender Adjustment

Tighten screws B into the holes and clamp firmly.

To accommodate various tyre diameters and working conditions the fenders can be adjusted vertically.

Tighten screws A to further clamp support arm C.

Repeat for second fender.

!MWARNING

To adjust rear fenders:

Remove nuts and bolts D and E.

Support the fender and then slacken bolt F until fender can be moved up or down.

Adjust the height of the fender, at the same time aligning holes in the brackets for bolts D and E with the alternative holes in the chassis.

Fit bolts and nuts D and E. Tighten all bolts and nuts.

2-3-2-1

To Adjust Front fenders

Fig 72.

Fig 71. 1

Slacken clamping screws A.

Support the fender and then slacken screws B until support arm C can be moved up or down.

Adjust the height of the fender, at the same time aligning the holes in support arm C with screws B.

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Section 3 - Maintenance Routine Maintenance Power Take-off (PTO)

Power Take-off (PTO) Front PTO

Clean the plug and sealing washer before refitting.

Checking the PTO Oil Level

Fig 73. 1

Prepare the Machine Park the machine on firm, level ground.

Check/Add Oil a

Clean the area around the fill/level plug B, then remove the plug. Oil should be level with the bottom of the hole.

b Add recommended oil, if necessary. K Fluids, Lubricants and Capacities ( T 3-14)

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Section 3 - Maintenance Routine Maintenance Power Take-off (PTO) Changing the PTO Oil and Filter 1

Prepare the Machine Park the machine on firm, level ground.

Note: As the filter is at the lowest point of the PTO gearbox lubrication system, all the oil will be drained when the filter is removed. There is no need to drain the oil directly from the gearbox. 2

Remove the filter and drain the oil a

Fig 74.

Place a container that can hold at least 10 litres (2 UK gal) below the filter F.

b Unscrew the filter F. Allow the oil to drain into the container. c

Clean the filter head, especially on its sealing face.

Fit the new filter a

Add clean lubricating oil to the new filter. Allow enough time for the oil to pass through the filter element.

b Smear the seal H on the new filter with oil. Screw in the new filter, hand-tight only. Do not overtighten the filter as this could damage the threads. 4

Add oil Fig 75. a

Clean the area around the fill/level plug B, then remove the plug.

Rear PTO

b Add recommended oil. K Fluids, Lubricants and Capacities ( T 3-14)

Checking the PTO Oil Level

The rear PTO is lubricated by the rear axle oil. K Rear Axle and PTO ( T 3-78)

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Clean the plug and sealing washer before refitting.

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Section 3 - Maintenance Routine Maintenance Windscreen Washer

Windscreen Washer Checking Fluid Level Fill the windscreen washer bottle Y with a suitable liquid. The liquid should contain a de-icing fluid to prevent freezing. Do not use engine coolant antifreeze.

A293830

Fig 76.

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Section 3 - Maintenance Routine Maintenance Automatic Trailer Coupling (Optional)

Automatic Trailer Coupling (Optional) Checking for Wear 1

The coupling pin diameter A is either 30 mm (1.18 in) or 38 mm (1.5 in) when new. The 30 mm pin must not wear down below 28 mm (1.1 in) at any point. The 38 mm pin must not show any measurable wear.

The coupling ring diameter B must not be more than 41.5 mm (1.63 in) at any point.

If wear exceeds the above limits, contact your nearest JCB Distributor.

Note: Whenever the coupling has been pressure-washed it must always be greased. K Greasing ( T 3-21). Any repair work or fitting of a new coupling must be done in accordance with the Service Manual and inspected by an officially recognised expert.

Fig 77.

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Section 3 - Maintenance Routine Maintenance Automatic Trailer Coupling (Optional)

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Section A Optional Equipment Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-6

Section A - Optional Equuipment

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Section A - Optional Equipment Contents Page No. Front Power Take-off (PTO) PTO Drive Shaft and Flexible Couplings ................................................ A - 1 Removal and Replacement ............................................................... A - 1 PTO Gearbox ......................................................................................... A - 3 Dismantling ........................................................................................ A - 4 Assembly ........................................................................................... A - 4 PTO Clutch Dismantling and Assembly ............................................. A - 6

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Section A - Optional Equipment Contents

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Page No.

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Section A - Optional Equipment

Front Power Take-off (PTO) PTO Drive Shaft and Flexible Couplings Removal and Replacement

Fig 1. The numerical sequence shown on the illustration is intended as a guide to removal and dismantling of the complete drive shaft assembly.

then be disconnected from the engine and/or PTO gearbox.

When Removing Note: Spacer A is removable so that the fan belt can be removed and replaced without removing the complete PTO drive shaft (see Fan Belt, Section 3). If only one of the flexible couplings is to be removed and replaced, removal of screws 13, 4, 5, and plate A will allow the shaft to be separated from the couplings which can

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Remove the radiator. Remove socket head screws 1 and 2 and lift out the drive shaft assembly 3.

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Section A - Optional Equipment Front Power Take-off (PTO) PTO Drive Shaft and Flexible Couplings Remove socket head screws 4 and 5 to separate the flexible couplings 6 and 7 from the drive shaft 3 and hub 8.

being re-used. (New socket head screws 1, 2, 4 and 5 are pre-coated with locking fluid.)

Remove socket head screws 9 to separate flywheel 10 from the PTO gearbox.

Torque Settings

Remove socket head screws 11 to separate adaptor plate 12 from the engine.

Item

kgf m

lbf ft

220

162

When Replacing

220

162

220

162

220

162

147

108

147

108

8.7

Make sure that the flexible couplings 6 and 7 are not distorted as shown at X. Correct alignment as shown at Y can be more easily achieved if general purpose grease is applied to socket head screws 1, 2, 4 and 5 to reduce friction between screws and couplings. Note: Spacer A is available in three different thicknesses. Select a suitable thickness of spacer to reduce the axial load on the flexible couplings 6 and 7.

Fig 2.

Fig 3. Apply locking fluid to socket head screws 9 and 11 also to socket head screws 1, 2, 4 and 5 if the existing screw are

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Section A - Optional Equipment Front Power Take-off (PTO) PTO Gearbox

PTO Gearbox

Fig 4.

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Section A - Optional Equipment Front Power Take-off (PTO) PTO Gearbox

Dismantling 1

Drain oil and remove filter (see Section 3).

Remove gearbox from machine.

Remove M6 bolts A and withdraw pump B through the front casing K. Take care to remove ‘O’ rings C and D from the PTO casing.

Remove M5 bolts E and proportional valve F complete with ‘O’ ring.

Remove M8 screws G and the two screws H with bonded seals J.

Hit the output shaft with a soft-faced hammer to separate the front and rear casings K and L.

Prise the clutch assembly M away from the rear casing using two levers. To service the clutch K PTO Clutch Dismantling and Assembly ( T A-6)

Remove bronze bush N, ‘O’ ring P and spring R.

9 10

Fig 5. 4

Pre-assemble the intermediate gears X and Y onto their shafts. Tighten nut b to 40 Nm whilst rotating the gear to seat the bearings. If they do not seat correctly apply more torque. Then release the nut, rotate the gear a few turns and re tighten to 10Nm. Lock the nut with washer c.

Remove input gear and bearings W.

Release intermediate gear X from its shaft by unscrewing nut b and removing washer c and inner race of bearing d.

Lay the rear casing on its back face and refit the clutch assembly and gears into rear casing L.

Grease gasket V to keep it in position and place the front casing in position, using a soft-faced hammer to bring the casings together.

Fit bolts G and H, making sure the the two ‘O’ rings are fitted to bolts H. Tighten bolts to specified setting.

Remove intermediate gear Y in the same way as removing intermediate gear X.

Remove screws U and Z to release rings e and f from the front casing.

Unscrew the adjusting discs g and h from the rings and remove ‘O’ rings j and k also oil seal m.

Assembly 1

Make sure that the working surface of bush N is in good condition and that length of spring R is 13mm (0.51 in). Renew if required.

Renew bearings if worn and all seals and ‘O’ rings.

Check that rotation ring S turns without restriction. Tighten M5 bolts T to 5 Nm (44 lbf in).

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Section A - Optional Equipment Front Power Take-off (PTO) PTO Gearbox

Z j

m h f Fig 6. 8

Fit new ‘O’ ring k to the input shaft adjusting disc g. Grease the threads and screw the adjusting disc g into the ring e. Fit the ring to the front casing and tighten screws U to the specified torque setting. Tighten adjusting disc g to 120 Nm whilst rotating the input shaft, then release the disc.

Repeat step 9 twice then tighten the disc to 40 Nm.

Fit new ‘O’ ring j and oil seal m to the output shaft adjusting disc h. Grease the threads and screw the adjusting disc h into the ring f. Fit the ring to the front casing and tighten screws Z to the specified torque setting.

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Fig 7. 12

Tighten adjusting disc h to 120 Nm whilst rotating the output shaft , then release the disc.

Repeat step 12 twice then tighten the disc to 60 Nm.

Make sure that it is possible to rotate the output shaft by hand. If not, decrease the torque of disc h and/or g.

Refit pump B making sure that new ‘O’ rings C and D are held in position with grease. Tighten bolts A to specified setting.

Torque Settings

Item

kgf m

lbf ft

1.0

4.3

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Section A - Optional Equipment Front Power Take-off (PTO) PTO Gearbox

PTO Clutch Dismantling and Assembly

Fig 8. 1

Remove clutch K Dismantling ( T A-4)

gearbox.

Check the condition of surface R which contacts bronze bush N K Fig 4. ( T A-3) If this surface is damaged, renew the complete clutch assembly.

Clamp the clutch assembly in a press with the shaft A pointing downwards.

Using the press, apply light pressure to clutch piston C and remove circlip E, â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring D and cylinder F.

Check that dowel pins G are free and not damaged.

from

Lever off rear bearing B.

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Section A - Optional Equipment Front Power Take-off (PTO) PTO Gearbox 7

Check length of springs H is 42.4 mm (1.67 in).

Check length of springs J is 22.5 mm (0.89 in).

Remove clutch from press and with shaft A pointing upwards, tip plates K and L out of the housing M.

Press shaft A out of the housing.

Clean and check all parts and sealing surfaces for wear or damage, especially dowel pins and mating surfaces of piston C and cylinder F. Renew all seals.

Check thickness of clutch pack and renew if worn, warped or damaged. Total thickness of new clutch pack is 28 mm (1.1 in). Minimum acceptable thickness of worn clutch pack for re-use is 24.2 mm (0.95 in).

Assemble paper plates K and metal plates L alternately, starting and finishing with a paper plate.

Refit springs H and J and dowel pins G, making sure that the rounded end of each dowel pin is pointing upwards.

Fit new â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring D. Locate the piston and cylinder in the housing, apply pressure with the press and fit circlip E.

Check operation of the clutch by means of compressed air at P.

Refit bearings. K Dismantling ( T A-4)

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Section A - Optional Equipment Front Power Take-off (PTO) PTO Gearbox

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Section B Body and Framework Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

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Section B - Body and Framework

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Section B - Body and Framework Contents Page No. Technical Data Air Conditioning ...................................................................................... B - 1 Special Tools Service Tools Selection List .................................................................... B - 2 Cab ............................................................................................................... B - 7 Direct Glazing .................................................................................... B - 7 Air Conditioning Operation .............................................................................................. Control ............................................................................................. Safety Procedures ................................................................................ Refrigerant Types ................................................................................. Hoses and Pipes .................................................................................. Hoses .............................................................................................. Pipes ............................................................................................... Leak Testing ......................................................................................... Fault Finding ......................................................................................... Component Removal and Replacement ............................................... Components Renewable without Discharging the Refrigerant ........ Components Inside Evaporator Unit Casing ................................... Pressure Switch .................................................................................... Testing ............................................................................................. Removal and Replacement ............................................................. Compressor Clutch ............................................................................... Removal .......................................................................................... Replacement ................................................................................... Heating System .................................................................................... Operation ......................................................................................... Heater Unit ......................................................................................

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B - 13 B - 14 B - 15 B - 16 B - 17 B - 17 B - 17 B - 18 B - 19 B - 22 B - 23 B - 25 B - 26 B - 26 B - 26 B - 27 B - 27 B - 28 B - 29 B - 29 B - 29

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Section B - Body and Framework

Technical Data Air Conditioning

Refrigerant Gas

HFC R134a

Charge Weight

1900 grams

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4 lb 3 oz

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Section B - Body and Framework

Special Tools Service Tools Selection List

Fig 1. Fig 2. Hand Cleaner - special blend for the removal of polyurethane adhesives.

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

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

JCB part number - 892/00845

Fig 3.

Fig 4. 12V Mobile Oven - 1 cartridge capacity - required to pre- Folding Stand for holding glass - essential for preparing heat adhesive prior to use. It is fitted with a male plug (703/ new glass prior to installation. 23201) which fits into a female socket (715/04300). JCB part number - 992/12300

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JCB part number - 892/00843

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Section B - Body and Framework Special Tools Service Tools Selection List

Fig 5. Fig 6. 240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request contact JCB Technical Service.

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

JCB part number:

JCB part number - 892/00842

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

Fig 8. Fig 7. Wire Starter - used to access braided cutting wire (below) Cut-Out Knife - used to remove broken glass. through original polyurethane seal. JCB part number - 892/00848

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JCB part number - 992/12800

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Section B - Body and Framework Special Tools Service Tools Selection List

Fig 10.

Fig 9. Glass Extractor (Handles) - used with braided cutting wire 'L' Blades - 25 mm (1 in) cut - replacement blades for cut(below) to cut out broken glass. out knife (above). JCB part number - 892/00846

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

Fig 11.

Fig 12. Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

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

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

JCB part number - 892/00844

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Section B - Body and Framework Special Tools Service Tools Selection List

Fig 13.

Fig 14.

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

JCB part number - 926/15500 (unit quantity = 500 off)

Fig 15. Fig 16. 892/00801 Clutch Spanner for air conditioning compressor 892/00807 Font Plate Puller for air conditioning compressor

Fig 18.

Fig 17.

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

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Section B - Body and Framework Special Tools Service Tools Selection List

Fig 19. 892/00803 Rotor Installer Set for air conditioning compressor

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Section B - Body and Framework

Cab !MWARNING

Direct Glazing TB-002_3

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

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

Always wear safety glasses during both removal and replacement.

BF-1-8_1

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

Wear protective overalls.

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

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

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

Removing the Broken Glass and Old Sealant

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

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

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

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

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

Glass should not be replaced at temperatures below 5Â°C (41Â°F). 3

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

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

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Section B - Body and Framework Cab a

Pneumatic Knife. K Fig 20. ( T B-8). This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.

Fig 20. Pneumatic Knife i

Press the handle to start the knife blade oscillating.

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

Fig 21. Braided Cutting Wire and Handles

Insert the knife blade into the sealant.

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

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

b Braided Cutting Wire and Handles. K Fig 21. ( T B-8). This method uses a 3-core wire, a wire starter tube and two handles. i

iv Secure each end of the braided cutting wire in the special handles 21-C.

Insert the steel tube 21-A into the old sealant on the inside of the glass.

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Insert the braided cutting wire 21-B down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire.

Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant.

Cut-out Knife. K Fig 22. ( T B-9). The cut-out knife can be used as a left handed or right handed tool.

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Section B - Body and Framework Cab 4

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

If necessary, trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab frame aperture. K Fig 24. ( T B-9)

1-2 mm Fig 22. Cut-out Knife i

Insert the knife blade into the sealant.

Make sure that the blade of the knife is against the glass 22-A.

iii Use the 'pull-handle' to pull the knife along and cut out the old sealant.

Fig 24. 6

d Craft Knife. K Fig 23. ( T B-9). The blades 23-A are replaceable. i

Insert the knife blade into the sealant.

Pull the knife along and cut out the old sealant.

Apply a coat of 'Black Primer 206J' to the paintwork if: a

Paintwork was damaged or scratched during the glass/sealant removal procedures.

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

Preparing the Cab Frame Aperture

Fig 23. Craft Knife Note: There are other tools available to cut out the old sealant. For example, there is a long handle type craft knife to give extended reach. Refer to Service Tools, for details of this and any other tools.

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

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

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

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Section B - Body and Framework Cab Preparing the New Glass

!MWARNING

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 26. ( T B-10).

Make sure that the new glass correctly fits the frame aperture 25-A. a

Put two spacer blocks 25-B onto the bottom part of the frame aperture. Fig 26. Glass Stand

b Install the new glass on the spacer blocks Always use glass lifters 25-C. Check that there is an equal sized gap all round the edge of the glass.

Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board 27-A, sourced locally to fit the glass stand. It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an anti-scratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

Note: The spacer blocks are rectangular in section to give two common gap widths. If necessary they can be trimmed to a smaller size to give an equal sized gap around the glass. Important: The glass edges must not touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass.

Fig 27.

Fig 25.

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

Clean the glass a

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Use 'Active Wipe 205' to thoroughly clean and 'prime' the black ceramic ink band printed on the

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Section B - Body and Framework Cab glass (see Note). Use a lint free cloth to apply the 'Active Wipe 205', allow 5 minutes flash off (drying) time. Note: Do not touch the glass after cleaning with the 'Active Wipe 205'. b If the glass does not have a black ceramic ink band, paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line. K Fig 28. ( T B-11).

Fig 29. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide 30-A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 30. ( T B-11)

Fig 28. 5

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

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

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

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

d Fit the pre-cut nozzle. K Fig 29. ( T B-11). e

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

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

Installing the New Glass 1

If the internal trim strip is damaged, renew it (cut to length as required) before fitting the new glass. Make sure the two spacer blocks are in position. K Preparing the New Glass ( T B-10) - step 1.

Install the glass in the frame aperture:

Install the cartridge in the applicator gun.

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

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Fig 30.

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Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 31. ( T B-12)

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Section B - Body and Framework Cab 4

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

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

Clean the glass after installation: a

Fig 31. Typical M/c. Installation

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

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

b Sit the bottom edge of the glass on the spacer blocks. K Fig 32. ( T B-12)

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

Clean the glass using a purpose made glass cleaner

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

Remove all broken glass from the cab area.

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

Renew all 'warning' and 'information' decals so that the new installation conforms with the original cab installation.

Fig 32. c

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

Make the inside seal smooth: a

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

b Use your finger to make the inside seal smooth.

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Section B - Body and Framework Air Conditioning Operation

Air Conditioning Operation

B C J

V Fig 33. 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 recirculated air, over an evaporator coil in the air conditioning unit. 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

B - 13

the system are the compressor A, condenser B, receiver drier C, expansion valve D and evaporator unit E. To operate the air conditioning system, move 3-position mode selector switch F to the extreme right (the centre position is OFF), turn thermostat switch G to give a suitably cool air temperature for the ambient conditions and select fan speed 1, 2 or 3 on air conditioning blower switch H.

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Section B - Body and Framework Air Conditioning Operation Note: Switch J is for the heater blower which will operate only when switch F is moved to the extreme left K Heating System ( T B-29). In this mode, the air conditioning blower motor R will also operate, always at its lowest speed, regardless of the setting of switch H. Provided that the ambient temperature is high enough, the air conditioning will switch on. The compressor's electromagnetic clutch operates, engaging the compressor drive from the engine fan drive. The compressor A draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. Increasing pressure also increases refrigerant temperature.

of a capillary tube and cycles the compressor clutch on and off to prevent freezing of condensate on the evaporator coil. The signal from the thermostat switch is sent to the compressor clutch via binary switch V which is designed to disengage the compressor clutch if the pressure either falls below the switch low pressure setting or rises above the switch high pressure setting. This will protect the system from damage that would be caused by either refrigerant loss or excessive pressure.

High pressure refrigerant is forced from the compressor to the condenser B, mounted in front of the engine radiator. Ambient air is drawn across the condenser fins by the engine cooling fan. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content. The refrigerant then passes through the receiver drier C. The receiver drier serves as a reservoir for refrigerant and also contains a desiccant to remove moisture from the system. The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve D, which meters the amount of refrigerant entering the evaporator. In the expansion valve the refrigerant expands to become a low pressure, low temperature liquid. The refrigerant is drawn through the evaporator E by the suction of the compressor. The temperature of refrigerant is now considerably below that of the air being drawn across the evaporator coil by the blower. Heat is transferred from the ambient and recirculated 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 coil and is drained away via condensate drain tubes through the cab floor. 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.

Control Control of the system is achieved by the cyclic action of the compressor's electromagnetic clutch. The thermostat switch senses the evaporator coil temperature by means

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Section B - Body and Framework Air Conditioning Safety Procedures

Safety Procedures The air conditioning system uses refrigerant under pressure in a closed circuit. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by an air conditioning engineer. The following guidelines should be adhered to by all personnel servicing the air conditioning system.

!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 steam components.

When charging or discharging the refrigerant system, no smoking or naked flames should be allowed in the immediate vicinity. The refrigerant itself does not give off a poisonous gas, but when it comes into contact with a naked flame a poisonous gas is produced

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 system components (e.g. charging hoses or pressure switch). 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.

4-3-4-1_2

It is critical that the correct refrigerant and related components are used and that charging is done only by qualified personnel, K Refrigerant Types ( T B-16). As a precaution against possible accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a well ventilated area.

It is illegal to discharge the refrigerant into the atmosphere during service operations. Either a recycling charging station should be used or the refrigerant gas should be discharged to a canister.

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

clean

refrigerant

system

!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

BF-1-2

Containers of refrigerant should be stored in a cool environment away from direct sunlight.

DO NOT perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses).

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Section B - Body and Framework Air Conditioning Refrigerant Types

Refrigerant Types The refrigerant used in the Fastrac air conditioning system is Freon R-134a.

!MCAUTION Air conditioning systems using R-134a refrigerant are not compatible with systems using R-12 refrigerant. No attempt should be made to charge a system with a different refrigerant from that originally used. No component that comes into contact with refrigerant can be interchanged between machines using the two different refrigerants, otherwise contamination of the system will occur. BF-1-6

The air conditioning system is fitted with quick connect type charging ports. These connectors are designed to be used with the charging equipment for the correct refrigerant.

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Section B - Body and Framework Air Conditioning Hoses and Pipes

Hoses and Pipes

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, orifice tube, evaporator coil and suction accumulator and at bulkhead connectors above and below the cab floor. If leakage is detected from a hose connector, tighten the connector 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.

Fig 34.

Note: It is essential that 'O' rings of the correct material (HNBR - colour coded green) are used. It is also essential to use the hoses specified by JCB as R134a refrigerant can permeate through the material used in the hoses designed for systems using R12 refrigerant.

Pipes Particular care must be taken when connecting the compressor hose end pipes to the compressor ports. Suction pipe M should be tightened to a torque of 32.5 ±3 Nm (24 ±3 lbf ft, 3.3 ±0.4 kgf m), discharge pipe N to a torque of 23.5 ± 3.4 Nm (17.5 ± 2.5 lbf ft, 2.4 ± 0.35 kgf m). Use of excessive torque could result in cracks in the compressor casting.

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Section B - Body and Framework Air Conditioning Leak Testing

Leak Testing 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 of leakage can be found by applying soap solution to suspect areas. 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. 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.

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

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Section B - Body and Framework Air Conditioning Fault Finding

Fault Finding The following fault finding checks can be undertaken without discharging the air conditioning system. Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers.

The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant pressure gauge should be used K Leak Testing ( T B-18). However, if a leak detector is not available an approximate source of leakage can be found by applying soap solution to suspect areas.

Table 1. General Fault Indications There are several indications that may help to determine the fault area on a system not working efficiently: a)

Poor Performance

Blower does not operate on all speeds

Condenser coil air flow restricted-

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

System overcharged-

Evacuate and recharge

Blower resistor failed-

Renew resistor.

Condenser coil blockage -

Remove debris from around coil/renew condenser.

Overcharging of refrigerant system-

Evacuate and recharge system

. c)

Compressor clutch continually cuts out

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Section B - Body and Framework Air Conditioning Fault Finding Table 2. No Air Conditioning CHECK 1

ACTION

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

Is the air conditioning (evaporator) blower working?

NO:

Reset controls and retest.

YES:

Check 3.

NO:

Check 4.

Is the compressor running (visual check of pulley/clutch)? YES: NO:

Is the air conditioning fuse blown? (See section 3 for fuse YES: number) NO:

Does the air conditioning relay operate when starter switch YES: is turned off and then to IGN? (Audible test.) NO:

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Check 2

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Check11. Check 7. Renew fuse and retest. Check 5. Check 10. Check 6.

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Section B - Body and Framework Air Conditioning Fault Finding CHECK

ACTION

YES:

Renew relay and retest.

NO:

Remake connections and retest.

Are the relay electrical connections OK?

Is there a 12V supply to the pressure switch? K Pressure YES: Switch ( T B-26).

Does the compressor clutch engage with the pressure switch bypassed? K Pressure Switch ( T B-26).

NO:

Check 9.

YES:

Renew pressure switch and retest.

NO:

Renew the compressor clutch and retest.

Does the clutch engage with thermostat switch bypassed? YES:

Are blower switch and wiring OK?

Is condensor air flow blocked?

Is evaporator air flow blocked?

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Check 8.

Renew thermostat switch and retest.

NO:

Check all electrical connections.

YES:

Renew blower motor.

NO:

Renew switch or wiring.

YES:

Clean condensor and radiator.

NO:

Check 12.

YES:

Clean filter and, if necessary the evaporator.

NO:

Call in refrigeration engineer.

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Section B - Body and Framework Air Conditioning Component Removal and Replacement

Component Removal and Replacement

Fig 35.

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Section B - Body and Framework Air Conditioning Component Removal and Replacement

Components Renewable without Discharging the Refrigerant

Switches The following switches can be serviced with the evaporator unit U in situ:

Air Conditioning Relay (see Relay Identification, Section C).

Mode selector switch

Thermostat switch

Air Conditioning (evaporator) blower switch

Heater blower switch

Binary pressure switch

Rectifier bridge

R X

Note: K Pressure Switch ( T B-26) and K Components Inside Evaporator Unit Casing ( T B-25). F

Mode selector Switch

Air Conditioning blower switch

Heater blower switch

Removal 1

Remove screws B and ease switch panel C/decal D away from evaporator unit U by about 100 mm (4 in), taking care not to damage capillary tube T.

Disconnect the electrical connections from the switch.

Air conditioning (evaporator) blower motor

Unscrew the switch mounting nut and remove the switch from the panel.

Compressor clutch

Replacement

Note: Any further dismantling can only be done after discharging the refrigerant. This requires special equipment and must be done only by qualified refrigeration engineers. Instructions for these jobs are therefore not included in this manual.

For replacement, reverse the sequence. Ensure that decal D is positioned correctly.

No component that comes into contact with refrigerant can be interchanged between machines using the two different refrigerants, otherwise contamination of the system will occur.

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Section B - Body and Framework Air Conditioning Component Removal and Replacement

Fig 36.

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Section B - Body and Framework Air Conditioning Component Removal and Replacement

Components Inside Evaporator Unit Casing The following components can be serviced after removal of the cover plate E: G

Thermostat Switch

Rectifier Bridge

Blower Motor

To gain access, remove the head lining, the 'B' post cover and 'P' clips, unbolt the evaporator unit and lower it onto the seat. The hose length is sufficient to allow this.

Thermostat Switch When removing thermostat switch G, follow the procedure for removal of the other switches, but remove the capillary tube T from between the evaporator coil fins so that the capillary tube can be withdrawn with the switch. Note the position of the tube to ensure correct replacement. When replacing, take care not to damage the capillary tube and insert the tube in its original position to the full depth of the evaporator coil fins.

Blower Motor 1

Remove thermostat switch G, see Thermostat Switch (X B-25).

Remove the electrical connector.

Remove the mounting screws/washers for blower motor R complete with mounting plate V and separate when clear of the casing.

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Section B - Body and Framework Air Conditioning Pressure Switch

Pressure Switch 936A). If the voltage is low or zero, check the fuses, the air conditioning relay and the thermostat switch. 3

Disconnect the wire from the compressor and connect the vehicle harness connector (wire 936) directly to the compressor. If the compressor clutch engages, the fault is at the pressure switch. If the compressor clutch does not engage, the fault is at the compressor clutch.

Removal and Replacement

!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

Removal 1

Disconnect the electrical connections and unscrew the pressure switch V.

Replacement

Fig 37. The 12V supply is fed from the thermostat to the compressor clutch via the binary pressure switch. The pressure switch contacts will be closed if the charge pressure is between the maximum and minimum refrigerant charge levels.

Screw the pressure switch into the pressure switch port and tighten just sufficiently to form a gas-tight seal.Do not overtighten.

Run the air conditioning and check the pressure switch for leaks as described under Leak Testing (X B-18) If any leaks are found, tighten the pressure switch further until the leaking stops.

The switch contacts must be closed for the compressor clutch to operate. If the compressor clutch will not operate when air conditioning is selected, the fault may be either electrical or system pressure.

Testing 1

Turn start switch to IGN. Do not start engine. Select air conditioning on mode switch, fan speed 1 and the coldest setting on the thermostat switch.

Disconnect the pressure switch V from the main vehicle harness and using a multimeter, check that there is 12V at the vehicle harness connector (wire

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Section B - Body and Framework Air Conditioning Compressor Clutch

Compressor Clutch Removal 1

Hold front clutch plate stationary using tool A (892/ 00801) and remove compressor shaft nut.

Fig 40.

Fig 38. 2

Using puller B (892/00807) remove clutch plate from rotor pulley.

Fig 39.

Fig 41. 4

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Remove shaft key C then release rotor pulley bearing and front housing circlips D.

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Fit shaft/thread protector E over compressor shaft then draw rotor pulley off shaft using puller F (892/ 00802). Check clutch spacer shims L remain on shoulder of shaft.

B - 27

Section B - Body and Framework Air Conditioning Compressor Clutch

Fig 42. 5

Release field coil wire G from cable clip then remove circlip H and coil J from compressor front housing.

Replacement

Fig 44. 4

Check rotor pulley bearing for serviceability. Clean and relubricate or replace as necessary.

Position field coil J on shaft and locate flange protrusion in hole in front housing. Secure coil with circlip H and fit lead G under cable clip.

Check clutch spacer shims L are in place then assemble key C and front clutch plate on compressor shaft. Using rotor installer set 892/00803 and shaft protector K (892/00808), tap clutch plate into position taking care not to damage shaft thread.

Fig 45. 5

Refit compressor shaft nut and torque tighten to 34 42 Nm (3.4 - 4.2 kgf m; 25 - 30 lbf ft).

Using a feeler gauge as shown, check clutch air gap is between 0.4 and 0.8 mm (0.016 and 0.031 in). If air gap is not consistent around circumference, prise front plate up or down at minimum and maximum as appropriate. If air gap is outside stated limits, remove front clutch plate and add or subtract spacer shims L as necessary.

Fig 43. 3

Support compressor on mounting ears at rear of body. Place rotor pulley squarely on compressor shaft then press (or carefully tap with soft faced mallet) rotor into place. Refit internal and external circlips D.

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Section B - Body and Framework Air Conditioning Heating System

Heating System Operation

Fig 46. Set mode selector switch F to the extreme left (the centre position is OFF) and use heater blower switch J to select a suitable heater blower motor speed. Vary the air temperature by means of temperature control K.

Clamp off the two hoses from the Fastrac cooling system and disconnect the hoses from the rear of the heater unit.

Separate the electric connectors at the rear of the heater unit and slide the unit clear. Remove to a work bench for Dismantling.

Heater Unit Removal

Replacement

Remove the cup tray C from above the heater unit by unscrewing the retaining screws from the top face and the screws along the top front edge.

Remove the nine retaining screws AD from the face of the heater unit K Fig 47. ( T B-30) and slide the unit towards the drivers seat to gain access to the hose connectors at the rear.

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Replacement is the reverse of Removal.

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Section B - Body and Framework Air Conditioning Heating System Dismantling and Assembly

Fig 47. 1

Remove grille AE by extracting push-pull retainer AF to gain access to air filter AG.

Remove cover AH to gain access to heater blower motor W, heater blower motor speed control resistor Z and heat exchanger AJ.

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Section C Electrics Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

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Section C - Electrics

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Section C - Electrics Contents Page No. General Using a Multimeter .................................................................................. C - 1 Measuring DC Voltage ...................................................................... C - 2 Measuring Resistance ....................................................................... C - 2 Measuring Continuity ......................................................................... C - 3 Measuring Frequency ........................................................................ C - 3 Testing a Diode or a Diode Wire ........................................................ C - 4 Battery .................................................................................................... C - 5 Maintenance ...................................................................................... C - 5 First Aid - Electrolyte ......................................................................... C - 5 Testing ............................................................................................... C - 6 Specific Gravity Testing ..................................................................... C - 7 Wire and Harness Number Identification ................................................ C - 8 Introduction ........................................................................................ C - 8 Wire Numbers and Functions ............................................................ C - 9 Wiring Harness Repair ......................................................................... C - 10 Introduction ...................................................................................... C - 10 Repair Procedure ............................................................................ C - 10 Electronics System Main Components Diagram .................................................................. C - 13 Harness Data Drawings and Interconnection .............................................................. C - 15 Harnesses ....................................................................................... C - 15 Instrument Cluster Description and Programming .............................................................. Instruments ...................................................................................... Warnings (Audible/Visual) ............................................................... Warnings (Visual only) ..................................................................... EMS Programming Mode Levels 0 and 1 ........................................ Wheel Slip .......................................................................................

C - 52 C - 52 C - 54 C - 56 C - 58 C - 64

Touch Screen Calibration Accessing Calibration Menu ................................................................. Calibration ............................................................................................ Hand Throttle ................................................................................... Foot Throttle .................................................................................... Joystick Centre Position .................................................................. Joystick Left/Right Positions ............................................................ Transmission Clutch Pedal .............................................................. Transmission Range ........................................................................ Transmission Ratio .......................................................................... Transmission Turbo Clutch .............................................................. Front PTO ........................................................................................ Rear PTO ........................................................................................ Steering Angle .................................................................................

C - 66 C - 67 C - 67 C - 69 C - 71 C - 73 C - 75 C - 77 C - 79 C - 81 C - 83 C - 85 C - 87

Spool Valve Controls Calibration Introduction ........................................................................................... C - 89 Accessing the Spool Valve Calibration Mode .................................. C - 89 Calibration Mode ............................................................................. C - 90

C-i

Section C - Electrics Contents Contents Page No. Spool Valve Slice Configuration Introduction ........................................................................................... C - 92 Accessing the Configuration Mode .................................................. C - 92 Valve Slices Currently Configured ................................................... C - 93 Configuring â&#x20AC;&#x2DC;Boschâ&#x20AC;&#x2122; Slices to an 8000 Series Fastrac ..................... C - 93 Diagnostic Error Codes Introduction ........................................................................................... C - 96 Non-displayable Fault Codes ......................................................... C - 96 Diagnostic Error Codes - ABS .............................................................. C - 97 Introduction ...................................................................................... C - 97 ABS Code Tables ............................................................................ C - 98 Codes Prefixed C to Z ........................................................................ C - 116

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Section C - Electrics

C - iii

Section C - Electrics

General Using a Multimeter TC-002

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

Fig 2. AVO 2003

Fig 1. FLUKE 85

Fig 3. A Typical Analogue Meter

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Section C - Electrics General Using a Multimeter 1

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

Measuring Resistance 1

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

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

Select the correct range on the multimeter. a

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

On the FLUKE 85. i

b On the AV0 2003.

Measuring DC Voltage

i 1

Select the correct range on the multimeter. a

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

On the FLUKE 85. c

Turn the switch to position 1-B.

On an analogue meter. i

b On the AV0 2003.

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

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

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

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

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

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Section C - Electrics General Using a Multimeter

Measuring Continuity

Measuring Frequency

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

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

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

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

Insert the red probe into socket 1-J.

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

Press button 1-H once.

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

Select the correct range on the multimeter. a

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

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

On an analogue meter. Turn the dial to the lowest Ohms (â&#x201E;Ś) range. If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.

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Section C - Electrics General Using a Multimeter

Testing a Diode or a Diode Wire

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

On an analogue meter. i

Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. The meter should read 20-400 kâ&#x201E;Ś, if it reads more than this the diode is faulty.

To test a Diode or a Diode Wire a

On the FLUKE 85. i

Turn the switch to position 1-D.

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

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

Select the Ohms 1000s (1k) range.

Select the Ohms 100s range. Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. The meter should read 300-400â&#x201E;Ś, if it reads less than this the diode is faulty.

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

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

b On the AV0 2003. i

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

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

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Section C - Electrics General Battery

Battery TC-001_3

!MWARNING

Maintenance To ensure that the battery provides optimum performance the following steps should be observed: 1

Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.

When applicable - never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates. Use only distilled water for topping up.

Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) - this condition makes recharging the battery very difficult.

Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery: – Never boost-charge a maintenance free battery. – Never charge a maintenance free battery at a voltage in excess of 15.8 Volts. – Never continue to charge a maintenance free battery after it begins to gas.

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first.

First Aid - Electrolyte Do the following if electrolyte:

GETS INTO YOUR EYES 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. 5-3-4-3_1

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Section C - Electrics General Battery

Testing

This test is to determine the electrical condition of the battery and to give an indication of the remaining useful `life'. Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27Â°C).

Set the CHECK/LOAD switch 4-A to LOAD and hold down for 5-10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

Note: Do not hold the switch in the LOAD position for more than 10 seconds. 6

K Table 1. Fault Diagnosis ( T C-6), if the foregoing tests are unsatisfactory.

Ensure that the battery is completely disconnected from the vehicle. Connect up the battery tester as follows: 1

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

Set rocker switch 4-B to the battery voltage (12V).

Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.

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

Battery Tester Readings 1

Fig 4. Battery Tester

Table 1. Fault Diagnosis Remedy

CHECK: 0 - 12.6 Volts

Renew battery

LOAD: less than 6 Volts 2

CHECK: 6 - 12.4 Volts

Recharge and re-test. If tests still unsatisfactory renew battery.

LOAD: less than 9 Volts and falls steadily but remains in yellow zone. 3

CHECK: less than 10 Volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

LOAD: less than 3 Volts 4

CHECK: more than 11 Volts

Charge battery which will probably recover.

LOAD: 6 - 10 Volts steady

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Section C - Electrics General Battery

Specific Gravity Testing The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15°C (60°F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing.

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15°C (60°F) a 'correction factor' must be applied to the reading obtained. Add 0.07 per 10°C (18°F) if the temperature is higher than 15°C (60°F) and subtract the same if the temperature is lower.

Table 2. Specific Gravity at 15°C (60°F) Fully Charged Half Discharged

Fully Discharged

Ambient temperature up to 27°C (80°F)

1.270 - 1.290

1.190 - 1.210

1.110 - 1.130

Ambient temperature above 27°C (80°F)

1.240 - 1.260

1.170 - 1.190

1.090 - 1.110

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Section C - Electrics General Wire and Harness Number Identification

Wire and Harness Number Identification TC-003

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

Fig 5. Typical Wire and Harness Number K Fig 5. ( T C-8) shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it's length.

The number stamped on the wire shown in K Fig 5. ( T C-8) identifies the following:

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

Description

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.

9/371

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

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Section C - Electrics General Wire and Harness Number Identification

Wire Numbers and Functions

Wires 800-999

Wires 000-199

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

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

Wires In Splices

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

Wires 200-399

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. Note: The letters I, O, Q and S are not used.

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.

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 6-A it is prefixed by the Earth symbol 6-B. This symbol is printed onto the wire, it may however be omitted from harness drawings.

Fig 6. Where a load is switched negative, the wire number from the load to the switch shall be different to that of the wire from the switch to the earth.

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9803/8040-5

C-9

Section C - Electrics General Wiring Harness Repair

Wiring Harness Repair TC-004

!MCAUTION

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

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

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

ELEC-2-3

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

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

Repair Procedure Part No.

Table 4. Tools Required Description

892/00350

Butane Heater assembly

892/00349

Crimp tool

892/00351

Splice 0.5-1.5 mm (Red)

892/00352

Splice 1.5-2.5 mm (Blue)

892/00353

Splice 3.0-6.0 mm (Yellow)

Qty

Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in K Table 4. ( T C-10), 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 7.

ELEC-2-2

C - 10

9803/8040-5

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 7. ( T C-10). Note that each of the splices detailed is colour-coded to make size and range readily visible.

C - 10

Section C - Electrics General Wiring Harness Repair 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 8. ( T C-11). a

seal

the

Remove the cap 9-A from the end of the disposable gas cartridge 9-B.

Fig 10. d Turn the small ring 11-E so that the air holes at 11F are completely closed. Fig 8. b Before assembling the gas cartridge to the reflector element 10-C, turn the red ring 10-D to the left, (in the direction of the minus sign marked on the ring).

Fig 11. e Fig 9. c

C - 11

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 10. ( T C-11). A click will be heard.

Turn the red ring 12-D to the right (in the direction of the plus sign) in order to turn on the gas.

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

9803/8040-5

C - 11

Section C - Electrics General Wiring Harness Repair i

Side wings 14-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).

Fig 12. f

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. 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 13-E until the air holes at 13-F are completely open. The tool is ready for use.

Fig 14. ii

Side wings 15-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 15. h To switch off the heater, turn the red ring 15-D to the left (in the direction of the minus sign). Fig 13. g The heater can be used in two modes:

C - 12

9803/8040-5

C - 12

Section C - Electrics

Electronics System Main Components Diagram

Fig 16. The electronic system consists of several main components. These all communicate with each other over one of the CAN bus networks on the vehicle. The illustration shows all of the main components and their interconnection. The main controller for the machine is the Touch Screen Display (DECU). This acts as the overall vehicle management controller. Briefly, the main components are: -

C - 13

9803/8040-5

Touch Screen Display (DECU) A colour VGA Liquid Crystal Display with touchscreen. It provides a graphical user interface in order to keep the driver informed of the vehicle status. Various menus are accessible for additional configuration purposes. The main user inputs for controlling transmission ratio, engine speed control, etc. are all processed by the DECU.

C - 13

Section C - Electrics Electronics System Main Components Diagram 2

Engine ECU (EDC)

b Transmission Actuator Bus.

An ECU to control engine speed, emissions, torque and engine braking. All commands to the ECU come from the DECU. If necessary, the ECU can be controlled via an analogue foot throttle signal to enable operation without the use of main vehicle CAN bus system. 3

A dedicated bus between the Transmission Control ECU and the Transmission Actuator ECU.

Transmission ECU (EST) The Transmission ECU handles the transmission direction, range and ratio control. As a secondary function it controls the front and rear Power Take Off. The majority of control is via CAN bus. Manual operation is available in case of electronic failure.

Fastrac Central Controller (ECU1) The Fastrac Central Controller handles a number of user control functions, this includes front hitch as well as rear hydraulic services.

Dashboard (EMS) The main user display for vehicle/engine speed and user warning / indication lamps.

ABS The DECU will listen to the communications from the ABS control unit in order to improve diagnostic capability in the field.

Rear Hitch Controller Control functionality as currently used on other Fastrac models but with the addition of CAN bus to allow for improved control and diagnostics.

CAN Bus System The CAN bus is logically split to perform a number of different functions. In summary the system consists of: a

Tractor Bus The main J1939 CAN bus for overall vehicle management of all the components listed above.

C - 14

9803/8040-5

C - 14

Section C - Electrics

Harness Data Drawings and Interconnection Harnesses Harness No. 1

Cab Harness 721/12166

Issue Remarks

Drawing K Fig 17. ( T C-17)

K Fig 18. ( T C-18) K Fig 19. ( T C-19) K Fig 20. ( T C-20) K Fig 21. ( T C-21) K Fig 22. ( T C-22) K Fig 23. ( T C-23) K Fig 24. ( T C-24) K Fig 25. ( T C-25) K Fig 26. ( T C-26) K Fig 27. ( T C-27) K Fig 28. ( T C-28) K Fig 29. ( T C-29) K Fig 30. ( T C-30) K Fig 31. ( T C-31) 2

Chassis Harness 721/12169

K Fig 32. ( T C-32) K Fig 33. ( T C-33) K Fig 34. ( T C-34) K Fig 35. ( T C-35) K Fig 36. ( T C-36) K Fig 37. ( T C-37) K Fig 38. ( T C-38) K Fig 39. ( T C-39) K Fig 40. ( T C-40) K Fig 41. ( T C-41)

CVT Harness 721/11671

K Fig 42. ( T C-42) K Fig 43. ( T C-43) K Fig 44. ( T C-44)

C - 15

9803/8040-5

C - 15

Section C - Electrics Harness Data Drawings and Interconnection 4

ABS Pannier Harness 721/11734

K Fig 45. ( T C-45)

ABS Chassis Harness 721/11807

K Fig 46. ( T C-46)

ABS Cab Harness 721/12168

K Fig 47. ( T C-47) K Fig 48. ( T C-48)

Rear Fender Harness 721/11980

K Fig 49. ( T C-49) K Fig 50. ( T C-50)

C - 16

9803/8040-5

C - 16

CR 89 8

CR 152

CR 47

C D

RSS2

15 0 X X X

CR 100

A B

D C

CR 12

700

1 2 3 4 5 6 7 8 9

500

x x x x x x x

IGNS1

x x x x x x x

BATS1

250

350

400

450

800

600

4 8

ECU 14 2

3 6

10 11 13

F 2

A 6

F 4 F

19 20

A 4

A 2

14 25

13 24

17 1

15 2

CRBL

13 12

200

10 0

! 200 100

200

150

0 CRES6

0 330

230

0 CRIS

TSSS1

CRES3

EDCIS 100

290

250

TO SHEET 3

4 3 2 1

150

EDCSSS

8 7 6 5

21 20

19 6

CR 38

CR 125

17 16

CR 142

20 7

CR 146

21 8

11 12 13

SES

500

100

400

RLSS

DATUM

0 DSES

180

250 50

200

TMES1 80

MSS1

9803/8040-5

TO SHEET 4

X CRBLS

PCCO

400

30 0

FLASHER

8 21

4 12

CR 101

29 17

11 23

600

250

F 6

B2 B6 A8 A5

650

B 5

350

B 8

ECURSS

E 8

300

B4 E 5

CR 82

ECURGS

A 4

A 2

250

A5 A 6 1

FLASHER

CR 104

9 10

SVCES

300

15 14

6 5

20 21

1 4

C 6

C 2

C 4

100

D 6

10 22 11

D 2

D 4

5 9

13 12

400

CR 148

B2 B6

F 4

2 6

B 5

F 2

10 11 13

CR 4

B4 B 8

F 6

5 9

ECUFRS

C 6

C5 C8

E 8

4 8

250

C 4

E 5

200

C 2

E6 E2

11 10

D 6

5 9

D 4

14 13 12

360

CR 121

11 10

CR 120

CR 1

CR 150

ECU 12 3

1 2

200

D 2

ECU 13

ECU 11

ITEM HK

100

300

PFSB9

BATS2

IGNS2

250

CR 45

500

100

350

470

CDS

1000

ITEM HJ

800

450

CR 46 X

CR 119

F G

500 B

X X

A J

220

200

X X 70

D C

75 X

CR 116

721/12166

TO SHEET 2

4 8

J1708+

4 2

550

600

FIT MATING HALF FITTED WITH CAVITY SEALS

600

CR 33 1

J1708-

CR 54 1

CR BS

9 8

CR 3

6 7

C - 17

F05/264 1 DMC 11/05 OTHER SHEETS MODIFIED. NEW ISSUE.

20 1

ENLARGED VIEW OF CAVITY ID'S FOR E1 E1

EDC ELECTRONIC CONTROL UNIT

LH DRAFT PIN

RH DRAFT PIN

721/12166 SHEET 1 OF 15

Harness Data

C - 17

Drawings and Interconnection

Cab Harness sheet 1 K Fig 18. ( T C-18)

Section C - Electrics

Fig 17.

C - 18

35 20

36 21

22 37

CR 69

49a

8 2

46 32

7 1

CR 51

47 33 19

24 38

10 0

13 14

CR 81

C 2

C 4

E 8

B 8

B 5

CR 73

150

100

XXXXXXXX

B2 B3

B6 A8 A5

F 4

A 6

A 4

A 2

300

CR 44

CR 85

BLACK

300

ITEM EL

CR 74

CR 63

CR 37

CR 98

CR 147

100 CR 48

100

ITEM ES 0

CR 79

500

CONNECT CR74 TO CR73

230

2 1 9

24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25

0 23

0 0 8

CR 66

24 23 22 21 20 19 18 17 16 15 14 13

3000

36 35 34 33 32 31 30 29 28 27 26 25

RED

DO NOT FIT HSG. ATTACH TO GAF USING TEARABLE TAPE

CR 107

RED TAPE IDENTIFIER

350

SSS

FWLSS

325

150

9 6 5

10 3 2

2925

PES1

12 11 10

CR 70

LHSLS

CR 83

3100

PLIS

100 0

CR 59

3150

ITEM EZ

ASS

950

3200

CR 65

12 11 10

2940

F 2 FLASHER

1000

F 6

XXXXXXXX

3350

E 5

E2 E1

0 50

CR 39

C 6

150

D 6

ITEM HZ (COVERED LENGTH = 300)

28 42

D 2

D 4

CONNECT CR73 TO CR74

1 2

300

RWLSS

1 8

4 7

10 3 2

9 6 5 4 7

9 6 5

1 8

4 7

CR 28

300

1 8

10 3 2

CR 24

YELLOW TAPE IDENTIFIER

2900

CR 106

300 1

300

20 0

375 600

XXXXX

11 10

XXXXX 2

350

3 25

10 3 2 1 8

10 3 2

9 6 5

1 8

4 7

18 17 5

1 8

4 7

9 6 5 4 7

CR 5

CR 68

CR 78

CR 77

PHLS

2620

11 10

14 13 12

300 25

2100 ITEM EL

0 A

300

950 ITEM EZ

2000

9 6 5

1 8

CR 126

APWLS

300

500

10 3

13 12

3 7

PISC4 4

300

10 3 2

PES3

35 0

2500

2300

CR 43

2650

CANBUS SPLICES SEE SHEET 5

CR 40

PISA4

2700

! PRIS

CR 36

CR 60

2 6

2850

CR 53

400

CR 57

850

2775

9803/8040-5

ITEM HZ (L=300 COVERED)

CR 32

CR 127 DO NOT FIT HSG. ATTACH TO GAF USING TEARABLE TAPE

1000 A

CR 71

721/12166 SHEET 2 OF 15

Cab Harness sheet 2 K Fig 19. ( T C-19)

Harness Data

C - 18

Section C - Electrics

Fig 18.

Drawings and Interconnection

TO SHEET 1

C - 19

CR 21

CR 18

2 2

CR 136 9

CR 128

200

RED

12 11 10

100

BLACK

CR 135 6

12 11 10

24 23 22 21 20 19 18 17 16 15 14 13

1 5

24 23 22 21 20 19 18 17 16 15 14 13

36 35 34 33 32 31 30 29 28 27 26 25

WRAP RED TAPE OR HEAT SHRINK AROUND ROUND PORTION OF CONNECTOR BODY FOR IDENTIFICATION 2100

CR 153

550

CR 154 0

500 CR 30

2 1

1400

700

CRPFS

100

1000

1 7

300

100

250

570 C

400

700 ECU 6

IFWLS

CR 94 A

1300

CR 137

CRES1

800

70 0

200

CR 7

CR 14

800

200

170

250

CR 8 OFWLS

300

4 7

200

9 6 5

ECU 17

1 8

4 7

250 130

9803/8040-5

100

250

100

CR 16

2 10 3 2

9 6 5

1 8

4 7

10 3 2

9 6 5

1 8

4 7

10 3 2

9 6 5

1 8

4 7

CR 9

CR 144

CR 26

E 11

CR 11

200

250

CR 151

3 7

DIA 10 PVC SLEEVE DO NOT TAPE IN PLACE CR 27

600

400

1 8

10 3 2

650

9 6 5

150

10 3 2

CR 31

1700

200 400

CRES2

2700

650

CR 25

Fig 19. Cab Harness sheet 2 K Fig 20. ( T C-20)

SOLID CONDUIT TO SUIT ITEM HC

CR 117

721/12166 SHEET 3 OF 15

Harness Data

C - 19

Section C - Electrics

3300

Drawings and Interconnection

CR 34

700

CR 10

3400 3200

CR 29 1

CR 35

2750

2300 ORWLS IRWLS

X X X X X X X

1800

X X X X X X X

CRES4

00 37

! 550

400

2160

TO SHEET 1

RHSLS

300

2220

C - 20

ECU 2 6

7 13

ECU 3

ECU 1 8

20 30

ECU 15 5

4 3 2 1

11 21

8 7 6 5

ECU 4

200

CR 115

13 12 11 10 9 8

9803/8040-5

7 6 5 4 3 2

41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24

ECUIS

65 64 63 62 61

SEE SHEET 5

ITEM HK

4 CR 143

C A B

150

ITEM EL

59 58

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

RESISTOR

56 55

XXXXXXXXX 1200

TMSS

XXXXXXXXXXX 1150

XXXXXXXXXX 1000

950

! 900

850

800

TO SHEET 1

NSS

700

670

500

1225

52 51 50

1270

49 48

300

150

16 15

ECUES

18 17

100

15 0

21 20

CR 134

800 REAR OF CONNECTOR

CR 130

10 9

300

10 9

721/12166

SHEET 4 OF 15 1300

ECU 8

CR 145

Fig 20. Cab Harness sheet 4 K Fig 21. ( T C-21)

Section C - Electrics

Harness Data

Drawings and Interconnection

C - 20

GREEN YELLOW

CR 154

GREEN YELLOW

C - 21

CR 153

250 TO BRANCHOUT

CANSS14 DR

IRE

WIRE

DR AIN

AIN

DRAIN

IRE

YELL OW

CANLS13

ATUM HEATSHRINK

YELL OW

G RE

GREE

EEN

OW YELL YELL OW

CANHS13

CAN_H

EN RE

CR 135

L N_

CANHS14

OW YELL

GREE

GR CANLS14

CAN_L

GREEN

RS1

YELLOW IRE W

GRE EN

DR AIN

YELL OW

GRE EN

CANSS15

CR 125

GREE

YELLOW

CR 1

INW

IRE

CANSS16

WIRE

DRAIN

CANLS16

CANHS16

IRE DRA

INW

IRE

DRA IN (628 WIRE B)

INW

WIRE DRAIN 8D) (62

DRA

500 TO DATUM

YELL OW

CANHS12

CANSS12 YELL OW

DRAIN

ECU 4

CANLS5

CANSS5

YELLOW

900 TO DATUM

IRE

APPLY CABLE IDENTIFIERS TO DISTINGUISH CANBUS 2 CABLE

N GREE

IRE

INW

DRA

CELL 12

IRE

GREEN

INW

GREE

YELLO

DRA

ECU 2

CELL 9

WIRE

YELL OW

APPLY CABLE IDENTIFIERS TO DISTINGUISH CANBUS 2 CABLE

DRA

INW

CANHS5

CANLS11

CANSS11

YELLO

CANHS11

IRE

YELLOW

1150 TO DATUM

INW

DRAIN

SCRN GREEN YELLOW YELLOW

GREEN

DRA

CR 119

GREEN

CR 66

CR 145

GREEN YELLOW

GRE

SCRN

YELLOW (515F)

GREEN (514F)

CR83

9803/8040-5

800 TO DATUM

GREE

DRA

CAN_H CAN_L

WIRE

IRE

INW

GREE

YELLOW

YELLOW GREEN SCRN

YELLOW

YELLOW (515B) YELL (515 OW D)

DRA

IRE NW DRAI 28E) (6

IRE INW DRA (628K)

CANSS3

CANLS15

CANHS15 CANLS12

N GREE

GRE

CANHS3 DRAI NW (628 IRE E)

GREE (514B N )

A DR

E WIR

GRE (514 EN F)

N GREE E) (514 YELLO (515 W E)

DRAIN WI (628F RE )

CANSS1

WIR

GRE

CANHS1

W YELLO ) (515F

W YELLO E) (515

CANLS3

EN GRE D) (514

YELLO (515K) W

675C

GREE (514E N )

1OO TO DATUM

100 MAX (TYP) 350 TO DATUM

YELLO

550 TO DATUM

SCRN

GREEN YELLOW

600 TO BRANCHOUT

2775 TO DATUM

CANLS1

W LLO

SPLICE WIRE SCRN TO DRAINWIRE/SHIELD AND INSULATE WITH HEATSHRINK AS PER JCB STD 7100/1000. (TYP 7 PLACES)

N GREE ) (514K

CAN_H

IRE

CANSS13

DR A

RE AINWI

RS2

DRAI

SC R

GRE

CR 51

CANBUS 2

CANBUS 1

SCRN GREEN YELLOW CELL 3 CELL 18 SCRN GREEN YELLOW CELL 21

YELLO

GREE

CELL 15 50

150

CR 130

CANLS2

CANHS2

CR 148

CELL 4 SCRN GREEN YELLOW

GREEN YELLOW

CAN_L RS1

CAN_H

RS2

CELL 5

FUNCTION

WIRE COLOUR J1939

WIRE BASE NUMBER

CAN_L

GREEN

CAN_L 514

CAN_H

YELLOW

CAN_H 515

CR 115

CELL 26

CAN_H CAN_L

CAN_L CAN_H

Cab Harness sheet 5 K Fig 22. ( T C-22)

721/12166

SHEET 5 OF 15

Harness Data

C - 21

Drawings and Interconnection

Fig 21.

CELL 27

Section C - Electrics

RESISTOR SEE SCRAP VIEW ABOVE

C - 22

NOTE: 1. ELECTRICAL STANDARD NOTE 7000/3000 APPLIES TO THIS HARNESS WHERE APPROPRIATE. 2. WIRE TO JCB STANDARD 7000/3300 - 100 C RATED U.O.S. 3. COVERING TO TERMINATE 50mm SHORT OF CONNECTORS U.O.S. 4. ACTUAL DIMENSIONS TO SPLICES TO BE AT THE DISCRETION OF THE MANUFACTURER U.O.S. IT IS INTENDED TO RESPECIFY ALL 0.6mm WIRE TO 0.5mm, AND ALL 1.4mm TO 1.5mm SUBJECT TO THE SUITABILITY OF THE TERMINALS AND WIRE SEALS SPECIFIED. IT IS THEREFORE ACCEPTABLE TO USE 0.5mm AND 1.5mm IN PLACE OF 0.6mm AND 1.4mm RESPECTIVELY, (AND VICE-VERSA) WHERE THE SPECIFIED TERMINALS AND WIRE SEALS ALLOW. ** SERIAL DATA COMMUNICATION WIRE TWISTED PAIR TO SAE J1708

EH 15A EF 7.5A

EE 5A

EJ 20A

EH 15A

EJ 20A

EG 10A

EH 15A

EG 10A

ED 3A

EK 30A

9803/8040-5

EU 40A

EF 7.5A

ED 3A EG 10A

COMPONENT PART NUMBERS SPECIFIED SERVE TO INDICATE THE COMPONENTS REQUIRED AND IT IS ASSUMED THAT THE HARNESS SUPPLIER WILL PROCURE THE COMPONENTS IN THE MOST COST EFFECTIVE MANNER.

EE 5A

EH 15A

EE 5A

EJ 20A

EF 7.5A

NOTE

EE 5A

EH 15A

EF 7.5A

EU 40A

EG 10A

EK 30A

EG 10A

EE 5A

EH 15A

EE 5A

EF 7.5A

*** THROTTLE SIGNAL WIRE CABLE DETAILS: TWISTED TRIPLE - LENGTH OF LAY 25 - 35mm.

1 2 3 4 5 6 7 8 9

EE 5A

EF 7.5A

B EF 7.5A

EH 15A

C EE 5A

CR150

CR12

ITEM

EC 15A

EE 5A

721/12166

EF 7.5A

EG 10A

EF 7.5A

EH 15A

FUSE RATING

SHEET 6 OF 15

Cab Harness sheet 6 K Fig 23. ( T C-23)

Harness Data

C - 22

Section C - Electrics

Fig 22.

Drawings and Interconnection

CR79

C - 23 *

9803/8040-5

ITEM A B C D E F G H J K L M N P R S T U V W X Y Z AA AB AC AD AE AF AG AH AJ AK AL AM AN AP AR AS AT AU AV AW AX AY AZ BA BB BC BD BE BF BG BH BJ BK BL BM BN BP BR BS BT BU BV BW BX BY BZ

DESCRIPTION

MANUFACTURER

JCB PART No

PART No

QTY

0-48 REV RECEPTACLE FOR PINS

ITT CANNON

192900-0437

7220/0043

NEPTUNE SIGNAL PIN (2.0)

ITT CANNON

192990-2480

7204/0004

NEPTUNE SIGNAL PIN (0.5-1.5)

ITT CANNON

192990-2490

7204/0003

4-28 REV RECEPTACLE FOR PINS

ITT CANNON

192900-0074

7220/0037

NEPTUNE POWER PIN (0.5-1.0)

ITT CANNON

121668-0000

7204/0013

NEPTUNE POWER PIN (1.5-2.5)

ITT CANNON

121668-0001

7204/0012

NEPTUNE POWER PIN (2.5-4.0)

ITT CANNON

121668-0002

7204/0005

6189-0133

7216/0001

6 WAY HW090 FEMALE HOUSING

SUMITOMO

6 WAY HW090 FEMALE RETAINER

SUMITOMO

6918-0330

7216/0003

HW090 SOCKET TERM (0.3-1.25)

SUMITOMO

1500-0106

7201/0001

HW090 WIRE SEAL (0.75-1.5) BLUE

SUMITOMO

7165-0118

7210/0002

HW090 SOCKET TERM (2.0)

SUMITOMO

8240-4828

HW090 WIRE SEAL (1.5-2.0) BROWN

7201/0002

SUMITOMO

7165-0119

7210/0003

4 WAY IGN. SWITCH CONNECTOR

MERIT

33 02 90

7234/0003

6 WAY IGN. SWITCH CONNECTOR

MERIT

7236/0003

AMP

280756-2

7201/0610

6.3 FASTIN-FASTON FEMALE (4.0-6.0)

AMP

180351-2

7201/0428

6.3 FASTIN-FASTON FEMALE (1.3-3.4)

AMP

42904-2

7201/0429

6.3 FASTIN-FASTON FEMALE (0.8-2.1)

AMP

1-42100-2

7201/0430

60295-2

7201/0458

9.5 FASTIN-FASTON FEMALE (4.0-6.0)

6.3 FASTIN-FASTON FEMALE (0.3-0.8)

AMP

6 WAY RELAY BASE

33 02 91

RISTS

51158524

7231/0003

INHIBITOR

RISTS

51158989

7231/0004

6.3 LUCAR (0.5-1.0)

RISTS

51102708

7201/0418

RISTS

51103592

7201/0419

RISTS

6.3 LUCAR (1.5-2.0) 6.3 LUCAR (2.5-3.0)

51103593

7201/0420

10 WAY SWITCH CONNECTOR (BLACK)

CARLINGSW.

VC2-01

7219/0013

10 WAY SWITCH CONNECTOR (RED)

CARLINGSW.

VC1-03

7219/0014

4 WAY WEATHER PACK MALE HOUSING

PACKARD

12015798

7214/0008

WEATHER PACK SOCKET TERM (0.5-0.8)

PACKARD

12089188

7201/0011

W/M-PACK 280 WIRE SEAL (0.6-1.0) PPL

PACKARD

7210/0042

12089679

WEATHER PACK SOCKET TERM (1.0-2.0)

PACKARD

12124580

7201/0012

W/M-PACK 280 WIRE SEAL (1.4-2.0) GRN

PACKARD

12015323

7210/0005

WEATHER PACK SOCKET TERM (3.0)

PACKARD

12124581

7201/0027

WIRE SEAL (3.0) GREY

PACKARD

12010293

7210/0006

2 WAY HW090 FEMALE HOUSING

SUMITOMO

6189-0129

7212/0001

2 WAY HW090 FEMALE RETAINER

SUMITOMO

6918-0322

7212/0003

8 WAY MDK3 CONNECTOR (SPEAKERS)

G&H

14070-559-668

7238/0002

8 WAY MDK3 CONNECTOR (POWER)

G&H

14171-559-699

7238/0003

DOUBLE LOCK LATCH TERM (0.5 - 1.0)

G&H

26187-123-178

7201/0013

DOUBLE LOCK LATCH TERM (0.75-1.5)

G&H

26188-123-171

7201/0074

8 WAY POSITIVE MATE RECEPTACLE HSG

AMP

POSITIVE MATE RECEPTACLE (0.5-1.5)

AMP

342642-2

7201/0083

POSITIVE MATE RECEPTACLE (1.0-2.5)

AMP

342867-2

7201/0084

AMP

342414-2

7201/0015

VOLEX

726078

7239/0008

POSITIVE MATE RECEPTACLE (3.0-5.3) 27 WAY FUSE BOX FUSE BOX RETAINING BAR

154761-0

7238/0006

VOLEX

726079

7239/0009

FUSE BOX CONTACT (0.5-1.25)

PRESSAC

11/6514

7201/0008

FUSE BOX CONTACT (1.0-3.2)

PRESSAC

7201/0009

FUSE BOX CONTACT (2.5-6.0)

PRESSAC

11/6515 11/6516

7201/0010

6.3 POSILOCK FEMALE TERM (0.5-1.5)

AMP

160759-3

7201/0400

6.3 POSILOCK FEMALE TERM (1.0-2.5)

AMP

160831-3

7201/0401

6.3 POSILOCK FEMALE TERM (2.5-4.0)

AMP

154717-3

7201/0402

6.3 POSILOCK FEMALE TERM (4.0-6.0)

AMP

790319-2

7201/0426

6.3 POSILOCK SINGLE HOUSING

AMP

154719-1

7201/0403

2.8 POSILOCK FEMALE TERM (0.5-1.2)

AMP

2.8 POSILOCK SINGLE HOUSING

AMP

2 WAY WEATHER PACK MALE HOUSING

174777-1 174779-1

7201/0082

7231/0007

7212/0006

7214/0001

PACKARD

12015792

4 WAY HW090 FEMALE HOUSING

SUMITOMO

6189-0132

4 WAY HW090 FEMALE RETAINER

SUMITOMO

6918-0328

7214/0003

926522

7232/0003

2 WAY POSILOCK "T" HOUSING

AMP

HEAVY DUTY RELAY BASE

AMP

927144-1

STANDARD-TIMER CONTACT (0.5-1.0)

AMP

927 847 -1

7201/0122

COMBI CONTACT (6.0-10.0)

AMP

926935-1

7201/0039

7202/1406

8.4 RING TERM (25.0-35.0)

G&H

BLACK HEATSHRINK 8.4 RING TERM (35.0-50.0) RED HEATSHRINK

03432.311.011

RAYCHEM

CGPT-19/9.5-0

G&H

03436.311.011

7231/0005

7207/1409

0 1 1

RAYCHEM

CGPT-19/9.5-2

4.3 RING TERM (0.5-1.0)

G&H

25203.123.011

7207/1105

5.4 RING TERM (2.5-6.0)

G&H

03411.311.011

7207/1206

USE ITEM GX FOR 0.5mm

WIRE

JCB PART No

MANUFACTURER PART No

QTY

AMP

963040-3

7212/0010

JNR POWER-TIMER CONTACT (0.5-1.0)

AMP

927770-3

7201/0016

JNR PWR-TIMER WIRE SEAL (0.5-1.0)

AMP

828904-1

7210/0012

JNR POWER-TIMER CONTACT (1.5-2.5)

AMP

927766-3

7201/0017

JNR PWR-TIMER WIRE SEAL (1.4-2.0)

828905-1

7210/0013

SUMITOMO

6181-0072

7213/0006

3 WAY HW090 MALE RETAINER

SUMITOMO

6918-0327

7213/0008

HW090 PIN TERM (0.3-1.25)

SUMITOMO

1500-0105

7204/0001

HW090 PIN TERM (2.0)

SUMITOMO

AMP

3 WAY HW090 MALE HOUSING

5.3 RING TERM (1.0-2.5)

G&H

3 WAY HW090 FEMALE HOUSING

SUMITOMO

8230-4480

4 0

7204/0002

7207/1215

6189-0131

7213/0005

25217.123.011

3 WAY HW090 FEMALE RETAINER

SUMITOMO

6918-0326

7213/0007

HW090 CAVITY SEAL BROWN

SUMITOMO

7161-9787

7210/0001

926820-6

7201/0405

6.3 90

POSILOCK FEMALE (0.5-1.5)

AMP

7201/0406

926291

7201/0407

10 WAY HW090 FEMALE HOUSING

SUMITOMO

6189-0135

7219/0001

10 WAY HW090 FEMALE RETAINER

SUMITOMO

6918-0334

7219/0003

AMP

344111-1

7220/0017

36 WAY ECONOSEAL HOUSING (RED) 36 WAY ECONOSEAL ANTI-BACKOUT

6.3 90

POSILOCK FEMALE (1.0-2.5)

6.3 90

POSILOCK HOUSING

AMP AMP

36 WAY ECONOSEAL HOUSING (BLACK)

926790-6

AMP

346189-5

7239/0015

AMP

344112-1

7220/0016

E/SEAL .070 CONTACTS (0.5-2.0) G/P

AMP

344113-1

7201/0067

ECONOSEAL WIRE SEALS (0.5-1.5) BLK

AMP

345791-1

7210/0014

AMP

172748-1

7210/0015

172888-2

7210/0016

ECONOSEAL CAVITY PLUG (0.6-1.4)BLK ECONOSEAL WIRE SEALS (2.0) GREY

AMP

ECONOSEAL CAVITY PLUG (2.0) GREY

AMP

5 WAY SWITCH CONNECTOR

MERIT

6 WAY 6.3 FASTIN-FASTON RECEP HSG

AMP

1 WAY WEATHERPACK FEMALE HOUSING

PACKARD

WEATHERPACK PIN TERM (0.5-0.8)

172748-2

1 0

25 99 91

7235/0004

180904-0

7236/0002

12010996

7211/0001

12089040

7204/0007

12124582

7204/0008

WEATHERPACK PIN TERM (3.0)

PACKARD

12124587

7204/0019

6 WAY HW090 MALE HOUSING

SUMITOMO

6181-0074

7216/0002

6 WAY HW090 MALE RETAINER

SUMITOMO

6918-0331

7216/0004

8 WAY HW090 FEMALE HOUSING

SUMITOMO

6189-0134

7218/0001

SUMITOMO

PACKARD

WEATHERPACK PIN TERM (1.0-2.0)

PACKARD

8 WAY HW090 FEMALE RETAINER

6918-0332

7218/0003

6 WAY FUSE BOX

LUCAS-RISTS

51155068

7241/0013

FUSE BOX CONTACT (0.5-1.0)

LUCAS-RISTS

51101980

7201/0035

FUSE BOX CONTACT (1.5-2.0)

LUCAS-RISTS

51101981

7201/0036

FUSE BOX CONTACT (2.5-3.0)

LUCAS-RISTS

51101982

7201/0037

BULB HOLDER

PRESSAC

13/1567

7240/0002

BULB HOLDER CONTACTS

PRESSAC

11/1568

7240/0004

RISTS

51154201

SINGLE RELAY BASE

14 WAY HW090 FEMALE HOUSING

SUMITOMO

6189-0136

7219/0005

14 WAY HW090 FEMALE RETAINER

SUMITOMO

6918-0336

7219/0007

SUMITOMO

6181-0075

7218/0002

8 WAY HW090 MALE HOUSING FLEXIBLE CONDUIT O/D

10.0

HARNESSFLEX

ULTRASONIC SPLICE

4 WAY POSITIVE MATE RECEPTACLE HSG

AMP

3A FUSE

LITTELFUSE

5A FUSE

LITTELFUSE

7.5A FUSE

LITTELFUSE

10A FUSE

LITTELFUSE

15A FUSE

LITTELFUSE

20A FUSE

LITTELFUSE

30A FUSE

LITTELFUSE

SPLIT FLEXIBLE CONDUIT O/D

2.8 LUCAR (0.5-1.0)

HARNESSFLEX

CTPA08 -

A/R

57 1

154976-0

7234/0007

257003

716/05701

257005

716/05703

257007.5

716/05704

2570010

716/05705

2570015

716/05706

716/05707

2570020

716/05709

2570030 CTPA08

-S

3 2 A/R

RISTS

51102676

7201/0092

4 WAY WEATHER PACK FEMALE HOUSING

PACKARD

12015024

7214/0007

WEATHER PACK CAVITY SEAL

PACKARD

12010300

7210/0008

PACKARD

12010973

2 WAY WEATHER PACK F/MALE HOUSING FLEXIBLE CONDUIT O/D

3 WAY WEATHER PACK MALE HOUSING

HARNESSFLEX PACKARD LITTELFUSE

40A FUSE

CTPA12 12015793

7212/0005

3 A/R

7213/0010

2 2

257040

716/24800

3 WAY SUPERSEAL 1.5 RECEP. HSG

AMP

282087-1

7213/0024

S/S 1.5 RECEP CONTACT (0.3-0.5)

AMP

282403-1

7201/0095

AMP

281934-4

7210/0049

12010717

7213/0009

S/S 1.5 WIRE SEAL (0.5) GREEN 3 WAY WEATHER PACK FEMALE HOUSING FLEXIBLE CONDUIT 0/D

PACKARD 11.5

## APPROVED BY VOLEX FOR USE WITH 2 x 2.0mm WIRES 2

HARNESSFLEX

NC10

11 0 A/R

721/12166 SHEET 7 OF 15

Fig 23. Cab Harness sheet 7 K Fig 24. ( T C-24)

Harness Data

C - 23

Section C - Electrics

** NOT SUITABLE FOR 0.5mm

EV EW EX EY EZ

DESCRIPTION 2 WAY JUNIOR-TIMER HOUSING

Drawings and Interconnection

* APPROVED BY VOLEX FOR USE WITH 4mm

ITEM CA CB CC CD CE CF CG CH CJ CK CL CM CN CP CR CS CT CU CV CW CX CY CZ DA DB DC DD DE DF DG DH DJ DK DL DM DN DP DR DS DT DU DV DW DX DY DZ EA EB EC ED EE EF EG EH EJ EK EL EM EN EP ER ES ET EU

C - 24 9803/8040-5

DESCRIPTION

MANUFACTURER

JCB PART No

PART No

QTY

10 WAY HW090 MALE HOUSING

SUMITOMO

6181-0076

7219/0002

10 WAY HW090 MALE RETAINER

SUMITOMO

6918-0335

7219/0004

7241/0001

10 WAY ATO FUSEBOX

G&H

14757-633-696

FUSEBOX SECONDARY LOCK

G&H

16291-578-698

7241/0002

DFK3 TERMINAL (0.5 - 1.0)

G&H

26462-201-179

7201/0044

DFK3 TERMINAL (1.5 - 2.5)

G&H

26231-331-179

7201/0045

DFK3 TERMINAL (2.5 - 4.0)

G&H

26222-201-179

7201/0046

DFK3 TERMINAL (4.0 - 6.0)

G&H

26233-331-179

2 WAY DFK3 BRIDGE (1.5 - 2.5)

7201/0047 7201/0048

2 0

G&H

26875-000-001

2 WAY DFK3 BRIDGE (4.0 - 6.0)

G&H

26879-000-001

7201/0049

3 WAY DFK3 BRIDGE (1.5 - 2.5)

G&H

26876-000-001

7201/0050

3 WAY DFK3 BRIDGE (4.0 - 6.0)

G&H

26876-000-001

7201/0051

4 WAY DFK3 BRIDGE (1.5 - 2.5)

G&H

26877-000-001

7201/0052

4 WAY DFK3 BRIDGE (4.0 - 6.0)

G&H

26881-000-001

7201/0053

G&H

26882-000-001

7201/0054

G&H

26896-000-001

7201/0055

5 WAY DFK3 BRIDGE (4.0 - 6.0) 6 WAY DFK3 BRIDGE (4.0 - 6.0) 2-13 ST'D RECEPTACLE FOR SOCKETS

ITT CANNON

192900-0508

NEPTUNE SIGNAL SOCKET (0.5 - 1.5)

ITT CANNON

192990-2530

7201/0003

NEPTUNE SIGNAL SOCKET (1.5 - 2.5)

ITT CANNON

192990-2520

7201/0004

NEPTUNE POWER SOCKET (0.5 - 1.0)

ITT CANNON

121668-0100

7201/0063

NEPTUNE POWER SOCKET (1.5 - 2.5)

ITT CANNON

121668-0101

7201/0034

NEPTUNE POWER SOCKET (2.5 - 4.0)

ITT CANNON

121668-0102

7201/0005

7165-0385

7210/0095

HW090 WIRE SEAL (0.5) GREY

SUMITOMO

3 WAY DT MALE (SKT) PLUG

DEUTSCH

DT06-3S-CE05

7213/0031

3 WAY DT MALE (SKT) RETAINER

DEUTSCH

W3S-P012

7213/0016

#16 SOCKET TERMINAL (0.5 - 1.0)

DEUTSCH

#16 SOCKET TERMINAL (1.0 - 2.5)

DEUTSCH

#20 SOCKET TERMINAL (0.5-1.0)

DEUTSCH

1062-20-0222

7204/0029

3 WAY DT FEMALE (PIN) RECEPTACLE

DEUTSCH

DT04-3P-CE03

7213/0030

3 WAY DT FEMALE (PIN) RETAINER

DEUTSCH

7213/0014

#16 PIN TERMINAL (0.5 - 1.0) #16 PIN TERMINAL (1.0 - 2.5) #20 PIN TERMINAL (0.5-1.0)

#20 SOCKET TERM (0.5-1.0) GOLD

DEUTSCH DEUTSCH

1062-16-0622 1062-16-1222

W3P 1060-16-0622 1060-16-1222

7201/0105 -

7204/0027 7204/0036

7201/0120

SUMITOMO

6181-0077

7219/0006

6918-0337

7219/0008

TBA

DEUTSCH

DT06-3S-CE13

DEUTSCH

W3S-1939-P012

#16 SOCKET TERMINAL (0.5-1.0) GOLD

DEUTSCH

1062-16-0644

#16 SOCKET TERM. (0.5-1.0) EXTENDED

DEUTSCH

0462-221-1631

DEUTSCH

HD10-9-1939PE

9 WAY CYLINDRICAL CONNECTOR PROTECTIVE CAP

DEUTSCH

HDC16-9

W'PACK/M'PACK 280 CABLE SEAL (0.5)

PACKARD

12015899

8.4 RING TERM (50.0-70.0) 8.4 RING TERM (10.0-16.0) 2 WAY 2.8 FASTON HOUSING 2.8 FASTIN-ON FEMALE TERM(0.5-1.0) RUBBER BOOT

G&H

03485-311-011

G&H

03422-311-011

7201/0127 7219/0040 7210/0004 7207/1404

2 15 0 1 1 2 1 0

12077292

62572-4

HELLA SUMITOMO SUMITOMO

2 WAY DT MALE (SKT) RETAINER

AMP

2 WAY HW090 MALE (PIN) HOUSING 8.4 RING TERM (2.5-6.0)

2 2

TBA

PACKARD

2 WAY HW090 MALE (PIN) RETAINER 2 WAY DT MALE (SKT) PLUG

5 2

1060-20-0222

1062-20-0244

SUMITOMO

3 WAY DT MALE (SKT) RETAINER (BLUE)

DEUTSCH

14 WAY HW090 MALE (PIN) RETAINER 3 WAY DT MALE (SKT) PLUG

DEUTSCH

14 WAY HW090 MALE (PIN) HOUSING BOOT (RUBBER OR HEATSHRINK)

9GT146757007 6181-0070 6918-0323

1 7212/0001 7212/0004

1 1

G&H

25231.123.011

7207/1213

DEUTSCH

DT06-2S-CE05

7212/0052

DEUTSCH

W2S-P012

7212/0031

F'BLE CONDUIT (I/D 13.0,O/D 16.1)

HARNESSFLEX

F'BLE CONDUIT (I/D 16.9.0,O/D 21.2)

HARNESSFLEX

CTPA16-S CTPA20-S

A/R

CONI-1 PIN 1.6MM DIA (0.75 - 1.5)

GHW

25523.123.178

7204/0045

CONI-1 PIN 1.6MM DIA (0.3 - 0.6)

GHW

25623.123.178

7204/0044

5 WAY CONI-1 FEMALE (PIN) HOUSING

7 WAY CONI 1 FEMALE (PIN) HSG

GHW

G&H

17037.050.000

16318.565.696

7237/0011

6 WAY M'PACK 150.2 MALE (SKT) HSG

DELPHI

12162261

M'PACK 150.2 SKT TERM (0.35-0.5)

DELPHI

12124076

4 WAY DT MALE (#16 SKT) PLUG

DEUTSCH

DT06-4S-CE05

7214/0025

4 WAY DT MALE (#16 SKT) RETAINER

DEUTSCH

W4S-P012

7214/0016

CAVITY BLANKING PLUG #12-#16

DEUTSCH

CAVITY BLANKING PLUG #20

DEUTSCH

0413-204-2005

47 WAY HDP RECEP. FOR SKTS 21 WAY HDP RECEP. FOR SKTS

DEUTSCH

HDP24-24-47SE

DEUTSCH

HDP24-24-21SE

DEUTSCH

1062-12-0166

ALLIANCE PLAST.

SGX12

7210/0030

7210/0052

7201/0104 -

0 0 3

DESCRIPTION

JCB PART No

MANUFACTURER PART No

MICRO/JUNIOR PWR TIMER GH66/2P HSG

AMP

963 598 -1

MICRO/JNR PWR TIMER GH66/2P COVER

AMP

965 053 -1

JUNIOR POWER TIMER CAVITY PLUG

AMP

828 922

MICRO-TIMER II CONTACT (0.5-1.0)

AMP

MICRO-TIMER II WIRE SEAL (0.5-1.0)

AMP

962 876 -1 963 530 -1

MICRO-TIMER II CAVITY PLUG

AMP

35 WAY HOUSING (CODE 1)

BOSCH

1 928 401 980

35 WAY HOUSING (CODE 5)

BOSCH

1 928 401 984

35 WAY HSG COVER

BOSCH

1 928 401 964

CABLE CLAMP (205 sq.mm)

BOSCH

1 928 401 963

SCREW

BOSCH

1 928 491 154

963 531 -1

JNR-PWR-TIMER CONTACT (0.5-1.0) SL

AMP

JNR-PWR-TIMER CONTACT (1.5-2.5) SL

AMP

929 937 -1

STANDARD-TIMER CONTACT (>1.0-2.5)

AMP

927 849 -1

929 939 -1

21 WAY HDP RECEP FOR SKTS (21x#20)

DEUTSCH

HDP24-18-21SN

31 WAY HDP RECEP FOR SKTS (31x#16)

DEUTSCH

HDP24-24-31SE

29 WAY HDP RECEP. FOR SKTS

DEUTSCH

25A FUSE (ATO) 8.4 RING TERMINAL (0.5-2.5)

LITTELFUSE

HDP24-24-29SE

257025

G&H

25089.123.011

PANEL NUT (SHELL SIZE 18)

DEUTSCH

2411-002-1805

PANEL NUT (SHELL SIZE 24)

DEUTSCH

2411-001-2405

4 WAY JPT HOUSING

BOSCH

4 WAY JPT ANTI-BACKOUT

BOSCH

4 WAY S/S EXT. CONNECTOR INTERFACE 8.4 RING TERMINAL (16.0-25.0)

HARNESSFLEX G&H

4 WAY S/S 1.5 MALE (RECEP) CONN.

1 928 403 913 1 928 403 424 CI08-AS4 03427.311.011

AMP

282 088 -1

S/S 1.5 RECEP. CONTACT (1.0-1.5)

AMP

282 110 -1

S/S 1.5 WIRE SEAL (0.6-1.5) YELLOW

AMP

281 934 -2

55 WAY TIMER RECEPTACLE HOUSING ASSY RUBBER BOOT

AMP BOSCH

0-967068-1

1-928300-194-900

JUNIOR-TIMER CONTACT (0.5-1.5)

AMP

925590-1

3 WAY JUNIOR-PWR-TIMER CONNECTOR

AMP

282191-1

40 WAY RECTANGULAR PLUG (#20 SKT TERMS) 26 WAY RECTANGULAR PLUG (#20 SKT TERMS) 40 WAY RECTANGULAR PLUG (#20 SKT TERMS)

DEUTSCH

DRC26-40SB

DEUTSCH

DRC26-24SA

DEUTSCH

DRC26-40SA

3 WAY METRI-PACK 150 MALE (SKT) CONN. ASSY 3 WAY METRI-PACK 150 MALE SECONDARY LOCK

DELPHI

12110293

DELPHI

12052845

METRI-PACK 150 SOCKET CONTACT (1.0) METRI-PACK 150 CABLE SEAL (0.6-1.0) WHITE METRI/MICR-PACK 150 CAVITY PLUG (RED)

DELPHI

12048074

DELPHI

12089678

DELPHI

12059168

DECAL - REAR FOG LIGHTS SWITCH

DECAL - MAIN LIGHTS SWITCH

DECAL - FRONT WORKLIGHTS SWITCH

DECAL - REAR WORKLIGHTS SWITCH

DECAL - BEACON SWITCH

DECAL - 2 WHEEL DRIVE SWITCH

DECAL - REAR WASH/WIPE SWITCH

DECAL - HITCH RAISE/LOWER SWITCH

DECAL - HYDRAULICS LOCK-OUT

DECAL - WHEEL SLIP

SINGLE ATO FUSE HOLDER

LITTELFUSE

868-062

ATO FUSE HOLDER TERMS (2.0)

LITTELFUSE

913-043

ATO FUSE HOLDER TERMS (5.0)

LITTELFUSE -

DECAL - PTO SPEED

913-042 -

7219/0072 7210/0017 7201/0152 7210/0083 7210/0082 7201/0090 7201/0076 7219/0055 -

QTY 1 1 0 38 38 28 0 0 0 0 0 14 0 0 1 3 1

716/05708 7207/1401 7210/0048 7207/1405 7201/0094 7210/0044

0 1 1 4 2 2 1 1 1 2 2

7239/0023 7239/0004 7201/0020 -

1 1 21 2 1 1 1 2 2 4 4 2 1 1 1 1 1 1 1 1 1 1 0 0 0 1

7219/0039 7219/0037 7219/0038 7201/0028 7210/0040 7210/0019 817/17256 817/17257 817/17258 817/17259 817/17260 817/17264 817/17297 817/17280 817/20267 817/20269 7201/0101 7201/0100 817/20270

2 WAY METRI-PACK 150 MALE (SKT) CONN. ASSY (TYPE 4)

DELPHI

12052643

7212/0070

2 WAY METRI-PACK 150 MALE SECONDARY LOCK

DELPHI

12052634

7212/0015

METRI-PACK 150 SOCKET CONTACT (0.5)

DELPHI

12084200

METRI-PACK 150 CABLE SEAL (0.5) BLUE

DELPHI

12048087

NOTE: SWITCH DECAL DETAILS ARE LOCATED ON DRAWING 817/18567

721/12166 Sheet 8

A/R

Fig 24. Cab Harness sheet 8 K Fig 25. ( T C-25)

Harness Data

C - 24

Section C - Electrics

#12 SKT TERM (2.5-4.0) SPIRALGUARD

114017

ITEM JA JB JC JD JE JF JG JH JJ JK JL JM JN JP JR JS JT JU JV JW JX JY JZ KA KB KC KD KE KF KG KH KJ KK KL KM KN KP KR KS KT KU KV KW KX KY KZ LA LB LC LD LE LF LG LH LJ LK LL LM LN LP LR LS LT LU LV LW LX LY LZ

Drawings and Interconnection

ITEM FA FB FC FD FE FF FG FH FJ FK FL FM FN FP FR FS FT FU FV FW FX FY FZ GA GB GC GD GE GF GG GH GJ GK GL GM GN GP GR GS GT GU GV GW GX GY GZ HA HB HC HD HE HF HG HH HJ HK HL HM HN HP HQ HR HS HT HU HV HW HX HY HZ

C - 25

REAR BULKHEAD 1

CR11

CR14

WIRE

SIZE

DEST

TYPE

TERM

WIRE

SIZE

DEST

TYPE

TERM

WIRE

SIZE

DEST

WIRE

SIZE

DEST

RANGE COLUMN SW

CAN_H*

0.5

CANHS5

379

1.0

CR150 10

170

4.0

CR12 A9

TYPE

CR44

0.5-2.5

800A

1.5

OFWLS

835B

1.5

IRWLS

944

0.5

CR136 10

874

1.0

CR40 1

TYPE

DEST

CANLS5

SIZE

0.5

WIRE

CAN_L*

TERM

0.5-2.5

600A

1.0

CRES1

610D

1.0

CRES2

720A

0.6

PES3

710Y

1.0

PES1

K,L

1.0

CR66 1

0.5-2.5

SCRN*

0.5-2.5

675JF

SIZE

DEST

CR4

TYPE

TERM

REAR RELAYS WIRE

875

1.4

CR40 2

DSES

876

2.0

CR40 3

0.5-2.5

585F

0.5

ECURGS

750U

0.5

CRES6

954

1.0

CR4 F4

0.5-2.5

100N

0.5

ECUIS

942

1.0

MSS1

843

670

4.0

CR38

0.5

HEATER/AC UNIT

0.5

D'WIRE

JS,JX

721/12166

X,Y

CAPAC'Y

1 2

CR1 TERM

0.5-2.5

100P

ECUIS

0.6

CR5 3

0.5-2.5

636T

0.5

ECUES

846

1.0

CR26 2

0.5-2.5

587

0.5

ECU3 22

750L

0.5

CRES6

0.5-2.5

942C

0.5-2.5

675FB

0.5-2.5

0.5

MSS1

847

1.0

CR26 4

1.0

TMES1

845

0.6

CR5 6

0.5

CR130 37

115C

1.0

CRIS

0.5

CR130 12

000

4.0

CR3 7

1.0

1495 1440

0.5-2.5

597

0.5

ECU1 35

0.5-2.5

598

0.5

ECU1 38

0.5-2.5

1418

0.5

ECU3 11

810E 750T

CDS

0.5

CRES6

0.5

E11 1

E11 3

0.5-2.5

500

0.5

RSS

0.5-2.5

501

0.5

CR66 25

0.5-2.5

920C

0.5

EDCSSS

0.5-2.5

424

0.5

E1 6

E1 38

105A

0.5

0.5-2.5

923

0.5-2.5

929

0.5 0.5

0.5-2.5

715

0.5

0.5-2.5

182

Z Z

4.0

CR104 1

CR12 A1

0.5-2.5

1453

0.5

0.5-2.5

1477

0.5

CR136 6

0.5-2.5

1484

0.5

CR130 14

0.5-2.5

1485

0.5

CR130 35

171

2.0

0.5-2.5

1487

0.5

CR136 5

954

1.0

CR11 5

936

1.0

CR104 13

936A

0.5

CR134 A

2.0

CR104 17

CR135 9 -

* SEE SHEET 5 FOR CANBUS DETAIL

949B

0.5

AMSS

750V -

0.5

CRES6

955A

0.5

CR146 1

955B

0.5

CR146 3

F8 CR5 TERM

950

CR12 A9

REAR WIPER SW WIRE

SIZE

DEST

115

A3a

BB BB

130

1.0

CR104 9

A5a

015G

1.0

IGNS2

BA BA

9803/8040-5 P,R

SIZE

DEST

TYPE

4.0

CR45

200B

4.0

CR45

CR153 1 IGNS2

BA BB

100

2.0

ECUIS

100R

0.5

CR154 1

015F

2.0

IGNS2

101

2.0

CR104 22

A8a

015D

2.0

IGNS2

170

4.0

CR11 1

171

2.0

CR4 F2

A9a

010G

4.0

IGNS1

804D

1.5

CR126 1

315B

1.4

FWLSS

CR126 2

PMLS

1.5

CR78 3

934

1.0

CR32 3

610F

1.0

CRES2

CRPFS

1.0

CR31 1

710D

0.6

PES1

880C

0.6

LHSLS

CR46

TERM

014

0.6

CR3 6

120B

1.0

PISA4

660F

0.6

CRES3

417

0.6

CR65 28

421

1.0

CR69 C2

710A

0.6

PES1

862

2.0

CR69 49

863

2.0

CR68 17

3 4

CR25

RH NO PLT LIGHT

TERM

WIRE

SIZE

DEST

TYPE

CR34

860F

0.6

RHSLS

AF,AG

TERM

CRES2

AF,AG

A B

610G

0.6

BM,BN

REAR WIPER MOTOR

1 2

1.0

CRES2

K,L

TERM

846

1.0

CR4 B2

K,L

115B

1.0

CRIS

K,L

847

1.0

CR4 B5

K,L

CR36

1.4

CR11 3

DEST

TYPE

876

2.0

CR11 4

0.6

CR12 A1

K,FZ

730

1.4

CR38

0.6

CDS

K,FZ

320A

1.4

RWLSS

CR126 7

CR38

155

0.6

CR121 A2

320B

1.4

RWLSS

610

C1a

010D

1.4

IGNS1

840

1.5

CR126 8

660

680

CR68 1

IGNS1

710N

0.6

PES1

320C

0.6

RWLSS

PISC4

C4a

015E

1493

0.5

CR136 16

635W

0.5

CRES4

860Z

0.5

RHSLS

6.0

IGNS2

014

0.6

CR33 3

000

4.0

CR4 C2

CR10

TERM

RRH OUTER W/LIGHT

ECU6 6

KX,KY

015

CRES4

TYPE

CRES1

0.5

DEST

635P

PES1

1.5

1.0

160

CRES4

710H

TERM

BATTERY NEGATIVE

805D

0.5

TYPE

CR5 6

635V

DEST

1.0

SIZE

844

WIRE 600

670

SIZE 6.0 4.0 2.0

CRES3

4.0

CR11 7

CRES2

3.0

CR30 2

685

3.0

CR94 C

710

3.0

PES1

720

3.0

PES3

1.0

IGNS2

730

1.4

161

0.5

EDCIS

CRES6

160H

0.6

PISC4

750J 760

2.0

C5a

3.0

CR85 B

365B

CR40 4

1.5

CR89 7

365A

1.5

CR119 B

665B

3.0 3.0

CR101 B CR101 C

C6a

240F

1.5

BATS2

635

2.0

CRES4

191

1.0

CR94 B

636

2.0

ECUES

C7a

010E

665A

1.0

IGNS1

637

2.0

CR104 21

355

3.0

CR94 A

638

2.0

SVCES

C8a

240E

3.0

BATS2

HG,HH

195

1.5

CR104 5

TYPE

C9a

015B

1.4

IGNS2

DEST

1.5

ORWLS

610A

1.0

CRES2

SIZE

200A

DEST

4.0

CR3 1

201

6.0

CR33 1

202

8.0

CR54 1

210

4.0

BATS1

240

4.0

BATS2

250

6.0

CR46 1

260

3.0

CR47 C

270

3.0

TYPE

GY, BX

CR47 D

200B

4.0

CR3 2

265A

3.0

CR100 B

265B

3.0

CR100 C

246

6.0

CR150 1

247

6.0

CR150 19

249

4.0

CR150 11

MAXI LIGHTS FUSE WIRE

SIZE

DEST

TYPE

250

6.0

CR45

PMLS

WIRE

SIZE

DEST

TYPE

015J

1.0

IGNS2

AH,AG

360

6.0

ABS CONNECTOR

440

0.6

CR65 6

AF,AG

260

3.0

CR45

AK,AL

270

3.0

CR45

AK,AL

CR48

FRONT WASHER PUMP

WIRE

SIZE

DEST

TYPE

842

1.0

CR43 9

710J

1.0

PES1

TERM

Fig 25. Cab Harness sheet 9 K Fig 26. ( T C-26)

CR43 TERM

RH COLUMN SWITCH WIRE

SIZE

DX,DY DEST

TYPE

859C

1.4

PLIS

864

1.4

CR69 49a

M,N

861C

1.4

PRIS

M,N

907

1.4

CR79 1

M,N

CR79 2

M,N

839

1.4

838A

1.4

PHLS

M,N

325

1.4

CR12 B5

M,N

120A

2.0

PISA4

M,N

842

1.0

CR48 1

833

K,L

1.0

CR51 28

K,L

834

1.0

CR51 29

K,L

831

1.0

CR39 E2

K,L

830

1.0

CR39 E1

K,L

841

2.0

CR51 30

M,N

721/12166 SHEET 9 OF 15

Harness Data

C - 25

Section C - Electrics

SIZE

805A

2 CR47 TERM

WIRE

Drawings and Interconnection

WIRE

BATTERY POSITIVE

WIRE

REAR WASHER PUMP

PFSB9

TYPE

BATS2

DEST

CR37 TERM

0.6

IGNS1

CR136 4

TYPE

0.6

1.0

0.5

AF,AG AC,LD

300

1.0

SIZE

CRES2

DEST

240D

1.4

1494

SIZE

1.4

WIRE

0.6

REAR WORKLIGHT SW

WIRE

B9a

145

875

AM,AN

SIZE

106

105

010F

TYPE

CR11 2

810

010K

DEST

1.0

TERM

BATS1

SIZE

874

CR82 +

C3a

WIRE

TYPE

1.4

C2a

AF,AG

1.4

CLUTCH DOWN SW

TERM

HEATER

CR40

RHSLS

335

TYPE

DEST

210E

KX,KY

TYPE

CRES2

DEST

1.0

B8a

CR136 17

HG,HH

610C

CR28

TERM

CRES2

TERM

AC,LF

IRWLS

1.0

4WD/DIFF LOCK SW

1.5

ORWLS

835A 610B

RLH OUTER W/LIGHT

TYPE

1.5

CR9

DEST

805B

BATS1

KV,KW

SIZE

3.0

610H

WIRE

DEST

210D

WIRE

HG,HH

SIZE

B7a

RRH INNER W/LIGHT

0.6

LH NO PLT LIGHT WIRE 860G

SIZE

CR27 TERM A

IGNITION RELAY

WIRE

0.5

SIZE

FRONT PTO SW

1.0

1486

CR43 13

IGNS1

WIRE

1.0

6.0

830

010

IGNS1

KX,KY

CR30 1

CRES4

CR128 3

0.5

3.0

635T

1.0

330

165

PES1

O10H

CR51 26

TYPE

CR43 12

KX,KY

0.6

B6a

DEST

1.0

CR136 18

832

0.5

831

SIZE

710K

1475

PES1

WIRE

LHSLS

KV,KW

0.6

REAR PTO SWITCH

TYPE

610E

CR45

C5 C6 C8

DEST

CR35

6.0

TYPE

BATS2

SIZE

DEST

CR54 2

201

SIZE

CR43 7

CR79 3

WIRE

CR33 TERM

WIRE

1.4

1.0

934

PES1

1.4

CR26

3.0

TYPE

305C

1.5

806

TERM

1.4

2 3

710R

B8 C2

6 CR45 TERM

204

DEST

SIZE

PES1

325

WIRE

BD BD AC,LE

BEACON SWITCH

FWLSS

BATS1

240B

K,L

1.5

BATS2

K,L

PES1

1.5

CR68 3

B5a

CR65 23

1.0

0.6

2.0

CR65 34

1.0

710Z

813

2.0

RWLSS

1.0

1425

315C

1.0

3.0

1424

4 5

1.4

BEACON SOCKET

K,L K,L

Z -

680

1423

H,J

CR66 9

710L

1.0

320

305

0.6

240A

TYPE

FWLSS

DEST

1.4

B1a

CRPFS

SIZE

315A

812

0.6

E1 24

0.6

A7a

IGNITION SWITCH

0.6 0.5

015C

AC,LC

F WORKLIGHT SW WIRE

1 2

423 360D

CR8

200A

135 135A

CR24 TERM

3.0

A5 A6 A8 B1 B4

710B

TERM

WIRE

880K

TYPE

CR12 B7

DEST

TERM

CR3

CRES1

DEST

3.0

SIZE

CR7

TERM

OFWLS

1.0

SIZE

330

WIRE

TERM

DEST

1.5

AUX POWER SKT WIRE

X,Y

FR. PANEL RELAYS

TYPE

SIZE

800B

TERM

CR38

CR32

600D

IGNS1

B4a

GD GC

CR39

TYPE

DEST

HG,HH

WIRE

IGNS1

CRES1

PIS A4

CR4 B6

IFWLS

HG,HH

SIZE

TERM

2.0

CR37 1

1.5 1.0

RLH INNER W/LIGHT

WIRE

2 CR31

TYPE

2.0

801B 600C

FLH OUTER W/LIGHT

HG,HH

2.0

B3a

CRES1

DEST

TERM

CR54 2

1.0

SIZE

WIRE

CR30

TYPE

CRIS

6.0

CR4 B1

600B

FLH INNER W/LIGHT

HG,HH

IGNS1

203

0.6

IFWLS

IGNS2

120

DEST

1.5

CR121 D2

CR127 A

843

SIZE

801A

1.4

2.5

WIRE

TERM

1.5

010B

2 CR18 TERM

FRH INNER W/LIGHT

CR29

TYPE

0.6

A6a

CR21

A4a

010C

CR16 TERM

HG,HH

2.0

315E

110 010A

FWLSS

CRIS

0.6

015A

A2 A2a

2.5

1.0

CR4 E2

315

115A

TYPE

CR36 1

0.5

310

844

DEST

0.6

210B

845

SIZE

105 105A

A1a

WIRE

B2a

AY,AZ

TYPE

TERM

MAIN FUSE BOX

AC,LG

8 CR12

FRH OUTER W/LIGHT

C - 26

FRONT BULKHEAD

CR51 CAPAC'Y

WIRE

SIZE

0.5-2.5

515K*

0.5

CANHS1

0.5-2.5

514K*

TERM

DEST

JS,JX

CR57

TYPE

TERM

BRAKELIGHT SW

HG,HH

CR66

TYPE

TERM

WIRE

SIZE

DEST

160L

0.5

PISC4

884

0.5

CRBSS

LH CLUSTER 2 RED WIRE

SIZE

1423

1.0

CW,CX

CR68

DEST

TYPE

TERM

CR44 2

CY,CZ

HAZARD SWITCH SIZE

145

1.4

CR12 C2

858

2.0

CR69 49

310

2.0

CR12 B2

DEST

TYPE V

0.5

CANLS1

0.5-2.5

SCRN*

0.5

D'WIRE

0.5-2.5

404

0.6

CR65 33

0.5-2.5

406

0.6

CR65 1

859

1.4

PLIS

0.5-2.5

CR65 30

0.5-2.5

0.6

CR65 3

0.5-2.5

560A**

1.0

J1708+

CR59

0.5-2.5

540***

0.5

CR106 2

TERM

0.5-2.5

541***

0.5

CR106 3

0.5-2.5

1420

0.5

CR65 10

407

0.6

408

LH A POST W/LIGHT WIRE

SIZE

DEST

804B

1.5

APWLS

720G

1.0

PES3

HG,HH TYPE GD GC

411

0.6

500AA

0.6

CY,CZ

880A

517

0.6

CR89 6

CY,CZ

720H

0.6

PES3

423

0.6

CR39 A8

CY,CZ

863

2.0

CR39 F8

865

2.0

CR69 49a

861

1.4

PRIS

RSS2

CY,CZ

0.5-2.5

836

1.4

CR74 1

0.5-2.5

905

1.4

CR74 2

0.5-2.5

881

0.6

CR74 3

0.5-2.5

866

0.6

CR74 4

0.5-2.5

880F

1.0

LHSLS

0.5-2.5

868

0.6

CR74 5

0.5-2.5

870

0.6

CR74 6

0.5-2.5

409

0.6

CR65 2

516

0.6

0.5-2.5

411

0.6

CR66 6

0.5-2.5

542***

0.5

CR106 1

0.5-2.5

561A**

1.0

J1708-

0.5-2.5

403

0.6

ASS

0.5-2.5

859B

1.0

861B

1.0

CR60

WIRE

SIZE

DEST

804A

1.5

APWLS

720F

1.0

PES3

CR43 11

841

2.0

CR43 14

814

1.5

CR126 6

* SEE SHEET 5 FOR CAN BUS DETAILS

1 2 CR65 TERM

CY,CZ

DOOR SWITCH WIRE

SIZE

DEST

914

0.5

CR128 5

720B

0.6

PES3

RH CLUSTER 1 BLK WIRE

SIZE

DEST

862

2.0

CR39 F6

838

2.0

PHLS

2.0

CR68 2

710F

1.0

PES1

865

2.0

CR68 17

160C

0.6

PISC4

864

1.4

CR43 2

421

1.0

CR39 F2

419

0.6

CR65 27

858 49a

838B

1.5

PHLS

812

1.5

CR39 B4

CP,CS

448

1.0

CP,CS

9803/8040-5 TYPE EW,EX

675JG

942P

0.5

MSS1

EW,EX

1456

0.5

CR135 20

EW,EX

CR101 A

CV,CX

513

0.6

TYPE

CY,CZ

300B

0.6

PFSB9

*SEE SHEET 5 FOR CAN BUS DETAILS

CR89 4 -

CY,CZ DA CY,CZ DA

CR71

WIRE

SIZE

861A

1.4

PRIS

AH,AJ

720D

1.4

PES3

AH,AJ

CY,CZ

CR73

CR147 2

CY,CZ

TERM

PES1

CY,CZ

CR83

CY,CZ

880B

0.6

CY,CZ

AUX LIGHTS IN

TYPE

H,J

WIRE

SIZE

DEST

829

1.4

CR79 1U

TYPE M,N

904

1.4

CR79 2U

880D

0.6

LHSLS

K,FZ

860C

0.6

RHSLS

K,FZ

859D

0.6

PLIS

K,FZ

DA CY,CZ

DEST

TERM

CY,CZ

0.5

RH SIDE REPEATER

6 CR74 TERM 1

861D

0.6

PRIS

M,N

K,FZ

720J

1.0

PES3

838C

1.5

PHLS

CR79

907

1.4

CR43 4

418

0.6

CR65 26

829

1.4

CR73 1

839

1.4

DEST

CR43 5

904

1.4

CR73 2

806

1.4

CR39 B8

CR98

LH COLUMN SW. 2

809

1.4

CR104 7

TERM

836

1.4

CR51 12

CJ,N

807

2.0

CR77 3

808

1.5

CR79 5

880

1.0

LHSLS

1.5

CR79 4

905

1.4

CR51 13

CJ,N

881

0.6

CR51 14

CH,FZ

866

0.6

CR51 15

CH,FZ

868

0.6

CR51 17

CH,FZ

860

870

0.6

CR51 18

CH,FZ

360B

1.5

PMLS

CR89

362

0.6

CR85 A

TERM

808

CR81

AIR GAUGE ILLUM

TERM

WIRE

1.0

RHSLS

SIZE

DEST

TYPE

880G

0.6

LHSLS

720L

0.6

PES3

DIAGNOSTIC WIRE

SIZE

CN CN

660Y

0.6

CRES3

K,FZ

513

0.6

CR66 31

K,FZ

0.6

CR66 19

K,FZ

CY,CZ

CR82

517

0.6

CR66 8

K,FZ

TERM

WIRE

SIZE

DEST

TYPE

365B

1.5

CR12 C6

0.6

PRIS

CY,CZ

335

1.4

CR12 B8

BD,BH

418

0.6

CR79 1U

CY,CZ

660Z

1.4

CRES3

BD,BH

FIT ALSO DZ+CN TO SEAL

419

0.6

CR69 C3

CY,CZ

860T

0.6

RHSLS

BD,BH

*SEE SHEET 5 FOR CAN BUS DETAILS

417

0.6

CR39 F2

CY,CZ DA

CR83

CY,CZ

TERM

407

0.6

TYPE

CR51 6

203

6.0

CR12 B3a

404

0.6

CR51 4

CY,CZ

204

3.0

CR12 B4a

1424

1.0

CR44 3

CY,CZ

860U

0.6

RHSLS

660W

0.6

CRES3

CLUSTER RF GROUND

WIRE

SIZE

DEST

626

1.0

CR66 36

*SEE SHEET 5 FOR CAN BUS DETAILS

TYPE

516

M,N CN

CR100 TERM

(SUPPLY)

TRACTOR ABS WIRE

SIZE

DEST

EN TYPE

015K

1.0

IGNS2

DH,AG

265A

3.0

CR45

DJ,AL

265B

3.0

CR45

DJ,AL

884F

0.5

CRBSS

CR101 TERM

(RETURN)

TRACTOR ABS

DG,AG ET

SIZE

DEST

TYPE

448

1.0

CR66 29

AH,AG

665A

3.0

CR38

AK,AL

665B

3.0

CR38

AK,AL

WIRE

721/12166 SHEET 10 OF 15

Harness Data

C - 26

Section C - Electrics

Cab Harness sheet 10 K Fig 27. ( T C-27)

K,L

TYPE

Drawings and Interconnection

Fig 26.

K,L

CR66 16

TYPE

CR45

PES1

1.0

DM,DN DEST

861G

DEST

1.0

1422

8.0

SIZE

710X

2 DT

CIGAR LIGHTER

AM,AN DEST

WIRE

SIZE

AK,AL

202

AH,AG

CR38

WIRE

CR12 C7

3.0

TYPE

1.0

685

DK,DL

CR44 4

191

DEST

SIZE

AUX LIGHTS OUT

AK,AL

WIRE

1.0

TYPE

CR12 C8

DEST

3.0

TYPE

1425

SIZE

355

FRONT FUSE PANEL SIZE

AUX POWER SKTS WIRE

WIRE

TERM

V V

CR94 TERM A

TYPE

1420

LHSLS

AH,AJ

DEST

AH,AJ

23 EV

E9 1

PES3

1.0

CR51 11

SIZE

PLIS

626

DEST

0.6

1.4

WIRE

AC,LA

1.4

415

TERM LH SIDE REPEATER

REAR FOG SW

CR78

SIZE

0.5

WORKLIGHTS RELAY

720C

710C

DSES

859A

160BA

0.5

PMLS

WIRE

DEST

2.0

SIZE

360A

CY,CZ

WIRE

CY,CZ

DJ,AL

CR51 7 -

CR51 5

CR79 4

CR51 19

CR47 B

PMLS

2.0

0.6

2.0

807

0.6

360C

0.6

406

DG,AG

CR38

408 -

TYPE

CR79 6U

3.0

501

409

440

DEST

0.6

3 5

SIZE

362 760

3 4

WIRE

DE TYPE

AUX LIGHTS SUPPLY

TYPE

DEST

CLUTCH POT'METER

DA CY,CZ

SIZE

TYPE

*** SEE SHEET 6 FOR TWISTED TRIPLE DETAILS

ASS

** SEE SHEET 6 FOR TWISTED PAIR DETAILS

CR54

0.6

MAIN LIGHTS SW WIRE

PES1

TERM

CR43 10

TERM

403A

CR85 AC,LB

TERM CR77 TERM

0.6

CY,CZ

CR63 TERM

710G

CR1 20

TERM

CR70

CR53

CY,CZ

PRIS

1.0

CR98 2

CY,CZ

CR39 E5

834

1.0

CANHS1

PISA4

0.5-2.5

1422

CANLS1

1.0

DEST

TRAILER 2 RELAY WIRE

0.6

1.0

0.5-2.5

LHSLS

SIZE

CR69

0.6

832

0.5-2.5

CR89 5

0.6

TERM

CANH515F

120C

DA CY,CZ

PLIS

CANL514F

0.5-2.5

0.6

23*

0.5-2.5

859G

24*

0.5-2.5

1.0

13 14

833

0.5-2.5

TYPE

PLIS

27 28

HG,HH

RH A POST W/LIGHT

TERM

CR51 20

721/12166

WIRE

C - 27

CR 125 TERM

DIAGNOSTIC SOCKET

CR 119 TERM

1.5

CRES4

365A

1.5

CR12 C6

CANH515D

0.5

CANHS3

CANL514D

0.5

CANLS3

SCRN

0.5

D'WIRE

F**

560B

1.0

J1708+

G**

561B

1.0

J1708-

** SEE SHEET 6 FOR TWISTED PAIR DETAILS

CR 120

1 2

CAPAC'Y

WIRE

SIZE

DEST

TYPE

1**

561

1.0

J1708-

CH,L

2**

560 1.0 ** SEE SHEET 6 FOR TWISTED PAIR DETAILS

J1708+

CH,L

RELAY BASE 3

4.0

CR4 C8

339

4.0

CR150 12

2.5-4.0

675A

4.0

CR125

195

0.5-2.5

1.5 1.4

CR12 C9

CR 121

CRBLS

TERM

CR 126 TERM

X,Y

WIRE

SIZE

804D

DX, DY DEST

TYPE M,N M,N M,N M,N

804

1.5

APWLS

814

1.5

CR51 31

M,N

805D

1.5

CR28 3

M,N

840

1.5

CR28 6

M,N

710V

1.5

PES1

825

1.5

CR104 8

800

1.5

OFWLS

M,N

801

1.5

IFWLS

M,N

805

1.5

ORWLS

M,N

835

1.5

IRWLS

M,N

CR79 3U

GD GD

0.5-2.5

130

1.0

CR12 A5

155A

0.6

CR121-A2

0.5-2.5

860L

1.0

RHSLS

CR 127

0.5-2.5

968A

0.5

PCCOS

816

0.5

CR136 13

TERM

0.5-2.5

963

0.5

CR130 49

877

0.6

CR104 16

M,N M,N

0.5-2.5

936

1.0

CR4 F6

0.5-2.5

961

0.5

CR130 63

0.5-2.5

959

0.5

CR130 53

0.5-2.5

877

0.5

CR121 A8

0.5-2.5

950

2.0

CR4 F8

WORKLIGHTS HARNESS INTERCONNECT 1

PHLS

CR126 10

DSES CR148 R

FWLSS

1.4

TYPE

4.0 2.0

CR24 3

1.5

DEST

675J 675K

CR24 6

825

CR12-C1

1.5

883

CR121-A4

TMES1

1.5

809

0.6

CR135 13

1.5

0.5-2.5

0.6

CR136 1

1.0

1.5

0.5-2.5

SIZE

CANSS15

1.0 2.0

813

0.5-2.5

155

3.0

675E 675F

838D

155A

675C

TYPE

315F

WIRE

CR104 4

DEST

4.0

HD,HE

TERM

182

2.5-4.0

J1708 CONNECTOR

SIZE

675A

TYPE

SIZE

2.5-4.0

GJ GJ

JT,JX

WIRE

DEST

635C

WIRE

675D

TYPE

TERM

DEST

REAR BULKHEAD 2

GV, GW

SIZE

CR104

WIRE

BATTERY NEGATIVE 2

WORKLIGHTS HARNESS INTERCONNECT 2

WIRE

SIZE

DEST

TYPE

315E

2.5

CR12 B3

DJ,AL

B1 CR 128 TERM -

ROOF LINER HARNESS CONNECTOR WIRE 305G

SIZE 1.0

DEST

TYPE

CRPFS

9803/8040-5

0.5-1.0

958

0.5

CR130 48

860E

0.5

RHSLS

0.5-2.5

932

0.5

RLSS

165

1.0

CR12 B6

0.5-1.0

586

0.5

ECU3 7

600N

1.5

CRES1

0.5-2.5

637

2.0

CR38

914

0.5

CR63 1

0.5-2.5

101

2.0

CR12 A8

0.5-1.0

576

0.5

ECU1 7

0.5-1.0

924

0.5

E1 35

0.5-2.5

161C

0.5

EDCIS

TERM

WIRE

SIZE

0.5-2.5

660GF

0.5

CRES3

515J

0.5

CANHS2

0.5-1.0

503

0.5

E1 37

514J

0.5

CANLS2

0.5-2.5

504

0.5-1.0

0.5

E1 19

C5 CR 115

TERM CR 106

THROTTLE PEDAL POSITION CONNECTOR

DEST

TYPE

RHSLS

DG,AG

10J

1.0

IGNS1

DH,AG

DEST

TYPE

CR51 21

EW,EX

540***

0.5

CR51 9

EW,EX

CR 117

541***

0.5

CR51 10

EW,EX

TERM

WIRE

SIZE

0.5

THROTTLE PEDAL IDLE VALIDATION SWITCH CONNECTOR

HEATED MIRRORS SUPPLY WIRE

HIGH LEVEL BRAKE LIGHT

110

1.5

CR12 A2

884D

0.5

CR136 21

884E

0.5

CR146 8

TYPE

SIZE

CR 107

DEST

860N

542***

*** SEE SHEET 6 FOR TWISTED TRIPLE DETAILS

GA,GS

1 3

WIRE

CANBUS THROUGH CONNECTOR

*SEE SHEET 5 FOR CAN BUS DETAILS CR 116

TERM

HA, HC

D4 D5

750K

0.5

CRES6

883F

1.5

CRBLS

WIRE

SIZE

DEST

TYPE

883E

0.5

CRBLS

610J

0.5

CRES2

0.5

DSES

EW,EX

942K

0.5

MSS1

EW,EX

544

0.5

CR135 19

EW,EX

721/12166 SHEET 11 OF 15

Fig 27. Cab Harness sheet 11 K Fig 28. ( T C-28)

Harness Data

C - 27

Section C - Electrics

TYPE

675JM

Drawings and Interconnection

DEST

C - 28 9803/8040-5

TRANS MANAGEMNT EST CSA DESTIN 1.0 DSES 1.0 CR148 U

WIRE 675JA 1451

CAN_L CAN_H 1448

0.5 0.5 0.5

CR148 26 CR148 27 CR148 F

949A

0.5

AMSS

1440 1443 1484 1447

0.5 0.5 0.5 0.5

CR1 13 CR148 T CR1 29 CR148 G

1445 1450

0.5 1.0

CR148 Q CR148 J

1473

0.5

CR148 W

1441 CAN_L CAN_H 104 1446

1.0 0.5 0.5 1.0 0.5

CR150 17 CANLS2 CANHS2 CR150 16 CR148 E

414A 1485

0.5 0.5

SSS CR1 30

1495

0.5

CR1 12

1444

0.5

CR148 H

1458

0.5

CR148 V

956 958 963 947 943

0.5 0.5 0.5 0.5 0.5

CR148 K CR104 18 CR104 12 NSS CR148 L

959 942B 675FA 374A 374B 374C 374D 374E 945 946 961 960

0.5 0.5 1.0 1.0 1.0 1.0 1.0 1.0 0.5 0.5 0.5 0.5

CR104 15 MSS1 TMES1 TMSS TMSS TMSS TMSS TMSS CR148 B CR148 C CR104 14 CR148 X

CR134

LR,LS

ACU PRESS SWITCH WIRE

SIZE

DEST

TYPE

936A

0.5

CR4 F6

LT,LU

660ZE

0.5

CRES3

LT,LU

TERM

CR 135 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

CVT DISPLAY ECU (RED) WIRE CSA DESTIN 1.0 CR150 4 376 103 1.0 CR150 14 1464 550 1453 1438 CAN_H SCRN 675E -

0.5 0.5 0.5 0.5 0.5 0.5 1.0 -

CR142 5 CR142 14 CR1 26 CR142 17 CANHS13 D'WIRE CR125 -

1463 544 1456 1439

0.5 0.5 0.5 0.5

CR142 4 CR107 3 CR53 3 CR142 15

CAN_L

0.5

CANLS13

676

2.0

CR137

1449 1465 1442A

0.5 0.5 0.5

CR142 13 CR142 6 TSSS1

CW CX TYPE CY,CZ CY,CZ DA DA DA CY,CZ DA CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ DA DA DA CY,CZ DA CY,CZ CY,CZ CY,CZ DA CY,CZ DA CY,DB DA DA DA CY,CZ CY,CZ CY,CZ DA DA DA DA DA

CR 136 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 CR 137 CAV

CR 142 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

CVT DISPLAY ECU (BLACK) WIRE CSA DESTIN 675D 1.0 CR125 1488 0.5 ECU6 3 1462 0.5 CR142 16 1494 0.5 CR9 1 1487 0.5 CR1 31 1477 0.5 CR1 28 884C 0.5 CRBSS 944

0.5

CR4 A4

816 1489

0.5 0.5

CR121 A6 ECU6 4

1493 1486 1475 1455 810G 884D 378 377

0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.0

CR9 3 CR8 A CR7 A CR143 1 CDS CR121 D4 CR150 8 CR150 6

1466 1467 1468 1469 1470 1471 1432 1481 1483

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

CR142 7 CR142 8 CR142 9 CR142 10 CR142 11 CR142 12 CR144 6 CR151 1 CR151 3

CVT DISPLAY ECU CHASSIS GROUND WIRE CSA DESTIN 676 2.0 CR135 25

CR 143 CAV 1 2 3 4

CV CX TYPE CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ DA CY,CZ DA CY,CZ DA DA CY,CZ CY,CZ DA CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ DA CY,CZ CY,CZ DA CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ CY,CZ DA DA

CR 144 CAV 2 4 5 6 7 8

WIRE 942G 675JB 675FF 1463 1464 1465 1466 1467 1468 1469 1470 1471 1449 550 1439 1462 1438

CSA 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

CSA 0.5 0.5 1.5 1.5

DESTIN CR136 19 CRES6 CRIS CRES6

WHEEL SLIP ENABLE WIRE 161D

CSA DESTIN 0.5 EDCIS

635ZA 1432 635ZB 860AA

0.5 0.5 0.5 0.5

AC LK TYPE W W W W W

CR ABS CANBUS 145 INTERCONNECT CAV WIRE CSA DESTIN 0.5 CANHS16 A CAN_H 0.5 CANLS16 B CAN_L C

GA GB TYPE GT GT HU

DIODE CONNECTOR 2 WIRE CSA DESTIN 955A 0.5 CR4 E8 0.5 CR152 B 962 0.5 CR4 E8 955B 0.5 CRBSS 884B 0.5 NSS 947B 0.5 AMSS 949 0.5 AMSS 949C 0.5 CR121 D4 884E

CR DIODE 147 CONNECTOR 3 CAV WIRE CSA DESTIN 0.5 MSS1 1 942L 0.5 CR66 34 2 160BA

TYPE JV JR,JW DESTIN MSS1 DSES TMES1 CR135 17 CR135 6 CR135 30 CR136 26 CR136 27 CR136 28 CR136 29 CR136 30 CR136 31 CR135 29 CR135 8 CR135 21 CR136 3 CR135 10

KC TYPE EW,EX EW,EX KD,KE KD,KE

CRES4 CR136 32 CRES4 RHSLS

CR 146 CAV 1 2 3 4 5 6 7 8

ARM REST CAPACTY O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O O.5-1.O

SEAT (INCL OPS) WIRE 1455 750R 115E 750

TYPE GE GE GE GE GE GE GE GE GE GE GE GE GE GE GE GE GE HV HV HV HV

DM DN TYPE K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ

AM AN TYPE K,FZ K,FZ

CR TRANSMISSION 148 BULKHEAD CAV CAPACTY CSA WIRE 675JH 1.0 1/A O.5-2.5 945 0.5 2/B O.5-2.5 946 0.5 3/C O.5-2.5 947A 0.5 4/D O.5-2.5 1446 0.5 5/E O.5-2.5 1448 0.5 6/F O.5-2.5 1447 0.5 7/G O.5-2.5 1444 0.5 8/H O.5-2.5 1450 1.0 9/J O.5-2.5 956 0.5 10/K O.5-2.5 943 0.5 11/L O.5-2.5 942D 0.5 12/M O.5-2.5 414 0.5 13/N O.5-2.5 675FV 1.0 14/O O.5-2.5 SCRN * 0.5 15 O.5-2.5 1442B 1.0 16/P O.5-2.5 1445 0.5 17/Q O.5-2.5 675K 2.0 18/R O.5-2.5 373 2.0 19/S O.5-2.5 1443 0.5 20/T O.5-2.5 1451 1.0 21/U O.5-2.5 1458 0.5 22/V O.5-2.5 1473 0.5 23/W O.5-2.5 960 0.5 24/X O.5-2.5 968B 0.5 25 O.5-2.5 CAN_L* 0.5 26 O.5-2.5 CAN_H* 0.5 27 O.5-2.5 28 O.5-2.5 29 O.5-2.5 30 O.5-2.5 31 O.5-2.5 * SEE SHEET 5 FOR CANBUS DETAIL

JS,JX DESTIN DSES CR130 61 CR130 62 NSS CR130 29 CR130 6 CR130 15 CR130 42 CR130 19 CR130 47 CR130 51 MSS1 SSS TMES1 D'WIRE TSSS1 CR130 18 CR125 CR150 2 CR130 13 CR130 2 CR130 45 CR130 21 CR130 64 PCCOS CR130 4 CR130 5

WIRE 246

CSA DESTIN 6.0 CR45

FC FD TYPE FR

249 15M

4.0 2.0

CR45 IGNS2

FG FL

1441 247 373 376 377 378 379 339 103 104 1442 374

1.0 6.0 2.0 1.0 1.0 1.0 1.0 4.0 1.0 1.0 1.0 6.0

CR130 23 CR45 CR148 S CR135 1 CR136 24 CR136 23 CR4 A2 CR104 2 CR135 2 CR130 28 TSSS1 TMSS

FE FH FF FE FE FE FE FG FE FE FE FH

CR 150 CAV 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 CR 151 CAV 1 2 3 7 8

WIRE 1481 635M 1483 635N 860W

CVT FUSEBOX

540/1000 PTO CSA 0.5 0.5 0.5 0.5 0.5

DESTIN CR136 33 CRES4 CR136 34 CRES4 RHSLS

TYPE GC GC GC GC GC GC GC GC GC GC GC GC GC GC GT GC GC GD GD GC GC GC GC GC GC GT GT HU HU HU HU

CR LIMP HOME SWITCH 152 CAV WIRE CSA DESTIN 0.5 CDS A 810F 0.5 CR146 2 B 962

ER TYPE DG,GX DG,GX

CR 153 CAV 1 2 3 4

WIRE 135A CAN_L CAN_H 635X

CR 154 CAV 1 2 3 4

FRONT HITCH PANEL

JY,JZ

WIRE 100R CAN_L CAN_H 635Y

TYPE JM,CC JM,CE JM,CE JM,CC

REAR HITCH PANEL CSA 0.5 0.5 0.5 0.5

CSA 0.5 0.5 0.5 0.5

DESTIN CR12 A6 CANLS14 CANHS14 CRES4

DESTIN CR12 A7 CANLS15 CANHS15 CRES4

JY,JZ TYPE JM,CC JM,CE JM,CE JM,CC

AC LP TYPE W W W W W

721/12166 SHEET 12 OF 15

Fig 28. Cab Harness sheet 12 K Fig 29. ( T C-29)

Harness Data

C - 28

Section C - Electrics

JA JB TYPE CB,CC JD,JE JF JD,JE JD,JE JD,JE JF JF JF JD,JE JF JD,JE JD,JE JD,JE JD,JE JF JF JD,JE JD,JE JF JD,JE JF CB,CC JF JF JD,JE JD,JE JD,JE JD,JE JF JF JF JF JD,JE JD,JE JF JD,JE JF JF JF JF JD,JE JF JF JD,JE JF JD,JE JD,JE JD,JE JD,JE JD,JE JF JD,JE JD,JE JD,JE JD,JE JD,JE JD,JE JD,JE JD,JE JD,JE JD,JE JD,JE JD,JE JF JF JF JF

Drawings and Interconnection

CR 130 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 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

C - 29

E1 TERM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

DEST.

SIZE

E5 1 2 3

E6 TERM

1 2 3

E9 TERM

1 2

9803/8040-5

E11 TERM

1 2 3 7 8

TYPE

424 0.6CR1 22 425 0.6 E5-2

KP KP

RLSS 930 0.6 500B0.6 RSS2 414B0.6 SSS

KP KP KP

403B0.6 ASS

CR104 29

SIZE

WIRE

SIZE

DEST.

660GA 28 0.6CRES3 29 300A0.6PFSB9 30 31 32 33 34 CR104 24 35 924 0.6 36 928 0.6E11-3 CR104 27 37 503 0.6

TYPE

KP KP

DEST.

RH DRAFT PIN SIZE

JACK SOCKET WIRE

SIZE

DEST.

RAISE/LOWER WIRE

SIZE

DEST.

922 0.6E1-17 923 0.6CR1 17 RLSS 931 0.6 928 0.6E1-36 929 0.6CR1 18 660GB 0.6CRES3 860R0.6RHSLS -

DEST

SIZE

ECU CONNECTOR B WIRE

SIZE

DEST

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

100D 100E CANH515N

1.0 1.0 0.5

ECUIS ECUIS CANHS5

100G 300C 818

1.0 0.5 1.0

ECUIS PFSB9 ECU17 3

CANL514N

0.5

CANLS5

CANHS12

CAN_L

CANLS12

0.5

TYPE

BP TYPE

TYPE

V W

V W W

** ** * * *

1413 583 1406

0.5 0.5 0.5

ECU14-8 ECU14-4

576 572 571 584 500AB

CR104 23 ECU13-6 ECU12-6

1414 1412 582 1408 1402

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

570

0.5

ECU11-6

585

0.5

ECURGS

1410 581 1401 1404 1400 819 574

0.5 0.5 0.5 0.5 0.5 0.5 0.5

ECU13-9 ECU12-4 ECU11-8 ECU12-7 ECU11-7 ECU17 3 ECUFRS

1409 580 597 1405

0.5 0.5 0.5 0.5

ECU13-8 ECU11-4 CR1 14 ECU12-8

598 573

636A SCRN 100B 100H CAN_H

1.0 0.5 1.0 1.0 0.5

ECURSS RSS2 ECU14-9 ECU14-7 ECU13-4 ECU13-7 ECU11-9

CR1 15 ECU13-2

ECUES D'WIRE ECUIS ECUIS CANHS11

636B SCRN

1.0 0.5

ECUES D'WIRE

CAN_L 632 636C

0.5

CANLS11 ECU8 ECUES

1.0 1.0

ECU3

ECU CONNECTOR C

TERM

WIRE

SIZE

HV HV GL GL GL HV GL GL GL GL GL GL GL GL GL GL HV GL HV GL HV HV GL GL GL GL GL GL GL HV HV HV GL GL GL GL HV GL GL HV

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 37 38 39 40

575

0.5

ECU14 6

586

0.5

CR104 20

636E 636D 1418

1.0 1.0 0.5

ECUES ECUES CR1 16

ECU4

TYPE

TERM

GL GL GL HV GL GL GL HV GL HV GL GL GL GL GL HV GL GL HV HV GL GL GL HV

A B C ECU6 TERM

1 2 3 4 5 6 7

527

0.5

ECU11-5

587

0.5

CR1 9

592

0.5

ECU11-11

594 596 536 528

0.5 0.5 0.5 0.5

ECU13-11 ECU14-11 RGSRS ECU12-5

1403 1407 1411 1415

0.5 0.5 0.5 0.5

ECU11-10 ECU12-10 ECU13-10 ECU14-10

593

0.5

ECU12-11

534 529

0.5 0.5

TGSRS ECU13-5

DEST

SIZE

CANH515J CANL514J -

CANHS5 CANLS5 -

0.5 0.5 -

ISO 11786 SKT CONNECTOR WIRE

ECU 11 TERM

WIRE

SIZE

GL HV HV HV HV HV GL HV GL GL GL HV HV HV HV HV HV HV HV GL HV GL HV HV GL HV GL GL GL GL HV GL GL GL GL HV GL HV GL GL

1 2 3 4 5 6 7 8 9 10 11 12 13 14

574A 574B 638A 580 527

0.5 0.5 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

GT GT HU HP

DEST

SIZE

TYPE

0.5 0.5 0.5 0.5

ECU15-6 ECU15-8 CR136 2 CR136 14

HM HM HM HM

106 635ZC

1.0 1.0

CR12 C3 CRES4

HL HL

WIRE

SIZE

632

1.0

DEST

ECU2-22

570 1400 1401 1402 1403 592 636F 636K

DEST

ECUFRS ECUFRS SVCES ECU1-34 ECU3-20 ECU1-18 ECU1-27 ECU1-25 ECU1-16 ECU3-32 ECU3-25 ECUES ECUES

TYPE

K,FZ K,FZ K,L K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ CN

LEVERS 1 & 2 CONNECTOR 2

GM GN

TERM

WIRE

SIZE

DEST

TYPE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

584A 585A

0.5 0.5

ECURSS ECURGS

581 528

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

ECU1-24 ECU3-30 ECU1-9 ECU1-26 ECU1-36 ECU1-5 ECU3-33 ECU3-37 ECUES

CH,FZ CH,FZ CN CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CN CN

ECU 13

571 1404 1405 1406 1407 593 636G

LEVERS 3 & 4 CONNECTOR 1

TERM

WIRE

SIZE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

574C 573 638B 582 529

0.5 0.5 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

572 1408 1409 1410 1411 594 636H 636L

ECU 15 TERM

1 2 3 4 5 6 7 8 ECU 17 TERM

DM DN

ISO 11786 RESISTOR CONNECTOR WIRE

100L 536B 100M 534B 536A 537 534A 535

DEST

SIZE

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

ECUIS RGSRS ECUIS TGSRS RGSRS ECU6-1 TGSRS ECU6-2

SIZE

K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ AC LJ

TRANSPORT SWITCH WIRE

TYPE

DEST

TYPE

1 2 3 4 5 6 7 8 9 10

100A 818 819

1.0 1.0 0.5

968 636U 636P

1.0 1.0 0.5

ECUIS ECU2 7 ECU1 28 PCCOS ECUES ECUES

V V

V V W

DX DY DEST

ECUFRS ECU1-39 SVCES ECU1-14 ECU3-40 ECU1-8 ECU1-15 ECU1-33 ECU1-23 ECU3-34 ECU3-27 ECUES ECUES

TYPE

K,FZ K,FZ K,L K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ K,FZ CN

TYPE

537 535 1488 1489

RF GROUND

ECU 12

DX DY

LEVERS 1 & 2 CONNECTOR 1

KS TYPE

GA GS

CAN BUS 2 WIRE

ECU8 TERM

DEST

TYPE

ECU 14

LEVERS 3 & 4 CONNECTOR 2

GM GN

TERM

WIRE

SIZE

DEST

TYPE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

584B 585B

0.5 0.5

ECURSS ECURGS

583 585C

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

ECU1-4 ECURGS ECU3 1 ECU1-13 ECU1-3 ECU1-12 ECU3-35 ECU3-28 ECUES

CH,FZ CH,FZ CN CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CH,FZ CN CN

575 1412 1413 1414 1415 596 636J

721/12166 SHEET 13 OF 15

SEE SHEET 5 FOR CANBUS DETAILS

Fig 29. Cab Harness sheet 13 K Fig 30. ( T C-30)

Harness Data

C - 29

Drawings and Interconnection

* CANBUS 1 ** CANBUS 2

0.5 0.5

ECU12-9

KU TYPE

Section C - Electrics

ECU2

CAN_H 0.5

725A0.6 SES JM,CC 426 0.6 E1-26JM,CC 920A0.6EDCSSSJM,CC

CR65 8 415 0.6 0.6CRES3 660GD

WIRE

TERM

KP KP KP

KR DEST.

ECU CONNECTOR A

AC LH

CR1 23 715 0.6 920 0.6EDCSSS SCRN 0.5 D'WIRE

725B0.6 SES JM,CC 425 0.6 E1-7 JM,CC 920B0.6EDCSSSJM,CC

WIRE

ECU1 TERM

BD BD

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

KP KP

LH DRAFT PIN WIRE

TERM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

922 0.6 E11-1 504 0.6

20 21 22 23 CR12 A6 24 135 0.6 25 26 426 0.6 E6-2 27

TERM

KM,KN

CONTROL BOX WIRE

725 0.6 SES

C - 30

IGNITION 1 IGNS1

WIRE

SIZE

010 010A 010B 010C 010D 010E 010F 010G 010H 010J 010K

6.0 1.4 2.0 2.0 1.4 1.0 1.4 4.0 1.0 1.0 1.0

DEST

CR33 2 CR12 A2a CR12 A4a CR12 A3a CR12 C1a CR12 C7a CR12 C2a CR12 A9a CR12 B6a CR116 B CR12 C3a

IGNITION 2 IGNS2 WIRE

SIZE

015 015A 015B 015C 015D 015E 015F 015G 015J 015K

6.0 0.6 1.4 0.6 2.0 1.0 2.0 1.0 1.0 1.0

EB DEST

CR3 5 CR12 A1a CR12 C9a CR12 A6a CR12 A8a CR12 C4a CR12 A7a CR12 A5a CR47 A CR100 A

BATTERY 1 BATS1 WIRE

210 210B 210D 210E

2.0

CR150 13

CAB ROOF IGNITION CRIS WIRE

SIZE

115 115A 115B 115C 115E

2.0 1.0 1.0 1.0 1.5

PANEL IGNITION A4 PISA4 WIRE

9803/8040-5

120 120A 120B 120C

SIZE

2.0 2.0 1.0 1.0

PANEL IGNITION C4 PISC4 WIRE

160 160C

SIZE

1.0 0.6

4.0 2.0 3.0 1.4

DEST

CR45 CR12 B2a CR12 B7a CR12 B8a

BATTERY 2 BATS2 WIRE

EB SIZE

DEST

240 240A 240B

4.0 1.0 1.4

CR45 CR12 B1a CR12 B5a

240D 240E 240F

0.6 3.0 1.5

CR12 B9a CR12 C8a C12 C6a

PERMANENT FEED B9 PFSB9 WIRE

300 300A 300B 300C

SIZE

0.6 0.6 0.6 0.5

EB DEST

CR12 B9 E1 29 CR66 33 ECU2 6

CABROOF PERMANENT FEED CRPFS WIRE

015M

EB SIZE

SIZE

1.0 1.0

CR12 B1 CR128 1

305C

1.0

CR32 2

EB DEST

CR12 A4 CR43 8 CR39 E8 CR51 27

EB DEST

CR12 C4 CR77 8

160H

0.6

CR12 C5a

160L

0.5

CR57 1

EDC IGNITION EB EDCIS CSA DESTIN WIRE 161 0.5 CR12 C5 161C 0.5 CR104 25 161D 0.5 CR144 2

FRONT WORKLIGHT SUPPLY FWLSS WIRE

315 315A 315B 315C 315F

SIZE

2.5 1.4 1.4 1.5 1.5

REAR WORKLIGHT SUPPLY RWLSS WIRE

320 320A 320B 320C

SIZE

3.0 1.4 1.4 0.6

PANEL MAIN LIGHTS PMLS WIRE

360 360A 360B 360C 360D

SIZE

6.0 2.0 1.5 2.0 1.4

WIRE

403 403A 403B

SIZE

CR51 23 CR66 17 E1 13

SPEED SIGNAL SSS WIRE

414 414A 414B

SIZE

0.5 0.6 0.6

DEST

CR148 N CR130 34 E1 11

RADAR SIGNAL 2 RSS2 WIRE

500 500AA 500AB 500B

SIZE

0.5 0.5 0.5 0.5

EB DEST

0.6 0.6 0.6

DEST

CR1 19 CR66 7 ECU1 11 E1 10

J1708 POSITIVE EB J1708+ CSA DESTIN WIRE 560** 1.0 CR120 2 560A** 1.0 CR51 8 560B** 1.0 CR119 F

CAB ROOF EARTH 4 CRES4 WIRE

SIZE

635 635C 635M 635N 635P 635T 635V 635W 635X 635Y 635ZA 635ZB 635ZC

2.0 1.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.0

WIRE

SIZE

660

2.0

EB DEST

CR38 CR119 A CR151 2 CR151 7 CR8 C CR7 C CR9 2 CR9 7 CR153 4 CR154 4 CR144 5 CR144 7 ECU6 7

CABROOF EARTH 3 CRES3

CR12 B3 CR24 2 CR24 5 CR24 8 CR126 4

EB DEST

DEST

CR46 2 CR77 5 CR79 6 CR77 2 CR39 B2

TRANS MAN SUPPLY EB TMSS CSA DESTIN WIRE 374 6.0 CR150 20 374A 1.0 CR130 56 374B 1.0 CR130 57 374C 1.0 CR130 58 374D 1.0 CR130 59 374E 1.0 CR130 60

710 710A 710B 710C 710D

0.6

J1708 NEGATIVE EB J1708CSA DESTIN WIRE 561** 1.0 CR120 1 561A** 1.0 CR51 22 561B** 1.0 CR119 G

CAB ROOF EARTH 1 CRES1 WIRE

600 600A 600B 600C 600D 600N

SIZE

6.0 1.0 1.0 1.0 1.0 1.5

WIRE

610 610A 610B 610C 610D 610E 610F 610G 610H 610J

SIZE

4.0 1.0 1.0 1.0 1.0 1.0 1.0 0.6 0.6 0.5

3.0 0.6 0.6 1.4 0.6

DEST

WIRE

800 800A 800B

1.0 0.6 1.0 1.0 0.6 0.6

CR77 7 CR69 31 CR37 2 CR48 2 CR39 E4 CR24 7

710N

0.6

CR28 7

1.5

CR39 B6

710V

1.5

CR126 9

1.5 1.5 1.5

WIRE

801 801A 801B

SIZE

1.5 1.5 1.5

DEST

CR126 12 CR16 1 CR18 1

A POST WORKLIGHTS APWLS 804 804A 804B

EB DEST

CR126 11 CR14 1 CR21 1

INNER FRONT WORKLIGHTS IFWLS

WIRE

710R

SIZE

EB DEST

1.5 1.5 1.5

CR126 5 CR60 1 CR59 1

CR38

CR33 4

660GA 660GB

0.5 0.5

E1 28 E11 7

660GD

0.5

E9 2

660GF

0.5

CR104 26

660W

0.6

CR54 4

660Y 660Z

0.6 1.4

CR89 3 CR82 2

660ZE

0.5

CR134 B

TRANS MAN EARTH 1 EB TMES1 CSA DESTIN WIRE 675F 2.0 CR125 675FA 1.0 CR130 55 675FB 1.0 CR1 11

675FF

1.0

CR142 3

675FV

1.0

CR148 O

EB DEST

CR38 CR10 2 CR34 2 CR35 2 CR29 2 CR26 1 CR31 2 CR25 B CR27 B CR117 2

OUTER FRONT WORKLIGHTS OFWLS

DEST

CR38 CR39 F4 CR5 7 CR66 35 CR32 7

1.0 1.0 1.0

CR98 1 CR44 1 CR44 5

PANEL EARTH 3 PES3

SIZE

3.0 0.6 1.4 1.4 0.6

CR38 CR63 2 CR70 B CR71 B CR39 A4

720H 720J

0.6 1.0

CR68 10 CR78 7

0.6 1.0 1.0

WIRE

805 805A 805B

CR81 2 CR60 2 CR59 2

CAB ROOF EARTH 6 CRES6 SIZE

CR1 4 CR53 1 CR148 A

675JM

0.5

CR107 1

1.5 1.5 1.5

EB DEST

CR126 13 CR10 1 CR35 1

CLUTCH DOWN SIGNAL EB CDS WIRE

SIZE

810

0.6

CR36 2

810E 810F 810G

0.5 0.5 0.5

CR4 C4 CR152 A CR136 20

DEST

INNER REAR WORKLIGHT IRWLS WIRE

WIRE

SIZE

1.0 1.0 0.6 0.5 0.6 0.6 0.5 0.5 0.6 0.6 0.6 0.5 0.5

DEST

CR79 5U CR104 10 CR73 4 CR128 2 CR25 A CR27 A CR151 8 CR116 A E11 8 CR82 3 CR54 3 CR9 8 CR144 8

PANEL RIGHT INDICATOR PRIS 861 861A 861B 861C 861D 861G

SIZE

1.4 1.4 1.0 1.4 0.6 0.6

DEST

CR68 18 CR71 A CR51 25 CR43 3 CR73 6 CR65 25

835 835A 835B

SIZE

1.5 1.5 1.5

EB DEST

CR126 14 CR34 1 CR29 1

DEST

750J 750 750K 750L

2.0 1.5 0.5 0.5

CR38 CR143 4 CR121 D6 CR4 B4

750R 750T 750U 750V -

0.5 0.5 0.5 0.5 -

CR143 2 CR4 C6 CR4 A6 CR4 E6 -

PANEL HEADLIGHTS PHLS WIRE

838 838A 838B 838C 838D

SIZE

2.0 1.4 1.5 1.5 1.5

859 859A 859B 859C 859D 859G

SIZE

1.4 1.4 1.0 1.4 0.6 0.6

WIRE

SIZE

DEST

880 880A 880B 880C 880D

1.0 0.6 0.6 0.6 0.6

CR79 4U CR68 8 CR65 14 CR32 8 CR73 3

880F 880G 880K

1.0 0.6 0.6

CR51 16 CR81 1 CR5 8

CABROOF BRAKE LTS CRBLS

WIRE

SIZE

883

1.4

CR104 6

DEST

883E 883F

0.5 1.5

CR117 1 CR121 D8

EB DEST

CR77 6 CR43 6 CR78 2 CR78 8 CR126 3

PANEL LEFT INDICATOR PLIS

LH SIDELIGHTS LHSLS

BRAKE SIGNAL EB CRBSS CSA DESTIN WIRE 884 0.5 CR57 2 884B 0.5 CR146 4 884C 0.5 CR136 8 884F 0.5 CR100 D

EB DEST

CR68 5 CR70 A CR51 24 CR43 1 CR73 5 CR66 14

MAINT SUPPLY 1 EB MSS1 CSA DESTIN WIRE 942 1.0 CR4 A8 942B 942C 942D

0.5 1.0 0.5

CR130 54 CR1 10 CR148 M

942G

1.0

CR142 1

942K 942L

0.5 0.5

CR107 2 CR147 1

942P

0.5

CR53 2

NEUTRAL SOLENOID EB NSS CSA DESTIN WIRE 947 0.5 CR130 50 947A 0.5 CR148 D 947B 0.5 CR146 5

AUX MODE SWITCH EB AMSS CSA DESTIN WIRE 949 0.5 CR146 6 949A 0.5 CR130 10 949B 0.5 CR4 E4 949C 0.5 CR146 7 PTO CLUTCHES C/O EB PCCOS CSA DESTIN WIRE 968 1.0 ECU17 5 968A 0.5 CR104 11 968B 0.5 CR148 25 TRANS SENS SUPP 1 EB TSSS1 CSA DESTIN WIRE 1442 1.0 CR150 18 1442A 0.5 CR135 31 1442B 1.0 CR148 P

SENSOR EARTH EB SES CSA DESTIN WIRE 725 0.5 E1 1 725A 0.5 E6 1 725B 0.5 E5 1 EDC SENSOR SUPPLY EB EDCSSS CSA DESTIN WIRE 920 0.5 E1 39 920A 0.5 E6 3 920B 0.5 E5 3 920C 0.5 CR1 21 RAISE/LOWER SWTCH EB RLSS CSA DESTIN WIRE 930 0.5 E1 9 931 0.5 E11 2 932 0.5 CR104 19 ECU IGNITION SPLICE EB ECUIS CSA DESTIN WIRE 100 2.0 CR12 A7 1.0 ECU17 2 100A 100B 1.0 ECU2-13 100D 100E 100G 100H

1.0 1.0 1.0 1.0

ECU2-1 ECU2-2 ECU2-5 ECU2-14

100L 100M 100N 100P

0.5 0.5 0.5 0.5

ECU15-1 ECU15-3 CR1 6 CR1 7

ECU EARTH SPLICE ECUES WIRE 636 636A 636B 636C 636D 636E 636F 636G 636H 636J 636K 636L

EB DESTIN

CSA 2.0 1.0 1.0 1.0 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5

CR38 ECU2-11 ECU2-17 ECU2-23 ECU3-10 ECU3-9 ECU11-12 ECU12-12 ECU13-12 ECU14-12 ECU11-13 ECU13-13

636P

0.5

ECU17 7

636T 636U -

0.5 1.0 -

CR1 8 ECU17 6 -

721/12166 TRUE GROUND SPEED RESISTOR SPLICE EB TGSRS CSA DESTIN WIRE 534 0.5 ECU3 39 534A 0.5 ECU15 7 534B 0.5 ECU15 4

RADAR GR'ND SPEED RESISTOR SPLICE EB RGSRS CSA DESTIN WIRE 536 0.5 ECU3 29 536A 0.5 ECU15 5 536B 0.5 ECU15 2

ECU FLOW RATE SPLICE ECUFRS WIRE 574 574A 574B 574C

CSA 0.5 0.5 0.5 0.5

EB DESTIN ECU1 29 ECU11 1 ECU11 2 ECU13 1

ECU REFERENCE SUPPLY SPLICE EB ECURSS CSA DESTIN WIRE 584 0.5 ECU1 10 584A 0.5 ECU12 1 584B 0.5 ECU14 1

ECU REFERENCE GROUND SPLICE EB ECURGS CSA DESTIN WIRE 585 0.5 ECU1 20 585A 0.5 ECU12 2 585B 0.5 ECU14 2 585C 0.5 ECU14 5 585F 0.5 CR1 5 SPOOL VALVE CONTROL EARTH SPLICE EB SVCES CSA DESTIN WIRE 638 2.0 CR38 638A 1.0 ECU11 3 638B 1.0 ECU13 3

721/12166 SHEET 14 OF 15

Fig 30. Cab Harness sheet 14 K Fig 31. ( T C-31)

Harness Data

C - 30

Section C - Electrics

0.5 0.5 1.0

860 860L 860C 860E 860F 860G 860W 860N 860R 860T 860U 860Z 860AA

Drawings and Interconnection

675JF 675JG 675JH

WIRE

DEST

720 720B 720C 720D 720A

720L 720F 720G

OUTER REAR WORKLIGHT ORWLS

WIRE

DED SENSOR EARTH EB DSES CSA DESTIN WIRE 675J 4.0 CR125 675JA 1.0 CR130 1 675JB 1.0 CR142 2

RH SIDELIGHTS RHSLS

WIRE

CR38 CR14 2 CR16 2 CR18 2 CR21 2 CR128 4

CAB ROOF EARTH 2 CRES2

SIZE

710F 710G 710H 710J 710K 710L

WIRE

CR12 B4 CR28 2 CR28 5 CR28 8

WIRE

EB DEST

PANEL EARTH 1 PES1

710X 710Y 710Z

660F

DEST

305 305G

DEST

CR12 A3 CR5 2 CR26 3 CR4 B8 CR143 3

ALTERNATOR SIGNAL ASS

C - 31 9803/8040-5

FUNCTION REAR BULKHEAD EDC INTERCONNECT

LOCATION SHEET 1 D6 -

IGNITION SWITCH

SHEET 1 H2

CAB ROOF RELAY BASE

SHEET 1 D4

REAR WASH WIPE SWITCH BASE

SHEET 2 D8

RADIO CASSETTE SPEAKER CONNECTION

REAR PTO SWITCH

SHEET 3 E5

FRONT PTO SWITCH

SHEET 3 E5

4WD/DIFF LOCK SWITCH

SHEET 3 D5

REAR RH OUTER WORKLIGHT

SHEET 3 B6

AIR CONDITIONING/HEATER UNIT

SHEET 3 C7

MAIN FUSE PANEL FRONT RH OUTER WORKLIGHT AG PANEL INTERIOR LIGHT FRONT RH INNER WORKLIGHT RH SPEAKER FRONT LH INNER WORKLIGHT LH INTERIOR LIGHT RADIO CASSETTE POWER CONNECTION FRONT LH OUTER WORKLIGHT

SHEET 1 F5 SHEET 3 E8 SHEET 3 D8 SHEET 3 H6 SHEET 3 H7

LH SPEAKER

FRONT WORKLIGHT SWITCH BASE

SHEET 2 E8

RH NO PLATE LIGHT

SHEET 3 B7

REAR WIPER MOTOR

SHEET 3 D8

LH NO PLATE LIGHT

SHEET 3 C8

REAR WORKLIGHT SWITCH BASE

SHEET 2 D8

REAR LH INNER WORKLIGHT

SHEET 3 B9

AUX POWER SOCKET

SHEET 3 E4

BEACON SOCKET

SHEET 3 C9

BEACON SWITCH

SHEET 2 D8

IGNITION RELAY

SHEET 1 H3

REAR RH INNER WORKLIGHT

SHEET 3 B7

REAR LH OUTER WORKLIGHT

SHEET 3 B9

CLUTCH DOWN MICROSWITCH

SHEET 2 C6

REAR WASHER PUMP (P132)

SHEET 2 E2

BATTERY NEGATIVE

SHEET 1 B9

FRONT PANEL RELAY BASE

SHEET 2 F2

HEATER (P132)

SHEET 2 B5

AIR CONDITIONING SWITCH (P100) WARNING BUZZER RH COLUMN SWITCH

SHEET 2 C7

RANGE COLUMN SWITCH

SHEET 2 F8

BATTERY POSITIVE

SHEET 1 F2

MAXIFUSE LIGHTS FUSE

SHEET 1 G5

ABS HARNESS CONNECTOR

SHEET 1 G3

FRONT WASHER PUMP (P132)

SHEET 2 E2

POWERSHIFT ECU HSG 1 BLACK

POWERSHIFT ECU HSG 2 RED

FRONT BULKHEAD SUSPENSION SEAT

SHEET 2 G3 -

CLUTCH POTENTIOMETER

SHEET 2 C5

WORKLIGHTS RELAY

SHEET 1 H2

RH SIDELIGHT/INDICATORS (P100) LH SIDELIGHT/INDICATORS (P100) BRAKELIGHT SWITCH PARKBRAKE WARNING SWITCH

SHEET 2 C6 -

FRONT LH A POST WORKLIGHT

SHEET 2 D3

FRONT RH A POST WORKLIGHT

SHEET 2 B4

ACCELERATOR PEDAL SWITCH

SHEET 2 C7

RF GROUND POWERSHIFT ECU DOOR SWITCH 4WS OPTION CONNECTOR (P100)

SHEET 2 E4 -

INSTRUMENT CLUSTER HSG 1 BLACK

SHEET 2 F5

INSTRUMENT CLUSTER HSG 2 RED

SHEET 2 E6

HEATER FAN SWITCH BASE (P100)

SHEET 2 C8

TRAILER 2 TURN RELAY

SHEET 2 G2

LH SIDE REPEATER (P132)

SHEET 2 D3

96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123

FUNCTION RH SIDE REPEATER (P132)

LOCATION SHEET 2 B7

AUX LIGHTS CONNECTOR IN

SHEET 2 G7

AUX LIGHTS CONNECTOR OUT

SHEET 2 F7

NEUTRAL SOLENOID CONNECTOR

RANGE SELECT CONNECTOR

MAIN LIGHTS SWITCH

SHEET 2 C8

REAR FOG SWITCH BASE

SHEET 2 C8

PANEL MOUNTED FUSE BOX

SHEET 2 F2

SHEET 2 G6

AIR GAUGE ILLUMINATION

SHEET 1 E10

CIGAR LIGHTER RF GROUND INSTRUMENT CLUSTER REVERSE LIGHTS RELAY

SHEET 2 E5 -

AUX. LIGHTS SWITCH SUPPLY (P132)

SHEET 2 F8

DIODE CONNECTOR

VANSCO OPTION CONNECTOR

CR REF 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157

FUNCTION ARM REST CONNECTOR SEAT (INCL OPERATOR PRESENT SWITCH) WHEEL SLIP ENABLE SWITCH ABS CANBUS INTERCONNECT DIODE CONNECTOR 2 DIODE CONNECTOR 3 TRANSMISSION BULKHEAD CVT FUSEBOX 540/1000 PTO SWITCH LIMP HOME SWITCH REAR HITCH CONTROL PANEL FRONT HITCH CONTROL PANEL -

LOCATION SHEET 1 B7 SHEET 4 E6 SHEET 3 D5 SHEET 4 C4 SHEET 1 C6 SHEET 2 F6 SHEET 1 E4 SHEET 1 E5 SHEET 3 D5 SHEET 1 H6 SHEET 3 F5 SHEET 3 F5 -

DIFF LOCK CUT OUT SWITCH

SHEET 1 G6

DIAGNOSTIC CONNECTOR REAR PTO DRIVE CUT-OUT

540 PTO RANGE SELECTED SWITCH

1000 PTO RANGE SELECTED SWITCH

FLOW DIVIDER WARNING LAMP

SHEET 1 F8

AUXILIARY POWER SUPPLY DUPLICATE AUTOSHIFT SWITCHES

DUPLICATE AUTOSHIFT SWITCH SPLITTER DUMP RELAY

COLUMN SWITCH 2

SHEET 2 G8 -

RESISTOR CONNECTOR

SHEET 1 G3

TRACTOR ABS (SUPPLY) TRACTOR ABS (RETURN)

SHEET 1 E6

ELECTRONIC ENGINE FUSEBOX

SHEET 1 F5

REAR BULKHEAD 2

SHEET 1 D5

INTERMEDIATE SPEED CONTROL 1 (ISC1)

FOOT THROTTLE

SHEET 2 F8

FOOT THROTTLE

SHEET 2 E7 -

HAND THROTTLE

ECU 1 INTERCONNECT

AUTOSHIFT CONNECTOR

ENGINE SPEED CONTROL SWITCH

ECU1 CANBUS INTRCONNECT OR TERM RESISTOR

SHEET 4 D2

HEATED MIRRORS SUPPLY

SHEET 1 G3

HIGH LEVEL BRAKE LIGHT ISC VALIDATION DIAGNOSTIC SOCKET J1708 CONNECTOR CAB ROOF RELAY BASE 2

SHEET 1 H6

SHEET 3 B8 SHEET 1 F7 SHEET 1 E2 -

124 125 126

BATTERY NAGATIVE 2 W/LIGHTS HARNESS INTERCONNECT 1

SHEET 1 B9

127 128 129 130 131 132 133 134 135 136 137 138 139 140

W/LIGHTS HARNESS INTERCONNECT 2 ROOF LINER HARNESS CANBUS TERMINATING RESISTOR (3170) CVT TRANSMISSION MANAGEMENT EST ACU COMPRESSOR PRESS SWITCH (BINARY) CVT DISPLAY ECU (RED) CVT DISPLAY ECU (BLACK) CVT DISPLAY ECU CHASSIS GROUND -

SHEET 2 B7

SHEET 2 B7 SHEET 3 G8 SHEET 4 C1 SHEET 4 E6 SHEET 3 G5 SHEET 3 G4 SHEET 3 G5 -

721/12166

SHEET 15 OF 15

Fig 31. Cab Harness sheet 15 K ( T C-15)

Harness Data

C - 31

Section C - Electrics

HAZARD SWITCH BASE

CR REF 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

Drawings and Interconnection

CR REF 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 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

C54

C65 A

C47

10k ohms 5% METAL FILM 1.0 watt -40/+85deg.C 250ppm/deg.C 350V

150

C53

C45

C - 32

RESISTOR SPECIFICATION RESISTANCE TOLERANCE TYPE POWER TEMP. RANGE TEMP. COEFF. MAX VOLTAGE

650

RS2

1429

RS1

1428

C60

C75 10 9

ATUM HEATSHRINK

300

11 21 31 41

30 40 50

C98

100

C85

XXXX

1850

CANBUS SPLICES SEE SHEET 10

C30

150

RE S

1000

800

ISTO

C34

0 200

550 1250

950

200

175

ITEM ED

1200

C79

C33

550

C E S 9

ITEM ED

300

280

31 30

20 8

19 18 17 28

C99 1050

XXXXXXXX

XXX

500

XXX

ITEM CT 0 0

0 0

0 35

SEE SHT. 2 230

ITEM EC

C41

XXX

C88

CES7

C28

C40

500

700

C20

ITEM DV

SEE SHT. 3

23 12

13 14

138

XXX X

15 27

ITEM DU

XXX X

C15

800

0 35

6 4

ITEM DV 50

E17

4 5

ITEM DU

XXXXXXXX

ITEM FB

140

APPLY RED TAPE FOR IDENTIFICATION

6 16

500

REAR OF CONNECTOR

ITEM GB

3 1

9803/8040-5

C39

9 2

DATUM

700

250

HARNESS - CHASSIS 8250 721/12169 SHEET 1 OF 10

Harness Data

C - 32

Section C - Electrics

Chassis Harness sheet 1 K Fig 33. ( T C-33)

Drawings and Interconnection

Fig 32.

ITEM FA

C49

2 1

1000

C89

ITEM DV ITEM DV

ITEM CU

XXXXXXXXXX

ITEM DV

XXXXXXXXXX

XXXXXXXXX

ITEM FB XXXXXXXXX

XXXX

1770

192 0

XXXX

C82

XXXXXXXXX

350

XXXXXXXXX

XXX

0 42 F RE

ITEM DY

ECU 29

C94

1970

XXX

C12

200 0

C - 33

C63 45 0

ITEM FA

ITEM DV

1550

1500

1600

XXXX

1000

1400

C96

X XXXX XXXX X X XXX XXXX

XXXX

750

PTO MBS

DBS

HBWLS

XXXX

1650

700

XXXX

600

ITEM FA

ECU 28

ITEM FC

1350

C97 XX XX XXX X

XXX 1500

1100

1090

XXXXXXXXX 2

1 2

0 170

ITEM DV

XXXXXXXXX

ITEM CU

XX XXX

XXXXXXXXX

ITEM DV XXXXXXXXX

9803/8040-5

XXXX

SEE SHT. 1

ITEM DV

FLES

1 2

C48

Fig 33. Chassis Harness sheet 2 K Fig 34. ( T C-34)

SHEET 2 OF 10

Harness Data

C - 33

Drawings and Interconnection

C64

HARNESS - CHASSIS 8250 721/12169

Section C - Electrics

C81

C - 34

190

E19

TO SHEET 4

R CO EAR O NN EC F TOR

ITEM HN

ITEM HB ITEM DY ITEM GY,GZ

ITEM DV

2 6

FLS

BLS

17 28

1540

1550

200

1000

150

ITEM FE

22 11 23

4 5

12 13

14 26

1750

6 15

100

10 3

1200

21 9

2 7

RSLS

C90

20 8

19 18

200

ITEM CT

ITEM FF 4

400

ITEM CT

24 25

ITEM CS

3 16

ITEM DV

ITEM FB

ITEM FA

ITEM DV

C84 3

C19

TMES4

1500

100

C91

9803/8040-5

ITEM CT

ITEM HG

1475

C83

ITEM DY

1750

1850

1950

2050

C18

2400

2375

2100

CES1

RLS

2000

RFWLS

1900

RPERS

SWFS

1800

MSS2

1400

LSLS

1350

LHIS

1300

TO SHEET 1

RHIS

1250

1200

HARNESS - CHASSIS 8250 721/12169 SHEET 3 OF 10

Fig 34. Chassis Harness sheet 3 K Fig 35. ( T C-35)

Section C - Electrics

Harness Data

Drawings and Interconnection

C - 34

X X X X

2400

X X

ITEM DV

450

200 X

X X X

BMS

500

2350

ITEM FE

ITEM FE ITEM FD

X X

20 0

ITEM DV

X X

A B

X X X X

X X

C - 35

X X

650

A B

ITEM CU (4 PLCS)

721/12169

C14

C73

300

200

55 0

5 00

C93

950

ITEM FD

C92

ITEM DV

D/L

ITEM DV

540

C95

400

ITEM GW

800

ECU 30

VSS

100

9803/8040-5

ITEM HK

ITEM GY,GZ

ITEM HC

ITEM DV

ITEM HK

ITEM HF

ECU 32

ITEM HE

750

ITEM HE

690

630

ITEM DY

ITEM HG 570

450

510

ITEM CS

C78 400

300

5 17

29 28

ESVES

ESVSS

ECU 25

ECU 24

ECU 23

ECU 22

ITEM HM (TYP 5 PLCS)

120

1 2

10 11

22 23

ECU 26

ITEM FC

HARNESS - CHASSIS 8250 721/12169

Fig 35. Chassis Harness sheet 4 K Fig 36. ( T C-36)

Harness Data

C - 35

Drawings and Interconnection

SHEET 4 OF 10

Section C - Electrics

ITEM HL (TYP 5 PLCS)

1 2 3 4

13 24

TO SHEET 3

ITEM DV

ECU 21

400

ITEM CT

120

CANBUS SPLICES SEE SHEET 10

ITEM CT

ITEM CT !

300

ITEM CT !

120

ITEM DV

120

800 ITEM HD

8 4

250

6 1

15 26

0 1100

500

750

470

ITEM DV A

C - 36 9803/8040-5

JCB PART No

MANUFACTURER/PART No -

QTY 25

DELPHI

12010973

7212/0005

DELPHI

12089040

7204/0007

12089679

7210/0042

12010996

7211/0001

51101600

7207/1413

ITT CANNON

192900-0550

7220/0035

ITT CANNON

192990-2530

7201/0003

ITT CANNON

192990-2520

DELPHI DELPHI RISTS

7201/0004

AMP

160759-3

7201/0400

AMP

154719-1

7201/0403

AMP

154717-3

7201/0402

SUMITOMO

6189-0133

7216/0001

SUMITOMO

6918-0330

7216/0003

SUMITOMO

1500-0106

7201/0001

SUMITOMO

7165-0118

7210/0002

SUMITOMO

7161-9787

7210/0001

SUMITOMO

8240-4828

7201/0002

SUMITOMO

7165-0119

7210/0003

6189-0132

7214/0001

SUMITOMO

6189-0129

7212/0001

6918-0322

7212/0003

G&H

03421.311.011

7207/1303

G&H

03422.311.011

7207/1404

RAYCHEM

CGPT-12.7/6.4-0

SUMITOMO SUMITOMO

SUMITOMO

6918-0328

7214/0003

SUMITOMO

6189-0134

7218/0001

SUMITOMO RAYCHEM ITT CANNON

6918-0332 CGPT-12.7/6.4-2 192900-0542

7218/0003 7220/0034

1 0 0

AMP

100101-2

7201/0619

AMP

735014-0

7201/0602

7210/0009

HARNESSFLEX HARNESSFLEX HARNESSFLEX

SC-M27-90 RSG02 RSGP01

7212/0007

7201/0014

7207/1201

G&H

25087.123.011

DELPHI

12015791

7211/0002

AMP

963040-3

7212/0010

AMP

927770-3

7201/0016

828904-1

7210/0012

SUMITOMO

6189-0136

7219/0005

SUMITOMO

6918-0336

7219/0007

AMP

DELPHI

15300008

7212/0035

DELPHI

15300020

7210/0043

0 0 2

DELPHI

12077412

7201/0065

DELPHI

12124582

7204/0008

DELPHI

15300014

7212/0018

AMP

927144-1

7231/0005

AMP

925575-1

7201/0019

AMP

926935-1

7201/0039

PACKARD

12015793

7213/0010

PACKARD

12124581

7201/0027

PACKARD

12010293

7210/0006

926522

7232/0003

AMP SUMITOMO

6189-0131

7213/0005

SUMITOMO

6918-0326

7213/0007

DELPHI

12124580

7201/0012

DELPHI

12052641

7212/0014

DELPHI

12052634

7212/0015

DELPHI

12084200

PACKARD

12048087

G&H

25205.123.011

7207/1211

7212/0008

7212/0009

7201/0022

AMP

344276-1

AMP

345254-1

AMP

345806-1 347874-1

7210/0032

AMP AMP RAYCHEM

172888-2 ATUM-24/6-0

7210/0016 -

2 1

121668-0100

7201/0063

ITT CANNON

121668-0101

7201/0034

ITT CANNON

121668-0102

7201/0005

DM DN DP DR DS DT DU DV DW DX DY DZ EA EB EC ED EE EF EV EW EX EY

DESCRIPTION

JCB PART No

MANUFACTURER/PART No

QTY

4 PIN BAYONET CONNECTOR (DIN72585)

SCHLEMMER

9800 421

7214/0026

2.5 SKT CONTACT FOR BV (0.5-1.0)

SCHLEMMER

7814125

7201/0110

2.5 WIRE SEAL FOR BW (0.5-1.0)

SCHLEMMER

7814128

7210/0063

7814130

7210/0064

CAVITY SEAL FOR BV

SCHLEMMER

HEATSHRINK SLEEVE (

16/

4) L=30

RAYCHEM

ATUM-16/4-0

5.4 RING TERMINAL (2.5-6.0)

G&H

03411.311.011

7207/1206

8.4 RING TERMINAL (16.0-25.0)

G&H

03427.311.011

7207/1405

RUBBER PROTECTIVE CAP

SUCO (OEM)

6.35 FASTON (0.5-1.5) SINGLE RECEPTACLE HOUSING 6.35 RUBBER BOOT

AMP

5-160432-4

AMP

3-925017-0

TIRUB BV

2 WAY JUNIOR-POWER-TIMER HOUSING (BLUE) 2 WAY JUNIOR-POWER-TIMER HOUSING (RED) LIGHTWEIGHT NYLON CONDUIT (O/D 10.0) SPLIT

5749

7201/0408

8 6

282189-5

7212/0034

AMP

282189-8

7212/0023

CTPA08-S

7201/0411

AMP HARNESSFLEX

GT150 SERIES SIDELOCK HOUSING

1166 621 003

2 0 0 0

DELPHI

15336027

7212/0048

GT150 FEMALE TERMINAL (SEALED)(0.75-1.0)

DELPHI

15305350

7201/0107

GT150 CABLE SEAL (0.75-1.0)

DELPHI

15305351

7210/0051

FLEXIBLE NYLON 12 CONDUIT (O/D 13.0) BLACK

HARNESSFLEX

23 WAY HDP PLUG FOR SKT TERMS #16 SOCKET TERM

(0.5-1.0) (#12-#16)

CAVITY BLANKING PLUG

PIFS13

DEUTSCH

HDP26-24-23SE

7220/0047

DEUTSCH

1062-16-0622

7201/0105

DEUTSCH

114017

7210/0030

0 0 0 37 13

RUBBER BOOT

HARNESSFLEX

ESN32

FLEXIBLE NYLON CONDUIT (0/D 21.2)

HARNESSFLEX

NC20

A/R

FLEXIBLE NYLON CONDUIT (O/D 13.0) SPLIT

HARNESSFLEX

NC12-S

A/R

FLEXIBLE NYLON CONDUIT (O/D 7.1) SPLIT

HARNESSFLEX

A/R

2 WAY DT MALE (SKT) PLUG SECONDARY LOCKING WEDGE #16 SOCKET TERMINAL (0.5 - 1.0) #16 SOCKET TERMINAL

GOLD (1.0 - 2.5)

#12 SOCKET TERMINAL (2.5-4.0)

NC06-S DT06-2S-CEO5

7212/0052

DEUTSCH

W2S-PO12

7212/0031

DEUTSCH

1062-16-0644

7201/0127

DEUTSCH

1062-16-1222

DEUTSCH

1062-12-0166

50 WAY RECTANGULAR CONNECTOR PLUG

DEUTSCH

DRC26-50S05

#20 SOCKET TERMINAL (0.5-1.0)

DEUTSCH

1062-20-0244

DEUTSCH

0413-204-2005

GOLD

CAVITY BLANKING PLUG (SIZE 20)

DELPHI

GT150 UNSHROUDED CONNECTOR ASSY (C'TR LOCK)

2-13 STD PLUG FOR PINS NEPTUNE SIGNAL PIN (0.5-1.5) NEPTUNE SIGNAL PIN (2.0) NEPTUNE POWER PIN (2.5-4.0) MINI BUCCANEER FLEX CABLE CON'R CRIMP CONTACT CARRIER INSERT CRIMP SOCKET CONTACT (0.2 - 0.5) AMPLIMITE SOCKET CONTACT (0.2-0.5) GOLD 3 WAY DT MALE (SKT) PLUG (E/SEAL & BOOT) 3 WAY DT MALE (SKT) RETAINER (BLUE) #16 SOCKET TERMINAL (1.0-2.5) GOLD #16 SOCKET TERMINAL (0.5-1.0) EXTENDED 3 WAY DT MALE (SKT) RETAINER (GREEN) HEATSHRINK OR RUBBER BOOT

5mm -7mm CABLE GLAND

2 0 13

7210/0052

7212/0047

192990-2490

7204/0003

ITT CANNON

192990-2480

7204/0004

ITT CANNON

121668-0002

7204/0005

0 0 0 0

BULGIN

PX0800

BULGIN

12735/3

BULGIN

SA3149

66504-3

AMP

DEUTSCH

DT06-3S-CE13

DEUTSCH

W3S-1939-P012

DEUTSCH

1062-16-1244

DEUTSCH

0462-221-1631

DEUTSCH -

FLEXIBLE NYLON CONDUIT (O/D 10.0) SPLIT

HARNESSFLEX

6 WAY DT MALE (SKT) PLUG (EUROSEAL/ENDCAP)

DEUTSCH DEUTSCH

13 RING TERMINAL (10.0-16.0)

7201/0120

192900-0561

6 WAY DT MALE (SKT) RETAINER

RUBBER BOOT

7201/0104

ITT CANNON

HARNESSFLEX

WEATHERPACK/METRI-PACK 280 CABLE SEAL (1.4-2.0)GRN 5.3 RING TERMINAL (2.5-6.0)

15336024

ITT CANNON

FLEXIBLE NYLON CONDUIT (O/D 11.5) SPLIT

FLEXIBLE NYLON CONDUIT (O/D 16.1) SPLIT

DEUTSCH

HARNESSFLEX DELPHI G&H G&H RISTS

W3S-P012 -

NC10-S NC08-S DT06-6S-CEO5

7213/0016

A/R

7216/0018

W6S-P012

7216/0016

NC16-S

7210/0005

A/R

7207/1213

12015323 25231.123.011 03424.311.011

7207/1604

1 0

860129

NC20-S

A/R

FLEXIBLE NYLON CONDUIT (O/D 21.2) SPLIT

HARNESSFLEX

FLEXIBLE NYLON CONDUIT (O/D 42.5) SPLIT

HARNESSFLEX

CTPA40-S

EXTERNAL Y PIECE

HARNESSFLEX

YPS161212

3 WAY SUPERSEAL 1.5 SERIES MALE (SKT) HSG

AMP

282087-1

7213/0024

SUPERSEAL 1.5 SERIES SKT CONTACT (0.3-0.5)

AMP

282403-1

7201/0095

SUPERSEAL 1.5 SERIES WIRE SEAL (0.5) GREEN

AMP

281934-4

7210/0049

SUPERSEAL 1.5 SERIES CAVITY PLUG (RED)

AMP

282081-1

7210/0034

NOTE COMPONENT PART NUMBERS SPECIFIED SERVE TO INDICATE THE COMPONENTS REQUIRED AND IT IS ASSUMED THAT THE HARNESS SUPPLIER WILL PROCURE THE COMPONENTS IN THE MOST COST EFFECTIVE MANNER.

Fig 36. Chassis Harness sheet 5 K Fig 37. ( T C-37)

HARNESS - CHASSIS 8250 721/12169 SHEET 5 OF 10

Harness Data

C - 36

Section C - Electrics

ITT CANNON

ITEM BV BW BX BY BZ CA CB CC CD CE CF CG CH CJ CK CL CM CN CO CP CQ CR CS CT CU CV CW CX CY CZ DA DB DC DD DE DF DG DH DJ DK DL

Drawings and Interconnection

ITEM DESCRIPTION ULTRASONIC SPLICE A 2 WAY WEATHERPACK FEMALE HOUSING B WEATHER PACK PIN TERM. (0.5-0.8) C WEATHER/METRI-PACK 280 CABLE SEAL (0.6-1.0)PPL D 1 WAY WEATHERPACK FEMALE HOUSING E 8.4 90 RING TERMINAL () F 4-28 REV PLUG FOR SOCKETS (PLR) G NEPTUNE SIGNAL SKT TERM (0.5-1.5) H NEPTUNE SIGNAL SKT TERM (2.0) I 6.35 POZILOK (0.5-1.5) J SINGLE RECEPTACLE HOUSING 6.35 K 6.35 POZILOK (2.5-4.0) L 6 WAY HW090 FEMALE HOUSING M 6 WAY HW090 FEMALE RETAINER N HW090 SOCKET TERMINAL (0.3-1.25) O HW090 WIRE SEAL (0.75-1.5) BLUE P HW090 CAVITY SEAL BROWN Q HW090 SOCKET TERMINAL (2.0) R HW090 WIRE SEAL (1.5-2.0) BROWN S 4 WAY HW090 FEMALE HOUSING T 2 WAY HW090 FEMALE HOUSING U 2 WAY HW090 FEMALE RETAINER V 6.5 RING TERMINAL (10-16 CSA) W 8.4 RING TERMINAL (10-16 CSA) X HEATSHRINK SLEEVE ( 12.7/ 6.4) L=30 BLACK Y 4 WAY HW090 FEMALE RETAINER Z 8 WAY HW090 FEMALE HOUSING AA 8 WAY HW090 FEMALE RETAINER AB HEATSHRINK SLEEVE ( 12.7/ 6.4) L=30 RED AC 0-48 REV PLUG FOR SOCKETS (PLR) AD 9.5 FASTON FEMALE TERM. (1.0-2.5) STRAIGHT AE 9.5 FASTON INSULATION SLEEVE (CLEAR) AF 2 WAY 90 SWIVEL CONNECTOR BODY AG 2 WAY SEALING GROMMET AH 3.5 SOCKET CONTACT (UPTO 3.0) CRIMP AI 5.3 RING TERMINAL (0.75-1.5) AJ 1 WAY WEATHERPACK MALE HOUSING AK 2 WAY JUNIOR-POWER-TIMER HOUSING (BLACK) AL JUNIOR-POWER-TIMER CONTACT (0.5-1.0) AM JUNIOR-POWER-TIMER WIRE SEAL (0.5-1.0) AN 14 WAY HW090 FEMALE HOUSING AO 14 WAY HW090 FEMALE RETAINER AP 2 WAY METRI-PACK 280 MALE HOUSING AQ 2 WAY METRI-PACK 280 MALE HSG SEAL AR METRI-PACK 280 SOCKET TERMINAL (1.0-2.0) AS WEATHER PACK PIN TERM. (1.0-2.0) AT 2 WAY METRI-PACK 280 SECONDARY LOCK AU HEAVY DUTY RELAY BASE AV H/DUTY RELAY COIL TERM. (0.5-1.0) AW H/DUTY RELAY POWER TERM. (6.0-10.0) AX 3 WAY WEATHER PACK MALE HOUSING AY WEATHER PACK SOCKET TERM. (3.0) AZ WEATHER/METRI-PACK 280 CABLE SEAL (3.0) GREY BA 2 WAY POZILOCK 'T' HSG BB 3 WAY HW090 FEMALE HOUSING BC 3 WAY HW090 FEMALE RETAINER BD WEATHER PACK SOCKET TERMINAL (1.0-2.0) BE 2 WAY METRI-PACK 150 MALE (SKT) HOUSING ASSY BF 2 WAY METRI-PACK 150 SECONDARY LOCK BG METRI-PACK 150 SOCKET TERM (0.5) BH METRI-PACK 150 CABLE SEAL (0.5) BLUE BI BJ (0.5-1.0) 5.3 RING TERMINAL BK 2 WAY ECONOSEAL .070 F/M HOUSING BL 2 WAY ECONOSEAL .070 F/M RETAINER BM ECONOSEAL .070 SKT TERM (0.75-2.0) BN ECONOSEAL .070 WIRE SEAL (0.5-1.5) GREEN BP ECONOSEAL .070 WIRE SEAL (2.0) GREY BQ HEATSHRINK SLEEVE ( 24/ 6) L=30 BR NEPTUNE POWER SKT TERM (0.5-1.0) BS NEPTUNE POWER SKT TERM (1.5-2.5) BT NEPTUNE POWER SKT TERM (2.5-4.0) BU 2 ** NOT SUITABLE FOR 0.5 mm WIRE 2 mm WIRE USE 12015899 FOR 0.5

C - 37 9803/8040-5

DESCRIPTION 90 CONNECTOR INTERFACE (3 WAY AMP S/S) CONNECTOR INTERFACE (3 WAY AMP S/S) 90 CONNECTOR INTERFACE (2 WAY AMP J-T) 90 CONNECTOR INTERFACE (2 WAY DEUTSCH DT) EXTERNAL Y-PIECE EXTERNAL Y-PIECE 4 WAY DT MALE (#16 SKT) PLUG 4 WAY DT MALE (#16 SKT) RETAINER 3 WAY DT MALE (#16 SKT) PLUG (E'SEAL+E'CAP) PROTECTION CAP HW090 WIRE SEAL (0.5) GREY 4 WAY METRI-PACK 150 MALE (SKT) HSG ASSY 4 WAY METRI-PACK 150 MALE SECONDARY LOCK METRI-PACK 150 SOCKET TERM (1.0) METRI-PACK 150 CABLE SEAL (0.6-1.0) WHITE METRI/MICRO-PACK 150 CAVITY PLUG RED 5.3 RING TERM (1.0-2.5) 50 WAY DRC PLUG (#20 SKT TERMS 0.5-1.0) 4 WAY DTP PLUG (#12 SKT TERMS 2.5-4.0) 4 WAY DTP WEDGE LOCK 8.5 0.25mm 30 RING TERMINAL (25mm 2 8.5 0.25mm RING TERMINAL (25mm ) 2 12.8 0.25mm RING TERMINAL (25mm ) 2 12.8 0.25mm RING TERMINAL (50mm ) HEATSHRINK SLEEVE ( 19.0/ 9.5) RED #16 PIN TERM (0.5-1.0) #16 PIN TERM (1.0-2.5) #20 PIN TERM (0.5-1.0) #20 PIN TERM (0.5-1.0) GOLD #16 PIN TERM (0.5-1.0) GOLD

)

MANUFACTURER/PART No CI08-90-AS3 HARNESSFLEX CI08-AS3 HARNESSFLEX CI08-90-AM2 HARNESSFLEX CI08-90-DT2 HARNESSFLEX YPS080808 HARNESSFLEX YPS121208 HARNESSFLEX DT06-4S-CE05 DEUTSCH W4S-P012 DEUTSCH DT06-3S-CE05 DEUTSCH A8401.01C FTE AUTO. 7165-0385 SUMITOMO 12186568 DELPHI 12047948 DELPHI 12048074 DELPHI 12089678 DELPHI 12059168 DELPHI 25217.123.011 G&H DRC26-50S04 DEUTSCH DTP06-4S-CE02-1 DEUTSCH WP-4S DEUTSCH 25-8BST-30 CTT 25-8BST CTT 25-12BST CTT 50-12BST CTT CGPT-19/9.5-2 RAYCHEM 1060-16-0622 DEUTSCH 1060-16-1222 DEUTSCH 1060-20-0222 DEUTSCH 1060-20-0244 DEUTSCH 1060-16-0644 DEUTSCH

JCB PART No

7243/0164 7243/0163 7243/0002 7243/0054 7243/0059 7214/0025 7214/0016 7213/0031 7210/0095 7201/0028 7210/0040 7210/0019 7207/1215 7219/0083 7204/0027 7204/0036 7204/0037 7204/0040

QTY 4 3 2 4 4 1 0 0 2 1 13 0 0 0 0 0 0 1 1 1 1 0 0 1 A/R 56 15 6 0 6

4 WAY JUNIOR-POWER-TIMER HOUSING (BLACK) 3 WAY JUNIOR-POWER-TIMER HOUSING (BLACK) 2 WAY JUNIOR-POWER-TIMER HOUSING (BLACK) JUNIOR-POWER-TIMER CONTACT (0.5-1.0) JUNIOR-POWER-TIMER CONTACT (1.5-2.5) JUNIOR-POWER-TIMER WIRE SEAL (1.4-2.0)

AMP AMP AMP AMP AMP AMP

282 192 -1 282 191 -1 282 189 -1 929 939 -1 929 937 -1 828 905 -1

7213/0029 7212/0013 7201/0090 7201/0076 7210/0013

5 1 2 24 3 3

4 WAY SUPERSEAL 1.5 SERIES MALE (RECEP) SUPERSEAL 1.5 SERIES RECEP TERM (1.0-1.5) S/S 1.5 SERIES WIRE SEAL (0.6-1.5) YELLOW

AMP AMP AMP

282 088 -1 282 110 -1 281 934 -2

7201/0094 7210/0044

1 1 1

7243/0136 7243/0135 7243/0134 7243/0061 7243/0063 7243/0066 7243/0003 7243/0012 7243/0010 7243/0017 7243/0018 7243/0024 7204/0026 -

1 0 2 2 0 1 1 1 3 1 2 0 0 2 5 A/R 1 0 0 0 3 1 1 1

CONNECTOR INTERFACE (2 WAY AMP J-T) CONNECTOR INTERFACE (4 WAY AMP S/S) CAP NUT REDUCING BUSH EXTERNAL Y-PIECE EXTERNAL Y-PIECE EXTERNAL Y-PIECE EXTERNAL T-PIECE EXTERNAL T-PIECE EXTERNAL T-PIECE EXTERNAL T-PIECE EXTERNAL T-PIECE EXTERNAL T-PIECE CONNECTOR INTERFACE (3 WAY DEUTSCH DT) 90 CONNECTOR INTERFACE (4 WAY AMP J-T) FLEXIBLE NYLON CONDUIT (O/D 13.0) CONNECTOR INTERFACE (3 WAY AMP J-T) 31 WAY HDP PLUG FOR SKT TERMS 47 WAY HDP PLUG FOR PIN TERMS 21 WAY HDP PLUG FOR PIN TERMS #12 PIN TERM (2.5-4.0) 29 WAY HDP PLUG FOR PIN TERMS 31 WAY HDP PLUG FOR PIN TERMS 31 WAY HDP PLUG FOR PIN TERMS

HARNESSSFLEX HARNESSSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH

CI08-AM2 CI08-AS4 CN21-20 RSB28-20 YPS121212 YPS161208 YPS161608 TPS080808 TPS121212 TPS121208 TPS161212 TPS161216 TPS201216 CI08-DT3 CI12-90-AM4 NC12 CI08-AM3 HDP26-24-31SE HDP26-24-47PE HDP26-24-21PE 1060-12-0166 HDP26-24-29PE-L015 HDP26-24-31PE HDP26-24-31PE-L015

Chassis Harness sheet 6 K Fig 38. ( T C-38)

IT IS INTENDED TO RESPECIFY ALL 0.6mm WIRE TO 0.5mm, AND ALL 1.4mm TO 1.5mm SUBJECT TO THE SUITABILITY OF THE TERMINALS AND WIRE SEALS SPECIFIED. IT IS THEREFORE ACCEPTABLE TO USE 0.5mm AND 1.5mm IN PLACE OF 0.6mm AND 1.4mm RESPECTIVELY, (AND VICE-VERSA) WHERE THE SPECIFIED TERMINALS AND WIRE SEALS ALLOW. *** THROTTLE SIGNAL WIRES TWISTED TRIPLE - LENGTH OF LAY 25-35mm. ** ENGINE POWER & INTAKE AIR HEATER CONTROL WIRES TWISTED PAIR - LENGTH OF LAY 25-35mm. WIRES #560A & #561A ARE SERIAL DATA COMMUNICATION TWISTED PAIR TO SAE J1708.

HARNESS - CHASSIS 8250 721/12169 SHEET 6 OF 10

Harness Data

C - 37

Section C - Electrics

Fig 37.

Drawings and Interconnection

ITEM FA FB FC FD FE FF FG FH FJ FK FL FM FN FP FR FS FT FU FV FW FX FY FZ GA GB GC GD GE GF GG GH GJ GK GL GM GN GP GR GS GT GU GV GW GX GY GZ HA HB HC HD HE HF HG HH HJ HK HL HM HN HP HR HS HT HU HV HW HX HY HZ

C - 38

AA, AB

TRAILER SOCKET

C1 TERM

1 (L) 2(54G) 3 (31) 4 (R) 5(58R) 6 (54) 7(58L) 8

WIRE

SIZE

DEST.

TYPE

859F 809C 620A 861F 860A 883C 880H -

1.0 1.4 2.0 1.0 1.0 1.4 1.0 -

LHIS FLS CES1 RHIS RSLS BLS LSLS -

O,P R,S R,S O,P O,P R,S O,P Q

(REF IN BRACKETS REFERS TO FINAL DESTINATION IN A SEPARATE HARNESS)

WIRE

SIZE

TYPE

AIR TANK NO. 3

C8 TERM

WIRE

DEST.

C28 7 CES7

REAR BRAKE RESERVOIR

C9 TERM

A B

SIZE

408 1.0 640H 1.0

1 2

C12

DEST.

195 1.5C78 5 AI 640K1.4CES7 AI

1 2

CAV

AG,AH BR

AIR DRYER

TERM

WIRE

SIZE

DEST.

9803/8040-5

A B

WIRE

0.5-2.5

CAN_H* CAN_L* SCRN* 675JF 585F 100N 100P 636T 587 942C 675FB 1495 1440 597 598 1418 923 929 500 501 920C 424 715 1453 1477 1484 1485 1487

0.5-2.5

TERM

TYPE

CSA 25

DESTIN C39

FRONT BRAKE RESERVOIR WIRE

DEST.

SIZE

TYPE FX

BF,BG TYPE

409A0.5BMS BH,BI 640F0.5CES7 BH,BI

C19

HEATER FUSE 1 WIRE

SIZE

DEST.

TYPE

1 2 3 4 5 6

TERM

1 2 3 4 5 6

DEST

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.0 1.0 1.5 1.5 1.5 0.5 0.5 0.5 0.5 0.5

* SEE SHEET 10 FOR CANBUS DETAIL

C20

TERM

0.5-2.5

SIZE

BF,BG

383 15.0 C45 X

C18

0.5-2.5

TERM

C15

0.5-2.5

TYPE

CD,CE CD,CE

ALTERNATOR B+

TERM

CAPAC'Y

409B0.5BMS BH,BI 640G0.5CES7 BH,BI

WIRE 225

C14

REAR BULKHEAD 1

C5 TERM

RH REAR LIGHT CLUSTER WIRE

SIZE

M,N DEST.

620C1.4CES1 R,S 861E0.6RHIS O,FL 883A0.6BLS O,FL 860D0.6RSLS O,FL 877B0.6RLS O,FL 809A0.6FLS O,FL

1 2

LH REAR LIGHT CLUSTER WIRE

SIZE

M,N DEST.

GG GG GG GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GC GD GD GD CQ CQ GC CQ GC GC GC GC

TYPE

FRONT WIPER MOTOR

C30

TYPE

WIRE

TERM

1 2 3 4 5 6

SIZE

TYPE

O,P O,P O,P O,P

SIZE

DEST.

0.5 0.5

C28 20 C5 4

C47 TERM

1 2

TERM

WIRE

C33 AIR TANK NO.1 WIRE

TERM

SIZE

407 1.0 650C 1.0

1 2

TERM

CAPAC'Y

WIRE

SIZE

DEST

TYPE

0.5-2.5

CAN_H*

0.5

CANHS4

0.5-2.5

CAN_L*

0.5

CANLS4

0.5-2.5

SCRN*

0.5

D'WIRE

0.5-2.5

404

0.6

C54 1

0.5-2.5

406

1.0

C34 1

0.5-2.5

407

1.0

C33 1

0.5-2.5

408

1.0

C8 1

0.5-2.5

1.0

C75-10

560A**

0.5-2.5

540***

1.0

C75 22

0.5-2.5

541***

1.0

C75 9

0.5-2.5

1420

1.0

C98 1

0.5-2.5

836

1.4

MBS

TERM

1 2

WIRE

SIZE

406 1.0 650D 1.0

SIZE

650H 1.0

DEST.

TYPE

C75

CES9

BE,D

TERM

DEST.

BL, BM

HORN SIZE

FU DEST

DEST.

C49 ALTERNATOR D+ WIRE

CD,CE CD,CE

1 2 3 4

403

SIZE

1.5

DEST.

C28 23

DC DC

TYPE

BN,BQ BN,BQ

***541

1.0

C28 10

**560A

1.0

C28 8

GS TYPE

EY GT,GU EY EY

DC DC

**561A

1.0

C28 22

C53 TERM

WIRE

SIZE

DEST.

TYPE

936

1.0

C78 13

AT,D

***540

1.0

C28 9

***542

1.0

C28 21

0.5-2.5

905

1.4

DBS

0.5-2.5

881

0.6

C63 4

0.5-2.5

866

0.6

C64 4

0.5-2.5

880F

1.0

LSLS

0.5-2.5

868

0.6

C63 5

0.5-2.5

870

0.6

C64 5

0.5-2.5

409

0.5

BMS

0.5-2.5

411

0.6

C20 1

0.5-2.5

542***

1.0

C75 23

C39

STARTER MOTOR +

0.5-2.5

561A**

1.0

C75-20

0.5-2.5

403

1.5

C49 2

CAV

WIRE 225 283

AIR FILTER SWITCH

TERM

WIRE

1 2

SIZE

DC DC DC

DC 1428

1.0

RS1

1429

1.0

RS2

AM,AN C28 4 404 0.6 650G0.6CES9 AM,AN

C73 TERM

A B

BRAKE RESERVOIR 3 WIRE

SIZE

DEST.

409C0.5BMS BH,BI 640P0.5CES7 BH,BI

BF,BG TYPE

DC DC DC

DC DC *SCRN

1.0

D'WIRE

130

1.0

C78 9

**553

1.0

C47 1

**1427

1.0

C47 2

*CAN_H

1.0

CANHS4

*CAN_L

1.0

CANLS4

37 38

0.5-2.5

859B

1.0

LHIS

0.5-2.5

861B

1.0

RHIS

0.5-2.5

832

1.0

C30 2

C40

0.5-2.5

120C

1.0

C30 3

TERM

0.5-2.5

833

1.0

C30 5

0.5-2.5

834

1.0

C30 6

0.5-2.5

841

2.0

C48 1

0.5-2.5

814

1.5

HBWLS

DESTIN C12 C88

C41 TERM

WIRE

DEST.

SIZE

STARTER MOTOR SLND

TERM

A EC

C63

WIRE

SIZE

DEST.

TYPE

TERM

4.0

C78 1

CP CP

1 2 3 4 5 6 C64 TERM

WIRE

SIZE

CF DEST.

383 15.0 C15 X

TYPE

C60

TYPE

TERM

45 TYPE

1 2 3 4 5 6

COMPRESSOR CLUTCH

WIRE

SIZE

DEST.

TYPE

950

2.0

C78 17

AT,DZ

LH HEADLAMP WIRE

SIZE

DEST.

905A1.0DBS 836A1.0MBS 881 0.6C28 14 C28 17 868 0.6 700A1.4FLES RH HEADLAMP WIRE

SIZE

DEST.

905B1.0DBS 836B1.0MBS 866 0.6 C28 15 C28 18 870 0.6 700B1.4FLES

* CANBUS CABLE. SEE SHEET 10. ** TWISTED PAIR. SEE SHEET 6. *** TWISTED TRIPLE. SEE SHEET 6.

DW,DX TYPE

CQ CP CP CP CP CY DW,DX TYPE

CQ CP CP CP CP CY

HARNESS - CHASSIS 8250 721/12169 SHEET 7 OF 10

Harness Data

C - 38

Section C - Electrics

Chassis Harness sheet 7 K Fig 39. ( T C-39)

Drawings and Interconnection

Fig 38.

DB DC

182

IND. HEATER RELAY 1

TYPE

C45

DB DC

STARTER MOTOR NEGATIVE 620 6.0CES1 640 3.0CES7 650 2.0CES9 690 2.0C48-2 700 4.0 FLES - - -

** SEE SHEET 6 FOR TWISTED PAIR DETAIL

TYPE GA

CSA 25 16

DB DC

TYPE

26 28

AL DEST.

C54

DB DC

22 24

COMPRESSOR SWITCHES

TYPE DC

TYPE

DEST.

SIZE

TYPE

C28 5 CES9

WIRE

TYPE

**553 1.0C75 40 BK **14271.0C75 42 BK ** TWISTED PAIR. SEE NOTE.

WIRE

ENGINE ECU

CD,CE CD,CE

*** SEE SHEET 6 FOR TWISTED TRIPLE DETAIL

COMPRESSOR SWITCH EARTH WIRE

DEST.

C28 6 CES9

C34 AIR TANK NO.2 HV

FRONT BULKHEAD

C28

SIZE

C65 TERM

IND. HEATER RELAY COIL 1

2.0 C28 30 841 690 2.0C40

1 2

CV, CW

WIRE

411 675JF

721/12169

M,N DEST.

650A1.0CES9 O,P 832 1.0 C28 26 120C1.0 C28 27 Q 833 1.0 C28 28 834 1.0 C28 29

C48

* SEE SHEET 10 FOR CANBUS DETAIL

620B1.4CES1 R,S 859E0.6LHIS O,FL 883B0.6BLS O,FL 880J0.6LSLS O,FL 877A0.6RLS O,FL 809B0.6FLS O,FL FUEL TANK SENDER

CANHS6 CANLS6 D'WIRE C20 2 ECU28 1 ECU28 2 ECU32 A ECU32 B ECU28 3 MSS2 TMES4 C96 2 C99 2 ECU29 2 ECU29 3 ECU32 C RS LS E17 1 E17 4 E19 3 E19 2 E19 1 C89 3 RPERS C90 2 C91 2 C94 1

C - 39

C78 TERM

REAR BULKHEAD 2 CAPAC'Y

DEST

WIRE

SIZE

2.5-4.0

182

4.0

C41

2.5-4.0

339**

4.0

C85 3

2.5-4.0

675A**

TYPE

4.0

C85 1

0.5-2.5

195

1.5

C6 1

0.5-2.5

883

1.4

BLS

2.5-4.0

C84 TERM 1

WIRE 825B

620E

1477B

932A 923C 929C

DW DX

LH REAR FENDER WORKLIGHT SIZE

1.5 1.0 0.5 0.5 0.5 0.5

DEST RFWLS CES1 RPERS

SWFS RS LS

809

1.4

FLS

0.5-2.5

825

1.5

RFWLS

0.5-2.5

130

1.0

C75 39

0.5-2.5

860L

1.0

RSLS

0.5-2.5

968A

0.5

C97 2

0.5-2.5

963

0.5

C97 1

C85

0.5-2.5

936

1.0

C53 A

0.5-2.5

961

0.5

C95 1

0.5-2.5

959

C93 1

CSA DESTIN WIRE CAV 4.0 C78 4 1 **675A 2 4.0 C78 2 3 **339 4 ** TWISTED PAIR. SEE SHEET 6.

0.5-2.5

0.5

0.5-2.5

877

0.5

RLS

0.5-2.5

950

2.0

C60 A

0.5-1.0

958

0.5

C92 1

0.5-2.5

932

0.5

SWFS

0.5-1.0

586

0.5

ECU26 1

0.5-2.5

637

2.0

ESVES

0.5-2.5

101

2.0

ESVSS

0.5-1.0

576

0.5

ECU27 2

0.5-1.0

924

0.5

VSS

0.5-2.5

161

1.0

E17 3

0.5-2.5

660GF

1.0

E17 2

0.5-1.0

503

0.5

E8 1

0.5-2.5

0.5-1.0

504

0.5

E7 1

ENGINE POWER

TYPE

CY CP CP CP CP CP

FV FW TYPE CZ CQ CZ CQ

DIFF LOCK C95 SOLENOID CVT CSA DESTIN WIRE CAV 0.5 C78 14 1 961 0.5 CES7 2 640W

CV CW TYPE CP CP

FRONT PTO C96 SPEED SENSOR CSA DESTIN WIRE CAV 0.5 TMES4 1 675GE 0.5 C5 12 2 1495 0.5 MSS2 3 942M

TYPE EW,EX EW,EX EW,EX

FRONT PTO C97 CLUTCH SOLENOID CSA DESTIN WIRE CAV 0.5 C78 12 1 963 0.5 C78 11 2 968A

TYPE GM,AN GM,AN

WIRE

SIZE

CAN_H

CAN_L

0.5 0.5

TERM

DM, DN, DT

TERMINATING RESISTOR CONNECTOR

TYPE CD CD

ENGINE SPEED C99 SENSOR CSA DESTIN WIRE CAV 0.5 TMES4 1 675GG 0.5 C5 13 2 1440 0.5 MSS2 3 942R

TYPE EW,EX EW,EX EW,EX

DEST CANHS4 CANLS4

C88

TYPE

CX CX CQ

INTAKE AIR HEATER MEGAFUSE CSA DESTIN WIRE 283 16 C39

STEERING ANGLE SENSOR CSA DESTIN WIRE CAV 0.5 TMES4 1 675GF 0.5 MSS2 2 942N 0.5 C5 26 3 1453 C89

9803/8040-5

REAR PTO SPEED SENSOR CSA DESTIN WIRE CAV 0.5 TMES4 1 675GC 0.5 C5 29 2 1484 0.5 MSS2 3 942E C90

C81 TERM

RH HEADLIGHT BAR W/LIGHT WIRE

814A

700C

C82 TERM

814B

700D

C83

WIRE 825A

620D 1477A

932B 923B 929B

HBWLS FLES

SIZE

1.5 1.0

SIZE

1.5 1.0 0.5 0.5 0.5 0.5

TYPE

CY CP CV, CW

DEST HBWLS FLES

TYPE

CY CP DW DX

RH REAR FENDER WORKLIGHT

3 5

1.5 1.0

CV, CW DEST

LH HEADLIGHT BAR W/LIGHT WIRE

TERM

SIZE

DEST RFWLS CES1 RPERS

SWFS RS LS

TYPE

CY CP CP CP CP CP

CV CW TYPE CP CP

ESVSS

GM,AN

2 **

514R

0.5

CANLS6

GM,AN

3 **

515R

0.5

CANHS6

GM,AN

637A

0.5

ESVES

GM,AN

ECU 22 TERM

CSA DESTIN 1.5 C5 23 1.5 C5 22 1.5 C5 21

GK TYPE GN,GP GN,GP GN,GP

WIRE

SPOOL VALVE 2 SOLENOID SIZE

DEST

101B

0.5

ESVSS

GM,AN GM,AN

514T

0.5

CANLS7

515T

0.5

CANHS7

GM,AN

637B

0.5

ESVES

GM,AN

SPOOL VALVE 3 SOLENOID WIRE 101C

2 **

514U

515U 637C

ECU 24 TERM 1 2 3

101D

0.5

CANLS8

GM,AN

0.5 0.5

CANHS8

GM,AN

ESVES

GM,AN

TYPE

SIZE

DEST

0.5

ESVSS

GM,AN GM,AN

TYPE

0.5

CANLS9

515V

0.5

CANHS9

GM,AN

0.5

ESVES

GM,AN

ECU 25 TERM 1

514V

SPOOL VALVE 5 SOLENOID

WIRE

SIZE

DEST

101E

0.5

ESVSS

GM,AN GM,AN

TYPE

2 **

514W

0.5

CANLS10

3 **

515W

0.5

CANHS10

GM,AN

637E

0.5

ESVES

GM,AN

PILOT VALVE

WIRE

SIZE

DEST

TYPE

586

0.5

C78 20

GM,AN

637F

0.5

ESVES

GM,AN

DEST

TYPE

LOCK OUT PRESSURE SWITCH WIRE

SIZE

101F

0.5

576

0.5

ECU 28

CV CW ESVSS C78 23

FRONT HITCH POS'N SENSOR

CP CP

SIZE

DEST

TYPE

585F

0.5

EW,EX

100N

0.5

C5 5 C5 6

587

0.5

C5 9

EW,EX

ECU 29 TERM 1

RAISE / LOWER INTERCONNECT WIRE 101G

TYPE

ESVSS C5 14 C5 15

O,FL O,FL O,FL

DEST

TYPE

597

0.5

598

0.5

ECU 30

BC BD DEST

0.5

TERM

TERMINATING RESISTOR CONN'R WIRE

SIZE

515X**

0.5

CANHS10

514X**

0.5

CANLS10

** TWISTED PAIR. SEE NOTE ON SHEET 6.

FJ DN

A C

EW,EX

SIZE

ITEMS CV,CW,CP, AND AN ADDITIONAL FD TO BE SUPPLIED SEPERATELY (BAGGED). WIRE ENDS TO BE INSULATED AND TERMINATED IN THE BRANCHOUT TO ECU32 SUCH THAT ECU27 CAN BE MADE TO REPLACE ECU32 IF REQUIRED.

WIRE

TERM

CX CX CQ

HARNESS - CHASSIS 8250 721/12169 SHEET 8 OF 10

Harness Data

C - 39

Section C - Electrics

Chassis Harness sheet 8 K Fig 40. ( T C-40)

GM,AN

637D

TERM

Fig 39.

ESVSS

** **

ECU 27

TYPE EW,EX EW,EX EY

DEST

0.5

ECU 26

SIZE

SPOOL VALVE 4 SOLENOID WIRE

FJ DS TYPE CP CP CP

TYPE

3 **

ECU PRESSURE 32 TRANSDUCER CSA DESTIN WIRE CAV 0.5 C5 7 A 100P 0.5 C5 8 B 636T 0.5 C5 16 C 1418

WIRE

2 **

TERM

TYPE

Drawings and Interconnection

FRONT PTO EXTERNAL REQUEST CSA DESTIN WIRE CAV 0.5 C5 31 1 1487 0.5 CES7 2 640V 3

POSITION SENSOR

DW DX TYPE CP CP CP CP CQ CQ

TYPE EW,EX EW,EX EW,EX

PTO 1000 SOLENOID CSA DESTIN WIRE CAV 0.5 C78 15 1 959 0.5 CES7 2 640U C94

RADAR SPEED SENSOR CSA DESTIN 1.0 C5 19 1.0 C78 26 1.0 C78 25 1.0 C5 20

WIRE 500 660GF 161 501

CV CW TYPE CP CP

DEST

0.5

3 **

E17

SIZE

101A

ECU 23

CAV 1 2 3 4 5 6

SPOOL VALVE 1 SOLENOID

AL TYPE AM,AN AM,AN

TYPE EW,EX EW,EX EW,EX

PTO 540 C92 SOLENOID CSA DESTIN WIRE CAV 0.5 C78 18 1 958 0.5 CES7 2 640T

ECU 21 TERM

TERM

WIRE CAV 1 715 2 424 3 920C

TYPE EW,EX EW,EX EW,EX

C93

CSA DESTIN 0.5 C78 27 0.5 VSS

AL TYPE AM,AN AM,AN

E19 TYPE X

REAR PTO SHAFT SPEED SENSOR CSA DESTIN WIRE CAV 0.5 TMES4 1 675GD 0.5 C5 30 2 1485 0.5 MSS2 3 942F C91

RAISE SOLENOID

WIRE CAV 1 503 2 924A

CAV

CSA DESTIN 0.5 C78 29 0.5 VSS

** SEE SHEET 6 FOR TWISTED PAIR DETAILS

C79

LOWER SOLENOID

CLUTCH FLUID LEVEL CSA DESTIN WIRE CAV 1.0 C28 11 1 1420 1.0 CES7 2 640Y C98

WIRE CAV 1 504 2 924B

C - 40

BLS TERM

BRAKE LIGHT SPLICE WIRE

A DEST.

SIZE

TYPE

CE CHASSIS EARTH S9 SPLICE 9 TERM

FOG LIGHT SPLICE

FLS TERM

WIRE

SIZE

A DEST.

TYPE

C78 7 809 1.4 809A0.6C18-6 809B0.6C19-6 809C1.4C1-2 RLS TERM

REVERSE LIGHT SPLICE WIRE

SIZE

TERM

WIRE

SIZE

DEST.

TYPE

WIRE

SIZE

HB H'LIGHT BARS WLS W'LIGHTS SPLICE TERM

DEST.

TYPE

LH IS

LH INDICATOR SPLICE SIZE

WIRE

DEST.

TYPE

9803/8040-5

859B 1.0 C28 24 859F 1.0 C1 1 859E0.6C19-2 RS LS TERM

WIRE

LS LS

DEST.

SIZE

C28 12 836 1.4 836A1.0C63-3 836B1.0C64-3 FL ES

HEADLIGHTS EARTH SPLICE WIRE

SIZE

TERM

DEST.

TYPE

LEFT SIDELIGHT SPLICE WIRE

SIZE

DEST.

TYPE

C28-16 880F1.0 880J0.6C19-4 880H1.0C1-7 A

DEST.

700 4.0C40 700A1.4C63-6 700B1.4C64-6 700C1.0C81-2 700D1.0C82-2

SIZE

WIRE

860A1.0C1-5 860D0.6C18-4 C78 10 860L1.0

MAIN BEAM SPLICE

MBS

RIGHT SIDELIGHT SPLICE

RH IS TERM

RH INDICATOR SPLICE WIRE

SIZE

TYPE

861B 1.0 C28 25 861F 1.0 C1 4 861E0.6C18-2 DIP BEAM SPLICE

DBS WIRE

SIZE

DEST.

C28 31 C81-1 C82-1

TERM

WIRE

SIZE

825 825A 825B

1.5 1.5 1.5

A DEST.

C78 8 C83-1 C84-1

942E 942F

0.5 0.5

C90 3 C91 3

942M 942N 942R

0.5 0.5 0.5

C96 3 C89 2 C99 3

TYPE

TRANS MANAGEMENT EARTH SPLICE 4 A TMES4 CSA DESTIN WIRE 675FB 1.0 C5 11 - - 675GC 0.5 C90 1 675GD 0.5 C91 1 675GE 0.5 C96 1 675GF 0.5 C89 1 675GG 0.5 C99 1 REAR PTO EXTERNAL REQUEST SPLICE A RPERS CSA DESTIN WIRE 1477 0.5 C5 28 1477A 0.5 C83 3 1477B 0.5 C84 3

TYPE

RAISE SIGNAL SPLICE RS WIRE 923 923B 923C

A CSA DESTIN 0.5 C5 17 0.5 C83 5 0.5 C84 5

VALVE SUPPLY SPLICE VSS WIRE 924 924A 924B

A CSA DESTIN 0.5 C78 24 0.5 E8 2 0.5 E7 2

SWITCH FEED SPLICE SWFS WIRE 932 932A 932B

ESV SS TERM

A CSA DESTIN 0.5 C78 19 0.5 C84 4 0.5 C83 4

EL'TRONIC SPOOL VALVE SUPPLY SPLICE

WIRE

SIZE

101

2.0

101A

ESV ES TERM

A DEST

0.5

ECU21-1

101B

0.5

ECU22-1

0.5

ECU23-1

101D

0.5

ECU24-1

101E

0.5

ECU25-1

101F

0.5

ECU27 1

101G

0.5

ECU29-1

EL'TRONIC SPOOL VALVE EARTH SPLICE

WIRE

SIZE

637

2.0

637A

0.5

TYPE

C78 22

101C

A DEST

TYPE

C78 21 ECU21-4

637B

0.5

ECU22-4

637C

0.5

ECU23-4

0.5

ECU24-4

637E

0.5

ECU25-4

637F

0.5

ECU26-2

637D

DEST.

SIZE

1.5 1.5 1.5

MAINTAINED SUPPLY SPLICE 2 A MSS2 CSA DESTIN WIRE 942C 1.0 C5 10

620 6.0C40 620A2.0C1-3 620B1.4C19-1 620C1.4C18-1 620D1.0C83-2 620E1.0C84-2 -

TERM

WIRE

814 814A 814B

REAR FENDER RF WLS W'LIGHTS SPLICE

TYPE

640 3.0C40 ------------- --------640F0.5C14-B 640G0.5C9-B 640H 1.0 C8 2 640K1.4C6-2 ------ ----------- ----------- -----640P 0.5 C73 B 640T 0.5 C92 2 640U 0.5 C93 2 640V 0.5 C94 2 640W 0.5 C95 2 640Y 1.0 C98 2 -

TYPE

877 0.6C78 16 877B0.6C18-5 877A0.6C19-5

CE CHASSIS EARTH S1 SPLICE 1

SIZE

CE CHASSIS EARTH S7 SPLICE 7

A DEST.

WIRE

650A1.0C30-1 ------------- --------650 2.0C40 650C 1.0 C33 2 650D 1.0 C34 2 650G0.6C54-2 650H 1.0 C65-A ---------------- ------

883 1.4 C78 6 883A0.6C18-3 883B0.6C19-3 883C1.4C1-6

LOWER SIGNAL SPLICE A LS CSA DESTIN WIRE 929 0.5 C5 18 929B 0.5 C83 6 929C 0.5 C84 6

A DEST.

905A1.0C63-2 905B1.0C64-2 905 1.4 C28 13 BMS

BRAKE MALF'N SPLICE WIRE

SIZE

DEST.

A TYPE

Fig 40. Chassis Harness sheet 9 K Fig 41. ( T C-41)

ECU CONTROL PANEL POWER IN POWER OPTION LH DRAFT PIN RH DRAFT PIN LOWER SOLENOID RAISE SOLENOID JACK SOCKET AREA CUT-OUT RAISE/LOWER SWITCH RH FENDER CONNECTOR LH FENDER CONNECTOR BULKHEAD - CHASSIS BULKHEAD - CAB RADAR SPEED SENSOR HITCH POSITION SENSOR PTO CUT-OUT INTERCONNECT PTO CUT-OUT DIODE CONNECTOR PTO CUT-OUT RELAY BASE WHEEL SLIP ENABLE SWITCH

ECU1 ECU CONNECTOR A ECU2 ECU CONNECTOR B ECU3 ECU CONNECTOR C ECU4 CANBUS 2 ECU5 SPOOL VALVE BULKHEAD (CAB) ECU6 ISO 11786 SOCKET ECU7 FLOW DIVIDER INTERCONNECT ECU8 RF GROUND ECU9 ECU TO CAB INTERCONNECT ECU10 FRONT HITCH CONTROL PANEL ECU11 LEVERS 1 & 2 CONNECTOR 1 ECU12 LEVERS 1 & 2 CONNECTOR 2 ECU13 LEVERS 3 & 4 CONNECTOR 1 ECU14 LEVERS 3 & 4 CONNECTOR 2 ECU15 ISO 11786 RESISTORS ECU16 ENGINE TORQUE DERATE RESISTORS ECU17 TRANSPORT SWITCH ECU18 TRANSPORT RELAY 1 ECU19 TRANSPORT RELAY 2 ECU20 BULKHEAD CONNECTOR (CHASSIS) ECU21 SPOOL VALVE 1 SOLENOID ECU22 SPOOL VALVE 2 SOLENOID ECU23 SPOOL VALVE 3 SOLENOID ECU24 SPOOL VALVE 4 SOLENOID ECU25 SPOOL VALVE 5 SOLENOID ECU26 PILOT VALVE ECU27 LOCK OUT PRESSURE SWITCH ECU28 FORNT HITCH POSITION SENSOR ECU29 RAISE/LOWER INTERCONNECT ECU30 CANBUS TERMINATING RESISTOR XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX ECU31 HEATING VALVE SOLENOID ECU32 PRESSURE TRANSDUCER

C100 C101

HARNESS - CHASSIS 8250 721/12169 SHEET 9 OF 10

Harness Data

C - 40

Drawings and Interconnection

409 0.5 C28 19 409A0.5C14-A 409B0.5C9-A 409C0.5C73-A

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23

Section C - Electrics

TERM

C1 TRAILER SOCKET C2 NEUTRAL DUMP SOLENOID C3 TRANS. OIL FILTER SWITCH C4 DIFF. LOCK SOLENOID C5 CABROOF BULKHEAD CONN. C6 START RELAY (185) OR AIR DRYER C7 C8 AIR TANK NO3 C9 REAR BRAKE RESERVOIR C10 REVERSE LIGHTS SWITCH C11 SPEEDO PICK-UP C12 ALTERNATOR (B+) C13 2WD SOLENOID C14 FRONT BRAKE RESERVOIR C15 HEATER FUSE 1 (185) C16 HEATER FUSE 2 (185) C17 START RELAY MAXI-FUSE (185) C18 RH REAR LIGHT CLUSTER C19 LH REAR LIGHT CLUSTER C20 FUEL LEVEL SENDER C21 NEUTRAL START SWITCH OR GEARKNOB CONNECTOR C22 C23 C24 C25 C26 LOW/REVERSE RAM CONNECTOR C27 MEDIUM/HIGH RAM CONNECTOR C28 FRONT BULKHEAD C29 C30 FRONT WIPER MOTOR C31 ENGINE OIL PRESS SWITCH C32 ESOS C33 AIR TANK N 1 C34 AIR TANK N 2 C35 REAR PTO DRIVE SOLENOID C36 REAR PTO BRAKE SOLENOID C37 FRONT PTO DRIVE SOLENOID C38 FRONT PTO BRAKE SOLENOID C39 STARTER MOTOR +VE C40 STARTER MOTOR -VE C41 STARTER MOTOR SOLENOID C43 IND HEATER RELAY 1 (-VE) (185) C44 IND HEATER RELAY 2 (-VE) (185) C45 IND HEATER RELAY 1 (FEED) (185) C46 IND HEATER RELAY 2 (FEED) (185) C47 IND HEATER RELAY 1 (COIL) (185) C48 HORN C49 ALTERNATOR (D+) C50 ALTERNATOR (W) C51 THERMOSTART OR ESOS TIMER MODULE (185) C52 WATER TEMPERATURE SENDER C53 COMPRESSOR SWITCHES C54 AIR FILTER SWITCH C55 TRANSMISSION OIL PRESSURE SWITCH C56 SPLITTER HIGH SOLENOID C57 IND HEATER RELAY 2 (COIL) (185) C58 REAR WASHER (P100) C59 FRONT WASHER (P100) C60 COMPRESSOR CLUTCH C61 THERMOSTART 2 (1155) C62 C63 LH HEADLAMP C64 RH HEADLAMP C65 COMPRESSOR SWITCH EARTH C66 C67 C68 C69 C70 C71 OIL TEMP 1 C72 TRANSMISSION BULKHEAD CONNECTOR C73 BRAKE RESERVOIR 3 C74 ELECTRONIC ENGINE BULKHEAD C75 ELECTRONIC ENGINE ECU C76 WATER IN FUEL SENSOR C77 FAN CLUTCH DRIVER C78 REAR BULKHEAD 2 C79 TERMINATING RESISTOR CONNECTOR C80 ENGINE CANBUS INTERCONNECT C81 RH HEADLIGHT BAR W/LIGHT C82 LH HEADLIGHT BAR W/LIGHT C83 RH REAR FENDER WORKLIGHT C84 LH REAR FENDER WORKLIGHT C85 ENGINE POWER C86 C87 C88 INTAKE AIR HEATER MEGAFUSE (SUPPLY) C89 STEERING ANGLE SENSOR C90 REAR PTO SPEED SENSOR C91 REAR PTO SHAFT SPEED SENSOR C92 PTO 540 SOLENOID C93 PTO 1000 SOLENOID C94 FRONT PTO EXTERNAL REQUEST SWITCH C95 DIFF LOCK SOLENOID CVT C96 FRONT PTO SPEED SENSOR C97 FRONT PTO CLUTCH SOLENOID C98 CLUTCH FLUID LEVEL C99 ENGINE SPEED SENSOR

C - 41

721/12169 950

_H CAN ) M (515

CANLS4 50

CAN_L (514L)

EN GRE K) (514

CANHS4 C28

CAN_H (515L)

YELLOW (515K)

GREEN (514K) YELLOW (515K) SCRN

C79

CAN_L ) (514M

C75

SCRN

SPLICE WIRE SCRN TO DRAINWIRE/SHIELD AND INSULATE WITH HEATSHRINK AS PER JCB STD 7100/1000. (TYP 2 PLACES)

514R ** CANLS6

CANHS6

CANLS7

CANHS7

515T **

515R **

514T **

514U ** CANHS8

CANLS8

515V ** CANLS9

CANHS9

ECU 21

ECU 22

515U **

514V **

515W ** 514W ** CANLS10

9803/8040-5

CANHS10

ECU 23

ECU 24

ECU 25

ECU 30 514X ** 515X **

CANL ** CANH **

CANBUS NOTES. 1. CABLE SPECIFICATION, 1xTWISTED PAIR WITH SHIELD AS PER SAE J1939/11 TABLE 7.EG RAYCHEM CHEMINAX 2021D0309-0 OR AN APPROVED EQUIVALENT, EXCEPT WIRES IDENTIFIED ** WHICH ARE TWISTED PAIR (360 /25mm). 2. CAN SPLICES TO BE IN ACCORDANCE WITH J1939/11, AND MAY BE STAGGERED. 3. WIRE NUMBERS SHOWN IN BRACKETS ARE FOR ILLUSTRATION PURPOSES AND NEED NOT BE PRINTED ON THE WIRES. 4. LENGTH OF UNSHIELDED CAN WIRES TO CONNECTORS ECU 21-ECU 25 (STUB LENGTHS) MUST NOT EXCEED 200mm, AND SHOULD NOT BE EQUAL IN LENGTH. 5. MINIMUM DISTANCE BETWEEN CAN SPLICES IS 100mm, AND THEY SHOULD NOT BE EQUALLY SPACED.

CANL ** CANH **

GREEN (514P) YELLOW (515P)

GREEN (514P) YELLOW (515P) SCRN

SPLICE WIRE SCRN TO DRAINWIRE/SHIELD AND INSULATE WITH HEATSHRINK AS PER JCB STD 7100/1000. FUNCTION

WIRE COLOUR J1939

WIRE BASE NUMBER

CAN_L

GREEN

CAN_L 514

CAN_H

YELLOW

CAN_H 515

HARNESS - CHASSIS 8250 721/12169

Chassis Harness sheet 10

Harness Data

C - 41

Section C - Electrics

Fig 41.

Drawings and Interconnection

SHEET 10 OF 10

C - 42

TH23

1 2

ITEM BE

ITEM BE ITEM AU

305 TH28

ITEM AW 0 1265

300

245

ITEM AY

ITEM AU

ITEM BE

620

ITEM BE

ITEM AW

ITEM AW TH25

TH33

TH32

TH24

ITEM AX

ITEM AZ 1 2

1 2 1

ITEM BE ITEM BE

195

ITEM BE

TH31

ITEM AT 0

ITEM BE

400

605

ITEM BD

ITEM AV

ITEM AW

ITEM BC

300

445

405

TH1 ITEM BA

ITEM BB

31 30

0 THES

TSES

17 28

240

365

620

ITEM AP ITEM AN ITEM BB

ITEM AM

ITEM BC

140

ITEM BE ITEM BD 1 2

ITEM BC ITEM BE

190

TH27 ITEM BE

22 11 23

12 13

14 26

ITEM AP ITEM AP

ITEM AP TH21

10 3

ITEM AZ

21 9

2 7

TSSS2

1 2

20 8

19 18

ITEM AS

TMES2

9803/8040-5

270

160

TH34

ITEM BC

PTO

1 2

ITEM BD

24 25

ITEM AM ITEM BE

ITEM AH,AJ

210

TH35

ITEM BE

ITEM AW

250

605

800

4WD

180

TH30

1 2

1900 REAR OF CONNECTOR

TH29

TH26 ITEM AW ITEM AY

ITEM AW

ITEM AR

ITEM AZ TH20 -

Fig 42. 806160

C - 42

CVT Transmission Harness sheet 1 K Fig 43. 806170 ( T C-43)

Harness Data

721/11671

Drawings and Interconnection

400

Section C - Electrics

ITEM BE

TH 21 CAV 1 2 3 4

HYDROSTAT SPEED/DIRECTION CSA DESTIN WIRE 675FD 0.5 TMES2 1443 0.5 TH1 T 1442C 0.5 TSSS2 1444 0.5 TH1 H

TYPE J,K J,K J,K J,K

TH SPEED LIMIT 23 SOLENOID CSA DESTIN WIRE CAV 0.5 TH1 L 1 943 0.5 THES 2 675KD

TYPE S,T S,T

TH NEUTRAL 24 SOLENOID CSA DESTIN WIRE CAV 0.5 TH1 D 1 947A 0.5 THES 2 675KC

TYPE S,T S,T

TH RANGE 1 25 SOLENOID CSA DESTIN WIRE CAV 0.5 TH1 B 1 945 0.5 THES 2 675KA

TYPE S,T S,T

9803/8040-5

TH HIGH PRESSURE 26 SENSOR CSA DESTIN WIRE CAV 0.5 TSES 1 675JK 0.5 TH1 E 2 1446 0.5 TH1 M 3 942D

H TYPE J,K J,K J,K J,K H

G TYPE J,K J,K J,K

TH1 CAV 1/A 2/B 3/C 4/D 5/E 6/F 7/G 8/H 9/J 10/K 11/L 12/M 13/N 14/O 15 16/P 17/Q 18/R 19/S 20/T 21/U 22/V 23/W 24/X 25 26 27 28 29 30 31

CAPACTY O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O O.5-2.O

TRANSMISSION BULKHEAD CSA WIRE 675JH 1.0 945 0.5 946 0.5 947A 0.5 1446 0.5 1448 0.5 1447 0.5 1444 0.5 1450 1.0 956 0.5 943 0.5 942D 0.5 414 0.5 675FV 1.0 SCRN* 0.5 1442B 1.0 1445 0.5 675K 2.0 373 2.0 1443 0.5 1451 1.0 1458 0.5 1473 0.5 960 0.5 968B 0.5 CAN_L* 0.5 CAN_H* 0.5

A DESTIN TSES TH25 1 TH27 1 TH24 1 TH26 2 TH28 3 TH29 1 TH21 4 TH30 3 TH34 1 TH23 1 TH26 3 TH20 2 TMES2 D'WIRE TSSS2 TH20 4 THES TH30 4 TH21 2 TH30 6 TH32 1 TH33 3 TH35 1 TH34 2 TH30 5 TH30 2

TYPE B B B B B B B B B B B B B B E B B C C B B B B B B E E D D D D

TH RANGE 2 27 SOLENOID CSA DESTIN WIRE CAV 0.5 TH1 C 1 946 0.5 THES 2 675KB

TYPE S,T S,T

TH RANGE 1/2 28 SENSOR CSA DESTIN WIRE CAV 0.5 TSES 1 675JJ 0.5 TSSS2 2 1442E 0.5 TH1 F 3 1448

TYPE J,K J,K J,K

TH TEMPERATURE 29 SENSOR CSA DESTIN WIRE CAV 0.5 TH1 G 1 1447 0.5 TSES 2 675JL

TYPE S,T S,T

TH 30 CAV 1 2 3 4 5 6 7 8

W X TYPE D Y Y Z Y Y Y Y

TH 31 CAV

TRANS CONTROL ACTUATOR CSA DESTIN

WIRE

CAN_H* 1450 373 CAN_L* 1451 675KE 677

WIRE 677 SCRN*

0.5 1.0 2.0 0.5 1.0 1.0 1.0

TH1 27 TH1 J TH1 S TH1 26 TH1 U THES TH31

CHASSIS GROUND CSA DESTIN 1.0 TH30 8 1.0 D'WIRE

TH TRANS OIL 32 FILTER SWITCH CSA DESTIN WIRE CAV 0.5 TH1 V 1 1458 0.5 TMES2 2 675FN TH PARK BRAKE 33 CALIPER SWITCH CSA DESTIN WIRE CAV 1 2 0.5 TH1 W 3 1473 0.5 TMES2 4 675FP

TRANS MANAGEMENT EARTH SPLICE 2 AD TMES2 CSA DESTIN WIRE 675FV 1.0 TH1 O 675FD 0.5 TH21 1 675FE 0.5 TH20 1 675FP 0.5 TH33 4 675FN 0.5 TH32 2

TRANS SENSOR EARTH SPLICE AD TSES CSA DESTIN WIRE 675JH 1.0 TH1 A 675JJ 0.5 TH28 1 675JK 0.5 TH26 1 675JL 0.5 TH29 2

TRANS HARNESS EARTH SPLICE AD THES CSA DESTIN WIRE 675K 2.0 TH1 R 675KA 0.5 TH25 2 675KB 0.5 TH27 2 675KC 0.5 TH24 2 675KD 0.5 TH23 2 675KE 1.0 TH30 7 675KF - 675KH 0.5 TH35 2

TYPE AB

TRANS SENSOR 8.5v SUPPLY SPLICE AD TSSS2 CSA DESTIN WIRE 1442B 1.0 TH1 P 1442C 0.5 TH21 3 1442D 0.5 TH20 3 1442E 0.5 TH28 2 - -

F TYPE J,K J,K

SPLICE WIRE SCRN TO DRAINWIRE/SHIELD AND INSULATE WITH HEATSHRINK AS PER JCB STANDARD 7100/1000 (TYP 2 PLACES)

TH31

TH1

SCRN GREEN YELLOW

677

CROWN WHEEL SPEED PICK-UP CSA DESTIN WIRE 675FE 0.5 TMES2 414 0.5 TH1 N 1442D 0.5 TSSS2 1445 0.5 TH1 Q

SCRN

C - 43

TH 20 CAV 1 2 3 4

GREEN YELLOW

TH30

H TYPE N N J,K J,K

TH 4WD 35 SOLENOID CSA DESTIN WIRE CAV 0.5 TH1 X 1 960 0.5 THES 2 675KH

TYPE S,T S,T

NOTE: 1. ELECTRICAL STANDARD NOTE 7000/3000 APPLIES TO THIS HARNESS WHERE APPROPRIATE. 2. WIRE TO JCB STANDARD 7000/3300 - 100 C RATED U.O.S. 3. COVERING TO TERMINATE 50mm SHORT OF CONNECTORS U.O.S. 4. ACTUAL DIMENSIONS TO SPLICES TO BE AT THE DISCRETION OF THE MANUFACTURER U.O.S. 5. COMPONENT PART NUMBERS SPECIFIED SERVE TO INDICATE THE COMPONENTS REQUIRED AND IT IS ASSUMED THAT THE HARNESS SUPPLIER WILL PROCURE THE COMPONENTS IN THE MOST COST EFFECTIVE MANNER.

C - 43

CVT Transmission Harness sheet 2

Harness Data

Fig 43. 806170

SHEET 2 OF 3 721/11671

Section C - Electrics

TYPE S,T S,T

Drawings and Interconnection

TH REAR PTO CLUTCH 34 SOLENOID CSA DESTIN WIRE CAV 0.5 TH1 K 1 956 0.5 TH1 25 2 968B

50 CANBUS CABLE CABLE SPECIFICATION, 1xTWISTED PAIR WITH SHIELD AS PER SAE J1939/11 TABLE 7.EG RAYCHEM CHEMINAX 2021D0309-0 OR AN APPROVED EQUIVALENT.

C - 44

9803/8040-5

Harness Data

Section C - Electrics

CVT Transmission Harness sheet 3

C - 44

Drawings and Interconnection

Fig 44.

REAR RIGHT MODULATOR

AP4

ITEM CA,CB ITEM CL

ITEM CE,CF

H G

TYPE

WIRE

SIZE

DEST.

1.0 1.0 1.0

AP1-J AP1-L AP1-K

A B M K C L D F E J

1 1804 2 1805 3 1803

TERM

MOUNTING FLANGE

C - 45

ITEM CH 100

ITEM CC

D D D

ITEM CM 500 ITEM CL

1 2

ITEM CC

100 RL

160

200 F 0

ITEM CM

9803/8040-5

ITEM CJ

ITEM CE,CF

TYP

ITEM CE,CF 1

1 2

10 20

FRONT MODULATOR

AP2

DEST.

1 1808 2 1806 3 1807

1.0 1.0 1.0

AP1-A AP1-C AP1-B

TYPE

D D D

REAR LEFT MODULATOR

AP3 WIRE

SIZE

DEST.

1 1801 2 1802 3 1800

1.0 1.0 1.0

AP1-E AP1-G AP1-F

TERM

C TYPE

D D D

SIZE

DEST.

A B C D E F G H J K L M

1808 1807 1806 1801 1800 1802 1804 1803 1805 -

1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 -

AP2-1 AP2-3 AP2-2 AP3-1 AP3-3 AP3-2 AP4-1 AP4-3 AP4-2 -

A TYPE

721/11734

ABS Pannier Harness sheet 1

C - 45

Harness Data

Fig 45. 806180

B B B B B B B B B -

Section C - Electrics

SIZE

NOTE: 1. ELECTRICAL STANDARD NOTE 7000/3000 APPLIES TO THIS HARNESS WHERE APPROPRIATE. 2. WIRE TO JCB STANDARD 7000/3300 - 100 C RATED U.O.S.

BULKHEAD CON' (PANNIER) WIRE

Drawings and Interconnection

WIRE

TERM

AP1 TERM

ABS T/SOCKET

TERM

WIRE

SIZE

370 150 605 615 440

4.0 1.5 1.5 4.0 1.5

1 2 3 4 5

ABS 8

DEST.

TYPE

TERM

ABS2 1 ABS2-A ABS3 ABS3 ABS2-B

C B B C B

1 2

REAR LH SPEED SENSOR

ABS2

TYPE

WIRE

SIZE

DEST.

BLUE

0.75 0.75

ABS2-H ABS2-M

BROWN

WIRE

SIZE

605 615

1.5 4.0

H G

B K

ITEM X,Y

ABS BELL HOUSING 3 BRACKET (-VE) TERM

450

C - 46

ABS 1

ITEM N

2550

1500

TYPE

DEST.

ABS1-3 ABS1-4

ABS3

0 SCRAP VIEW (ENLARGED) SHOWING BRAID OVER SEALED CONDUIT ENDS.

ABS8 0

CE FA

ITEM R

ITEM N (SEE DETAIL BELOW) FREE TO SLIDE OVER CONDUIT, TEMPORARILY SECURED USING TEARABLE TAPE.

IN AT

M ITEM S TO BE CABLE TIED TO TRAILER SOCKET

LH 55 45

ITEM M 0 0 0

XXXXXXX

55 45

1100

800

RH ITEM L

9803/8040-5

ITEM T

BRAID OVER CONDUIT AS SHOWN

280 ITEM R

ITEM N (2 PLACES) ITEM L

AT IN

ABS1

12 APPROX

ITEM N (SEE DETAIL BELOW) FREE TO SLIDE OVER CONDUIT, TEMPORARILY SECURED USING TEARABLE TAPE.

FA CE

SCRAP VIEW (ENLARGED) TO SHOW WHEEL SENSOR ARRANGEMENT (2 PLACES)

0 52

ABS9

BLUE BLUE BROWN BLUE

BLUE BROWN BROWN BROWN

E F F F F F F F F F F

1 2

SIZE

DEST.

BLUE

0.75 0.75

ABS2-K ABS2-N

BROWN

MA TIN GF AC E

TYPE

ABS10

ABS11

CE FA ING

T MA

ABS 10 TERM

1 2

FRONT RH SPEED SENSOR WIRE

SIZE

BLUE

0.75 0.75

BROWN

ABS 11

FRONT LH SPEED SENSOR

TERM

WIRE

SIZE

BLUE

0.75 0.75

1 2

BROWN

DEST.

SHADED AREAS DENOTE 13MM WIDE TAPE TO INDICATE HARNESS FIXING POINTS

TYPE

ABS2-F ABS2-G

ABS CHASSIS HARNESS (4000 SERIES)

J 721/11807

DEST.

ABS2-E ABS2-L

TYPE

Fig 46. 806190

C - 46

ABS Chassis Harness

Section C - Electrics

ABS1 1 ABS1-2 ABS1-5 ABS11-1 ABS10-1 ABS10-2 ABS8-1 ABS9-1 ABS11-2 ABS8-2 ABS9-2

REAR RH SPEED SENSOR WIRE

Harness Data

4.0 1.5 1.5 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75

ABS 9 TERM

Drawings and Interconnection

370 150 440 -

D TYPE

DEST.

A B C D E F G H J K L M N

SIZE

1 2

BULKHEAD CONNECTOR WIRE

ABS 2 TERM

C - 47

721/12168

A21

B C D

1000

K M H G L F E

A1 1

B 1

A18

K D

J C

0 10

ITEM BE

C D

LITTELFUSE

2 LITTELFUSE

2 1

1150

XXXXXXXXXXXXXXXXXXXXXXXX

A24

5 1

400

1250

800

XXXXXXXXXXXXXXXXXXXXXXXX

DATUM

1000

8 13

2 LITTELFUSE

C B

GROMMET 828/00162

200

100

80 75

A10

A17 A4

100

A B

ITEM BJ

2 LITTELFUSE

1 8

4 7

8 0

9 6 5

9803/8040-5

A22

10 3 2

A23

1200 TYP

A19

80 75

A13

ABS DIA

A11

A25

ABS 6 - CAB HARNESS 721/12168

TO BE SUPPLIED AS PART OF HARNESS TO BLANK UNUSED CONNECTOR ON ECU

SHEET 1 OF 2

Fig 47. ABS Cab Harness Sheet 1 K Fig 48. ( T C-48)

Section C - Electrics

Harness Data

Drawings and Interconnection

C - 47

C - 48

A1 TERM

A B C D A2 TERM

SIZE

DEST.

A3 1 2 A4

SIZE

DEST.

FUSE E1 SIZE

DEST.

2.5 2.5 4.0 -

A1 C A1 D A2 1 -

FUSE E2 SIZE

DEST.

1.0 1.0

A1 A A2 A

A8 TERM

1 2 A9

9803/8040-5

TERM

A B C D A10 TERM

A B C A11 TERM

FUSE F1 WIRE

DEST.

A9 A A8 1 A18 9

SIZE

TRACTOR ABS POWER IN WIRE

SIZE

15K 1.0 265A 3.0 884F 0.5

DEST.

SIZE

TRACTOR ABS DIAG'C RELAY SIZE

DEST.

1.0 1.0 1.0 1.0 1.0 -

A11-4 A8-2 A11-2 A10-A A13 3 -

DIAGNOSTIC SWITCH WIRE

SIZE

TYPE

M M

TYPE

M M

TYPE

M M

TYPE

AD,E BM BK,G BL,C V

DEST.

448 1.0 A11-5 665A 3.0 A18 15 665B 1.0 A13 1

WIRE

TRACTOR ABS ECU CONNECTOR X1 CSA WIRE **561 1.0 CAN_L 0.5 ***564 1.0 ***562 1.0 **560 1.0 CAN_H 0.5 ***565 1.0 ***563 1.0 156 1.0 465 1.0 371 3.0 665A 3.0

DEST.

A25

TYPE BA BA BA BA BA BA BA BA BA BU BU BA BU BR BR

CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

DESTIN A2 H A2 M A2 K A2 N A9 D A21 C A21 B A21 F A21 G A21 A A21 E A21 J A21 K A21 L

TYPE BA BA BA BA BA BU BU BA BA BU BA BA BA BU BA BA BA BA

D,E F,G D,E BV TYPE

BW BX BW BW BP TYPE

Y Y Y X X

CAPACTY O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5

TRACTOR ABS ECU CONNECTOR X3 CSA WIRE

CAPACTY O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5

BY DESTIN

TO BE SUPPLIED AS PART OF HARNESS TO BLANK UNUSED CONNECTOR ON ECU

A B C D E F G H J K L M

BULKHEAD CON' (PANNIER) WIRE

SIZE

DEST.

1808 1807 1806 1801 1800 1802 1804 1803 1805 -

1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 -

A19 13 A19 9 A19 18 A19 15 A19 11 A19 12 A19 16 A19 17 A19 18 -

BC,BF BG,BH TYPE

BD BD BD BD BD BD BD BD BD -

CSA DESTIN 3.0 A9 C 3.0 A18 14

L, BN TYPE N N

A DIAGNOSTIC SWITCH 23 INTERCONNECT CSA DESTIN WIRE CAV 0.5 A13 5 A 810F 0.5 A13 6 B 962

TYPE BL,C BL,C

A 22 WIRE CAV 1 265A 2 371

FUSE F5

NOTE 1. WIRE TO JCB STANDARD 7000/3300 - 100 C RATED U.O.S. 2. "ABS" TO BE PRINTED ON EACH WIRE PRECEEDING THE WIRE NUMBER. 3. ITEMS MARKED:

TYPE BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU

A B C D E F G H J K L M N P Q R S T U V W X Y Z AA AB AC AD AE AF AG AH AJ AK AL AM AN AP AR AS AT AU AV AW AX AY AZ BA BB BC BD BE BF BG BH BJ BK BL BM BN BP BR BS BT BU BV BW BX BY

4 WAY FEMALE WEATHERPACK HOUSING MALE WEATHERPACK TERM (0.5-0.8) WEATHERPACK/M-PACK 280 CABLE SEAL (0.5) RED MALE WEATHERPACK TERM (1.0-2.0) W'PACK/M-PACK 280 CABLE SEAL (0.6-1.0) PURPLE MALE WEATHERPACK TERM (3.0) W'PACK/M-PACK 280 CABLE SEAL (2.5-3.0) GREY * 2/13 WAY BULKHEAD CONNECTOR POWER PIN (2.5-4.0) SIGNAL PIN (0.5-1.5) SINGLE ATO FUSE HOLDER TERMINALS FOR L (2.0) TERMINALS FOR L (5.0) 5 AMP ATOFUSE 25 AMP ATOFUSE 3 AMP ATOFUSE 10 AMP ATOFUSE TERMINALS FOR L (0.8) W'PACK/M-PACK 280 CABLE SEAL (1.4-2.0) GREEN 3 WAY FEMALE WEATHERPACK HOUSING SINGLE RELAY BASE 6.3 FASTIN-FASTON FEMALE TERM (0.3-0.8) 6.3 FASTIN-FASTON FEMALE TERM (0.8-2.1) 6.3 FASTIN-FASTON FEMALE TERM (4.0-6.0) ULTRASONIC SPLICE NEPTUNE SIGNAL PIN (1.5-2.5) 2 WAY WEATHERPACK MALE HOUSING WEATHERPACK SOCKET TERM (1.0-2.0) 3 WAY DT F/M (#16 PIN) RECEPT. (E'SEAL & ENDCAP) 3 WAY DT FEMALE (#16 PIN) RETAINER #16 PIN TERM (0.5-1.0) (INS O/D 1.40-2.10) GOLD #16 SKT TERM (0.5-1.0) (INS O/D 1.40-2.10) GOLD 4 WAY MALE WEATHERPACK HOUSING 8 WAY HWO90 MALE (PIN) HOUSING - WAY HWO90 MALE (PIN) RETAINER 8 HWO90 PIN TERM (0.3-1.25) HWO90 WIRE SEAL (0.75-1.5) BLUE HWO90 CAVITY SEAL BROWN 2 WAY HWO90 MALE (PIN) HOUSING 2 WAY HWO90 MALE (PIN) RETAINER 2 WAY HWO90 FEMALE (SKT) HOUSING 2 WAY HWO90 FEMALE (SKT) RETAINER HWO90 SOCKET TERM (0.3-1.25) 12 WAY DT MALE (#16 SKT) PLUG (E'SEAL) (GREY) 12 WAY DT MALE (#16 SKT) PLUG (E'SEAL) (BLACK) 12 WAY DT MALE (#16 SKT) PLUG (E'SEAL) (GREEN) 12 WAY DT MALE (#16 SKT) RETAINER #16 SOCKET TERM (0.5-1.0) (INS O/D 1.40-2.10) #16 SOCKET TERM (1.0-2.5) (INS O/D 1.90-3.55) 0-12 REVERSED PLUG FOR SOCKETS (METAL COLLAR) NEPTUNE SIGNAL SOCKET (0.5-1.5) FLEXIBLE CONDUIT O/D 16.1 ADAPTOR CAP NUT SEALING BUSH FLEXIBLE CONDUIT O/D 21.2 WEATHERPACK SOCKET TERMINAL (3.0) WEATHERPACK SOCKET TERMINAL (0.5-0.8) WEATHERPACK/METRI-PACK CAVITY SEAL (GREEN) 30 AMP ATO FUSE 10 WAY SWITCH CONNECTOR #12 SOCKET TERM (2.5-4.0) (INS O/D 2.87-4.47) 15 WAY DT MALE (#16/#12 SKT) PLUG (KEY A) 18 WAY DT MALE (#16 SKT) PLUG (KEY B) CAVITY BLANKING PLUG (#12-#16) SINGLE RELAY BASE 6.3 LUCAR (0.5-1.0) 6.3 LUCAR (1.5-2.0) 18 WAY DT MALE (#16 SKT) PLUG (KEY C)

JCB PART No

7214/0007 7204/0007 7210/0004 7204/0008 7210/0042 7204/0019 7210/0006 7220/0042 7204/0005 7204/0003 7201/0101 7201/0100 716/05703 716/05708 716/05701 716/05705 7201/0102 7210/0005 7213/0009 7231/0001 7201/0458 7201/0430 7201/0428 7204/0004 7212/0006 7201/0012 7213/0030 7213/0014 7204/0040 7201/0127 7214/0008 7218/0002 7218/0004 7204/0001 7210/0002 7210/0001 7212/0002 7212/0004 7212/0001 7212/0003 7201/0001 7201/0105 7220/0044 7201/0003 647/06500 7201/0027 7201/0011 7210/0008 716/05709 7219/0013 7201/0104 7210/0030 7201/0418 7201/0419 -

SUPPLIER

SUPPLIER PART No

QTY

PACKARD PACKARD PACKARD PACKARD PACKARD PACKARD PACKARD ITT CANNON ITT CANNON ITT CANNON LITTELFUSE LITTELFUSE LITTELFUSE LITTELFUSE LITTELFUSE LITTELFUSE LITTELFUSE LITTELFUSE PACKARD PACKARD BOSCH AMP AMP AMP ITT CANNON PACKARD PACKARD DEUTSCH DEUTSCH DEUTSCH DEUTSCH PACKARD SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO SUMITOMO DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH ITT CANNON ITT CANNON HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX HARNESSFLEX PACKARD PACKARD PACKARD LITTELFUSE CARLINGSW. DEUTSCH DEUTSCH DEUTSCH DEUTSCH RISTS RISTS RISTS DEUTSCH

12015024 12089040 12015899 12124582 12089679 12124587 12010293 192900-0583 121668-0002 192990-2490 868-062 913-043 913-042 257005 257025 257003 257010 913-044 12015323 12010717 3334485008 60295-2 1-42100-2 180351-2 192990-2480 12015792 12124580 DT04-3P-CE03 W3P 1060-16-0644 1062-16-0644 12015798 6181-0075 6918-0333 1500-0105 7165-0118 7161-9787 6181-0075 6918-0323 6189-0129 6918-0322 1500-0106 DT06-12SA-CE06 DT06-12SB-CE06 DT06-12SC-CE06 W12S-P012 1062-16-0622 1062-16-1222 192900-0236 192990-2530 NC16 HSO180 CN11 SRN11 CTPA 20-S 12124581 12089188 12010300 257030 VC2-01 1062-12-0166 DT16-15SA-K003 DT16-18SB-K004 114017 51154201 51102708 51103592 DT16-18SC-K004

1 1 4 3 4 3 4 1 1 10 5 6 4 3 1 0 0 0 0 1 0 0 3 0 0 0 1 1 1 1 2 0 1 0 0 0 2 0 0 0 1 1 2 0 0 0 0 24 0 1 9 A/R 1 1 1 A/R 1 3 1 1 1 2 1 1 26 1 3 1 1

ABS 6 - CAB HARNESS 721/12168

* MUST INCLUDE JAM NUT.

SHEET 2 OF 2

** SERIAL DATA COMMUNICATION WIRE. TWISTED PAIR TO SAE J1708.

Fig 48. ABS Cab Harness Sheet 2

Harness Data

C - 48

Section C - Electrics

*** WHEEL SPEED SENSOR WIRE. TWISTED PAIR - LENGTH OF LAY 25-35mm.

Drawings and Interconnection

1 665B 1.0 A10 C 2 465 1.0 A18 12 3 449 1.0 A11 6 4 5 810F 0.5 A23 A 6 962 0.5 A23 B 7 8 9 10

BS DESTIN A17 1 A24 B A2 E A2 F A17 2 A24 A A2 L A2 G A5 2 A13 2 A22 2 A10 B

DESCRIPTION

ITEM

*** WHEEL SPEED SENSOR WIRE. SEE NOTE

TERM

TYPE

TRACTOR ABS ECU CONNECTOR X2 CSA WIRE ***566 1.0 ***567 1.0 ***568 1.0 ***569 1.0 884F 0.5 1806 1.0 1807 1.0 1800 1.0 1802 1.0 1808 1.0 1801 1.0 1804 1.0 1803 1.0 1805 1.0

A19 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

A21

TRACTOR ABS RETURN WIRE

A5-1 A22 1 A19 5

TYPE

AV,AN AV,AN

721/12168

AE AF TYPE AG AG BU

A ABS CANBUS 24 INTERCONNECT CSA DESTIN WIRE CAV 0.5 A18 6 A CAN_H 0.5 A18 2 B CAN-L C

AT,AU DEST.

** SERIAL DATA WIRE. *** WHEEL SPEED SENSOR WIRE. SEE NOTE

L,P DEST.

A5 1 A11-4

SIZE

CAPACTY O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 O.5-2.5 2.5-4.0 2.5-4.0

TYPE

L,P

FUSE F4 WIRE

15KA 1.0 153 1.0

153A 153 4 153A 5 448 6 449 8

TERM

SIZE

15K 1.0 15KA 1.0 156 1.0

A13

A18 CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

J K K K K K K K K K K

L,P

WIRE

15J 150

H TYPE

L,Q

WIRE

260 270 370 -

1 2

TERM

ABS J1708 DIAGNOSTIC WIRE

1** 561 1.0 A18-1 2** 560 1.0 A18-5 ** SERIAL DATA WIRE. SEE NOTE

A3-2 A4-2 A1-B A18 3 A18 4 A18 8 A19 1 A19 3 A18 7 A19 2 A19 4

TERM

TYPE

BULKHEAD WIRE

370 4.0 1 2 A 150 1.0 B 440 0.5 C D E*** 564 1.0 F*** 562 1.0 G*** 563 1.0 H*** 566 1.0 J K*** 568 1.0 L*** 565 1.0 M*** 567 1.0 N*** 569 1.0 *** WHEEL SPEED SENSOR WIRE. SEE NOTE

TERM

A17

POWER IN WIRE

15J 1.0A4-1 D,E 440 0.5A2-B B,C 260 A3-1 2.5 F,G 270 A3-1 2.5 F,G

C - 49

Rear Fender Harness sheet 1

9803/8040-5

Fig 49.

Section C - Electrics Harness Data Drawings and Interconnection

C - 49

C - 50

9803/8040-5

Harness Data

Section C - Electrics

Rear Fender Harness sheet 2

C - 50

Drawings and Interconnection

Fig 50.

Section C - Electrics Harness Data Drawings and Interconnection

Page left intentionally blank

C - 51

9803/8040-5

C - 51

Section C - Electrics Instrument Cluster Description and Programming

Instrument Cluster Description and Programming Instruments

Fig 51. 1

Clock a

icon below the digital display indicates that a service is due. However, for the first 10 seconds after ‘ignition switch ON’ the display shows how many hours remain until the next service is due and is accompanied by solid illumination of the spanner icon. If the service is overdue, the ‘hours remaining’ display indicates negative and the spanner icon flashes. The normal display returns when the engine is started, RPM/EXIT button C is pressed or after a 10 second delay. The spanner icon will continue to flash after the display reverts to the normal display.

Time of day in 12 hour format with AM/PM indication is permanently displayed except when Level 1 programming is in progress. K Level 1 Programming Mode ( T C-61) for setting the correct time and appropriate alternative displays.

Engine/PTO data display a

Engine or PTO RPM is shown digitally across the middle of the display. The LCD bar graph around the outer rim always shows engine rpm even when PTO rpm is shown on the digital display. Press RPM/EXIT button C to toggle between digital ENGINE and PTO readings as identified by the icon above the digital display.

When different front and rear PTO speeds are selected, the higher one is shown. b Hourmeter

Road speed display a

The current road speed is shown on the digital display in the centre of the dial as well as on the LCD bar graph around the outer rim. The speed can be either kph or mph, with the selected units shown below the display, and this setting can be 1 Programming changed K Level Mode ( T C-61).

The digital display below the RPM icon is the vehicle hourmeter and normally shows the total running time of the engine. A flashing spanner

C - 52

9803/8040-5

C - 52

Section C - Electrics Instrument Cluster Description and Programming

Fig 52. b The tyre icon at the bottom of the dial will be illuminated when the system has been set up for a non-standard (i.e. optional) tyre size. c

The contents of the fuel tank are displayed on an LCD bar graph. When the tank is only 10% full the bar graph flashes. An audible alarm also sounds for 5 seconds every 10 minutes until the tank is topped up to more than 10%.

The radar icon illuminates if the tractor has radar fitted and it is actually measuring speed. Above 32 kph, when a gearbox sensor takes over speed measurement, the radar icon is extinguished. 6

Fuel gauge

Engine coolant temperature gauge

Centre display a

Coolant temperature is displayed on an LCD bar graph. the top of the graph corresponds to 140°C while the bottom corresponds to 40°C. If the temperature exceeds 105°C the currently displayed segments of the bar graph flash and an alarm sounds. The alarm sounds for 5 seconds every 10 minutes until the temperature falls below 105°C. In this event, stop the engine and investigate the cause of the overheating.

For the first 10 seconds after power up, the total distance travelled by the machine is displayed. Press RPM/EXIT button C, start the engine or wait 20 seconds for the normal display to be resumed.

b The left hand part of this area can be set to display either ‘area worked’ or ‘trip distance travelled’ K Level ‘0’ Programming Mode (Normal Operation) ( T C-58) 7 c

The right hand part of this area can be set to display either ‘hours of fuel remaining at present work rate’, ‘current work rate’, ‘percentage wheel slip’ or ‘rate of fuel usage’ K Level ‘0’ Programming Mode (Normal Operation) ( T C-58)

The twin needle display indicates the air pressure in the brake system air tanks. Scale 1 monitors the tractor front system air tank and scale 3 monitors the trailer tank. 8

d The display also indicates, when appropriate, that a machine parameter is being set up. K EMS Programming Mode Levels 0 and 1 ( T C-58) for details of selecting these parameters.

C - 53

Brake Pressure Gauge

9803/8040-5

Gear display Shows range and direction selected .

C - 53

Section C - Electrics Instrument Cluster Description and Programming

Warnings (Audible/Visual)

Fig 53.

!MWARNING

Indicates an engine fault other than low oil pressure. Engine performance may be affected. Error code will be displayed on touch screen.

When you hear an audible warning relating to one of the following functions, stop the machine as soon as possible. Get the fault put right before using the machine again. 4

13-2-1-12

Immediately following ignition switch-on and for a period of 3 seconds, all lamps and display LCD segments illuminate and a bleeper operates. This is followed by a brief sounding of the buzzer. If any of the lamps, the LCD segments or either of the audible alarms do not operate, carry out the necessary repairs before using the machine.

Transmission fault light Operates if the transmission has a fault.

External hydraulics system fault light Operates if the external hydraulics system has a fault.

6 1

Engine fault light

PTO system fault light

No charge light Operates if the PTO system has a fault. Operates if the battery charging circuit fails while the engine is running. The light should go out a few seconds after the engine is started.

Engine oil pressure low light Operates if the engine oil pressure is low. The light should go out when the engine is started.

C - 54

9803/8040-5

C - 54

Section C - Electrics Instrument Cluster Description and Programming

Fig 54. 7

Front brake circuit air tank pressure light K Park/ trailer brake circuit air tank pressure light ( T C-55).

Rear Brake circuit air tank pressure light K Park/ trailer brake circuit air tank pressure light ( T C-55).

Park/trailer brake circuit air tank pressure light

turned on and then remain lit until road speed exceeds 10 km/h (6 mph). If the lamp does not light when the starter switch is turned on or it remains lit above 10 km/h (6 mph), there is a fault in the ABS system. Do not use the trailer until the fault has been put right.

Lights 7, 8 and 9 operate if the air pressure is low in the relevant circuit(s). Note: When the engine is started the pressure builds up progressively through the circuits. Lights 7 and 8 should therefore go out before light 9. The foot brakes require pressure to apply them whilst the park brake requires pressure for release. This ensures that the machine cannot be driven away until all the brake circuits are charged. 10

Brake fluid light Operates if the fluid level is low in one or more of the brake fluid reservoirs.

Trailer anti-lock brake system (ABS) light When a trailer fitted with ABS is connected, the warning lamp should light as the starter switch is

C - 55

9803/8040-5

C - 55

Section C - Electrics Instrument Cluster Description and Programming

Warnings (Visual only)

Fig 55. Immediately following ignition switch-on and for a period of 3 seconds, all lamps and display LCD segments illuminate and a bleeper operates. This is followed by a brief sounding of the buzzer. If any of the lamps, the LCD segments or either of the audible alarms do not operate, carry out the necessary repairs before using the machine.

Flashes with items 2 or 3 and 4 when a second trailer is fitted. 6

Indicates that engine cold start system is operating. Do not start engine until this light has gone out. 7

Left direction indicators on - green flashing light

Differential lock engaged - red light Lights up when the differential locks are selected.

Flashes with the left direction indicators. 3

Wait to start light

Main beam on - blue light Lights up when the headlight main beams are switched on. Switch the main beams off for oncoming vehicles.

Second trailer direction indicators on - green flashing light

Right direction indicators on - green flashing light

Air filter blocked light Operates if the engine air filter element needs renewal.

Flashes with the right direction indicators. 9 4

First trailer direction indicators on - green flashing light Flashes with items 2 or 3 when a trailer is fitted.

C - 56

9803/8040-5

Park Brake light Operates when the park brake is engaged. The light should go out when the park brake control is pushed down and the air pressure is high enough to release the park brake. Always engage the park brake before leaving the machine.

C - 56

Section C - Electrics Instrument Cluster Description and Programming

Fig 56. 10

Four wheel drive engaged - green light

Operates when the four wheel drive is actually engaged. 11

System errors light The icon illuminates to alert the operator to the existence of control system error(s). Error code will be displayed on touch screen. .

Side lights on light 18

Tractor anti-lock brake system (ABS) light

Lights when the side lights are switched on. 12

Rear power take off (PTO) speed 540 rpm light After selection of 540 rpm rear PTO speed, illuminates when PTO is switched on.

Rear power take off (PTO) speed 1000 rpm light

When the starter switch is turned ON the lamp illuminates while the ABS ECU carries out a selfcheck. If the ABS is functioning correctly the lamp extinguishes after a short time. If the lamp remains lit or subsequently lights, a system fault is indicated. . In this condition the effects of braking without ABS will be available. Have the system checked by a JCB dealer as soon as possible.

After selection of 1000 rpm rear PTO speed, illuminates when PTO is switched on. 14

Front power take off selected light Illuminates upon selection of front PTO operation.

Rear power take off selected light Illuminates upon selection of rear PTO operation.

Wheel slip active light Illuminates when slip control has been selected.

C - 57

9803/8040-5

C - 57

Section C - Electrics Instrument Cluster Description and Programming

EMS Programming Mode Levels 0 and 1

Fig 57.

Level ‘0’ Programming Mode (Normal Operation)

‘FIELD ALL’ to display the sum total of the area worked in all the fields. After scrolling has ceased and following a short delay or after pressing RPM/ EXIT button C the FIELD icon stops flashing. c

During the progress of an area count the cross hatched icon to the left of the field number flashes when work is interrupted due to the raising of the rear hitch or, if the optional area cut-out system is fitted, due to the implement sending a signal to indicate cessation of its function.

Fig 58. 1

Distance travelled and area worked a

The LH side of centre display 4 shows either ‘trip distance travelled’ or ‘area worked’ data. Press button A to toggle between ‘trip distance travelled’ and ‘area worked’ to select the desired item. To select imperial or metric data (i.e. miles or km, acres or Ha. K Level 1 Programming Mode ( T C-61) (step 2).

b With the ‘area worked’ feature selected, press SET UP/SELECT button D to cause the FIELD icon to flash. While it is still flashing use buttons A and B to scroll through the list of fields (1 - 25) to select the one required. The facility enables individual recordings to be made of the area worked in each of a number of fields. Select

C - 58

9803/8040-5

Fig 59. d To reset the stored value of ‘area worked’ for one or more of the fields listed, select each one in turn as described earlier and then press buttons A and B together and hold for 5 seconds. To reset the stored values for all fields, select ‘FIELD ALL’ and then press the buttons as described for individual fields.To return to the display showing ‘trip distance travelled’, press button A with the FIELD icon not flashing.

C - 58

Section C - Electrics Instrument Cluster Description and Programming 2

To change the RH side of centre display 4 press button B to step between the four available options: a

Hours of fuel remaining at current average work rate averaged over 10 minutes.

b Work rate, acres or hectares (Ha) per hour.

Fig 60.

To select imperial or metric data, K Level 1 Programming Mode ( T C-61), step 2. c

Wheel slip (if a radar is present) During normal operation the display shows the actual percentage rate of wheel slip. If active, the display indicates by means of a bar in front of the figure, whether the actual wheel slip is above, below or equal to the programmed level.

Fig 61.

d Fuel usage This facility is provided so that where fuel economy is of paramount importance, the operator can compare readings obtained with the machine in alternative speed ranges. The figures are averages over a 5 second period and indicate litres/hour.

Fig 62.

Fig 63.

C - 59

9803/8040-5

C - 59

Section C - Electrics Instrument Cluster Description and Programming

Fig 65.

Fig 64. 3

Adjusting Implement Width a

Press and hold the SET UP/SELECT button D for approximately 3 seconds to bring up on the centre display 4 the flashing message ‘IMPWIDTH’. Release button D. The clock display 1 shows the previously stored implement width in metres. Use button A or B to select the width of the new implement. Press the EXIT button to resume the normal display and store the new value. If the EXIT button is not pressed, the storing procedure is carried out automatically 20 seconds after the last operation of the SET UP/SELECT or the A or B buttons.

C - 60

9803/8040-5

Adjusting Warning Lamps Dimming Level a

Switch ON the sidelights or headlamps so that the warning lamps are dimmed. Press and hold SET UP/SELECT button D for approximately 3 seconds to bring up the flashing message ‘IMPWIDTH’ on centre display 4. Release button D. Press button D again to bring up the flashing ‘DIMMING’ message on the centre display. Release button D. The number in clock display 1 shows, as a percentage, the current dimming level of the warning lamps. 100% indicates zero dimming, i.e. maximum brightness, 10% indicates the maximum available dimming. Press arrow button A or B to set up the required level. If buttons A, B or D are not pressed for 20 seconds, or if EXIT button is pressed, the normal displays 1 and 4 are resumed.

C - 60

Section C - Electrics Instrument Cluster Description and Programming Level 1 Programming Mode

Fig 66. Level 1 programming mode is concerned with the settingup of various parameters which may be subject to change from time-to-time. To access level 1 programming press SET UP/SELECT button D before and whilst turning the ignition switch ON. Do not start the engine. This will initiate the following sequence of events: 1

A or B to toggle between MET and IMP units for level ‘0’ programming displays of area/distance (ha/km or acres/miles) and work rate (acres or hectares (Ha)/ hour) for the appropriate LH side display at Level 0 Programming.

The centre display 4 shows the message ‘SPEEDO’ and Road Speed Display 3 shows either mph or kph, depending on the setting previously made. Press button A or button B to toggle between the two options and select the desired setting.

Fig 68.

Fig 69. 3

Press SET UP/SELECT button D to initiate the flashing message ‘SERVICE’ on centre display 4. a

Fig 67. 2

The engine running hours display on right hand display 2 shows the total running hours at which

Press SET UP/SELECT button D to bring up the message ‘CENTRE’ on centre display 4. Press button

C - 61

9803/8040-5

C - 61

Section C - Electrics Instrument Cluster Description and Programming the next service is due. Press button A or B to adjust this setting.

Depending on the current requirement, press button A or button B to toggle between the current value stored for the radar calibration, radar OFF or CAL.

E.g. If current engine hours is 520 and the next service is due at 1000 hours, (this can only be incremented in 50 hour steps) set up the display at 1000. On next power-up, the service hours counter (shown with the spanner icon) will show 480 hours, being the time remaining until the next service is due. 4

Press SET UP/SELECT button D to initiate the flashing message ‘CLOCK’ on centre display 4. The clock display 1 shows the current setting. Step the display setting forwards or backwards to set-up the correct time by pressing button A or button B respectively. Note that the clock is 12 hour format with AM or PM indication.

CAL. Ready to do a new calibration.

Fig 72. Note: Radar calibration should only be necessary if the radar unit has been replaced or if the operator has reason to suspect that the radar is inaccurate. It should be carried out on level ground in dry conditions. Very wet ground, particularly pools of standing water will cause inaccuracies.

Fig 70.

Fig 73. 6

To re-calibrate the radar: a

Fig 71. 5

Press SET UP/SELECT button D to initiate the flashing message ‘RADARCAL’ on centre display 4. The clock display 1 shows one of the following: a

OFF. The factory set calibration value will be used by the EMS.

b The current numerical calibration value in pulses/ metre (132.2 in the example shown).

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Accurately measure a distance along the ground of 100 metres in a straight line from the point directly below the centre of a wheel hub. Mark a line at this point

b Ensure that the clock display 1 is showing ‘CAL’. c

Drive the tractor along the course to the point where the wheel hub is directly above the mark made 100 metres from the start position. It is advised that someone walks alongside the tractor to ensure that the final position is accurate.

d When the 100 metre mark is reached, exit Level ‘1’ Programming Mode to complete the calibration.

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Section C - Electrics Instrument Cluster Description and Programming Note: During the 100 metre run, display 1 changes from displaying ‘CAL’ to a continually increasing number. This number ceases to increase at the end of the run. The final value displayed is the value in pulses/metre which is stored as the calibration value. If this value differs by more than ±10% from the factory set value (132.7 for UK machines, 131.8 for non-UK machines), then the value is deemed invalid and the calibration value defaults to the setting in use before calibration started. 7

To return to the MPH-KPH mode (step 1) press SET UP/SELECT button D. To exit level 1 programming either switch the ignition OFF or start the engine or press EXIT/RPM button C.

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Section C - Electrics Instrument Cluster Description and Programming

Wheel Slip Slip Control Re-calibration

The following procedure should be carried out when one set of wheels has been exchanged for a set of a different size, or if a slip reading not near 0% is observed when the machine is being driven on a tarmac surface. Proceed as follows: 1

Fit an implement to the rear hitch e.g. a plough.

Operate the draft control up and down after starting the engine to ensure that the draft control is unlocked.

Set the draft control main lever to the UP position i.e. in the transport position.

Drive the tractor on tarmac at a speed in excess of 15 kph for a minimum of 12 minutes.

The draft control and instrument cluster by now will have been automatically re-calibrated.

Slip Control - Normal Operations Press switch H to toggle between active and disabled. Warning lamp T, K Fig 56. ( T C-57) illuminates when ‘wheel slip’ is active.

J 10 %

50 %

Fig 75. When wheel slip switch H is on, icon F/R on the touch screen is replaced by the slip control button J. Press this button then use + and - buttons on the arm rest to adjust the percentage wheel slip.

Fig 76. 1

The measured wheel slip is more than 1% higher than the ‘wheel slip’ setting. Note that the top bar is illuminated.K Fig 77. ( T C-65)

Fig 74.

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Section C - Electrics Instrument Cluster Description and Programming

A286241

Fig 77. 2

The measured wheel slip is more than 1% lower than the ‘wheel slip’ setting. Note that the bottom bar is illuminated.

A286251

Fig 78. 3

The measured wheel slip is within ± 1% of the ‘wheel slip’ setting. Note that the centre bar is illuminated.

A286011

Fig 79. 4

‘Wheel slip’ is switched OFF, as indicated by the absence of a bar in front of the current reading, which continues to be displayed. Warning lamp 16 on the Instrument Cluster is not illuminated.

A286261

Fig 80.

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Section C - Electrics

Touch Screen Calibration Accessing Calibration Menu 1

Switch the Ignition ‘On’

Access the ‘Settings’ screen on the touch screen. Normally the ‘Calibration’ icon will be ‘greyed out’ so it can not be accessed by non-service personnel.

Fig 82. 4

Fig 81. 3

To activate the calibration icon A, hold the clutch pedal down and press the armrest + and – buttons simultaneously.

Select the calibration icon for the item to be calibrated as listed below.

Engine

PTO

Joystick

Transmission

Steering Angle

The icon will turn blue allowing it to be selected by gently pressing on the screen.

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Section C - Electrics Touch Screen Calibration Calibration

Calibration Hand Throttle 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 84. 3

Select the hand throttle icon G.

Fig 83. 2

Select the engine calibration icon B.

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Section C - Electrics Touch Screen Calibration Calibration

Fig 85.

Fig 86.

Select the top icon J to program the hand throttle ‘Idle’ position. It will become highlighted green

Select the lower icon L to program the hand throttle maximum position.

Move the hand throttle to its idle position and check the value shown in the box is the highest possible value in the hand throttle’s range.

Move the hand throttle to the maximum engine speed position. Check the value is the lowest in the hand throttle’s range.

Store the value in the memory by pressing the save icon K.

In order to return to settings screen, press the ‘Return’ icon R.

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Section C - Electrics Touch Screen Calibration Calibration

Foot Throttle 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 88. 3

Select the foot throttle icon H.

Fig 87. 2

Select the engine calibration icon B.

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Section C - Electrics Touch Screen Calibration Calibration

784

181

R Fig 89.

K Fig 90.

Select the top icon J to program the foot throttle ‘up’ position. It will become highlighted green

Select the lower icon L to program the foot throttle ‘down’ position.

With the foot throttle at the top of its travel, check the value shown in the box is the highest possible value in the foot throttle’s range.

Move the foot throttle to the maximum engine speed position. Check the value is the lowest in the sensor’s range.

Store the value in the memory by pressing the save icon.

In order to return to settings screen, press the ‘Return’ icon R.

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Section C - Electrics Touch Screen Calibration Calibration

Joystick Centre Position 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 92. 3

Select the upper icon G to access the joystick central position calibration menu.

Fig 91. 2

Select the joystick calibration icon D.

Fig 93.

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Section C - Electrics Touch Screen Calibration Calibration 4

Check that movement of the joystick in either axis registers a change in the numbers displayed in the box J.

Ensure that the joystick is in the middle position and both values are similar.

Store the value in the memory by pressing the save icon.

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Section C - Electrics Touch Screen Calibration Calibration

Joystick Left/Right Positions Important: Calibrate the joystick centre position before calibrating the joystick left and right positions. 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 95. 3

Select the lower icon H to display the joystick left/right position calibration values as shown below.

Fig 94. 2

Select the joystick calibration icon D.

Fig 96.

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Section C - Electrics Touch Screen Calibration Calibration 4

Select icon L and check that the values change as the joystick is moved from side to side.

Fig 98. 8

Select box N, it will become green.

Pull the joystick to the left but not beyond the detent position.

Store the value in the memory by pressing the save icon K.

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Fig 97. 5

Select box M, it will become green.

Push the joystick to the right but not beyond the detent position.

Store the value in the memory by pressing the save icon K.

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Section C - Electrics Touch Screen Calibration Calibration

Transmission Clutch Pedal 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 100. 3

Select the transmission clutch icon M.

Fig 99. 2

Select the transmission icon E.

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Section C - Electrics Touch Screen Calibration Calibration

Fig 101.

Fig 102.

Select the top icon T to record the position value of the clutch pedal ‘up’. It will become highlighted green

Select the lower icon V to record the clutch pedal ‘down’ position.

With the pedal at the top of its travel i.e. clutch fully engaged, check the value shown in the box is the lowest possible value in the clutch pedal’s range.

Move the clutch pedal to the fully down position. Check the value is the highest in the sensor’s range.

Store the value in the memory by pressing the save icon K.

Return to the previous menu using the ‘Return’ icon.

When the clutch has been correctly calibrated the transmission range icon will be activated so that it can be selected.

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Section C - Electrics Touch Screen Calibration Calibration

Transmission Range Note: The transmission must be calibrated in the following sequence. 1

Clutch Pedal

Range

Ratio

Turbo Clutch

Make sure the clutch pedal is calibrated before doing the range. K Transmission Clutch Pedal ( T C-75) Certain transmission calibration icons will be disabled until the previous calibration has been done. 1

Ensure there are no active fault codes.

Ensure the transmission oil is warm.

Assuming the transmission calibration menu has been accessed during clutch pedal calibration, switch on the ignition.

Fig 104. 5

Select the top icon T. A number of system prerequisite icons will then appear in grey. As each one appears, the action shown below must be done. The icon will then turn green and the next icon will appear. a

Park brake engaged

b Neutral selected c

Clutch - press and hold down

d Engine - Set to 600 -900 rpm

Fig 103. 4

Select the transmission range icon N.

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Section C - Electrics Touch Screen Calibration Calibration

Fig 105. 6

Fig 106. Calibration successful

When all the pre-requisites have been satisfied, they will all be highlighted green and the system will then start counting up in the display box as it does the calibration process.

Note: All the pre-requisites must be held throughout the calibration process. When calibration is complete, one of the following screens will appear:

Fig 107. Calibration unsuccessful If the calibration unsuccessful screen appears, a fault code will be generated. Access by pressing icon Z.

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Section C - Electrics Touch Screen Calibration Calibration

Transmission Ratio Note: The transmission must be calibrated in the following sequence. 1

Clutch Pedal

Range

Ratio

Turbo Clutch

Make sure the clutch pedal and range are calibrated before doing the ratio. Certain transmission calibration icons will be disabled until the previous calibration has been done. 1

Ensure there are no active fault codes.

Ensure the transmission oil is warm.

Assuming the transmission calibration menu has been accessed during the previous calibration and the engine is running, select the transmission ratio icon P

Fig 109. 4

Park brake engaged

b Range calibration completed c

Clutch pedal up

Note: The clutch pedal should be in its up position unless the clutch sensor has been fitted incorrectly. d Engine - Set to 1580 - 1620 rpm

Fig 108.

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Section C - Electrics Touch Screen Calibration Calibration

Fig 110. 5

Fig 111. Calibration successful

When all the pre-requisites have been satisfied, they will all be highlighted green and the system will then start counting up in the display box as it does the calibration process.

Note: All the pre-requisites must be held throughout the calibration process. When calibration is complete, one of the following screens will appear:

Fig 112. Calibration unsuccessful If the calibration unsuccessful screen appears, a fault code will be generated.

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Section C - Electrics Touch Screen Calibration Calibration

Transmission Turbo Clutch Note: The transmission must be calibrated in the following sequence. 1

Clutch Pedal

Range

Ratio

Turbo Clutch

Make sure the clutch pedal, range and ratio are calibrated before doing the turbo clutch. Certain transmission calibration icons will be disabled until the previous calibration has been done. 1

Ensure there are no active fault codes.

Ensure the transmission oil is warm.

Assuming the transmission calibration menu has been accessed during the previous calibration and the engine is running, switch off the engine and wait for the touch screen to power off.

Fig 113. 5

Select the transmission icon E.

Switch on the ignition and access the Calibration Menu K Accessing Calibration Menu ( T C-66)

Fig 114. 6

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Select the turbo clutch icon S.

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Section C - Electrics Touch Screen Calibration Calibration Note: All the pre-requisites must be held throughout the calibration process. When calibration is complete, a calibration successful or calibration unsuccessful screen will appear showing either a tick or a cross. If the calibration unsuccessful screen appears, a fault code will be generated.

Fig 115. 7

Start the engine. Select the top icon T. A number of system pre-requisite icons will then appear in grey. As each one appears, the action shown below must be done. The icon will then turn green and the next icon will appear. a

Park brake engaged

b Neutral selected c

Select high range on arm rest control

d Engine - Set to 1080 - 1120 rpm 8

When all the pre-requisites have been satisfied, they will all be highlighted green and the system will then start counting up in the display box as it does the calibration process.

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Section C - Electrics Touch Screen Calibration Calibration

Front PTO Note: Ensure PTO is not set to auto-disengage with front linkage position as this will prevent front PTO starting up. Ensure transmission oil is warm. 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 117. 3

Select the front PTO icon G.

Fig 116. 2

Select the PTO calibration icon C.

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Fig 118. 4

Park brake engaged

b Neutral selected c

Engine - Set to 900 - 600 rpm

d Start PTO on main instrument panel. PTO will start then automatically stop. After a delay of approximately 2 seconds, the PTO will restart automatically. 5

When all the pre-requisites have been satisfied, they will all be highlighted green and the system will then start counting up in the display box as it does the calibration process.

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Section C - Electrics Touch Screen Calibration Calibration

Rear PTO Note: Ensure PTO is not set to auto-disengage with rear linkage position as this will prevent front PTO starting up. Ensure transmission oil is warm. 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 120. 3

Select the rear PTO icon H.

Fig 119. 2

Select the PTO calibration icon C.

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Fig 121. 4

Park brake engaged

b Neutral selected c

Engine - Set to 900 - 600 rpm

d Start PTO on main instrument panel. PTO will start then automatically stop. After a delay of approximately 2 seconds, the PTO will restart automatically. 5

When all the pre-requisites have been satisfied, they will all be highlighted green and the system will then start counting up in the display box as it does the calibration process.

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Section C - Electrics Touch Screen Calibration Calibration

Steering Angle Important: Calibrate the joystick centre position before calibrating the joystick left and right positions. 1

Access the Calibration Menu Calibration Menu ( T C-66)

K Accessing

Fig 123. 3 Fig 122. 2

With the arrow pointing left selected, start the engine and turn the steering to full left lock. Check that the value changes as the steering turns.

Select the steering angle icon F. 4

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Select icon T to turn it green and display the calibration values.

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Store the value in the memory by pressing the save icon K.

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Section C - Electrics Touch Screen Calibration Calibration

250

408

W 495

K Fig 124. 5

Fig 125.

Select icon V to turn it green and display the calibration values.

Turn the steering to straight ahead. Check that the value changes as the steering turns. 6

Store the value in the memory by pressing the save icon K.

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Select icon W to turn it green and display the calibration values. Turn the steering to full right lock. Check that the value changes as the steering turns.

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Store the value in the memory by pressing the save icon K.

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Section C - Electrics

Spool Valve Controls Calibration Introduction The spool valve slices are controlled by a separate canbus linking the valve block to ECU1. This is totally separate from the main tractor canbus.

Spool control levers are wired to ECU1 and the front hitch communicates to ECU1 over the main tractor canbus. The spool control levers must be calibrated to record the limits of movement. The front hitch needs to be operated to record the limits of the front hitch position sensor. The spool controls can be calibrated in a separate operation from configuring the spool valve slices.

Accessing the Spool Valve Calibration Mode

B N A

T Fig 127.

Important: Be aware that this process is time critical – read the following steps before commencing.

Ensure the transport lock K is not engaged, the green spool lever 1 is in its neutral position N, and the touch screen is powered ‘Off’.

Switch the Ignition ‘On’.

As the first instrument panel buzzer has finished sounding engage the transport lock K.

Before the second instrument panel buzzer has finished sounding, cycle the green spool lever 1 from its central neutral position to extend A, then to retract B, and back to neutral N. The instrument panel will display a code and begin to count down from 25 seconds. Upon access, the current valve slice configuration status will be displayed.

1 S

Fig 126.

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Section C - Electrics Spool Valve Controls Calibration Introduction

Calibration Mode

U D

B N A

T Fig 129.

Move all spool levers to the retract position B. (Should be approximately 170.) Take care not to move the levers into the float position F.

Fig 128. 1

Using the down arrow D - scroll to ‘RA’. Move all spool levers to the extend position A. (Should be approximately 830.)

Scroll down to ‘RB’.

Press button C to store the values. ‘OK’ message should be displayed. 4

Scroll down to ‘RLO’.

Press button C to store the values. ‘OK’ message should be displayed.

Move all rotary controls T to the minimum position (Should be approximately 235.)

Scroll down to ‘RN’.

Press button C to store the values. ‘OK’ message should be displayed.

Move all spool levers to the neutral position N. (Should be approximately 490.)

Press button C to store the values. ‘OK’ message should be displayed.

Scroll down to ’RHi’. Move all rotary controls T to the maximum position (Should be approximately 860.) Press button C to store the values. ‘OK’ message should be displayed.

Scroll down to ‘START’. Start the engine.

Scroll down to ‘Tx OFF’. Disengage the transport lock.

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Scroll down to ‘SHi’.

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Section C - Electrics Spool Valve Controls Calibration Introduction

Fig 130. Using the front hitch control lever G, select ‘Up’ position H to move the front linkage to the highest position. (Should be approximately 755.) 9

Scroll down to ‘SLo’. Using the front hitch control lever G, select ‘Down’ position J to move the front linkage to the lowest position. (Should be approximately 250.)

Scroll down to ‘SAVE’. Press button C to save changes and exit the calibration mode.

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Section C - Electrics

Spool Valve Slice Configuration Introduction All Fastrac spool valve slices are controlled over a canbus from the central controller ECU1. On an 8000 series Fastrac this is totally separate from the main tractor canbus and is used solely for communicating between ECU 1 and the valve block. Until each spool slice is configured, the tractor cannot identify the 5 spool slices: Green, Blue, Brown, Grey, Front Hitch. The 8000 series Fastrac uses a slightly different method of configuring the valve block from the 3000 series Fastrac. The Configuration process is carried out on the instrument panel and the valve slices are each assigned a number (1 to 5) which is stored in the valve slice memory. Table 5. Slice Slice Description Number 1

Green

Blue

Brown

Grey

Front Hitch

1 S

Fig 131.

ALL Fastrac models are only capable of configuring valve slices to a new machine from their Bosch state i.e. when they are blank. As with 3000 series Fastrac models, the 8250 has the ability to return configured valve slices to their Bosch state. This therefore allows 3000 series valve slices to be configured to an 8000 model Fastrac.

Accessing the Configuration Mode Important: Be aware that this process is time critical – read the following steps before commencing.

Ensure the transport lock K is not engaged, the green spool lever 1 is in its neutral position N, and the touch screen is powered ‘Off’.

T Fig 132.

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B N A

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Switch the Ignition ‘On’.

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Section C - Electrics Spool Valve Slice Configuration Introduction 3

As the first instrument panel buzzer has finished sounding engage the transport lock K.

Before the second instrument panel buzzer has finished sounding, cycle the green spool lever 1 from its central neutral position to extend A, then to retract B, and back to neutral N. K Fig 132. ( T C-92) The instrument panel will display a code and begin to count down from 25 seconds. Upon access, the current valve slice configuration status will be displayed.

Fig 135. Valve slice number 2 just fitted.

Valve Slices Currently Configured Upon accessing Configuration Mode the spool valve slices which are configured for that particular machine will be displayed on the instrument panel.Slices configured for 8000 series can be identified by the prefix ‘CV’. Some examples of valve slice configuration that may be seen on the instrument panel are as follows. K Fig 133. ( T C-93) to K Fig 137. ( T C-93)

Fig 136. Slices 1, 3 and 5 configured to an 8000 series Fastrac. Slices 2 and 4 either not connected or not in a Bosch state.

Fig 137. Either: No slices connected or the slices that are connected are not in a Bosch state. Fig 133. No slices connected or configured.

Configuring ‘Bosch’ Slices to an 8000 Series Fastrac The object of this procedure is to make sure that each valve slice is correctly identified to its proper position number on the Fastrac. K Table 5. ( T C-92) When configured, each valve slice will store this identity even if it is unplugged.

Fig 134. All five slices connected and configured correctly.

To wipe the slice memory it must be restored to Bosch state, K Returning 8000 Series Configured Slices to Bosch State ( T C-95) As with 3000 series machines, only one new valve slice can be configured at a time.

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Section C - Electrics Spool Valve Slice Configuration Introduction Configuration is very quick. To avoid confusion it is best to work methodically through the configuration process and configure all valve slices.

Configuration Procedure 1

Identify which slices require configuration. K Valve Slices Currently Configured ( T C-93)

Disconnect all slices requiring configuration by unplugging the relevant connectors 1, 2, 3, 4 or 5. K Fig 138. ( T C-94)

Fig 139. Slices 1, 2 and 3 are connected and configured correctly. The ‘0’ shows at least one new slice is connected. 5

To select the required dash (“-”), use the green spool lever 1 K Fig 132. ( T C-92). Pulling back the lever will move the flashing digit to the right. Pushing the lever forward will move the flashing digit to the left. The dash (“-”) selected will blink. In the following example the dash selected is shown in red (position 4). K Fig 140. ( T C-94)

Important: It is very important to make sure that the slice selected on screen is the connected UNCONFIGURED slice. Make sure that there is only one unconfigured slice connected during configuration.

5 4 3 2 1 Fig 138. 3

Reconnect only ONE slice requiring configuration. In the following example this will be number 4. The order is not important as long as the relevant spool number is selected later in the procedure. K Fig 140. ( T C-94)

Note: Having more than one unconfigured slice connected makes it possible to store several slices as the same number. 4

4 Fig 140. 6

If the selected slice is in a Bosch state, the display will now show ‘CV0’ and the slice can be assigned a number. K Fig 139. ( T C-94) This example shows slices 1, 2 and 3 are connected and configured correctly. The ‘0’ shows at least one new slice is connected.

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Press column switch C to save the slice in this position. K Fig 141. ( T C-95) The screen will then show that slice 4 has been programmed. K Fig 142. ( T C-95)

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Section C - Electrics Spool Valve Slice Configuration Introduction Returning 3000 Series Configured Slices to Bosch State

As already stated, valve slices from a 3000 series Fastrac can be configured for use on an 8000 series Fastrac. K Introduction ( T C-92) However they do need to be returned to Bosch state before doing this.

Note: This can be carried out after fitting to the 8000 series tractor. Any slices configured for 3000 Fastrac models will not appear under the ‘CV’ heading on the menu list. These will appear under a new heading titled ‘JV’ within the menu list. The following procedure should be used to return the slices to Bosch state: 1

Fig 141. Note: Pressing column switch C with an uconfigured slice selected, will cause any connected and unconfigured slice to be configured for the required position.

Fig 142. Slice 4 programmed

Scroll down the menu until ‘JV-----’ is found using the instrument panel down arrow D. K Fig 141. ( T C-95) Any 3000 series configured slices will be shown similar to the ‘CV’ screen.

Use the green spool lever to select the required slice.

If a slice is connected and configured, pressing the column switch C returns that slice to the default Bosch state and removes it from the ‘JV -----‘ screen.

Scrolling back to the ‘CV -----‘ screen within the menu list, the slices can now be configured as 8000 series valve slices.

Returning 8000 Series Configured Slices to Bosch State

Note: Remember that only one unconfigured slice can be connected during programming. K Configuring ‘Bosch’ Slices to an 8000 Series Fastrac ( T C-93)

Slices configured for 8000 series Fastracs will appear under ‘CV’ on the menu list.

Spool Controls Calibration is accessed from the same menu.

By returning it to Bosch state the selected slice memory is wiped and it can be reassigned to another position or machine. The following procedure should be used:

It is not essential to do Spool Control Calibration at the same time as Slice Calibration.

Use the green spool lever to select the required slice. (There is no need to disconnect the slices.)

If a slice is connected and configured, pressing the column switch C returns that slice to the default Bosch setting.

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Section C - Electrics

Diagnostic Error Codes Introduction In the following tables, the possible causes for each error code are listed in order of probability, and should always be checked in the order given. Error codes are able to identify individual faults within the system. It is unlikely that individual error codes will be generated erroneously by either the EMS or the transmission ECU. In the unlikely event that either of these units should fail, there will be a major failure. Before any diagnostic work is carried out, it is recommended that the initial start up sequence is watched closely to ensure that both the EMS and the Transmission ECU are functioning correctly. To check both units: 1

Turn the starter key to ‘ON’.

For a period of approximately 3 seconds the display is tested. Ensure that each of the display segments on the EMS display are functioning. Check that all of the display lamps are also illuminated.

Ensure that the external buzzer sounds following display test; if not check the buzzer.

If any of this does not happen, suspect a fault within the EMS. Reprogramming the EMS may cure this; if this fails, change the EMS.

Following directly on from this, the centre display will display “HI THERE” for approximately 2 seconds. This is done to inform the operator that the data link between the Transmission ECU and the EMS has been established correctly. If this does not happen, suspect the Transmission ECU is disconnected, or has an internal fault. Check all connections between the EMS and Transmission ECU, particularly the CAN bus. Turn the ignition off and on again to retest; if the fault persists, change the Transmission ECU.

The prefix letters of the number error codes denote the part of the machine affected. These are given below for information only. Prefix Affected Part of Machine letter A

Anti-lock Brake System (ABS)

Central Controller (mainly external hydraulics controls)

Instrument cluster

Gearbox

Touch Screen

Engine

Rear 3-point Linkage

Front 3-point Linkage

Electronic spool valve green slice

Electronic spool valve blue slice

Electronic spool valve brown slice

Electronic spool valve grey slice

For JCB Dealer information only

Non-displayable Fault Codes There are certain fault codes that are not displayed to the driver but are recorded by the EMS. These are all numbered 200 or above regardless of the letter prefix. For example, codes D224 - D236 and T230 are used for datalogging purposes but are not displayed to the driver. this is because these codes represent “abuse” information as opposed to an actual failure of the vehicle electrical system. E.g. If the oil pressure warning lamp is on for more than 10 seconds of engine running, a fault code will be generated inside the EMS for datalogging purposes. The driver does not see this code as it is already supported by the warning lamp. Remember that the codes are historical data and oil levels, etc., may have been corrected since the faults were recorded

The dashboard will then revert back to its normal operation mode.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS

Diagnostic Error Codes - ABS Introduction

Duration of a blink pulse

0.5 seconds

Pause between blink pulses

0.5 seconds

Pause between first block and second block

1.5 seconds

Pause between second block of one 4.5 seconds code and the first block of following code The blink codes are listed alongside the equivalent error code numbers. See ABS Code Tables (X C-98)

Fig 143. When a fault arises in the ABS icon V will glow continually and the fault icon will appear on the touch screen. If the fault icon is pressed the error codes will then be displayed The error codes are in the form of a letter A followed by a number. See ABS Code Tables (X C-98)

To completely erase an existing fault memory, press the diagnostic push button while the ignition switch is being turned ON and for a short period thereafter. Leave the ignition switched On for a further 5 seconds. After erasing the fault memory, the storage of further fault codes in the memory is inhibited. To overcome this inhibition the ignition must be switched OFF and then On again before driving the machine.

Alternatively, or especially if there is a fault in the CANBUS which prevents the error codes from being displayed on the touch screen, the ABS faults can be conveyed in the form of blink codes. The blink codes are displayed in response to pressing the bottom of diagnostic switch A.

Fig 144. The blink codes consist of two numbers. These are displayed by two blink-code blocks. The blocks can be identified as follows (times are approximate):

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ABS Code Tables

Key to abbreviations HLD

Hold

Key to abbreviations

CMN

Solenoid Common

PMV

Pressure Modulating Valve

WSS

Wheel Speed Sensor

REL

Release

Error Code

Blink Code

Description

Possible Cause

Action and Remedy

A0101

1-1

No Faults

System Fully Operational - No Faults Detected

A0201

2-1

Front Left Wheel Speed Sensor Excessive Air Gap

Adjust sensor to contact exciter ring. Wheel speed sensor has been knocked back Rotate wheel and verify a min. of 0.25 VAC sensor output @ ~ 0.5 RPS. away from the exciter ring teeth. – Verify condition of sensor head. – Verify mounting of exciter ring and condition of teeth. – Verify proper bearing end-play. – Verify condition and retention of clamping sleeve. – Verify sensor lead routing and clamping.

A0202

2-2

Front Left Wheel Speed Sensor Output Low at Drive-Off

– Damaged Sensor. – Sensor to pole wheel air gap too large. – Damaged wiring.

Adjust sensor to contact exciter ring. Rotate wheel and verify a min. of 0.25 VAC sensor output @ ~ 0.5 RPS. – Verify condition of sensor head. – Verify mounting of exciter ring and condition of teeth. – Verify proper bearing end-play. – Verify condition and retention of clamping sleeve. – Verify sensor lead routing and clamping.

A0203

2-3

Front Left Hand Wheel Speed Sensor Open or Shorted

– Damaged Sensor. – Damaged wiring.

– Verify 1500 – 2500 ohms across sensor leads (with sensors at room temperature). – Verify no continuity between sensor leads and ground or voltage. – Verify no continuity between sensor leads and other sensors. – Check for corroded/damaged wiring or connectors between the ECU and the WSS.

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Blink Code

A0204

2-4

Description Front Left Hand Wheel Sensor Loss of Sensor Signal

Possible Cause – Damaged Sensor. – Damaged wiring.

Action and Remedy Adjust sensor to contact exciter ring. Rotate wheel and verify a min. of 0.25 VAC sensor output @ ~ 0.5 RPS. – Verify condition of sensor head. – Verify mounting of exciter ring and condition of teeth. – Verify proper bearing end-play. – Verify condition and retention of clamping sleeve. – Verify sensor lead routing and clamping. – Check for corroded/damaged wiring or connectors between the ECU and the WSS.

A0205

2-5

Front Left Hand Wheel End Fault

– Damaged sensor exciter ring.

– Verify mounting of exciter ring and condition of teeth.

– Damaged wiring.

– Verify proper bearing end-play.

– Kinked or restricted air lines.

– Verify condition and retention of clamping sleeve.

– Faulty wheel bearings.

– Verify sensor lead routing and clamping. – Check mechanical function of brake. – Check for kinked or restricted air lines.

A0206

2-6

Front Left Wheel Speed Sensor Erratic Signal

– Damaged wheel speed sensor exciter ring.

Adjust sensor to contact exciter ring. Rotate wheel and verify a min. of 0.25 VAC sensor output @ ~ 0.5 RPS.

– Damaged wheel speed sensor.

– Verify condition of sensor head.

– Wheel speed sensor knocked back from exciter ring.

– Verify proper bearing end-play.

– Damaged wiring or connectors.

– Verify mounting of exciter ring and condition of teeth. – Verify condition and retention of clamping sleeve. – Verify sensor lead routing and clamping. – Check for corroded/damaged wiring or connectors between the ECU and the WSS.

– Faulty wheel bearings.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS Error Code

Blink Code

A0207

2-7

Description Front Left Wheel Speed Sensor Tyre Size Calibration

Possible Cause – Wrong size tyres fitted. – Incorrect tyre pressure. – Wrong exciter ring fitted.

Action and Remedy – Verify correct tyre size as desired. – Verify proper tyre inflation. – Verify correct number of exciter ring teeth. – Verify that the ECU has the proper tyre size settings.

– Incorrect tyre size entered into ECU. A0301

3-1

Front Right Wheel Speed Sensor Excessive Air Gap

– Damaged Sensor. – Sensor to pole wheel air gap too large. – Damaged wiring.

A0302

3-2

Front Right Wheel Speed Sensor Output Low at Drive-Off

– Damaged Sensor. – Sensor to pole wheel air gap too large. – Damaged wiring.

A0303

3-3

Front Right Hand Wheel Speed Sensor Open or Shorted

– Damaged Sensor. – Damaged wiring.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS Error Code

Blink Code

A0304

3-4

Description Front Right Hand Wheel Sensor Loss of Sensor Signal

Possible Cause – Damaged Sensor. – Damaged wiring.

A0305

3-5

Front Right Hand Wheel End Fault

– Damaged sensor exciter ring.

– Verify mounting of exciter ring and condition of teeth.

– Damaged wiring.

– Verify proper bearing end-play.

– Kinked or restricted air lines.

– Verify condition and retention of clamping sleeve.

– Faulty wheel bearings.

– Verify sensor lead routing and clamping. – Check mechanical function of brake. – Check for kinked or restricted air lines.

A0306

3-6

Front Right Wheel Speed Sensor Erratic Signal

– Damaged wheel speed sensor exciter ring.

Adjust sensor to contact exciter ring. Rotate wheel and verify a min. of 0.25 VAC sensor output @ ~ 0.5 RPS.

– Damaged wheel speed sensor.

– Verify condition of sensor head.

– Wheel speed sensor knocked back from exciter ring.

– Verify proper bearing end-play.

– Damaged wiring or connectors.

– Faulty wheel bearings.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS Error Code

Blink Code

A0307

3-7

Description Front Right Wheel Speed Sensor Tyre Size Calibration

Possible Cause – Wrong size tyres fitted. – Incorrect tyre pressure. – Wrong exciter ring fitted.

– Incorrect tyre size entered into ECU. A0401

4-1

Rear Left Wheel Speed Sensor Excessive Air Gap

– Damaged Sensor. – Sensor to pole wheel air gap too large. – Damaged wiring.

A0402

4-2

Rear Left Wheel Speed Sensor Output Low at Drive-Off

– Damaged Sensor. – Sensor to pole wheel air gap too large. – Damaged wiring.

A0403

4-3

Rear Left Hand Wheel Speed Sensor Open or Shorted

– Damaged Sensor. – Damaged wiring.

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Blink Code

A0404

4-4

Description Rear Left Hand Wheel Sensor Loss of Sensor Signal

Possible Cause – Damaged Sensor. – Damaged wiring.

A0405

4-5

Rear Left Hand Wheel End Fault

– Damaged sensor exciter ring.

– Verify mounting of exciter ring and condition of teeth.

– Damaged wiring.

– Verify proper bearing end-play.

– Kinked or restricted air lines.

– Verify condition and retention of clamping sleeve.

– Faulty wheel bearings.

– Verify sensor lead routing and clamping. – Check mechanical function of brake. – Check for kinked or restricted air lines.

A0406

4-6

Rear Left Wheel Speed Sensor Erratic Signal

– Damaged wheel speed sensor exciter ring.

Adjust sensor to contact exciter ring. Rotate wheel and verify a min. of 0.25 VAC sensor output @ ~ 0.5 RPS.

– Damaged wheel speed sensor.

– Verify condition of sensor head.

– Wheel speed sensor knocked back from exciter ring.

– Verify proper bearing end-play.

– Damaged wiring or connectors.

– Faulty wheel bearings.

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Blink Code

A0407

4-7

Description Rear Left Wheel Speed Sensor Tyre Size Calibration

Possible Cause – Wrong size tyres fitted. – Incorrect tyre pressure. – Wrong exciter ring fitted.

– Incorrect tyre size entered into ECU. A0501

5-1

Rear Right Wheel Speed Sensor Excessive Air Gap

– Damaged Sensor. – Sensor to pole wheel air gap too large. – Damaged wiring.

A0502

5-2

Rear Right Wheel Speed Sensor Output Low at Drive-Off

– Damaged Sensor. – Sensor to pole wheel air gap too large. – Damaged wiring.

A0503

5-3

Rear Right Hand Wheel Speed Sensor Open or Shorted

– Damaged Sensor. – Damaged wiring.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS Error Code

Blink Code

A0504

5-4

Description Rear Right Hand Wheel Sensor Loss of Sensor Signal

Possible Cause – Damaged Sensor. – Damaged wiring.

A0505

5-5

Rear Right Hand Wheel End Fault

– Damaged sensor exciter ring.

– Verify mounting of exciter ring and condition of teeth.

– Damaged wiring.

– Verify proper bearing end-play.

– Kinked or restricted air lines.

– Verify condition and retention of clamping sleeve.

– Faulty wheel bearings.

– Verify sensor lead routing and clamping. – Check mechanical function of brake. – Check for kinked or restricted air lines.

A0506

5-6

Rear Right Wheel Speed Sensor Erratic Signal

– Damaged wheel speed sensor exciter ring.

Adjust sensor to contact exciter ring. Rotate wheel and verify a min. of 0.25 VAC sensor output @ ~ 0.5 RPS.

– Damaged wheel speed sensor.

– Verify condition of sensor head.

– Wheel speed sensor knocked back from exciter ring.

– Verify proper bearing end-play.

– Damaged wiring or connectors.

– Faulty wheel bearings.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS Error Code

Blink Code

A0507

5-7

Description Rear Right Wheel Speed Sensor Tyre Size Calibration

Possible Cause – Wrong size tyres fitted. – Incorrect tyre pressure. – Wrong exciter ring fitted.

– Incorrect tyre size entered into ECU. A0601

A0602

6-1

6-2

Battery Voltage Too Low as measured by the ABS ECU.

Battery Voltage Too High as measured by the ABS ECU

– Faulty battery.

– Measure battery voltage under load.

– Alternator not charging

– Check vehicle battery and associated components.

– Fault y supply wiring to the ABS ECU.

– Check for damaged wiring.

– Faulty battery.

– Measure battery voltage.

– Alternator over charging

– Ensure that battery voltage is correct for the model of ECU.

– Fault y supply wiring to the ABS ECU.

– Check vehicle battery and associated components.

– Check for damaged or corroded connectors and connections.

– Check for damaged wiring. – Check for damaged or corroded connectors and connections.

A0603

A0604

6-3

6-4

Battery Voltage Too Low During ABS as measured by the ABS ECU.

Battery Voltage Input Open Circuit

– Faulty battery.

– Measure battery voltage under load.

– Alternator under charging

– Check vehicle battery and associated components.

– Fault y supply wiring to the ABS ECU.

– Check for damaged wiring.

– Fault supply wiring to the ABS ECU.

– Measure battery voltage under load.

– Failed fuse.

– Check vehicle battery and associated components.

– Check for damaged or corroded connectors and connections. – Check condition of fuse.

– Check for damaged wiring. – Check for damaged or corroded connectors and connections.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS Error Code

Blink Code

A0605

6-5

Description Ignition Voltage Too Low

Possible Cause – Fault supply wiring to the ABS ECU. – Failed fuse.

Action and Remedy – Measure ignition voltage under load. – Check vehicle battery and associated components. – Check for damaged wiring. – Check for damaged or corroded connectors and connections. – Check condition of fuse.

A0606

6-6

Ignition Voltage Too High

Faulty supply wiring to the ABS ECU.

– Measure ignition voltage. – Ensure that ignition voltage is correct for the model of ECU. – Check vehicle battery and associated components. – Check for damaged wiring. – Check for damaged or corroded connectors and connections.

A0607

6-7

Ignition Voltage Too Low During ABS

– Faulty supply wiring to the ABS ECU. – Faulty battery. – Faulty alternator.

A0608

A0609

6-8

6-9

Input Voltage Has Excessive Noise (Temporary)

Faulty alternator.

Input Voltage Has Excessive Noise

Faulty alternator.

– Measure ignition voltage under load. – Check vehicle battery and associated components. – Check for damaged wiring. – Check for damaged or corroded connectors and connections. – Check alternator output for excessive noise. – Check for other devices causing excessive noise. – Check alternator output for excessive noise. – Check for other devices causing excessive noise.

A0701

7-1

Front Left PMV REL Solenoid Shorted to Ground

Faulty wiring.

– Verify no continuity between PMV leads and ground. – Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

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Blink Code

A0702

7-2

Description Front Axle Left Hand PMV (Pressure Modulating Valve) REL (Release) Solenoid Shorted to Voltage

Possible Cause Faulty wiring.

Action and Remedy – Verify no continuity between PMV leads and voltage. – Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0703

7-3

Front Axle Left PMV REL Solenoid Open Circuit

Faulty wiring.

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0704

7-4

Front Axle Left Hand PMV HLD Solenoid Shorted to Ground

Faulty wiring.

– Verify no continuity between PMV leads and voltage. – Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0705

7-5

Front Axle Left PMV HLD Solenoid Shorted to Voltage

Faulty wiring.

A0706

7-6

Front Axle Left Hand PMV Faulty wiring. HLD Solenoid Open Circuit

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0707

7-7

Front Axle Left Hand PMV CMN Open Circuit

Faulty wiring.

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0708

7-8

Front Axle Left Hand PMV Configuration Error

Faulty installation or configuration.

A mis-match exists between the ECU configuration and the modulator installation and wiring. – Verify PMV wiring and installation. – Verify ECU configuration.

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Blink Code

A0801

8-1

Description Front Right PMV REL Solenoid Shorted to Ground

Possible Cause Faulty wiring.

Action and Remedy – Verify no continuity between PMV leads and ground. – Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0802

8-2

Front Axle Right PMV REL Faulty wiring. Solenoid Shorted to Voltage

A0803

8-3

Front Axle Right PMV REL Faulty wiring. Solenoid Open Circuit.

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0804

8-4

Front Axle Right Hand PMV Faulty wiring. HLD Solenoid Shorted to Ground.

A0805

8-5

Front Axle Right Hand PMV Faulty wiring. HLD Solenoid Shorted to Voltage

A0806

8-6

Front Axle Right Hand PMV Faulty wiring. HLD Solenoid Open Circuit.

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

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Section C - Electrics Diagnostic Error Codes Diagnostic Error Codes - ABS Error Code

Blink Code

A0807

8-7

Description

Possible Cause

Front Axle Right Hand PMV Faulty wiring. CMN Open Circuit

Action and Remedy – Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0808

8-8

Front Axle Right Hand PMV Faulty installation or Configuration Error configuration.

A mis-match exists between the ECU configuration and the modulator installation and wiring. – Verify PMV wiring and installation. – Verify ECU configuration.

A0901

9-1

Rear Left PMV REL Solenoid Shorted to Ground

Faulty wiring.

A0902

9-2

Rear Axle Left Hand PMV REL Solenoid Shorted to Voltage

Faulty wiring.

A0903

9-3

Rear Axle Left PMV REL Solenoid Open Circuit.

Faulty wiring

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0904

9-4

Rear Axle Left Hand PMV HLD Solenoid Shorted to Ground

Faulty wiring.

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Blink Code

A0905

9-5

Description Rear Axle Left Hand PMV HLD Solenoid Shorted to Voltage

Possible Cause Faulty wiring.

A0906

9-6

Rear Axle Left Hand PMV Faulty wiring. HLD Solenoid Open Circuit

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0907

9-7

Rear Axle Left Hand PMV CMN Open Circuit

Faulty wiring.

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A0908

9-8

Rear Axle Left Hand PMV Configuration Error

Faulty installation or configuration.

A mis-match exists between the ECU configuration and the modulator installation and wiring. – Verify PMV wiring and installation. – Verify ECU configuration.

A1001

10-1

Rear Right PMV REL Solenoid Shorted to Ground

Faulty wiring.

A1002

10-2

Rear Axle Right Hand PMV Faulty wiring. REL Solenoid Shorted to Voltage

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Blink Code

Description

A1003

10-3

Rear Axle Right PMV REL Solenoid Open Circuit.

Possible Cause Faulty wiring.

Action and Remedy – Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A1004

10-4

Rear Axle Right Hand PMV Faulty wiring. HLD Solenoid Shorted to Ground.

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A1005

10-5

Rear Axle Right Hand PMV Faulty wiring. HLD Solenoid Shorted to Voltage.

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A1006

10-6

Rear Axle Right Hand PMV Faulty wiring. HLD Solenoid Open Circuit

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A1007

10-7

Rear Axle Right Hand PMV Faulty wiring. CMN Open Circuit

– Verify 4.9 to 5.5 ohms from REL to CMN & HLD to CMN, and 9.8 to 11 ohms from REL to HLD1. – Check for corroded/damaged wiring or connectors between the ECU and PMV.

A1008

10-8

Rear Axle Right Hand PMV Faulty installation or Configuration Error configuration.

A mis-match exists between the ECU configuration and the modulator installation and wiring. – Verify PMV wiring and installation. – Verify ECU configuration.

A1101

11-1

J1939 Serial Link

Faulty wiring or ECU

Loss of communications between the EC-60 and other devices connected to the J1939 link. – Check for damaged or reversed J1939 wiring. – Check for corroded or damaged connectors. – Verify ECU configuration. – Check for other devices inhibiting J1939 communications.

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Blink Code

A1102

11-2

Description J1939 Retarder

Possible Cause Faulty wiring or ECU

Action and Remedy Loss of communications between the EC-60 and a retarder over the J1939 link. – Check for damaged or reversed J1939 wiring. – Check for corroded or damaged connectors. – Verify presence of retarder on the J1939 link. – Verify ECU configuration. – Check for other devices inhibiting J1939 communications.

A1103

11-3

J1939 Engine Communications

Faulty wiring or ECU

Loss of communications between the EC-60 and a retarder over the J1939 link. – Check for damaged or reversed J1939 wiring. – Check for corroded or damaged connectors. – Verify presence of retarder on the J1939 link. – Verify ECU configuration. – Check for other devices inhibiting J1939 communications.

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Blink Code

A1201

12-1

Description Stop Lamp Switch Not Detected

Possible Cause Faulty wiring or switch.

Action and Remedy ECU has not detected the presence of the stop lamp switch since ignition power was applied (note that stop lamp switch input may be applied to the EC-60 using either hardwire input or J1939). – Apply and release service brake. – Check for brake switch input into ECU (see system wiring schematic). – With service brake released, check for presence of the stop lamp bulb. – Check for damaged wiring between ECU, stop lamp switch and bulb. – With service brake applied, verify system voltage is now present at the stop lamp switch input to the ECU. – Check for corroded or damaged connectors. – Check for damaged or reversed J1939 wiring. – Check for corroded or damaged connectors on J1939 link. – Verify presence of engine ECU on the J1939 link. – Verify ECU configuration.

A1202

12-2

Stop Lamp Switch Defective

Faulty wiring or switch.

– Apply and release service brake. – Check for brake switch input into ECU (see system wiring schematic). – With service brake released, check for presence of the stop lamp bulb. – With service brake applied, verify system voltage is now present at the stop lamp switch input to the ECU. – Check for damaged wiring between ECU, stop lamp switch and bulb. – Check for corroded or damaged connectors. – Check for damaged or reversed J1939 wiring. – Check for corroded or damaged connectors on J1939 link. – Verify presence of engine ECU on the J1939 link. – Verify ECU configuration.

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Blink Code

Description

Possible Cause

Action and Remedy

A1203

12-3

Dynamometer Test Mode

ECU has been placed in Remove and re-apply ignition power.. the Dynamometer Test Mode by either the diagnostic blink code switch or an offboard diagnostic tool. ATC is disabled.

A1204

12-4

Retarder Relay Open Circuit or Shorted to ground.

Faulty ECU configuration.

– Verify vehicle contains a retarder relay. – Verify ECU configuration. – Check wiring between ECU and retarder relay. – Verify no continuity between retarder disable output of EC-60 and ground. – Verify condition and wiring of the retarder relay.

A1205

12-5

Retarder Relay Circuit Shorted to Voltage

Faulty ECU configuration.

– Check wiring between ECU and retarder relay. – Verify no continuity between retarder disable output of EC-60 and voltage. – Verify condition and wiring of the retarder relay.

A1206

12-6

ABS Warning Lamp Circuit Faulty wiring Fault.

– Check operation of diagnostic blink code switch. – Check wiring of diagnostic blink code switch, ABS WL, and ABS WL relay (frame ECUs only). – Verify ABS WL ground input (cab ECUs only)

A9999

Wheel Speed Sensor Tyre Size Calibration Fault

– Wrong size tyres fitted. – Incorrect tyre pressure – Wrong exciter ring fitted

– Verify correct tyre size as desired – Verify proper tyre inflation – Verify correct number of exciter ring teeth – Verify that the ECU has the proper tyre size settings.

– Incorrect tyre size entered into ECU

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Codes Prefixed C to Z

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

C0000 No CAN alive messages from the Central Controller ECU arriving at the instrument cluster

Power supply to engine ECU failed. Open circuit in CAN Bus wiring. Short circuit in CAN Bus wiring. Faulty resistor in CAN Bus wiring diagram. Central Controller ECU faulty.

Check fuse and power supply. Check connections. Check integrity of insulation with multimeter. Check CAN Bus resistors; refer to wiring. Change Central Controller ECU.

C0080 Resistive pull-down driver open circuit, check only when Low torque curve is selected

Damaged wiring, connectors or resistor.

Check continuity of wiring between Central Controller and Engine ECU. Check resistor is 1500 ohms.

C0081 Ground pull-down driver open circuit, check only when Low torque curve is selected

Damaged wiring or connectors.

Check continuity of wiring between Central Controller and Engine ECU.

Damaged wiring or connectors. C0090 Fan override driver open circuit, check only when fan is in override mode

Check continuity of wiring between Central Controller and Engine ECU.

C0100 Flow divider valve driver open circuit

Internal breakdown of flow divider valve driver. Damaged wiring.

Check flow divider valve driver for continuity. Check continuity of wiring from flow divider valve driver to both Central Controller ECU and earth; refer to wiring diagram.

C0101 Flow divider valve driver over temperature or over current

Caused by abnormally high current drawn from Central Controller ECU (the driver is inside the ECU and is not serviceable). Flow divider valve driver faulty internally. Damaged wiring.

Check flow divider valve driver resistance, which should be approximately 5 Ohms. Check for short circuit to earth in wiring between flow divider valve driver and Central Controller ECU.

C0120 Supply voltage too low (less that 9.0 volts)

Alternator not charging. Damaged wiring or faulty batteries.

Measure voltage at battery to determine if the fault is Central Controller specific.

C0121 Supply voltage too high (more that 16.0 volts)

Alternator over-charging or machine has been connected to 24V system.

Measure voltage at battery to determine if the fault is Central Controller specific.

C0122 Sensor reference voltage too low (less than 4.60 volts)

Wiring shorted to ground or excessive electrical load.

Check continuity of wiring. Check for damage to wiring. Check for short to earth.

C0123 Sensor reference voltage too high (more than 5.40 volts)

Wiring shorted to 12V.

Check continuity of wiring. Check for damage to wiring. Check for short to 12V.

C0124 Front hitch control panel off line

– Faulty 12 volt supply to front hitch control panel failed. – Poor earth connection between the control panel – CanBus lead fault

– Check the 12 volt fused supply to the Front Hitch Operator control panel connector pin 1. – Check the earth connection to the control panel connector pin 4. – Check the CANBus wires are properly connected to the Front Hitch control panel pins 2 and 3.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

C0129 Pilot valve driver open circuit

Internal breakdown of pilot valve driver. Damaged wiring.

The valve block uses a pilot valve to control a low pressure feed to the valve slice. Check the pilot valve’s internal resistance. Check continuity of signal and earth wiring.

C0130 Pilot valve driver open circuit

Internal breakdown of pilot valve driver. Damaged wiring.

Check pilot valve driver for continuity. Check continuity of wiring from pilot valve driver to both Central Controller ECU and earth; refer to wiring diagram.

C0131 Pilot valve driver short circuit or over temperature

Caused by abnormally high current drawn from Central Controller ECU (the driver is inside the ECU and is not serviceable). Pilot valve driver faulty internally. Damaged wiring.

Check pilot valve driver resistance, which should be approximately 5 Ohms. Check for short circuit to earth in wiring between pilot valve driver and Central Controller ECU.

C0150 Spool valve Inlet Pressure Sensor open circuit.

– Open signal circuit between sensor and Fastrac Central Controller (ECU 1) pin C11. – Faulty 12 volt sensor supply.

– Inlet pressure to the spool valve block is monitored using a pressure sensor. This is used for: Spool valve kick-out. To ensure an adequate minimum pilot valve inlet pressure is maintained. – Measure the 12 volt supply to the sensor. – Measure the resistance of the sensor signal lead is less than 10 ohms.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

C0151 Inlet pressure sensor output low.

Possible Cause – Low oil pressure. – Accidental short in signal lead. – Faulty pressure sensor. – 12 volt sensor supply low.

Action and Remedy – Inlet pressure to the spool valve block is monitored using a pressure sensor. This is used for: Spool valve kick-out. To ensure an adequate minimum pilot valve inlet pressure is maintained. – Measure the oil pressure at the valve block test point. Compare the value with the displayed value from the sensor off the diagnostic program. If the pressure is low then investigate the reason for this. – With no load on the system the spool pilot valve should create about 20 bar circuit pressure. – Disconnect the ECU connector and unplug the Pressure sensor. Inspect the connectors for damage or corrosion. – Check that the signal lead connecting the sensor to Fastrac Central Controller pin C11 is not shorting to earth. – Measure the resistance between both ends of the signal lead and check it is less than 5 ohms. A high resistance might cause the signal voltage to drop. – Measure the 12 volt sensor supply.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

C0152 Inlet pressure sensor output high.

Possible Cause – High oil pressure. – Sensor signal lead shorting to a high voltage. – Faulty pressure sensor.

Action and Remedy – Inlet pressure to the spool valve block is monitored using a pressure sensor. This is used for: Spool valve kick-out. To ensure an adequate minimum pilot valve inlet pressure is maintained. – Measure the oil pressure at the valve block test point. Compare the value with the displayed value from the sensor off the diagnostic program. If the pressure is significantly above 20 bar pressure with no circuit load or above 210 bar with a spool dead-ended, then investigate the reason for this. – If the measured pressure is lower than the sensor’s value then check for an electrical fault. – Disconnect the pressure sensor and Fastrac Central Controller ECU connector. Test for a short to a high source by measuring resistance between the lead and the battery + terminal. – Note that certain leads only carry voltage when the ignition is switched ‘On’.

C0199 ECU1 loaded at least one EEPROM default value during ‘Power Up’.

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Incorrect calibration or faulty ECU1 Calibrate / Reprogram ECU1. memory. Contact JCB Landpower for advice.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

C0200 At least one EEPROM default value loaded on power up.

Possible Cause Caused by incorrect calibration or faulty memory.

Action and Remedy Run through calibration procedure. If problem persists replace ECU.

Contact JCB Landpower. C0202 Software fault - Event stack The software event stack overflow error. mechanism has overflowed making correct operation uncertain. This should never happen. D0001 EMS ROM memory error

EMS internal fault.There are no serviceable parts inside the EMS

D0002 EMS memory error

May occur once after updating EMS Contact JCB Landpower to change the EMS if software or setup values. EMS the problem persists. internal fault.

D0003 EMS CAN BUS has switched off due to error

EMS has detected a problem with the CAN Bus link.

Check CAN Bus link for short or open circuit.

D0004 EMS executed COP watchdog reset

Internal fault detected by the internal monitoring system. There are no serviceable parts inside the EMS.

If the problem persists contact JCB Landpower and replace the EMS.

D0005 EMS Application ROM memory Error.

EMS internal fault. There are no serviceable parts inside the EMS.

Replace the EMS if problem persists.

D0006 EMS ROM memory Error.

EMS internal fault. There are no serviceable parts inside the EMS.

Replace the EMS if problem persists.

D0042 Over voltage detected (greater than 16V)

Faulty alternator/voltage regulator. Jump start attempted from 24V battery.

Check supply voltage. Only use 12V battery for jump start. Continuous fused 12 volt supply is to Red Connector pin R33. Switched 12 volt supply is from the ignition, through a fuse to Red Connector pin R34.

D0224 Engine Oil Pressure

Low engine oil pressure. Faulty engine oil pressure switch. Damaged wiring.

Check engine oil pressure; refer to engine service manual for causes of low oil pressure. Check pressure switch for correct operation. Check integrity of wiring from switch to EMS.

D0227 Air Filter Blocked

Blockage in air filter. Faulty blockage switch. Damaged wiring.

Change the outer air filter and also the inner filter if required; see Changing the Air Filter Elements in Section 3. Check pressure switch for correct operation. Check integrity of wiring from switch to EMS.

D0228 Trailer ABS fault

Signal from trailer ABS system.

Investigate trailer system.

D0229 Alternator â&#x20AC;&#x153;no chargeâ&#x20AC;? warning

Slack or worn alternator drive belts. Check alternator drive belt tension and Internal alternator fault. condition. See Fan Belt, Section 3. Check alternator output and operation.

D0230 Brake fluid level

Low brake fluid in one or both actuator reservoirs. Faulty fluid level switch.

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Reprogram EMS using updated software. Contact JCB Landpower to change the EMS if the problem persists.

Check level of fluid on both brake fluid reservoirs. Check operation of switches by pressing test buttons on switch body.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

D0231 Air tank 1 pressure low

Low pressure in air tank. Faulty air pressure switch. Air tank not charging. Damaged wiring.

Check for leaks, etc. Check air pressure switch for correct operation and function. Check operation of circuit protection valve. Check integrity of wiring from switch to EMS.

D0232 Air tank 2 pressure low

Low pressure in air tank. Faulty air pressure switch. Air tank not charging. Damaged wiring.

Check for leaks, etc. Check air pressure switch for correct operation and function. Check operation of circuit protection valve. Check integrity of wiring from switch to EMS.

D0233 Air tank 3 pressure low

Low pressure in air tank. Faulty air pressure switch. Air tank not charging. Damaged wiring.

Check for leaks, etc. Check air pressure switch for correct operation and function. Check operation of circuit protection valve. Check integrity of wiring from switch to EMS.

D0234 Handbrake on when Driving before handbrake is moving. The fault will be released. Faulty air pressure logged when the vehicle switch. Damaged wiring. has been moving at >3 kph for 10 seconds and the handbrake is on.

Check air pressure switch for correct operation and function. Check integrity of wiring from switch to EMS.

D0236 Radar speed signal inconsistent with gearbox speed

The ‘radar present’ signal is detected at EMS pin R25 but the radar speed signal received at EMS pin R7 is zero despite the gearbox speed being between 5kph and 20kph.This may be due to excess wheel slip, faulty wiring or a faulty radar unit.

This speed signal is shared with EHR Draft Controller – fault code R0401 may also be active if no speed signal is detected.

EMS has detected a problem with the CAN Bus link.

Check the EMS is correctly connected to the CanBus.

D0240 EMS CAN Bus has reset due to error.

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Check wiring for continuity between radar signal pin and EMS pin R25.

Check radar unit.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

Action and Remedy

G0001

Emergency Mode / Auxiliary Mode / Limp Home.

Indicates that the transmission has This could be because the driver activated this entered emergency mode. mode.

G0002

Handbrake On When Moving Warning.

The Handbrake has been applied Code logged for information. Machine should and the speed is above 0.1kph not be driven with the park brake engaged. there is a delay of 1.5s before this occurs.

G0003

High Pressure Sensor Fault.

– Fuse blown in sensor supply line. – Damaged wiring on Supply or Earth. – Damaged wiring on Signal line.

– Check supply fuse. – Check the sensor operation using JCB Service Master diagnostics. – Consult Transmission High Pressure Sensor to check the sensor and related wiring.

– Faulty sensor. G0004

Transmission Range I/II Sensor Fault.

Faulty sensor or wiring.

– Check the 8.5 volt supply wiring is OK. – Check the earth connection to battery negative (-) terminal is satisfactory. – Check the sensor by measuring the current drawn by the sensor supply lead. – Current range should be between 2mA and 22mA depending on oil pressure. 0 Bar pressure should equate to approx. 4mA current. Values outside this range indicate an internal sensor fault has been detected.

G0005 G0006

Oil Filter Blocked sensor fault. Park Brake: Fault.

– Wiring fault to sensor. – Faulty Sensor. – Faulty wiring to the switch – Faulty Switch

G0007

Fault with Reference Signal from Transmission Actuator.

– Damaged wiring. – Faulty Transmission Actuator.

G0008

Crown Wheel Direction Sensor Fault.

Faulty sensor or wiring.

G0009

Range Change request.

Wiring fault between DECU and “range change request button.

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Rectify Fault.

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Check the switch operation using JCB Service Master diagnostics “Brakes”- “limp Home, Brakes & Steering”. Check signal wiring from Actuator pin 3 to EST pin 19.

Check the switch operation using JCB Service Master diagnostics “Transmission controls”.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

Action and Remedy

G0010

Temperature Sensor Fault.

– Fault logged when temperature sender reaches 110oc.

– Check the sensor operation using JCB Service Master diagnostics “Transmission”- “Transmission Management”

– Possible Fault with transmission. – Wiring fault causing low resistance between signal and earth. G0011

Hydrostat speed / direction sensor direction signal fault.

– Investigate cause of transmission overheat. – Check Sensor operation. – Check sensor wiring.

– Sensor supply failure.

– Check supply fuse J9

– Wiring fault.

– Check the sensor operation using JCB Service Master diagnostics “Transmission”- “Transmission Management”.

– Faulty Sensor

– Check harness wiring: refer to (further information). G0012

Hydrostat speed / direction sensor Speed signal Fault.

– Faulty wiring

– Check supply fuse J9.

– Faulty sensor

– Check the sensor operation using JCB Service Master diagnostics “Transmission”- “Transmission Management”. – Check harness wiring: refer to “further information”.

G0013

Engine Speed Sensor Fault.

– Damaged wiring. – Faulty sensor.

Check wiring and sensor mounting, see further information about this sensor for how to test.

– Faulty sensor mounting. G0014

Crown Wheel output speed sensor fault.

– Sensor supply failure.

– Check supply fuse J9

– Wiring fault.

– Check the sensor operation using JCB Service Master diagnostics “Transmission”- “Transmission Management”.

– Faulty Sensor.

– Check harness wiring: refer to (further information). G0015

Oil filter blocked. Just a warning but error code stored.

G0016

Transmission Temperature above 110°C.

Filter Blocked.

Replace filter.

– Faulty sensor. – Faulty wiring. – Blocked oil cooler.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

G0017

Transmission Slip Values: Beyond acceptable limits.

This is indicative of mechanical errors. Depending on Oil temperature, range I / II and driving direction the slippage. (1-(measure ratio / set ratio)) Must not exceed programmable values.

G0018

Auxiliary Operation manually requested

The driver selected auxiliary manual mode.

G0019

Range 1 (Low Range) Solenoid: Activation Fault.

Error is detected if: – Valve is switched off - short circuit to U (bat) detection

Action and Remedy

– Faulty wiring. – Faulty solenoid.

– Valve is active and current <0.75A or short circuit to Ground. G0020

Range 2 (high range) Solenoid: Activation Fault.

Error is detected if: – Valve is switched off - short circuit to U(bat) detection

– Faulty wiring. – Faulty solenoid.

– Valve is active and current <0.75A or short circuit to Ground. G0021

Speed Limit Solenoid: Activation Fault. Maximum speed limited.

– Error is detected if I>1500mA or I<200mA or PWM>96% or PWM<18%. – In normal operation the current is regulated to 800mA.

G0022

Transmission Neutral Solenoid Activation Fault.

Error is detected if: – Valve is switched off - short circuit in wiring. – valve is active and current >3.1A or current does not fit to PWM signal.

G0023

Speed Plausibility Error: Hydrostat speed sensor to Crown Wheel Speed sensor.

Speed indications are not in corresponding direction.

G0024

Direction plausibility Error. Hydrostat direction sensor to Crown Wheel Direction sensor.

Faulty Hydrostat direction sensor, Crown Wheel Direction sensor or the wiring for these sensors.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code G0025

Description Plausibility error between requested CAN commands.

Possible Cause This generally means either:-

Action and Remedy Contact JCB Landpower.

– An ratio request to increase at the same time as a decrease. – An ratio request to increase at the same time as a decrease during a fast reversal. – Software fault.

G0026

Speed Plausibility Error on Engine Speed Sensor.

– Fault with speed sensor signal.

– Check the Engine Speed Sensor used by the Transmission.

– Increase or decrease rate of speed change is outside permitted limits.

– Test signal lead connected to EST pin 12 for shorts to earth, short to a supply voltage or an open circuit. – Test the sensor’s 12 volt power and earth contacts. – Contact JCB Landpower.

G0027

Transmission Control Actuator: Fault.

Actuation fault in Transmission Management EST.

– Tractor can be operated using the manual transmission override. – Monitor Can activity of the EST and Transmission Actuator. – Contact JCB Landpower.

G0028

G0029

Transmission Control Actuator not responding properly.

Transmission Control Actuator: CAN bus fault.

– Actuator shaft has not moved to correct position within 2 seconds.

– Check the rotation of the Actuator shaft manually using the manual override system.

– Mechanical stop preventing the Actuator shaft rotating properly.

– Examine the Actuator motor drive assembly for damage.

Damage to CAN Bus wiring.

– Tractor can be moved using the Manual override system. – Monitor CAN activity using JCB Service Master. – Check the CANBus for faults.

G0030

Transmission Control Actuator. Position Sensor signal not plausible

– Monitor Actuator and Transmission EST activity using JCB Service Master. – Recalibrate the transmission. – Contact JCB Landpower.

G0031

Faulty or missing signal between Transmission Actuator and Transmission EST.

– Damaged wiring. – Internal fault. – CAN Bus fault.

– Check signal lead between Transmission Actuator and Transmission EST. – Monitor CAN activity using JCB Service Master. – Check the CANBus for faults.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code G0032

Description Transmission Control Actuator: Reference not found.

Possible Cause

Action and Remedy

During ignition ‘On’, Transmission Actuator could not locate approximate neutral position.

– The tractor can be operated using the manual override system with the extension bar provided. – Check free movement of the Actuator Shaft.

G0033

Transmission Control Transmission Actuator could not Actuator: Incorrect locate neutral position. Examine reference during operation. Transmission Actuator and all relevant wiring.

G0034

Transmission CanBus initialisation error.

Problem with the CanBus.

– CanBus communication is restricted. Monitor CanBus activity using JCB Service Master of the Transmission EST and Transmission Actuator. – Examine connectors between Transmission EST and Transmission Actuator. – Test the CanBus for faults.

G0035

Transmission Low / High range selection error detected.

– Transmission Range sensor faulty. – Transmission ‘range 1’ or ‘range 2’ solenoid faulty. – Transmission requires calibrating.

G0036

G0037

Fault in Transmission EST EEPROM programming on fast reversal data. Default parameters used.

– Fault programming of Transmission EST.

EEPROM checksum failed on Transmission Engine speed data. data for plausibility check (4.1.85) address 886.

– Engine Speed sensor or wiring to Transmission EST faulty.

– Faulty wiring to Transmission EST.

– Transmission requires calibrating.

G0038

Engine speed exceeds 2900rpm.

G0039

Transmission error relating Should this fault code become to Turbo clutch. Warning active contact JCB Landpower. active if transmission is active (not in Neutral), turbo clutch function is not active and engine speed is less than 500rpm.

G0040

Primary conditions not fulfilled during Transmission calibration.

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Engine speed has exceeded warning limit.

Error during transmission calibration.

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– Check Transmission range sensor. – Using JCB Service Master watch the virtual solenoid switches as Transmission Range 1 solenoid and Transmission Range 2 solenoid are operated. – Recalibrate the Transmission. – Recalibrate Transmission EST. – Monitor all ‘virtual’ switches and values of the EST using JCB Service Master. – Check supply and earth connections. – Monitor Transmission Engine Speed sensor wired to Transmission EST pin 12 using JCB Service Master. Compare the value to other engine speed sensors. – Recalibrate the Transmission. Engine speed is monitored using the Transmission Engine Speed sensor.

Re-calibrate the transmission.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

G0041

Power down fault on Transmission Management ECU (EST). EST has not powered down after Ignition has been switched ‘Off’.

– Relay stuck.

Transmission Actuator Shaft not reaching specified position.

– Actuator shaft jammed.

G0042

Possible Cause

– Damaged connectors or wiring.

– Fault in drive between Actuator Electric Motor and Actuator Shaft.

Action and Remedy – Listen for the relay to audibly click ‘off’ when the ignition is switched ‘Off’. – Check the connectors and wiring from the EST.

– Check the free movement of the manual override bar to manually operate the Actuator shaft. – Examine the drive system for faults. – Check all pins in the Transmission Actuator connector.

G0043

Transmission Actuator Shaft not reaching correct position within 8 seconds.

– Actuator shaft jammed. – Fault in drive between Actuator Electric Motor and Actuator Shaft.

– Check the free movement of the manual override bar to manually operate the Actuator shaft. – Examine the drive system for faults. – Check all pins in the Transmission Actuator connector.

G0044

Transmission cannot identify gearbox neutral position.

The Transmission Actuator locates the neutral position by rotating first one way and then the other. – Step 1: cannot identify from central point to forwards. – Step 2: cannot identify from central point to reverse.

G0045

G0046

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Transmission cannot identify the gearbox neutral position which is midway between forwards and reverse.

– Transmission Management EST and DECU CanBus communication faulty.

Transmission ‘Neutral position’ between Forwards and Reverse are greater than 8° apart.

Upon Ignition ‘On’ and engine Start-up the Transmission Actuator locates the gearbox neutral position. This ‘Neutral position’ exceeds the acceptable 8° shaft rotation limit between forwards and reverse.

– Gearbox neutral position is midway between forwards and reverse. – Check CAN communication between Transmission Management EST and DECU. – Communication fault between Transmission Management EST and Transmission Actuator. See Fault Code G0044.

– Communication fault between Transmission Management EST and Transmission Actuator.

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– Check the link between the Transmission Management EST and Transmission Actuator. Examine the Actuator connector for damage. – Examine the Actuator for signs of damage between the motor and the Actuator shaft.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code G0047

Description Transmission could not locate maximum forward and reverse ratio within acceptable limits.

Possible Cause Check link between Transmission Management EST and Transmission Actuator.

Action and Remedy – Maximum forward ratio should be between 155°and 187° rotation of the Actuator Shaft. – Maximum reverse ratio should be between 136° and 165° rotation of the Actuator Shaft. – Check link between Transmission EST and Transmission Actuator. – Check CAN activity of the DECU, EST and Actuator.

G0048

– Link shaft rotation angle exceeds 155° forwards. Transmission does not react proportionally.

Poor communication between Transmission EST and Transmission Actuator.

– Check link between Transmission EST and Transmission Actuator.

Engaged travel direction and travel direction from gearbox speed sensor signal do not agree.

– Re-calibrate transmission.

– Check CAN activity of the DECU, EST and Actuator.

– Link shaft rotation angle exceeds 135° reverse. Transmission does not react proportionally. G0049

G0050

Transmission ratio is not logical. Transmission Ratio error.

– Wiring fault. – Internal Gearbox fault.

– Check Gearbox Speed Sensor. – Manually override the gearbox, operating the gearbox manually with the provided extension bar. Check for correct gearbox operation. – Check link between Transmission EST and Transmission Actuator. – Check CAN activity of the DECU, EST and Actuator. – Recalibrate the Transmission.

G0051 G0052

Transmission Ratio not logical. – Transmission programming incorrect. – Transmission Management EST values are not logical.

G0053

Refer to fault code G0050.

G0054

Maximum Transmission Ratio cannot be reached. (Forwards or Reverse).

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See fault code G0050. – EST needs reprogramming. – EST wiring faulty. – EST internal fault.

– Check CAN activity of EST, DECU and Transmission Actuator. – Monitor activity of EST sensors and check the supply voltages and earths. – Recalibrate the Transmission.

– Transmission out of calibration. – Speed limiting valve faulty.

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– Recalibrate the Transmission. – Check the Transmission Speed Limiting valve.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

G0055

Transmission EEPROM error - failed ‘Turbo-clutch’.

Possible Cause

Action and Remedy

– Transmission EST has invalid Recalibrate the Transmission EST. clutch values stored. – “Turbo clutch” uses stored default values.

G0056

Transmission Range shift not within tolerance.

– Values for shift between range II (High) to I (Low) outside tolerance.

Recalibrate the Transmission.

– Shifting between ranges will become possible only when stationary. G0057

Incorrect Transmission programming. Unknown tractor type - no default parameters.

Transmission EST internal fault.

– Continuation in ‘Emergency Mode’ possible. – Recalibrate Transmission and select correct tractor type. – Contact JCB Landpower.

G0058

– EEPROM checksum Values out of calibration. failed on Transmission range Low / high. – Range function disabled.

– Recalibrate the Transmission – Check for other active fault codes relating to Range I or Range II solenoid. Examine connectors and wiring to solenoids. – Contact JCB Landpower.

G0059

Accelerator pedal to Transmission calibration error. Should not occur disabled in software.

Contact JCB Landpower.

G0060

Clutch pedal to Transmission calibration error. Should not occur disabled in software.

Contact JCB Landpower.

G0061

Transmission calibration data error. EST enters emergency mode.

G0062

Transmission Calibration error with Neutral / “Turbo Clutch”.

G0063

Transmission is in active standstill.

G0064

Transmission Temperature exceeds 95 °C.

Transmission not calibrated or values drifted.

Recalibrate the Transmission.

– Recalibrate the Transmission. – Contact JCB Landpower. Transmission is in Emergency Mode. – Faulty Transmission Temperature sensor. – Transmission fault.

Recalibrate the Transmission. – Using JCB Service Master monitor the Transmission Oil temperature to check if the temperature values appear logical, e.g. temperature when cold. – Compare the Oil Temperature sensor’s internal resistance to those specified. – Beware of causing damage to the Transmission if Oil Temperature is excessive.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

G0065

Temperature exceeds 105 °C.

Possible Cause – Faulty Transmission Temperature sensor or damaged wiring. – Transmission fault.

Action and Remedy – Using JCB Service Master monitor the Transmission Oil temperature to check if the temperature values appear logical, e.g. temperature when cold. – Compare the Oil Temperature sensor’s internal resistance to those specified. – Look for fault code being active which might indicate a reason for high transmission oil temperature. G0064 also relates to high transmission temperature. – Beware of causing damage to the Transmission if Oil Temperature is excessive.

G0066

Warning: Transmission is in Transmission is in ‘Neutral’ rather an intermediate position. than Range I or II.

G0067

Transmission EST programming error.

G0068

4WD Solenoid fault. 4WD will be engaged permanently.

No application task running: missing or incorrect ECU programming. – Faulty wiring between Transmission EST pin 64 and 4wd solenoid. – Faulty 4wd Solenoid.

– Select Range I or II. – Recalibrate the Transmission. Recalibrate the Transmission.

– Check wiring between EST pin 64 and the 4wd solenoid. – With 2wd selected, EST pin 64 should direct 12 volts to the solenoid pin 1 to allow oil pressure to disengage the 4wd clutch. – Check solenoid Coil resistance is 2.1Ω. – Check the connection between solenoid pin 2 and the battery negative (-) terminal.

G0069

Diff Lock Solenoid Fault. Diff Lock cannot be engaged.

– Faulty wiring between Transmission EST pin 63 and Diff-Lock solenoid. – Faulty Diff-Lock Solenoid.

– Check wiring between EST pin 63 and the solenoid. – With Diff-Lock selected, EST pin 63 should direct 12 volts to the solenoid pin 1 to allow oil pressure to engage the DiffLock clutch. – Check the solenoid’s internal resistance is 2.1Ω.

G0070

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Transmission programming/data error.

Internal Transmission EST fault: EPROM / FLASH checksum / RAM / watchdog error.

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– Recalibrate the Transmission. – Contact JCB Landpower for further information.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

G0071

Rear PTO Clutch Solenoid Fault.

Possible Cause – Fault with solenoid connectors or wiring. – Faulty solenoid.

Action and Remedy – Test the solenoid for internal faults. – Measure the 12 volt supply from Transmission EST pin 47 to the Solenoid connector pin 1. – Check the earth contact of the solenoid when the Transport Switch is engaged. (Refer to PTO Solenoid).

G0072

Rear PTO Speed Sensor Fault. Note: This is not PTO Shaft Speed Sensor.

– Faulty supply wiring to PTO Speed Sensor. – Sensor faulty or damaged signal lead. – Poor Earth connection.

– The PTO Speed Sensor is fitted into the rear axle and monitors the rotation speed of the Rear PTO shaft inside the back axle. – It has a maintained 12 volt supply voltage from Transmission EST pin 54. This supply is shared with other Transmission Sensors. – Check the 12 volt supply voltage is reaching the sensor pin 3. – Check the Earth connector between pin 1 and the battery negative (-) terminal. – With the sensor connected compare the signal voltage from sensor connector pin 2 to the listed values.

G0073

PTO shaft speed sensor error. Output shaft speed no longer calculated.

PTO Shaft speed is monitored by a PTO Shaft Speed Sensor.

– Using JCB Service Master compare the values shown by the PTO speed sensor and the PTO shaft speed sensor. – Examine the connectors and wiring for damage. – Refer to PTO Shaft Speed Sensor and relevant troubleshooting.

G0074

PTO 540 Speed Selector Solenoid Fault.

– Wiring or connector damage. – Speed selector solenoid faulty.

– The Transmission EST supplies 12 volts from pin 48 to the solenoid pin 1. – The solenoid is earthed by a splice to the battery negative (-) terminal. – Check the internal resistance of the solenoid is approximately 8.1 ohms. – With the ignition ‘On’ and the PTO ‘On’ connect the Ammeter in series and check the solenoid draws 1.5 amps.

G0075

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PTO 750 solenoid: fault.

If Fitted: Rear 750 PTO replaces rear 540 PTO - Refer to 540 PTO Solenoid.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code G0076

Description Rear PTO 1000 Speed Selector Solenoid Fault.

Possible Cause Actuation fault due to: – Wiring or connector damage. – Speed selector solenoid faulty.

Action and Remedy – The Transmission EST supplies 12 volts from pin 68 to the solenoid pin 1. – The solenoid is earthed by a splice to the battery negative (-) terminal. – Check the internal resistance of the solenoid is approximately 8.1 ohms. – With the ignition ‘On’ and the PTO ‘On’ connect the Ammeter in series and check the solenoid draws 1.5 amps.

G0077

Rear PTO Speed Sensor: Plausibility fault.

– PTO speed selector in neutral – not engaging 540/1000 PTO gear in back axle.

Note: Rear PTO Speed Sensor is not Rear PTO Shaft Speed Sensor.

– PTO clutch jammed – either stuck ‘on’ or ‘off’. – PTO speed is detected as more than 20% different to engine speed – PTO clutch is slipping.

– Using JCB Service Master check that the PTO shaft speed sensor and PTO speed sensor are recording comparable PTO speed values. – Check the 12 volt supply and earth from the relevant Speed Sensor. – Watch the PTO propshaft between the gearbox and the rear axle to identify whether the fault is in the gearbox (PTO clutch not engaging/disengaging) or rear axle (PTO speed selector in neutral). Note: the CVT Fastrac has a combined PTO Clutch/Brake assembly. Both are controlled by the PTO Clutch solenoid. – PTO speed is changed by two solenoids mounted above the rear axle. 540 (750) solenoid. 1000 solenoid.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code G0078

Description Rear PTO Shaft Speed Sensor: Plausibility fault. Note: Rear PTO Shaft Speed Sensor is not Rear PTO Speed Sensor.

Possible Cause

Action and Remedy

– Speed at stub-shaft greater than 1300 rpm.

– Examine the PTO Shaft Speed Sensor for visible damage.

– Wrong PTO output shaft fitted for PTO speed.

– Check correct PTO output shaft fitted and the sensor is in close proximity to the ring.

– PTO Shaft Speed sensor supply or signal fault.

– Using JCB Service Master check that both PTO speed sensors are recording similar realistic PTO speed values.

– PTO speed sensor supply or signal fault. – Speed selection solenoid jammed in ‘Off’ position and not engaging correct PTO speed. – Knocked out of position.

– Check the 12 volt supply and earth from both PTO Speed Sensors. – Check the signal output of the sensors. – Check that the PTO output speed changes when changed between 540/ 1000 or 750/1000 when relevant. – PTO speed is changed by two solenoids mounted above the rear axle. 540 (750) solenoid. 1000 solenoid.

G0079

Rear PTO Speed Plausibility error between Shaft Speed Sensor and Speed Sensor.

– PTO Shaft speed differs by more than 12% from PTO speed.

– Two sensors monitor Rear PTO Speed. Using JCB Service Master check that the PTO speed values are different.

– Fault with one of the Rear PTO speed sensors.

– Check for active fault codes which might cause G0079 to become active.

– Incorrect PTO shaft fitted.

– Examine rear PTO shaft and check that actual PTO speed changes when the speed selector is changed. If PTO speed is not being changed, suspect either the PTO Speed Solenoids or internal mechanical failure.

– PTO speed selector mechanism/solenoid faulty.

540 (750) solenoid. 1000 solenoid. – Check for other active fault codes relating to one of these sensors. G0080

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Rear PTO Transmission EST memory error. Rear PTO Out of order.

Transmission EST has illogical stored values.

– Recalibrate the Transmission EST Rear PTO values. – Contact JCB Landpower.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

G0081

Front PTO clutch solenoid valve fault.

Possible Cause

Action and Remedy

– Faulty Front PTO Clutch Solenoid.

– The Transmission EST controls the Front PTO clutch solenoid from EST pin 49.

– Faulty wiring or connectors.

– Inspect the terminals for damage or corrosion. – Check the internal resistance of the solenoid. – Measure resistance of the solenoid supply lead between EST pin 49 and solenoid connector pin 1. – With both ends of the supply lead unplugged, measure resistance between the supply lead and a suitable ground. Resistance should be infinite unless the lead is shorting. – Check the earth from the solenoid pin 2 when the transport switch is switched ‘on’ and ‘off’ (ignition switched ‘On’). – Connect the multimeter in series with the supply lead to solenoid pin 1 and measure solenoid current.

G0082

Front PTO Speed Sensor Fault.

– Faulty sensor or damaged connectors. – Maintained 12 volt sensor supply fault. – Earth lead fault. – Signal lead fault.

– Check that the sensor is plugged in correctly and the connector is not damaged or corroded. – Measure the maintained 12 volt sensor supply to Connector Pin 3 from EST pin 54. – Check the earth from sensor connector pin 1. – Compare the sensor voltage signal to listed values.

P0000

To record at the first opportunity what is the time and date when the ignition was turned on.

P0001

CAN error when the EMS stops communicating with the DECU

This fault code is for information None required. only. It may be created if another fault occur as the ignition is turned on. – Faulty CanBus wiring between the EMS and the DECU.

Check the CanBus

– The EMS is not switched on. P0002

CAN error when the ABS stops communicating with the DECU

– Faulty CanBus wiring between the ABS and the DECU.

Check the CanBus

– The ABS is not switched on.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

P0003

CAN error when the engine ECU stops communicating with the DECU

Possible Cause

Action and Remedy

– Faulty CanBus wiring Check the CanBus between the engine ECU and the DECU. – The engine ECU is not switched on.

P0004

CAN error when ECU 1 stops communicating with the DECU

– Faulty CanBus wiring between ECU 1 and the DECU.

Check the CanBus

– ECU 1 is not switched on. P0005

P0006

P0007

CAN error when the rear linkage ECU stops communicating with the DECU

– Faulty CanBus wiring between the rear linkage ECU and the DECU.

CAN error when the gearbox ECU stops communicating with the DECU

– Faulty CanBus wiring between the gearbox ECU and the DECU.

DECU Service Master settings failed to save

– Faulty CanBus wiring between the DLA and the DECU

Check the CanBus

– The rear linkage ECU is not switched on. Check the CanBus

– The gearbox ECU is not switched on. Check the CanBus

– Faulty connection between the DLA and the laptop – Faulty DECU memory P0008

The Trip Min / Max Log has This is not a fault. It is for been reset by the service information. laptop.

None required.

P0009

The Min / Max Log has been reset by the service laptop.

This is not a fault. It is for information.

None required.

P0010

Transmission Operating Characteristics Reset.

This is not a fault. It is for information.

None required.

P0011

The Engine Operating This is not a fault. It is for Characteristics Were Reset information.

None required.

P0012

DECU calibration value reset on power up.

Unknown.

Repeat re calibrate and see if the fault reoccurs. If the fault reoccurs contact JCB Landpower.

P0013

DECU calibration value failed to save.

Unknown.

Repeat re calibrate and see if the fault reoccurs. If the fault reoccurs contact JCB Landpower.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0014

Description Hand Throttle Minimum Calibration Failed.

Possible Cause

Action and Remedy

– Faulty wiring.

– Attempt calibration again.

– Faulty hand throttle.

– Check mechanical operation of the hand throttle. – Measure the hand throttle output with a meter.

P0015

Hand Throttle Maximum Calibration Failed.

– Faulty wiring.

– Attempt calibration again.

– Faulty hand throttle.

– Check mechanical operation of the hand throttle. – Measure the hand throttle output with a meter.

P0016

Foot Throttle Minimum Calibration Failed.

– Faulty wiring.

– Attempt calibration again.

– Faulty foot RED throttle.

– Check mechanical operation of the foot throttle. – Measure the foot throttle output with a meter.

P0017

Foot Throttle Maximum Calibration Failed.

– Faulty wiring.

– Attempt calibration again.

– Faulty foot RED throttle.

– Check mechanical operation of the foot throttle. – Measure the foot throttle output with a meter.

P0018

Joystick centre position calibration failed.

– Faulty joystick sensor. – Faulty wiring.

– Check mechanical operation of the joystick. – Measure the output of the joystick sensors.

P0019

Joystick right position calibration failed.

– Faulty joystick sensor. – Faulty wiring.

– Check mechanical operation of the joystick. – Measure the output of the joystick sensors.

P0020

Joystick left position calibration failed.

– Faulty joystick sensor. – Faulty wiring.

– Check mechanical operation of the joystick. – Measure the output of the joystick sensors.

P0021

Clutch Up Position Calibration Failed

– Incorrect calibration. – Faulty clutch pedal sensor. – Faulty clutch pedal mechanical parts.

P0022

Clutch Down Position Calibration Failed.

– Incorrect calibration. – Faulty clutch pedal sensor. – Faulty clutch pedal mechanical parts.

P0023

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Transmission Range Calibration Failed.

Repeat the transmission range calibration carefully ensuring the correct conditions are achieved.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

Action and Remedy

P0024

Transmission Range Calibration Passed.

This is not a fault. It is for information.

None required.

P0025

Transmission Ratio Calibration Failed.

The correct conditions for calibration were not achieved.

Repeat the transmission ratio calibration carefully ensuring the correct conditions are achieved.

P0026

Transmission Ratio Calibration Passed.

This is not a fault. It is for information.

None required.

P0027

Transmission Turbo Clutch The correct conditions for Calibration Failed. calibration were not achieved.

Repeat the transmission ratio calibration carefully ensuring the correct conditions are achieved.

P0028

Transmission Turbo Clutch This is not a fault. It is for Calibration Passed. information.

None required.

P0029

Front PTO Configuration Loading Failed.

P0030

Rear PTO Configuration Loading Failed.

P0031

Front PTO Configuration Failed To Save.

P0032

Rear PTO Configuration Failed To Save.

P0033

4WD Configuration Failed To Save.

P0034

4WD Configuration Failed To Load.

P0035

Area Cut Out Configuration Failed To Save.

P0036

Area Cut Out Configuration Failed To Load.

P0037

Steering Angle Left Calibration Failed.

– Faulty steering angle sensor.

– Check operation using service master.

– Faulty wiring.

– Recalibrate again.

– Faulty steering angle sensor mechanical parts P0038

Steering Angle Right Calibration Failed.

– Faulty steering angle sensor.

– Check operation using service master.

– Faulty wiring.

– Recalibrate again.

– Faulty steering angle sensor mechanical parts P0039

Rear PTO Calibration Failed.

P0040

Rear PTO Calibration Passed.

P0041

Front PTO Calibration Failed.

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This is not a fault. It is for information.

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None required.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

P0042

Front PTO Calibration Passed.

P0043

Joystick Calibration Value Failed To Save.

P0044

Joystick Calibration Value Failed To Load.

P0045

DECU User Settings Failed to Save.

P0046

DECU User Settings Failed to Load.

P0047

DECU Internal Faulty DECU internal temperature Temperature Sensor Out sensor. Of Range Low. The temperature measured by the DECU using its internal temperature sensor is so low that it must be faulty.

– If the problem persist replace the DECU.

DECU Internal Temperature Sensor Low.

– If the problem persist replace the DECU.

P0048

P0049

This is not a fault. It is for information.

Action and Remedy

The DECU has experienced very low temperatures or the DECU internal temperature sensor is faulty.

DECU Internal Faulty DECU internal temperature Temperature Sensor Out sensor. Of Range Low. The temperature measured by the DECU using its internal temperature sensor is so high that it must be faulty.

None required.

– There are no serviceable parts inside the DECU.

– There are no serviceable parts inside the DECU. – If the problem persist replace the DECU. – There are no serviceable parts inside the DECU.

P0050

DECU Internal Temperature Sensor High.

The DECU has experienced very high temperatures or the DECU internal temperature sensor is faulty.

If the problem persist replace the DECU. There are no serviceable parts inside the DECU.

P0051

Analogue Sensor Supply Very Low.

Wiring Fault

If fitted the DECU provides a sensor supply voltage from pin R14.This fault code becomes active if the supply voltage from this pin (which is not connected) is above 4.5 volts. Check that DECU pin R14 is not accidentally connected.

P0052

Analogue Sensor Supply Low.

Wiring Fault This error should not occur on an 8000 series Fastrac

If fitted the DECU provides a sensor supply voltage from pin R14.This fault code becomes active if the supply voltage from this pin (which is not connected) is below 0.5 volts. Check that DECU pin R14 is not accidentally connected.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

Action and Remedy

P0053

Analogue Sensor Supply High.

Wiring Fault. This error should not If fitted the DECU provides a sensor supply occur on an 8000 series Fastrac voltage from pin R14.This fault code becomes active if the supply voltage from this pin (which is not connected) is above 4.5 volts. Check that DECU pin R14 is not accidentally connected.

P0054

Analogue Sensor Supply Very High.

Wiring Fault. This error should not If fitted the DECU provides a sensor supply occur on an 8000 series Fastrac voltage from pin R14.This fault code becomes active if the supply voltage from this pin (which is not connected) is above 5.5 volts. Check that DECU pin R14 is not accidentally connected.

P0055

Analogue Sensor Ground Low

Wiring Fault. This error should not If fitted the DECU provides a sensor reference occur on an 8000 series Fastrac voltage from pin DECU pin R3.This fault code becomes active if the supply voltage from this pin (which is not connected) becomes shorted to ground. Check that DECU pin R3 is not accidentally connected.

P0056

Analogue Sensor Ground Low

Wiring Fault. This error should not If fitted the DECU provides a sensor reference occur on an 8000 series Fastrac voltage from pin DECU pin R3.This fault code becomes active if the supply voltage from this pin (which is not connected) drops below 0.2 volts. Check that DECU pin R3 is not accidentally connected.

P0057

Analogue Sensor Ground High

Wiring Fault. This error should not If fitted the DECU provides a sensor reference occur on an 8000 series Fastrac voltage from pin DECU pin R3.This fault code becomes active if the supply voltage from this pin (which is not connected) drops below 0.2 volts. Check that DECU pin R3 is not accidentally connected.

P0058

Analogue Sensor Ground Very High.

Wiring Fault. This error should not If fitted the DECU provides a sensor supply occur on an 8000 series Fastrac voltage from pin R14.This fault code becomes active if the supply voltage from this pin (which is not connected) is above 5.5 volts. Check that DECU pin R14 is not accidentally connected.

P0059

Ignition Supply Voltage Very Low.

P0060

P0061

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Ignition Supply Voltage Low.

Ignition Supply Voltage Very High.

– Faulty alternator.

– Measure the battery voltage.

– Faulty supply wiring to the DECU touch screen.

– Check the alternator output.

– Faulty alternator.

– Measure the battery voltage.

– Faulty supply wiring to the DECU touch screen.

– Check the alternator output.

– Faulty alternator - over charging.

– Measure the battery voltage.

– Vehicle has been connected to a 24 volt system.

– Check the earth wiring for the DECU.

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– Measure the voltage supplied to the DECU.

– Measure the voltage supplied to the DECU. – Check the alternator output.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0062

Description Ignition Supply Voltage High.

Possible Cause

Action and Remedy

– Faulty alternator - over charging.

– Measure the battery voltage.

– Vehicle has been connected to a 24 volt system.

– Check the earth wiring for the Display ECU (DECU).

– Check the alternator output.

P0063

Steering Angle Straight Ahead Calibration Failed

– Faulty steering angle sensor. Calibration will fail if the values being stored fall outside the allowable range. Check the – Faulty wiring. steering is in the straight ahead position when – Faulty steering angle sensor the calibrated value is stored. linkage

P0099

Display ECU (DECU) Service Master Settings Failed To Load

– Faulty CanBus wiring between the DLA and the DECU.

Check the USB connection between the Laptop and DLA.If the problem persists contact JCB Landpower before replacing the DECU

– Faulty connection between the DLA and the laptop – Faulty DECU memory P0100

Display ECU (DECU) supply voltage below 9 volts.

– The alternator is not charging correctly.

– Measure the battery voltage and investigate the cause if it is low.

– Wiring fault.

– Check the fused supply voltage to the DECU touch screen to pins R1 (continuous supply) and R2 (switched supply). If it is low check the terminals are free from damage or corrosion, lead resistance is below 10 ohms and that they are not shorting to earth.

P0110

DECU sensor supply voltage less than 4.5 volts

Wiring Fault. This error should not If fitted the DECU provides a sensor supply occur on an 8000 series Fastrac voltage from pin R14. 8000 series Fastrac does not use the DECU sensor supply function. This fault code becomes active if the supply voltage from this pin (which is not connected) drops below 4.5 volts. Check that pin R14 is not connected to anything.

P0111

DECU sensor supply voltage greater than 5.5 volts

Wiring Fault. This error should not If fitted the DECU provides a sensor supply occur on an 8000 series Fastrac voltage from pin R14. This fault code becomes active if the supply voltage from this pin (which is not connected) is above 4.5 volts. Check that pin R14 is not connected to anything.

P0120

DECU sensor reference voltage less than 0.2 volts

Wiring Fault. This error should not If fitted the DECU provides a sensor supply occur on an 8000 series Fastrac voltage from pin R3. This fault code becomes active if the supply voltage from this pin (which is not connected) drops below 0.2volts. Check that pin R3 is not connected to anything.

P0121

DECU sensor reference voltage greater than 0.6 volts

Wiring Fault. This error should not If fitted the DECU provides a sensor supply occur on an 8000 series Fastrac voltage from pin R3. This fault code becomes active if the supply voltage from this pin (which is not connected) is above 0.2 volts. Check that pin R3 is not connected to anything.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0130

Description Foot Throttle Under Calibration.

Possible Cause – Wiring fault. – Potentiometer fault. – Foot throttle mechanism or mounting fault.

Action and Remedy – This fault code concerns the Red sensor monitoring the position of the Foot Accelerator Pedal and connected to the DECU. – Check continuity of the signal wiring between the red sensor connector pin 3 and the DECU pin R19 by measuring resistance along its length. It should be less than 5 ohms unless an open circuit is detected. With both ends of the signal lead disconnected measure resistance between the signal lead and a suitable earth. Unless there is a short, resistance should be infinite. – When cause is known and fixed re calibrate.

P0131

Foot Throttle signal to DECU under range.

– Wiring fault. – Potentiometer fault. – Foot throttle mechanism or mounting fault.

– Check the sensor signal wire is not shorting to earth or has an open circuit. – Check the terminals for corrosion or other reasons that might cause a high resistance. – Measure the maintained 12 volt sensor supply voltage. – When cause is known and fixed re calibrate.

P0132

Foot Throttle signal to DECU over calibration.

– Wiring fault. – Potentiometer fault. – Foot throttle mechanism or mounting fault.

– Check the sensor signal lead is not shorted to a supply voltage or any other leads in the DECU connector. – Check wiring for damage. – When cause is known and fixed re calibrate.

P0133

Foot Throttle position signal to DECU over range.

– Short to a high source. – Potentiometer fault.

– Check the signal lead is not shorting to a high source by disconnecting the sensor and measuring resistance between the signal lead and the battery + terminal and other pins in the DECU connector. – Check wiring for damage. – When cause is known and fixed re calibrate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0150

Description Hand Throttle Under Calibration.

Possible Cause – Mounting fault. – Wiring fault. – Potentiometer fault.

Action and Remedy – Examine for the hand throttle being knocked out of line or loose mountings. Recalibrate when repositioned. – Check continuity of the hand throttle signal lead between the DECU pin R8 and the throttle connector pin B. Resistance should be less than 5 ohms. Examine the lead and terminals for reasons for a high resistance. – With the hand throttle unplugged, check that the DECU pin R8 signal lead is not shorting to other leads in the harness or shorting to earth. – Check wiring for damage. – When cause is known and fixed re calibrate.

P0151

Hand Throttle Under Range.

– Wiring fault. – Potentiometer fault.

– Check continuity of the hand throttle signal lead between throttle connector pin ‘B’ and DECU R8 looking for an open circuit. Resistance should be less than 5 ohms. – Check the signal lead for high resistance caused by wiring damage or corroded terminals. – Check the signal lead for accidental shorts. Unplug the hand throttle and measure resistance at the DECU red connector between the signal lead (R8) and a suitable earth and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check the maintained 12 volt supply and the sensor earth from pin ‘C’ to the battery negative (–) terminal. – When cause is known and fixed re calibrate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0152

Description Hand Throttle Over Calibration

Possible Cause – Loose hand throttle mounting. – Wiring fault. – Potentiometer fault.

Action and Remedy – Over calibration may be caused by the hand throttle being knocked into a different position, wear or loose mountings. Reposition the sensor and re calibrate. – Check the signal lead for accidental shorts. Unplug the hand throttle and measure resistance at the DECU red connector between the signal lead and the battery + terminal and other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check maintained 12 volt sensor supply to hand throttle pin ‘A’. – When cause is known and fixed re calibrate.

P0153

Hand Throttle Over Range.

– Wiring fault. – Potentiometer fault.

– Check the signal lead for accidental shorts: Unplug the hand throttle and measure resistance at the DECU red connector between the signal lead (R8) and the battery + terminal and also to other pins in the DECU connector. – It is likely the lead is shorting to a high source. A low resistance (less than 100k ohms) indicates a short to another lead. – Test the hand throttle position sensor. – Check the maintained 12 volt supply. – When cause is known and fixed re calibrate.

P0160

Clutch Pedal Under Calibration.

– Clutch pedal mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

– Check if the clutch pedal rotary sensor has been knocked out of position, is worn or loose on its mounts. – Check the signal lead for accidental shorts. Unplug the clutch pedal and measure resistance at the DECU red connector between the signal lead (R20) and a suitable earth and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check the signal lead for high resistance. – Test the clutch pedal rotary sensor. – When cause is known and fixed re calibrate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

P0161

Clutch Pedal Under Range.

– Clutch pedal mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

Action and Remedy – Check the rotary clutch pedal sensor signal lead for accidental shorts: Unplug the rotary sensor and measure resistance at the DECU red connector R20 between the signal lead and a suitable earth and other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check continuity of signal wiring from the rotary clutch position sensor pin 3 (signal) and DECU Red connector pin R20. – Test the clutch pedal rotary sensor. – When cause is known and fixed re calibrate.

P0162

Clutch Pedal Over Calibration.

– Clutch pedal mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

– Check if the clutch pedal rotary sensor has been knocked out of position, is worn or loose on its mounts. Reposition and re calibrate. – Check the signal lead for accidental shorts. Unplug the clutch pedal and measure resistance at the DECU red connector between the signal lead (R20) and the battery positive (+) terminal and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check the signal lead for high resistance. – Test the clutch pedal rotary sensor. – When cause is known and fixed re calibrate.

P0163

Clutch Pedal Over Range

– Wiring fault. – Potentiometer fault.

– Check the rotary clutch pedal sensor signal lead for accidental shorts: Unplug the rotary sensor and measure resistance at the DECU red connector R20 between the signal lead and the battery + terminal and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check continuity of signal wiring from the rotary clutch position sensor pin 3 (signal) and DECU Red connector pin R20. – Test the clutch pedal rotary sensor. – When cause is known and fixed re calibrate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0170

Description Steering Angle Sensor Under Calibration.

Possible Cause – Steering angle mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

Action and Remedy – Check if the sensor has been knocked or is loose on its mounts. Position correctly and re calibrate. – Check the steering angle sensor signal lead for accidental shorts: Unplug the sensor and measure resistance between the DECU red connector R9 (signal) and a suitable earth and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check continuity of signal lead and examine it for high resistance. Caused by wire damage or corroded terminals. – Check the maintained 12 volt supply voltage to the sensor pin 2. – When cause is known and fixed re calibrate.

P0171

Steering Angle Sensor Under Range.

– Wiring fault. – Potentiometer fault.

– Check the steering angle sensor signal lead for accidental shorts: Unplug the sensor and measure resistance between the DECU red connector R9 (signal) and a suitable earth and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check continuity of signal lead and examine it for high resistance caused by wire damage or corroded terminals. – Check the maintained 12 volt supply voltage to the sensor pin 2. – Check the sensor earth between sensor connector pin 1 and the battery – terminal. – When cause is known and fixed re calibrate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0172

Description Steering Angle Sensor Over Calibration.

Possible Cause – Steering angle mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

Action and Remedy – Check if the sensor has been knocked or is loose on its mounts. Position correctly and re calibrate. – Check the steering angle sensor signal lead for accidental shorts: Unplug the sensor and measure resistance between the DECU red connector R9 (signal) and the battery + terminal and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check the maintained 12 volt supply voltage to the sensor pin 2. – When cause is known and fixed re calibrate.

P0173

Steering Angle Sensor Over Range.

– Steering angle mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

– Check the steering angle sensor signal lead for accidental shorts: Unplug the sensor and measure resistance between the DECU red connector R9 (signal) and the battery + terminal and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Check the maintained 12 volt supply voltage to the sensor pin 2. – When cause is known and fixed re calibrate.

P0180

Joystick Forwards / Backwards Under Calibration.

– Joystick mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0181

Description Joystick Forward / Backwards Under Range.

Possible Cause – Wiring fault. – Potentiometer fault.

Action and Remedy – Check continuity of signal wiring between DECU R17 and sensor pin 2. Look for signs of high resistance, including damaged wires or corroded terminals. – Check the signal lead for shorts: unplug the sensor and measure resistance between the DECU Red connector R17 and a suitable earth as well as other pins in the socket.Unless a short is detected, resistance should be infinite. – Test the joystick position sensor. – When cause is known and fixed re calibrate.

P0182

Joystick Forward / Backwards Over Calibration.

– Joystick mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

– Check that the forwards/backwards sensor (mounted on the side of the joystick) has not moved out of line. – Examine the joystick and sensor pivot for wear. – Recalibrate the joystick movement. – Check continuity of signal wiring between DECU R17 and sensor pin 2. – Check the joystick forward/backward sensor signal lead for accidental shorts: Unplug the sensor and measure resistance between the DECU red connector R17 (signal) and the battery + terminal and also to other pins in the DECU connector. A low resistance (less than 100k ohms) indicates a short to another lead. – Test the joystick position sensor. – When cause is known and fixed re calibrate.

P0183

Joystick Forward / Backwards Over Range.

– Wiring fault. – Potentiometer fault.

– Check the signal lead for shorts: unplug the sensor and measure resistance between the DECU Red connector R17 and the battery + terminal as well as other pins in the socket. Unless a short is detected, resistance should be infinite. – Test the joystick position sensor. – When cause is known and fixed re calibrate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

P0190

Joystick Left / Right Under Calibration.

Possible Cause – Joystick mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

Action and Remedy – Check that the left/right sensor (mounted on the back of the joystick) has not moved out of line. Examine the joystick and sensor pivot for wear. – Recalibrate the joystick movement. – Check continuity of signal wiring between DECU R6 and sensor pin 5. Look for signs of high resistance, including damaged wires or corroded terminals. – Test the joystick sensor. – When cause is known and fixed re calibrate.

P0191

Joystick Left / Right Under Range.

– Wiring fault. – Potentiometer fault.

– Check continuity of signal wiring between DECU R6 and sensor pin 5. Look for signs of high resistance, including damaged wires or corroded terminals. – Check the signal lead for shorts: unplug the sensor and measure resistance between the DECU Red connector R6 and a suitable earth as well as other pins in the socket. Unless a short is detected, resistance should be infinite. – Test the joystick sensor. – When cause is known and fixed re calibrate.

P0192

Joystick Left / Right Over Calibration.

– Joystick mechanism or mounting fault. – Wiring fault. – Potentiometer fault.

– Check that the left/right sensor (mounted on the side of the joystick) has not moved out of line. Examine the joystick and sensor pivot for wear. – Recalibrate the joystick movement. – Check the signal lead between DECU R6 and sensor pin 5 for shorts: unplug the sensor and measure resistance between the DECU Red connector R6 and the battery + terminal as well as other pins in the socket. Unless a short is detected, resistance should be infinite. – Test the joystick sensor. – When cause is known and fixed re calibrate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0193

Description Joystick Left / Right Over Range.

Possible Cause – Wiring fault. – Potentiometer fault.

Action and Remedy – Check the signal wiring between DECU R6 and sensor pin 5 for shorts: unplug the sensor and measure resistance between the DECU Red connector R6 and the battery + terminal as well as other pins in the socket. Unless a short is detected, resistance should be infinite. – Test the joystick position sensor. – When cause is known and fixed re calibrate.

P0230

Transmission Sensor Supply Under Range

Transmission EST provides a fused 8.5 volt supply voltage to several Transmission sensors.The DECU (which is spliced to this supply lead) has detected the sensor voltage is below 8 volts.

– Check the fuse – Measure the 8.5 volt sensor supply between DECU pin R22 (supply signal) and a suitable earth. – With the Transmission EST connected check the 8.5 volt supply from EST pin 23. – Check the 8.5 volt signal passing through Transmission Bulkhead Connector pin ‘P’ (16) from the EST to the Transmission sensors

P0231

Transmission Sensor Supply Very Low

Transmission EST provides a fused 8.5 volt supply voltage to several Transmission sensors.The DECU (which is spliced to this supply lead) has detected the sensor voltage is below 8 volts.

P0232

Transmission Sensor Supply Over Range

Transmission EST provides a fused 8.5 volt supply voltage to several Transmission sensors.The DECU (which is spliced to this supply lead) has detected the sensor voltage is above 9 volts.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code P0233

Description Transmission Sensor Supply High

Possible Cause Transmission EST provides a fused 8.5 volt supply voltage to several Transmission sensors.The DECU (which is spliced to this supply lead) has detected the sensor voltage is above 9 volts.

Action and Remedy – Check the fuse – Measure the 8.5 volt sensor supply between DECU pin R22 (supply signal) and a suitable earth. – With the Transmission EST connected check the 8.5 volt supply from EST pin 23. – Check the 8.5 volt signal passing through Transmission Bulkhead Connector pin ‘P’ (16) from the EST to the Transmission sensors

P0300

P0301

P0302

P0303

Foot Throttle Plausibility Error.

Clutch Sensor Plausibility Error

Gearbox Ratio Plausibility Error

Engine Speed Plausibility Error

The Engine ECM and the DECU each use a separate sensor to monitor Foot Throttle Pedal position. This fault code becomes active if the DECU detects a difference between the value from the DECU sensor and that transmitted from the Engine ECU over the CanBus.

– Monitor the Foot Throttle Pedal Position using the JCB Service Master Diagnostic screen.

The Clutch Pedal uses a sensor to monitor movement of the Clutch Pedal and also an ‘Activation Switch’ to confirm when the Pedal has been fully depressed. This fault code becomes active if Activation Switch detects the Clutch Pedal as being depressed but the Position Sensor value is not logical.

– Monitor the Clutch Pedal Activation Switch using JCB Service Master

The gearbox ratio is incorrect when compared with the direction the machine is traveling in.

– Check the DECU software is the latest available.

The actual engine speed, the requested speed and the engine are not as expected.

– Check the DECU software is the latest available.

– Assuming the two sensors provide similar values to the Engine and the DECU, check the CanBus is operating correctly. – Recalibrate the Foot Throttle

– Monitor the Clutch Position Sensor values using JCB Service Master. – Compare the values to those specified in Sensor Calibration Values.

– Contact JCB Landpower if this fault repeatedly occurs.

P0304

Maximum vehicle speed occurred

For Information

Not a Fault.

P0305

Maximum engine speed occurred

For Information

The maximum engine speed should not be above 2750 rpm.

P0306

Maximum voltage occurred For Information

The maximum vehicle voltage should not be above 16 volts.

P0307

Maximum engine coolant temperature occurred

The maximum engine coolant temperature should not be above 103 deg C.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description

Possible Cause

Action and Remedy

P0308

Maximum transmission temperature occurred

For Information

P0309

An increase in the DECU maximum internal temperature has occurred

High internal DECU None possible as this error code is for temperatures.The DECU records information only. the maximum internal temperature and when this is increased this fault code is logged.

P0310

The DECU internal temperature has exceed the trip alarm point

The DECU internal temperature was very hot.

None possible as this error code is for information only.

P0311

The DECU has shut down the LCD because the temperature was too hot.

The DECU internal temperature was very hot.

None possible as this error code is for information only.

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The maximum gearbox temperature should not be continuously above 90 deg C.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code Q0111

Q0115

Description and Effect Engine Control Module Critical internal failure

Possible Cause

Action and Remedy

This fault code can only be caused Repairs are not possible for the ECM. Replace by an internal ECM problem. the ECM.

– Engine may not start.

Note: To reduce the possibility of damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.

Engine Speed/Position Sensor Circuit lost both signals from the two sensors. Data Erratic, Intermittent, or incorrect.

Make sure that the main engine speed sensor (crankshaft position sensor) and the backup engine speed sensor (camshaft position sensor) are connected to the engine wiring harness correctly.

The main engine speed sensor (crankshaft position sensor) and the backup engine speed sensor (camshaft position sensor) are located in close proximity to one another. The same sensor is used in both locations. (Connector key is – Fueling to the injectors the same.) A P-clip on the engine is disabled. The engine wiring harness prohibits the can not be started. harness connectors from being connected to the incorrect sensors. However, if the P-clip is omitted, it is possible to plug the wiring harness connectors into the incorrect sensors. If this occurs, the ECM will detect the problem and the engine will not start. Once the connector problem is corrected, the engine can be started and the fault code will become inactive.

Q0122 Intake Manifold Pressure Sensor Circuit. Voltage above normal or shorted to high source.

The intake manifold pressure Check for damaged wiring or faulty sensor. sensor shares supply and return wires in the engine harness with other sensors. Opens and shorts in the engine harness can cause – Derate in power output multiple fault codes to be active. of the engine. Before troubleshooting Fault Code 122, check for multiple faults. Possible causes of this fault code include: – Open return circuit in the engine harness, connectors, or sensor – Signal wire shorted to sensor supply or battery voltage.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Possible Cause

Action and Remedy

Q0123 Intake Manifold Pressure Sensor Circuit. Voltage below normal or shorted to low source.

The intake manifold pressure Check the sensor and wiring. sensor monitors intake manifold pressure and passes information to the electronic control module (ECM) through the engine harness. – Derate in power output On automotive applications, if the of the engine. intake manifold pressure becomes too low, it will cause a derate condition.

Q0124 Intake Manifold 1 Pressure Sensor Circuit - Data Valid but Above Normal Operational Range. Intake manifold pressure has exceeded the maximum limit for the given engine rating.

– Moderately Severe Level. Derate in power output of the engine. Q0131 Accelerator Pedal Position Sensor Circuit. Voltage above normal or shorted to high source. – Severe derate in power output of the engine. Limp home capability only.

Q0132 Accelerator Pedal or Lever Position Sensor Circuit. Voltage Below Normal, or Shorted to Low Source – Severe derate in power output of the engine. Limp home capability only.

This fault code become active Check the pressure sensor and wiring. when the intake manifold pressure exceeds the maximum pressure limit for a given engine rating. Possible causes:– Malfunctioning turbocharger – Possible tampering of the fuel system or turbocharger system.

– Accelerator pedal position signal circuit shorted to battery or +5 volt supply.

Check wiring and throttle position sensor

– Open accelerator pedal or lever return circuit in the harness or connections – Accelerator supply shorted to battery. – Failed accelerator pedal position sensor. – Accelerator pedal or lever Check the wiring and the throttle position position signal shorted to sensor. engine ground or return wires in the OEM harness or sensor. – Open circuit in the accelerator signal, supply or return wire in the harness or connectors. – Failed accelerator pedal or lever position sensor.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0135 Oil Pressure Sensor Circuit – Signal Voltage Above Normal or Shorted to High Source

Possible Cause – Oil Pressure Signal lead shorted to a high source. – Oil Pressure Sensor failed.

Action and Remedy Check the sensor 5 volt supply voltage by measuring voltage between the Oil Pressure Sensor pin 1 (supply) and 2 (return). Confirm the voltage is within the range 4.75 – 5.25 volts when the Ignition is ‘On’. If the voltage appears high then check the 5 volt supply between Engine ECU J1 connector pins 33 (supply) and 38 (return). Unplug the Engine ECU J1 connector as well as the sensor. – Check that the signal lead is not shorted to the supply lead – resistance between sensor pins 3 (signal) and 1 (supply) should be infinite. – Check that the sensor signal lead is only connected to J1 connector pin 13 – resistance to all other pins should be infinite. – With the sensor unplugged check there is no voltage shorting to the sensor’s signal lead when the ignition is switched ‘On’.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0141 Oil Pressure Sensor Circuit – Signal Voltage Above Normal or Shorted to Low Source

Possible Cause – Oil Pressure Signal lead shorted to a low source or open circuit. – Oil Pressure Sensor failed.

Action and Remedy Unplug the Engine ECU J1 connector and the sensor. – Check the signal lead for open circuit – measure resistance between Engine ECU J1 connector pin 13 (signal) and sensor pin 3 (signal). Resistance should be less than 5 ohms. A high resistance indicates wiring or connector damage. – Measure resistance between the sensor’s signal lead and a suitable earth. Resistance should be infinite unless a short to earth is detected. – Check that the signal lead is not shorted to the return lead – resistance between sensor pins 3 (signal) and 2 (return) should be infinite. – Measure the supply voltage at the sensor between sensor pin 1 (supply) and pin 2 (return). With the Ignition switched ‘On’ the supply voltage should be between 4.75 – 5.25 volts. If the voltage is incorrect confirm the voltage at the Engine ECU J1 connector between pins 33 (supply) and 38 (return). – Check the sensor’s supply and return leads for open circuit or shorts to ground.

Q0143 Oil Pressure Low. Data valid The Engine ECU has detected low Check actual engine oil pressure using a but below normal operating Oil Pressure based on the Oil pressure gauge. If the reading appears range. Pressure Sensor signal. suspect then check the sensor signal, supply and return circuits. – Torque derate. (Moderately Severe Level)

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0144 Coolant Temperature Sensor Circuit. Voltage above normal or shorted to high source. – Possible white smoke.

Possible Cause

Action and Remedy

– Open sensor return circuit in the harness, connectors, or sensor.

– Refer to Coolant Temperature Sensor. Inspect the ECM Engine Harness Connector J1 for damage and also the temperature sensor connector.

– Open sensor signal circuit or shorted to a voltage source.

– Compare the internal resistance of the temperature sensor to the guide values by measuring resistance between the sensor’s signal and return pins. – Disconnect the Coolant Temperature Sensor and the ECM Engine Harness connector J1. – Measure the resistance between both ends of the sensor’s signal lead. Resistance should be less than 10 ohms unless there is an open circuit. – Measure the resistance between both ends of the sensor’s return lead. Resistance should be less than 10 ohms unless there is an open circuit. – Measure the resistance between the signal and return pins at the sensor connector. Unless the leads are shorting together in the harness, resistance should be infinite. – Measure the resistance between the signal lead and the other pins in the ECM J1 connector. A short to other pins in the harness will be identified by a low measured resistance.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0145 Coolant Temperature Sensor Circuit. Voltage below normal or shorted to low source.

Possible Cause – Signal shorted to ground in the harness. – Signal shorted to return or ground in the sensor.

Action and Remedy – Refer to Coolant Temperature Sensor. – Inspect the ECM Engine Harness Connector J1 for damage and also the temperature sensor connector. – Disconnect the Sensor from the Engine Harness but leave the ECM plugged in. Switch the Ignition ‘On’ and wait 30 seconds. Does fault code Q0145 become ‘previously active’ and Q0144 become active?

– Possible white smoke.

– This indicates a faulty sensor. – Check if the resistance between either of the terminals and a suitable ground is less than 100k ohms. – Compare the internal resistance of the temperature sensor to the guide values. – Disconnect the Coolant Temperature Sensor and the ECM Engine Harness connector J1. Measure the resistance between the supply and return pins at the sensor connector. Unless the leads are shorting together in the harness, resistance should be infinite. – Measure the resistance between the signal lead and the other pins in the ECM J1 connector. A short to other pins in the harness will be identified by a low measured resistance.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0146 Engine Coolant Temperature High. Data valid but above normal operating range.

Possible Cause Engine Coolant Temperature Sensor indicates coolant temperature is above the critical limit.

– Progressive power derate. Moderately Severe Level

Action and Remedy – Inspect coolant radiator for debris blocking the cooling fins or internal obstructions. – Check fan drive belt and correct fan operation. – Check water pump drive belt tension and check it is functioning correctly. – Inspect the coolant system for external leaks. Look for evidence of white smoke from the exhaust due to internal coolant loss. – Inspect coolant pipes and couplings for collapse, incorrect routing or internal blockage. Water is pulled from the bottom of the radiator through the water pump, through the engine and returned to the radiator by the top hose. With the engine coolant above 90°C (thermostat open) and engine at high speed inspect the water pipe into the water pump for visible collapse. – Check thermostat opens at 82°C. – Check correct radiator cap is fitted. Ensure not malfunctioning opening at too low pressure. – Check engine oil level is correct level and grade which could cause increased engine temperature. – Check sensor for malfunction: – Inspect the ECM Engine Harness Connector J1 for damage and also the temperature sensor connector. – Compare the internal resistance of the temperature sensor to guide values. – Disconnect the Coolant Temperature Sensor and the ECM Engine Harness connector J1. Check the resistance between both ends of the signal lead is less than 5 ohms. Repeat for the return lead. A high resistance indicates an open circuit.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Possible Cause

Q0151 Coolant Temperature high. Engine Coolant Temperature Data valid but above normal Sensor indicates coolant operating range. temperature is above the critical limit. – Progressive power derate. Most Severe Level

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0153 Intake Manifold Air Temperature Sensor Circuit. Voltage above normal or shorted to high source. – Possible white smoke

Possible Cause – Open return circuit in the harness, connectors or sensor. – Open signal circuit or shorted to voltage source.

Action and Remedy – Refer to Inlet Manifold Air Temperature Sensor. – Examine the connectors for damage or corrosion. – Disconnect the Inlet Manifold Air Pressure sensor from the Engine Harness. Measure the resistance between the signal and return pins, as described in Inlet Manifold Air Temperature and compare to listed values. – Check for an open circuit in the sensor signal lead by measuring resistance between sensor connector pin 1 and Engine Harness Connector J1 pin 23. An open circuit will be detected by a resistance higher than 5 ohms. – Repeat the test checking for an open circuit in the return leads: measure resistance between sensor connector pin 4 and Engine Harness Connector J1-47. An open circuit will be detected by a resistance higher than 5 ohms. – Disconnect the ECM J1 connector from the Engine Harness and unplug the sensor connector: – Check for a short to voltage between the signal lead (sensor connector pin 3) and the battery + terminal. – Test for a short to other leads in the J1 connector by measuring the resistance between the signal pin (J1 – 23) and the other pins in the J1 engine harness connector. If a resistance can be measured between two pins then a short has been detected.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0154 Intake Manifold Air Temperature Sensor Circuit -Voltage Below Normal, or Shorted to Low Source

Possible Cause

Action and Remedy

– Signal circuit shorted to ground in the harness.

– Refer to Inlet Manifold Air Temperature Sensor.

– Signal circuit shorted to return or ground in the sensor.

– Disconnect the Inlet Manifold Air Pressure sensor from the Engine Harness. Switch the ignition ‘On’. Does Q0154 become ‘previously-active’ after 30 seconds and Q0153 become active? This indicates it is unlikely the wiring is faulty unless there is a damaged connector.

– Possible white smoke

– Check the Air Pressure Sensor. With the sensor in position, check if sensor connector pins 3 or 4 are connected to earth by measuring resistance between the pins and earth. Resistance should be very high (over 100k ohms). Compare the sensor’s resistance to the stated values. – Disconnect the ECM J1 Connector from the Engine Harness and unplug the sensor. Check for a short to earth in the signal lead by measuring resistance between the lead and a suitable earth. – Check for a short to other leads in the J1 connector by measuring the resistance between the signal pin (J1 – 23) and the other pins in the J1 engine harness connector. Resistance should be infinite unless a short is detected. Q0155 Intake Manifold Air Temperature High. Data valid but above normal operating range. Most Severe level

– Restricted air flow through the intercooler.

– Check Intercooler radiator and pipework for restrictions.

– High turbocharger compressor outlet temperature.

– Examine inlet pipework for evidence of heat sources.

– Progressive power derate

– IF FITTED Check EGR (Exhaust Gas Re circulation) is operating correctly and not generating fault codes. Excess high temperature exhaust gases might activate Q2946 fault code. – Check Turbocharger is operating correctly and not generating a fault code. – Check Inlet Manifold Air Temperature sensor supply and earth. – Check Temperature signal lead for open circuit, short to earth or voltage feed. – Check resistance value of sensor.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0187 Sensor Supply Voltage #2 Circuit. Voltage below normal or shorted to low source. – Engine power derate.

Possible Cause Low voltage on the +5-VDC sensor supply line can be caused by a short circuit to ground in a supply line, a short circuit between a supply line or a return line, a failed sensor or a failed ECM power supply.

Action and Remedy – This sensor supply circuit provides 5 volt supply to the Camshaft speed/position sensor, intake manifold pressure sensor, and fuel rail pressure sensor from Engine ECU (ECM) connector J1pin 37. – Inspect all connectors for evidence of damage or corrosion. – Measure the voltage at the fuel rail pressure sensor between the supply and return contacts to confirm that the supply voltage is below 4.75 volts. – Measure the voltage between ECM J137 and a suitable ground to confirm the ECM produces within the 4.75 to 5.25 voltage range. – Unplug the ECM and measure resistance between the inlet manifold pressure sensor supply and return pins at the inlet manifold pressure sensor. Unless the wires are shorting together there should be no resistance measured. – Unplug the sensors in turn. Does fault code 187 change to ‘previously active’ after 30 seconds with the ignition ‘On’. If it does, the sensor that is unplugged is faulty.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0221 Barometric Pressure Sensor Circuit. Voltage above normal or shorted to high source.

Possible Cause – Open sensor return circuit. – Signal circuit sorted to sensor supply or battery voltage.

Action and Remedy – Check if fault code Q0386 is active. This relates to sensor supply voltage and might cause Q0221 to be active. – Examine the ECM Engine Harness J1 connector and sensor connector for damage or corrosion.

– Engine power derate.

– Refer to Barometric Pressure Sensor. – Measure the resistance between both ends of the sensor return lead. A reading higher than 5 ohms suggests an open return circuit. – With the ECM connected and the ignition switched ‘On’, measure the voltage between the supply and return pins at the Barometric Pressure Sensor connector. Unless the lead is shorting to a high voltage source in the harness, voltage should be between 4.75 and 5.25 volts. – Unplug the ECM connector J1 and measure resistance between the Barometric Pressure sensor signal pin and the battery + terminal. Since there should be no contact with the battery, resistance should be infinite unless there is a short to a power lead. – Unplug the Barometric Pressure Sensor and measure the resistance between ECM J1 pin 3 and the other pins in the J1 connector. Unless the signal lead is shorting to one of the other leads in the harness resistance to the other pins should be infinite.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0222 Barometric Pressure Sensor Circuit. Voltage below normal or shorted to low source. – Engine power derate.

Possible Cause

Action and Remedy

– Signal circuit open or shorting to ground..

– Check if fault code Q0352 is active which might cause Q0222 to be active.

– Supply lead open or shorting to ground.

– Measure the voltage between the sensor supply and return pins and check it is within the range 4.75 to 5.25 volts. If it is out of range check if the voltage between Engine ECU (ECM) connector J1 pins 33 and 38 is within range.

– Faulty Air Pressure Sensor.

– Measure resistance between both ends of the Air Pressure Sensor’s supply and return leads. Unless there is an open circuit, resistance should be less than 5 ohms. – With the harness unplugged at the ECM and at the Air Pressure sensor, measure resistance between the supply contact and a suitable ground. Resistance should be infinite unless a short to ground in the harness is present. Repeat the test between the sensor’s signal lead and a suitable earth. Again resistance should be infinite unless the lead is shorting to earth. – With the sensor unplugged, measure the resistance between ECM J1-33 (supply) and other pins in the ECM Engine Harness connector. Unless there is a short resistance should be infinite. Repeat the test measuring resistance between J1-3 and other pins in the connector. – Connect the sensor supply and return pins together and switch the ignition ‘On’. Does fault code Q0222 become active and Q0221 become in-active? This identifies a faulty pressure sensor.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0227 Sensor Supply Voltage #2 Circuit. Voltage above normal or shorted to high source.

Possible Cause High voltage on the 5 volt supply line due to a short to battery voltage.

– Engine power derate.

Action and Remedy – This supply circuit provides 5 volt supply to the Camshaft speed/position sensor, intake manifold pressure sensor, and fuel rail pressure sensor from Engine ECU (ECM) connector J1 pin 37. – Measure the voltage at any of the listed related sensors to confirm that the supply voltage is above 5.25 volts. – Measure the voltage between J1 pin 37 and a suitable ground to confirm the ECM produces within the 4.75 to 5.25 voltage range. – Unplug the Engine ECU (ECM) from the Engine Harness and switch the ignition on. If fault code Q0227 remains active with the ECM unplugged then check the ECM supply voltage (continuous power J3-3 and switched power J2-39), then contact JCB Landpower for advice on replacing the ECM. – With the ECM J1 connector unplugged from the Engine harness measure resistance between pin J1-37 and the battery positive (+) terminal. Since there should be no contact, unless a short is present, resistance should be infinite. – Unplug the Camshaft speed/position sensor, intake manifold pressure sensor, and fuel rail pressure sensor. Check for pin to pin contact between J137 and the other pins in the J1, J2 and J3 ECM connectors. If resistance can be measured of less than 100k ohms then a short is present between the sensor’s supply lead and another lead in the engine harness.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0234 Engine Speed High. Data valid but above normal operating range. Most Severe Level – Fuel Injection disabled until engine speed drops below the overspeed limit 3400 rpm.

Possible Cause

Action and Remedy

– Engine speed, measured by the Crankshaft Sensor, indicates the engine speed is above the protection limit..

– Check the engine oil level in case the turbocharger is leaking oil into the inlet system.

– This may be caused by: external fuel sources being drawn into the engine. the engine tampering of the engine speed sensors.

– Examine the engine for alternative fuel sources. – Inspect the Engine Speed Sensors for damaged connectors or active fault codes. – Check for fault code Q0234 being active when the engine is at idle. This code should only become active when the engine speed is above 3400 rpm. – Contact JCB Landpower after the previous steps have been re-checked.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0238 Crankshaft Sensor Supply Voltage Circuit. Voltage below normal or shorted to low source. – Possible rough running or hard starting. Camshaft speed sensor will be used instead.

Possible Cause

Action and Remedy

– Damaged connectors.

– Refer to Crankshaft Speed Sensor.

– Short in Crankshaft sensor supply wiring.

– Check the Engine ECU (ECM) connector and Crankshaft Speed Sensor connector for damage or corrosion.

– Internal Crankshaft Speed sensor fault.

– Unplug the Crankshaft Speed Sensor from the Engine Harness. – Does fault code Q0238 change to ‘previously-active’ after 30 seconds with ignition ‘On’? – Faulty Crankshaft Speed Sensor identified. – If Q0238 remains active after 30 seconds with the ignition ‘On’ then the Sensor 5 volt ‘supply’ wiring is probably shorting to ground or a return wire. – The supply wire is from Engine ECU (ECM) Connector pin 16 to the sensor connector pin 1. – Disconnect the Crankshaft Speed Sensor connector and with the ignition switched ‘On’ measure the voltage between pin 1 and a suitable earth. The voltage should be 5 volts. If it is less than 4.75 then measure the voltage between the ECM pin J1 16 and a suitable earth to confirm the ECM is supplying the correct voltage. – With the ECM and sensor disconnected measure resistance between the Crankshaft sensor supply pin and earth. Unless there is a short to earth, resistance will be infinite. – Measure resistance between the Crankshaft Sensor Supply pin and the other pins in the ECM J1 connector to test for shorts to other leads in the harness.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0268 Fuel Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect

Possible Cause – Damaged connector. – Faulty Pressure Sensor.

Action and Remedy – Check if fault codes Q0451 or Q0452 are active. Investigate these first. – Testing the Fuel Rail Pressure Sensor:

– Power is reduced. The Engine ECU (ECM) will estimate Fuel Rail Pressure.

Disconnect the Fuel Rail Pressure sensor from the Engine Harness. Does Q0452 become active at ignition ‘On’? If it 0452 becomes active, use a jumper wire to short the signal and return pins at the pressure sensor connector. Does Q0451 become active at ignition ‘On’? – If these fault codes become active under these circumstances, replace the Fuel Pressure Sensor. – If Q0451 does not become active when the sensor is unplugged, examine the connectors and wiring. – If Q0452 becomes active but Q0451 does not then the ECM may be faulty. Contact JCB Landpower for advice.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0271 Fuel Pressure Valve Solenoid Circuit. Voltage below normal or shorted to low source.

Possible Cause Short to high voltage or an open circuit in the fuel pump actuator circuit.

Action and Remedy – The Fuel Pump Actuator controls fuel flow to the high pressure fuel pump. It is installed in the adapter in the back of the high pressure fuel pump. – The Engine Control Module (ECM) changes the signal to the Fuel Pump Actuator Valve to vary fuel flow based on engine operating conditions. The sensor is earthed back to the ECM, connected by ECM Connector J1 pins 32 and 2. The valve has a normally open position.

– Engine will have low power. Engine might run poorly at idle

– Check all connectors for damage or corrosion. If the fault code is intermittent then examine them closely for loose pins. – With the sensor connected check for an open circuit between the signal and return leads from the ECM by measuring resistance between the signal and return pins. A resistance less than 5 ohms is expected, higher than this suggests an open circuit. – Check both the signal and return leads for a short to a earth by measuring resistance between the contact and a suitable ground. Unless there is a short to earth, resistance should be infinite when the ECM disconnected. – With the fuel pump actuator in place, check for an internal short to ground by measuring resistance between each contact and a suitable earth in turn. An internal fault will cause a resistance of less than 100k ohms. – Measure the resistance between the two contacts. Resistance between the two contacts should be less than 5 ohms unless there is an internal fault. – Ensure a PWM signal is emitted from the Engine ECU (ECM) Connector J1 between pins 32 and 2. A frequency measurement is most appropriate.

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Description and Effect

Q0272 Fuel Pressure Valve Solenoid Circuit. Voltage above normal or shorted to high source.

Possible Cause Short to high voltage or an open circuit in the fuel pump actuator circuit.

– Engine will have low power. Engine might run poorly at idle.

– Check all connectors for damage or corrosion. If the fault code is intermittent then examine them closely for loose pins. – With the sensor connected check for an open circuit between the signal and return leads from the ECM by measuring resistance between the signal and return pins. A resistance less than 5 ohms is expected, higher than this suggests an open circuit. – Check both the signal and return leads for a short to a supply by measuring resistance between the contact and the battery + terminal. Unless there is a short in the harness to a supply voltage, resistance should be infinite with the ECM disconnected. – With the fuel pump actuator in place, check for an internal short to ground by measuring resistance between each contact and a suitable earth in turn. An internal fault will cause a resistance of less than 100k ohms. – Measure the resistance between the two contacts. Resistance between the two contacts should be less than 5 ohms unless there is an internal fault. – Ensure a PWM signal is emitted from the Engine ECU (ECM) Connector J1 between pins 32 and 2. A frequency measurement is most appropriate.

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Description and Effect

Q0275 Fuel High Pressure Pump not responding or out of adjustment.

Possible Cause – Fuel Pressure Sensor poor connectors or leads. – Air in fuel.

Action and Remedy – Check whether other fault codes are active relating to the fuel pressure sensor. Investigate these first. – Check the fuel pressure sensor terminals for damage or corrosion.

– Engine will not run or low power.

– Check the fuel pressure signal wire for continuity or shorts. This might cause Q0275 to be active. – Check if there is air in the fuel. Cummins tap off the fuel pressure line at the pressure outlet from the fuel filters. – If these steps do not rectify the problem after being re-checked, the cause may be related to failed pump seals or plungers in the High Pressure Fuel pump. This will cause excessive drain flow from the pump, perhaps to the extent that the engine will not start as there is no fuel rail pressure. – Inspecting the pump seals and plungers is a specialist task performed by Cummins. Contact JCB Landpower.

Q0281 High Pressure Fuel Pump not responding properly or out of adjustment.

– Faulty fuel Pressure Sensor connector or leads. – Air in fuel.

– Check whether other fault codes are active relating to the Fuel Pressure Sensor. Investigate these first. – Check the Fuel Pressure Sensor terminals for damage or corrosion.

– Possible low power or engine may not run.

– Check the Fuel Pressure Sensor signal wire for continuity or shorts. This might cause Q0275 to be active. – Check if there is air in the fuel. Cummins tap off the fuel pressure line at the pressure outlet from the fuel filters. – If these steps, after being re-checked, do not rectify the problem, the cause may be related to failed pump seals or plungers in the High Pressure Fuel pump. This will cause excessive drain flow from the pump, perhaps to the extent that the engine will not start as there is no fuel rail pressure. – Inspecting the pump seals and plungers is a specialist task performed by Cummins. Contact JCB Landpower.

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Description and Effect

Q0284 Engine Crankshaft speed/ position sensor supply voltage circuit. Voltage below normal or shorted to low source.

Possible Cause Low voltage on the 5 volt sensor supply line caused by short circuit, failed sensor or failed Engine ECU (ECM) power supply.

– Possible hard starting or rough running.

Action and Remedy – Check if the voltage between the crankshaft sensor supply and return pins is below the minimum 4.75 volts. – Disconnect the Engine ECU (ECM) and measure the voltage between ECM Connector J1 pins 38 and 33. – With the ECM and sensor disconnected measure the resistance between the Crankshaft speed sensor supply and return pins at the sensor connector. Resistance should be infinite unless the supply and return leads are shorting together. – Reconnect the ECM to the engine harness. Measure resistance between the crankshaft sensor supply pin at the sensor connector and a suitable earth. Unless the supply lead is shorting to earth, resistance should be infinite. – Check the 12 volt constant and switched power supply to the ECM. – Determine if the Crankshaft Speed sensor is faulty using the link below.

Q0285 SAE J1939 Multiplexing PGN Timeout Error Abnormal Update Rate

One of the Vehicle ECU’s is disconnected from the CANBus

Check the CanBus

Q0286 SAE J1939 Multiplexing One of the Vehicle ECU’s is Configuration Error – Out of disconnected from the CANBus Calibration

Check the CanBus

Q0295 Barometric Pressure Sensor Circuit. Data erratic, intermittent or incorrect. – Engine power derate. Q0319 Real Time Clock Power Interrupt - Data Erratic, Intermittent, or Incorrect.

– Check for fault codes Q0689 and Q0778 being active. – These might cause fault code Q0295 to be active.

– Check there is 5 volts between the barometric pressure sensor supply and return pins. – Check the signal lead for shorts to earth or to other pins in the harness.

– The clock feature allows the The Cummins software is required to time and date time to be reprogram the ECM with the correct date and displayed with the error code. time. – It becomes active after the battery supply to the Engine ECU (ECM) has been disconnected.

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Description and Effect

Q0322 Injector Solenoid Cylinder #1 Circuit. Current below normal or open circuit.. – Engine can misfire or run rough. The fault code may not always register if the fault is very intermittent.

Possible Cause – The Engine ECU (ECM) controls the injector opening. Although each injector is controlled individually, injectors 1, 2 and 3 are connected internally in the ECM as are injectors 4, 5 and 6. – If single injector fault is active the causes may include: – Open circuit in the engine harness or injector solenoid.

Action and Remedy – The ECM connects to the Engine Harness which in turn connects to each injector by a ‘pass through connector’ at the rocker cover. – Inspect all connectors for damage. – Single injector fault code: – Measure the resistance between cylinder injector #1 Driver and Return pin at the ECM Engine harness connector. Resistance should be less than 2 ohms.

– High resistance in a single injector or injector solenoid.

– Measure the resistance between the injector #1 signal and return leads at the pass-through connector which again should be less than 2 ohms.

– Extremely low resistance in an injector solenoid (injector shorted internally but not to ground)

– Remove the rocker cover and disconnect injector #1 connector. If the resistance across the injector terminals is higher than 2 ohms, replace the injector.

– Failed ECM.

– Measure the resistance between the injector driver terminal and the engine block earth. If resistance is less than 100k ohms replace the injector.

– If a bank of injectors have active fault codes, the causes may include: – Short circuit in the engine harness - either shorts to ground or to other wires in the engine harness – Short circuit in any of the three injectors in the bank - shorts to ground – Failed ECM.

– If the injector is less than 2 ohms and there is no internal short to earth then check the wiring: – Disconnect the ECM to ‘pass-through connector’ lead at both ends. – Measure resistance between the driver and return pin. – Since there should be no connection, unless the wires are shorting together, resistance should be infinitely high. – Measure the resistance between the driver and return pins at both ends of the lead. A resistance higher than 1 ohm indicates an open circuit. – Measure resistance between the driver pin and a suitable earth. Repeat with the return pin. A measured resistance indicates a short to earth. – Measure the resistance between both the return pin and driver pin to other pins in the ECM Engine Harness connector. – Repeat the test using the ‘pass-through connector’ to injector terminal lead.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0323 Injector Solenoid Cylinder #5 Circuit. Current below normal or open circuit. – Engine can misfire or run rough. The fault code may not always register if the fault is very intermittent.

Action and Remedy – The ECM connects to the Engine Harness which in turn connects to each injector by a ‘pass through connector’ at the rocker cover. – Inspect all connectors for damage. – Single injector fault code: – Measure the resistance between cylinder injector #5 Driver and Return pin at the ECM Engine harness connector. Resistance should be less than 2 ohms.

– High resistance in a single injector or injector solenoid.

– Measure the resistance between the injector #5 signal and return leads at the pass-through connector which again should be less than 2 ohms.

– Extremely low resistance in an injector solenoid (injector shorted internally but not to ground)

– Remove the rocker cover and disconnect injector #5 connector. If the resistance across the injector terminals is higher than 2 ohms, replace the injector.

– Failed ECM.

– Measure the resistance between the injector driver terminal and the engine block earth. If resistance is less than 100k ohms replace the injector.

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Description and Effect

Q0324 Injector Solenoid Cylinder #3 Circuit. Current below normal or open circuit – Engine can misfire or run rough. The fault code may not always register if the fault is very intermittent.

Action and Remedy – The ECM connects to the Engine Harness which in turn connects to each injector by a ‘pass through connector’ at the rocker cover. – Inspect all connectors for damage. – Single injector fault code: – Measure the resistance between cylinder injector #3 Driver and Return pin at the ECM Engine harness connector. Resistance should be less than 2 ohms.

– High resistance in a single injector or injector solenoid.

– Measure the resistance between the injector #3 signal and return leads at the pass-through connector which again should be less than 2 ohms.

– Extremely low resistance in an injector solenoid (injector shorted internally but not to ground)

– Remove the rocker cover and disconnect injector #3 connector. If the resistance across the injector terminals is higher than 2 ohms, replace the injector.

– Failed ECM.

– Measure the resistance between the injector driver terminal and the engine block earth. If resistance is less than 100k ohms replace the injector.

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Description and Effect

Q0325 Injector Solenoid Cylinder #6 Circuit. Current below normal or open circuit. – Engine can misfire or run rough. The fault code may not always register if the fault is very intermittent.

Action and Remedy – The ECM connects to the Engine Harness which in turn connects to each injector by a ‘pass through connector’ at the rocker cover. – Inspect all connectors for damage. – Single injector fault code: – Measure the resistance between cylinder injector #6 Driver and Return pin at the ECM Engine harness connector. Resistance should be less than 2 ohms.

– High resistance in a single injector or injector solenoid.

– Measure the resistance between the injector #6 signal and return leads at the pass-through connector which again should be less than 2 ohms.

– Extremely low resistance in an injector solenoid (injector shorted internally but not to ground)

– Remove the rocker cover and disconnect injector #6 connector. If the resistance across the injector terminals is higher than 2 ohms, replace the injector.

– Failed ECM.

– Measure the resistance between the injector driver terminal and the engine block earth. If resistance is less than 100k ohms replace the injector.

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Description and Effect

Q0331 Injector Solenoid Cylinder #2 Circuit. Current below normal or open circuit – Engine can misfire or run rough. The fault code may not always register if the fault is very intermittent.

Action and Remedy – The ECM connects to the Engine Harness which in turn connects to each injector by a ‘pass through connector’ at the rocker cover. – Inspect all connectors for damage. – Single injector fault code: – Measure the resistance between cylinder injector #2 Driver and Return pin at the ECM Engine harness connector. Resistance should be less than 2 ohms.

– High resistance in a single injector or injector solenoid.

– Measure the resistance between the injector #2 signal and return leads at the pass-through connector which again should be less than 2 ohms.

– Extremely low resistance in an injector solenoid (injector shorted internally but not to ground)

– Remove the rocker cover and disconnect injector #2 connector. If the resistance across the injector terminals is higher than 2 ohms, replace the injector.

– Failed ECM.

– Measure the resistance between the injector driver terminal and the engine block earth. If resistance is less than 100k ohms replace the injector.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0332 Injector Solenoid Cylinder #4 Circuit. Current below normal or open circuit – Engine can misfire or run rough. The fault code may not always register if the fault is very intermittent

Action and Remedy – The ECM connects to the Engine Harness which in turn connects to each injector by a ‘pass through connector’ at the rocker cover. – Inspect all connectors for damage. – Single injector fault code: – Measure the resistance between cylinder injector #4 Driver and Return pin at the ECM Engine harness connector. Resistance should be less than 2 ohms.

– High resistance in a single injector or injector solenoid.

– Measure the resistance between the injector #4 signal and return leads at the pass-through connector which again should be less than 2 ohms.

– Extremely low resistance in an injector solenoid (injector shorted internally but not to ground)

– Remove the rocker cover and disconnect injector #4 connector. If the resistance across the injector terminals is higher than 2 ohms, replace the injector.

– Failed ECM.

– Measure the resistance between the injector driver terminal and the engine block earth. If resistance is less than 100k ohms replace the injector.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0334 Coolant Temperature Sensor Circuit – Data Erratic, Intermittent, or Incorrect

Possible Cause

Action and Remedy

– Faulty temperature sensor.

– See Coolant Temperature Sensor. Inspect the ECM Engine Harness connector J1 for damage and also the temperature sensor connector.

– High resistance in the signal or return leads.

– Compare the internal resistance of the temperature sensor to guide values.

– Engine ECU (ECM) will estimate coolant temperature.

– Disconnect the Coolant Temperature Sensor and the ECM Engine Harness connector J1. Check the resistance of the signal and return leads is less than 1 ohm.

Q0341 Engine Control Module data ECM power supply faulty. lost. Data erratic, intermittent or incorrect.

– The Engine ECU (ECM) receives constant voltage through a fused unswitched battery wire, connected directly to the positive (+) battery post. – The ECM receives switched battery input through the vehicle ignition when the key is switched ‘On’.

– Possibly no performance effects. Engine may die or have difficult starting. Fault information may be inaccurate.

– The earth wire is connected directly to the negative (-) battery post. – Check the battery voltage is higher than 12 volts with the engine ‘off’ and higher than 6.2 volts when cranking. – Unplug the ECM power connector (connector J3). – Measure the resistance between the 12 volt supply (pin 3) and the battery + terminal to check it is less than 0.5 ohms. If it is higher check the terminals and fuse for damage or corrosion. – Measure the voltage to the switched power pin 39. – Check the resistance between the ECM earth pin (pin 1) and a suitable earth is less than 10 ohms.

Q0343 Engine Control Module Warning. Internal hardware failure.

Internal ECM fault.

– If there are less than three disconnect the ECM Engine Harness Connectors. Reconnect and wait 5 minutes. Start the engine and idle for one minute.

– No performance effects. Possible power derate.

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– Check the number of previously-active fault codes.

– If fault code Q0343 becomes active, contact JCB Landpower before replacing the ECM.

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Description and Effect

Q0351 Injector Power Supply. Measured injector voltage is low. – Possible smoke, low power, engine misfire, and/or engine will not start.

Possible Cause

Action and Remedy

– This fault code will become active when the engine is running, the Crankshaft Speed Sensor signal is present, the battery is charged but the measured injector power supply voltage is lower than the commanded voltage.

– Inspect the Engine ECM Connector J1 and J3 (power) for pin damage or corrosion.

– This fault code will become inactive whenever the key is turned ‘On’.

– Measure the 12 volt supply at the switched voltage pin (pin 39) with the ignition switched on.

– This fault code will become inactive whenever the engine is running and measured injector power supply voltage reaches the commanded voltage.

– Measure the resistance between the ECM ground (J3 pin 1) and a suitable earth. Resistance should be less than 10 ohms.

– Measure the resistance between the constant power ECM supply (pin 3) and the battery + terminal. Resistance should be less than 0.5 ohms unless an open circuit or terminal corrosion is present.

– The likely cause is faulty power or earth wiring to the Engine ECU (ECM). Fault codes Q0322, Q0323, Q0324, Q0325, Q0331 or Q0332 being active indicate faulty injector circuits and may cause Q0351 to be active.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0352 Barometric Pressure Sensor Supply Circuit. Voltage below normal or shorted to low source. – Engine power derate.

Possible Cause

Action and Remedy

– Sensor supply lead shorting to ground.

– The Barometric Pressure sensor monitors air pressure.

– Sensor supply lead shorting to return lead.

– It has a 5 volt supply, a return and a signal lead. This fault code is active when the 5 volt supply lead is shorting to a low voltage.

– Failed sensor. – Failed ECM power supply.

– Measure the voltage between the pressure sensor supply and return contacts with the ignition on. If the reading is less than 4.75 volts then check the voltage between ECM Engine Harness Connector pins J1-33 and J138. – If the voltage from the ECM is low check the power supply and ground from ECM Engine Harness Connector 3. – Disconnect the ECM Engine Harness and the pressure sensor. – Measure resistance between the supply and return pins. Unless there is a short between the two leads, resistance should be infinite. – Measure resistance between the pressure sensor supply lead and a suitable earth. If a resistance can be measured then this indicates a short to earth in the harness. – Check for pin to pin contact by measuring resistance between the pressure sensor connector supply contact and the pins in the ECM Engine Harness connectors. This will check for a short to other leads in the engine harness.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0386 Barometric Pressure Sensor Supply Circuit. Voltage above normal or shorted to high source.

Possible Cause Sensor supply lead shorting to a high voltage.

Action and Remedy – The Barometric Pressure Sensor monitors air pressure. It has a 5 volt supply, a return and a signal lead. – This fault code is active when the 5 volt supply lead is shorting to a high voltage.

– Engine power derate.

– Measure the voltage between the pressure sensor ‘supply’ and ‘return’ contacts with the Ignition ‘On’. If the reading is higher than 5.25 volts then measure the voltage between ECM engine harness connector pins J1-33 and J1-38. – Disconnect the ECM from the engine harness. Switch the ignition ‘On’ and see if fault code Q0386 changes to ‘previously-active’. If it does then a short between the sensor supply lead and a high voltage has been identified. – Check that the ECM switched power supply to Connector J2 pin 39 is 0 volts when the ignition is switched ‘off’. – Measure resistance between the ECM connector J3 pin 3 (constant 12 volt supply) and the Engine Harness connector J1 pin 33 (Barometric sensor supply). If a resistance can be measured then there is a short between the sensor supply lead and either the ECM Power lead or another lead in the engine harness connected to the battery + terminal.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0387 Accelerator Pedal Position Sensor. Supply voltage circuit. Voltage above normal.

Possible Cause Position sensor 5 volt supply lead shorting to a voltage higher than 5.25 volts in the harness.

– Engine will only idle.

Action and Remedy – Refer to Accelerator Pedal Position Sensor. With the ignition switched on, disconnect the yellow accelerator pedal sensor connector. Measure the voltage between the supply and return pins to check if it is higher than 5.25 volts. – If the voltage is higher than 5.25 volts then measure the voltage between ECM engine harness connector pins J2-22 and J2-23. Voltage should be less than 5.25 volts. – Check that the ECM switched power supply is 0 volts when the ignition is switched ‘off’. – Measure for a short between the ECM switched and constant 12 volt supply contacts and the sensor supply pin,. Since there should be no link between the sensor supply lead and the battery, there must be a short to either the ECM power lead or another lead connected to the battery + terminal. – Disconnect the ECM engine harness and unplug the yellow pedal sensor. Check for pin to pin shorts in the ECM engine harness connector caused by wires shorting in the engine harness.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0415 Oil Pressure Low. Data Valid but below normal operating range. Most Severe Level – Progressive power derate increasing in severity from time after alert. If Engine Shutdown Feature is enabled using Cummins software, the engine will shutdown 30 seconds after warning.

Possible Cause

Action and Remedy

– Low oil pressure.

– Check oil level.

– Low oil level.

– Switch the machine off. Check if the switch is faulty by measuring resistance between the contact and a suitable earth. The oil pressure switch assumes a closed position when oil pressure is below 7 psi. Consequently a low resistance should be measured unless.

– Failed oil pressure switch. – Engine Harness shorted to ground.

– Measure the oil pressure switch is receiving 5 volts between the sensor connector lead and a suitable earth. – Disconnect the engine harness and measure resistance between the oil pressure sensor and a suitable earth. Resistance should be infinitely high since there should be no contact unless a short is present. – Measure resistance between the engine oil pressure signal lead and other pins in the engine harness connector plug for pin to pin shorts. – When oil pressure is above 7 psi the switch opens and prevents any voltage reaching ground. Check that the oil pressure is above 7 psi.

Q0418 Water in Fuel Indicator High. Data valid but above normal operating range. – Water has been detected in the fuel. Possible white smoke or difficult starting. Least Severe Level.

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– Water in fuel. – Short circuit to another signal wire. – Faulty water in fuel sensor.

– Undo the drain plug on the fuel filter assembly and look of evidence of water being present. – Clear the fault code and switch the ignition on. See if the fault code becomes active again. – Refer to Water in Fuel sensor. Check the internal resistance of the sensor. – Check the signal wire for shorts to other pins in the harness.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0426 SAE J1939 data link cannot transmit. – None on performance – Communication with other ECU’s is not possible

Possible Cause

Action and Remedy

– Unplugging an electronic service tool before keying off the ECM, SAE J1939 data link has an intermittent electrical problem

– This fault occurs whenever the ECM starts communicating with any other device using the SAE J1939 data link and then can no longer transmit on the data link.

– An ECU tying up communications because of an electrical problem or by sending too many messages without stopping.

– Check that the fault code becomes active within 30 seconds when the ignition is switched back ‘On’. – Examine the Can-Bus contacts (ECM connector J2 pins 37, 47 and 46) for corrosion or damage. – Look for other active fault codes relating to CanBus errors which might cause Q0426 to be active.

Q0427 CanBus Datalink Abnormal Update Rate. – Engine speed will decrease to idle.

– Electrical problems with the SAE J1939 data link wiring such as grounded, shorted, or open circuits. – The ECM (or another SAE J1939 device) tying up communications by sending too many consecutive messages. – Another ECU has failed or can no longer transmit on the datalink

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– This fault occurs whenever the ECM starts communicating with any other device using the SAE J1939 data link and then can no longer transmit on the data link. – Check that the fault code becomes active within 30 seconds when the ignition is switched back ‘On’. – Examine the Can-Bus contacts (ECM connector J2 pins 37, 47 and 46) for corrosion or damage. – Look for other active fault codes relating to CanBus errors which might cause Q0426 to be active.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0428 Water in Fuel Sensor Circuit. Voltage above normal or shorted to a high source. – None on engine performance. No water in fuel warning available

Possible Cause

Action and Remedy

– Open return or signal lead to sensor.

– Disconnect sensor connector and examine for damage or corrosion.

– Signal wire shorted to a high voltage source.

– Check the sensor’s internal resistance is within limits.(see water in fuel sensor)

– Faulty sensor.

– Reconnect the sensor and confirm the fault code is active with the ignition ‘On’. – Check for an open circuit on the signal or return leads. Measure resistance between the relevant ECM engine harness connector and the contacts in the water-in-fuel sensor connector. Resistance should be less than 5 ohms unless an open circuit has been detected. – Disconnect the ECM Engine Harness connector J1. Measure resistance between the signal wire contact in the sensor connector and the battery + terminal (or a contact linked to the battery + terminal). Resistance should be in excess of 100k ohms unless a short circuit to supply has been detected. – Measuring resistance, check pin to pin contact in the ECM Engine Harness connector for short circuit between the water in fuel signal pin and other connector pins. Resistance should be in excess of 100k ohms unless a short has been detected.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0429 Water in Fuel Sensor Circuit. Voltage below normal or shorted to low source.

Possible Cause – Signal lead open circuit or shorted to ground. – Return lead open circuit or shorted to ground.

Action and Remedy – The water-in-fuel sensor is attached to the fuel filter and is replaced with the fuel filter. As water collects in the filter the signal changes. – Disconnect the water-in-fuel sensor connector. Switch the ignition ‘On’ and wait 30 seconds. Watch for Error code Q0429 becoming inactive and Q0428 being active. This identifies a faulty sensor rather than damaged wiring.

– None on engine performance. No water in fuel warning available.

– If fault code Q0429 remains active when the sensor connector is unplugged then it suggests a wiring fault. – Disconnect the ECM Engine Harness Connector. Measure resistance between each of the two contacts in the water-infuel sensor connector and a suitable earth. Unless one of the wires is shorting to ground resistance should be very high. – Check for an open circuit on the signal or return leads. Measure resistance between the relevant ECM engine harness connector and the contacts in the water-in-fuel sensor connector. Resistance should be less than 5 ohms unless an open circuit has been detected. Q0433 Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent, or Incorrect – Derate in engine power.

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– At key-on, before the engine is started, the readings for intake manifold pressure, barometric pressure, and exhaust pressure are compared. – This fault code occurs if the intake manifold pressure sensor reading is different from the other three. This check is only done once after the key-switch is turned on.

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– Check connectors. – See if fault code Q0433 becomes repeatedly active after 30 seconds with the ignition switched ‘On’. – Replace the intake manifold pressure sensor.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0435 Oil Pressure Sensor Circuit. Data Erratic, Intermittent or Incorrect. – No effect on engine performance but oil pressure sensor will not work.

Possible Cause – Failed engine oil pressure switch. – Open circuit in the engine oil pressure switch signal wire. – Failed ECM. – Short circuit in the engine oil pressure switch signal wire to a voltage source.

Action and Remedy – The oil pressure switch is closed when there is no oil pressure. And open when oil pressure is present. The fault code is logged when an open circuit is detected for five consecutive key cycles when the ECM expected a closed circuit at key-on. – Check the resistance of the oil pressure sensor. Resistance should be less than 10 ohms. – Disconnect the ECM Engine Harness Connector and measure the resistance of the oil pressure sensor signal wire. Unless there is an open circuit resistance should be less than 10 ohms. – Determine whether the Oil pressure switch is shorting to another wire. Measure resistance between the oil switch signal wire and every other pin in the ECM Engine Harness Connector. Resistance should be more than 100k ohms unless a short between wires has been detected.

Q0441 Battery Voltage Low. Data valid but below normal operating range. – Engine may stop or have difficult starting. Moderately Severe Level

– Under charged batteries caused by a faulty alternator or regulator. – Battery voltage dropping below 6.2 volts while cranking. – High resistance in power leads.

– Check that the battery voltage between the battery terminals is at least 6.2 volts while cranking. If it is less the battery may need replacing. – Check that the resistance of the battery continuous supply lead is less than 10 ohms (as below). If it is high the voltage reaching the ECM may reduce caused by corroded terminals or damaged wiring. – Check the resistance of the switched power supply between the ignition switch and the ECM switched power contact is less than 10 ohms.

A0442

Battery Voltage High. Data valid but above normal operating range. – Possible electrical damage to all electrical components. Moderately severe level.

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– Faulty alternator or regulator that is overcharging the system. – Incorrect jump-starting procedure.

Measure the battery voltage while the machine is running at above 1500rpm. Battery voltage should not exceed 16 volts. A higher voltage indicates a faulty alternator or regulator.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0443 Accelerator Foot Pedal YELLOW Position Sensor. Voltage is below normal or shorted to low source. – Engine will stop.

Possible Cause Low voltage on the +5 volt supply line can be caused by a short circuit to ground in the supply line, a short circuit between the supply line and return circuit, a failed Accelerator position sensor, or a failed ECM power supply.

Action and Remedy – Read Accelerator Position Sensors. Measure the voltage between the sensor connector pins 1 and 2. If voltage is significantly less than 5 volts examine the terminals for corrosion or damage. – Measure the resistance between the sensor connector pin 1 (supply) and a suitable earth contact. Resistance should be very high unless a short is occurring. Check the wiring carefully for shorts to other leads. – Disconnect the ECM Engine Harness Connector and measure resistance between the sensor connectors pin 1 (supply) and pin2 (return). – Resistance should be in excess of 100k ohms unless a short between the wires has been detected.

Q0449 Fuel Rail Pressure High. Data valid but above normal operating range – Moderately Severe Level – None or possible power interruption while dump valve resets

– Fault Code 449 is activated when the sensed Fuel-rail pressure exceeds the opening pressure of the Fuel-rail pressure relief valve but no error is detected with the fuel pump actuator. – Purging air through the fuel system can cause a pressure overshoot causing Fault Code Q0449 to log.

– Are other fault codes present relating to the fuel injection system? Investigate these first. – Inspect the fuel rail pressure sensor wires and connectors. – The next step is to measure diesel pressure at various stages of the injection system. This requires specialist tools. Contact JCB Landpower.

– High fuel restriction possibly due to blocked filters. – A fuel pressure sensor that reads low or a poor electrical connection. – Intermittent electrical circuit problems in the fuel pump actuator circuit. – Faulty ECM wiring harness such as poor grounds, battery voltage spikes, electrical noise, low alternator output, and large disturbances of battery voltage, as when jump starting the vehicle.

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Description and Effect

Q0451 Fuel Rail Pressure Sensor Circuit. Voltage above normal or shorted to high source. – Power derate.

Possible Cause – Voltage (+5 VDC or higher) shorted to the signal wire. – Open circuit on the signal wire. – Open circuit on the +5-VDC supply wire. – Open circuit on the return wire. – Failed sensor. – Failed ECM.

Action and Remedy – The Fuel Rail Pressure Sensor is supplied with 5 volts from ECM pin 37 to sensor pin 3. – The sensor is grounded by pin 1 (return) to ECM pin 47. – Sensor connector pin 2 transmits the signal voltage to ECM pin 25. – This 5 volt power supply is shared with: Intake manifold pressure sensor. Backup engine position sensor. Fuel pressure sensor. – Check for active fault codes related to these sensors that may indicate a supply fault or short in the 5 volt supply wiring. – Check if the supply lead is shorting to a supply: Disconnect the 3 pin sensor connector. Measure the 5 volt supply between Fuel Rail Pressure Sensor connector pins 1 and 3. The expected range is 4.75 to 5.25 volts. – If the voltage reading between pins 1 and 3 is high then disconnect the ECM Engine Harness. – Measure the resistance between the sensor pin 3 (+5 volt supply) and the battery + terminal (or a suitable alternative linked to the battery + terminal). – There should be no connection between the lead and a power supply so resistance should be in excess of 100k ohm. If resistance is low then a short to a supply voltage has been detected. – Check if the signal lead is shorting to a supply: With the ECM Engine harness connected and the pressure sensor connector disconnected, switch the ignition ‘On’. Measure voltage between signal pin 2 and a suitable earth. No reading should be detected unless there is a short present.

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Description and Effect

Q0452 Fuel Rail Pressure Sensor Circuit. Voltage Below Normal, or Shorted to Low Source. – Engine power derate.

Possible Cause – The fuel pressure sensor is used by the Engine ECU (ECM) to monitor the fuel pressure in the fuel rail. – This fault code will become active when the key is ‘ON’ and the signal voltage is too low. – This can be caused by a short circuit to ground on the +5VDC supply or signal wire. – It may also be cause if a device that is powered by the common +5-VDC power supply is shorted to ground. – Pressure switch has internal fault.

Action and Remedy – The Fuel Rail Pressure Sensor is supplied with 5 volts from ECM pin 37 to sensor pin 3. – The sensor is grounded by pin 1 (return) to ECM pin 47. – Sensor connector pin 2 transmits the signal voltage to ECM pin 25. – This 5 volt power supply is shared with: Intake manifold pressure sensor. Backup engine position sensor. Fuel pressure sensor. – Check for active fault codes related to these sensors that may indicate a supply fault or short in the 5 volt supply wiring. – Measure the 5 volt supply between Fuel Rail Pressure Sensor connector pins 1 and 3. The expected range is 4.75 to 5.25 volts. – If there is no voltage reading between pins 1 and 3, measure voltage between pin 3 (5 volt supply) and a suitable earth. If voltage is now measured an open circuit or poor earth contact in the sensor return lead has been detected. – Disconnect the ECM engine harness and the Fuel Rail Pressure Sensor connector: – Measure resistance between the sensor connector pin 2 (signal) and a suitable earth. Resistance should be very high (100k ohms) unless a short to earth is detected. – Repeat the test measuring resistance between the sensor connector pin 3 (supply) and a suitable earth. Resistance should be very high (100k ohms) unless a short to earth is detected.

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Description and Effect

Q0553 Engine Fuel Rail Pressure High. Data valid but above normal operating range. Moderately severe level. – No noticeable effect or possible engine noise associated with higher injection pressures especially at idle or light load.

Possible Cause – Fuel Pump Actuator, which controls fuel flow to the high pressure pump may be faulty. – The Fuel Pump Actuator may have excessive leakage which may also cause fault code Q0449 to be active.

– The fuel circuit relies on an electric lift pump priming a low pressure gear pump supplying fuel to a high pressure pump. The amount of fuel reaching the high pressure fuel pump is controlled by a fuel pump actuator which in turn controls the volume of fuel reaching the injection rail. – The Engine Control Module (ECM) changes the signal to the Fuel Pump Actuator Valve to vary fuel flow based on engine operating conditions. – Examine for leakage:

– Engine power is reduced.

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Action and Remedy

Remove the fuel pump actuator (circled below) and inspect the inboard O-ring. If it is damaged it may allow fuel to bypass the actuator and enter the high pressure pump thus causing a higher rail pressure than expected. To remove, clean the area around the fuel pump and remove the three cap-screws. Install a new Oring (oil lightly first). Be sure the fuel pump actuator flange is flush with the mounting surface of the fuel pump. Seat the actuator by turning in a clockwise direction while pushing it into the bore. Tighten the cap-screws evenly to a final torque of 6Nm.

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Description and Effect

Q0554 Injector Metering Rail Pressure Low. Data valid but below normal operational range. – The ECM will estimate fuel pressure and engine power is reduced.

Possible Cause – This fault code can become active any time the engine is loaded and the Engine ECU (ECM) detects the fuel pressure in the rail fuel is not changing. – It may be caused by a faulty pressure switch, the signal wire shorting to another source or connector damage.

Action and Remedy – The Fuel Rail Pressure Sensor is supplied with 5 volts from ECM pin 37 to sensor connector pin 3. – This 5 volt power supply is shared with: Intake manifold pressure sensor. Backup engine position sensor. Fuel pressure sensor. – Check for active fault codes related to these sensors that might indicate a supply fault or short in the 5 volt supply wiring. – Measure the 5 volt supply between Fuel Rail Pressure Sensor connector pins 1 and 3. Test for a short to other leads in engine harness: – Disconnect the ECM engine harness and also the Fuel Rail Pressure Sensor connector – The Pressure signal is sent from sensor connector pin 2 (the centre pin of the sensor connector) to ECM pin 25. – Check that the signal contact (pin 2) is ONLY connected to Pin 25 at the ECM Engine Harness Connector. – Resistance to every other pin should be very high (100k ohms) unless a short between leads has been detected.

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Description and Effect

Q0559 Injector Metering Rail Pressure Low. Data valid but below normal operational range. – Possibly hard to start, low engine power or excess exhaust smoke. Moderately severe level.

Possible Cause

Action and Remedy

– If Fault Code Q0559 is inactive and there are no existing performance complaints, the engine may have been run out of fuel or was not primed after fuel filter replacement.

– The code is activated when the engine is running and measured rail fuel pressure remains at least 1450 psi less than commanded pressure. Once active fault code Q0559 will remain active until the engine is turned off or until the measured rail fuel pressure matches the commanded rail fuel pressure.

– Check that the system is correctly primed with no air in the system. Listen for the electric lift pump operating with the ignition switched on.

– It is possible for the fault code to be active only when the engine is heavily loaded and become inactive when the engine is lightly loaded. – The fuel system has lost its ability to maintain fuel rail pressure. This may be due to: – Fuel inlet restrictions – Fuel filter plugging – Fuel gear pump output low

– Check fuel is reaching the gear pump inlet port from the electric lift pump (approx. 5psi fuel pressure is expected) – Check fuel is reaching the fuel filters at the inlet port from the gear pump when the engine is running. (approx. 70psi fuel pressure is expected with the engine at high idle). – Ensure the pressure drop between the filter’s inlet and outlet ports are not greater than 20psi. – Further tests will typically require a specialist engineer. Look if other fault codes are active or have recently been active and rectify these first. Clear all fault codes. – If fault code Q0559 becomes active again contact JCB Landpower.

– Fuel gear pump pressure regulator sticking or leaking – High pressure pump capacity decay (high leakage to drain from the high pressure pump) – Fuel rail pressure relief valve leaks to drain – Fuel rail pressure relief valve opens at too low a pressure – Injector fuel circuit leaks to drain – Pressure sensor reads more than 100 bar lower than actual pressure.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0596 Electrical Charging System Voltage High. Data valid but above normal operating range. – Warning lamp may be illuminated. Moderately severe level.

Possible Cause – The Electronic Control Module (ECM) receives constant voltage through leads connected directly to the positive (+) battery post through a 30-ampere fuse.

Action and Remedy Check the battery voltage while the engine is running and the alternator is charging. Typically this voltage should not be above 16 volts.

– The ECM receives switched battery input through the ignition when the vehicle key is turned on. – The battery return wires are connected directly to the negative (-) battery post. – The ECM has sensed that it is receiving high voltage. – Overcharged battery caused by a faulty alternator or regulator.

Q0597 Electrical Charging System Voltage Low. Data valid but below normal operational range. – A warning lamp may be illuminated. Moderately Severe Level.

– The Electronic Control Module (ECM) receives constant voltage through leads connected directly to the positive (+) battery post through a 30-ampere fuse. – The ECM receives switched battery input through the ignition when the vehicle key is turned on. – The battery return wires are connected directly to the negative (-) battery post. – The ECM has sensed that it is receiving low voltage.

– Check that the battery voltage is at least 12 volts. – Undercharged batteries caused by a faulty alternator or regulator. – Check that the battery voltage between the battery terminals is at least 6.2 volts while cranking. If it is less the battery may need replacing. – Check that the ECM is receiving power directly from the battery and has not been connected to the starter motor. – Check that the resistance of the battery continuous supply lead is less than 10 ohms (as below). If it is high the voltage reaching the ECM may reduce caused by corroded terminals or damaged wiring. – Check the resistance of the switched power supply between the ignition switch and the ECM switched power contact is less than 10 ohms.

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Description and Effect

Q0598 Electrical Charging System Voltage Low. Data valid but below normal operating range. – Warning lamp should be illuminated. Most Severe Level

Possible Cause – The Electronic Control Module (ECM) receives constant voltage through leads connected directly to the positive (+) battery post through a 30-ampere fuse. – The ECM receives switched battery input through the ignition when the vehicle key is turned on. – The battery return wires are connected directly to the negative (-) battery post. – The ECM has sensed that it is receiving low voltage.

Action and Remedy – Check that the battery voltage is at least 12 volts. – Undercharged batteries caused by a faulty alternator or regulator. – Check that the battery voltage between the battery terminals is at least 6.2 volts while cranking. If it is less the battery may need replacing. – Check that the ECM is receiving power directly from the battery and has not been connected to the starter motor. – Check that the resistance of the battery continuous supply lead is less than 10 ohms (as below). If it is high the voltage reaching the ECM may reduce caused by corroded terminals or damaged wiring. – Check the resistance of the switched power supply between the ignition switch and the ECM switched power contact is less than 10 ohms.

Q0689 Engine Crankshaft Speed Sensor Error. Data erratic, intermittent or incorrect. – – – –

Fault code Q0689 becomes active when the Engine ECU (ECM) does not receive a signal from the crankshaft engine speed sensor, or Engine can run rough. the signal it receives is degraded. Possibly poor starting This may be due to: capability. – Open circuit on the supply, Engine runs using signal, or return circuits in the backup speed sensor. sensor, engine harness, or Engine power is ECM. reduced. – Short circuits to ground or return circuits in the sensor, engine harness, or ECM. – Short circuits to a voltage source in the sensor, engine harness.

– Check for sensor supply fault code 284 being active. – Measure the 5 volt supply to the sensor using the supply and return pins is within limits. (see Engine Speed Sensors). – Unplug the ECM engine harness and measure resistance between the two ends of the Crankshaft Signal wire. Unless an open circuit is detected resistance should be less than 10 ohms. – Measure resistance between the ‘signal’ pin in the Crankshaft sensor connector and a suitable earth. Resistance should be very high (over 100k ohms) unless the signal lead is shorting to Earth. – Repeat the test measuring resistance between the signal lead and the battery positive terminal (or a contact connected to the battery positive terminal). Again resistance should be in excess of 100k ohms unless a short to a supply voltage is detected. – If no fault is found examine the sensor for damage, check the air gap is within specification and that the tone wheel is not damaged. (See Engine Speed Sensor)

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q0731 Engine Speed/Position #2 mechanical misalignment between camshaft and crankshaft sensors Mechanical System Not Responding Properly or Out of Adjustment

Possible Cause – Fault with either Crankshaft or Camshaft speed/position sensor or wiring. – Camshaft and Crankshaft out of phase.

Action and Remedy – This fault will become active any time the ECM receives a signal from both the Crankshaft speed sensor and the Camshaft speed sensor, and the ECM determines that the two signals are not in the correct phase. – If this fault code is active immediately following a repair that includes camshaft removal, the camshaft gear may be installed incorrectly and not timed correctly. – Inspect the ECM and sensor connectors for damage or corrosion. – Check the power supply to the crankshaft and Camshaft Sensors. Measure the voltage between both the sensor connector pins 5 volt supply (pin 1) and sensor return (pin 2). Both sensors should show between 4.75 and 5.25 volts between the two pins. – Disconnect the ECM engine harness and measure the resistance between the ends of the supply, return and signal leads in turn for both the Crankshaft and Camshaft sensors. Resistance should be less than 10 ohms unless an open circuit is present. – With the ECM engine harness disconnected measure resistance between the Camshaft and Crankshaft sensor’s supply, return and signal leads and a suitable earth in turn. (The return lead earths through the ECM). Resistance should be very high (100k ohms) unless the lead shorts to ground. – Repeat the test measuring resistance between the Camshaft and Crankshaft sensor’s supply, return and signal leads and the battery positive terminal (or a suitable 12volt contact to the battery). Resistance should be very high (greater than 100k ohms) unless the lead is shorting to a supply voltage. – If fault has not been found check the air gap clearance between each sensor and the target is within tolerance. – Examine both target wheels for damage or excess run-out.

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Description and Effect

Possible Cause

Q0753 Engine Camshaft Speed/ Position sync error - Data Erratic, Intermittent, or Incorrect

Engine Camshaft Speed/Position Sensor signal error.

Q0757 Engine ECU (ECM) data lost.

The Electronic Control Module (ECM) receives constant voltage from the battery through leads connected directly to the positive (+) battery post through a single 30ampere fuse. The ECM receives switched battery input through the ignition when the vehicle key is turned on. The battery return wires are connected directly to the negative (-) battery post. Code Q0757 may become active if:

– Range from no noticeable effect to difficult starting or engine dying. – Fault information can be inaccurate.

– ECM battery supply voltage drops below 6.2 volts momentarily while the key is in the ON position. – A fuse has blown. – The battery was disconnected within 30 seconds of the ignition being switched off. The ECM needs 30 seconds to power down after the ignition is switched ‘off’.

Action and Remedy Refer to Q0778 for details on how to check the Camshaft Sensor and associated wiring.

– Check the fuses and relevant connectors for corrosion or damage. – Check that the battery voltage between the battery terminals is at least 6.2 volts while cranking. – Check the resistance of the constant power supply lead is less than 10 ohms between the ECM constant supply contact and the positive battery terminal as below. Check that the resistance between the ECM switched (ignition) supply connector and the key ignition post is less than 5 ohms through the ignition. (Ignition should be switched ‘off’.) – If resistances appear high examine connectors for corrosion or damaged wiring. Check the fuses and fuse holder.

– Resistance in the ECM supply or earth circuits is excessive. High resistance can cause a low voltage at the ECM input.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Possible Cause

Q0778 Engine Camshaft Speed This fault is recorded when the Sensor Error. Data incorrect ECM does not receive a signal from or intermittent. the camshaft position sensor or the signal the ECM receives is – Possible power derate. degraded. This may be due to: – Possible poor starting.

– Open circuit on the supply, signal, or return circuits in the sensor, engine harness, or ECM Short circuits to ground or return circuits in the sensor, engine harness, or ECM. – Short circuits to voltage source in the sensor, engine harness, or ECM.

Action and Remedy – Check if fault codes Q0187 and Q0227 are active. These may cause fault code Q0778 to become active. – Inspect the ECM and sensor connectors for damage or corrosion. – Measure the voltage between the sensor connector pins 5 volt supply pin 1 and sensor return pin 2. Should be between 4.75 and 5.25 volts. – Disconnect the ECM engine harness and measure the resistance between the ends of the supply, return and signal leads in turn. Resistance should be less than 10 ohms unless an open circuit is present. – With the ECM engine harness disconnected measure resistance between the sensor supply, return and signal leads and a suitable earth. (The return lead earths to ground through the ECM). The resistance should be very high (100k ohms) unless the lead is shorting to ground. – Repeat the test measuring resistance between the sensor supply, return and signal leads and the battery positive terminal (or a suitable 12volt contact linked to the battery). Resistance should be very high (greater than 100k ohms) unless there the lead is shorting to a supply voltage. – If fault has not been found check the air gap clearance between sensor and target is within tolerance. – Examine target wheel for damage or excess run-out.

Q0951 Cylinder power imbalance – Possible low power, rough idle or misfire.

The Engine ECU (ECM) monitors Look for other active fuel related error codes. engine speed as each injector fires Check for: while the engine is at idle. If a cylinder has high or low – air in the fuel (particularly following a fuel contribution to engine speed, this change) fault will become active. – signs of head gasket failure – This is the limit of investigation before contacting JCB Landpower. Cummins Engine Software is required to accurately further diagnose the fault before the engine is worked on.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Possible Cause

Q0117

Engine ECU (ECM) power supply lost without ignition switched ‘off’ or not allowed 30 seconds to ‘power down’ after ignition switched ‘Off’.

– Range from no noticeable effect to difficult starting or engine dying. – Fault information can be inaccurate.

– ECM battery supply voltage drops below 6.2 volts momentarily while the key is in the ON position. – A fuse has blown.

Action and Remedy – Check the fuses and relevant connectors for corrosion or damage. – Check that the battery voltage between the battery terminals is at least 6.2 volts while cranking. – Check the resistance of the constant power supply lead is less than 10 ohms between the ECM constant supply contact and the positive battery terminal as below. Check that the resistance between the ECM switched (ignition) supply connector and the key ignition post is less than 5 ohms through the ignition. (Ignition should be switched ‘off’.) – If resistances appear high examine connectors for corrosion or damaged wiring. Check the fuses and fuse holder.

– The battery was disconnected within 30 seconds of the ignition being switched off. The ECM needs 30 seconds to power down after the ignition is switched ‘off’. – Resistance in the ECM supply or earth circuits is excessive. High resistance can cause a low voltage at the ECM input.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code Q1139

Description and Effect Injector Cylinder #1 - Not responding properly or out of adjustment. – Engine will shut down since injector cannot be controlled properly.

Possible Cause – The electronic control module (ECM) can detect when unintended fuel injection occurs by monitoring fuel rail pressure and engine speed. This fault code is logged when the ECM determines that unintended fuel injection has occurred. – Examine the pass through connectors for corrosion or damage. – The fault code can become active if an injector becomes damaged and jams open, fuelling continuously.

Action and Remedy – Examine the pass through connectors for obvious damage or corrosion. If an injector is fuelling continuously the engine will typically die or not start. Excessive exhaust smoke and an audible engine knock is often associated with the problem. Fault code Q2115 will be active during cranking since the injector is fuelling continuously and Injection Rail pressure will be low. – Cummins engineers use a fuel blocking tool that prevents fuel reaching the suspect injector. If the symptoms then disappear and fault code Q1144 becomes inactive, a faulty injector has been diagnosed. – Be aware that if the injector is fractured or broken then damage to the piston, liner or head may have occurred and needs investigating. – Replace fuel injector number 1.

Q1141

Injector Cylinder #2 - Not responding properly or out of adjustment. – Engine will shut down since injector cannot be controlled properly.

– The electronic control module (ECM) can detect when unintended fuel injection occurs by monitoring fuel rail pressure and engine speed. This fault code is logged when the ECM determines that unintended fuel injection has occurred. – Examine the pass through connectors for corrosion or damage. – The fault code can become active if an injector becomes damaged and jams open, fuelling continuously.

– Examine the pass through connectors for obvious damage or corrosion. If an injector is fuelling continuously the engine will typically die or not start. Excessive exhaust smoke and an audible engine knock is often associated with the problem. Fault code Q2115 will be active during cranking since the injector is fuelling continuously and Injection Rail pressure will be low. – Cummins engineers use a fuel blocking tool that prevents fuel reaching the suspect injector. If the symptoms then disappear and fault code Q1144 becomes inactive, a faulty injector has been diagnosed. – Be aware that if the injector is fractured or broken then damage to the piston, liner or head may have occurred and needs investigating. – Replace fuel injector number 2.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code Q1142

Description and Effect Injector Cylinder #3 - Not responding properly or out of adjustment. – Engine will shut down since injector cannot be controlled properly.

Q1143

Injector Cylinder #4 - Not responding properly or out of adjustment. – Engine will shut down since injector cannot be controlled properly.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code Q1144

Description and Effect Injector Cylinder #5 - Not responding properly or out of adjustment. – Engine will shut down since injector cannot be controlled properly.

Q1145

Injector Cylinder #6 - Not responding properly or out of adjustment. – Engine will shut down since injector cannot be controlled properly.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2185 Accelerator pedal YELLOW position sensor. Voltage above normal or shorted to high source. – Engine will ONLY idle.

Possible Cause

Action and Remedy

This fault is activated when the ECM senses more than 5.25 volts on the Accelerator Pedal. This can be caused by a short circuit to a voltage source in the wiring harness or a short circuit to a signal lead greater than 5 volts.

– Refer to Accelerator Pedal. Disconnect the Yellow Accelerator Position Sensor and confirm the voltage between pins 1 and 2 is above 5.25 volts.

Note: Read this carefully. The Accelerator Pedal has two sensors, a yellow one connected to the Engine ECM and a red one connected to the DECU. (SEE ACCELERATOR PEDAL). Fault code Q2186 refers to the Yellow Pedal Sensor. The throttle Handlever is not related to this fault. It is connected separately to the DECU and will activate ‘P’ fault codes.

– Disconnect the ECM engine harness and unplug the yellow accelerator pedal position connector. Inspect the connectors for signs of corrosion or damage that could cause a short circuit. – With the harness disconnected refer to the Accelerator Pedal ‘Pin-Out’ diagram. Measure resistance between the Accelerator Pedal connector pin 2 (supply voltage) and the battery. – Since there should be no connection between the battery and the lead, resistance should be very high (100k ohms). – Confirm that the other connector pin 1 and 3 are also not shorting to a feed voltage. Measure resistance between the Accelerator Pedal Connector Voltage supply pin (Pin 2) and every pin in the ECM Engine Harness connector in turn. Resistance should be very high (100k ohms) between all pins except for ECM pin 22 (intended connection). A low resistance to any other pin indicates a short to another wire. – Be aware that the accelerator pedal connector is part of the vehicle wiring harness and consequently could short to wires in the harness other than those to the ECM. Look for other active fault codes that may indicate a short between two wires.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2186 Accelerator Pedal YELLOW Sensor. Supply voltage below normal or shorted to low source. – Engine will die.

Possible Cause – Accelerator sensor signal supply lead shorting to earth. – Accelerator sensor signal return lead shorting to earth. – Signal supply and return lead shorting together.

Action and Remedy – Unplug the ECM from the engine harness and unplug the accelerator pedal connector. – Measure the resistance between each of the three contacts in the accelerator pedal connector and a suitable earth in turn. Since the wires should not be earthed (unless damaged), resistance should be greater than 100k ohms. – Check the Accelerator Pedal signal supply lead is not shorting to the Accelerator Pedal signal return lead by measuring the resistance between the two relevant contacts in the Accelerator Pedal connector. – Check neither the Accelerator Signal lead or Signal return lead aren’t shorting to a lead in the Engine Harness: – Measure the resistance between the Accelerator Pedal signal pin and the other pins in the ECM harness connector. – Repeat this test between the Accelerator Pedal signal return pin and the other pins in the ECM harness connector. – Resistance should be greater than 100k ohms unless there is a short between leads. – Check the 5 volt supply to the Accelerator Pedal Connector.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2215 High Pressure Fuel Pump pressure low. Voltage below normal or shorted to low source. – May include: difficult starting, low power or excess engine smoke

Possible Cause – Vehicle run out of diesel or not primed after change of fuel filter. – Fuel inlet restrictions. – Fuel filter blocked. – Low pressure fuel gear pump output low. – Fuel pump actuator sticking or leaking. – High pressure pump faulty – high leakage to drain. – Fuel rail relief valve leaks to drain or opens at too low pressure. – Injector fuel circuit leaks to drain. – Pressure sensor reading significantly lower than actual pressure.

Action and Remedy – If the fault codes Q0275, Q0449, Q1117 or Q2311 are active or show high counts of inactive faults then investigate these first as they may cause fault code Q2215 to be active. – If the engine is running and fault codes Q0449 or Q2311 are not present, check the ECM power supply. – The fuel circuit relies on an electric lift pump priming a low pressure gear pump supplying fuel to a high pressure pump. The amount of fuel reaching the high pressure fuel pump is controlled by a fuel pump actuator which in turn controls the volume of fuel reaching the injection rail. – Check that the system is correctly primed with no air in the system. Listen for the electric lift pump operating with the ignition switched on. – Check fuel is reaching the gear pump inlet port from the electric lift pump (approx. 5psi fuel pressure is expected) – Check fuel is reaching the high pressure fuel pump inlet port from the gear pump when the engine is running. (approx. 70psi fuel pressure is expected with the engine at high idle). – Ensure the pressure drop between the filter’s inlet and outlet ports are not greater than 20psi.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2216 Fuel Pump Delivery Pressure valid but above normal operating range. – Possible engine noise associated with higher injection pressures (especially at idle or light load). Moderately Severe Level.

Possible Cause – Fuel pump actuator supplying more fuel than intended to the high pressure fuel pump. – Fuel lift pump supplying excessive fuel pressure.

Action and Remedy – Check if fault codes 271, 272 or 2311 are active. (These relate to the Fuel pump actuator and may cause higher than required fuel flow). – Remove the fuel pump actuator (circled below) and inspect the inboard O-ring. If it is damaged it may allow fuel to bypass the actuator and enter the high pressure pump. – To remove, clean the area around the fuel pump and remove the three capscrews. Install a new O-ring (oil lightly first). Be sure the fuel pump actuator flange is flush with the mounting surface of the fuel pump. Seat the actuator by turning in a clockwise direction while pushing it into the bore. Tighten the capscrews evenly up to a final torque of 6Nm. – Check if the lift pump is supplying excess fuel pressure by measuring fuel pressure at the pressure side fuel filter outlet port. Pressure with the engine running should not be greater than 175psi. If it is higher than 175 psi then replace the fuel pump gear assembly.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2217 Engine Control Module (ECM) Program Memory corruption. Severe loss of data from the ECM.

Possible Cause – Poor power supply. – Damaged wiring.

Action and Remedy – The Engine Control Module (ECM) receives constant 12 volt supply from the battery to ECM pin 3. – The un-switched fused circuit is connected directly to the positive (+) battery post.

– Range from no noticeable performance effect to engine dying or hard starting.

– The ECM receives switched battery input through a fused supply to ECM pin 39 when the vehicle key is turned on. – The battery return wires are connected directly to the negative (-) battery post.

– Fault information, trip information, and maintenance monitor data can be inaccurate.

– Check fuses are not blown and installed correctly. – Check battery voltage is at least 12 volts. – Check the battery terminals are free from corrosion. – Disconnect the power lead to the Engine Control Module (ECM). Measure the resistance between the battery positive connector and the two ECM power leads. – Resistance should be less than 10 ohms. A higher reading suggests corrosion in terminals, damaged fuse holder or an open circuit. – When the reason for the fault code has been corrected re calibrate the ECM and clear the fault codes.

Q2249 Injector Metering Rail 1 Pressure. Data valid but below normal operating range.

Fault Code Q2249 is very similar to If Fault Code 2249 is active, the Fault Code Q0559 except that the troubleshooting procedures for Fault Code fault triggers at a different fuel Q0559 must be followed. pressure threshold limit.

– Possibly hard to start, low power, or engine smoke.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2265 Fuel Lift Pump Control Signal Circuit. Voltage above normal or shorted to high source. – Engine can be difficult to start.

Possible Cause – The Fuel Lift Pump is controlled by a Pulse Width Modulated (PWM) signal from the Engine Management ECM. – Fault code Q2265 becomes active at key ‘On’ if an open circuit is detected. An open circuit cannot be detected once the engine is running. – Open circuit or short circuit. – Fuel Lift Pump faulty.

Action and Remedy – The Fuel Lift Pump is located behind the ECM on the inlet side of the engine. It is behind the cooler plate which fuel passes through to help cool the ECM. The Lift pump is controlled and earthed through the ECM pins 01 and 11. Inspect the harness wiring connectors for damage. – Unplug the fuel lift pump and disconnect the engine ECM harness. Check the resistance is less than 10 ohms between each end of the supply and return wires. – With the engine harness unplugged, measure resistance between the two contacts in the engine harness connector to the fuel pump. Since there should be no connection between the two wires, Resistance should be very high (100k ohms) unless they are shorting together. – Now re-connect the engine harness to the ECM. – Measure voltage between the two contacts (as above). Since the supply signal from the ECM is pulse width modulated (PWM) it is difficult to accurately measure the signal voltage but it should be above 6 volts. – Measure the resistance between the two pins in the Fuel Priming Pump connector. Resistance should be less than 20 ohms unless the Fuel Lift Pump is defective.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2266 Fuel Lift Pump Control Signal Circuit. Voltage below normal or shorted to low source. – Engine can be difficult to start. Note: Fault code Q2266 will also become active if the priming pump motor stalls. Stall current for the priming pump motor is approximately 9 amperes. A good priming pump typically runs with less than 3 amperes. If the fault code is intermittent, observe the snapshot data priming pump measured current. If current was near 9 amperes when the fault condition occurred, conclude that the rotor has stalled and replace the electric lift pump.

Possible Cause – The Fuel Priming Pump is controlled by a Pulse Width Modulated (PWM) signal from the Engine Management ECM – This fault code becomes active whenever the ECM detects a short circuit to ground or high current in the electric lift pump circuit caused by a low resistance. – During cold weather, (less than -29°C) gelled fuel can plug the lift pump and cause this fault code. – This fault code can also become active if the lift pump rotor stalls or seizes.

Action and Remedy – When the fault condition is detected, the ECM driver to the lift pump is turned off to protect the circuit. It is necessary to switch the key ‘OFF’ and then back ‘ON’ before the ECM will retest for fault codes. If the cause is no longer present, the fault code will become inactive and can be cleared. – The Lift Pump is located behind the ECM on the inlet side of the engine. The Lift pump is controlled and earthed through the ECM pins 01 and 11. Since it is controlled by a PWM signal it is difficult to accurately measure the voltage signal. However should be greater than 6 volts. – Wiring Diagram:- Inspect the wiring between the ECM for damage. – Inspect the Lift pump SUPPLY lead for shorts to earth. – With the Engine harness connected to the ECM, measure the resistance between the engine fuel pump return pin and earth. (The pump earths through the ECM pin 11). Resistance should be less than 10 ohms unless there is an open circuit. – Check for a short circuit to other leads in the engine harness. – Disconnect the lift pump connector and see if fault code Q2266 becomes inactive and Q2265 becomes active at ‘key on’. This indicates a faulty lift pump.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2292 Fuel Inlet Meter Device Data Valid but Above Normal Operational Range – The fuel flow demand is higher than expected. Moderately severe level.

Possible Cause Fault Code 2292 sets when the ECM commands the electronic fuel control actuator to open more than expected to maintain rail pressure. This might be due to: – High fuel inlet restriction. – Blocked fuel filters. – low lift pump pressure. – stuck or restricted electronic fuel control actuator. – Fuel rail relief valve opening at too low pressure.

Q2293 Fuel Flow Demand Lower Than Expected. Data valid but below normal operating range. – None or possible engine noise associated with higher injection pressures (especially at idle or light load). Engine power is de-rated.

Fault Code Q2293 is activated when the Fuel Control Actuator is closed more than expected to lower rail fuel pressure. This might be due to: – Blocked fuel return line. – Excessive leakage from the Fuel Pump actuator. – Air in the fuel. – Faulty fuel pressure sensor.

Action and Remedy – Check that fuel is reaching the Gear pump inlet port from the electric lift pump through the fuel filters (approx. 5psi fuel pressure is expected). – Check fuel is reaching the high pressure pump inlet port from the gear pump when the engine is running. (approx. 70psi fuel pressure is expected with the engine at high idle). – Ensure the pressure drop between the filter’s inlet and outlet ports are not greater than 20psi. – Once the repair has been made, this fault code will require approximately 15-20 minutes of road test or dynamometer run to be set inactive. – Check if other fault codes relating to the fuel system are active. These may cause Q2293 to become active. – Check the fuel return line for blockages. – Check the fuel pump actuator for excessive leakage. – Fuel pressure sensor reading inaccurately. – Further tests involve measuring fuel pressure at different stages of the fuel system to identify a component causing excessive fuel pressure. – Refer to JCB Landpower.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code Q2311

Description and Effect Fueling Actuator Circuit Error. Resistance too high or too low. – Possible low power. – Engine might run poorly at idle.

Possible Cause – Engine harness high resistance or shorting to ground. – Faulty Fuel Pump Actuator – internal resistance too high or too low. Internally shorting to ground.

Action and Remedy – The Fuel Pump Actuator controls fuel flow to the high pressure fuel pump. It is installed in the adapter in the back of the high pressure fuel pump. The Engine Control Module (ECM) changes the signal to the Fuel Pump Actuator Valve to vary fuel flow based on engine operating conditions. The sensor is earthed back to the ECM, connected by ECM connector J1 pins 32 and 2. – The valve has a normally open position. Check all connectors for damage or corrosion. If the fault code is intermittent then examine them closely for loose pins. – With the sensor connected check for an open circuit between the sensor signal and return leads from the ECM by measuring resistance between the signal and return pins. – A resistance less than 5 ohms is expected, higher than this suggests an open circuit. – Repeat the test measuring resistance between the signal and return pins and a suitable earth. Unless there is a short to ground resistance should be infinite. – With the fuel pump actuator connected to the machine, check for a fault shorting to ground by measuring resistance between each contact and a suitable earth in turn. An internal fault will cause a resistance of less than 100k ohms. Check the resistance between the two contacts. Resistance between the two contacts should be less than 5 ohms unless there is an internal fault. – Ensure a PWM signal is emitted from the Engine Control Module (ECM) connector J1 between pins 32 and 2. – A frequency measurement is most appropriate.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2321 Engine Crankshaft Speed / Position Sensor. Data Erratic, Intermittent, or Incorrect. – Engine can misfire as control switches from the primary to the backup speed sensor.

Possible Cause – Intermittent open or short circuit between ECM and sensor. – Sensor air gap too large or too small. – Damage to teeth on tone wheel. – Sensor faulty.

– Engine power is reduced while the engine operates on the backup speed sensor.

Action and Remedy Refer to Engine Speed Sensor (SPN190). – Look for intermittent engine harness connections in the primary engine speed sensor circuit. – Look for loose connections at the ECM connector where the pins can not be locked into the socket. – Look for places where the engine harness has worn into a nearby component causing an intermittent short circuit – Look for tip damage at the speed sensor and check connector – Air gap between sensor and tone wheel incorrect. – Inspect the target wheel for damage.

Q2322 Engine Camshaft Speed / Position Sensor. Data Erratic, Intermittent, or Incorrect – As the Camshaft sensor is not required for normal engine operation (it is a backup to the Crankshaft sensor), no symptoms should be obvious.

– Most likely cause of intermittent fault is intermittent open or short circuit.

– Inspect wiring connectors for damage at ECM, engine harness connector and sensor connector.

– Sensor air gap that is marginally too small or too large, or target wheel exhibits excessive run-out.

– Inspect wiring along its length for signs of faults or earths. Check if other fault codes are active that might suggest a short between sensors. – If fault has not been found check the air gap clearance between sensor and target is within tolerance. – Examine target wheel for damage or excess run-out.

– Slight low engine power is possible.

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– For wiring checks refer to Q0778.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2347 Turbocharger Compressor Outlet Temperature above normal operating range (Calculated). – Engine power derate. Least severe level.

Possible Cause

Action and Remedy

This fault code is activated when Before Proceeding: the temperature of the air at the turbocharger compressor is above – Check for active fault codes from any of the normal operating range. the previously mentioned sensors which (NOTE: This temperature is not a are used by the ECM to calculate measured value). The Engine Turbocharger Compressor outlet Air Management ECU (ECM) Temperature. A fault from one of these calculates the air temperature sensors may also activate fault code leaving the turbocharger based on Q2347. engine operating conditions – Carefully examine air intake pipework for including: evidence of splits, loose connections or internal blockages. – Turbocharger compressor – Remove the intake pipe from the inlet air temperature. turbocharger to the intake side of the – Barometric pressure. engine. Inspect the compressor blades – Turbocharger speed. for damage and wear. If damage is noted inspect all piping and air filter before re– Engine speed. starting engine. – Intake manifold air – Remove the exhaust pipe to the temperature. turbocharger. Inspect the turbine wheel – Intake manifold pressure. for damage and wear. – Check oil level and type. – Check airflow through intercooler. Note: Unless the failure is a failed barometric pressure sensor or intake manifold pressure sensor, this fault code will most likely not be active with no engine load. The engine will most likely need to be loaded to activate fault code Q2347, and to determine if the failure has been found and fixed.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Possible Cause

Q2555

– Intake Air Heater #1 Circuit - Voltage Above Normal, or Shorted to High Source.

– Signal wire from EEM pin 40 to Intake manifold heater relay not connected, shorting to ground or a voltage source.

– The Intake Manifold Grid Heater will be either ‘on’ or ‘off’ all of the time.

– Return wire from Intake manifold heater relay to EEM pin 42 not connected, shorting to ground or a voltage source.

– The Grid heater, located in the Engine Inlet manifold, heats inlet air in cold ambient temperatures to improve cold starting and white smoke control.

– Shorted air heater intake relay.

Action and Remedy – Check wiring and connectors for damage. Test signal solenoid signal feed and return leads from EEM pins 40 and 42 for open circuit and shorts to earth or supply voltage. – Measure the resistance of the solenoid between the signal and return contacts. A value of more than 100 ohms indicates an internal fault in the solenoid.

– The Engine Management EEM supplies a 12 volt signal to the relay between pins 40 and 42 to switch the grid heaters on. – The heater is then energised by a 12 volt fused direct supply.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2556

– Engine Inlet Manifold Grid Heater Circuit. Voltage below normal or shorted to low source. – The Intake Manifold Grid Heater will be either ‘on’ or ‘off’ all of the time. – The Grid heater, located in the Engine Inlet manifold, heats inlet air in cold ambient temperatures to improve cold starting and white smoke control.

Possible Cause – Signal wire from EEM pin 40 to Intake manifold heater relay not connected, shorting to ground or a voltage source. – Return wire from Intake manifold heater relay to EEM pin 42 not connected, shorting to ground or a voltage source. – Shorted air heater intake relay.

Action and Remedy – Check wiring and connectors for damage. Test signal feed and return leads from EEM pins 40 and 42 to Intake Manifold heater solenoid for open circuit and shorts. – Disconnect the Intake manifold grid heater relay. Switch the ignition ‘on’ and wait 30 seconds. Does fault code Q2556 become inactive and fault code Q2555 become active? – Reconnect Intake manifold grid heater relay. Switch ignition ‘on’ and wait 30 seconds. Does fault code Q2556 become active again and fault code Q2555 now become inactive? – Faulty solenoid identified.

– The Engine Management EEM supplies a 12 volt signal to the relay between pins 40 and 42 to switch the grid heaters on. – The heater is then energised by a 12 volt fused direct supply.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2963 Engine Coolant Temperature High - Data Valid but Above Normal Operational Range.

Possible Cause Fault code becomes active when coolant temperature signal indicates coolant temperature is above the limit of the engine protection system.

– Progressive power derate increasing from time of alert. Least severe level.

Action and Remedy – Inspect coolant radiator for debris blocking the cooling fins or internal obstructions. – Check fan drive belt and correct fan operation. – Inspect the coolant system for external leaks. Look for evidence of white smoke due to internal coolant loss. – Inspect coolant pipes and couplings for collapse, incorrect routing or internal blockage. Water is pulled from the bottom of the radiator through the water pump, through the engine and returned to the radiator by the top hose. With the engine coolant above 90°C (thermostat open) and engine at high speed inspect the water pipe into the water pump for visible collapse. – Check engine oil level is correct level and grade which could cause increased engine temperature. – Check correct radiator cap is fitted. Ensure not malfunctioning opening at too low pressure. – Inspect sensor for malfunction. – Check water pump drive belt tension and check it is functioning correctly. – Check thermostat opens at 82°C.

Q2964 Intake Manifold Temperature High. Data valid but above normal operating range. – Progressive power derate increasing in severity from time of alert. Least severe level.

Fault code becomes active when the air temperature at the inlet manifold becomes too high. May be caused by: – Restricted airflow through intercooler fins. – Undersized intercooler. – High turbocharger outlet temperature. – Incorrect temperature voltage signal received at ECM.

– Check Intercooler radiator and pipework for restrictions. – Examine inlet pipework for evidence of heat sources. – IF FITTED Check EGR (Exhaust Gas Recirculation) is operating correctly and not generating fault codes. Excess high temperature exhaust gases might activate Q2946 fault code. – Check Turbocharger is operating correctly and not generating a fault code. – Check Inlet Manifold Air Temperature sensor supply and earth. – Check Temperature signal lead for open circuit, short to earth or voltage feed. – Check resistance value of sensor.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code

Description and Effect

Q2973 Intake Manifold Pressure Sensor Circuit. Data Erratic, Intermittent, or Incorrect – Derate in power output of the engine

Possible Cause – The pressure switch compares measured inlet manifold pressure to that expected based on inlet manifold air temperature, turbocharger speed and external air pressure. This fault code becomes active when a difference occurs between expected and measured inlet manifold pressure. – The intake manifold pressure sensor shares the engine harness with other sensors. Before troubleshooting Fault Code Q2973, check for multiple fault codes being active caused by a short between wiring.

Action and Remedy If multiple fault codes are active the reason may include: – Open return circuit in the engine harness, connectors, or sensor. – Signal wire shorted to sensor supply or battery voltage. – Check the intercooler and associated connections for leaks or restrictions. – Check related sensor connectors are in good condition. – Inspect the Engine Control Module, engine harness connector pins and sensor connector pins. – Check Inlet Manifold pressure sensor supply. – Check sensor for internal fault.

– Leak in the intake system between turbocharger and intake manifold. – Restriction in the intercooler or air filter. – Failed intake manifold pressure sensor. – Failed intake manifold temperature sensor. – Failed turbo speed sensor. – Failed barometric pressure sensor. Error Code R0101

Description Rear Linkage Control Valve. Raise Fault.

Possible Cause – Lead connected between EHR pin 35 and Rear Linkage ‘Raise’ solenoid connected to ground or feed.

– Check continuity of wiring from EHR pin 35 to the raise solenoid.

– ‘Raise’ solenoid faulty.

– Check 12V supply voltage to EHR pin 29, including fuse C9.

– No supply voltage to EHR pin 29. – Open circuit on lead connecting pin 37 to solenoid.

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Action and Remedy

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– Check resistance across solenoid (see ‘Rear Linkage Solenoid’).

– Check power output to solenoid from pin 37. – Once fault fixed switch ignition from OFF to ON and carry out System Activation Procedure.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code R0102

Description Rear Linkage Control Valve. Down Fault.

Possible Cause – Lead connected between EHR pin 35 and Rear Linkage ‘Lower’ solenoid connected to ground or feed.

– Check continuity of wiring from EHR pin 35 to the lower solenoid.

– Lower solenoid faulty.

– Check 12V supply voltage to EHR pin 29, including fuse C9.

– No supply voltage to EHR pin 29. Lower solenoid output stage faulty.

R0103

Short in Rear Linkage raise/lower circuit.

Action and Remedy

– Check resistance across solenoid. (See Rear linkage solenoid).

– Check power output to solenoid from pin 19.

– Open circuit on lead connecting pin 19 to solenoid.

– Once fault fixed switch ignition from OFF to ON and carry out System Activation Procedure.

– Short circuit between pins 35 and 19 (lower solenoid).

– Check wiring and connectors for shorts.

– Short circuit between pins 35 and 37 (raise solenoid).

– Check the lift/lower solenoid resistances. (See links below).

– Solenoid short circuit. R0104

R0105

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Rear Linkage Raise Control fault. The rear linkage cannot be raised using the external push buttons or the in-cab rocker switch. (In-cab rocker switch is NOT the Main Control Lever).

– Open circuit/short from EHR pin 9 to one of the button feeds. – Open circuit/short from one of the buttons to pin 17. – One of the buttons is faulty. Note: EHR Pin 9 supplies 5V to the in-cab lift/lower rocker switch and the external mounted linkage raise/lower buttons.

Rear Linkage lower control – Open circuit/short from EHR fault. Rear linkage cannot pin 9 to button feeds. be lowered using the – Open circuit/short from one of external push buttons or the buttons to pin 36. the in-cab rocker switch. – Button faulty. (Note: In-cab rocker switch is NOT the Main Control Note: EHR Pin 9 supplies 5V to Lever). the in-cab raise/lower rocker switch and the external mounted linkage raise/lower buttons.

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– With ignition switched ‘On’, check power supply to both external control switches and the in-cab rocker switch from EHR draft controller pin 9. – Check leads linking pin 9 (5V supply) to the linkage raise switch are not shorting. – Check lead from raise switch to pin 17 for continuity or short. – Check for switch failure: Disconnect leads to pins 9 and 17 on EHR draft controller. If operating correctly resistance across the two wires will drop when selecting ‘raise’ from the external buttons and in-cab rocker switch in turn. – Switch Ignition ‘On’. Check power supply to both mudguard mounted external control switches and the in-cab rocker switch from EHR draft controller pin 9. – Check leads linking pin 9 (5V supply) to the linkage lower switch are not shorting. – Check lead from lower switch to pin 17 for continuity or short. – Check for switch failure: Disconnect leads to pins 9 and 36 on EHR draft controller. If operating correctly resistance across the two wires will drop when selecting ‘raise’ from the external buttons and in-cab rocker switch in turn.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code R0106

Description Rear Linkage Control 10 Volt Supply Fault.

Possible Cause – Switched supply voltage from ignition to EHR control unit faulty. – Poor earth connection to EHR control unit.

R0107

Rear Linkage Control Battery Voltage Too High.

– The machine has been connected to a 24 volt system.

Action and Remedy – Check switched supply voltage (from ignition) to EHR pin 24 including fuse. – Check 12V continuous supply including fuse to pin 29. – Check earth connection on lead to pin 28. Measure the battery voltage and if it is over 16 volts, investigate and correct the reason.

– The alternator is faulty and is over charging. R0202

Rear Linkage Control Position Sensor Fault.

– Sensor open circuit or not connected. – Possible short circuit or short to earth. – Position sensor needs adjusting.

– Check lead between Position Sensor’s pin 2 - signal contact (see Position Sensor below) and pin 6 on EHR Draft Controller for continuity, shorts or feeds. – Compare actual position of rear linkage to position value on Display ECU where 100% is fully up position and 0% indicates fully down position. – Compare the signal lead voltages to those specified. (see Position Sensor link). Note: this sensor is not a potentiometer – resistance checks are not appropriate. Pins 1 and 3 must be connected to the Position Sensor before a voltage signal can be measured on pin 2. Measure the signal voltage at EHR Draft Controller pin 6 if necessary. – Read installation note if installing a new sensor.

R0205

Rear Linkage Control Panel Fault.

– Faulty supply to the Rear Linkage Control panel.

– Check 12V ignition supply to Operator Control Panel pin 1 including fuse.

– Faulty CanBus connection between the control panel and the Draft Control ECU.

– Check CANBus connection between operator control panel and EHR Draft Controller.

– Faulty operator control panel. R0206

EHR Draft Controller. External Sensor fault.

– External sensor facility not used.

Check EHR contacts for accidental feeds or shorts.

– Bosch EHR Draft Controller could be used with additional sensors.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code R0207

R0301

Description DECU (Display ECU) CANBus messages lost.

Rear Linkage Right Draft Pin Fault.

Possible Cause

Action and Remedy

– DECU (Display ECU) is not communicating CANBus messages.

– Check contacts of DECU (Display ECU) to CANBus.

– CANBus wire unplugged.

– Check the CanBus is not shorted to 0 volts.

– CANBus is shorted to 0 volts or 12 volts.

– Check the CanBus is not shorted to 12 volts.

– Check both 120 ohms CanBus terminating resistors are present.

– Check CanBus resistance. With both resistors fitted the CanBus resistance should be 60 ohms.

– Sensor open circuit or not connected.

– Check lead from right draft pin signal contact (see link below) to EHR Draft Controller pin 26 for continuity, shorts and accidental feeds.

– Possible short circuit or short to earth. – Possible overload of force sensing pin.

– Check supply voltage to connector from EHR Draft Controller pin 39. Pin 39 also supplies power to the rear linkage position sensor and the left draft pin. – Check earth lead between EHR Draft Controller pin 1 and draft pin connector. – Disconnect signal lead to EHR Draft Controller pin 26 and compare voltage values to those specified. – Check draft force reading on Display ECU. Value should be 0 N with no load and change as mounted implement is pulled.

R0302

Rear Linkage Left Draft Pin Fault.

– Sensor open circuit or not connected. – Possible short circuit or short to earth. – Possible overload of force sensing pin.

– Check signal lead from left draft pin to EHR Draft Controller pin 7 for continuity, shorts and feeds. – Check lead from left draft pin signal connector to EHR Draft Controller pin 7 for continuity, shorts or accidental feeds. Inspect lead between cab and draft pin for damage. – Check supply voltage to connector from Draft controller pin 39. Pin 39 also supplies power to the rear linkage position sensor and the left draft pin. – Check earth lead between Draft controller pin 1 and draft pin connector. – Disconnect signal lead to Draft Controller pin 7 and compare signal voltage values. – Check draft force reading on Display ECU. Number should read 0 N with no load and change as mounted implement is pulled.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Error Code R0303

Description Rear Linkage Control Battery Voltage Too Low.

R0306

Mix Potentiometer Fault.

R0307

Rear linkage failed to move to required position.

Possible Cause – Faulty wiring. – Faulty alternator.

Action and Remedy Measure the battery voltage and if this is low investigate and repair the cause.

– Power supplied to raise/lower solenoids but no movement seen from position sensor.

– Operate raise/lower spool on control valve block manually. Check if oil is reaching valve block.

– Lack of oil pressure.

– Check power reaching solenoids and solenoid operation.

– Relief valve set incorrectly. – Valve seized. R0401

Radar Speed Signal Fault.

– Wire disconnected.

– Refer to Radar connector wiring.

– Wire shorting to a feed or shorting to earth.

– Check radar is being supplied 12V (this is not from an ECU).

– Radar signal not being received.

– Check the earth connection.

– Internal Radar fault.

– Check the 12V ‘radar present’ signal is being transmitted between radar connector and EMS pin R25. – A signal voltage is sent from the radar to: EHR Draft Controller pin 10, EMS pin R7, and ECU 1 (central controller) pin A11. Check these wires for continuity or shorts. – The signal voltage should range continually between about 0.8V and 4.6V. (This may be difficult to measure). The signal frequency however will vary only depending on forward speed. Compare the signal frequency with that expected when driving forwards.

R0402

Transmission Speed Signal Fault.

– A transmission speed sensor is fitted in the side of the gearbox. It has two functions, to measure propshaft speed and also monitor direction of rotation (i.e. forwards or reverse). – The speed signal is sent to both the Transmission ECU (EST) and the EHR Draft Controller. – The Error code may be caused by the speed signal wire being disconnected, a short to earth or a voltage short. – Sensor faulty.

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– Refer to link ‘Transmission speed sensor’. – Check the connections between the Speed sensor signal lead and the Transmission EST (pin 34) and EHR Draft Controller (pin 11). – Check the signal lead for continuity, shorts to earth or short to voltage between the sensor and Transmission EST and also between the sensor and EHR Draft Controller. – Check the 8.5 volt sensor supply including fuse. – Check the earth contact. – Check the speed signal voltage at the ECU end of the signal lead and compare to target values.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

U0000

No CANBUS receive Central Controller ECU CAN Bus message - Front hitch slice messages not received by front hitch slice.

Check CAN Bus wiring. Turn ignition off and unplug valve slice showing fault. Reconnect from centre of tractor one at a time waiting for LED to flash before plugging in next slice. If no LED flash, suspect faulty valve slice.

U0001

No CANBUS receive Central Controller ECU CAN Bus message - Front hitch slice messages not received by front hitch slice.

U0002

Implausible CANBUS receive message - Front hitch slice

Central Controller ECU CAN Bus messages not received by front hitch slice.

U0003

Implausible CANBUS receive message - Front hitch slice

Central Controller ECU CAN Bus messages not received by front hitch slice.

U0004

Potentiometer / PWM fault - Spool valve slice internal fault. Front hitch slice

If this error persistently occurs replace spool valve slice.

U0005

EEPROM inconsistent Front hitch slice

Spool valve slice internal fault.

If this error persistently occurs replace spool valve slice.

U0006

No faults but valve has switched off for > 4 seconds - Front hitch slice

Internal valve slice fault or CAN Bus fault.

Unplug slice, put control lever to stop and reconnect. If fault persists suspect faulty slice.

U0007

Supply voltage < 11.0 volts Alternator not charging. Damaged Measure voltage at battery to determine if the - Front hitch slice wiring or faulty batteries. fault is slice specific.

U0008

Supply voltage > 16.0 volts Alternator over-charging or Measure voltage at battery to determine if the - Front hitch slice machine has been connected to a fault is front hitch slice specific. higher voltage system.

U0009

Spool Movement Too short Spool valve slice internal fault. - Front Hitch Slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. Recalibrate spool. If this fault is only on one slice and it persistently occurs, replace the valve slice.

U0010

Excessive spool movement Front hitch valve slice fault. - Front hitch slice

Check manual lever is not jammed or been operated. If this is not the case and the error occurs persistently, replace spool valve slice.

U0011

Float position not reached - Front hitch valve slice fault. Front hitch slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

U0012

Spool valve operated Front hitch valve slice fault. manually - Front hitch slice

Check manual lever is not jammed or been operated. If this is not the case and the error occurs persistently, replace spool valve slice.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

U0013

Supply < 8 volts - Front hitch slice

U0014

Supply > 36 but < 45 volts - Alternator over-charging or Measure voltage at battery to determine if the Front hitch slice machine has been connected to a fault is front hitch slice specific. higher voltage system.

U0015

High over-voltage (> 45 volts) - Front hitch slice

Alternator over-charging or Measure voltage at battery to determine if the machine has been connected to a fault is front hitch slice specific. higher voltage system.

U0016

Output stage fault - Front hitch slice

Front hitch valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

U0017

Position transducer fault Front hitch slice

Front hitch valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

U0018

Spool cannot return to neutral position - Front hitch slice

Front hitch valve slice fault.

Check manual lever or spool is not jammed or spool has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

U0019

Spool not in neutral when powered up - Front hitch slice

Front hitch valve slice fault.

Check manual lever or spool is not jammed or spool has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

U0020

Program Memory Error Front hitch slice

Spool valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

U0021

Spool valve off-line - Front hitch slice

Central Controller ECU CAN Bus messages not received by front hitch slice.

U0066

Linkage potentiometer input too high

Voltage signal to Central Controller ECU too high. Out of calibrated range.

Check wiring. Recalibrate. Replace potentiometer if problem persists.

U0067

Linkage potentiometer input too low

Voltage signal to Central Controller ECU too low. Out of calibrated range.

Check wiring. Recalibrate. Replace potentiometer if problem persists.

U0068

Linkage potentiometer input open circuit

Voltage signal to Central Controller ECU disconnected.

Check wiring. Recalibrate. Replace potentiometer if problem persists.

U0071

Spool valve very high temperature - front hitch slice

Very high hydraulic temperature measured on the front hitch slice.

Check cooling system for blockage and clean as necessary. Check that implement is set up correctly to match the Fastrac.

C - 227

Alternator not charging. Damaged Measure voltage at battery to determine if the wiring or faulty batteries. fault is front hitch slice specific.

9803/8040-5

C - 227

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code U0124

Description FCC Front Hitch Control Panel off-line

Possible Cause – Faulty 12 volt supply to front hitch control panel. – Poor earth connection. – CanBus lead fault.

Action and Remedy – Check the fused 12 volt supply to the front hitch operator control panel connector pin 1. – Check the earth connection to the control panel connector pin 4. – Check the CanBus wires are properly connected to the front hitch control panel pins 2 and 3. – Monitor Can activity using the JCB Service Master diagnostic screen. – Check the CanBus.

U0201

Spool movement too short - Front hitch valve slice fault. Front hitch slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

U0203

Spool valve very high temperature – Front hitch slice

Very high temperature measured at the valve slice.

Check the cooling system for blockage and clean as necessary. Check the implement is correctly set up to match the Fastrac.

V0000

No CANBUS receive message - Green slice

Central Controller ECU CAN Bus messages not received by slice.

V0001

No CANBUS receive message - Green slice

Central Controller ECU CAN Bus messages not received by slice.

V0002

Implausible CANBUS receive message - Green slice

Central Controller ECU CAN Bus messages not received by slice.

V0003

Implausible CANBUS receive message - Green slice

Central Controller ECU CAN Bus messages not received by slice.

V0004

Potentiometer / PWM fault - Spool valve slice internal fault. Green slice

If this error persistently occurs replace spool valve slice.

V0005

EEPROM inconsistent Green slice

Spool valve slice internal fault.

If this error persistently occurs replace spool valve slice.

V0006

No faults but valve has switched off for > 4 seconds - Green slice

Internal valve slice fault or CAN Bus fault.

Unplug slice, put control lever to stop and reconnect. If fault persists suspect faulty slice.

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C - 228

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

V0007

Supply voltage < 11.0 volts Alternator not charging. Damaged Measure voltage at battery to determine if the - Green slice wiring or faulty batteries. fault is slice specific.

V0008

Supply voltage > 16.0 volts Alternator over-charging or Measure voltage at battery to determine if the - Green slice machine has been connected to a fault is front hitch slice specific. higher voltage system.

V0009

Spool movement too short - Spool valve slice internal fault. Green slice

V0010

Excessive spool movement Spool valve slice internal fault. - Green slice

If this error persistently occurs replace spool valve slice.

V0011

Float position not reached - Spool valve slice internal fault. Green slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

V0012

Spool valve operated manually - Green slice

Spool valve slice internal fault.

If this error persistently occurs replace spool valve slice.

V0013

Supply < 8 volts - Green slice

Alternator not charging. Damaged Measure voltage at battery to determine if the wiring or faulty batteries. fault is slice specific.

V0014

Supply > 36 but < 45 volts - Alternator over-charging or Measure voltage at battery to determine if the Green slice machine has been connected to a fault is slice specific. higher voltage system.

V0015

High over-voltage (> 45 volts) - Green slice

Alternator over-charging or Measure voltage at battery to determine if the machine has been connected to a fault is slice specific. higher voltage system.

V0016

Output stage fault - Green slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

V0017

Position transducer fault Green slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

V0018

Spool cannot return to neutral position - Green slice

Valve slice fault.

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

V0019

Spool not in neutral when powered up - Green slice

Valve slice fault.

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

V0020

Program Memory Error Green slice

Spool valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

V0021

Spool valve off-line - Green Central Controller ECU CAN Bus slice messages not received by slice.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

V0050

Main lever electrical input too low - Green slice

Voltage signal to Central Controller ECU too low, less than 200 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

V0051

Main lever electrical input too high - Green slice

Voltage signal to Central Controller ECU too high, greater than 4.1 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

V0052

Lever kick-out solenoid Spool valve control pod fault or high side driver output wiring fault between control pod disconnected - Green slice and central controller ECU.

Check wiring.

V0053

Lever kick-out solenoid Spool valve control pod fault or high side driver output over wiring fault between control pod temperature or current. and central controller ECU. Tested on power up Green slice

Check wiring.

V0054

Flow or duration control driver open circuit - Green slice

Voltage signal to Central Controller ECU disconnected.

Check wiring. Recalibrate. If problem persists replace control pod.

V0055

Flow or duration control input too low - Green slice

Voltage signal to Central Controller ECU too low, less than 850 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

V0056

Flow or duration control Voltage signal to Central input too high - Green slice Controller ECU too high, greater than 4.5 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

V0069

Lever kick-out indicator driver disconnected Green slice

Spool valve control pod fault or wiring fault between control pod and central controller ECU.

Check wiring. If problem persists change pod.

V0070

Implausible lever position - Caused by faulty lever validation Check wiring. If problem persists then replace green slice switches or wiring from green slice lever pod. to ECU.

V0071

Spool very high temperature - green slice

V0072

Lever kick-out solenoid Wiring fault. high side driver, general Faulty solenoid in the control pod output failure â&#x20AC;&#x201C; Green Slice

Check wiring. Check control pod solenoid, replace control pod if necessary

V0201

Spool movement too short - Spool valve slice internal fault. Green slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

V0203

Spool valve very high temperature â&#x20AC;&#x201C; Green slice

Check the cooling system for blockage and clean as necessary. Check the implement is correctly set up to match the Fastrac.

C - 230

Very high hydraulic oil temperature measured on green slice.

Very high temperature measured at the valve slice.

9803/8040-5

Check cooling system for blockage and clean as necessary. Check that implement is set up correctly to match the Fastrac.

C - 230

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

W0000 No CANBUS receive message - Blue slice

Central Controller ECU CAN Bus messages not received by slice.

W0001 No CANBUS receive message - Blue slice

Central Controller ECU CAN Bus messages not received by slice.

W0002 Implausible CANBUS receive message - Blue slice

Central Controller ECU CAN Bus messages not received by slice.

W0003 Implausible CANBUS receive message - Blue slice

Central Controller ECU CAN Bus messages not received by slice.

W0004 Potentiometer / PWM fault - Spool valve slice internal fault. Blue slice

If this error persistently occurs replace spool valve slice.

W0005 EEPROM inconsistent Blue slice

Spool valve slice internal fault.

If this error persistently occurs replace spool valve slice.

W0006 No faults but valve has switched off for > 4 seconds - Blue slice

Internal valve slice fault or CAN Bus fault.

Unplug slice, put control lever to stop and reconnect. If fault persists suspect faulty slice.

W0007 Supply voltage < 11.0 volts Alternator not charging. Damaged Measure voltage at battery to determine if the - Blue slice wiring or faulty batteries. fault is slice specific. W0008 Supply voltage > 16.0 volts Alternator over-charging or Measure voltage at battery to determine if the - Blue slice machine has been connected to a fault is front hitch slice specific. higher voltage system. W0009 Spool movement too short - Spool valve slice internal fault. Blue slice

W0010 Excessive spool movement Spool valve slice internal fault. - Blue slice

If this error persistently occurs replace spool valve slice.

W0011 Float position not reached - Spool valve slice internal fault. Blue slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

W0012 Spool valve operated manually - Blue slice

If this error persistently occurs replace spool valve slice.

C - 231

Spool valve slice internal fault.

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C - 231

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

W0013 Supply < 8 volts - Blue slice Alternator not charging. Damaged Measure voltage at battery to determine if the wiring or faulty batteries. fault is slice specific. W0014 Supply > 36 but < 45 volts - Alternator over-charging or Measure voltage at battery to determine if the Blue slice machine has been connected to a fault is slice specific. higher voltage system. W0015 High over-voltage (> 45 volts) - Blue slice

Alternator over-charging or Measure voltage at battery to determine if the machine has been connected to a fault is slice specific. higher voltage system.

W0016 Output stage fault - Blue slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

W0017 Position transducer fault Blue slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

W0018 Spool cannot return to Valve slice fault. neutral position - Blue slice

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

W0019 Spool not in neutral when powered up - Blue slice

Valve slice fault.

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

W0020 Program Memory Error Blue slice

Spool valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

W0021 Spool valve off-line - Blue slice

Central Controller ECU CAN Bus messages not received by slice.

W0500 Main lever electrical input too low - Blue slice

Voltage signal to Central Controller ECU too low, less than 200 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

W0051 Main lever electrical input too high - Blue slice

Voltage signal to Central Controller ECU too high, greater than 4.1 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

W0052 Lever kick-out solenoid high side driver output disconnected - Blue slice

Spool valve control pod fault or wiring fault between control pod and central controller ECU.

Check wiring.

W0053 Lever kick-out solenoid Spool valve control pod fault or high side driver output over wiring fault between control pod temperature or current. and central controller ECU. Tested on power up - Blue slice

Check wiring.

W0054 Flow or duration control driver open circuit - Blue slice

Check wiring. Recalibrate. If problem persists replace control pod.

C - 232

Voltage signal to Central Controller ECU disconnected.

9803/8040-5

C - 232

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

W0055 Flow or duration control input too low - Blue slice

Voltage signal to Central Controller ECU too low, less than 850 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

W0056 Flow or duration control input too high - Blue slice

Voltage signal to Central Controller ECU too high, greater than 4.5 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

W0069 Lever kick-out indicator driver disconnected - Blue slice

Spool valve control pod fault or wiring fault between control pod and central controller ECU.

Check wiring. If problem persists change pod.

W0070 Implausible lever position - Caused by faulty lever validation blue slice switches or wiring from blue slice to ECU.

Check wiring. If problem persists then replace lever pod.

W0071 Spool valve very high temperature - blue slice

Very high hydraulic oil temperature measured on blue slice.

Check cooling system for blockage and clean as necessary. Check that implement is set up correctly to match the Fastrac.

W0072 Lever kick-out solenoid high side driver, general output failure â&#x20AC;&#x201C; Blue Slice

Wiring fault. Faulty solenoid in the control pod

Check wiring. Check control pod solenoid, replace control pod if necessary

W0201 Spool movement too short - Spool valve slice internal fault. Blue slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

W0203 Spool valve very high temperature â&#x20AC;&#x201C; Blue slice

Very high temperature measured at the valve slice.

Check the cooling system for blockage and clean as necessary. Check the implement is correctly set up to match the Fastrac.

X0000

No CANBUS receive message - Brown slice

Central Controller ECU CAN Bus messages not received by slice.

X0001

No CANBUS receive message - Brown slice

Central Controller ECU CAN Bus messages not received by slice.

X0002

Implausible CANBUS receive message - Brown slice

Central Controller ECU CAN Bus messages not received by slice.

X0003

Implausible CANBUS receive message - Brown slice

Central Controller ECU CAN Bus messages not received by slice.

X0004

Potentiometer / PWM fault - Spool valve slice internal fault. Brown slice

C - 233

9803/8040-5

If this error persistently occurs replace spool valve slice.

C - 233

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

X0005

EEPROM inconsistent Brown slice

Spool valve slice internal fault.

If this error persistently occurs replace spool valve slice.

X0006

No faults but valve has switched off for > 4 seconds - Brown slice

Internal valve slice fault or CAN Bus fault.

Unplug slice, put control lever to stop and reconnect. If fault persists suspect faulty slice.

X0007

Supply voltage < 11.0 volts Alternator not charging. Damaged Measure voltage at battery to determine if the - Brown slice wiring or faulty batteries. fault is slice specific.

X0008

Supply voltage > 16.0 volts Alternator over-charging or Measure voltage at battery to determine if the - Brown slice machine has been connected to a fault is front hitch slice specific. higher voltage system.

X0009

Spool movement too short - Spool valve slice internal fault. Brown slice

X0010

Excessive spool movement Spool valve slice internal fault. - Brown slice

If this error persistently occurs replace spool valve slice.

X0011

Float position not reached - Spool valve slice internal fault. Brown slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

X0012

Spool valve operated manually - Brown slice

Spool valve slice internal fault.

If this error persistently occurs replace spool valve slice.

X0013

Supply < 8 volts - Brown slice

Alternator not charging. Damaged Measure voltage at battery to determine if the wiring or faulty batteries. fault is slice specific.

X0014

Supply > 36 but < 45 volts - Alternator over-charging or Measure voltage at battery to determine if the Brown slice machine has been connected to a fault is slice specific. higher voltage system.

X0015

High over-voltage (> 45 volts) - Brown slice

Alternator over-charging or Measure voltage at battery to determine if the machine has been connected to a fault is slice specific. higher voltage system.

X0016

Output stage fault - Brown slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

X0017

Position transducer fault Brown slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

X0018

Spool cannot return to neutral position - Brown slice

Valve slice fault.

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

X0019

Spool not in neutral when powered up - Brown slice

Valve slice fault.

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

X0020

Program Memory Error Brown slice

Spool valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

X0021

Spool valve off-line - Brown Central Controller ECU CAN Bus slice messages not received by slice.

X0050

Main lever electrical input too low - Brown slice

Voltage signal to Central Controller ECU too low, less than 200 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

X0051

Main lever electrical input too high - Brown slice

Voltage signal to Central Controller ECU too high, greater than 4.1 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

X0052

Lever kick-out solenoid Spool valve control pod fault or high side driver output wiring fault between control pod disconnected - Brown slice and central controller ECU.

Check wiring.

X0053

Check wiring.

X0054

Flow or duration control driver open circuit - Brown slice

Voltage signal to Central Controller ECU disconnected.

Check wiring. Recalibrate. If problem persists replace control pod.

X0055

Flow or duration control input too low - Brown slice

Voltage signal to Central Controller ECU too low, less than 850 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

X0056

Flow or duration control Voltage signal to Central input too high - Brown slice Controller ECU too high, greater than 4.5 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

X0069

Lever kick-out indicator driver disconnected Brown slice

Spool valve control pod fault or wiring fault between control pod and central controller ECU.

Check wiring. If problem persists change pod.

X0070

Implausible lever position - Caused by faulty lever validation brown slice switches or wiring from brown slice to ECU.

Check wiring. If problem persists then replace lever pod.

X0071

Spool valve very high temperature - brown slice

Check cooling system for blockage and clean as necessary. Check that implement is set up correctly to match the Fastrac.

X0072

Lever kick-out solenoid Wiring fault. high side driver, general Faulty solenoid in the control pod output failure â&#x20AC;&#x201C; Brown Slice

Check wiring. Check control pod solenoid, replace control pod if necessary

X0201

Spool movement too short - Spool valve slice internal fault. Brown slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice

C - 235

Very high hydraulic oil temperature measured on brown slice.

9803/8040-5

C - 235

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

X0203

Spool valve very high temperature â&#x20AC;&#x201C; Brown slice

Very high temperature measured at the valve slice.

Check the cooling system for blockage and clean as necessary. Check the implement is correctly set up to match the Fastrac.

Y0000

No CANBUS receive message - Grey slice

Central Controller ECU CAN Bus messages not received by slice.

Y0001

No CANBUS receive message - Grey slice

Central Controller ECU CAN Bus messages not received by slice.

Y0002

Implausible CANBUS receive message - Grey slice

Central Controller ECU CAN Bus messages not received by slice.

Y0003

Implausible CANBUS receive message - Grey slice

Central Controller ECU CAN Bus messages not received by slice.

Y0004

Potentiometer / PWM fault - Spool valve slice internal fault. Grey slice

If this error persistently occurs replace spool valve slice.

Y0005

EEPROM inconsistent Grey slice

Spool valve slice internal fault.

If this error persistently occurs replace spool valve slice.

Y0006

No faults but valve has switched off for > 4 seconds - Grey slice

Internal valve slice fault or CAN Bus fault.

Unplug slice, put control lever to neutral and reconnect. If fault persists suspect faulty slice.

Y0007

Supply voltage < 11.0 volts Alternator not charging. Damaged Measure voltage at battery to determine if the - Grey slice wiring or faulty batteries. fault is front hitch slice specific.

Y0008

Supply voltage > 16.0 volts Alternator over-charging or Measure voltage at battery to determine if the - Grey slice machine has been connected to a fault is front hitch slice specific. higher voltage system.

Y0009

Spool movement too short - Spool valve slice internal fault. Grey slice

Y0010

Excessive spool movement Spool valve slice internal fault. - Grey slice

If this error persistently occurs replace spool valve slice.

Y0011

Float position not reached - Spool valve slice internal fault. Grey slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

C - 236

9803/8040-5

Action and Remedy

C - 236

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Y0012

Spool valve operated manually - Grey slice

Y0013

Supply < 8 volts - Grey slice Alternator not charging. Damaged Measure voltage at battery to determine if the wiring or faulty batteries. fault is slice specific.

Y0014

Supply > 36 but < 45 volts - Alternator over-charging or Measure voltage at battery to determine if the Grey slice machine has been connected to a fault is slice specific. higher voltage system.

Y0015

High over-voltage (> 45 volts) - Grey slice

Alternator over-charging or Measure voltage at battery to determine if the machine has been connected to a fault is slice specific. higher voltage system.

Y0016

Output stage fault - Grey slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

Y0017

Position transducer fault Grey slice

Valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

Y0018

Spool cannot return to Valve slice fault. neutral position - Grey slice

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

Y0019

Spool not in neutral when powered up - Grey slice

Valve slice fault.

Check spool is not jammed or has been operated manually. If this is not the case and this error persistently occurs, replace spool valve slice.

Y0020

Program Memory Error Grey slice

Spool valve slice internal fault.

If this error persistently occurs replace this spool valve slice.

Y0021

Spool valve off-line - Grey slice

Central Controller ECU CAN Bus messages not received by slice.

C - 237

Spool valve slice internal fault.

Action and Remedy

9803/8040-5

If this error persistently occurs replace spool valve slice.

C - 237

Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

Y0050

Main lever electrical input too low - Grey slice

Voltage signal to Central Controller ECU too low, less than 200 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

Y0051

Main lever electrical input too high - Grey slice

Voltage signal to Central Controller ECU too high, greater than 4.1 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

Y0052

Lever kick-out solenoid high side driver output disconnected - Grey slice

Spool valve control pod fault or wiring fault between control pod and central controller ECU.

Check wiring.

Y0053

Check wiring.

Y0055

Flow or duration control input too low - Grey slice

Voltage signal to Central Controller ECU too low, less than 850 mV.

Check wiring. Recalibrate. If problem persists replace control pod.

Y0506

Flow or duration control input too high - Grey slice

Voltage signal to Central Controller ECU too high, greater than 4.5 volts.

Check wiring. Recalibrate. If problem persists replace control pod.

Y0069

Spool valve control pod fault or Lever kick-out indicator driver disconnected - Grey wiring fault between control pod and central controller ECU. slice

Check wiring. If problem persists change pod.

Y0070

Implausible lever position - Caused by faulty lever validation grey slice switches or wiring from grey slice to ECU.

Check wiring. If problem persists then replace lever pod.

Y0071

Spool valve very high temperature - grey slice

Very high hydraulic oil temperature measured on grey slice.

Check cooling system for blockage and clean as necessary. Check that implement is set up correctly to match the Fastrac.

Y0072

Lever kick-out solenoid high side driver, general output failure â&#x20AC;&#x201C; Grey Slice

Wiring fault. Faulty solenoid in the control pod

Check wiring. Check control pod solenoid, replace control pod if necessary

Y0201

Spool movement too short - Spool valve slice internal fault. Grey slice

Check operation of the pilot valve. If error codes C0130 or C0131 are present fix these first. If this fault is only on one slice and it persistently occurs replace the valve slice.

Y0203

Spool valve very high temperature â&#x20AC;&#x201C; Grey slice

Very high temperature measured at the valve slice.

Check the cooling system for blockage and clean as necessary. Check the implement is correctly set up to match the Fastrac.

Z0200

Datalog erased by service tool.

For information

Not a fault

Z0201

EMS erased some old datalogs to make room for new ones

For information

Not a fault

Z0211

Datalogs were downloaded For information by service tool

Not a fault

C - 238

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Section C - Electrics Diagnostic Error Codes Codes Prefixed C to Z Code

Description

Possible Cause

Action and Remedy

Z0220

Maximum vehicle speed occurred

For information

Not a fault

Z0221

Maximum engine speed occurred

For information

Not a fault

Z0222

Maximum voltage occurred For information

Not a fault

Z0223

Maximum engine coolant temperature occurred

For information

Not a fault

Z0224

Maximum transmission temperature occurred

For information

Not a fault

C - 239

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C - 239

Section E Hydraulics Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-6

Section E - Hydraulics

E-0

9803/8040-6

E-0

Section E - Hydraulics Contents Page No. Technical Data External Hydraulics ................................................................................. E - 1 Control Valve - Electronically Actuated ............................................. E - 1 Other Hydraulic Circuits .................................................................... E - 1 Special Tools Service Tools Selection List .................................................................... E - 2 Schematic Circuits Introduction to Hydraulic Schematic Symbols ........................................ E - 7 General (Basic and Functional Symbols) .......................................... E - 7 Control Valves .................................................................................. E - 11 Example of Schematic Circuit ......................................................... E - 12 Complete Machine Circuit without Power Beyond Service ................... E - 13 Component Key ............................................................................... E - 13 Complete Machine Circuit with Power Beyond Service ........................ E - 15 Component Key ............................................................................... E - 15 System Descriptions External Hydraulics ............................................................................... E - 17 Electronically Actuated Spool Valve ................................................ E - 17 Typical Electronically Actuated Spool .............................................. E - 18 Pressure Testing External Hydraulics ............................................................................... E - 20 Maximum System Pressure ............................................................ E - 20 Pilot Stand-by Pressure ................................................................... E - 21 Pumps Removal and Replacement .................................................................. Removal .......................................................................................... Replacement ................................................................................... Piston Pump (External Hydraulics) ....................................................... Control Valve ................................................................................... Sealing the Driveshaft ..................................................................... Pump Dismantling and Assembly .................................................... Gear Pump (Suspension and Steering) ................................................ Dismantling and Assembly ..............................................................

E - 22 E - 22 E - 23 E - 24 E - 24 E - 25 E - 26 E - 32 E - 33

Control Valves Electronically Actuated Spool Valve ..................................................... Removal and Replacement ............................................................. Dismantling and Assembly .............................................................. Valve Slices (Green, Blue, Brown, Grey and Front Hitch) ............... Pilot Control Valve Slice .................................................................. Rear Hitch Slice ...............................................................................

E - 34 E - 34 E - 36 E - 38 E - 46 E - 48

Rams Rear Lift Ram ....................................................................................... E - 50 Removal and Replacement ............................................................. E - 50 Dismantling and Assembly .............................................................. E - 51

E-i

Section E - Hydraulics Contents

E - ii

Page No.

E - ii

Section E - Hydraulics

Technical Data External Hydraulics Maximum system pressure at 1500 engine rev/min(1) Flow at maximum system pressure and 2200 engine rev/min

(2)

210 bar

214 kgf/cm2

3045 lbf/in2

180 litres/min

40 UK gal/min

48 USgal/min

(1) This is controlled by the piston pump de-stroking to neutral. There is no main relief valve fitted. (2) When checking flow, be aware of the limits of flow through the control valves (see below).

Control Valve - Electronically Actuated Pilot stand-by pressure - no service selected

22 bar

22 kgf/cm2

320 lbf/in2

Spools All external hydraulics spools

Double acting with provision for timed hydraulic kick-out and flow control.

Maximum flow from each spool

80 litres/min

17.6 UK gal/min

21 US gal/min

Other Hydraulic Circuits Note: For technical data of other hydraulic systems, refer to the following sections of the Service Manual: Transmission

Section F

Steering

Section H

Suspension

Section S

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Section E - Hydraulics

Special Tools Service Tools Selection List

892/00253 Hydraulic Circuit Pressure Test Kit 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

Fig 1.

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Section E - Hydraulics Special Tools Service Tools Selection List

Fig 3. Fig 2. Pressure Test ‘T’ Adapters

Pressure Test Adapters

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point

892/00255 1/4 in BSP x Test Point

816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point

892/00256 3/8 in BSP x Test Point

816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point

892/00257 1/2 in BSP x Test Point

892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point

892/00258 5/8 in BSP x Test Point

892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point

816/15118 3/4 in BSP x Test Point

892/00265 1 in M BSP x 1 in F 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

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Section E - Hydraulics Special Tools Service Tools Selection List Flow Test Equipment 892/00268 Flow Monitoring Unit 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) 892/00293 Connector Pipe 892/00270 Load Valve 1406/0021 Bonded Washer 1604/0006 Adapter 3/4 in M x 3/4 in M BSP 1612/0006 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

Fig 4.

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 892/00273 Sensor Head 0 - 380 l/min 892/00294 Connector Pipe 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

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Section E - Hydraulics Special Tools Service Tools Selection List

Fig 5.

Fig 6. Hand Pump Equipment

892/00318 Hose and Adapter Kit

892/00223 Hand Pump

To enable flow and pressure test equipment to be connected to adapters fitted with ‘O’ ring face seals.

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)

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Section E - Hydraulics Special Tools Service Tools Selection List

Fig 8. Fig 7. 892/00334 Gland Seal Fitting Tool

Bonded Washers 1406/0011 1/4 in. BSP 1406/0018 1/2 in. BSP 1406/0014 5/8 in. BSP 1406/0021 3/4 in. BSP 1406/0029 1.1/4 in. BSP

Fig 10.

Fig 9. 331/64265 Retaining Bush for Valve Spool

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331/64246 Tool Kit for Non-return Valve

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Section E - Hydraulics

Schematic Circuits Introduction to Hydraulic Schematic Symbols TE-001

General (Basic and Functional Symbols) Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.

Table 2. Rams Single acting

Double acting There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components. Table 1. General

Double ended

Double acting with damping at rod area end

Table 3. Pumps and Motors Variable capacity pump two directions of flow

Spring Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow Fixed capacity motor two directions of flow

Indication of rotation

Variable capacity motor one direction of flow

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

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Section E - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols Table 4. Control Valves Used to enclose several valves indicating they are supplied as one unit

Throttling orifice - normally closed

3-Position, 4-port spring centered pilot operated valve

Throttling orifice - normally open

3-position, 6-port spring centered pilot operated valve Relief valve

3-Position, 4-port spring centered solenoid & pilot pressure operated valve 3-Position, 4-port spring centered detent hand operated valve

Variable restrictor

Non-return valve

Non-return valve with back pressure spring

Pilot operated non-return valve

One way restrictor

High pressure selector (shuttle valve)

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Section E - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning Working line, return or feed Pilot control

Reservoir - return line below fluid level

Drain lines Header tank Flexible pipe

Pressure sealed tank Line junction

Accumulator

Crossing lines

Filter or strainer

Water trap Air bleed Line plugged, also pressure test point Line plugged with take off line

Cooler - with no indication of coolant flow

Cooler - indicating direction of coolant flow

Quick release couplings connected Heater Quick release couplings disconnected

Reservoir - return line above fluid level

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Section E - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols Table 6. Control Mechanisms Solenoid one winding

Rotating shaft - one direction

Solenoid two windings

Rotating shaft - two directions

Detent

Locking device

Electric motor operated

Internal pressure pilot operated

Over centre device

External pressure pilot operated

Simple linkage Pressure operated spring release General control Pilot operated by solenoid pilot valve Push button operated Pilot operated by a solenoid or seperate pilot valve Lever operated Pressure guage Pedal operated Pressure switch Stem operated

Spring operated

Roller operated

Roller trip operated (one directional)

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Section E - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols

Control Valves Control valves are usually represented by one or more square boxes. K Fig 11. ( T E-11) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes - 3 positions etc).

Fig 14. Fig 11. K Fig 12. ( T E-11) - In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).

It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. K Fig 14. ( T E-11) shows a 'D' type spool.

Fig 12. K Fig 14. ( T E-11) shows a valve described as a 3position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked.

K Fig 15. ( T E-11) - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.

Fig 15. K Fig 16. ( T E-11) - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port

Fig 13. If the valve spool was moved to Position 1, movement of the spool would connect Port P1 to Port P2, and Port P3 to Port P4. K Fig 14. ( T E-11). If the valve spool was moved to Position 3, movement of the spool would connect Port P1 to Port P4, and Port P3 to Port P2. K Fig 14. ( T E-11).

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Fig 16.

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Section E - Hydraulics Schematic Circuits Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

Fig 17. Simple Schematic Circuit Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit. K Fig 17. ( T E-12). Hydraulic tank 17-A is a pressurised tank with an internally mounted strainer 17-B on the suction line to the fixed displacement pump 17-C. System pressure is limited to the setting of relief valve 17-D. Valve spool 17-E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.

Example Circuit Key 17-A

Hydraulic Tank

17-B

Strainer

17-C

Fixed Displacement Pump

17-D

Relief Valve

17-E

Spool

17-F

One Way Valve

17-G

Double Acting Hydraulic Ram

If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram 17-G. Notice that the fluid must first open one way valve 17-F before flowing to the ram.

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Complete Machine Circuit without Power Beyond Service Component Key K Fig 18. ( T E-14)

Feed to Hydraulic Trailer Brake Connector TH

Steering Circuit Cooler

Main Filter

Front Lift Rams

Rear Auxiliary Circuits

Main Pump Pressure Test Connection

Ride Height Corrector Valves

Pump - External Hydraulics

Pump - Suspension and Trailer Brake Valve

Pump - Steering

Drop Flow Control Valve (front lift rams ) (optional)

Rear Lift Rams

Suspension Cylinders

Steering Box

Steering Relief Valve

Steering Assistor Ram

Tank

Hydraulic Trailer Brake Connector

Suspension Pressure Maintenance/ Differential Lock/PTO Selector Valve

Rear Axle Differential Lock

Pilot Pressure Test Connection

Section E - Hydraulics

Hydraulic Trailer Brake Valve (optional)

Schematic Circuits

E - 13

External Hydraulics/Draft Control Valve

Complete Machine Circuit without Power Beyond Service

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Section E - Hydraulics Schematic Circuits Complete Machine Circuit without Power Beyond Service

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Fig 18.

E - 15

Complete Machine Circuit with Power Beyond Service Component Key K Fig 19. ( T E-16)

Feed to Hydraulic Trailer Brake Connector TH

Steering Circuit Cooler

Main Filter

Front Lift Rams

Rear Auxiliary Circuits

Main Pump Pressure Test Connection

Ride Height Corrector Valves

Pump - External Hydraulics

Pump - Suspension and Trailer Brake Valve

Pump - Steering

Power Beyond Pressure Connection

PBL

Power Beyond Load Sense Connection

PBT

Power Beyond Tank Connection

Drop Flow Control Valve (front lift rams ) (optional)

Rear Lift Rams

Suspension Cylinders

Steering Box

Steering Relief Valve

Steering Assistor Ram

Tank

Hydraulic Trailer Brake Connector

Suspension Pressure Maintenance/ Differential Lock/PTO Selector Valve

Pilot Pressure Test Connection

Section E - Hydraulics

Hydraulic Trailer Brake Valve (optional)

Schematic Circuits

E - 15

External Hydraulics/Draft Control Valve

Rear Axle Differential Lock

Complete Machine Circuit with Power Beyond Service

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Section E - Hydraulics Schematic Circuits Complete Machine Circuit with Power Beyond Service

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Fig 19.

Section E - Hydraulics

System Descriptions External Hydraulics Electronically Actuated Spool Valve

Fig 20. The electronically actuated spool valve is a sectional valve, held together by three tie rods R and nuts N.

Item

Description

Shuttle Valve

The main components are:

Green Slice

Blue Slice

E - 17

Item

Description

Brown Slice

Inlet Slice

Grey Slice

Pilot Control Slice

Front Hitch Slice

Rear Hitch Slice

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Section E - Hydraulics System Descriptions External Hydraulics

Typical Electronically Actuated Spool

Fig 21.

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Section E - Hydraulics System Descriptions External Hydraulics General Description The illustration, K Fig 21. ( T E-18), shows a typical electronically actuated spool AA. Oil is fed to the spool AA from the inlet slice of the valve block via gallery 4A.

Note: In the event of an electrical failure, cover Z may be removed from over the end of the spool to allow the spool to be manually actuated. Machines fitted with an agricultural front hitch have a lever already fitted to the relevant spool to allow such manual actuation.

Electronic Actuation Pilot pressure is fed from the pilot control slice PC K Fig 20. ( T E-17) via gallery 6A to the pilot valve 4. Electronic signals from the spool controllers in the cab are processed via the central computer and the digital electronic circuit 7. These signals control the movement of pilot valve 4 which then supplies pilot pressure to the spool control piston 3. The electronic signals fed to the pilot valve 4 take account of the operator settings for timed kick-out or flow control so that control piston 3 moves the spool accordingly.

Fig 22.

Spool AA in Neutral When the spool is in neutral, the pressure in gallery 4A is dead-ended by the spool and is fed to the right hand end of diverter valve V. This moves valve V to the left, closing the flow path through the diverter valve to the main spool AA. A restricted path past spool V remains to allow a bleed of pressure from 4A up to the main spool AA. Pilot pressure in gallery 5A is vented to tank gallery 3A via the main spool. The leak free check valves LV are held closed by spring pressure and oil pressure at port A or B.

Spool AA Selected When the spool is actuated, the spool seals the cavity between the pilot feed 5B and tank gallery 3A. Pressure is fed from the main pressure gallery 4A past the land of spool AA into the pilot gallery 5B. This pressure is fed to the left hand end of diverter spool V and assisted by spring force, moves the spool V to the right. A flow path is then open for oil from gallery 4A, past spool AA to the load hold check valve L. Pressure in 5B enters gallery 5A via shuttle valve S, K Fig 22. ( T E-19) The pressure from 4A opens the load hold check valve L and is fed via the main spool cavity out to the service via port A or B (depending on direction of spool movement). Spool AA raises the plunger of the appropriate leak free check valve LV to allow oil to return from the service via the opposite service port to that being fed by the spool.

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Section E - Hydraulics

Pressure Testing External Hydraulics

P Fig 23.

Maximum System Pressure Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test point P. Disable the time and pressure controlled kick-out on the spool to be operated. Ensure that there is no implement connected to the relevant quick release couplings so that the closed coupling can hold the M.R.V. pressure. Run the engine at 1500 r.p.m., select the spool to ram extend or retract position. check the gauge reading against the maximum system pressure setting in Technical Data. K Technical Data ( T E-1)

Fig 24.

If necessary, adjust the setting at screw B on top of the piston pump.

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Section E - Hydraulics Pressure Testing External Hydraulics

Pilot Stand-by Pressure

P Fig 25. Connect a 0-40 bar (0-600 lbf/in2) pressure gauge in place of plug C. Operate any spool to activate the load sensing system, then select neutral. Check the gauge reading with the engine running at low idle against the pilot stand-by pressure setting in Technical Data. K Technical Data ( T E-1) Important: The gauge reading must be checked within 1 minute of the spool having been operated otherwise the reading will not be correct. If necessary, adjust the setting at screw A on top of the piston pump.

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Fig 26.

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Section E - Hydraulics

Pumps Removal and Replacement

14 15

11 9 10

16 20 B 5

17 T

7 Fig 27.

Removal

Gear Pump A (Suspension and Steering)

The numerical sequence shown on the illustration is intended as a guide to removal.

Before removing and dismantling the pump, check the flow and pressure for each section of the pump (see Section H, Steering and Section S, Suspension - Technical Data).

Blank off all open ports and hoses to prevent excessive oil loss and entry of dirt.

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If the values are low, renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, dismantle the pump for re-sealing only.

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Section E - Hydraulics Pumps Removal and Replacement

Replacement Reverse the removal sequence.

Gear Pump A (Suspension and Steering) Before fitting adapter 10, make sure the pump gear teeth are well oiled. Torque Settings

Item

kgf m

lbf ft

2.5

0.9

47.5

4.9

Piston Pump B (External Hydraulics) Important: If fitting a new pump or one that has been drained of oil, it is essential that the pump is filled with hydraulic oil via port T before starting the engine. Torque Settings

Item

kgf m

lbf ft

133

13.6

8.2

200

20.4

148

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics)

Piston Pump (External Hydraulics) Control Valve

Dismantling and Assembly

Removal and Replacement

Note: Before dismantling, measure and record dimensions X and Y K Fig 28. ( T E-24). If required, the control valve can be dismantled for cleaning and reassembled K Fig 29. ( T E-24).

Make sure that dimensions X and Y are as recorded.

G H J

Fig 28. 1

Remove caps E, measure and record dimensions X and Y.

Remove screws F and lift off control valve G.

Check â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings H and sealing surface J.

Fit the control valve using new seals. Make sure that dimensions X and Y are as recorded. Fig 29.

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics)

Sealing the Driveshaft

C A B Fig 30. 1

Wrap tape around shaft A to protect the seal from damage. Remove circlip B and seal C.

B C D Fig 31. 2

Make sure that the shaft is not damaged. Grease the new seal C and insert it as far as washer D. Refit circlip B.

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics)

Pump Dismantling and Assembly

4 5 6 8 9

17 19

11 12

15 18

3 2 1 20 22

Fig 32. K Dismantling ( T E-27)

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics) Dismantling

Inspection

Follow the numerical sequence K Fig 32. ( T E-26).

14 15

Fig 33.

To allow removal of piston 14 and swash plate 15, turn swash plate slightly along axis Z K Fig 33. ( T E-27).

Fig 34. Check for wear on surfaces indicated by the arrows K Fig 34. ( T E-27)

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics)

Fig 38. Make sure there are no grooves or signs of wear.

Fig 35. Check that the retaining plate is free from grooves and that there is no wear in the slipper pad area K Fig 35. ( T E-28).

Fig 39. Check that cylinder sliding surface (arrowed) is free of grooves, wear and embedded foreign particles. Check that there are no scratches on the control plate D. Fig 36.

Check that there are no scratches or metal deposits on sliding surfaces A. Check that there is no end-play in direction of arrows.

Fig 40. Check that surface E is undamaged.

Fig 37. Check cylinder bores B and splines C.

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics) Assembly

4 5 6 8 9

17 19

11 12

15 18

3 2 1 20 22

Fig 41. Reverse the dismantling sequence K Fig 41. ( T E-29).

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics)

14 Z

9 15

0 - 0,05 Fig 42. Taper bearings must have a preload of 0 - 0.05 mm, measured at the housing joint face K Fig 42. ( T E-30). If necessary, grind the shim washer 9 to achieve correct preload. Renew all seals.

Fig 43. Before fitting swash plate 15 and piston 14, hold bearings 16 and spring 17 in position with grease. Make sure that swash plate locates correctly on spring and piston. Apply JCB Threadlocker and Sealer to plug 11 and tighten to 320 Nm (236 lbf ft).

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Section E - Hydraulics Pumps Piston Pump (External Hydraulics)

Fig 44. When inserting the cylinder and pistons assembly 10, use an â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring as shown to keep the pistons in position K Fig 44. ( T E-31). When fitting the end plate 5, make sure index marks are aligned on end plate and housing. Tighten capscrews 4 to 310 Nm (230 lbf ft).

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Section E - Hydraulics Pumps Gear Pump (Suspension and Steering)

Gear Pump (Suspension and Steering)

Fig 45.

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Section E - Hydraulics Pumps Gear Pump (Suspension and Steering)

Dismantling and Assembly

is permissible. If the wear is greater than 0.3mm (0.01 in), renew the pump.

The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 45. ( T E-32). Before removing and dismantling the pump, check the flow and pressure for each section of the pump (see Section H, Steering and Section S, Suspension - Technical Data). If the values are low, renewal of components such as gears, bearings and housings will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, dismantle the pump for re-sealing only. Note: If the steering flow rate is low, make sure that there is no dirt in the end cover 12 and that the spool 10 moves freely. The size of washer 9 controls the steering flow rate (see Technical Information Bulletin 10/183).

The bores and side faces of the bearing blocks and gears are coated with Teflon during manufacture. If the coating is worn away, or if the bearing surfaces are scored or damaged the pump must be renewed. If the faces of the gear teeth are damaged the pump must be renewed. DO NOT use any abrasives on the bearing blocks or gears as this would destroy critical manufacturing dimensions It is only worth reassembling (with new seals) if the body, bearings, bushes and gears are in perfect condition.

When Assembling Renew all seals and â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings. Pack between lips of the shaft seals with grease. Protect the lips of the shaft seals from damage using a tapered sleeve, or, alternatively, by wrapping tape around the shaft splines whilst they are passing through the seal.

For assembly the sequence should be reversed.

When Dismantling Mark housings and covers to ensure correct re-assembly. Remove sharp edges and burrs from shafts to avoid seal damage.

Note the correct orientation of bearing blocks and use of dowels.

Remove all the seals.

Note the location of dowels 21 (2 off), 32 (2 off) and 37 (2 off).

Keep bearing blocks 25, 27, 38, 40 and gears 26 and 39 together in sets to ensure refitting of the bearing blocks in their original positions.

Ensure that the ends of seals 14, 23, 34 and 41 and backup rings 15, 24, 35 and 42 do not overhang the bearing blocks to become trapped in the housings.

Inspection

Torque Settings

Clean all the components using a proprietary washing agent (do not use trichloroethylene or similar as this will damage the seals). Dry the components immediately afterwards with compressed air. Be sure to blow out the ports and cross drillings in the end cover 12. Inspect the flow control valve spool 10 for signs of wear or damage. Inspect the spool bore in end cover 12. Make sure the flow control components 1 to 10 are free from dirt.

Item

kgf m

lbf ft

7.6

47-55

4.8-5.6

35-41

12-16

1.2-1.6

9-12

12-16

1.2-1.6

9-12

Inspect all components for damage or signs of wear. It is normal for the gears to have cut a slight track in the body bore on the inlet (large port) side. A groove up to 0.3mm (0.01 in) deep across the full width of the gear teeth

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Section E - Hydraulics Control Valves Electronically Actuated Spool Valve

Control Valves Electronically Actuated Spool Valve

Fig 46.

Removal and Replacement

Label the hoses to assist correct refitting.

Note: Lever and fittings sown at P are provided to allow manual actuation of the front hitch spool that may be needed in the event of an electrical failure. If necessary, these parts can be transferred to any of the other spools.

The valve slices are identified as shown in the following table. Table 7. Slice Slice Description Number

Removal Important: Do not clean the valve block using a high pressure washer. Free all surfaces from contaminants, dirt, paint residues and rust but do not use cleaning agents that: â&#x20AC;&#x201C; affect plastics or change their properties â&#x20AC;&#x201C; corrode metals or react to them â&#x20AC;&#x201C; leave residues. Before disconnecting hoses, it is important to release any trapped pressure in the service line hoses as follows: With the engine running, lower the front and rear linkages, put each spool control into the float position. Then switch off the engine.

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Rear Hitch

Green

Blue

Brown

Grey

Front Hitch

Note: For clarity the service line hoses are not illustrated. (Positions will vary depending on number of valve slices fitted.) Blank the open ports to prevent loss of oil and entry of dirt. Uncouple all the electrical connectors at the control valve.

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Section E - Hydraulics Control Valves Electronically Actuated Spool Valve Remove the fixing nuts K.

Replacement K Fig 46. ( T E-34) Reverse the removal procedure, ensuring that fasteners K are tightened to the correct torque as overtightening could cause valve block distortion and impair spool movement. Fit all electrical connectors except the ones to the spools items 1 to 5. Important: Before fitting the electrical connections to the valve slices(1 to 5), the valve slices must be reconfigured if any replacement valve slices have been fitted. See Spool Valve Slice Configuration, Section C.

Torque Settings Item

kgf m

lbf ft

2.3

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Section E - Hydraulics Control Valves Electronically Actuated Spool Valve

Dismantling and Assembly

Y P PC

E F G

C044190

Fig 47.

Dismantling

The valve slices are identified as shown in the following table. K Table 8. ( T E-36)

Important: Do not clean the valve block using a high pressure washer. Free all surfaces from contaminants, dirt, paint residues and rust but do not use cleaning agents that: – affect plastics or change their properties – corrode metals or react to them – leave residues. Important: This control valve must not be dismantled any further than as shown in this manual K Valve Slices (Green, Blue, Brown, Grey and Front Hitch) ( T E-38).

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Table 8. Slice Slice Description Number PC

Pilot Control

Rear Hitch

Green

Blue

Brown

Grey

Front Hitch

E - 36

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve Remove the nuts E, F and G and then remove the pilot control section PC followed by the valve slices as applicable. Note positions of any spacing washers on the tie rods so that they can be refitted in their original positions. Take care not to lose the shuttle valves S that are positioned loosely between valve slices.

Tighten the tie rod nuts in the sequence E, F, G. Ensure fasteners are tightened to the correct torque as overtightening could cause valve block distortion and impair spool movement. Important: Before fitting the electrical connections to the valve slices(1 to 5), the valve slices must be reconfigured if any replacement valve slices have been fitted. See Spool Valve Slice Configuration, Section C.

Remove any adhesive shims from between the slices. Check that the sealing surfaces for O-rings on the flange surface and on the undercut of the flange surface are not damaged. In case of damage, the respective valve slice must be replaced by a new one.

Torque Settings Item

E, F, G 25+ 8

kgf m

lbf ft

2.5+ 0.8

18 + 6

Assembly Renew all â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings and seals with back-up rings fitted at ports P and Y. Ensure that shuttle valves S are positioned between the spool slices K Fig 47. ( T E-36). Important: Do not tilt the shuttle valves. Make sure that there is a clearance of approximately 0.5 mm between the face of the valve slice and the top face of the shuttle valve at X K Fig 48. ( T E-37).

Fig 48. Lubricate the seals with JCB Hydraulic Fluid before assembly. Oil the tie rods and ensure that any spacing washers on the tie rods are refitted in their original positions. If any adhesive shims have been applied previously, one spacer must be threaded onto each of tie rods. If the slice face has corrugations which have been smoothed with a dressing stone, one spacer must be threaded onto each of tie rods.

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E - 37

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve

Valve Slices (Green, Blue, Brown, Grey and Front Hitch)

17 18 19 20 21 22

13 14

15 16

U 26 25 29 28 27

V 4 2 3

23 24

5 S

8 7

1 10

12 11 Fig 49.

Dismantling and Assembly

K Removing the Non-Return Valves ( T E-43)

See Fig 49. (X E-38).

K Removing the Electronic Actuator ( T E-43)

Important: During the warranty period, do not remove the electronic actuator U from the valve slices V. Outside the warranty period, the electronic actuator U can be removed and replaced to allow access to the spool S or non-return valve 29 but the electronic actuator must be replaced on the same valve slice from which it was removed.

K Locking the Spool in Neutral ( T E-39)

Important: Do not try to service the check valves items 13 to 22 , the non return valve items 23 to 29 or the electronic actuator U without following the procedures in this manual. Using any other procedures will cause damage to the valve slice. K Repairing the Check Valves ( T E-40)

E - 38

The numerical sequence shown on the illustration is intended as a guide to dismantling. To remove spool 10, use a suitable M6 x 120 mm screw, inserted into the end of the spool. When Assembling Always renew all ‘O’ rings and seals. Lubricate all parts with JCB ‘Special’ Hydraulic Fluid before assembly.

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E - 38

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve When refitting spool 10 K Fig 49. ( T E-38), ensure that it slides freely in its bore.

Locking the Spool in Neutral 1

If spool movement is impaired, this may be due to distortion caused by overtightening of screws and bolts. Care must be taken in maintaining the correct torque settings K Table 9. Torque Settings ( T E-39). Table 9. Torque Settings kgf m lbf ft

Item

5.5 + 2

0.6 + .0.2

4+1

67 + 22

6.8 + 2.2

49 + 16

67 + 22

6.8 + 2.2

49 + 16

67 + 22

6.8 + 2.2

49 + 16

Service tool 331/64265 must be used. This tool consists of retaining bush B and a selection of screws. Fit the retaining bush B over spool S and fit screw C through the spool eye end K Fig 49. ( T E-38). Tighten screw C as tightly as possible by hand.

Note: The retaining bush is not symmetrical. Make sure that it is fitted the correct way round so that the holes in the retaining bush align with the hole in the spool eye end and holes D in the spool body K Fig 48. ( T E-37).

Fig 50. 2

Fit M6 screws E into holes D in the spool body. Tighten the screws to no more than 2 Nm (17 lbf in).

Fig 51.

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Section E - Hydraulics Control Valves Electronically Actuated Spool Valve Repairing the Check Valves Important: To avoid the possibility of parts dropping into the valve slice and causing serious damage, it is essential to lock the spool in neutral before starting to remove the check valves K Locking the Spool in Neutral ( T E-39).

Fig 54. c

Guide the retaining plate out of port B. Remove the circlip K Fig 55. ( T E-40). Continue at step 2.

Fig 52. Each slice contains a check valve in port A and a check valve in port B K Fig 52. ( T E-40). The check valve in port A is retained by a plug. The check valve in port B is retained by a circlip 13 and retaining plate 14 K Fig 49. ( T E-38). 1

Port B only: a

Fig 55. 2

Use a screwdriver to bend both clips on the circlip upwards about 20 degrees. Turn the circlip clockwise 90 degrees.

Ports A and B: Take the large compression spring out of the housing. Use a magnetic gripper to remove the valve cone from the bore together with the small compression spring, the disk and the ball; discard.

Note: Check valves in ports A and B must be measured independently of the other. 3

Measure depth dimension Z from the top edge of the housing to the thrust pin.Take out the thrust pin with tweezers.Measure thrust pin length DL.

Fig 53. b Grasp the retaining plate with flat-nose pliers and press down and out of the groove K Fig 54. ( T E-40).Twist the retaining plate with circlip counter clockwise 90 degrees to turn it into the recess. Tilt the retaining plate in the recess in port B. Fig 56.

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Section E - Hydraulics Control Valves Electronically Actuated Spool Valve 4

Insert new valve cone with new ball.

Lightly grease the new ball, compression springs, washer, valve cone and thrust pin.

Measure depth dimension Y from top edge of housing to the ball.

Insert the thrust pin into the bore with the narrow section facing upwards K Fig 59. ( T E-41).

Insert the ball in the valve cone.

Insert the small compression spring in the valve cone bore.

Lightly grease the valve cone and insert in the corresponding valve bore.

Remove the valve cone together with the ball.

Fig 57. 7

Clean the bore and remove any pieces that have broken off. Ensure that no dirt is introduced.

Calculate length of new thrust pin K Table 10. ( T E-41) (all dimensions in millimetres) K Fig 58. ( T E-41):

Fig 59. 15

Table 10. + Depth dimension Z

+ Thrust pin length DL

– Depth dimension Y

Port B only: Place the circlip in the valve bore so that the circlip lies in the cavity, properly flush with the check valve seating K Fig 60. ( T E-41).

– Gap width X (0.2. to 0.3 mm) =

– 0.2

– Ball Ø mm

– 4.0

Length of new thrust pin .......

Align the circlip so that the open side of the ring faces in the axial direction of the valve spool.

–0.1

Ports A and B: Using tweezers, place the washer in the greased valve cone bore on top of the small compression spring K Fig 60. ( T E-41).

Fig 58. Fig 60. 9

Select the new thrust pin from the repair kit according to the calculations.

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Section E - Hydraulics Control Valves Electronically Actuated Spool Valve 17

Port B. Use needle-nose pliers or tweezers to insert the retaining plate at an angle in the valve bore in the direction of the moulded pocket assemblies, so that the pin on the retaining plate engages with the spring K Fig 61. ( T E-42).

Note: The moulded pocket assemblies lie in the same direction as the axis of the valve spool.

Fig 63. 22

Port A: Check that the large compression spring and the washer are correctly seated. Inspect the O-ring on the threaded plug for damage and proper seating. Sealing surfaces must be clean and undamaged.

Fig 61. 18

Thread the spring guide pin on the threaded plug into the compression spring K Fig 64. ( T E-42).

Gently press the retaining plate down and clockwise through 90 degrees to seat it in the securing recess K Fig 62. ( T E-42). The circlip turns with it.

Seal the bore with the threaded plug and tighten to 67+22 Nm (49 + 16 lbf ft).

Use tweezers to turn the circlip counter clockwise until the securing clip is located over the retaining plate.

Note: The retaining plate must not be allowed to become dislodged from its seating.

Fig 64. 23

Remove the retaining bush from the spool.

Fig 62. 20

Check that the large compression spring and the washer are correctly seated in the valve cone.

Use a screwdriver to press the circlip down so that the end of the retaining clip touches the circlip. The circlip holds the retaining plate in place and must therefore not be allowed to turn any further.

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E - 42

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve Removing the Electronic Actuator

Removing the Non-Return Valves

To allow access to the non-return valve, the spool must be locked in neutral K Locking the Spool in Neutral ( T E-39) and the electronic actuator must be the Electronic removed K Removing Actuator ( T E-43). 1

Disconnect the electrical connections and separate and the spool slices K Dismantling Assembly ( T E-36).

Lock the spool in neutral K Locking the Spool in Neutral ( T E-39).

Unscrew the three socket head bolts 1, 2 and 3 K Fig 65. ( T E-43).

Service tool kit 331/64246 must be used. Press the edge of the protective cap gently with the wire hook provided in the tool kit until the cap twists slightly K Fig 66. ( T E-43). Pull the protective cap out of the bore with the hook.

Fig 66. 2

Open the collet of the mandrel provided in the tool kit about 3 mm and grease lightly. Insert the mandrel into the bore and push in until the mandrel is flush with the plug K Fig 67. ( T E-43).

Fig 65. 4

Carefully pull off the actuator without tilting it. Fig 67. 3

Continue to push in hard until the tool touches the valve housing and the circlip is forced out of its groove. Tighten the mandrel with the rotary handle and the circlip is drawn into the retaining bush K Fig 68. ( T E-43).

Fig 68.

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E - 43

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve 4

Pull the tool out of the valve bore. Open the mandrel with the rotary handle and remove the circlip and plug K Fig 69. ( T E-44)

Replacing the Non-return Valves 1

Insert the valve cone and compression spring into the bore. Thread the plug into the compression spring and push it into the bore.

Fig 69. 5

Fig 72.

Using the wire hook, remove the compression spring from the bore.

Push the snap ring and mandrel into the bore until it the mandrel meets resistance and touches the valve housing.The snap ring will slide into the groove. Remove the mandrel.

Fig 70. 6

Pull the valve cone out of the valve housing using the magnetic gripper. Clean the bore and ensure no dirt is introduced

Fig 73. 3

Check the security of the snap ring as follows: a

Insert the testing tool. Retract the retaining sleeve and hook the testing hook on to the pin on the plug.

Fig 71.

Fig 74. b Push the retaining sleeve until it stops against the plug. Check the seating of the snap ring by puling with the testing tool. If the plug can be pulled out of the housing, repeat the assembly procedure. 4

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Remove the testing tool and insert the plastic sealing cap 23 K Fig 49. ( T E-38).

E - 44

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve Replacing the Actuator 1

Check the ‘O’ rings on control piston 1, control oil hole 2 and valve housing 3 for damage and renew if necessary K Fig 75. ( T E-45). Oil the ’O’ ring 1.

Fig 75. 2

Carefully fit the actuator without tilting it.

Important: Any chips that are stripped off when the actuator is tightened can cause leakage if they get between the sealing surfaces. 3

Tighten the socket head bolts 1, 2 and 3 crosswise and evenly to 5.5 +1.8 Nm (4 +1.3 lbf ft) K Fig 76. ( T E-45). Remove the retaining bush.

Fig 76.

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E - 45

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve

Pilot Control Valve Slice

4 5 6 7

8 9 10 11 12

25 27 26

13 23 31

21 20

3 2 1

19 18 24

17 16 15

C044200

Fig 77.

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E - 46

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling K Fig 77. ( T E-46). For assembly the sequence should be reversed. Do not disturb any adjustments within the valve system. When shims are removed, always replace the same total thickness as those removed. Always renew all 'O' rings and seals. If spool movement is impaired, this may be due to distortion caused by overtightening of screws and bolts. Care must be taken in maintaining the correct torque settings given below. Table 11. Torque Settings Item

kgf m

lbf ft

67 + 22

6.8 + 2.2

49 + 16

3.5 + 1.5

0.4 + 0.15

2.5 + 1

35 + 5

3.6 + 0.5

26 + 3.7

5.5 + 1.8

0.6 + 0.2

4 + 1.3

11 + 3.7

1.1 + 0.4

8 + 2.7

11 + 3.7

1.1 + 0.4

8 + 2.7

23.5 + 8

2.4 + 0.8

17 + 6

23.5 + 8

2.4 + 0.8

17 + 6

38 +13

3.9 + 1.3

28 + 10

E - 47

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E - 47

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve

Rear Hitch Slice

Fig 78.

E - 48

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E - 48

Section E - Hydraulics Control Valves Electronically Actuated Spool Valve Dismantling and Assembly

Torque Settings

See Fig 78. (X E-48).

Item

kgf m

lbf ft

2.6 + 0.5

0.26 + 0.0.5

1.9 + 0.4

64 + 10

6.6 + 1

48 + 7.4

15 + 4

1.5 + 0.5

11 + 2.9

46 + 15

4.7 + 1.5

34 + 11

46 + 15

4.7 + 1.5

34 + 11

0.5 + 1

0.05 + 1

0.4 + 0.7(1)

11 + 3.7

1.1 + 0.4

8 + 2.7

Solenoid Valves - Items 1 to 9. Internal Check valve - Items 10 to 16. Pressure Compensator - Items 17 to 22. Service Port Check Valve, etc. - Items 23 onwards. Note: Solenoids 2 can be renewed without the need for recalibration. Simply follow the dismantling sequence.

(1) This is equivalent to 4.4 + 8.8 lbf inch.

The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling The assembly comprising items 1, 3, 4 should be removed intact to release solenoid 2. Check protective cap 3, and ‘O’ ring 4 for damage and renew if necessary. Do not disturb any adjustments within the valve system, especially items 7 and 27. Important: Disturbance of pressure tube 7 will result in loss of factory calibration. Having removed solenoid 2, if there is evidence of hydraulic oil leakage onto pressure tube 7, remove items 5, 6 and 8. Renew ‘O’ ring 8. Otherwise do not disturb. When Assembling Always renew all 'O' rings and seals. Lubricate all parts with JCB 'Special' Hydraulic Fluid before assembling. When shims are removed, always replace the same total thickness as those removed. If spool movement is impaired, this may be due to distortion caused by overtightening of screws and bolts. Care must be taken in maintaining the correct torque settings.

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E - 49

Section E - Hydraulics

Rams Rear Lift Ram Removal and Replacement Note: The procedure given is for the right hand ram. The procedure for the left hand ram is similar.

Removal 1

Ensure that lift rams are fully closed as pressure cannot be vented by operating controls with engine stopped.

Support the weight of the lift arm on the same side as the ram to be removed.

Disconnect and blank the hydraulic connections A and B.

Remove bolt C and keep plate D and drive out pin E.

Support the ram, remove bolt F and keep plate G and extract pin H, using a slide hammer and a suitable M12 bolt in the threaded hole in the end of pin H.

Replacement Reverse the removal procedure. Make sure that flats on pins E and H are aligned with the flats on the keep plates D and G.

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Fig 79.

E - 50

Section E - Hydraulics Rams Rear Lift Ram

Dismantling and Assembly

Fig 80.

E - 51

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E - 51

Section E - Hydraulics Rams Rear Lift Ram Dismantling K Fig 80. ( T E-51) Heat the threaded area of end cap A to a minimum of 300째C (570째F) to release the locking sealant and unscrew the end cap using a suitable peg spanner located in holes B. Withdraw the piston rod C from the cylinder D complete with all of the internal parts. Heat the threaded area of piston head E to a minimum of 300째C (570째F) to release the locking sealant and unscrew the piston head using a suitable peg spanner. Removal of the piston head will allow end cap A to slide off the piston rod.

Fig 81. 2

Close the tool as shown at Fig 82. (X E-52). The seal must form a reniform (kidney shape).

Remove and discard the sealing components F to M. Take extreme care not to damage the cylinder bore or the grooves in the end cap A and piston head E.

Assembly Before assembling, check the components for damage and wear, especially the cylinder bore. Renew the complete assembly if necessary.

Fig 82. 3

Renew all items in the seal kit. Lightly oil the seals with JCB Hydraulic Fluid. See Wiper Seal Fitting Procedure (X E-52) for fitting wiper seals F and G. Apply JCB Retainer (High Strength) to the threads of end cap A and piston head E. Tighten both to the specified torque setting.

Wiper Seal Fitting Procedure

Torque Settings Item

kgf m

lbf ft

400

295

550

405

Testing

The size (diameter) and position of pins P is determined by the diameter and radial width of the wiper seal being fitted. The pins are screwed into threaded holes in the tool body. The spacing of the holes is designed to suit small or large diameter wiper seals. 1

Locate the seal in the end cap groove. When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool.

Using a hydraulic hand pump (see Service Tools), check for smooth operation of the ram. With the ram extended, pressurise to 250 bar (3625 lbf/in2) and check for leakage. No leakage is permitted.

Open the tool as shown at Fig 81. (X E-52) and insert the new wiper seal. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

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E - 52

Section F Transmission Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-2

Section F - Transmission

F-0

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F-0

Section F - Transmission Contents Page No. Technical Data Continuously Variable Transmission (CVT) ............................................. F - 1 Axles ........................................................................................................ F - 3 Service Tools Service Tools Section List ........................................................................ F - 4 General Description Drive Line Layout ..................................................................................... F - 6 CVT Description Main Component Identification ................................................................ F - 7 Actuator Unit ............................................................................................ F - 9 Hydraulic Circuit .................................................................................... F - 10 Valve Block 1 ......................................................................................... F - 12 Valve Block 2 ......................................................................................... F - 14 High Pressure Relief Valve, Forward/Reverse ...................................... F - 16 Purge Valve ........................................................................................... F - 17 CVT Operation Operation in Different Modes ................................................................. F - 18 Pressure Testing CVT Pressures ...................................................................................... F - 24 Diferential Lock and PTO Speed Selection ........................................... F - 27 CVT Valves Purge Valve ........................................................................................... F - 28 Forward and Reverse High Pressure Relief Valves .............................. F - 29 Clutch Hydraulics Master Cylinder ..................................................................................... F - 30 Filling and Bleeding the System ............................................................ F - 32 CVT Cartridge Removal and Replacement ................................................................... F - 34 Front Axle Removal and Replacement ................................................................... F - 50 Hub ........................................................................................................ F - 53 Drive Head ............................................................................................. F - 67 Rear Axle Removal and Replacement ................................................................... F - 84 Hub ........................................................................................................ F - 87 Drive Head ............................................................................................. F - 98 Rear PTO Gearbox .............................................................................. F - 116

F-i

Section F - Transmission Contents

F - ii

Page No.

F - ii

Section F - Transmission Technical Data Continuously Variable Transmission (CVT)

Technical Data Continuously Variable Transmission (CVT) Type

A continuously variable transmission for forward and reverse travel

Low Range Speed Forward

Speeds depend on tyre size

Low Range Speed Reverse

Speeds depend on tyre size

High Range Speed Forward

Speeds from 0 to 67 km/h (42 mph)

High Range Speed Reverse

Speeds depend on tyre size

F-1

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F-1

Section F - Transmission Technical Data Continuously Variable Transmission (CVT)

Pressure Settings Note: All presures are at transmission oil temperature of 37-43 deg C and an engine speed of 1200 rev/min.

Test

Test Point

bar

lbf/in2

Circuit Pressure - hydrostatic angle servo and range shift P

23-27

334-392

Servo Pump Outlet Pressure

23.5-27.5

341-399

Supply Pressure to Hydrostatic Loop

18-22

261-319

Return Pressure from Hydrostatic Loop

11.5-15.5

167-225

Lubrication Pressure

3-4

44-58

Supply Pressure for 4WD and Rear PTO Clutches

PHA

18-21

261-305

Rear PTO Valve Outlet Pressure

ZWK

18-21

261-305

4WD Valve Outlet Pressure

18-21

261-305

Low Range Solenoid Pressure

23-27

334-392

High Range Solenoid Pressure

23-27

334-392

High Pressure Relief Valves (forward and reverse)

PH (New Valves)

535-565

7760-8195

(Used Valves)

520-560

7540-8120

Differential Lock pressure

260

PTO 540 rpm

260

PTO 1000 rpm

260

F-2

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F-2

Section F - Transmission Technical Data Axles

Axles Front Axle Type

Crown wheel and pinion primary reduction with epicyclic hub reduction

Mounting

4 leading link control arms and Panhard rod

Differential

Soft engaged differential lock with electro-hydraulic control

Dry Weight

902 kg

1989 lb

Rear Axle

Type

Crown wheel and pinion primary reduction with epicyclic hub reduction

Mounting

2 trailing link control arms and 'V' link

Differential

Soft engaged differential lock with electro-hydraulic control

Dry Weight

1460 kg

F-3

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3219 lb

F-3

Section F - Transmission

Service Tools Service Tools Section List

Fig 1.

Fig 2. 892/00280 Gauge 0-600 bar (0-8500 lbf/in ). Required specifically for CVT high pressure check. 2

993/45400 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication)

Fig 3.

Fig 4. 892/00817 17 mm A/F x 3/4in. square drive

892/00179 Bearing Press

892/00818 22 mm A/F x 3/4in. square drive 892/00819 15 mm A/F x 1/2in. square drive 892/00333 19 mm A/F x 3/4in. square drive

F-4

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F-4

Section F - Transmission Service Tools Service Tools Section List

Fig 5.

Fig 6.

892/00224 Impulse Extractor Set for Hub Bearing Seals

892/00225 Adapter - Impulse Extractor

892/01053 Adapter for Impulse Exrtractor (PTO intermediate shaft, wet clutch transmission)

Small17mm to 25mm, Medium25mm to 45mm, Large45mm to 80mm

Retaining tool for differential lock spring and circlip. To be made from M24 threaded rod, nuts and spacers as shown

F-5

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F-5

Section F - Transmission General Description Drive Line Layout

General Description Drive Line Layout

Fig 7. The CVT transmission is driven from the engine via a damper and drive shaft. The transmission is also resiliently mounted in the chassis.

Key 1

Engine

CVT Input shaft

CVT Transmission

Rear PTO shaft

Rear axle including PTO

Rear drive shaft

Hydraulic pump assembly

Front drive shaft

Front steer axle

Front PTO and input shaft from engine crankshaft

The Fastrac components:

drive

line

The drive shaft output from the transmission to the rear axle incorporates the park brake disc.

comprises

The PTO output from the gearbox drives the input to the PTO box incorporated in the rear axle. The fully suspended rear axle incorporates a 2 speed PTO box. Axle lubrication, soft engage differential lock .

the

The front wheel drive is via a soft engage clutch in the transmission driving the front fully suspended steer axle.

following

The front PTO box is driven directly from the front crankshaft coupling on the engine

A Turbo-charged 6 cylinder engine which is resiliently mounted in the chassis with 4 rubber mounts.

F-6

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F-6

Section F - Transmission CVT Description Main Component Identification

CVT Description Main Component Identification

INE

ENG

A Q

D B C

J P L N

M Fig 8.

F-7

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F-7

Section F - Transmission CVT Description Main Component Identification Key A

Input from engine

Output to front axle

Oil Filter

Mounting shaft - bottom

Mounting shaft - top

Top cover

Actuator unit

Valve block 1

Valve block 2

Speed sensor

Oil Strainer

Output to rear axle

Output to rear PTO

High/low range sensor

The CVT is a continuously variable transmission for forward and reverse travel with integrated synchronised range shifting. Power transmission can be hydrostatic or mechanical or hydrostatic and mechanical. The CVT cartridge is flexibly mounted in the transmission housing by mounting shafts D and F. The transmission housing is also the oil reservoir for the hydrostatic drive. Low Range For speeds from 0 - 32 km/h (20 mph). Intended for heavy traction work at low travel speeds i.e. less than 12 km/h (7.5 mph). High Range For speeds from 0 - 67 km/h (42 mph). Intended for use on roads (transporting applications). Note: In circumstances where the engine will run but it is not possible to select the required mode due to selector failure, the transmission can be put into a limp home mode to enable the machine to be moved to a location suitable for repairs to be made. In limp home mode the actuator shaft is operated manually from the cab (see Operator Handbook) and the transmission is automatically limited to approximately 30km/h.

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F-8

Section F - Transmission CVT Description Actuator Unit

Actuator Unit The actuator unit controls the actuator shaft, changing the transmission ratio in the CVT transmission.

the analogue position sensor (potentiometer) on the accelerator.

The actuator unit comprises:

When control set point transmission ratio has been reached, the machine is put under load and the engine speed drops. The automatic maximum output control only ever changes the transmission ratio towards slow. The automatic maximum output control is engaged if the reduction in engine speed of over 180 rev/min.+ set value

Drive for limp home mode (if required to move the machine in case of failure of the electronic control system).

The clutch for the drive.

Incremental encoder which is a position sensor with digital resolution emitting 8000 pulses per revolution.

Planetary gear i = 192:1 (electric motor to the actuator shaft).

Electric motor 12V DC 0.4 to 7 amps (actuator unit no load sped of 4500 rev/min).

Slip clutch 2.5 to 3.5 Nm. (4 to 5 Nm at key operated actuator of limp home control).

Example: Engine speed according to accelerator pedal position

2000 rev/min

Setting for automatic maximum output control 10%

200 rev/min

Once the ignition is on, the actuator unit locates the reference point (approximate neutral point between forward and reverse travel). Once the engine has started, the actuator unit locates the reference point (exact neutral point between forward and reverse travel). 7

Automatic maximum output control

Calculation: 2000 rev/min minus

180 rev/min

minus

200 rev/min

Result

1620 rev/min

This means that the automatic maximum output control changes the transmission ratio toward slow from 1620 rev/min. Theoretically the automatic maximum output control changes the transmission ratio when under load until the travel speed reaches 0.

This restricts the reduction in engine speed or adaptation to the engine output. The engine speed is reduced when a load is applied. The electronics change the transmission ratio towards slow so that the engine speed is not reduced too far. Automatic maximum output control is always engaged once the engine is started. However, the reduction in engine speed can be changed from 0 to 30% The default setting is 14%. Automatic maximum output control functions: The electronics detect the set point engine speed from the position of the accelerator pedal by means of

F-9

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F-9

F - 10

Hydraulic Circuit 25

M18

6A4 (AR)

6A1

M11 (ZWK)

26 6V1

27 6V4

M10 4Z2 V=0.3 l p =10 bar o

4S1 II p

23 4Z1

M9 (PH)

M6 (P)

M22 (PH) 4V5

M7 (I)

PHA p=18 bar

4V4

4V6

4V3

4V1

M8 (II)

4V2

9803/8040-3

21 3Z2

6 1Z4

1V6 unter Last lastlos

100 l/min 110 l/min

20 3Z1

3A3

4A1

p=25bar

3V1

1Z2 ø2%

3V2

ø2%

ø3%

1V1

1Z3

3A1

3A2

p=3.5bar

ì10 =75 (10Ým abs)

1V2 1V5 p=6.5bar

p=50bar

68l/m n 68 l/min

T U

4 1P2

1S1

p=7bar

ø1%

2V5

2P1

p=0- 500bar

3 1P1

14 ccm/U

2V2

1V4

p=0- 500bar

2V6

ø1%

233 ccm/U p=0.25bar %75)

m nom.

F - 10

Fig 9.

2A1

7 233 ccm/U

2A2 233 cm/U

Hydraulic Circuit

11 2V3

1Z1

CVT Description

23.4 ccm/U p=10bar

12 2V4

9 2V1

p=6.5bar

Section F - Transmission

p=5bar

p =7bar

F - 11

Key

23 (4Z1) Clutch master cylinder

Main Components Note: The item numbers/letters in brackets are shown in red on the circuit diagram. 1 2

25 (6A4) 4WD clutch 26 (6V1) Solenoid valve, PTO 27 (6V4) Solenoid valve, 4WD clutch 28 (1Z3) Oil cooler K Valve Block 2 ( T F-14)

Valve block 1 (items in purple box) K Valve Block 1 ( T F-12)

The system uses different pressures:

Valve block 2 (items in blue box) K Valve Block 2 ( T F-14)

System pressure for CVT transmission control unit approximately. 25 bar (360 lbf/in2) and enhanced pressure approximately. 18 bar (260 lbf/in2) for rear PTO clutch and differential locks.

High pressure in CVT transmission. Max. pressure-measuring point approximately. 500 bar (7250 lbf/in2).

(1P1) Servo pump

Lubrication pump K Valve Block (1P2) 2 ( T F-14)

24 (6A1) Rear PTO clutch

Suction filter

9803/8040-3

(1Z4) Transmission lubrication

(2A1 Hydraulic motors & 2A2)

(2P1) Hydraulic pump

(2V1) Charge valve, forwards

10 (2V2) Charge valve, reverse 11 (2V3) High pressure relief valve - forwards 12 (2V4) High pressure relief valve - reverse

to be supplied or consumed. The variable displacement pump and motors swivel accordingly. If the clutch pedal, park brake or neutral switch is operated, the turbo clutch pressure limiting valve is used to depressurise the high pressure circuit by means of two high pressure relief valves. Operation of the turbo clutch is controlled by the turbo clutch pressure limiting valve. K Valve Block 1 ( T F-12)

Cooled transmission oil is supplied to the high pressure circuit by two non-return valves alternately.

13 (2V5) Purge valve 14 (2V6) Shuttle valve 15 (3A1) Pump control cylinder 16 (3A2) Motor control cylinder 18 (3V1) Pump control valve 20 (3Z1) Control shaft 21 (3Z2) Transmission control actuator

F - 11

22 (4A1) Range selector cylinder

The actuator shaft is rotated as required by the actuator unit, thereby setting the correct quantity of oil

Hydraulic Circuit

19 (3V2) Motor control valve

The regulator cylinders of the variable-displacement pump and variable-displacement motors are actuated by two 4/3-way valves. The 4/3-way valves are activated by the actuator shaft.

CVT Description

17 (3A3) Emergency speed limiter

The circuit also includes a turbo clutch pressure limiting valve (4V4), a clutch pressure limiting valve (4V5) and a test connection.K Valve Block 2 ( T F-14)

Section F - Transmission

The high pressure circuit incorporates a variable displacement charge pump (2P1) and two variable displacement motors (2A1/2A2), two non-return valves, two servo assisted high pressure relief valves (2V3/2V4). Hot transmission oil is discharged from the high pressure circuit via the purge valve (2V5).

Section F - Transmission CVT Description Valve Block 1

Valve Block 1

Fig 10. Note: The item numbers/letters in red are shown in brackets in the component key.

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F - 12

Section F - Transmission CVT Description Valve Block 1 Component Key 1

(4S1)

Main circuit pressure sensor (high pressure)

(4V1)

Low range solenoid

(4V2)

High range solenoid

(4V3)

Solenoid valve, speed limiter

(4V4)

Tuboclutch pressure limiting valve

(4V5)

Clutch pressure limiting valve

(4V6)

Pressure reducer valve (proportional valve), pressure reduction to 18 bar, for rear PTO and 4WD clutches

(4Z2)

Accumulator

Test point, Operating pressure, transmission

(I)

Test point, low range solenoid pressure

(II)

Test point, high range solenoid pressure

(PH)

Test point, High Pressure

PHA

Test point, Operating pressure, rear PTO and 4WD clutches

Test point, Leak flow clutch valve/turboclutch valve

Note: Some pressure test points are remotely mounted on a panel at the rear of the cab. K CVT Pressures ( T F-24)

F - 13

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F - 13

Section F - Transmission CVT Description Valve Block 2

Valve Block 2

10 5

11 6

7 9

1 2

7 5 6 12

Fig 11. Note: The item numbers/letters in red are shown in brackets in the component key.

F - 14

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F - 14

Section F - Transmission CVT Description Valve Block 2 Component Key 1

(1P1)

Servo pump

(1P2)

Lubrication pump

(1S1)

Oil temperature switch

(1S2)

Filter restriction switch

(1V1)

Cooler bypass valve (3.5 bar)

(1V2)

Pressure limiting valve, feed line (6.5 bar)

(1V3)

Pressure limiting valve, supply line (6.5 bar)

(1V4)

Lubrication pressure limiting valve

(1V5)

Servo-pump pressure limiting valve (50 bar)

(1V6)

Servo circuit pressure limiting valve (25 bar)

(1Z2)

Pressure filter with by-pass

(1Z3)

Oil cooler

M1 (KV)

Test point, Cooler supply Flow

M2 (SM)

Test point, Lubrication Pressure

M3 (AS)

Test point, Return from hydrostatic loop

M4 (ES)

Test point, Supply to hydrostatic loop

M5 (PU)

Test point, servo pump outlet pressure

Note: Some pressure test points are remotely mounted on a panel at the rear of the cab. K CVT Pressures ( T F-24) The transmission oil temperature is monitored by the temperature sensor (1S1). Oil flow through the oil cooler (1Z3) depends on the temperature. This means that if the transmission oil is cold, little oil flows through the oil cooler, while most flows via the bypass valve which opens when the pressure differential exceeds approximately. 3.5 bar (50 lbf/in2). The servo-pump (1P1) generates the system pressure for the CVT control valves and the enhanced control valves. The system pressure of approximately. 25 bar (360 lbf/in2) is restricted by the pressure-relief valve with its throttling port. Contamination of the pressure filter is monitored by a pressure operated switch (1S2) as a function of the transmission oil temperature. If the transmission oil temperature is below 50 deg C, filter contamination is not monitored.

F - 15

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F - 15

Section F - Transmission CVT Description High Pressure Relief Valve, Forward/Reverse

High Pressure Relief Valve, Forward/Reverse 1

The pressure is equal in both chambers if the clutch/ turbo clutch valve is closed. the spring holds the position closed.

PH (4V4/4V5) ES

If the clutch or the turbo clutch valve is open, the pressure drop via the diaphragm (x piston surface area) is greater than the spring load. The piston moves to the right and connects PH with ES.

The pressure is relieved by the clutch and the turbo clutch valves.

2V4 Ă¸1%

p=0- 500bar

2V6

p=0- 500bar Ă¸1%

2V3

ES PH

F - 16

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F - 16

Section F - Transmission CVT Description Purge Valve

Purge Valve

B XA

p=7bar

2V5

Fig 14. Tractive mode pA > pB, delta p > 7 bar

Fig 12.

Piston is pushed upwards via control bore XA.

Pressure at A, B max 500 bar

Channel B is linked to T. Hot oil can flow from low pressure side B via T to discharge connection and to the oil cooler.

Pressure at T max 50 bar Opening pressure: delta p = 7 bar between A and B.

pB pA

Fig 13.

Fig 15.

Transmission in Neutral

Pushing Mode

pA = pB, delta p < 7 bar The piston is held in mid position by spring force Both channels (A, B) are closed.

F - 17

pA < pB, delta p > 7 bar Piston is pushed downwards via control bore XB. Channel A is linked to T. Hot oil can flow from low pressure side A via T to discharge connection and to the oil cooler.

9803/8040-3

F - 17

Section F - Transmission CVT Operation Operation in Different Modes

CVT Operation Operation in Different Modes Engine at idle, Machine stopped

540

1000

Fig 16.

F - 18

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F - 18

Section F - Transmission CVT Operation Operation in Different Modes Key 1

Planetary gears

Hydraulic pump

Connecting shaft

Hydraulic Motors

Range shift

Planetary gear/power splitting A

Planet carrier (drive from engine)

Annulus (Drive to pump)

Planet wheel

Sun wheel (Drive to accumulator shaft)

F - 19

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F - 19

Section F - Transmission CVT Operation Operation in Different Modes

99% Hydrostatic - 1% Mechanical

540

1000

Fig 17.

F - 20

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F - 20

Section F - Transmission CVT Operation Operation in Different Modes

50% Hydrostatic - 50% Mechanical

540

1000

Fig 18.

F - 21

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F - 21

Section F - Transmission CVT Operation Operation in Different Modes

0% Hydrostatic - 100% Mechanical, Machine Speed 67 km/h, Engine 1500 rev/min

540

1000

Fig 19.

F - 22

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F - 22

Section F - Transmission CVT Operation Operation in Different Modes

100% Hydrostatic Power Transmission, Medium Speed, Annulus rotates faster than engine

540

1000

Fig 20.

F - 23

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F - 23

Section F - Transmission

Pressure Testing CVT Pressures Low Pressures

Table 2. Test Point Early Machines

Test

Some pressure test points are located behind the cab on panel X (early machines) or panel Y (later machines). Do all low pressure tests at a transmission oil temperature of 37-43 deg C and an engine speed of 1200 rev/min. For specified pressures see Technical Data.

Test Point Later Machines

Low Range Solenoid Pressure

1 (on panel X) l on Valve Block 1 K Fig 22. ( T F-25)

High Range Solenoid Pressure

11 (on panel X)

Connect a pressure gauge to the relevant test point.

l l on Valve Block 1 K Fig 22. ( T F-25)

Test the following pressures with the transmission in neutral. K Table 1. ( T F-24)

Test

Table 1. Test Point Early Machines

Test Point Later Machines

Circuit Pressure hydrostatic angle servo and range shift

P (on panel X) P (on panel Y)

Servo Pump Outlet Pressure

PU (on panel X)

PU on Valve Block 2 K Fig 22. ( T F-25)

Supply Pressure to Hydrostatic Loop

ES (on panel X)

ES (on panel Y)

Return Pressure from Hydrostatic Loop

AS (on panel X)

AS (on panel Y)

Lubrication Pressure

SM (on panel SM (on panel X) Y)

Supply Pressure for 4WD PHA K Fig 23. ( T F-25) and Rear PTO Clutches

PHA K Fig 21. ( T F-24)

To test the following pressures, K Table 2. ( T F-24) select the appropriate range and check the gauge reading as the range is selected.

P T

ES PH PHA

Note: The pressure reading will be shown for only half a second.

Fig 21.

F - 24

9803/8040-3

F - 24

Section F - Transmission Pressure Testing CVT Pressures

Fig 22. Test the following with Rear PTO or 4WD selected as appropriate. Test

Test Point

Rear PTO Valve Outlet Pressure

ZWK K Fig 23. ( T F-25)

4WD Valve Outlet Pressure

VR K Fig 24. ( T F-25)

PHA

VR Fig 24.

ZWK Fig 23.

F - 25

9803/8040-3

F - 25

Section F - Transmission Pressure Testing CVT Pressures

High Pressure

!MCAUTION Do not select forward or reverse drive with brakes applied for any longer than 5 seconds as there is a risk of overheating the transmission oil.

13-2-4-17

Ensure transmission oil temperature is 37-43 deg C.

Apply park brake. Connect 0-600 bar (0-8500 lbf/in2) pressure gauge to test point PH on panel X (early machines or Y (later machines).

Select 4WD, select high range, select powershift range, gear 1.

Apply foot brakes, select forward travel, increase engine speed to 1600 rev/min and check gauge reading. The tractor should not move. For specified pressures see Technical Data.

Repeat the above procedure but select reverse drive instead of forwards.

PHA

P T

Important: Make sure the correct 0-600 bar (0-8500 lbf/ in2) pressure gauge is used as lower capacity gauges would be damaged by the high pressure.

Note: Do not depress clutch pedal during the test. Fig 25.

F - 26

9803/8040-3

F - 26

Section F - Transmission Pressure Testing Diferential Lock and PTO Speed Selection

Diferential Lock and PTO Speed Selection

Pressure test points are mounted on the differential lock/ PTO solenoid block. Differential Lock

TP2

PTO 540 rpm

TP3

PTO 100 rpm

TP4

For specified pressures see Technical Data.

F - 27

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F - 27

Section F - Transmission

CVT Valves Purge Valve Removal and Replacement 1

Drain the transmission oil, unscrew the screw plug A on the bottom of the transmission housing.

Remove the purge valve using a socket wrench. Only renew the â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122;-rings if there is damage. Check the position of the support rings. Tighten the purge valve to 200 - 210 Nm (150 - 155 lbf ft).

Fill the transmission with oil using the pressurised oil filling procedure. See Filling the Transmission Oil.

C B

Fig 26.

F - 28

9803/8040-3

F - 28

Section F - Transmission CVT Valves Forward and Reverse High Pressure Relief Valves

Forward and Reverse High Pressure Relief Valves Removal and Replacement 1

Drain the transmission oil, unscrew the two screw plugs B and C on the bottom of the transmission housing.

Remove the high pressure relief valves using a socket wrench.

High pressure relief valve - Reverse

High pressure relief valve - Forward

The high pressure relief valve is a pilot controlled pressure relief valve.

Pressure Setting New:

500 + 20 bar (7250 + 290 lbf/in )

Used:

460 - 500 bar (6670 - 7250 lbf/in2)

Only renew the â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122;-rings if there is damage. Check the position of the support rings. Tighten the high pressure relief valve to 250 - 270 Nm (185 - 200 lbf ft). 4

Fig 27.

Fill the transmission with oil using the pressurised oil filling procedure. See Filling the Transmission Oil.

F - 29

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F - 29

Section F - Transmission

Clutch Hydraulics Master Cylinder Dismantling and Assembly

Fig 28.

Dismantling

While preventing the piston from flying out due to the force of the internal spring, remove retaining ring C and washer D.

Remove piston assembly E and spring F.

If renewal is required, remove insert plug G.

!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

Disengage boot A from the cylinder and pull out the push rod B.

Before assembly, clean all components carefully and lubricate with the specified clutch system fluid, see Fluids, Capacities and Lubricants, Section 3. Do not let any other fluid come into contact with the components of the master cylinder.

Note: Avoid using sharp edged tools that could damage the boot.

F - 30

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F - 30

Section F - Transmission Clutch Hydraulics Master Cylinder

!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

Assembly 1

Fit new insert plug G.

Fit spring F onto a new piston assembly E.

Push piston and spring into the bore and hold in position while fitting washer D and retaining ring C.

Fit push rod B and boot A.

F - 31

9803/8040-3

F - 31

Section F - Transmission Clutch Hydraulics Filling and Bleeding the System

Filling and Bleeding the System

C D B

Fig 29. Important: Filling and bleeding cannot be done by the conventional method. The system must be filled and bled via the remotely-mounted bleed screw B using a pressure bleeding kit as detailed below. 1

Remove the cap from fluid reservoir A. Do not fill this reservoir with fluid.

Remove cover below battery compartment to gain access to bleed screw B.

Connect a spare fluid reservoir C to bleed screw B, using a suitable bleeding tube D.

F - 32

Fig 30. 4

Fill the spare reservoir C with the specified fluid (see Fluids, Lubricants and Capacities, Section 3) and connect a commercially available pressure bleeding kit to the spare reservoir.

Slacken bleed screw B. Watch for fluid rising in reservoir A and apply pressure via the pressure bleeding kit. Shut off the pressure supply as soon as reservoir A is full of fluid.

9803/8040-3

F - 32

Section F - Transmission Clutch Hydraulics Filling and Bleeding the System 6

Refit the cap to reservoir A. Tighten the bleed screw. Operate the clutch and check the clutch hydraulic system for leaks.

Disconnect the spare reservoir and pressure bleeding kit.

F - 33

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F - 33

Section F - Transmission CVT Cartridge Removal and Replacement

CVT Cartridge Removal and Replacement 2 9

8 6 1 7 4

14 5

3 15 Fig 31. Key - upper view

Key - upper view

18 bar for control line adjustment

Mounting shaft - bottom

Mechanical speed limiting

Mounting shaft - top

Range change control 1

Range change control 2

High pressure to clutch and turbo-clutch function

Pressure supply to the enhanced shift system

Clamps - top

CVT Cartridge

F - 34

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F - 34

Section F - Transmission CVT Cartridge Removal and Replacement

13 10

11 12

Key - lower view 10

Access to clamp nuts

HP valve - forwards

HP valve - reverse

Access to flushing valves and transmission oil drain

Fig 32. 7

Unscrew the pressure pipe and bleed line of clutch actuation system from the valve unit 1.

Loosen the fastening screws. Screw two M8 stud bolts into the gearbox housing. remove the complete valve unit 1.

Remove the bolts from gearbox housing cover.

Fit eye bolt to the cover and hoist, taking appropriate safety precaution

9803/8040-3

F - 35

Removal 1

Drain the transmission oil.

Disconnect and unscrew the range control cable.

Unscrew the range control bracket.

Unscrew the range control support.

Remove the actuator unit from the gearbox and disconnect the electrical lead.

Mark the electrical leads to the solenoid valves and disconnect.

F - 35

Close the pressure hose of the clutch actuation system to prevent it from draining.

Section F - Transmission CVT Cartridge Removal and Replacement 12

Unclip all circlips and discard, always use new circlips Press hose assemblies inwards.

Disconnect the electrical lead and remove the sensor.

Unscrew the hydraulic lines from the valve housing. Disconnect the electrical lead.

Remove the valve 2 housing.

Fig 33.

Unclip the three circlips and remove the valve plate.

Fig 34.

F - 36

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F - 36

Section F - Transmission CVT Cartridge Removal and Replacement 17

Remove the hydraulic hose (pressure supply) to the enhanced shift system.

Fig 35. 18

Unclip the drive shaft circlip, push the drive to the rear.

Fig 36. 19

Unscrew the three M8 hexagon screws from the planetary gear, push the drive shaft to the rear.

Fig 37.

F - 37

9803/8040-3

F - 37

Section F - Transmission CVT Cartridge Removal and Replacement 20

Unclip the circlip from the pinion shaft. Slide the circlip, washer and the coupling sleeve onto the pinion shaft in the direction of the arrow.

Fig 38. 21

Pivot the hydraulic motors inwards using a tyre lever.

Unscrew the two M20 hex nuts on each side of the housing.

Fig 39. 23

Loosen the two M12 clamping screws at the top. Unscrew two drain plugs on the underside of the gearbox. Collect any draining oil. Loosen the two M12 clamping screws.

Fig 40.

F - 38

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F - 38

Section F - Transmission CVT Cartridge Removal and Replacement 24

Attach a hoisting yoke to the CVT cartridge. Take up the tension. Take appropriate safety precautions

Fig 41. 25

Attach a slide hammer puller with a modified M20 nut adaptor. Withdraw the mounting shafts.

Note: The weight of the CVT cartridge is approximately 169 kg (373 lb).

Fig 42.

!MDANGER Do not stand underneath a raised load. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load. If you do not follow these precautions you or others could be killed or seriously injured. 2-3-5-4

Raise the CVT cartridge carefully out of the gearbox housing using the hoist.

Fig 43.

F - 39

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F - 39

Section F - Transmission CVT Cartridge Removal and Replacement

Replacement

Attach a hoist to theCVT cartridge taking appropriate safety precautions. Make sure the shift range change control is set to Neutral (centre position).

Fig 44. 2

Clean the seal surfaces on the transmission housing to remove oil and seal residues. Move the selector finger of the range control in transmission housing to Neutral (mid position).

Fig 45.

F - 40

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F - 40

Section F - Transmission CVT Cartridge Removal and Replacement 3

Fit the circlip onto the collar of the pinion shaft. Slide the bushing onto the pinion shaft up to the stop. Locate the flange on the connection shaft (PTO drive) and insert the connection shaft.

Fig 46. 4

Insert the CVT cartridge into the gearbox housing. Ensure clearance for all components. Insert the two shafts into the bores of the gearbox housing and the CVT cartridge.

Fig 47. 5

Check the flexible bushes for wear, if necessary fit new bushes. Insert the four bushes into the bores as far as the stop.

Fig 48.

F - 41

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F - 41

Section F - Transmission CVT Cartridge Removal and Replacement 6

Locate the ring - with the groove pointing to the flexible bush. Fit the M20 lock nut. Fit the other three nuts in the same manner.

Fig 49. 7

Tighten all four M20 nuts to 250 Nm (184 lbf ft). Counterhold the nuts when tightening. Remove the lifting hoist and the M12 eye bolt.

Fig 50. 8

Turn one planet wheel of the planetary gear of the power splitting system upwards. Align the CVT cartridge using a feeler gauge. Example: it must be possible to fit a 0.6 mm (0.02 in) between the annulus and the transmission housing on each side.

Fig 51.

F - 42

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F - 42

Section F - Transmission CVT Cartridge Removal and Replacement 9

Tighten all four clamp screws to 86 Nm (63 lbf ft). Replace the seals on the two screw plugs in the bottom of the transmission housing and tighten. Operate the range change control (check at the shift finger).

Fig 52. 10

Turn theCVT cartridge until one tooth of the toothed washer is in the centre of the sensor aperture.

Fig 53.

F - 43

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F - 43

Section F - Transmission CVT Cartridge Removal and Replacement 11

Measure the distance to the face of the tooth. Set to a measurement of 64.25 mm (2.530 in).

64.25

110.5

115

234.4 - 234.8

Fig 54. 12

Coat the seal surface of the Hall-effect sensor with sealant and insert into the bore of the transmission housing. Tighten the fastening screws to 25 Nm (18 lbf ft). Connect the electric cable.

Note: If the Hall-effect sensors are reused, stick two cardboard strips each 0.9mm (0.030 in) thick into the slit in the Hall effect sensor on the left and right (for centring when fitting).

Fig 55. 13

Pivot the hydraulic motors outwards as far as the stop (45Â°).

Fig 56.

F - 44

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F - 44

Section F - Transmission CVT Cartridge Removal and Replacement 14

Slide the sleeve onto the pinion shaft until the groove for the circlip is uncovered. Fit the circlip into the groove.

Note: If the sleeve does not engage, jack up one of the front wheels and rotate until the sleeve engages.

Fig 57. 15

Mount the flange on the planetary gear of the power splitting system. tighten the three M8 hexagon screws to 25 Nm (18 lbf ft).

Fig 58. 16

Insert the hydraulic hoses into the bores of the transmission housing behind valve block 2. Secure the inserted hoses in place with circlips (opening facing down). a

Short blue hose (discharge)

b Long blue hose (feed) c

Black hose (lubrication)

Fig 59.

F - 45

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F - 45

Section F - Transmission CVT Cartridge Removal and Replacement 17

Top front of the transmission housing: Fit the circlip into the shaft groove. Slide the shaft forward. Insert the washer. Engage the circlip in the groove on the spur gear.

Fig 60. 18

Fit the hydraulic hose (pressure supply to enhanced shift system).

Fig 61. 19

Insert the pressure hoses into the bores behind the valve block.. a

Pressure supply hydraulic hose (enhanced pressure)

b Low Range control c

Mechanical speed governor

d High Range control e

Control valves (adjustment)

High pressure to clutch and turbo-clutch operation (steel line)

Secure the pressure hoses using circlips. Fig 62.

F - 46

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F - 46

Section F - Transmission CVT Cartridge Removal and Replacement 20

Screw two M8 stud bolts into the transmission housing. Fit a new gasket, stick new o-rings into the valve unit 1 using a little grease.

Fig 63. 21

Screw two M8 stud bolts into the transmission housing at valve block 2. Fit a new gasket, stick new o-rings into the valve unit 2 using a little grease. Install valve block 2 and secure with fastening screws tightened to 25 Nm (18 lbf ft). Connect cable coupler.

Fit new o-rings to the pressure filter with a little grease, secure to the transmission housing using screws tightened to 25 Nm (18 lbf ft).

Fig 64. 23

Coat the new shaft seal with 1:1 spirit/water mixture and insert as far as the stop. Fill sealing lips 2/3 full of grease. Insert actuator shaft.

Fig 65.

F - 47

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F - 47

Section F - Transmission CVT Cartridge Removal and Replacement 24

Mate the depression in the actuator shaft with the threaded bore. Coat the thread of the hexagon bolt with synthetic bonding agent and tighten to 25 Nm (18 lbf ft).

Fig 66. 25

Locate the driver plate with the two raised sections facing the actuator unit.

Mount the pre-assembled actuator unit onto the transmission housing. Tighten the M8 socket head cap screws to 25 Nm (18 lbf ft). Connect the electric cable.

Unscrew the drain plug PU. Connect the external oil filling unit and fill with specified oil. K Filling the Transmission Oil ( T F-49)

Note: During filling pivot hydraulic motors and pump by turning the shaft. Check that there are no leaks visible from the hydraulic connections. 28

Coat the transmission housing with sealant and replace the cover. Torque tighten the M12 hex screws to 86 Nm (63 lbf ft).

Fig 67.

F - 48

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F - 48

Section F - Transmission CVT Cartridge Removal and Replacement

Filling the Transmission Oil 1

During normal maintenance, e.g. transmission oil change and/ or filter change, fill with transmission oil at left rear. See Changing the Transmission Oil and Strainer, Section 3. The external oil filling unit must be used if: a

the transmission unit is replaced or

b the high pressure unit is empty, e.g. after removal of the high pressure valves or the purge valve. 2

Unscrew the drain plug marked PU and connect the external oil filling unit. Make sure you use the correct oil type and volume. See Fluids, Lubricants and Capacities, Section 3.

Note: At least 10 Litres (2.2 UK gal, 2.6 US gal) must be added via the connection PU. 3

External oil filling unit with superfine filter. If there is no oil in the high pressure circuit, the transmission must be filtered via an external hydraulic oil filling unit. The external oil filling unit prevents the hydraulic pump and the hydraulic motor from running dry.

Note: During filling pivot hydraulic motors and pump by turning the shaft. Check that there are no leaks visible from the hydraulic connections. Item Description 1

Suction line from reservoir.

Vacuum meter.

Pump.

Electric drive motor 230 VAC

Superfine pressure filter with filter monitor

Pressure hose to port PU.

Pressure hose to oil cleaner service hydraulics (does not operate when external oil filling unit is used).

F - 49

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F - 49

Section F - Transmission

Front Axle Removal and Replacement

E H F D

Fig 68.

F - 50

9803/8040-3

F - 50

Section F - Transmission Front Axle Removal and Replacement

Removal

Remove the road wheels and drain oil from hubs and axle.

Disconnect the axle mounted speed sensor flying leads B, one at each hub, from their chassis mounted mating connectors. Tie the cable sheathing to the axle for protection during the following procedure.

Disconnect brake pipes C and seal to prevent entry of dirt.

3-3-1-1

!MCAUTION

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

Disconnect the steering assistor ram from the steering swivel at D, using a suitable ball joint splitter. Tie up the ram clear of the axle.

Disconnect the steering drag link from the steering lug on the right side hub E, using a suitable ball joint splitter. Tie up the drag link clear of the axle.

Disconnect the shock absorbers from the axle F.

Disconnect the 4WD shaft at G.

Remove Panhard rod at the axle end H, using a suitable ball joint splitter. Tie up the rod clear of the axle.

Lower the jack until springs J are fully extended.

!MWARNING Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1-1-6

Remove the two front fender assemblies.

Loosen the front road wheel retaining nuts.

Position a jack under the axle and jack the machine just far enough to allow clearance under the front of the chassis for the axle to pass beneath. Install axle stands (see Step 4).

Position axle stands (which should be capable of taking the full weight of the machine) on either side of the chassis. Lower the jack until the chassis rests on the axle stands, but make sure it still supports the weight of the axle.

!MCAUTION Keep your hands clear of the springs until they have been released and are no longer under load or you may trap your fingers. SUS-1-4

Two alternatives to steps 3 and 4: a

Lever the springs so that they are not jammed on the axle spigots.

With the axle still supported, disconnect the four control arms K from the axle (see Front Suspension, Control Arm, Section S). Tie up the control arms to prevent them hanging on the ground. The axle is now free and can be pulled forwards.

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F - 51

Hoist the whole of the front of the machine (if suitable equipment is available) and then insert axle stands as described above. Position a jack beneath the axle and raise it to take the axle weight.

b Position axle stands as described above. Use a hoist with a cross beam and two chain links around the axle (one each side) and raise it to take the axle weight.

F - 51

Section F - Transmission Front Axle Removal and Replacement

Replacement Replacement is the reverse of the removal procedure. Ensure that the chassis is correctly supported as described previously. K Removal ( T F-51) See the relevant Removal and Replacement pages for correct fitting procedures and torque settings of the following: 1

Springs, see Section G

Shock absorbers, see Section G

Panhard rod, see Section G

Control arms, see Section G

4WD shaft, see Propshafts, Section F

Bleed the brakes, see Section G Check front wheel alignment, see Checking and Adjusting the Front Wheel Alignment in section 3. On completion, fill the axle with the correct oil, see Fluids, Lubricants and Capacities, Section 3.

F - 52

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F - 52

Section F - Transmission Front Axle Hub

Hub

Fig 69.

Component Key

Gear Carrier

Hub

Screw

Circlip

Cover

Sun gear

O ring

10 Thrust washer

Backing plate

11 Drive shaft

Screw

12 Circlip

F - 53

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F - 53

Section F - Transmission Front Axle Hub 13 Lock plate 14 Ring nut 15 Ring gear 16 Lock ring 17 Ring gear support 18 Outer wheel bearing 20 O ring 21 Bolt 22 Brake disc 23 Spacer 24 Seal 25 Bearing 28 Pole wheel 30 Bolt 31 Sleeve 32 Seal 33 Bearing 37 Stud 38 Cover 39 Bolt 40 Cover 41 Shim 42 Swivel pin 43 Bearing 45 Steering knuckle 46 Seal 48 Bearing 49 Pin 50 Bearing 53 Side Gear

F - 54

9803/8040-3

F - 54

Section F - Transmission Front Axle Hub

AIN

OIL LEVEL

Dismantling

Fig 70. 1

If not already done, drain the oil from the axle and hub.

Remove the ring nut 14 using an accurately fitted tool A (see Service Tools)

Remove the service brake caliper units from the axle.(See Footbrake Calipers, Section G).

Suitably support the hub 7 and pull out the ring gear assembly 15.

Remove the six screws 1 and, using the three tapped holes provided, use screws to pull off the cover 2. Remove and discard O-ring 3.

Pull out the axle shaft backing plate 4 using a puller screw (M8).

Remove the screws 5 and, suitably supporting the side gear carrier 6, pry the carrier 6 from the wheel hub 7, using levers in the recesses provided.

Remove the circlip 8 retaining the sun gear 9 on the drive shaft 11 and pull out the sun gear.

Remove the thrust washer 10.

Pull out the circlip 12 securing the ring nut lock plates 13. Remove the lock plates. Fig 71.

F - 55

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F - 55

Section F - Transmission Front Axle Hub 11

Pry off the circlip 16 from the ring gear 15 using a suitable screwdriver.

Disassemble the ring gear support 17 from the ring gear 15.

If the replacement of the outer wheel bearing 18 inner race is necessary, the bearing may be removed by a suitable puller or by a remover that can be inserted in the holes of the ring gear support 17.

Fig 72.

Fig 73. 14

Pull out the complete wheel hub 7. Remove and discard the O-ring 20.

Pry out the seal 24 from the wheel hub and remove the inner race of the inner wheel bearing 25.

Remove fourteen bolts 21.

Remove brake disc 22 and spacer 23.

Using a suitable press, press out the outer races of the outer wheel bearing 27 and inner wheel bearing 26 from hub 7.

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F - 56

Section F - Transmission Front Axle Hub 19

If the pole wheel 28 is damaged, it can be removed using a suitable extracting tool.

Fig 74. 20

Remove dust shield guard 29.

Remove bolts 30 and sleeve 31.

Pry out seal 32 and remove the roller bearing 33 from sleeve 31.

Note: A threaded extraction hole is provided in the end of each swivel pin 42.

Remove the drive shaft and universal joint assembly 11.

Remove nuts 35 and track rod 36.

Remove studs 37 and cover 38.

Remove bolts 39 and cover 40 with shims 41. Retain the shims or note the thickness for re-assembly.

F - 57

9803/8040-3

Support the steering knuckle 45 and remove upper and lower swivel pins, bearings and seals, items 42, 43 and 44.

Remove seal 46, circlip 47 and bearing 48.

F - 57

Section F - Transmission Front Axle Hub

52 50 51 50

DR AIN

OIL LEVEL

53 54

Fig 75. 29

Mark the side gear pins 49 and their seating area on the carrier 6 for identification of original position at reassembly.

Arrange the carrier 6 on wooden blocks and, using a suitable press, push out the pins 49.

Pick up all the needle rollers 50 and spacers 51.

smooth and uniform. Renew all gears showing signs of such defects. Check that the shimming surfaces of the gears, the spacers and the shoulder rings show no signs of snagging or seizure. Check the threading and the grooving on the shafts are in good condition.

Note: It is important to keep matched needle rollers and thrust washers 52 with corresponding pins 49, because of predetermined assembly tolerance limits. 32

Remove the side gears 53 and corresponding thrust washers 54.

Inspection Thoroughly wash all the metallic parts using a solvent, biodegradable if possible, and blow them with compressed air. Pay particular attention to the internal lubrication channels on the shafts, housings and covers, which must be spotlessly clean. Check that the housings and the covers show no indentations and that the bearing seats are intact, without scoring or ridging. Check that the surfaces and the edges of the gear teeth show no signs of wear or spalling. The contact area must extend over the whole surface of the teeth and must look

F - 58

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F - 58

Section F - Transmission Front Axle Hub

Assembly Note: Before assembly, all oil seals for rotating parts should be soaked in axle oil for half an hour. 1

Fit roller bearing 48 into the axle housing and secure with circlip 47. Apply grease between lips of seal 46 and fit flush with end of housing

Smear seals 44 with grease and fit using suitable seal driver.

Locate the steering knuckle 45 and fit two swivel pins 42 and bearings 43.

43 42 44

48 47 46

44 42 43

Fig 76.

F - 59

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F - 59

Section F - Transmission Front Axle Hub

33 32

30 29

Fig 77. 4

Fit upper cover 38, using JCB Threadlocker and Sealer on studs 37.

Note: Do not fit the lower cover at this stage as shims need to be selected when checking bearing pre-load. 5

Insert drive shaft 34, making sure that the inner end locates in the splines of the differential gear.

Fit sleeve 31, use JCB Threadlocker and Sealer (High Strength) on bolts 30 and tighten to 570-630 Nm (420-465 lbf ft). Fit dust shield guard 29.

F - 60

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F - 60

Section F - Transmission Front Axle Hub

23 7

27 21 22

Fig 78. 7

Fit the outer races of the wheel inner and outer bearings 27 and 26 into the wheel hub 7, ensuring that they are correctly seated. Position the inner race of the inner wheel bearing 25 before fitting lip seal 24.

Smear JCB Multigasket on the outer rim of seal 24 and fit the seal as shown. Apply grease to the seal lips.

Lubricate and fit a new O-ring 20 and spacer 23.

Fit brake disc 22. Tighten bolts 21 to 570-630 Nm (420-465 lbf ft).

Mount the support 17 in the ring gear 15 and secure with the circlip 16. Fig 79.

F - 61

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F - 61

Section F - Transmission Front Axle Hub

Fig 80. 12

Suitably support the wheel hub 7 to prevent damage to seal 24 and mount the hub and ring gear assemblies onto the sleeve 31.

the wheel bearings by setting the rolling force as follows: Note: To prevent wrong measurement of rolling force, it is advisable to seat the bearings properly before measurement by revolving the wheel hub repeatedly. Measure the rolling force required to maintain rotation of the hub using cord wrapped around the wheel studs and a force meter as shown. Ignore the extra force needed to start rotation. Check the alignment for the lock plates 13 and adjust the nut 14 to achieve a pull load of 167 to 206 N (38 to 46 lbf).

Fig 81. 13

Tighten the ring nut 14 using an accurately fitted tool (see Service Tools) to reach the correct pre-load for

F - 62

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F - 62

Section F - Transmission Front Axle Hub adjust the swivel bearing pre-load as detailed in step 16. Tighten bolts 39 to 120-130 Nm (89-96 lbf ft).

14 13 12

Fig 82. 14

Insert the lock plates 13 and fit the circlip 12.

41 40 39 Fig 83. 15

If no parts of the steering swivel assembly have been renewed, fit cover 40 using the original thickness of shims 41. If new parts have been fitted, check and

F - 63

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F - 63

Section F - Transmission Front Axle Hub Example D.T.I. Reading

0.3 mm

Add pre-load

0.9 mm

Total

1.2 mm

Subtract 1.2 from 1.5

0.3 mm

When correct shim is fitted, fit grease nipple in cover 38 and tighten bolts 39 to 120-130Nm (89-96 lbf ft).

35 Fig 84. 16

Check and adjust swivel bearing pre-load as follows: a

Insert a 1.5mm thick shim 41 and fit cover 40. Tighten bolts 39 to 120-130 Nm (89-96 lbf ft).

b Remove the grease nipple from the upper cover 38 and position a dial test indicator (D.T.I.) B as shown. Zero the D.T.I. c

Fig 85. 18

Make sure that the wheel alignment is correct and connect the track rod 36 (see Checking and Adjusting the Front Wheel Alignment in section 3). Tighten nut 35 to 250 Nm (184 lbf ft). If the split pin holes are not aligned, tighten further until split pin can be inserted.

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F - 64

c)Using a lever, lift the hub and steering knuckle assembly as far as possible and note the D.T.I.reading.

d Add a pre-load of 0.9 to 1.0mm to the D.T.I. reading and subtract the total from 1.5mm. The result is the thickness of shim to be fitted in place of the existing 1.5mm shim.

F - 64

41 40 39

Section F - Transmission Front Axle Hub

52 50 51 50

DR AIN

OIL LEVEL

53 54

Fig 86. 19

Arrange the three side gears 53 in their seats in the side gear carrier 6.

Note: Two rows of needle rollers of the same selection class should be used for replacement on each single side gear pin. 20

Insert the inner thrust washers 54. Smear the pin lower portion (head end) with grease and position the first row of needle rollers 50. Fit the spacers 51. Smear the pin upper portion with grease and position the second row of needle rollers 50.

Position the outer thrust washers 52 on the side gears and align holes.

Insert and force fit pins 49, making sure that the rollers are not dislodged.

F - 65

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F - 65

Section F - Transmission Front Axle

AIN

OIL LEVEL

Hub

49 Fig 87. 23

Insert the thrust washer 10.

Insert the sun gear 9 and secure with the circlip 8.

Mount the side gear carrier assembly 6 onto the hub. tightening the fixing screws 5 to 67-74 Nm (49-54 lbf ft).

Fit drive shaft backing plate 4.

Lubricate and fit O-ring 3.

Rotate and align pins 49 to allow mounting of cover 2. Fit cover 2. The cover locks the pins, preventing them rotating.

Smear fixing screws 1 with sealing compound, then tighten to 33-37 Nm (24-27 lbf ft).

Ensure the axle is filled with the correct oil (see Fluids, Lubricants and Capacities, Section 3)

F - 66

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F - 66

Section F - Transmission Front Axle Drive Head

Drive Head Removal and Replacement Important: The axle must be removed from the machine first because the position of the engine sump prevents the drive head being removed with the axle in situ. K Removal ( T F-51)

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Removal 1

Drain the oil from hubs/axle.

Position the axle so that the input shaft is pointing upwards. Remove the road wheels.

Fig 88.

!MCAUTION Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

Disconnect hydraulic pipes at brake calipers. Remove the track rod and both sets of top and bottom trunnions. K Dismantling ( T F-55)

Pull the complete hub and swivel assemblies out of the axle, complete with drive shafts.

Remove bolts 1 and lift out the drive head 2.

Remove and discard axle oil seals 3.

F - 67

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F - 67

Section F - Transmission Front Axle Drive Head Replacement Apply JCB Multigasket to the mating faces of drive head and main axle casing. Apply JCB Threadlocker and Sealer to bolts 1 and torque tighten to 105-116 Nm (77-86 lbf ft). Replacement is the reverse of the removal procedure Before assembly, soak seals 3 in axle oil for half an hour and then pack JCB HP Grease between the seal lips. Ensure that the seals are fitted squarely and take care not to damage them when inserting the drive shafts. Grease the exposed parts of the trunnion pivots to prevent rusting.

Fig 89. Refit the hub and drive shaft. K Assembly ( T F-59) Refit the axle. K Replacement ( T F-52) Refill the axle with the specified oil. (See Fluids, Lubricants and Capacities, Section 3.) Check the front wheel alignment. (See Checking and Adjusting the Front Wheel Alignment in section 3). Bleed the brakes. (See Section G.)

F - 68

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F - 68

Section F - Transmission Front Axle Drive Head

Component Key

5 2

10 9 8

1 3 6

7 11

14 38 22 28

16 31 33 34 35 37 41 39 46 40 43 42 18

45 30 27 29 24 23 21 20

13 12

44 19 Fig 90. Circlip

Thrust sleeve

Piston back plate

Roller bearing

O ring

End plate

O ring

Anti-rotation screw

Piston

Roll pin

O ring

Castellated nut

Spring

Castellated nut

F - 69

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F - 69

Section F - Transmission Front Axle Drive Head 16

Bearing

Split bearing carrier

Bearing

Nut

Drive flange

Pinion shaft

Oil seal

Bearing

Pinion bearing depth shim

Pinion bearing pre-load shim

Spacer

Bearing

Bolt

Differential lock actuating sleeve

Counter plate

Friction plate

Shim

Pinion gear

Trunnion pin

Bevel gear

Shim

Pinion gear

Shim

Differential case

Bolt

Crown wheel

F - 70

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F - 70

Section F - Transmission Front Axle Drive Head

Dismantling

9 10

A 5

1 3 4

Fig 91.

!MWARNING

Apply compressed air to the oil feed port B to force out the piston back plate 2 from the differential lock housing. Remove and discard 'O' rings 3 and 4.

BF-4-1_1

Remove piston 5. Remove 'O' ring 6 and discard.

Remove the drive head from the axle K Removal and Replacement ( T F-67) Secure it in a vice or suitable jig for dismantling and examination.

Remove compression spring 7, thrust sleeve 8, axial roller bearing 9 and end plate 10.

6 2

Fit tool to retain differential lock assembly. (see Service Tools). Remove circlip 1 from the differential lock housing.

Remove the anti-rotation screw 11 and roll pin 12 from the castellated nuts. Remove castellated nuts 13 and 14.

Lay the drive head on a flat surface positioned with the split bearing carrier 18 uppermost. The weight of

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

F - 71

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F - 71

Section F - Transmission Front Axle Drive Head the assembly 15 should be sufficient to push the bearing outer cup 16 off its seat. If not, tap the cup out gently, using the weight of the differential assembly. If the cup cannot be removed using this method, remove as detailed in step 8. 8

Rotate the drivehead through 90Â° to lie in the position shown in the illustration. Undo bolts 17 and remove the split bearing carrier 18 and bearing outer cup 19. Insert a three leg bearing puller into the differential lock housing and remove bearing outer cup 16.

Rotate drivehead back through 90Â° to the vertical position and remove the differential assembly 15.

Note: During a differential lock repair or piston replacement, inspect the housing for scores, marks or damage which could cause a leak. If necessary, polish the housing with oil-lubricated 800 grade or fine abrasive paper to remove any marks. Alternatively, renew the housing.

22 30 26 27 29

28 25 24 23 21 20 Fig 92. 10

Remove the pinion nut 20. Discard the nut.

Remove the drive flange 21.

Drive the pinion shaft 22 out of the drive head carrier.

Prise the shaft seal 23 out of the bore.

Remove the taper roller bearing 24 and tap out the bearing cup 25.

F - 72

Tap out the bearing cup 26 from the opposite bearing housing and remove the pinion bearing depth shim 27.

Remove the pinion bearing pre-load shim 28, spacer 29 and bearing 30 from the pinion shaft.

9803/8040-3

F - 72

Section F - Transmission Front Axle Drive Head

42 41

41 39 40

37 36

31 19 40 41 40 41

32 35

Fig 93. 17

Remove the bolts 31 and separate the differential lock case 32 from the rest of the assembly.

Remove actuating sleeve 33.

Remove 11 counter plates 34 and 10 friction plates 35 from the differential pinion gear 38.

Separate the differential case halves 36 and 44.

Remove the pinion gears 38 and 42, bevel gears 40, trunnion pins 39, and thrust washers 41 from the case halves. Remove the thrust washers 37 and 43 from both case halves.

Remove bolts 45 and separate differential assembly from the crown wheel 46.

F - 73

Inspection Thoroughly wash all the metallic parts using a solvent, biodegradable if possible, and blow them with compressed air. Check that the housings show no indentations and that the bearing seats are intact, without scoring or ridging. Check that the surfaces and the edges of the gear teeth show no signs of wear or spalling. Renew all gears showing signs of such defects. Check that the shimming surfaces of the bearings and spacers show no signs of snagging or seizure. Check the threading and the grooving on the shafts are in good condition.

9803/8040-3

F - 73

Section F - Transmission Front Axle Drive Head Check the mating faces of crown wheel and differential case. These must be perfectly smooth or fretting will cause the bolts to work loose. Note: The bevel gears are a matched set, as are the two differential case halves also the crown wheel and pinion. These must be renewed as sets if any of their components are damaged or excessively worn. Do not use unmatched components. Note: The differential case halves are stamped for matching purposes. The stamp on the crown wheel case half can only be seen when the crown wheel is removed.

F - 74

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F - 74

Section F - Transmission Front Axle Drive Head

Assembly

42 41

41 39 40

37 36

31 19 40 41 40 41

32 35

Fig 94. To enable fitting of inner races of bearings 16, 19 and 30 pre-heat to 90-110 deg C in oil or in an oven. Do not use a flame. Before assembly, lightly oil all bearings and soak all seals for rotating parts in axle oil for half an hour. 1

Assemble the trunnion pins 39, bevel gears 38, 40, 42, and their thrust washers 37, 41 and 43 into the differential case half 44.

Position the differential case half 36 aligning the match mark letters.

Fit 11 counter plates 34 and 10 friction plates 35, starting and finishing with a counter plate. Make sure the counter plate tabs are aligned.

Position the actuating sleeve 33 on top of the last counter plate. Position the differential lock case 32

F - 75

over the counter and friction plates and align the bolt holes with those of the differential case half 36. 5

Check free rotation of the gears in the horizontal position (If held vertically the friction and counter plates would prevent rotation).

Fit crown wheel 46 using new bolts 45 and tighten to 120-133 Nm (89-98 lbf ft). Tighten bolts 31 to 65 Nm (41 lbf ft) and check free rotation of the gears in the horizontal position (see previous step).

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F - 75

Section F - Transmission Front Axle Drive Head

22 30 26 27 29

28 25 24 23 21 20 Fig 95. 7

Fit bearing cup 26 in the drive head housing with the correct thickness of shims 27 as calculated for pinion depth setting. K Pinion Depth ( T F-81)

Fit pinion bearing 30 onto pinion 22. Fit pinion into housing.

Fit bearing spacer 29, outer race 25 and a thick enough pre-load shim 28 (e.g 1.5 mm) to provide end play in the bearings.

Fit bearing inner race 24, drive flange 21 (without oil seal) and tighten nut 20 to 570-630 Nm (420-465lbf ft).

Check and adjust pinion bearing pre-load as follows: a

b Lift the pinion as far as possible and note the D.T.I. reading.

Fig 96.

F - 76

Position a dial test indicator (D.T.I.) C as shown. Zero the D.T.I.

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F - 76

Section F - Transmission Front Axle Drive Head c

Add a pre-load of 0.05 mm to the D.T.I. reading and subtract the total from the existing shim thickness (e.g 1.5 mm). The result is the thickness of shim to be fitted in place of the existing 1.5mm shim.

When pinion bearing pre-load is correct, remove the drive flange and fit seal 23 to the dimension shown at D. Apply grease to the inner lips of the seal.

Fit drive flange and tighten nut 20 to 570-630 Nm (420-465lbf ft). Stake the nut by splitting axially and bending into the notches on the pinion.

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F - 77

Example D.T.I. Reading

0.45 mm

Add pre-load

0.05 mm

Total

0.50mm

Subtract 0.5 from 1.5

1.0 mm

Replace the 1.5 mm shim by a 1.0 mm shim d Check the rolling torque of pinion bearings (without oil seal), using a torque meter driving a socket fitted to nut 20. The reading should be: For new bearings 2-4 Nm (18-35 lbf inch) For re-used bearings 1-2 Nm (9-18 lbf inch) If the rolling torque is too high, increase the shim thickness. If the rolling torque is too low, decrease the shim thickness.

Fig 97.

F - 77

Section F - Transmission Front Axle Drive Head

9 10

A 5

4 1 3 2

Fig 98. 15

Fit inner races of bearings 16 and 19 to differential case spigots (if previously removed) while turning them continuously.

Locate differential case assembly 15 into the housing. Locate the differential lock end first by rotating the assembly about the differential lock housing.

Position split bearing carrier 18. Apply JCB Threadlocker and Sealer to the threads of bolts 17. Fit bolts but do not fully tighten. Fit bearing cup 19 and when correctly seated, torque tighten bolts 17 to 315345 Nm (232-254 lbf ft).

Rotate drive head through 90Â° so that the differential lock housing is uppermost. Tap bearing cup 16 into position over its inner race.

F - 78

Fit both castellated nuts 13 and 14. Tighten both nuts equally to seat all components, then slacken back nut 13 so that a notch is aligned with the hole for roll pin 12. Position a D.T.I. to check bearing end play as shown at E. Slacken nut 14 until there is a little end play in the bearings then retighten until there is no end play and a notch is aligned with the hole for screw 11.

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F - 78

Section F - Transmission Front Axle Drive Head

Fig 99. 20

Tighten one of the nuts 13 or 14 by one complete turn to provide bearing pre-load.

Fig 100. 21

Using a D.T.I. with a magnetic base, check the crown wheel backlash as shown at F. This should be 0.20 0.28 mm (0.008-0.011 in). To achieve this figure, back off one of the castellated nuts and tighten the other one by the same number of notches. It is recommended that backlash is checked in four diametrically opposed places.

F - 79

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Section F - Transmission Front Axle Drive Head

9 10

A 5

4 1 3 2

Fig 101. 22

Apply engineersâ&#x20AC;&#x2122; marker to 3 or 4 teeth then check the crown wheel and pinion for correct meshing. K Crown Wheel and Pinion Adjustment ( T F-83). If this is incorrect, adjust nuts 13 and 14 and shim 27 accordingly.

Fit new 'O' rings 3 and 4 to piston back plate 2. Fit back plate 2 over piston 5.

Gently tap the differential lock assembly with a soft faced hammer to seat all components.

Ensure that the groove A in the piston 5 lines up with screw 11.

Compress the assembly sufficiently to fit circlip 1.

Using a hand pump, test the differential lock for correct operation and leaks. Do not exceed a pressure of 35 bar (500 lbf/in).

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F - 80

Fit screw 11 and roll pin 12.

Position the drive head with the differential lock housing uppermost. Fit new 'O' ring 6 to piston 5. Sub-assemble piston 5, end plate 10, axial roller bearing 9, thrust sleeve 8 and compression spring 7.

Grease the differential lock housing bore and fit subassembly over differential lock actuator. Make sure that the piston is inserted squarely into the bore.

F - 80

Section F - Transmission Front Axle Drive Head Pinion Depth

Fig 102. The following dimensions are required to do the the pinion depth shim calculation: Dimension A

As stamped on the housing or measured

Dimension B

A standard dimension corrected by the deviation figure on the pinion

Dimension D

Measured

F - 81

Dimension A should be stamped on the drive head flange F, otherwise it must be measured. To do this, bolt a rigid flat plate P onto the differential bearing housing flange as shown and take the measurement A from the underside of the plate to the seating surface of the pinion bearing outer race 26 (e.g.198 mm). The standard dimension B for the front axle is 162 mm.

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F - 81

Section F - Transmission Front Axle Drive Head From the face of the pinion obtain the etched deviation figure which is in units of 0.1mm (e.g. â&#x20AC;&#x2DC;+2â&#x20AC;&#x2122; etched on the pinion denotes +0.2 mm). If positive, add this to standard dimension B. If negative, subtract this from standard dimension B. The result is the corrected dimension B (e.g. 162.2 mm). Measure the depth D of assembled bearing outer race 26 and bearing inner race 30, (e.g. 35.59 mm). Obtain the theoretical shim thickness S by the following calculation: S = A minus B (corrected) minus D. Add 0.05 to the theoretical thickness S to compensate for pre-load. The result will be the thickness of shims 27 required behind the pinion bearing outer race 26. Example Calculation (all dimensions in millimetres) Dimension A

198.00

Minus Corrected Dimension B

162.20 =

Minus Bearing Depth D

35.80 35.59

0.21

Plus Pre-load

0.05

TOTAL

0.26

Use shim pack size to the nearest 0.10mm which in this example is 0.30mm.

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F - 82

Section F - Transmission Front Axle Drive Head Crown Wheel and Pinion Adjustment Meshing of the gears should be checked by marking three of the pinion teeth with engineers' marking compound and rotating the pinion.The marking will then be transferred to the crown wheel teeth.

Fig 105. Pinion too far out of mesh Increase the thickness of shim 27 between the pinion inner bearing cup and the axle casing. K Fig 95. ( T F-76) Move the crown wheel away from the pinion to correct the backlash.

Fig 103. Correct tooth marking.

Fig 104. Pinion too deeply in mesh Decrease the thickness of shim 27 between the pinion inner bearing cup and the axle casing. K Fig 95. ( T F-76) Move the crown wheel towards the pinion to correct the backlash.

F - 83

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F - 83

Section F - Transmission

Rear Axle Removal and Replacement

Fig 106.

!MWARNING

Removal

Raised Equipment Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1-1-6

Remove any mounted implements.

Jack up or hoist the chassis to take all load off the axle. Support the chassis with stands. Leave the wheels on the axle. Position a jack under the pick-up hitch to steady the axle

Drain oil from the hubs/axle.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

F - 84

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F - 84

Section F - Transmission Rear Axle Removal and Replacement 4

Disconnect the axle mounted speed sensor flying leads A, one at each hub, from their chassis mounted mating connectors. Tie the cable sheathing to the axle for protection during the following procedure.

Disconnect brake pipes B, hydraulic hoses and connections C and D. Ensure that all opened connections are sealed to prevent loss of fluid and ingress of dirt.

C030310

Fig 109.

Fig 107.

Remove the mounting bolts E for the quick release coupling and rotary position sensor brackets. Lay the brackets on the chassis with hoses still connected.

Disconnect the 'V' link arms S at the top of the axle.

Remove driveshafts (i.e. main drive and PTO).

Disconnect the lower pin of the two suspension cylinders N.

Remove the clamps/bushes P securing anti-roll bar to the axle

Disconnect the two control arms T at the axle end.

If necessary, raise the chassis to allow clearance for the axle and pull the axle clear

Replacement Replacement is the reverse of the removal procedure. Ensure that the chassis is correctly supported as described previously. K Removal ( T F-84) Fig 108.

Treat all bolt threads with JCB Threadlocker and Sealer. See the relevant Removal and Replacement pages for correct fitting procedures and torque settings of the following: 1

F - 85

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Cylinders N, see Section S

F - 85

Section F - Transmission Rear Axle Removal and Replacement 2

Anti-roll bar P, see Section S

Control arms T, see Section S

Drive shafts, see Drive shafts, Section F

Bleed the brakes, see Section G Set the ride height see Section S. On completion, fill the axle with the correct oil, see Fluids, Lubricants and Capacities, Section 3.

F - 86

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F - 86

Section F - Transmission Rear Axle Hub

Hub 16

7 28 27

18 19

15 6

25 20 31

3 17 2 34 38 12

24 11

13 4 8 9 10

Fig 110.

Component Key

Hub

Circlip

Screw

Sun gear

Cover

10 Thrust washer

O ring

11 Drive shaft

Backing plate

12 Circlip

Screw

13 Lock plate

Gear carrier

14 Ring nut

F - 87

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F - 87

Section F - Transmission Rear Axle Hub 15 Ring gear 16 Circlip 17 Ring gear support 18 Outer wheel bearing 19 O ring 20 Bolt 21 Nut 22 Spacer 23 Brake disc 24 Spacer 25 Bolt 26 Pole wheel 27 Seal 28 Inner wheel bearing 31 Sleeve 34 Side gear pin 38 Side Gear

F - 88

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F - 88

Section F - Transmission Rear Axle Hub

Dismantling

Fig 111. 1

If not already done, drain the oil from the axle and hub.

Remove the ring nut 14 using an accurately fitted tool (see Service Tools)

Remove the service brake caliper units from the axle.(See Footbrake Calipers, Section G).

Suitably support the hub 7 and pull out the ring gear assembly 15.

Remove the six screws 1 and, using the three tapped holes provided, use screws to pull off the cover 2. Remove and discard O-ring 3.

Pull out the axle shaft backing plate 4 using a puller screw (M8).

Remove the screws 5 and, suitably supporting the side gear carrier 6, pry the carrier 6 from the wheel hub 7, using levers in the recesses provided.

Remove the circlip 8 retaining the sun gear 9 on the drive shaft 11 and pull out the sun gear.

Remove the thrust washer 10.

Remove the drive shaft 11.

Pull out the circlip 12 securing the ring nut lock plates 13. Remove the lock plates.

F - 89

9803/8040-3

Fig 112.

F - 89

Section F - Transmission Rear Axle Hub 12

Pry off the circlip 16 from the ring gear 15 using a suitable screwdriver.

Disassemble the ring gear support 17 from the ring gear 15.

Fig 113.

Fig 114. 15

Pull out the complete wheel hub 7. Remove and discard the O-ring 19.

Pry out the seal 27 from the wheel hub and remove the inner race of the inner wheel bearing 28.

Remove the bolts 20, nuts 21, spacers 22, brake disc 23 and spacer 24.

Using a suitable press, press out the outer races of the outer wheel bearing 29 and inner wheel bearing 30 from hub 7.

Remove bolts 25 and pole wheel 26.

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F - 90

Section F - Transmission Rear Axle Hub 20

If the sleeve 31 is damaged, it can be removed by undoing the fixing screws 32 and removing the caliper support 33.

AIN

OIL LEVEL

Fig 115.

Fig 116. 21

Mark the side gear pins 34 and their seating area on the carrier 6 for identification of original position at reassembly.

Arrange the carrier 6 on wooden blocks and, using a suitable press, push out the pins 34.

Pick up all the needle rollers 35 and spacers36.

Note: It is important to keep matched needle rollers and thrust washers 37 with corresponding pins 34, because of predetermined assembly tolerance limits.

F - 91

Remove the side gears 38 and corresponding thrust washers 39.

9803/8040-3

F - 91

Section F - Transmission Rear Axle Hub Check that the housings and the covers show no indentations and that the bearing seats are intact, without scoring or ridging. Check that the surfaces and the edges of the gear teeth show no signs of wear or spalling. The contact area must extend over the whole surface of the teeth and must look smooth and uniform. Renew all gears showing signs of such defects. Check that the shimming surfaces of the gears, the spacers and the shoulder rings show no signs of snagging or seizure. Check the threading and the grooving on the shafts are in good condition.

F - 92

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F - 92

Section F - Transmission Rear Axle Hub

Assembly

Fit the outer races of the wheel inner and outer bearings 28 and 30 into the wheel hub 7, ensuring that they are correctly seated. Position the inner race of the inner wheel bearing 28 before fitting lip seal 27.

Note: Before assembly, all oil seals for rotating parts should be soaked in axle oil for half an hour.

2 mm

Fig 119. 3

Smear JCB Multigasket (see Section 1) on the outer rim of seal 27 and fit the seal to the dimension shown at X. Apply grease to the seal lips. Lubricate and fit a new O-ring 19.

Fig 117. 1

Smear JCB Multigasket (see Section 1) on the axle cast joining flange, fit sleeve 31, mounting plate 33 and tighten screws 32 to 900-90 Nm (663-730 lb ft).

Fig 118.

F - 93

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F - 93

Section F - Transmission Rear Axle Hub

Fig 120. 4

Fit spacer 24, brake disc 23, spacers 22, nuts 21 and bolts 20. Tighten bolts 20 and nuts 21 to 620-680 Nm (457-502 lbf ft). Fit pole wheel 26 and bolts 25, tightened to 33-37 Nm (24-27 lbf ft).

Fig 121. 5

Mount the support 17 in the ring gear 15 and secure with the circlip 16.

F - 94

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F - 94

Section F - Transmission Rear Axle Hub

Fig 122. 6

Suitably support the wheel hub 7 to prevent damage to seal 27 and mount the hub and ring gear assemblies onto the sleeve 31.

Fig 123. 7

Tighten the ring nut 14 using an accurately fitted tool (see Service Tools) to reach the correct pre-load for

F - 95

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F - 95

Section F - Transmission Rear Axle Hub 8

Insert the lock plates 13 and fit the circlip 12.

Fig 124.

52 50 51 50

DR AIN

OIL LEVEL

53 54

Fig 125. 9

Arrange the three side gears 38 in their seats in the side gear carrier 6.

Position the outer thrust washers 37 on the side gears and align holes.

Note: Two rows of needle rollers of the same selection class should be used for replacement on each single side gear pin.

Insert and force fit pins 34, making sure that the rollers are not dislodged.

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F - 96

Insert the inner thrust washers 39. Smear the pin lower portion (head end) with grease and position the first row of needle rollers 35. Fit the spacers 36. Smear the pin upper portion with grease and position the second row of needle rollers 35.

F - 96

Section F - Transmission Rear Axle Hub

Fig 126. 13

Fit the drive shaft 11.

Insert the thrust washer 10.

Insert the sun gear 9 and secure with the circlip 8.

Mount the side gear carrier assembly 6 onto the hub. tightening the fixing screws 5 to 67-74 Nm (49-54 lbf ft).

Fit drive shaft backing plate 4.

Lubricate and fit O-ring 3.

Rotate and align pins 34 to allow mounting of cover 2. Fit cover 2. The cover locks the pins, preventing them rotating.

Smear fixing screws 1 with sealing compound, then tighten to 33-37 Nm (24-27 lbf ft).

Ensure the axle is filled with the correct oil (see Fluids, Lubricants and Capacities, Section 3)

F - 97

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F - 97

Section F - Transmission Rear Axle Drive Head

Drive Head Removal and Replacement

Fig 127. Important: The axle must be removed from the machine first because the drive head is too heavy to remove with the axle in situ. K Removal ( T F-84)

!MWARNING

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

BF-4-1_1

3-3-1-1

!MWARNING

Removal

F - 98

Drain the oil from hubs/axle.

Remove the two bolts 1. Lever off the planet gear carrier 2 at one end of the axle, at levering points provided. Remove and discard the â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring.

9803/8040-3

F - 98

Section F - Transmission Rear Axle Drive Head K Dismantling ( T F-89) Repeat for the other end of the axle. 3

Pull the driveshafts out of the axle.

Remove the PTO input shaft.. K Rear PTO Input Shaft ( T F-115)

Position the axle so that the input shafts are pointing upwards.

Fig 128. 6

Remove bolts 3 and lift the drive head 4 from the axle.

Remove two dowels from the axle, if loose.

Replacement Replacement is the reverse of the removal procedure Treat all mating surfaces with JCB Multigasket. Treat bolts 3 with JCB Threadlocker and Sealer. Tighten to a torque of 285 - 315 Nm (210 - 232 lbf ft). Tighten the two bolts 1 to a torque of 67 - 74 Nm (50 - 54 lbf ft).

F - 99

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F - 99

Section F - Transmission Rear Axle Drive Head

Component Key

18 6 5 8 2 4

9 1

3 21 7 25

43 28

45 47 48 49 12

52 50 11 16 17

32 33 35 34 30 29

24 51

26 27

Fig 129. 12

Crown wheel guard

Circlip

Screw

Piston back plate

Roll pin

O ring

Castellated nut

O ring

Castellated nut

Piston

Oil passage dowel

O ring

Bearing

Spring

Bearing

Thrust sleeve

Pinion nut

Roller bearing

Drive flange

End plate

Pinion shaft

Screw

Oil seal

F - 100

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F - 100

Section F - Transmission Rear Axle Drive Head 30

Bearing

Pinion bearing depth shim

Pinion bearing pre-load shim

Spacer

Bolt

Differential lock actuating sleeve

Counter plate

Friction plate

Shim

Pinion gear

Trunnion pin

Bevel gear

Shim

Pinion gear

Shim

Differential case

Bolt

Crown wheel

F - 101

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F - 101

Section F - Transmission Rear Axle Drive Head

Dismantling

Fig 130.

!MWARNING

Apply compressed air to the oil feed port B to force out the piston back plate 2 from the differential lock housing. Remove and discard 'O' rings 3 and 4.

BF-4-1_1

Remove piston 5. Remove 'O' ring 6 and discard.

Remove the drive head from the axle K Removal and Replacement ( T F-98) Secure it in a vice or suitable jig for dismantling and examination.

Remove compression spring 7, thrust sleeve 8, axial roller bearing 9 and end plate 10.

Remove three screws 11 and crown wheel guard 12.

Fit tool to retain differential lock assembly. (see Service Tools). Remove circlip 1 from the differential lock housing.

Remove bolts 13 and 14.

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

F - 102

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F - 102

Section F - Transmission Rear Axle Drive Head 8

Remove the anti-rotation screw 15 and roll pin 16 from the castellated nuts. Remove castellated nuts 17 and 18; remove the split bearing carriers 19 and 20.

Remove the oil passage dowel 21. Remove and discard O-rings 22.

Remove the differential assembly 23 with bearings 24 and 25.

Fig 131. 11

Remove the pinion nut 26. Discard the nut.

Remove the drive flange 27.

Drive the pinion shaft 28 out of the drive head carrier.

Prise the shaft seal 29 out of the bore.

Remove the taper roller bearing 30 and tap out the bearing cup 31.

F - 103

Tap out the bearing cup 32 from the opposite bearing housing and remove the pinion bearing depth shim 33.

Remove the pinion bearing pre-load shim 34, spacer 35 and bearing 36 from the pinion shaft.

9803/8040-3

F - 103

Section F - Transmission Rear Axle Drive Head

Fig 132. 18

Remove the bolts 37 and separate the differential lock case 38 from the rest of the assembly.

Remove actuating sleeve 39.

Remove 7 counter plates 40 and 6 friction plates 41 from the differential pinion gear 44.

Separate the differential case halves 42 and 50.

Remove the pinion gears 44 and 48, bevel gears 46, trunnion pin 45, and thrust washers 47 from the case halves. Remove the thrust washers 43 and 49 from both case halves.

Remove bolts 51 and separate differential assembly from the crown wheel 52.

F - 104

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F - 104

Section F - Transmission Rear Axle Drive Head Check the mating faces of crown wheel and differential case. These must be perfectly smooth or fretting will cause the bolts to work loose. Note: The bevel gears are a matched set, as are the two differential case halves also the crown wheel and pinion. These must be renewed as sets if any of their components are damaged or excessively worn. Do not use unmatched components. Note: The differential case halves are stamped for matching purposes. The stamp on the crown wheel case half can only be seen when the crown wheel is removed.

F - 105

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F - 105

Section F - Transmission Rear Axle Drive Head

Assembly

Fig 133. To enable fitting of inner races of bearings 24, 25 and 26 pre-heat to 90-110 deg C in oil or in an oven. Do not use a flame. Before assembly, lightly oil all bearings and soak all seals for rotating parts in axle oil for half an hour. 1

Assemble the trunnion pin 45, bevel gears 44, 46, 48, and their thrust washers 43, 47 and 49 into the differential case half 50.

Position the differential case half 42 aligning the match mark letters.

Fit 7 counter plates 40 and 6 friction plates 41, starting and finishing with a counter plate. Make sure the counter plate tabs are aligned.

Position the actuating sleeve 39 on top of the last counter plate. Position the differential lock case 38

F - 106

over the counter and friction plates and align the bolt holes with those of the differential case half 42. 5

Check free rotation of the gears in the horizontal position (If held vertically the friction and counter plates would prevent rotation).

Fit crown wheel 52 using new bolts 51 and tighten to 450-480 Nm (332-354 lbf ft). Tighten bolts 37 to 115130 Nm (85-96 lbf ft) and check free rotation of the gears in the horizontal position (see previous step).

9803/8040-3

F - 106

Section F - Transmission Rear Axle Drive Head

Fig 134. 7

Fit bearing cup 32 in the drive head housing with the correct thickness of shims 33 as calculated for pinion depth setting. K Pinion Depth ( T F-112)

Fit pinion bearing 36 onto pinion 28. Fit pinion into housing.

Fit bearing spacer 35, outer race 31 and a thick enough pre-load shim 34 (e.g 1.5 mm) to provide end play in the bearings.

Fit bearing inner race 30, drive flange 27 (without oil seal) and tighten nut 26 to 570-630 Nm (420-465lbf ft).

Check and adjust pinion bearing pre-load as follows: a

b Lift the pinion as far as possible and note the D.T.I. reading.

Fig 135.

F - 107

Position a dial test indicator (D.T.I.) C as shown. Zero the D.T.I.

9803/8040-3

F - 107

Section F - Transmission Rear Axle Drive Head c

Example D.T.I. Reading

0.45 mm

Add pre-load

0.05 mm

Total

0.50mm

Subtract 0.5 from 1.5

1.0 mm

Replace the 1.5 mm shim by a 1.0 mm shim d Check the rolling torque of pinion bearings (without oil seal), using a torque meter driving a socket fitted to nut 26. The reading should be: For new bearings 2-4 Nm (18-35 lbf inch) For re-used bearings 1-2 Nm (9-18 lbf inch) If the rolling torque is too high, increase the shim thickness. If the rolling torque is too low, decrease the shim thickness.

Fig 136. 13

When pinion bearing pre-load is correct, remove the drive flange and fit seal 29 to the dimension shown at D. Apply grease to the inner lips of the seal.

Fit drive flange and tighten nut 26 to 665-735 Nm (490-540 lbf ft). Stake the nut by splitting axially and bending into the notches on the pinion.

F - 108

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F - 108

Section F - Transmission Rear Axle Drive Head

Fig 137. 15

Renew â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings 22 and fit oil passage dowel 21.

Fit bearings 24 and 25 to differential case spigots (if previously removed) while turning them continuously. Locate differential case assembly 23 into the housing.

Position split bearing carriers 19 and 20. Apply JCB Threadlocker and Sealer to the threads of bolts and 14and tighten to 315-345 Nm (232-254 lbf ft).

Fit both castellated nuts 17 and 18. Tighten both nuts equally to seat all components, then slacken back nut 17 so that a notch is aligned with the hole for roll pin 16. Position a D.T.I. to check bearing end play as shown at E. Slacken nut 18 until there is a little end play in the bearings then re tighten until there is no end play and a notch is aligned with the hole for screw 15.

F - 109

9803/8040-3

Fig 138.

F - 109

Section F - Transmission Rear Axle Drive Head 19

Tighten one of the nuts 17 or 18 by one complete turn to provide bearing pre-load.

Fig 139. 20

F - 110

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F - 110

Section F - Transmission Rear Axle Drive Head

Fig 140. 21

Apply engineersâ&#x20AC;&#x2122; marker to 3 or 4 teeth then check the crown wheel and pinion for correct meshing. Wheel and Pinion K Crown Adjustment ( T F-114). If this is incorrect, adjust nuts 17 and 18 and shim 33 accordingly.

Fit new 'O' rings 3 and 4 to piston back plate 2. Fit back plate 2 over piston 5.

Gently tap the differential lock assembly with a soft faced hammer to seat all components.

Ensure that the groove A in the piston 5 lines up with screw 15.

Compress the assembly sufficiently to fit circlip 1.

Using a hand pump, test the differential lock for correct operation and leaks. Do not exceed a pressure of 35 bar (500 lbf/in).

9803/8040-3

F - 111

Fit screw 15 and roll pin 16.

Grease the differential lock housing bore and fit subassembly over differential lock actuator. Make sure that the piston is inserted squarely into the bore.

F - 111

Section F - Transmission Rear Axle Drive Head Pinion Depth

Fig 141. The following dimensions are required to do the the pinion depth shim calculation: Dimension A

As stamped on the housing or measured

Dimension B

A standard dimension corrected by the deviation figure on the pinion

Dimension D

Measured

F - 112

If positive, add this to standard dimension B. If negative, subtract this from standard dimension B. The result is the corrected dimension B (e.g. 208.2 mm).

Dimension A should be stamped on the drive head flange F, otherwise it must be measured. To do this, bolt a rigid flat plate P onto the differential bearing housing flange as shown and take the measurement A from the underside of the plate to the seating surface of the pinion bearing outer race 32 (e.g.244 mm). The standard dimension B for the rear axle is 208 mm.

From the face of the pinion obtain the etched deviation figure which is in units of 0.1mm (e.g. â&#x20AC;&#x2DC;+2â&#x20AC;&#x2122; etched on the pinion denotes +0.2 mm).

Measure the depth D of assembled bearing outer race 32 and bearing inner race 36, (e.g. 35.59 mm). Obtain the theoretical shim thickness S by the following calculation: S = A minus B (corrected) minus D.

9803/8040-3

F - 112

Section F - Transmission Rear Axle Drive Head Add 0.05 to the theoretical thickness S to compensate for pre-load. The result will be the thickness of shims 33 required behind the pinion bearing outer race 32. Example Calculation (all dimensions in millimetres) Dimension A

244.00

Minus Corrected Dimension B

208.20 =

Minus Bearing Depth D

35.80 35.59

0.21

Plus Pre-load

0.05

TOTAL

0.26

Use shim pack size to the nearest 0.10mm which in this example is 0.30mm.

F - 113

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F - 113

Section F - Transmission Rear Axle Drive Head Crown Wheel and Pinion Adjustment Meshing of the gears should be checked by marking three of the pinion teeth with engineers' marking compound and rotating the pinion.The marking will then be transferred to the crown wheel teeth.

Fig 144. Pinion too far out of mesh Increase the thickness of shim 33 between the pinion inner bearing cup and the axle casing. K Fig 134. ( T F-107) Move the crown wheel away from the pinion to correct the backlash.

Fig 142. Correct tooth marking.

Fig 143. Pinion too deeply in mesh Decrease the thickness of shim 33 between the pinion inner bearing cup and the axle casing. K Fig 134. ( T F-107) Move the crown wheel towards the pinion to correct the backlash.

F - 114

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F - 114

Section F - Transmission Rear Axle Drive Head

Rear PTO Input Shaft

Replacement

Removal

Fit bearing 5 onto shaft 6.

Disconnect the drive shaft from the transmission to the PTO input shaft.

Install shaft and bearing into the housing and fit circlip 4.

Prevent the flange 1 from turning using a suitable bar reacting against two bolts refitted into the flange. Unscrew nut 2.

Fit new oil seal 3.

Fit flange 1 and nut 2.

Remove flange and prise out seal 3.

Remove circlip 4, bearing 5 and shaft 6.

Prevent the shaft from turning using a suitable bar reacting against two bolts refitted into the flange. Tighten nut 2 to 570 to 630 Nm (420 to 465 lb ft).

Fig 145.

Fig 146.

F - 115

9803/8040-3

F - 115

Section F - Transmission Rear Axle Rear PTO Gearbox

Rear PTO Gearbox

Fig 147.

F - 116

9803/8040-3

F - 116

Section F - Transmission Rear Axle Rear PTO Gearbox

Component Key 1

Sensor

Nut

Output shaft

Bolt

Circlip

Bearing

Screw

Selector support

Adjustment spacers

Driving gear

Circlip

Bearing

Screw

Flange

Spacer

O ring

Oil seal

Bearing

Nut

Bearing

Shoulder ring

Bush

Roller cage

Spacer

Driven gear

Hub

Sleeve

Driven gear

Shaft

Nut

Circlip

Retainer

Outer spring

Inner spring

Piston

Screw

F - 117

Selector fork

O ring

Oil pipe

9803/8040-3

F - 117

Section F - Transmission Rear Axle Rear PTO Gearbox

Dismantling

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Drain oil from rear axle (see Section 3).

Fig 149.

Fig 148. 2

Remove sensors 1 and 1a.

Remove the eight nuts 2 and remove the PTO output shaft 3.

F - 118

Fit a suitable retaining plate A to prevent the gears from moving when the rear cover is removed.

Remove nineteen bolts 4, leaving two bolts 5 in position until the weight of the cover is safely supported by a hoist at B.

Remove the remaining bolts 5, pull the cover backwards and lift clear

9803/8040-3

F - 118

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 150. 7

Remove screws 6 and oil conveyor 7.

Remove circlip 8 and extract bearing sleeve 9.

Remove screws 10.

Support the gears 12 and remove plate A.

Remove selector 11 and gear assembly 12 together, collecting the adjustment spacer(s) 13. Retain the spacers for assembly.

F - 119

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F - 119

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 151. 12

Remove screws 14 and guard 14a.

Extract driving gear 15.

Remove circlip 16 and remove bearing 17 from driving gear 15.

Remove screws 18 and extract flange 19, collecting the adjustment spacer(s) 20.

Remove ‘O’ ring 21 and seal 22 from the flange.

Remove ‘O’ rings 23.

Drive bearing race 24 out of the cover.

F - 120

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F - 120

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 152. 19

Support the shaft and gear assembly and unscrew nut 25.

Remove gear 36 and extract roller cage 35 and spacer 34 from the gear.

Remove bearing inner race 26, and shoulder ring 27.

Extract bearing inner race 38 from shaft 37.

Remove gear 31 and extract bush 28, roller cage 29 and spacer 30 from the gear.

Check condition of studs A. These should be held by retaining compound.

Remove sleeve 33 and hub 32.

Fig 153. 26

Remove nuts 39. Extract circlip 40 and remove springs 42, 43 and retainers 41, 44.

F - 121

Remove screw 47 and extract fork 48 and piston 46 from the support 45. Remove â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings 49, 50 and 51.

9803/8040-3

F - 121

Section F - Transmission Rear Axle Rear PTO Gearbox Check the threading and the grooving on the shafts are in good condition Check the sides of the sliding sleeve for wear, along with the contact surfaces of the gear selector fork.

Assembly

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Fig 154. 28

If necessary, remove pipes 52, 53 and oil deflectors 55, 56.

If bearing outer race 54 needs renewal, remove it using an extractor.

Fig 155. 1

Fit bearing outer race 54.

Fit oil deflectors 55 and 56. Tighten screws 57 to 9-11 Nm (7-8 lbf ft).

Fit pipes 52 and 53. Tighten the connections to 19-21 Nm (14-15 lbf ft). Test the sealing of the circuit using a hand pump. A pressure of 30 bar (435 lbf/in2) should be maintained over a period of 30 minutes.

Check that the spacers and shoulder rings show no signs of snagging or seizure.

F - 122

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F - 122

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 156. 4

Fit new â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings 49, 50 and 51.

Locate retainer 44, springs 42 and 43 and retainer 41 in the support 45. Secure with circlip 40.

Locate piston 46 and fork 48 in the support 45. Apply retaining compound when fitting screw 47.

Fit nuts 39 and adjust to achieve a piston stroke of 8.5 mm (0.33 in).

F - 123

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F - 123

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 157. 8

Fit bearing outer race 24 into the cover.

Fit bearing inner races 26 and 38 onto the shaft 37.

Position spacer(s) 20 and fit flange 19.

To set the bearing pre-load, fit the cover and shaft 37 without the gears as shown.

Make up and fit a suitable tool A to allow the shaft to be rotated using a torque meter.

Check that the rolling torque of shaft 37 is 1-2 Nm (917 lbf in). If the rolling torque is incorrect, adjust the thickness of spacers 20 and recheck the rolling torque until it is correct.

When the rolling torque is correct, remove the flange, cover and shaft. Retain the determined thickness of spacers for re-assembly. Remove bearing inner race 26 from the shaft.

F - 124

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F - 124

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 158. 15

Fit roller cage 35 and spacer 34 into gear 36 and fit the gear onto shaft 37.

Fit hub 32 and sleeve 33 onto the shaft.

Fit spacer 30, roller cage 29 and bush 28 into gear 31 and fit the assembly onto the shaft.

Fit shoulder ring 27, bearing inner race 26 and tighten nut 25 to 665-735 Nm (490-540 lbf ft). Stake the nut into the groove on the shaft.

Fit bearing 17 and circlip 16 onto gear 15.

Fit gear 15 into the cover.

Fit guard 14a. Tighten screws 14 to 9-11 Nm (7-8 lbf ft).

Fit new â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; rings 23.

Fig 159.

F - 125

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F - 125

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 161. 27

Make up a suitable retaining plate C and secure the gear and shaft assemblies as shown.

Important: It is essential that the retaining plate is fitted to make the assembly procedure safe and easy. Fig 160. 23

Fit spacer(s) 13 to the same thickness as removed when dismantling.

Apply a little grease to the selector support 11 to ease its assembly into the cover.

5Locate the selector fork onto sleeve 33. K Fig 158. ( T F-125) Enter the shaft, gears and selector assemblies into the cover.

Apply retaining compound to screws 10 and tighten to 73-77 Nm (54-57 lbf ft).

F - 126

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F - 126

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 162. 28

Fit bearing inner race 9 and secure with circlip 8.

Position guard 7, apply retaining compound to screws 6 and tighten to 9-11 Nm (7-8 lbf ft).

F - 127

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F - 127

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 163. 30

Lubricate and fit new â&#x20AC;&#x2DC;Oâ&#x20AC;&#x2122; ring 21 and oil seal 22. Smear grease on the inner diameter of the seal.

Position the correct thickness of adjustment spacers 20 as determined when checking rolling torque.

Fit flange 19, apply retaining compound to screws 18 and tighten to 73-77 Nm (54-57 lbf ft).

To prevent the gears from moving and allow plate C to be removed, fit the retaining plate A (as used during dismantling).

Remove retaining plate C.

Clean the mating faces of cover and housing and apply sealing compound as shown.

Fig 164.

F - 128

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F - 128

Section F - Transmission Rear Axle Rear PTO Gearbox

Fig 166. 38

Fit output shaft 3. Tighten nuts 2 to 63-67 Nm (47-50 lbf ft).

Apply sealing compound to threads of sensors 1 and 1a. Tighten to 22-24 Nm (16-18 lbf ft).

Refill the rear axle and PTO with the specified oil (see Section 3).

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F - 129

Fig 165. 36

Fit the cover using twentyone new self-locking bolts 4; tighten to 428-473 Nm (315-350 lbf ft). Remove retaining plate A.

F - 129

Section F - Transmission Rear Axle Rear PTO Gearbox

F - 130

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F - 130

Section G Brakes Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-2

Section G - Brakes

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Section G - Brakes Contents Page No. Technical Data Brake System ......................................................................................... G - 1 Special Tools Service Tools Selection List .................................................................... G - 2 Circuit Descriptions Brake System ......................................................................................... G - 3 Tractor ABS System ............................................................................... G - 6 Fault Finding Introduction ............................................................................................. G - 9 Fault Tables .......................................................................................... G - 11 Footbrake Calipers Removal and Replacement .................................................................. G - 15 Brake System Bleeding ........................................................................ G - 17 Park Brake Caliper Removal and Replacement .................................................................. G - 18 Dismantling and Assembly ................................................................... G - 20 Valves Air Drier/Unloader Valve ....................................................................... Circuit Protection Valve ........................................................................ Pressure Modulating Valves ................................................................. Non-Return Air Valve ............................................................................ Trailer Brake Hydraulic Valve ...............................................................

G - 22 G - 25 G - 27 G - 28 G - 29

Trailer Brake Palm Couplings Dismantling and Assembly ................................................................... G - 32

G-i

Section G - Brakes Contents

G - ii

Page No.

G - ii

Section G - Brakes

Technical Data Brake System Operating Pressure (air)

8 bar

120 lbf/in2

Parking Brake Minimum Permissible Lining Thickness

3 mm

(0.12 in)

New

9.5 mm

(0.374 in)

Minimum after Skimming

8.9 mm

(0.350 in)

3 mm

(0.12 in)

New

22 mm

(0.866 in)

Minimum after Skimming

19.8-20.2 mm

(0.780-0.795 in)

Disc Thickness

Foot (Service) Brake Minimum Lining Thickness (at renewal) Front Disc Thickness

Rear Disc Thickness New

22 mm

(0.866 in)

Minimum after Skimming

19.8-20.2 mm

(0.780-0.795 in)

Safety

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

Stop the engine and block all four wheels.

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

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

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

G-1

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

BRAK-8-3_1

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

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G-1

Section G - Brakes

Special Tools Service Tools Selection List

892/00311

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

Fig 1.

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Section G - Brakes Circuit Descriptions Brake System

Circuit Descriptions Brake System

Fig 2.

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Section G - Brakes Circuit Descriptions Brake System Component Key for Fig 2. (X G-3) A

Engine air filter

Compressor

Air dryer/unloader/exhaust silencer

Circuit protection valve

Front brake circuit reservoir

Rear brake circuit reservoir

Trailer/parking brake circuit reservoir

H1-H3

Low pressure warning light switches

Foot brake valve

Front brake air/hydraulic actuator

Rear right brake air/hydraulic actuator

Rear left brake air/hydraulic actuator

Front brake calipers

Rear left brake caliper

Rear right brake caliper

Pressure modulating valve (front brakes) (ABS)

Inverse relay valve (single line air trailer brakes) (if fitted)

Hydraulic trailer brake valve (if fitted)

Line Types DD

Signal lines to and from ECU

In-line check valve (hydraulic brake fluid line)

Hydraulic brake fluid lines

Main hydraulic fluid lines

ABS Electronic Components AA

Electronic Control Unit (ECU)

Wheel hub mounted sensing rings

Axle mounted wheel speed sensors

Trailer Connectors SL

Single line air trailer brake (if fitted) Twin line air trailer brake, control (if fitted)

Pressure modulating valve (rear right brake) (ABS)

Pressure modulating valve (rear left brake) (ABS)

Hydraulic trailer brake (if fitted)

Trailer brake air control valve

Twin line air trailer brake, supply (if fitted)

Feed to pressure gauge

Parking brake control valve

Parking brake actuator

TP1 - TP8

Air pressure test points

Non-return valve

Filtered air is drawn via engine air filter A into the engine mounted compressor B, see Fig 2. (X G-3) Air from the compressor is directed to the air dryer/ unloader valve C which senses the air pressure stored in the braking system. When the braking system pressure is less than the pressure from the compressor, air is directed to the circuit reservoirs. When the braking system reaches its operating pressure a purge valve in valve C opens to allow the dryer internal pressure to expel accumulated condensate and solid matter. This decompression of the dryer allows dry air direct from the air system to exhaust via the dryer desiccant, taking with it the accumulated desiccant moisture, preventing it from becoming saturated. The air flows from the unloader valve into circuit protection valve F. In the event of a loss of pressure, such as a pipe failure in one or more of the four circuits, the circuit protection valve F ensures that the remaining circuits still receive sufficient air to operate normally. The four

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Section G - Brakes Circuit Descriptions Brake System independent circuits are front brakes, rear brakes, trailer/ parking brake and feed to air pressure gauge.

Front Brake Circuit Air from the circuit protection valve is fed into the front brake circuit reservoir G1 which is fitted with a pressure test point TP1. Air from the reservoir passes a low pressure warning light switch H1 before entering the dual foot brake valve J. When the foot brake is operated, air is allowed through the valve. The flow divides, some flowing to the trailer brake air control valve P to apply the trailer brakes. The rest of the air flows via ABS pressure modulating valve N1 into the front brake air/hydraulic actuator K1, see Tractor ABS System (X G-6). Air pressure entering the actuator is converted into hydraulic pressure and fed to the front brake calipers L where it applies the brakes.

Rear Brake Circuit Air from circuit protection valve F is fed into rear brakes reservoir G2 which is fitted with a pressure test point TP2. Air from the reservoir passes low pressure warning light switch H2 before entering dual foot brake valve J. The air which passes through the valve when the foot brake is operated flows to the rear brake air/hydraulic actuators K2 and K3, via ABS pressure modulating valves N2 and N3 respectively, to actuate rear brake calipers MR and ML.

Parking Brake Circuit From non-return valve V, the air is fed to the parking brake control valve R. When this valve is put into the off position it supplies air pressure to parking brake actuator T to release the caliper parking brake. It also supplies a signal pressure to the trailer brake air valve which then cuts off the tractor control pressure. When the control valve R is set to the on position, it exhausts all air downstream of non-return valve V with the following effects: (1) The parking brake actuator applies the parking brake by the force of its integral spring. (2) The signal pressure is exhausted from the trailer brake air valve which then supplies control pressure to apply the trailer brakes.

Hydraulic Trailer Brakes (if fitted) A hydraulic trailer brake facility can be provided. A hydraulic trailer brake valve X is fed via port P at pump pressure which is output via port N to the external hydraulics valve as well as used internally. A tank return is provided via port R. The hydraulic brake output (port B) to connector TH is activated by pilot pressure into port Y from the front axle service brake circuit. The pressure of hydraulic brake output at port B is proportional to the service brake pressure.

Trailer/Parking Brake Circuit Air from the circuit protection valve F is fed into the trailer/ parking brake circuit reservoir G3 which is fitted with a manual drain valve and a pressure test point TP3. Air from the reservoir passes a low pressure warning light switch H3 before feeding the trailer brake air valve P. Before it enters the trailer brake air valve the line branches to feed the parking brake circuit via non-return valve V. Trailer brake air valve P provides a permanent supply to the trailer brake coupling TS. It receives control signals from the front and rear brakes when they are operated and responds by feeding the control line to the trailer brake coupling TC. When a machine is fitted with single line trailer air braking, inverse relay valve W controls the feed via line SL.

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Section G - Brakes Circuit Descriptions Tractor ABS System

Tractor ABS System General Description

Operation

The Fastrac ABS system incorporates sensor rings attached to each of the four wheel hubs with a speed sensor mounted on the axle adjacent to each.

Refer to the following diagrams:

The interaction of the speed sensors and sensor rings generates signals which are sent to the ABS Electronic Control Unit (ECU). The ECU interprets the signals and sends out appropriate control signals to pressure modulating valves (PMV), one controlling the pair of front brakes and one controlling each of the two rear brakes individually The control signals from the ECU are applied to solenoid valves in the PMVâ&#x20AC;&#x2122;s. The solenoid valves and two check valves control the building-up, maintaining or releasing of brake pressure to the relevant brake cylinders according to the requirements of the braking situation.

Fig 3. Braking situation K Fig 3. ( T G-6)

Pressure modulating valve (PMV) reaction

Normal Check valves A and B closed. . roading. Foot Solenoid C de-energised (open). brake E Solenoid D de-energised (closed). released. No air pressure from foot brake E. No air pressure at air/hydraulic brake actuator F

Zero Pressure

Braking/trapped pressure

Decaying pressure

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Section G - Brakes Circuit Descriptions Tractor ABS System

Fig 4. Braking situation K Fig 4. ( T G-7)

Fig 5.

Pressure modulating valve (PMV) reaction

Foot brake E Against spring pressure, check valve A applied.. opens under air pressure from the foot brake. Check valve B remains closed due to equal air pressure on both sides. Solenoids C and D remain de-energised. .Air pressure flows to actuator F to apply the brakes.

Braking situation K Fig 5. ( T G-7)

Pressure modulating valve (PMV) reaction

Foot brake E applied. ABS ECU senses imminent wheel lockup and sends signal to PMV.

ECU signal energises solenoid C which closes. Braking pressure is routed to both sides of check valve A which closes, due to spring pressure, to isolate the foot brake. Pressure in the actuator chamber is trapped and remains constant. Check valve B still remains closed. Solenoid D still remains de-energised.

Zero Pressure

Braking/trapped pressure

Decaying pressure

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Section G - Brakes Circuit Descriptions Tractor ABS System

Fig 6. Braking situation K Fig 6. ( T G-8)

Pressure modulating valve (PMV) reaction

Foot brake E applied. ECU still senses imminent wheel lock-up. It also senses the need to reduce braking pressure and sends a further signal to the PMV.

Solenoid C remains energised (closed).

Fig 7.

The foot brake remains isolated by check valve A Solenoid D energises (opens). Solenoid D exhaust port opens to remove the pressure behind check valve B. Against spring pressure, check valve B is forced open by the trapped actuator pressure which decays to atmosphere via exhaust port G.

Braking situation K Fig 7. ( T G-8)

Pressure modulating valve (PMV) reaction

Foot brake E applied. ECU senses that wheel lock-up is no longer imminent and stops sending signals to the PMV.

Solenoid C de-energises (opens) and solenoid D de-energises (closes). Braking pressure overcomes the decaying pressure behind both check valve A which opens and check valve B which closes. Foot brake pressure flows directly to actuator F to re-apply the brake. The pressure behind check valves A and B continues to decay via port G until fully exhausted.

Zero Pressure

Braking/trapped pressure

Decaying pressure

G-8

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G-8

Section G - Brakes Fault Finding Introduction

Fault Finding Introduction Component Key C

Air Dryer/Unloader Valve

Circuit Protection Valve

Front Circuit Air Reservoir

Rear Circuit Air Reservoir

Trailer/Parking Brake Air Reservoir

Air/Hydraulic Actuator - Both Front Brakes

Air/Hydraulic Actuator - Rear Right Brake

Air/Hydraulic Actuator - Rear Left Brake

Pressure Modulator Valve - Both Front Brakes

Pressure Modulator Valve - Rear Right Brake

Pressure Modulator Valve - Rear Left Brake

Trailer Brake Air Control Valve

TP1

Test Point, Front Circuit

TP2

Test Point, Rear Circuit.

TP3

Test Point, Trailer and Parking Brake Circuit

TP4

Test Point, Front Circuit (not shown) (see Description, Brake System)

TP5

Test Point, Rear Circuit (not shown) (see Description, Brake System)

TP6

Test Point, Front Circuit

TP7

Test Point, Rear Right Circuit

TP8

Test Point, Rear Left Circuit

Non-return Valve

TP7 Fig 8.

G-9

Fig 9. View from other side of Fig 1

9803/8040-2

G-9

Section G - Brakes Fault Finding Introduction Refer to the illustrations during fault finding.

Fig 10. For diagnostic purposes the air brake system is fitted with test points, on the circuit reservoirs (TP1, TP2), (TP3), on the foot brake air valve (TP4, TP5) and on the air/hydraulic actuators (TP6, TP7, TP8). Diagnosis of system faults requires the use of suitable gauges (three are usually sufficient). A service kit of gauges, hoses and fittings is available as JCB Service Tool 892/00311. General air leaks are usually audible with the engine stopped. For smaller air leaks on valves, soak the valve in soap solution and watch for the formation of bubbles. As an aid to fault finding the air system pipes are colour coded as follows: Red

Front brake circuit

Yellow

Rear brake circuits

Blue

Parking brake circuit

Black

Trailer brake system circuit

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G - 10

Section G - Brakes Fault Finding Fault Tables

Fault Tables Low Pressure Warning Lights On CHECK 1

ACTION

Are all three warning lights on?

YES Check 2. NO

Is there a leak between the compressor and the circuit protection YES Rectify leak. valve? NO

Is air continually pumping from air dryer/unloader valve exhaust?

If only one light is on, pressure test relevant tank. Is pressure OK?

Strip and examine compressor.

YES Renew defective low pressure switch. NO

Check 3.

YES Renew defective air dryer/unloader valve. NO

Check 4.

Check 5.

Drain air from complete system. Recharge. Does fault still exist? YES Renew circuit protection valve. NO

System now OK.

Service Brakes Poor CHECK 1

ACTION

Do disc pads have a minimum of 3 mm (0.12 in) friction material? YES Check 2. NO

Do both brake fluid reservoirs have adequate fluid?

YES Check 3. NO

Have brakes been bled?

Top up and check for leaks.

YES Check 4. NO

Renew pads (in complete axle sets).

Bleed brakes.

Fit a gauge first to TP4 and then to TP5. Each time press the YES Check 5. brake pedal. Does the gauge indicate that air system pressure is reaching the footbrake valve.

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Section G - Brakes Fault Finding Fault Tables CHECK

ACTION NO

Are air/hydraulic actuators functioning?

Check that air system pressure is reaching the circuit protection valve. If not check for a leak in the circuit from the compressor. If pressure is reaching the circuit protection valve check the valve for faults.

YES Bleed brakes. NO

Strip and inspect actuator(s).

Poor Front Brakes, Good Rear Brakes CHECK 1

ACTION

Fit a gauge to TP1. Charge system. Does TP1 reach system pressure?

YES Check 2. NO

Operate footbrake. Does the front air/hydraulic actuator function?

YES Check 4. NO

Operate footbrake. Does TP4 or TP6 reach system pressure?

Has the front hydraulic circuit been bled?

Check 3.

YES Check pressure modulator valve. NO

Check for leaks or faulty circuit protection valve.

Check footbrake valve.

YES Check operation of the calipers and serviceability of the brake friction pads. NO

Bleed front hydraulic circuit.

Poor Rear Brakes, Good Front Brakes CHECK 1

ACTION

Fit a gauge to TP2. Charge system. Does TP2 reach system pressure?

YES Check 2. NO

Operate footbrake. Does the rear air/hydraulic actuator function? YES Check 4. NO

Check for leaks or faulty circuit protection valve.

Operate footbrake. Does TP5, TP7 or TP8 reach system pressure?

G - 12

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Check 3.

YES Check both pressure modulator valves.

G - 12

Section G - Brakes Fault Finding Fault Tables CHECK

ACTION NO

Has the rear hydraulic circuit been bled?

Check footbrake valve.

YES Check operation of the calipers and serviceability of the brake friction pads. NO

Bleed rear hydraulic circuit.

Trailer Brakes Poor CHECK

ACTION

1 Fit a gauge to TP3. Charge system. Is tank up tosystem pressure? YES Check 3. NO 2 Drain air from complete system. Recharge. Is tank up to system pressure?

YES System now OK. NO

3 Fit gauges to trailer tappings TS and TC. Is TS at system pressure?

Renew circuit protection valve.

YES Check 4 NO

4 Operate footbrake. Is TC at system pressure?

Check 2.

Defective trailer brake valve.

YES Fault on trailer brakes. NO

Defective trailer brake valve.

Park Brake Not Holding CHECK 1

ACTION

Do disc pads have a minimum of 3 mm (0.12 in) friction material? YES Check 2. NO

Are pads adjusted correctly?

YES Check 3.. NO

Is caliper clamping on disc?

Adjust.

YES Suspect fault in rear axle. NO

G - 13

Renew pads.

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Suspect fault in spring brake actuator.

G - 13

Section G - Brakes Fault Finding Fault Tables

Park Brake Not Releasing

CHECK

ACTION

1 Fit gauge to TP1 and TP3. Charge system. Is pressure OK?

YES Check 3. NO

Check 2.

2 Is there a leak between the trailer brake valve and the park brake YES Rectify leak. actuator? NO 3 Are pads adjusted correctly?

YES Suspect fault in spring brake actuator. NO

G - 14

Defective park brake valve.

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Adjust.

G - 14

Section G - Brakes

Footbrake Calipers Removal and Replacement Note: Illustrations show typical caliper mounting positions.

Removal 1

Park the machine on firm, level ground, apply the parking brake and remove the starter key.

!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. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1

Chock the front wheels. Jack up the appropriate wheel, support the machine on an axle stand and remove the wheel.

Disconnect the brake pipe A (front) or B (rear) and catch the fluid in a suitable container.

If the pistons are free, force the pads back until they clear the disc. If necessary remove the pads to provide clearance (see Section 3). Remove bolts C (front) or D (rear) and remove the caliper.

Fig 11.

Fig 12.

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Section G - Brakes Footbrake Calipers Removal and Replacement

Replacement Reverse the removal procedure, ensuring that spacers E and F are fitted. Apply JCB Threadlocker and Sealer to the fasteners and make sure that the correct torque settings are used. Note: Fasteners C are capscrews. Bleed the brakes K Brake System Bleeding ( T G-17)

Torque Settings Important: ABS MACHINES: Refer to Safety at the front of this section before proceeding further. Item

kgf m

lbf ft

C (capscrews)

654

482

D (10.9 grade)

300

220

Fig 14.

Fig 13.

G - 16

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Section G - Brakes Footbrake Calipers Brake System Bleeding

Brake System Bleeding Note: The hydraulic systems for the front and rear brakes are completely separate and must be bled separately as detailed below. Note: If two front calipers are fitted, they should be bled as a wheel pair via the uppermost caliper in each case. .

!MWARNING Before proceeding with the bleeding procedure it is important to ensure that the park brake is engaged and that one pair of wheels is blocked on both sides. BRAK-1-2

With the engine running, check that all three low air pressure warning lights are extinguished, indicating there is enough air pressure. Stop the engine.

Fill the relevant fluid reservoir with the specified fluid (see Section 3). Ensure that throughout the bleeding process the level is not allowed to fall below the lower mark on the reservoir.

Fig 15.

!MCAUTION Using incorrect fluid could damage the system. See Fluids, Capacities and Lubricants for the correct fluid. The fluid can harm your skin. Wear rubber gloves. Cover cuts or grazes. 2-3-5-1_2

Attach a tube to the bleed screw to be bled (X - front, Y - rear), ensuring that the free end is immersed in fluid in a suitable container.

Open the bleed screw and apply full pedal strokes until all air is expelled. Close the bleed screw with the pedal fully depressed.

Repeat the procedure for the other brake on the opposite side of the machine.

When bleeding the rear system of a vehicle fitted with a trailer brake hydraulic valve, bleed air from the bleed screw on the valve after having bled the rear calipers. (See Trailer Brake Hydraulic Valve Removal and Replacement for position of bleed screw.)

Fig 16.

Top up the brake fluid reservoirs.

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Section G - Brakes

Park Brake Caliper Removal and Replacement

Supporting the caliper, remove split pins C and support pins E. Withdraw the pads F as they become detached from the guide pins, followed by spring plate G. Lower the complete brake assembly clear of the brake disc and remove. Note: If the surface of the disc is badly warped, pitted or showing signs of overheating, it must be renewed.

!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

Important: Refer to Safety at the start of this section before proceeding further.

Fig 17.

Removal Slacken locknuts X and remove pin from clevis Y. Apply brake, causing rod Z to draw back into the actuator H. Turn clevis Y through 90Â°. Disconnect the air feed J by first pushing in the hose, pushing in the sleeve, then pulling out the hose. Blank the open ports to prevent entry of dirt. Remove plastic cap and insert a 1/4 in hexagon allen key at B and turn it clockwise to back the pads right away from the disc. Do not turn the screw further than necessary to free the pads. Fig 18.

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G - 18

Section G - Brakes Park Brake Caliper Removal and Replacement

Fig 20.

Fig 19.

Replacement Insert top guide pin E just enough to support the brake caliper. Fit the thicker pad and push in the top guide pin through the thinner pad as it is inserted from the underside of disc. Fit bottom guide pin. Secure guide pins E with split pins C. Release brake, reconnect clevis and tighten locknuts. Check that park brake warning light operates correctly. Adjust the brake using the allen key. Support the weight of the brake with one hand and turn the allen key anticlockwise until the pads are tight on the disc. From this position, turn the allen key half a turn clockwise. Drive the machine for a short distance of 300-400m. If the brake disc is getting hot, turn the allen key clockwise slightly. The final adjustment should never be more than 3/ 4 of a turn from tight.

G - 19

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G - 19

Section G - Brakes Park Brake Caliper Dismantling and Assembly

Dismantling and Assembly

Fig 21.

G - 20

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G - 20

Section G - Brakes Park Brake Caliper Dismantling and Assembly

!MWARNING

line with the keyway of stator C by screwing out as required.

The actuator contains a large spring which can exert a force of up to 1134 kgf (2500 lbf) and cause injury if suddenly released. When working on or near the actuator, carefully follow all service instructions.

Lubricate the following with a molybdenum disulphide grease:

13-3-1_11_1

Entire bore of casting 22.

!MWARNING

Keyway and all surfaces of shaft, spring and stator assembly 18.

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

Ball pockets of rotor 16 and stator C. Shank of rotor. Thrust bearing 14 and washers 13 and 15.

The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Note: Items 1 to 5 should be removed when the caliper is removed from the machine but are shown here for reference, see Removal and Replacement (X G-18).

When Dismantling

Fit bracket 12 to caliper casting 22 in the position shown at F. After fitting bracket 12, turn rotor 16 fully anti-clockwise and fit lever 9 in the position shown at F. Renew pads if lining thickness is 3 mm (0.12 in) or less. Connect clevis G when fitting the caliper to the machine, see Removal and Replacement (X G-18).

Torque Settings

Apply compressed air pressure of 4 to 7 bar (60 to 100lbf/ in2) to inlet A to extend the pushrod until there is clearance for removal of clevis pin 5. Once the pin is removed, release the compressed air slowly. Take care when removing bolts 11. The internal components are loaded by spring 19 and balls 17 can be lost easily. Do not dismantle shaft, spring and stator assembly 18 as spring B will easily be distorted and components of this assembly are not supplied separately.

Inspection Ensure that all parts are free from excessive wear, damage or corrosion. Light scores or stains should be removed. Renew corroded or deeply scored parts. Ensure rotor 16 and stator C are free from cracks.

Item

kgf m

lbf ft

150 - 200

15 - 21

110 - 150

102 - 108

10 - 11

75 - 80

Actuator Cylinder

The actuator cylinder 7 is a non-serviceable item and no attempt should be made to interfere with it. If the cylinder is faulty it MUST be renewed.

When Assembling Position anti-rotation key 21 so that dimension E is approximately 50 mm (2 in), then ensure that its flats are in

G - 21

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Section G - Brakes Valves Air Drier/Unloader Valve

Valves Air Drier/Unloader Valve Removal and Replacement

b Repeatedly press the foot brake pedal until the stored pressure in the front and rear air reservoirs is exhausted. 2

Disconnect hoses by pushing in the hose, then pushing in the sleeve in the elbow or adapter and pulling out the hose. Blank the open ports to prevent entry of dirt and label the hoses to assist correct refitting.

Remove the electrical connector from the air dryer/ unloader unit A.

Fig 22. Important: Refer to Safety at the beginning of this section before proceeding further. Park the machine on level ground, switch off the engine and remove the starter key.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

!MCAUTION If this item is to be dismantled (even partially) on the machine, ensure that all pressure has been removed from the system. BRAK-8-1

Removal 1

Release the system air pressure as follows: a

Grip the â&#x20AC;&#x2DC;key ringâ&#x20AC;&#x2122; fitting K and pull sideways until all air is released.

Fig 23. 4

G - 22

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Support the unit and remove the three mounting nuts B. Lift the unit clear.

G - 22

Section G - Brakes Valves Air Drier/Unloader Valve Replacement Reverse the Removal procedure. When fitting elbows and adapters, clean the threads and apply Clayton System Seal SC1251. Torque Settings Item

kgf m

lbf ft

1.7

G - 23

9803/8040-2

G - 23

Section G - Brakes Valves Air Drier/Unloader Valve

Dismantling and Assembly The numerical sequences on the illustration are intended as a guide to dismantling. Assembly is the reverse of dismantling.

To replace the desiccant canister (see Service Schedule, Section 3) unscrew item A1. Secure the replacement canister hand tight. Items E1 to E9 - all are held in place by circlip E1. After releasing the circlip, take care to prevent the rest of the components flying apart. Items F1 to F22 - F1 is a push fit into the base of the air dryer body.

Fig 24.

G - 24

9803/8040-2

G - 24

Section G - Brakes Valves Circuit Protection Valve

Circuit Protection Valve Removal and Replacement Removal Important: Refer to Safety at the beginning of this section before proceeding further.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Note: The pressure settings of the circuit protection valve are factory-set. Adjustment and repairs are not permitted in service. If the fault finding procedure indicates a fault in this valve, a new unit must be fitted.

Fig 25. 1

Release the system air pressure as follows: a

Grip the â&#x20AC;&#x153;keyringâ&#x20AC;? fitting K and pull sideways until all air is released

b Repeatedly press the foot brake pedal until the stored pressure in the front and rear air reservoirs is exhausted 2

Disconnect the hoses from the ports by first pushing in the hose, then pushing in the sleeve in the elbow or adapter, and then pulling out the hose. Blank the open ports to prevent entry of dirt and label the hoses to assist correct refitting.

G - 25

9803/8040-2

G - 25

Section G - Brakes Valves Circuit Protection Valve

F C029540

Fig 26. 3

Remove the two mounting screws B and lift the valve F clear.

Torque Settings

Replacement

Item

kgf m

lbf ft

Reverse the Removal procedure.

2.0

When fitting elbows, clean the threads and apply Clayton System Seal SC1251.

G - 26

9803/8040-2

G - 26

Section G - Brakes Valves Pressure Modulating Valves

Pressure Modulating Valves Removal and Replacement

valve is to be removed, label the hoses to assist correct refitting.

Important: Refer to Safety at the beginning of this section before proceeding further.

Removal 1

Exhaust all air from the foot brake circuits by pressing the foot brake pedal several times.

Disconnect the air hoses from the valve by pushing in the hose, then pushing in the sleeve in the elbow or adapter and pulling out the hose. If more than one

Remove the screws/nuts A and lift valve B clear.

Note: The M8 mounting screws/nuts A are shown for only one of the valves B. The mounting screws/nuts for the remaining valves can be easily located and accessed.

Replacement Replacement is the reverse of Removal.

Fig 27.

G - 27

9803/8040-2

G - 27

Section G - Brakes Valves Non-Return Air Valve

Non-Return Air Valve Dismantling and Assembly Important: Refer to Safety at the front of this section before proceeding further. The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

When Dismantling Note: A Service Kit should be obtained before starting this job. Ensure that the kit obtained is correct for the valve fitted. Items shown grouped as K are the only parts available and are obtainable only as a complete kit.

When Assembling Use the components from the Service Kit during assembly.

Fig 28.

G - 28

9803/8040-2

G - 28

Section G - Brakes Valves Trailer Brake Hydraulic Valve

Trailer Brake Hydraulic Valve Testing Important: Refer to Safety at the front of this section before proceeding further. 1

Connect a 0-400 bar (0-6000 lbf/in2) gauge into the trailer hydraulic brake coupling.

Start the engine. Wait for the low air pressure lamps to go out. Press the foot brake pedal and check the gauge reading which should be 140 bar (2000 lbf/in2).

An incorrect pressure reading can be caused by dirt in the pilot valve. To rectify, stop the engine, disconnect hose 5 and remove screws B and pilot valve housing C. Wash the valve in clean hydraulic fluid, re-assemble, bleed and re-test.

3 2

1 6

4 7 A

B 5

Fig 29.

G - 29

9803/8040-2

G - 29

Section G - Brakes Valves Trailer Brake Hydraulic Valve

Removal and Replacement

3 Important: Refer to Safety at the front of this section before proceeding further.

Park the machine on firm, level ground, apply the parking brake and remove the starter key.

The numerical sequence on the illustration is intended as a guide to removal.

1 6

7 A

For replacement, the sequence should be reversed.

When Removing Label and blank all hydraulic connections to assist correct replacement and to prevent entry of dirt and excessive oil loss.

B 5

When Replacing Renew the 'O' ring seals in the hose connections (see Torque Settings in Section 1).

Fig 30.

Bleed the rear hydraulic brake circuit of the Fastrac at the calipers and at screw A, see Brake system Bleeding. Port Connections 1

Tank

High pressure carryover to suspension valve

Trailer coupling

Feed from pump

Pilot feed from rear hydraulic brake system

Torque Settings Item

kgf m

lbf ft

6/7

2.3

G - 30

9803/8040-2

G - 30

Section G - Brakes Valves Trailer Brake Hydraulic Valve

Dismantling and Assembly

Assembly

Before dismantling, the trailer brake hydraulic valve must be removed from the machine, see Removal and Replacement (X G-30).

Assembly is the reverse of dismantling. Torque Settings

Dismantling The numerical sequence on the illustration is a guide to dismantling.

Item

kgf m

lbf ft

10 - 13

1 - 1.3

7 - 10

2.5 - 3.5

0.25 - 0.35

1.8 - 2.6

56 - 75

5.7- 7.7

41 - 55

Fig 31.

G - 31

9803/8040-2

G - 31

Section G - Brakes

Trailer Brake Palm Couplings Dismantling and Assembly Palm couplings coded black are shown at Fig 1. Palm couplings coded red and yellow are shown at Fig 2. Important: Refer to Safety at the front of this section before proceeding further. The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Note: A Service Kit should be obtained before starting this job. Ensure that the kit obtained is correct for the coupling fitted. Items shown grouped as K are the only parts available and are obtainable only as a complete kit

When Dismantling Mark the relative positions of the body components to ensure correct alignment on assembly.

Fig 32.

When Assembling Use the new components from the Service Kit during assembly.

Fig 33.

G - 32

9803/8040-2

G - 32

Section H Steering Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-6

Section H - Steering

H-0

9803/8040-6

H-0

Section H - Steering Contents Page No. Technical Data Pressures and Flow Rates ..................................................................... H - 1 Description Steer Box ................................................................................................ H - 2 Pressure Testing Steering Relief Valve .............................................................................. H - 4 Steer Box Removal and Replacement .................................................................... H - 5 Steering Limiters ..................................................................................... H - 8

H-i

Section H - Steering Contents

H - ii

Page No.

H - ii

Section H - Steering

Technical Data Pressures and Flow Rates Maximum system pressure

170 bar (2465 lbf/in2)

Maximum flow - to machine number 1138257

30 litres/min (6.6 UK gal/min, 7.9 US gal/min)

Maximum flow - from machine number 1138258

25 litres/min (5.5 UK gal/min, 6.6 US gal/min)

H-1

9803/8040-6

H-1

Section H - Steering

Description Steer Box

Fig 1.

Table 1. Component Key Housing

Piston

Input shaft

Ball chain and worm

Torsion bar

H-2

Sector shaft

Pressure relief valve

Replenishment valve

The recirculating ball power assisted steer box is fed by oil from the pump at P. Oil returns to the tank via T.

9803/8040-6

H-2

Section H - Steering Description Steer Box Piston B and input shaft C are in positive engagement via the ball chain and worm D which cause rotation of the input shaft to be converted to axial movement of the piston. Pump pressure is applied to the piston B to provide power assistance to the manual steering effort. The teeth of piston B engage with the teeth of sector shaft F and axial movement of the piston causes rotation of the sector shaft. The sector shaft carries the drop arm (or Pitman arm) which is connected to the front axle by the drag link and assistor ram.

H-3

9803/8040-6

H-3

Section H - Steering Pressure Testing Steering Relief Valve

Pressure Testing Steering Relief Valve

!MCAUTION Do not turn the steering to full lock with any steering linkage disconnected, otherwise the steering limiters will be damaged and must be renewed. 13-3-2-18_1

!MWARNING When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned. 13-3-2-15

Remove one of the steering lock stops A and obtain a flat washer of at least the diameter of the lock stop base and 4-5 mm thick. Refit the lock stop with the washer between it and the axle casing. Important: Do not try to use any other spacer in place of the washer as the angular movement of the steering arm could cause damage to the lock stop. Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to the pressure test point P which is located below the suspension pressure maintenance valve in the line from the pump to the steer box.

Fig 2.

Note: Later machines have the test point located at the steering pump. Run the engine at 1500 r.p.m., hold the steering on full lock towards the lock stop with the washer fitted and check the gauge reading against the relief valve pressure setting in Technical Data. K Pressures and Flow Rates ( T H-1) If the setting is not correct, the relief valve in the steer box must be removed and cleaned. If this does not clear the fault the valve must be renewed as it is not adjustable. Remove the washer and refit the lock stop.

Fig 3.

H-4

9803/8040-6

H-4

Section H - Steering Steer Box Removal and Replacement

Steer Box Removal and Replacement

Fig 4.

H-5

9803/8040-6

H-5

Section H - Steering Steer Box Removal and Replacement

When Removing Note: Before assuming that the steer box is the cause of a steering problem, ensure that all other steering system faults have been rectified. To gain access to the top of the steer box, remove the cooling pack including radiator and coolers. Note: To avoid having to exhaust the air conditioning refrigerant, do not disturb the condensor connections. Simply remove the condensor from its mountings and fold back the hoses to put the condensor out of the way. The numerical sequence shown on the illustration is intended as a guide to removal.K Fig 4. ( T H-5) For replacement the sequence should be reversed.

Fig 5. Remove position sensor A as an assembly by removing bolts B from the drop arm and unbolting bracket C from the chassis. Slacken nut 4. Use a suitable ball joint splitter when removing drag link 5.

Do not disturb the length adjustment of the drag link which is preset to 1095-1105 mm (43.1-43.5 in) between centres of ball pins Note the positions of index marks on shaft and drop arm 6.

!MWARNING

3-3-1-1

!MCAUTION Do not turn the steering to full lock with any steering linkage disconnected, otherwise the steering limiters will be damaged and must be renewed.

The drop arm will be very tight on the splines. Take great care when pulling off the arm as it is likely to be released suddenly with considerable force. HYD ST-5-2

!MWARNING

13-3-2-18_1

Turn the steering to full left lock and remove the left front wheel.

Do not weld, hammer or apply heat to the drop arm or its shaft. These actions will cause weakness and may result in steering failure. HYD ST-5-1

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

To remove the drop arm, remove nut 4 and use a suitable puller with bolts screwed into the tapped holes provided.

13-3-2-15

Before disconnecting hoses 1 and 2, label them to assist correct refitting. Blank the open ports to prevent loss of oil and entry of dirt.

H-6

9803/8040-6

H-6

Section H - Steering Steer Box Removal and Replacement

When Replacing

Torque Settings

!MCAUTION After a new or repaired steering box has been fitted or if the lock stops have been adjusted to provide a smaller turning circle, do not start the engine before doing the steering limiter setting procedure, otherwise the steering limiters will be damaged and must be renewed.

Item

kgf m

lbf ft

550

405

250

184

520

384

13-3-2-19_1

When fitting bolts 7 make sure that the fitted bolt (identified by the hole in its head) is located in the middle hole of the line of three holes. It is absolutely critical that the steer box mounting bolts are tightened to the torque setting specified. Failure to do this may result in erratic steering. When fitting drop arm, align marks on shaft and drop arm. Fit nut 4 finger tight until after drag link 5 has been fitted. Tighten drag link nut 5 to specified torque setting and then on to next split pin hole before fitting split pin. Tighten nut 4 to specified torque setting and peen the nut into the slot in the shaft. Before fitting pinch bolt 3, ensure that the steering wheel is correctly aligned and that the steering shaft is not exerting any end load on the input shaft of the steer box. After fitting pipework and all linkages, ensure the limiters are correctly set K Setting ( T H-8). After setting the limiters, purge air from the hydraulic system by turning the steering wheel from lock to lock 3 times and then back to straight ahead (with engine running at idle). When fitting the position sensor A, make sure road wheels are straight ahead and turn the position sensor shaft so that the flat on the shaft faces forward and at right angles to the axis of the mounting bracket. The lower of the two allen screws must be tightened against the flat on the shaft. Apply JCB Lock and Seal to the allen screws and tighten to no more than 2.6 Nm

H-7

9803/8040-6

H-7

Section H - Steering Steer Box Steering Limiters

Steering Limiters Setting A

!MCAUTION Do not turn the steering to full lock with any steering linkage disconnected, otherwise the steering limiters will be damaged and must be renewed. 13-3-2-18_1

Fig 6.

Important: The engine must not be started before or during this procedure. 1

Raise the front wheels clear of the ground.

Turn the steering to full left lock and then back to full right lock.

Note: The action of turning to full lock should have automatically adjusted the limiters to suit the setting of the lock stops. The limiters cannot be reset to suit a larger turning circle although they can be reset to suit a smaller turning circle.

Removal and Replacement There are two limiters fitted, one at the front of the steer box (A) and one at the rear (B). When fitting, tighten to 9-15 Nm (7-11 lbf ft). After fiting a new limiter the setting procedure must be carried out K Setting ( T H-8).

H-8

9803/8040-6

Fig 7.

H-8

Section S Suspension Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-6

Section S - Suspension

S-0

9803/8040-6

S-0

Section S - Suspension Contents Page No. Technical Data Rear Suspension .................................................................................... S - 1 Front Suspension Description .............................................................................................. Shock Absorber ...................................................................................... Control Arm ............................................................................................ Panhard Rod .......................................................................................... Coil Spring and Microcellular Spring .......................................................

S-2 S-3 S-4 S-6 S-7

Rear Suspension Description .............................................................................................. S - 8 Pressure Testing .................................................................................... S - 11 Ride Height ........................................................................................... S - 13 Discharging Hydraulic Pressure ........................................................... S - 14 Pressure Maintenance Valve ................................................................ S - 15 Suspension Cylinder and Gas Spring ................................................... S - 17 Anti-roll Bar ........................................................................................... S - 22 ‘V’ Link .................................................................................................. S - 24

S-i

Section S - Suspension Contents

S - ii

Page No.

S - ii

Section S - Suspension

Technical Data Rear Suspension Pressures bar

kgf/cm2

lbf/in2

Pressure Maintenance Valve Cut-out Pressure

200

204

2900

Cut-in Pressure

180

184

2610

Accumulator Charge Pressure

76.5

1087

Gas Spring Charge Pressure

508

Flow Rates Maximum flow

S-1

36.5 litres/min (8 UK gal/min, 9.6 US gal/min)

9803/8040-6

S-1

Section S - Suspension

Front Suspension Description The front axle is located by a four link system consisting of two upper control arms A, two lower control arms Band Panhard rod C. Primary suspension stiffness is provided by coil springs D, supplemented by microcellular polyurethane springs

which offer progressively increasing suspension stiffness over bumps. Suspension movement is controlled by two telescopic shock absorbers E.

Fig 1.

S-2

9803/8040-6

S-2

Section S - Suspension Front Suspension Shock Absorber

Shock Absorber

Fig 2.

!MWARNING

When Replacing

Removal and Replacement The numerical sequence shown on the illustration (items E1 to E12) is intended as a guide to removing.

When fitting the mounting pin E12 into the axle, apply JCB Threadlocker and Sealer to the threads.

Torque Settings

Item

kgf m

lbf ft

180

18.4

133

180

18.4

133

E12

300

220

For Replacement the sequence should be reversed. Note: This job can be done with the machine standing on its wheels.

S-3

9803/8040-6

S-3

Section S - Suspension Front Suspension Control Arm

Control Arm

Fig 3.

!MWARNING

Removal

Just support the weight of the chassis by means of axle stands beneath the lower control arm chassis mount cross member. Note: If more than one arm is to be removed it is also necessary to support the axle on stands, so as to maintain its location relative to the chassis. Support the control arm 5 or 10 and remove bolts 1 and 3 or 6 and 9, spacers 2 and 4 or 7 and nuts 8 (where applicable).

S-4

9803/8040-6

S-4

Section S - Suspension Front Suspension Control Arm

Replacement Replacement is the reverse of Removal. Make sure that spacers are fitted where shown. Tighten all bolts to the specified torque with the machine standing on its wheels.

Torque Settings

Item

kgf m

lbf ft

392

290

392

290

392

290

392

290

S-5

9803/8040-6

S-5

Section S - Suspension Front Suspension Panhard Rod

Panhard Rod Removal and Replacement

Torque Settings

The numerical sequence shown on the illustration (items 1 to 6) is intended as a guide to dismantling.

Item

kgf m

lbf ft

250

185

For assembly the sequence should be reversed.

250

185

Note: This job can be done with the machine standing on its wheels.

70-80

7-8

52-59

When Removing Separate the taper ball pins from their brackets using a ball joint splitter.

!MCAUTION Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure. AXL 8-2

When Replacing Before fitting, check dimension X which should be 625 to 650 mm (24.6 to 25.9 in). If necessary, adjust by slackening nut Y and screwing ball joint 6 in or out as required. Retighten nut Y to the specified torque. Tighten nuts 2 and 5 to the specified torque and then tighten further until the next slot in the castellation is in line with the split pin hole. Fit the split pins. After fitting the Panhard rod, recheck adjustment by measuring the distance between the top of each front wheel rim and the chassis side member when the wheels are in the straight ahead position. The two measurements should be within 5 mm (0.4 in) of each other. If required, readjust the length of the rod. 100 hours after fitting the Panhard rod, check the torque tightness of nuts 2 and 5.

S-6

9803/8040-6

Fig 4.

X Fig 5.

S-6

Section S - Suspension Front Suspension Coil Spring and Microcellular Spring

Coil Spring and Microcellular Spring

Fig 6.

Removal

Pry out coil spring D from the top and lift it clear of the locating boss on the axle along with microcellular spring D2 and spacer D3.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

The coil spring D and the microcellular spring D2 must be removed together. Raise both sides of the machine equally by one of the following methods: 1

Use an overhead hoist to raise front of chassis (minimum lift capacity for basic machine is 3.5 tonnes or 5 tonnes with optional equipment). Lift until front wheels are about to clear the ground. Insert a piece of timber 50 x 50 mm (2 x 2 in) between the axle and each bump stop as at X to prevent the springs from compressing and to achieve maximum lift on the jack. Use a jack under the axle to raise the machine and insert stands under the chassis. Lower the jack so that the load is off the springs.

!MCAUTION Keep your hands clear of the springs until they have been released and are no longer under load or you may trap your fingers. SUS-1-4

Unscrew the microcellular spring from the spacer.

Replacement Reverse the dismantling sequence. Note: Tighten the microcellular spring onto the spacer using hand pressure only.

Torque Settings Item

kgf m

lbf ft

392

289

Remove bolt D1 which holds the springs to the chassis. Allow the microcellular spring D2 and spacer D3 to rest on top of the axle.

S-7

9803/8040-6

S-7

Section S - Suspension Rear Suspension Description

Rear Suspension Description

Fig 7. The variable rate hydropneumatic rear suspension minimises fore and aft vehicle pitch whilst maintaining 'low rate' characteristics for ride quality and tractive performance. Axle location is by control rods J and 'V' link L. An anti-roll bar is also fitted (not shown).

Movement of the axle varies the pressure in the cylinders which in turn works against the pressure in the gas springs to give a variable rate suspension. Spring/cylinder assemblies operate independently on either side of the vehicle to eliminate any tendency to ride height difference caused by uneven load distribution.

Primary suspension comprises two nitrogen-charged gas springs G and one hydraulic cylinder S on each side of the machine. These work in conjunction with height corrector valves N and spring boxes H to maintain vehicle ride height.

S-8

9803/8040-6

S-8

Section S - Suspension Rear Suspension Description

Fig 8. The gearbox-driven gear pump has two sections. The rear section P3 feeds the steering system whilst the front section P2 feeds the suspension system via line 1. K Fig 8. ( T S-9) If the machine is fitted with a hydraulic trailer brake valve B, the flow from P2 feeds the trailer brake valve first and then continues via line 2 to the suspension valve block V. If there is no hydraulic trailer brake valve, the flow from P2 goes direct via lines 1, 1A and 2. The suspension valve block V contains pressure maintenance valve CT1 which works in conjunction with accumulator A. Note: Valve block V also feeds the differential lock and rear PTO.

S-9

From valve block V the feed is split between the two height corrector valves N which are connected by spring boxes H to the control arms J. K Fig 7. ( T S-8) The height corrector valves open or close in response to axle vertical travel in order to regulate the flow to and from the suspension cylinders. In operation, as increasing loads cause the chassis to lower in relation to the rear axle, the height corrector valves N are displaced by the spring boxes H. The valve ports then open to allow oil flow into the system, pressurising the gas springs and restoring the pre-set ride height by means of cylinders S. At this point the valves close, trapping oil within the system. The extra pressure in the gas springs increases suspension stiffness, thereby maintaining vehicle pitching control.

9803/8040-6

S-9

Section S - Suspension Rear Suspension Description As the load is taken off the chassis, it is lifted by the pressure retained in the system. This action once again displaces the height corrector valves, but in the opposite direction, opening an escape path to tank for the hydraulic oil. The reducing pressure allows the chassis to settle until the corrector valves close, retaining the new volume of oil in the system and again restoring the ride height to the preset level. The height control valves are not affected by normal suspension movements which are too rapid for the 6 to 12 second in-built response delay.

S - 10

9803/8040-6

S - 10

Section S - Suspension Rear Suspension Pressure Testing

Pressure Testing Pressure Maintenance Valve

!MWARNING The procedure below must be carried out with the engine running. Apply the park brake, block the wheels and ensure that no-one enters the cab. SUS-1-1

Connect a 0-400 bar (0 - 6000 lbf/in2) gauge to test point TP1. With engine running, push on one of the spring boxes and check the gauge reading which should be between the cutin and cut-out pressures. See Technical Data. If the reading is incorrect, adjust the valve at B. Note: If this is the first time the valve has been adjusted, the adjusting screw will be covered by a plastic cap which should be removed and discarded.

Fig 9.

S - 11

9803/8040-6

S - 11

Section S - Suspension Rear Suspension Pressure Testing

Gas Spring and Accumulator

Operate the hand pump and watch the reading on the gauge.

Note: Gas spring and accumulator are similar in appearance but can be positively identified by the nominal pressure (bar) stamped on the face of the threaded mounting boss: 35

Indicates gas spring

Indicates accumulator

If the gas spring or accumulator is in good condition, the pressure should rise steadily to the charge pressure, see Technical Data) and then rise much more slowly for a period before climbing again. If the pressure continues to rise steadily to well past the charge pressure, the diaphragm is ruptured and the unit must be renewed.

Remove the gas spring G or accumulator A from the machine and screw it into adapter block X, part number 892/00314. Connect a hand pump and a 0 to 400 bar (0 to 6000 lbf/in2) pressure gauge.

!MCAUTION Do not exceed 245 bar (3500 lbf in2) or the body may rupture. SUS-1-7

Fig 10.

S - 12

9803/8040-6

S - 12

Section S - Suspension Rear Suspension Ride Height

Ride Height

!MWARNING

spring boxes will telescope freely in each direction. If necessary, free off using penetrating oil.

The procedure below must be carried out with the engine running. Apply the park brake, block the wheels and ensure that no-one enters the cab.

Reconnect the spring boxes and adjust the length by slackening nut C and turning the spring box body D until dimension X is correct. (Lengthening the spring box will raise the chassis and vice-versa). Set the left side, then the right side and re-check and re-adjust as required until both clearances X are correct. Note that this must be done with the engine running and pay special attention to the WARNING at the top of this page.

Reconnect the anti-roll bar.

SUS-1-1

Checking the Ride Height The chassis side members should both be the same height above the rear axle. With engine running, check that dimension X between the bottom of each bump stop and the axle casing is 50 mm (2 in).

Adjustment 1

Disconnect one end of the rear anti-roll bar. K Antiroll Bar ( T S-22) .

C032550

Fig 12. Fig 11. 2

Remove nut A to disconnect each spring box bottom ball joint from the control arm B and check that the

S - 13

9803/8040-6

S - 13

Section S - Suspension Rear Suspension Discharging Hydraulic Pressure

Discharging Hydraulic Pressure The rear of the chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve. Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure as follows:

Stop the engine. Pull downwards on the spring box rods D to allow fluid to be discharged from the cylinders and the chassis to be lowered down onto the axle.

!MCAUTION

Fig 13.

Keep clear of the chassis members as they are lowering otherwise you could be trapped between them and the axle casing. SUS-1-6

Release the rods and wait a few moments for pressure in the accumulators to raise the chassis.

Repeat steps 1 and 2 until the chassis remains firmly down on the axle.

Slowly slacken the pipes on either side of the height corrector valve E to release any residual pressure.

S - 14

9803/8040-6

S - 14

Section S - Suspension Rear Suspension Pressure Maintenance Valve

Pressure Maintenance Valve Dismantling and Assembly

Fig 14.

S - 15

Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure. See Discharging Hydraulic Pressure (Section S) for correct procedure. SUS-1-2_2

Note: Provided that the above WARNING is observed, the valve can be dismantled in situ.

9803/8040-6

S - 15

Section S - Suspension Rear Suspension Pressure Maintenance Valve If the cartridge A leaks oil or cannot be adjusted to give the correct pressure setting, it can be removed for cleaning and/or renewal of seals. Unscrew the cartridge from the body. Immerse the cartridge in clean hydraulic fluid and operate the plunger by means of a plastic rod inserted through the nose of the valve. Remove cap B to clean and check the non-return valve. Check the condition of spring C/ball D and also the seat for the ball inside the housing V. If this is damaged, the complete housing must be renewed. Renew the seals and refit the valves. Check the pressure setting, see Pressure Testing (X S-11)

Torque Settings

Item

kgf m

lbf ft

7.6

6.1

S - 16

9803/8040-6

S - 16

Section S - Suspension Rear Suspension Suspension Cylinder and Gas Spring

Suspension Cylinder and Gas Spring

Fig 15.

S - 17

9803/8040-6

S - 17

Section S - Suspension Rear Suspension Suspension Cylinder and Gas Spring

Gas Spring Removal and Replacement

After Replacement

Note: This job can be done with the machine standing on its wheels but heed the WARNINGS below.

Check the suspension ride height, see Ride Height (X S-13).

Simply unscrew the unit from its mounting (complete with square section seal ring G1). Renew the seal when refitting the unit

Suspension Cylinder Removal and Replacement Note: This job can be done with the machine standing on its wheels but heed the WARNINGS below.

!MWARNING

The rear of the chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve. Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure. See Discharging Hydraulic Pressure (Section S) for correct procedure. SUS-1-2_2

Note: Gas spring and accumulator are similar in appearance but can be positively identified by the nominal pressure (bar) stamped on the face of the threaded mounting boss:

!MWARNING The rear of the chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve. Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure. See Discharging Hydraulic Pressure (Section S) for correct procedure. SUS-1-2_2

The numerical sequence shown on the illustration is intended as a guide to removal.

Indicates gas spring (see Technical Data).

For replacement the sequence should be reversed.

Indicates accumulator

When Removing

Torque Settings

Disconnect hose at S1. Remove nut S2. Remove circlips S3 and S4 together with pin S5.

Item

kgf m

lbf ft

23 - 30

2.4 - 3.0

17 - 22

When Replacing Lugs Z at the lower end of the cylinder should face the rear of the machine.K Fig 16. ( T S-19)

S - 18

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S - 18

Section S - Suspension Rear Suspension Suspension Cylinder and Gas Spring

Fig 16.

Torque Settings Item

kgf m

lbf ft

800

592

Note: The torque setting given for pin S6 is for use when fitting the pin into the axle.

After Replacement Check the suspension ride height, see Ride Height (X S-13).

S - 19

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S - 19

Section S - Suspension Rear Suspension Suspension Cylinder and Gas Spring

Dismantling and Assembly

Fig 17. The numerical sequence shown on the illustration is intended as a guide to dismantling.

S - 20

For assembly the sequence should be reversed.

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S - 20

Section S - Suspension Rear Suspension Suspension Cylinder and Gas Spring Take extreme care not to damage the cylinder bore or the grooves in gland bearing 3 or seal carrier 5.

Dismantling Remove grease nipple 1 and prise off the dust cover 2 in the direction of the arrow. Heat the threaded area of gland bearing 3 to a minimum of 300째C (570째F) to release the locking sealant and unscrew the gland bearing from the cylinder 4. Fig 18.

Withdraw the piston rod 18 complete with the internal parts Heat the threaded area of piston head 5 to a minimum of 300째C (570째F) to release the locking sealant and unscrew the piston head using a suitable peg spanner to fit holes W. The holes are 5 mm (0.2 in) diameter, positioned at a pitch circle diameter of 35 mm (1.38 in). Removal of the seal carrier will allow gland bearing 3 to slide off the piston head.

Close the tool as shown at Fig 19. (X S-21). The seal must form a reniform (kidney shape).

Remove and discard the sealing components 6 to 9 and 10 to 12.

Assembly Fig 19. Before assembling, check the components for damage and wear, especially the cylinder bore. Renew the complete assembly if necessary.

Lightly oil all seals. Use the Gland Seal Fitting Procedure for fitting gland seals 6 to 8. Apply JCB Retainer (High Strength) to the threads of gland bearing 3 and piston head 5. Tighten both to a torque of 200 Nm (148 lbf ft).

Gland Seal Fitting Procedure

Locate the seal in the gland bearing groove. When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool.

Testing Using a hydraulic hand pump (see Service Tools), check for smooth operation of the ram. With the ram extended, pressurise to 250 bar (3625 lbf/in2) and check for leakage. No leakage is permitted.

The size (diameter) and position of pins P is determined by the diameter and radial width of the gland seal being fitted. The pins are screwed into threaded holes in the tool body. The spacing of the holes is designed to suit small or large diameter gland seals. 1

Open the tool as shown at Fig 18. (X S-21) and insert the new gland seal. The seal must be fitted behind the two front pins but in front of the rear pin as shown.

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S - 21

Section S - Suspension Rear Suspension Anti-roll Bar

Anti-roll Bar Removal and Replacement

2 1 4

4 10 3

Fig 20.

S - 22

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S - 22

Section S - Suspension Rear Suspension Anti-roll Bar Removal

Torque Settings

Item

kgf m

lbf ft

185

136

125

3-3-1-1

Note: This job can be done with the machine standing on its wheels. Discharge hydraulic pressure from the suspension system so that the chassis is lowered onto its bump stops. K Discharging Hydraulic Pressure ( T S-14) The numerical sequence shown on the illustration is intended as a guide to removal.

Replacement Replacement is the reverse of Removal. When Replacing Note: Install clamps 6 with the chamfered sides of the antiroll bar cut-out facing outwards. Before tightening nuts 5, slide clamps 6 outwards towards clamps 4 to leave a 5 mm gap between the two. Before connecting the ball joints 2 to the chassis mounting brackets, adjust the length of the vertical links as follows: 1

Make sure that the chassis is lowered onto its bump Hydraulic stops. K Discharging Pressure ( T S-14)

Slacken nut 8 and set the length of one vertical link to 310mm (centre-line of ball joint 2 to bottom boss flat). Fit that link and tighten to specified torque settings.

Fit the bottom end of the other vertical link and set the length so that the ball joint will enter the chassis mounting bracket without putting any load on the antiroll bar.

Tighten all bolts and nuts to specified torque settings.

Re-set the ride height. K Ride Height ( T S-13)

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S - 23

Section S - Suspension Rear Suspension ‘V’ Link

‘V’ Link Removal and Replacement

Fig 21. Note: This job can be done with the machine standing on its wheels but the rear axle must be supported by means of an overhead hoist to prevent it from rotating out of position.

!MWARNING

The numerical sequence shown on the illustration is intended as a guide to removal. For replacement the sequence should be reversed.

When Removing

The two arms of the ‘V’ link A and B can be removed separately. Support axle and arm to be removed. Remove screws 1, spacers 2 and block nuts 3 from front end of 'V' link.

3-3-1-1

S - 24

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S - 24

Section S - Suspension Rear Suspension â&#x20AC;&#x2DC;Vâ&#x20AC;&#x2122; Link Remove screws 4 and spacers 5 holding arm to axle and lift the arm clear. Repeat the above procedure for the second arm. To remove bracket C, remove both arms, screws 6 and 8.

When Replacing Always replace damaged fasteners by the specified JCB supplied parts which will be to the correct grade. Ensure that special screws, hardened washers, spacers and block nuts are assembled as shown..

Torque Settings

Item

kgf m

lbf ft

654

480

654

480

392

291

392

291

S - 25

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S - 25

Section S - Suspension Rear Suspension ‘V’ Link

S - 26

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S - 26

Section S - Suspension Rear Suspension ‘V’ Link

S - 27

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S - 27

Section S - Suspension Rear Suspension ‘V’ Link

S - 28

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S - 28

Section T Engine Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension Section T - Engine

Publication No.

9803/8040-2

Section T - Engine

T-0

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T-0

Section T - Engine Contents Page No. Technical Data General .................................................................................................... T - 1

T-i

Section T - Engine Contents

T - ii

Page No.

T - ii

Section T - Engine

Technical Data General The 8250 Fastrac is powered by a QSCT3 engine which incorporates a new high pressure fuel pump and a common rail fuel system. The fuel pump with the engine Model

ECM provides full electronic contol over engine fuelling and timing. QSCT, Turbocharged, 6-cylinder, water cooled.

Displacement

8.3 litres (504.5 in3 )

Stroke

135 mm (4.72 in)

Bore

114 mm (4.49 in)

Firing Order

1, 5, 3, 6, 2, 4

Rated engine speed (rpm)

2200

Idling Speed

700-1000 rev/min

Gross power at rated speed

194 kW (250 hp)

Max torque at 1400 rpm

1179 Nm (870 lbf ft)

Torque back up

29%

Injection

CM 850 Common rail

Aspiration

Turbocharged and intercooled

Engine Weight (with standard accessories)

694 kg (1530 lb)

Oil Pressure at idle (minimum allowable)

0.69 bar (10 lbf/in2 )

Oil Pressure at rated speed (minimum allowable)

2.07 bar (30 lbf/in2 )

Oil Pressure, regulated

5.17 bar (75 lbf/in2 )

T-1

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T-1

Section T - Engine Technical Data General

T-2

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T-2