JCB TM310 Wheeled Loader Shovel Service Repair Manual – PDF Download by www.heydownloads.com

Service Manual TM310 Service Manual - TM310 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-9

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

Section 1 General Information Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-8

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 Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 - 1

Notes:

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Section 1 - General Information Contents Page No. Introduction About this Manual ...................................................................................... 1-1 Machine Model and Serial Number .......................................................1-1 Using the Service Manual .....................................................................1-1 Section Numbering ................................................................................1-1 Left Side, Right Side ..............................................................................1-2 Cross References ..................................................................................1-2 Identifying your Machine ............................................................................ 1-3 Machine Identification Plate ..................................................................1-3 Component Identification Plates ............................................................1-4 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Introduction ............................................................................................1-7 Bolts and Screws ...................................................................................1-7 Hydraulic Connections ............................................................................. 1-11 'O' Ring Face Seal System .................................................................. 1-11 'Torque Stop' Hose System .................................................................1-14 Service Tools Numerical List .......................................................................................... 1-15 Tool Detail Reference .............................................................................. 1-16 Section B - Body and Framework ........................................................1-16 Section C - Electrics ............................................................................1-20 Section E - Hydraulics .........................................................................1-23 Section H - Steering ............................................................................1-31 Section K - Engine ...............................................................................1-32 Service Consumables Sealing and Retaining Compounds ......................................................... 1-35 Terms and Definitions Colour Coding .......................................................................................... 1-37 Hydraulic Schematic Colour Codes .....................................................1-37

1-i

Section 1 - General Information Contents

1-ii

Page No.

1-ii

Section 1 - General Information

Introduction About this Manual Machine Model and Serial Number

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

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

Section Numbering T11-005

â&#x20AC;&#x201C; TM310, TM310S and TM310WM from machine serial number 1314700.

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

â&#x20AC;&#x201C; TM320 from machine serial number 1314700.

Using the Service Manual T11-004

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them.

General Information - includes torque settings and service tools.

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

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

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

Attachments

Body and Framework, etc.

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

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.

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Section 1 - General Information Introduction About this Manual

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

Fig 1.

C087420

Cross References T1-004_2

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

1-2

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Section 1 - General Information Introduction Identifying your Machine

Identifying your Machine Machine Identification Plate

Typical Product Identification Number (PIN)

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

T033160-1.

Fig 3. 1

World Manufacturer Identification (3 Digits)

Model Number (3 Digits)

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

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

Designation (1 Digit) S = Farmmaster O = None Farmmaster I = India

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

Year of Manufacture (1 Digit) 7 = 2007

A = 2010

8 = 2008

B = 2011

9 = 2009

C = 2012

Machine Serial Number (7 Digits) Each machine has a unique serial number.

Fig 2.

1-3

C051170-C1

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Section 1 - General Information Introduction Identifying your Machine Typical Vehicle Identification Number

Country of manufacture U = United Kingdom

SLP

TM310

1314700

Engine Serial Number Year of Manufacture

World Manufacturer Identification (SLP = JCB)

Machine Type (TM310, TM-W, TM320)

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

Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7 = 2007)

Manufacturers Location (E = England)

Machine Serial Number (1314700)

00001

Component Identification Plates Typical Engine Identification Number T1-005_3

Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). K Fig 4. ( T 1-4). The data label contains important engine information and includes the engine identification number E.

D B

A typical engine identification number is explained as follows: SA

320/40001

00001

Engine Type

Fig 4. Engine

S = 4.4 litre series.

B C007820-C2

JCB Dieselmax (Tier 2) A = Naturally aspirated B = Turbocharged C = Turbocharged and intercooled JCB Dieselmax (Tier 3) D = Turbocharged E = Electronic common rail fuel injection F = Turbocharged and after-cooled 2

1-4

Engine part number

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Section 1 - General Information Introduction Identifying your Machine Transmission Identification Numbers The transmission serial number is stamped on label A which is mounted on the front face. The drop box serial number is stamped on plate B mounted on the drop box. The axle serial number is stamped on plate C mounted on the axle.

B Fig 6.

Fig 5.

C Fig 7.

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Section 1 - General Information Introduction Identifying your Machine FOPS Data Plate

ROPS Data Plate

!MWARNING

Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury.

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.

8-2-8-17

If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides. There are two levels of FOPS: – Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services. – Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry.

INT-2-1-9_6

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

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

A JCB CAB SYSTEMS LTD RIVERSIDE, RUGELEY, STAFFORDSHIRE WS15 2WA, ENGLAND .ROPS/FOPS PART No: 335/13012 .CERTIFIED FOR JCB TELESCOPIC HANDLERS OF MAX. UNLADEN MASS: 10,250Kg .CERTIFIED TO EN 13627:2000 LEVEL 2: FOPS .CERTIFIED TO EN 13510:2000: ROPS

817/20828

C051290

Fig 8.

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C051290

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

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002

Introduction

Bolts and Screws

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

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

The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-7).

Torque settings are given for the following conditions:

Fastener Type

Table 1. Fastener Types Colour Part No. Suffix

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

Condition 1 – Un-lubricated fasteners – Zinc fasteners

Zinc and Yellow

Golden finish

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

Dacromet

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

– Yellow plated fasteners

Condition 2

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

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

Verbus Ripp Bolts

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

1-7

Fig 9. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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

Bolt Size in.

in.

kgf m

lbf ft

kgf m

lbf ft

1/4

6.3

7/16

11.2

1.1

8.3

10.0

1.0

7.4

5/16

7.9

1/2

22.3

2.3

16.4

20.0

2.0

14.7

3/8

9.5

9/16

40.0

4.1

29.5

36.0

3.7

26.5

7/16

11.1

5/8

64.0

6.5

47.2

57.0

5.8

42.0

1/2

12.7

3/4

98.00

10.0

72.3

88.0

9.0

64.9

9/16

14.3

13/16

140.0

14.3

103.2

126.0

12.8

92.9

5/8

15.9

15/16

196.0

20.0

144.6

177.0

18.0

130.5

3/4

19.0

1 1/8

343.0

35.0

253.0

309.0

31.5

227.9

7/8

22.2

1 15/16

547.0

55.8

403.4

492.0

50.2

362.9

25.4

1 1/2

814.0

83.0

600.4

732.0

74.6

539.9

1 1/8

31.7

1 7/8

1181.0

120.4

871.1

1063.0

108.4

784.0

1 1/4

38.1

2 1/4

1646.0

167.8

1214.0

1481.0

151.0

1092.3

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

Bolt Size ISO Metric Thread

1-8

Condition 2

kgf m

Condition 2

lbf ft

kgf m

lbf ft

5.8

0.6

4.3

5.2

0.5

3.8

9.9

1.0

7.3

9.0

0.9

6.6

24.0

2.4

17.7

22.0

2.2

16.2

M10

47.0

4.8

34.7

43.0

4.4

31.7

M12

83.0

8.5

61.2

74.0

7.5

54.6

M16

205.0

20.9

151.2

184.0

18.8

135.7

M20

400.0

40.8

295.0

360.0

36.7

265.5

M24

690.0

70.4

508.9

621.0

63.3

458.0

M30

1372.0

139.9

1011.9

1235.0

125.9

910.9

M36

2399.0

244.6

1769.4

2159.0

220.0

1592.4

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

Bolt Size ISO Metric Thread

kgf m

Condition 2 lbf ft

kgf m

lbf ft

8.1

0.8

6.0

7.3

0.7

5.4

13.9

1.4

10.2

12.5

1.3

9.2

34.0

3.5

25.0

30.0

3.0

22.1

M10

67.0

6.8

49.4

60.0

6.1

44.2

M12

116.0

11.8

85.5

104.0

10.6

76.7

M16

288.0

29.4

212.4

259.0

26.4

191.0

M20

562.0

57.3

414.5

506.0

51.6

373.2

M24

971.0

99.0

716.9

874.0

89.1

644.6

M30

1930.0

196.8

1423.5

1737.0

177.1

1281.1

M36

3374.0

344.0

2488.5

3036.0

309.6

2239.2

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

Bolt Size

Condition 2

ISO Metric Thread

kgf m

lbf ft

kgf m

lbf ft

9.8

1.0

7.2

8.8

0.9

6.5

16.6

1.7

12.2

15.0

1.5

11.1

40.0

4.1

29.5

36.0

3.7

26.5

M10

80.0

8.1

59.0

72.0

7.3

53.1

M12

139.0

14.2

102.5

125.0

12.7

92.2

M16

345.0

35.2

254.4

311.0

31.7

229.4

M20

674.0

68.7

497.1

607.0

61.9

447.7

M24

1165.0

118.8

859.2

1048.0

106.9

773.0

M30

2316.0

236.2

1708.2

2084.0

212.5

1537.1

M36

4049.0

412.9

2986.4

3644.0

371.6

2687.7

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

kgf m

lbf ft

1.2

0.1

0.9

3.0

0.3

2.0

6.0

0.6

4.5

10.0

1.0

7.5

24.0

2.5

18.0

M10

48.0

4.9

35.5

M12

82.0

8.4

60.5

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

1-10

ISO Metric Thread

kgf m

lbf ft

2.0

0.2

1.5

6.0

0.6

4.5

11.0

1.1

8.0

19.0

1.9

14.0

46.0

4.7

34.0

M10

91.0

9.3

67.0

M12

159.0

16.2

117.0

M16

395.0

40.0

292.0

M18

550.0

56.0

406.0

M20

770.0

79.0

568.0

M24

1332.0

136.0

983.0

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Section 1 - General Information Torque Settings Hydraulic Connections

Hydraulic Connections T11-003

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

1-11

in.

kgf m

lbf ft

1/4

19.0

18.0

1.8

13.0

3/8

22.0

31.0

3.2

23.0

1/2

27.0

49.0

5.0

36.0

5/8

30.0

60.0

6.1

44.0

3/4

32.0

81.0

8.2

60.0

38.0

129.0

13.1

95.0

1 1/4

50.0

206.0

21.0

152.0

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

SAE Tube Size

Thread Size

kgf m

lbf ft

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

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

Fig 10. Hoses 10-B screwed into adaptors 10-A seal onto an `O' ring 10-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-12

Note: Dimension 10-D will vary depending upon the torque applied.

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

1/8

14.0

14.0 - 16.00

1.4 - 1.6

10.3 - 11.8

1/4

19.0

24.0 - 27.0

2.4 - 2.7

17.7 - 19.9

3/8

22.0

33.0 - 40.0

3.4 - 4.1

24.3 - 29.5

1/2

27.0

44.0 - 50.0

4.5 - 5.1

32.4 - 36.9

5/8

30.0

58.0 - 65.0

5.9 - 6.6

42.8 - 47.9

3/4

32.0

84.0 - 92.0

8.6 - 9.4

61.9 - 67.8

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

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kgf m

lbf ft

1-12

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

1-13

in.

kgf m

lbf ft

1/8

20.0

2.1

15.0

1/4

34.0

3.4

25.0

3/8

75.0

7.6

55.0

1/2

102.0

10.3

75.0

5/8

122.0

12.4

90.0

3/4

183.0

18.7

135.0

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

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Section 1 - General Information Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 11. `Torque Stop' Hoses 11-B screwed into adaptors 11-A seal onto an 'O' ring 11-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 11-D, which acts as a physical stop. Note: Minimum dimension 11-E fixed by shoulder 11-D.

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

1-14

in.

kgf m

lbf ft

1/8

14.0

1.4

10.0

1/4

19.0

27.0

2.7

20.0

3/8

22.0

40.0

4.1

30.0

1/2

27.0

55.0

5.6

40.0

5/8

30.0

65.0

6.6

48.0

3/4

32.0

95.0

9.7

70.0

38.0

120.0

12.2

89.0

1 1/4

50.0

189.0

19.3

140.0

1 1/2

55.0

244.0

24.9

180.0

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Section 1 - General Information

Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

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Section 1 - General Information Service Tools Tool Detail Reference

Tool Detail Reference Section B - Body and Framework

Fig 12. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

993/68107

Bar - M20 x M20 X 800 mm

2 3

993/68102

End Stops

993/68108

Adaptor - M20 x 7/8" UNF

993/68103

Adaptor - M20 x 5/8" UNF

993/68109

Adaptor - M20 x M12

993/68104

Adaptor - M20 x 1" UNF

993/68110

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

993/68105

Adaptor - M20 x M20

993/68111

Adaptor - M20 x 1/2" UNF

993/68106

Adaptor - M20 x M24 1

826/01099

M6 x 16 mm Rivet Nut

826/01101

M6 x 19 mm Rivet Nut

826/01102

M8 x 18 mm Rivet Nut

826/01103

M8 x 21 mm Rivet Nut

826/01104

M10 x 23 mm Rivet Nut

826/01105A M10 x 26 mm Rivet Nut 2

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

Fig 13. Rivet Nut Tool

1-16

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 14. 892/00842 Glass Lifter Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

Fig 17. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K Fig 20. ( T 1-18).

Fig 18. 892/00847 Nylon Spatula

Fig 15. 892/00843 Folding Stand

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

Essential for preparing new glass prior to installation.

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

Fig 16. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

1-17

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 20. 892/00849 Braided Cutting Wire

Fig 23. 992/12400 Static Oven 240V

Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 17. ( T 1-17). Approx 25 m length.

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

Fig 21. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 24. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 22. 992/12300 Mobile Oven 12V 1 cartridge capacity. Required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

1-18

Fig 25. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K Fig 24. ( T 1-18). Unit quantity = 5 off.

9803/9520-8

1-18

Section 1 - General Information Service Tools Tool Detail Reference

Fig 26. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). Fig 29. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal.

Fig 27. 892/00913 Grease Gun Attachment

Fig 30. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 28. 892/00844 Long Knife Used to give extended reach for normally inaccessible areas.

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1-19

Section 1 - General Information Service Tools Tool Detail Reference

Section C - Electrics

AVO Test Kit: 1 892/00283

Tool Kit Case

2 892/00298

Fluke Meter 85

3 892/00286

Surface Temperature Probe

4 892/00284

Venture Microtach Digital Tachometer

5 892/00282

100 amp Shunt - open type

6 892/00285

Hydraulic Temperature Probe

Fig 31. AVO Test Kit

Fig 32. 993/85700 Battery Tester

Fig 34. 892/00905 LMI Test Box D

E F

For testing load moment indicator system

A406130-C2

Fig 33. 721/10885 Interconnecting Cable Use with 892/01033

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Section 1 - General Information Service Tools Tool Detail Reference

A406130-C1

Fig 35. 892/01033 Electronic Test Kit Note: Also requires 721/10885 interconnecting cable Item

Description

Data Link Adaptor (DLA), enables data exchange between the machine ECUs (Electronic Control Units) and laptop PC loaded with the applicable ServiceMaster diagnostics software

Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types

Kit carrying case

711300-C1

Fig 36. 892/01096 Speed Sensor Test Harness

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1-21

Section 1 - General Information Service Tools Tool Detail Reference K Electrical Repair Kit ( T 1-22) 1

Electrical Repair Kit

7212/0002

2 Way Pin Housing

7212/0004

2 Way Pin Retainer

7212/0003

2 Way Socket Retainer

7212/0001

2 Way Socket Connector

7213/0002

3 Way Pin Housing

7213/0004

3 Way Pin Retainer

7213/0003

3 Way Socket Retainer

7213/0001

3 Way Socket Connector

7213/0006

3 Way Pin Housing (DT)

7213/0008

3 Way Pin Retainer (DT)

7213/0007

3 Way Socket Retainer (DT)

7213/0005

3 Way Socket Connector (DT)

7214/0002

4 Way Pin Housing

7214/0004

4 Way Pin Retainer

7214/0003

4 Way Socket Retainer

7214/0001

4 Way Socket Connector

7216/0002

6 Way Pin Housing

7216/0004

6 Way Pin Retainer

7216/0003

6 Way Socket Retainer

7216/0001

6 Way Socket Connector

7218/0002

8 Way Pin Housing

7218/0004

8 Way Pin Retainer

7218/0003

8 Way Socket Retainer

7218/0001

8 Way Socket Connector

7219/0002

10 Way Pin Housing

7219/0004

10 Way Pin Retainer

7219/0003

10 Way Socket Retainer

7219/0001

10 Way Socket Connector

7219/0006

14 Way Pin Housing

7219/0008

14 Way Pin Retainer

7219/0007

14 Way Socket Retainer

7219/0005

14 Way Socket Connector

7210/0001

Dummy Plug

7210/0002

Wire Seal (1.4 - 2.2 mm dia.)

7210/0003

Wire Seal (2.2 - 2.9 mm dia.)

1-22

Fig 37. Electrical Repair Kit

9803/9520-8

1-22

Section 1 - General Information Service Tools Tool Detail Reference

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

3/8 in. x 1/4 in.

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

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

1606/0004

1/2 in. x 1/4 in.

1606/0007A 1/2 in. x 3/8 in. Fig 38. Male Adaptors

1604/0004A 1/2 in. x 1/2 in. 1606/0017

5/8 in. x 1/2 in.

1606/0008

3/4 in. x 3/8 in.

Male Adapters - BSP x NPT (USA only)

1606/0009

3/4 in. x 1/2 in.

816/00439

3/8 in. x 1/4 in.

1604/2055

3/4 in. x 3/4 in.

816/00440

1/2 in. x 1/4 in.

1606/0012

3/4 in. x 1 in.

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

1606/0014

3/4 in. x 1.1/4 in.

816/15008

1606/0015

1 in. x 1.1/4 in.

892/00255

1/4 in. BSP x Test Point

892/00256

3/8 in. BSP x Test Point

892/00257

1/2 in. BSP x Test Point

892/00258

5/8 in. BSP x Test Point

816/15118

3/4 in. BSP x Test Point

892/00259

1 in BSP x Test Point

892/00260

1.1/4 in. BSP x Test Point

892/00261

5/8 in. UNF x Test Point

816/55045

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

816/55038

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

816/55040

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

892/00263

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

892/00264

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

892/00265

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

892/00266

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

892/00267

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

1/2 in. x 3/8 in.

Fig 39. Pressure Test Adapters

Fig 40. Pressure Test 'T' Adapters

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Section 1 - General Information Service Tools Tool Detail Reference

Fig 41. 'T' Adapters

892/00047

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

892/00048

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

892/00049

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

816/50043

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

892/00051

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

816/50005

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

816/60096

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

816/00017

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

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

1/2 in. BSP

892/00058A 5/8 in. BSP 892/00059A 3/4 in. BSP Fig 42. Female Blanking Caps

892/00060

1 in. BSP

816/90045

1/4 in. BSP

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

Fig 43. Male Cone Blanking Caps

816/90022

5/8 in. BSP

816/90274

3/4 in. BSP

816/90205

1 in. BSP

892/00074

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

892/00075

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

892/00076

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

892/00077

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

1406/0011

1/4 in. BSP

1406/0018

1/2 in. BSP

1406/0014

5/8 in. BSP

Fig 44. Female Connectors

Fig 45. Bonded Washers

1-24

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

9803/9520-8

1-24

Section 1 - General Information Service Tools Tool Detail Reference

Fig 46. Ram Protection Sleeves

892/01016

For 25 mm Rod Diameter

892/01017

For 30 mm Rod Diameter

892/01018

For 40 mm Rod Diameter

892/01019

For 50 mm Rod Diameter

892/01020

For 50 mm Rod Diameter (slew ram)

892/01021

For 60 mm Rod Diameter

892/01022

For 60 mm Rod Diameter (slew ram)

892/01023

For 65 mm Rod Diameter

892/01024

For 70 mm Rod Diameter

892/01025

For 75 mm Rod Diameter

892/01026

For 80 mm Rod Diameter

892/00167

For 90 mm Rod Diameter

7mm 11o 20mm

10mm

Fig 47. 892/00334 Ram Seal Fitting Tool 5mm

m 3m

110mm 175mm 3o

Fig 48. Hexagon Spanners for Ram Pistons and End Caps 992/09300

55mm A/F

992/09400

65mm A/F

992/09500

75mm A/F

992/09600

85mm A/F

992/09700

95mm A/F

992/09900

115mm A/F

992/10000

125mm A/F

1-25

1.4

Fig 49. 892/01027 Piston Seal Assembly Tool

9803/9520-8

1-25

Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 51. ( T 1-26).

892/00268

Flow Monitoring Unit

892/00269

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

892/00273

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

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

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

Fig 50. Flow Test Equipment

1612/2054

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

892/00271

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

892/00272

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

816/20008

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

892/00275

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

892/00276

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

892/00277

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

1606/0015

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

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

998/11047

600 LPM Flow Turbine with Loading Valve

998/11048

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

998/11049

Carrying Case for Flow Test Kit

998/11050

Temperature Sensor (125Â°C Max)

Fig 51. 998/11046 JCB ServiceMaster Flow Test Kit

1-26

9803/9520-8

1-26

Section 1 - General Information Service Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 53. ( T 1-27).

892/00201

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

892/00202

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

892/00203

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

892/00254

Replacement Hose

993/69800

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

892/00706

Test Probe

892/00347

Connector - Hose to gauge

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

0-600 Bar Pressure Transduce x2

998/11056

0-100 Bar pressureTransducer x2

998/11057

RPM Tachometer (includes fixed cable, 2 meters)

998/11058

5 Meter Connecting Cable

998/11059

M16 Metric Adaptors for Test Points x4

998/11060

400mm Test Hose 90Â° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

Fig 52. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 53. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

1-27

9803/9520-8

1-27

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

Hand Pump

892/00137

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

892/00274

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

892/00262

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

892/00706

Test Probe

892/00278

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

892/00279

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

892/00280

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

892/00279

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

892/00346

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

892/00347

Connector

892/00254

Hose

Fig 54. Hand Pump Equipment

Fig 55. 892/00881 Valve Spool Seal Fitting Tool

Fig 56. Hydraulic Circuit Test Gauges and Connections

1-28

9803/9520-8

1-28

Section 1 - General Information Service Tools Tool Detail Reference

JS07050

Fig 57. Ram Piston Nut Removal/Fitting Spanner

993/99512

Spanner 55 mm A/F

993/99513

Spanner 60 mm A/F

993/99514

Spanner 65 mm A/F

993/99515

Spanner 70 mm A/F

993/99516

Spanner 75 mm A/F

993/99517

Spanner 85 mm A/F

993/99518

Spanner 90 mm A/F

993/99519

Spanner 100 mm A/F

993/99520

Spanner 110 mm A/F

993/99521

Spanner 115 mm A/F

SSP0046

Spanner 80 mm A/F

SSP0047

Spanner 95 mm A/F

993/99525

Rig Assembly (not including spanners and ram)

993/99522

Anchor Side Plate (supplied loose unwelded)

993/99523

Anchor Cross unwelded)

993/99524

Ram Eye End Modification Plate Assembly

556/43400

Lift Ram

545/18000

Lynch Pin

811/50232

1.1/4in Pivot Pin

Member

(supplied

loose

Fig 58. Ram Piston Nut Removal/Fitting Rig

Fig 59. 892/00964 Test Point 1/8 BSP

1-29

Fig 60. 892/00965 Test Point 3/8 BSP

9803/9520-8

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Section 1 - General Information Service Tools Tool Detail Reference

3 4 6 5

Fig 62. Nitrogen Charging Kit 892/00948

Charging Kit (without gauge)

892/00949

Gauge

992/09100

Spool Clamp

892/00011

Spool Clamp

2 A313250-C1

Fig 61. 460/15708 Flow Test Adaptor Note: Components listed below also required Item

Description

460/15707 Banjo bolt

2401/0222 O-ring

2403/0110 O-ring

2403/0108 O-ring

1604/0004 Adaptor - 2 off

1406/0018 Sealing washer - 2 off

1-30

Fig 63. Spool Clamps

9803/9520-8

1-30

Section 1 - General Information Service Tools Tool Detail Reference

Section H - Steering

Fig 66. 892/00180 - Seal Fitting Tool Seal Fitting Tool for fitting 'O' ring and back-up ring to Danfoss Orbitrol Unit. Fig 64. 892/00881 Valve Spool Seal Fitting Tool

892/00181 - Replacement Plastic Boss

Fig 65. 892/00180

Seal Fitting Tool for fitting 'O' ring and kin ring to Hydraulic Steer Unit

892/00181

Replacement plastic boss

1-31

9803/9520-8

1-31

Section 1 - General Information Service Tools Tool Detail Reference

Section K - Engine

Fig 70. 892/00812 Drive Coupling Spanner

Fig 67. 320/20050 Engine Lifting Bracket Kit Note: Brackets are designed to lift only the engine. They MUST NOT be used to lift the engine and transmission assembly.

Fig 68. 992/04000 Torque Multiplier

Fig 69. 892/00822 Splined Bolt Socket

1-32

9803/9520-8

1-32

Section 1 - General Information Service Tools

60 mm

300 mm

970 mm

1030 mm

m m

Tool Detail Reference

A 400 mm

10 mm

m 0 10

440 mm

Fig 71. Engine and Transmission Lifting Frame When removing the engine and transmission assembly suitable lifting equipment must be used. The engine and transmission assembly weighs 1000 kg excluding the main hydraulic pump assembly. Presently there is no approved lifting frame available from JCB Service. K Fig 71. ( T 1-33). The drawing shows guide dimensions for fabricating a frame that can be made locally from mild steel bar. The frame should be designed to lift the assembly by supporting the bottom of the engine between the sump and flywheel housing on plate 71-A. Important: Before using such a frame you must make sure it is tested and complies with all local regulations relating to lifting equipment.

1-33

9803/9520-8

1-33

Section 1 - General Information Service Tools Tool Detail Reference

370.0

65.0

185.0

A 171.0 0.3 X 2 DOWELS 8 x 32 LONG PRESS FIT

30.2 30.1

SECTION

A-A

10.0 TYP

8.0 REF 2 DOWELS

10.0

12.0

0.3

43.4 43.3

10.0

3 x 35(25)

1.0

x 45

57.0

TYP

342.0

A436700

Fig 72. 892/01110 Torque Converter Alignment Tool For use with 12" and W300 torque converters

1-34

9803/9520-8

1-34

Section 1 - General Information Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_4

Table 13. Type

Description

JCB Multi-Gasket

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

50 ml

JCB High Strength Threadlocker

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

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0601

10 ml

4101/0651

50 ml

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

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

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

10 ml 200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

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

4104/0251

200 ml (Aerosol)

4104/0253

1 ltr (Bottle)

JCB Cleaner/Degreaser

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

4104/1557

400 ml (Aerosol)

Direct Glazing Kit

For one pane of glass; comprises of:

993/55700

JCB Threadlocker and Sealer

Part No.

Quantity

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

For direct glazing.

4103/2109

310 ml

Active Wipe 205

For direct glazing.

4104/1203

250 ml

Black Primer 206J

For direct glazing.

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass.

4102/0901

Plastic to Metal Bonder

To seal plastic to metal joints.

4103/0956

50 g

Black Polyurethane Sealant

To finish exposed edges of laminated glass.

4102/2309

310 ml

1-35

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Section 1 - General Information Service Consumables Sealing and Retaining Compounds

Page left intentionally blank

1-36

9803/9520-8

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Section 1 - General Information

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

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

Red

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

Pink

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

Orange

Blue

Green

Light Green

Yellow

1-37

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

Neutral: Neutral circuit pressure.

Exhaust

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

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

9803/9520-8

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Section 1 - General Information Terms and Definitions Colour Coding

Page left intentionally blank

1-38

9803/9520-8

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Section 2 Care and Safety Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-8

Section 2 - Care and Safety

Notes:

2-0

9803/9520-8

2-0

Section 2 - Care and Safety Contents Page No. Safety Notices Important Information ................................................................................ 2-1 The Operator Manual ............................................................................2-1 Safety Warnings ....................................................................................2-1 Safety Check List ....................................................................................... 2-2 Safety - Yours and Others .....................................................................2-2 General Safety ......................................................................................2-2 Operating Safety ...................................................................................2-4 Maintenance Safety ...............................................................................2-7 Safety Labels ........................................................................................... 2-12 Introduction ..........................................................................................2-12 Safety Label Identification ...................................................................2-12 Part Numbers and Descriptions ..........................................................2-14

2-i

Section 2 - Care and Safety Contents

2-ii

Page No.

2-ii

Section 2 - Care and Safety

Safety Notices Important Information T1-042

The Operator Manual

Safety Warnings

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

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

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

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

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

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

2-1

9803-9520-8

2-1

Section 2 - Care and Safety Safety Notices Safety Check List

Safety Check List P4-1004_3

Safety - Yours and Others

General Safety INT-1-3-1_3

All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE

!MWARNING

T1-043

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

!MWARNING Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. INT-1-3-5

!MWARNING Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery. INT-1-3-6_2

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

!MDANGER

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

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

8-1-2-4

!MWARNING

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

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

INT-3-3-9

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

!MWARNING Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). Make sure that no-one goes near the machine while you install or remove the mechanical device. 13-2-3-7_3

!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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

Operating Safety

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

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

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

Work Sites Work sites can be hazardous. Inspect the site before working on it. You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs, ironwork etc. Any of these could cause you to lose control of your machine. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures. INT-2-2-1_2

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

!MWARNING

INT-2-1-5

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

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

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

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

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

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

INT-2-2-8

!MDANGER

5-3-1-12_3

!MWARNING

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

Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine.

INT-2-2-10

2-2-3-6

!MWARNING

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

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

INT-2-1-14

!MWARNING

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

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

!MWARNING 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-2-1-1

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

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MCAUTION

!MWARNING

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

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

5-5-1-1_2

!MWARNING

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

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

!MWARNING

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

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

2-4-5-2_1

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

5-1-4-1

5-1-5-9

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

!MWARNING The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open. 5-2-6-5

!MWARNING

INT-2-2-7

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

!MWARNING Controls You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated. 0179_2

!MCAUTION

INT-2-1-9_6

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

Maintenance Safety

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

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

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

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

!MWARNING

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

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

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

!MWARNING

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

!MCAUTION

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

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

!MWARNING

INT-3-1-10_3

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11_2

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

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

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

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

INT-3-2-2_3

!MCAUTION

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

Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MCAUTION

!MWARNING

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

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

INT-3-2-12

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

!MWARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged. INT-3-3-2_4

!MCAUTION Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. 5-3-1-9

!MWARNING Working Under the Machine Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery. INT-3-3-8_2

Used fluoroelastomeric components whose temperatures have not exceeded 300째C (572째F) require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300째C (572째F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1

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

Thoroughly wash contaminated detergent and water.

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

area

with

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

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

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Section 2 - Care and Safety Safety Notices Safety Check List

!MWARNING

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

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

HYD-1-3_2

!MWARNING Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements. If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.

INT-3-1-17

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

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

!MWARNING

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.

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-3-1-15_2

0125

!MWARNING

Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them.

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-3-2-5

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

INT-3-1-8

0147_1

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Section 2 - Care and Safety Safety Notices Safety Check List

!MDANGER

!MWARNING

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

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

INT-3-2-1_3

13-3-1-7_1

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

!MWARNING

!MCAUTION

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

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

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

8-3-4-8

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

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

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

!MCAUTION

2-3-2-7_2

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

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

INT-3-2-8

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

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Section 2 - Care and Safety Safety Notices Safety Labels

Safety Labels Introduction

Safety Label Identification

!MWARNING

T1-014_2

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

Item

Qty.

ISO Number

ISO-06C

ISO-02A

ISO-01A

ISO-10A

ISO-07D

ISO-06C

INT-1-3-11

Safety labels are strategically placed around the machine to remind you of possible hazards.

F If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-stretch or place yourself in dangerous positions to read the safety labels. If you do not understand the hazard shown on the safety label, then refer to Safety Label Identification.

G H

ISO-04A

ISO-09A

ISO-05C

ISO-06A

ISO-06D

Note: The illustration(s) show a typical machine model. Your machine may look different from the model shown. Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB distributor.

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Section 2 - Care and Safety Safety Notices Safety Labels ISO-02A

ISO-06C

ISO-10A

ISO-06D

ISO-01A

ISO-06A

ISO-09A

ISO-04A

ISO-07D

Fig 1.

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C087410-C2

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Section 2 - Care and Safety Safety Notices Safety Labels

Part Numbers and Descriptions

ISO-06A Part Number: 332-F5855

ISO-01A

Description: Pressure hazard. Read operators manual

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

332-F5855-1

817-70014-3

ISO-06C ISO-02A

Part Number: 817/70002

Part Number: 332/S9994

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

Description: Crush of whole body. Install the articulation lock before you start maintenance work or transport the machine.

817-70002-2 817-70028-2

ISO-06D ISO-04A

Part Number: 817/70005

Part Number: 817/70004

Description: Hot fluid under pressure. Refer to Cooling System (Routine Maintenance Section).

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

817-70005-3 817-70004-4

ISO-07D ISO-05C

Part Number: 817/70112

Part Number: 817/70012

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

Description: Runover. Start the engine from the operator seat only. Do not short across the terminals.

817-70112-2 817-70012-2

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Section 2 - Care and Safety Safety Notices Safety Labels ISO-09A Part Number: 817/70009 Description: Hazard to hands. Severing of hands and fingers.

817/70009

817-70009

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

817-70029-3

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Section 2 - Care and Safety Safety Notices Safety Labels

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Section 3 Routine Maintenance Service Manual - TM310 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-9

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

Section 3 - Routine Maintenance

Notes:

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Section 3 - Routine Maintenance Contents Page No. Maintenance Service Requirements ............................................................................... 3-1 Introduction ............................................................................................3-1 Owner/Operator Support .......................................................................3-1 Service/Maintenance Agreements ........................................................3-1 Initial Service and Inspection .................................................................3-1 Fit for Purpose Tests for Lifting Equipment ............................................3-2 Obtaining Replacement Parts ................................................................3-2 Health and Safety ...................................................................................... 3-3 Lubricants ..............................................................................................3-3 Battery ...................................................................................................3-5 Service Schedules ..................................................................................... 3-7 Introduction ............................................................................................3-7 How to Use the Service Schedules .......................................................3-7 Calendar Equivalents ............................................................................3-7 Pre-start Cold Checks, Service Points and Fluid Levels .......................3-8 Functional Test and Final Inspection ...................................................3-12 Fluids, Lubricants and Capacities ............................................................ 3-14 Specifications ......................................................................................3-14 Fuel .....................................................................................................3-15 Coolant Mixtures .................................................................................3-17 Tools ........................................................................................................ 3-19 Tool Locations .....................................................................................3-19 Carrying Tools onto the Machine .........................................................3-19 Prepare the Machine for Maintenance .................................................... 3-20 Introduction ..........................................................................................3-20 How to Make the Machine Safe (Boom Lowered) ...............................3-21 How to Make the Machine Safe (Boom Lifted) ....................................3-21 Cleaning the Machine .............................................................................. 3-22 Introduction ..........................................................................................3-22 Preparing the Machine for Cleaning ....................................................3-22 Checking for Damage .............................................................................. 3-23 Check the Machine Body and Structure ..............................................3-23 Check the Tyres ..................................................................................3-23 Check the Seat and Seat Belt .............................................................3-23 Check the Electrical Circuits ................................................................3-23 Check the Hydraulic Hoses and Fittings .............................................3-24 Checking the ROPS/FOPS Structure ..................................................3-24 Greasing .................................................................................................. 3-25 Introduction ..........................................................................................3-25 Preparing the Machine for Greasing ...................................................3-25 Boom Pivot Pins ..................................................................................3-26 Centre Pivot and Steering Ram ...........................................................3-27 Inner and Outer Booms .......................................................................3-27 Driveshaft Joints ..................................................................................3-28 Access Panels ......................................................................................... 3-29 Engine Cover .......................................................................................3-29 Heating and Ventilation ........................................................................... 3-30 Cleaning the Cab Heater Filter ............................................................3-30 Brakes ..................................................................................................... 3-31 Park Brake ...........................................................................................3-31

3-i

Section 3 - Routine Maintenance Contents Contents Page No. Electrical System ..................................................................................... 3-33 Battery .................................................................................................3-33 Jump Starting the Engine ....................................................................3-34 Fuses ...................................................................................................3-36 Relay Identification ..............................................................................3-36 Engine ..................................................................................................... 3-37 Oil and Filter ........................................................................................3-37 Cooling System ...................................................................................3-40 Front End Accessory Drive (FEAD) Belt .............................................3-42 Engine Crankcase Ventilation .............................................................3-44 Engine Air Filter ...................................................................................3-45 Fuel System ............................................................................................. 3-46 Introduction ..........................................................................................3-46 Water Separator and Fuel Filter ..........................................................3-47 Hydraulic System ..................................................................................... 3-53 Introduction ..........................................................................................3-53 Release the Hydraulic Pressure ..........................................................3-53 Checking the Fluid Level .....................................................................3-54 Changing the Filter Element ................................................................3-55 Transmission ........................................................................................... 3-56 Checking the Oil Level ........................................................................3-56 Changing the Oil and Filter ..................................................................3-57 Transfer Gearbox ................................................................................3-60 Axles ....................................................................................................3-61 Tyres and Wheels .................................................................................... 3-62 Tyre Inflation ........................................................................................3-62 Windscreen Washer ................................................................................ 3-64 Fire Extinguisher (if fitted) ........................................................................ 3-65 Checking the Fire Extinguisher ...........................................................3-65

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Section 3 - Routine Maintenance

Maintenance Service Requirements Introduction

Owner/Operator Support T3-095

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

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 Distributor's Service Department who are there to help you!

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

To get the most from your Distributor please help them to satisfy you by:

You will have been given the names of the relevant service contacts at your Distributor when the machine was installed.

Giving your name, address and telephone number.

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 Manual for your machine is available from your JCB Distributor. The Service Manual contains information on how to repair, dismantle and assemble your machine correctly.

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.

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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 T3-005_2

To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever

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Section 3 - Routine Maintenance Maintenance Service Requirements occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.

Fit for Purpose Tests for Lifting Equipment T3-097

All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a competent person to ensure they are fit for purpose. This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice.

Obtaining Replacement Parts T3-096

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

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Section 3 - Routine Maintenance Maintenance Health and Safety

Health and Safety Lubricants T3-060_3

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

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

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

Handling

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

Storage

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

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

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

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

Waste Disposal

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

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

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Wash your skin thoroughly with soap and water.

b Using a nail brush will help. c

Use special hand cleansers to help clean dirty hands.

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

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Section 3 - Routine Maintenance Maintenance Health and Safety 3

Avoid skin contact with oil soaked clothing.

Don't keep oily rags in pockets.

Wash dirty clothing before re-use.

Throw away oil-soaked shoes.

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

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

Fires

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

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Section 3 - Routine Maintenance Maintenance Health and Safety

!MCAUTION

Battery

!MWARNING

T3-061

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

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

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

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

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

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

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Section 3 - Routine Maintenance Maintenance Health and Safety Warning Symbols

First Aid - Electrolyte

The following warning symbols may be found on the battery.

Do the following if electrolyte: Gets into your eyes

Symbol

Meaning

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

Keep away from children.

Is swallowed A289230-1

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

Shield eyes.

Gets onto your skin

A289260-1

No smoking, no naked flames, no sparks.

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

A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

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Section 3 - Routine Maintenance Maintenance Service Schedules

Service Schedules Introduction

How to Use the Service Schedules

!MWARNING

T3-036_3

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

T3-012_4

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

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

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

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

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

8-3-1-1

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

795390-1

Calendar Equivalents Every 10 Hours = Daily

T3-051

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

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Section 3 - Routine Maintenance Maintenance Service Schedules

Pre-start Cold Checks, Service Points and Fluid Levels Table 1. Engine Operation

100

500

- Check



 

   



     

       

Oil Level Oil and Filter

- Change

(1)

- Clean

Air Cleaner Dust Valve(2) Air Cleaner Pre-Cleaner Cyclone Block

- Dismantle and Clean - Check

Air Cleaner Outer Element(2) Air Cleaner Outer Element

- Change

Air Cleaner Inner Element(2)

- Change

(2)

Fuel Filter

- Drain

Fuel Filters (Includes the Fuel Sedimenter)

- Drain

FEAD Valve Clearances



 

   

 



    

- Change

Fuel Sedimenter

- Check

1000 2000

- Check and Adjust

Generally For Leaks

- Check

Coolant Level

- Check

Coolant

 

- Change

Exhaust Smoke

- Check

Engine Mount Security

- Check

Torque Converter Stall Speed

- Check

Exhaust System Security

- Check

Air Inlet Security

- Check

Oil Filler and Dipstick O-Rings

- Change

Rocker Cover Gasket and Injector Seals

- Change

Crankcase Ventilation Filter (If Fitted)

- Change



          

(1) If operating under arduous conditions, change oils and filters more frequently. (2) If operating in dusty working environments, clean more frequently.

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Section 3 - Routine Maintenance Maintenance Service Schedules Table 2. Transmission and Axles Operation

100

500

- Change

Oil

(1)

Oil Filter

- Change

Hub Oil

- Change

(1)

Tyre Pressures/Condition

- Check

Wheel Nut Security

- Adjust

Transmission Oil Level

- Check

Steering Operation

- Check

Driveshafts

  

- Grease

Drive Axle(s) Oil (LSD Only)

- Change

Drive Axle(s) Oil (Non LSD Only)(1)

- Change

Transfer Gearbox Oil

- Change

(1)

Transfer Gearbox Oil Level

- Check

Driveshaft Security

- Check

Transmission Strainer

- Clean

    

      

 

1000 2000

             

(1) If operating under arduous conditions, change oils and filters more frequently. Table 3. Hydraulics Operation

100

500

Oil Level

- Check



Oil Filter

- Change

 



 

     

Oil

- Drain

Suction Strainer

- Clean

Hoses, Rams and Pipework for Damage or Leaks

- Check

1000 2000

MRV Pressure

- Check and Adjust

All ARVs

- Check and Adjust



Steer Circuit MRV

- Check and Adjust



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Section 3 - Routine Maintenance Maintenance Service Schedules Table 4. Brakes Operation

100

500

Foot Brake Operation

- Check



Park Brake Operation

- Check and Adjust

 

100

500

Table 5. Electrics Operation Battery Electrolyte Level

- Check

Battery Terminals for Condition and Tightness

- Check

Wiring for Chafing

- Check

All Electric Functions

- Check

EMS Download Codes and Correct Any Issues

- Check

Longitudinal Load Motion Control(1)

-System Check

Longitudinal Load Motion Control

     



 



100

500

      

       

           

- Calibrate

1000 2000

 

1000 2000

      

(1) Refer to the Daily Functional Check, Safety Equipment in the Operators Manual. Table 6. Body and Cab Operation Mirrors Condition and Security

- Check

Seat and Seatbelt

-Check

All Articulation, Steer and Boom Pivots

-Grease

Windscreen Washer Fluid Level

- Check

Attachment Security

- Check

Fire Extinguisher Condition

-Check

SWL Labels Condition

-Check

Boom Wear Pad Security

-Check

Boom Wear Pads

-Check

Boom Wear Pads Runways

-Waxoyl

Pin and Bushes

-Check

Pin Securing Bolt Torques

-Check

ROPS/FOPS Structures

-Check

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1000 2000

           



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Section 3 - Routine Maintenance Maintenance Service Schedules Table 7. Attachments Operation Additional Equipment (As Required)

-Check

Attachment Condition and Operation

- Check Table 8. Lifting Equipment Operation 10

Fit for Purpose Test(1)

- Complete

100

500



100

First 100

500



1000 2000

 

1000 2000



(1) This may be required every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes.

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Section 3 - Routine Maintenance Maintenance Service Schedules

Functional Test and Final Inspection Table 9. Engine Operation 10 Idle Speed

- Check/Adjust

Maximum No Load Speed

- Check/Adjust

Throttle System and Control Cable

- Check/Adjust

Exhaust Smoke - Excessive

- Check

Exhaust System - Security

- Check

Air Inlet System - Security

- Check

Crankcase Breather

- Check

100

100(1) 500

   

1000

2000

     

      

1000

2000

(1) First 100 Hours Service only, to be completed by your JCB Dealer. Table 10. Transmission, Axles and Steering Operation 10 50 100 Transmission - Operation

- Check

Forward/Reverse/Speed Range - Operation

- Check

Neutral Start - Operation

- Check

Steering - Operation

- Check

100(1)

500

   

500

1000

2000



   

(1) First 100 Hours Service only, to be completed by your JCB Dealer. Table 11. Hydraulics Operation 10 Operation Of All Services

- Check

Hose Burst Protection Valves (If Fitted)

- Check

Piston Rods Chrome - Condition

- Check

Parallel Lift/Lower Forks

- Check



100



100(1)

   

(1) First 100 Hours Service only, to be completed by your JCB Dealer.

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Section 3 - Routine Maintenance Maintenance Service Schedules Table 12. Electrics Operation 10 Gauges and Warning Lights

- Check

Wiper Motors

- Check

Cab Switches

- Check

Horn

- Check

Heater (If Fitted)

- Check

Reverse Alarm (If Fitted)

- Check

Lights and Indicators (If Fitted)

- Check

     

100

     

100(1)

      

500

1000

2000

     

      

500

1000

2000

(1) First 100 Hours Service only, to be completed by your JCB Dealer. Table 13. Bodywork and Cab Operation 10 50

100

100(1)

- Check

 

Generally for Damage, Leaks and Wear (Include the ROPS/FOPS)

- Check



Paintwork - Condition

- Check

Fluid Leaks (Example Engine Oil, Hydraulic Oil)

- Check



 

SWL Stickers and Load Charts

- Check



Seat/Seat Belts

- Check

Air Conditioning (If Fitted)



(1) First 100 Hours Service only, to be completed by your JCB Dealer.

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Section 3 - Routine Maintenance Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities Specifications JCB recommend that you use the JCB lubricants shown as they have been verified by JCB for use on JCB machines. However, you could use other lubricants that are equivalent to the JCB standards and quality or offer the same machine component protection.

Item

Fuel System

Capacity Litres

UK Gal

160

Engine (Oil)

Table 14. Fluid/Lubricant

JCB Part Number

Container Size(1)

4001/1805

20 Litres

Diesel JCB Engine Oil EP 15/W40

- Minimum

11.5

2.5

-10 C to +50 C (5 F to 122 F)

- Maximum

3.1

Caution: Do not use ordinary engine oil

Engine (Coolant)

5.6

JCB HP Antifreeze HP/Coolant

4006/1120

20 Litres

Gearbox

4.2

JCB Transmission Fluid EP 10W

4000/2505

20 Litres

Transfer Box

1.3

0.3

JCB Gear Oil HP 90

4000/0305

20 Litres

Axles

4.4

JCB Gear Oil HP

4000/0505

20 Litres

Hydraulic System

135

JCB Hydraulic Fluid EP 46

4002/1605

20 Litres

JCB Biodegradable Hydraulic 46 Fluid

4002/2605

20 Litres

(2)

Grease Points

---

JCB Special MPL-EP Grease

4003/1501

24x400g

Wear Pad Runways

---

JCB Waxoyl

4004/0502

5 Litres

(1) For information about the different container sizes that are available (and their part numbers), contact your JCB Dealer (2) Superior grade oils may be more appropriate for heavy duty applications (such as sustained high loads and operation at elevated temperatures).

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Section 3 - Routine Maintenance Maintenance Fluids, Lubricants and Capacities

!MCAUTION

Fuel Acceptable and Unacceptable Fuels T3-031

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

Fuel Specification

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

Table 15. Applicable Engines

Service Requirements

EN590 Diesel fuel types - Auto/C0/C1/C2/ All Dieselmax engines. C3/C4

Obey the maintenance procedures.

BS2869 Class A2

usual routine schedules and

ASTM D975-91 Class 2, US DF1, US DF2, US DFA JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3 ASTM D975-91 Class 1DA MIL T38219 XF63 NATO F63 French EN590 (RME5) with 5% maximum

All Dieselmax engines.

Obey the usual routine maintenance schedules and Important: Engines operated with procedures. Fuel additives are these fuels may have a reduced recommended for use with low service life. sulphur fuels. K Additives ( T 3-16).

AVTURFSII, NATO F34, JP8, MIL T83133, All Dieselmax engines. DERD 2463, DEF STAN 91-87 AVCAT FSII, NATO F44, JP5, MIL T5624, Important: Engines operated with these fuels may have a reduced DERD 2452, AVTOR service life. NATO F35, JET A1, DEF STAN 91-91, DERD 2494, JP7

Obey the usual routine maintenance schedules and procedures. Fuel additives must be used. K Additives ( T 3-16).

AVCAT, NATO F43 (obsolete), JP5 without additives JET A (ASTM D1655) ASTM D3699 Kerosene B20 Biodiesel - RME content blended with Dieselmax engines mineral derived diesel (20% maximum) - from 2007 on only(1). ASTM D6751, DIN 51606, ISO 14214

manufactured You must obey special routine maintenance schedules and procedures. K Warranty ( T 3-16).

AVTAG (obsolete)

These fuels are not acceptable with or without additives. Engines must not AVTAG FSII (obsolete), NATO F40, JP4, be operated with these fuels. DERD 2454 JET B (ASTM D1655) BS MA100 JIS K2203 No.2 Unmodified vegetable oils (1) The year of manufacture is part of the engine serial number. Refer to Typical Engine Identification Number.

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

and factory filled with CH4 oil) - this is not approved with other manufacturers.

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 must be used as specified by your fuel supplier who will understand the concentration level necessary. – 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%). Note: These products are given as examples only. The information is derived from the manufacturers data. The products are not recommended or endorsed by JCB. Service Requirements for use of B20 Biodiesel – The engine oil must be a grade CH4 as minimum specification. – Do not leave unused B20 biodiesel in the fuel tank for extended periods (top up each day). – Make sure that 1 in 5 fuel tank fills use standard diesel to EN590 specification, this will help to prevent 'gumming'. – Make sure regular oil sampling is completed (look for excessive unburnt fuel content, water or wear particles.

– Use heater kits in low ambient temperature territories. – The biodiesel must meet the following standards: ASTM D6751, DIN 51606, ISO 14214 Note: If necessary use a test kit to confirm the fuel specification. Testing kits are available (not from JCB currently), use the internet as a source for the kits. Note: If performance related issues are to be reported to JCB Service, and the engine has been run on biodiesel, then the fuel system must be filled with standard diesel (at least 2 x tank fills) to EN590 specification and relevant stall speeds recorded prior to making the report. Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels. Using a B20 blend of biodiesel requires caution and additional servicing of the engine is required. K Service Requirements for use of B20 Biodiesel ( T 3-16). Failure to follow the additional recommended service requirements may lead to a warranty claim being declined. Failures resulting by the incorrect use of biodiesels or other fuel additives are not defects of the JCB Dieselmax engine workmanship and therefore will not be supported by JCB Warranty.

– Change the engine oil and filter more frequently (as a minimum half the recommended intervals), or as indicated by oil sampling. – Change the fuel filters more frequently (as a minimum half the recommended intervals), or if there are engine performance related issues. – Make sure the fuel is stored correctly, care must be taken to make sure no water enters the machine fuel tank (or the storage tank). Water will encourage micobacterial growth. – Make sure that the fuel pre-filter is drained daily (not every week as currently advised). – Only JCB engines built after Jan. 2007 are applicable (i.e. engines with 07 on the end of their serial number

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Section 3 - Routine Maintenance Maintenance Fluids, Lubricants and Capacities Sulphur Content

Effects of Fuel Contaminates T3-032

T3-033

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. K Table 16. Sulphur Content ( T 3-17).

The effect of dirt, water and other contaminants in diesel can be disastrous for injection equipment:

Low sulphur fuels must have the appropriate fuel lubricity additives, these lubricity improvers must not create residual deposits that block the fuel system, e.g. injectors, filters etc. Contact your fuel Supplier.

!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

Table 16. Sulphur Content 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

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

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.

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

Tools Tool Locations The grease gun and wheel brace are inside the lockable engine cover A. All tools must be secured in their correct positions when not in use.

)

Fig 1.

C051120-C1

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

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Section 3 - Routine Maintenance Maintenance Prepare the Machine for Maintenance

Prepare the Machine for Maintenance Introduction

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

Make the machine safe before you start a maintenance procedure. You can complete most of the maintenance procedures with the boom lowered (Position A). Unless a maintenance procedure instructs you differently, you must lower the boom. Refer to How to Make the Machine Safe (Boom Lowered).

Fig 2.

T015850-3

If you lift the boom to get access for maintenance (Position B), you must install the maintenance strut on the boom. Refer to How to Make the Machine Safe (Boom Lifted).

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Section 3 - Routine Maintenance Maintenance Prepare the Machine for Maintenance

How to Make the Machine Safe (Boom Lowered) 1

How to Make the Machine Safe (Boom Lifted)

!MWARNING

Park the machine on level, solid ground If necessary, refer to Stopping and Parking the Machine.

Lower the boom.

Put the attachment flat on the ground.

Install the articulation lock. Refer to Articulation Lock

5-3-1-14

Stop the engine and remove the starter key.

Disconnect the battery to prevent accidental operation of the engine. Refer to Battery Isolation.

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

Note: If you lift the boom to get access for maintenance, you must properly support the boom. Important: You can complete most of the maintenance procedures with the boom lowered. Unless a maintenance procedure instructs you differently, you must lower the boom. 1

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

3-21

Park the machine on level, solid ground If necessary, refer to Stopping and Parking the Machine.

Install the articulation lock. Refer to Articulation Lock

Support the boom.

Stop the engine and remove the starter key.

Disconnect the battery to prevent accidental operation of the engine. Refer to Battery Isolation.

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

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Section 3 - Routine Maintenance Maintenance Cleaning the Machine

Cleaning the Machine

!MCAUTION

Introduction T3-062_3

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

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

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

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

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

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

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

Detergents

Use a pressure washer to remove soft dirt and oil.

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

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

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

Pressure Washing and Steam Cleaning

Preparing the Machine for Cleaning 1

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

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

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

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

Remove the undershield.

13-3-2-10_2

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

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Section 3 - Routine Maintenance Maintenance Checking for Damage

Checking for Damage Check the Machine Body and Structure T3-063_5

Make sure that all guards and protective devices are in place, attached by their locking devices and free from damage. Inspect all steelwork for damage. Pay particular attention to the following:

Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre pressures. Inspect the tyre valve for leaks, when you check the tyre pressures.

Check the Seat and Seat Belt

!MWARNING

– Inspect all lifting point welds. – Inspect all pivot point welds. – Inspect the condition of all pivot pins. – Check pivot pins are correctly in place and secured by their locking devices. Check steps and handrails are undamaged and secure. Check for broken, cracked or crazed window glass and mirrors. Replace damaged items. Check all lamp lenses for damage.

T3-008_2

When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years. 2-3-1-7_1

Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.

Check all attachment teeth are undamaged and secure.

Check that the belt mounting bolts are undamaged, correctly fitted and tightened.

Check all safety and instructional labels are in place and undamaged. Fit new labels where necessary.

Check seats are undamaged and secure. Check seat adjustments for correct operation.

Note damaged paintwork for future repair.

Check the Electrical Circuits T3-099

Check the Tyres

!MWARNING

Inspect the electrical circuits regularly for: T3-065_2

– Damaged connectors

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. 13-2-1-2

Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example:

– Loose connections – Chafing on wiring harnesses – Corrosion – Missing insulation – Incorrect routing of harness Do not use the machine if one or more of these faults are found. You must make sure that the electrical circuit is repaired immediately.

– Signs of distortion (bulges) – Cuts or wear – Embedded objects (nails, etc.)

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Section 3 - Routine Maintenance Maintenance Checking for Damage

Check the Hydraulic Hoses and Fittings

!MWARNING

T3-072

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged. INT-3-3-2_4

Inspect the hoses regularly for: – Damaged hose ends – Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again. Replacement hoses must be of the same size and standard.

Checking the ROPS/FOPS Structure

For assistance, contact your JCB distributor. Failure to take these precautions could result in death or injury to the operator. 1

Check the structure for damage.

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

Make sure that the ROPS/FOPS mounting bolts A are tightened to the correct torque setting.

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Section 3 - Routine Maintenance Maintenance Greasing

Greasing Introduction

Preparing the Machine for Greasing T3-028_2

You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's working life. Refer to the Service Schedule for the correct intervals. Note: The machine must always be greased after pressure washing or steam cleaning.

Make the machine safe before you start a greasing procedure. Refer to Prepare the Machine for Maintenance. Important: You can complete most of the greasing procedures with the boom lowered. If you lift the boom to get access for greasing, you must install the maintenance strut on the boom.

Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient. Stop greasing when fresh grease appears at the joint. Use only the recommended type of grease. Do not mix different types of grease, keep them separate. In the following illustrations, the grease points are numbered. Count off the grease points as you grease each one. Refit the dust caps after greasing. Note: Where applicable, refer to the manufacturers manual for instructions on the maintenance of optional attachments.

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Section 3 - Routine Maintenance Maintenance Greasing

Boom Pivot Pins

1,2,3

7,8

13 14 15,16

9,10,11 6

4,5

Fig 3. Total of 17 grease points. Note: Grease points 5, 8 and 16 are on the opposite side of the machine. Grease points 6, 9, 10, 11 are on the main ram and will require the boom to be raised and correctly supported to gain access. Access to grease points 10 and 11 are through holes cut in the bottom structure.

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Section 3 - Routine Maintenance Maintenance Greasing

Centre Pivot and Steering Ram

Inner and Outer Booms

There are a total of 2 grease points.

Extend the boom fully. Spray Waxoyl evenly over the outer faces of the inner boom and the inner faces of the outer boom. Allow 2-3 hours drying time before retracting the boom.

!MWARNING Make sure the articulation lock is in the transport position before you transport the machine. The articulation lock must also be in the transport position if you are carrying out daily checks or doing any maintenance work in the articulation danger zone. If the articulation lock is not in the transport position you could be crushed between the two parts of the chassis. 4-3-5-7

Note: Grease points 2 and 3 are repeated on the other steer ram. Grease point 4 is the lower grease point for the centre pivot and is accessible through a hole in the bottom of the rear chassis.

4 Fig 4.

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Section 3 - Routine Maintenance Maintenance Greasing

!MWARNING

Driveshaft Joints Intermediate Driveshaft - Total of 3 grease points (1 to 3). Driveshaft (Except Intermediate) - Total of 7 grease points (4 to 10)

Make the machine safe before working underneath it. Park the machine on level ground and lower the attachments, (If it is necessary to work with boom raised, then the boom safety strut must be fitted). See Boom Safety Strut in MAINTENANCE section. Engage the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. If you are working near the articulation danger zone, fit the articulation safety lock. See Articulation Lock in MAINTENANCE section. 4-3-2-6

Fig 5.

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Section 3 - Routine Maintenance Maintenance Access Panels

Access Panels Engine Cover

Closing the Cover

!MCAUTION

Opening the Cover

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

The struts holding the engine cover can over time become weak. This will be noticed by the fact that the cover will not hold in the fully open position, but will tend to sag slightly. Do not work under an engine cover that will not retain its fully open position.

5-2-6-5

0107

!MWARNING

Close cover, make sure cover is latched.

Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit. 10-1-1-40

Note: Before you stop the engine, you must allow the engine to operate at low idle for four minutes. The delay allows the coolant temperature to stabilise before you open the engine cover.

!MCAUTION

)

Do not use the machine with the engine exposed. 5-3-1-6

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20)

Press the handle lock A to unlatch the cover.

Lift cover.

Fig 6.

Note: The raising of the engine cover is assisted by two gas struts. The struts also hold the cover in the fully open position.

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Section 3 - Routine Maintenance Maintenance Heating and Ventilation

Heating and Ventilation Cleaning the Cab Heater Filter

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

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

The filter is behind a grille panel on the right hand side of the cab. To gain access to the cab heater filter A, undo bolts B and remove cover C.

Remove the filter and shake out the loose dust. Trapped dust can be removed using a low pressure airline. (The pressure must be no greater than 25 psi.) Replace the filter as necessary.

Refit the cover.

B A

Fig 7.

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Section 3 - Routine Maintenance Maintenance Brakes

Brakes Park Brake

Testing the Park Brake

!MWARNING

Introduction

!MWARNING

T3-071

Do not use a machine with a faulty park brake.

Before testing the park brake make sure the area around the machine is clear of people. 2-2-4-5

3-2-3-10_2

!MWARNING

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the park brake. 3-2-3-11

Make sure that you obey all health and safety precautions before you test or adjust the park brake. If you have any queries concerning the park brake test or adjustment procedures, consult your local JCB distributor.

Fig 8.

385720

With the park brake fully applied, ensure the park brake lever `locks' in the applied position by `knocking' the lever with the palm of your hand in the direction of release. The park brake lever must not release without the safety catch being released.

With the park brake fully applied, remove the chocks from the wheels and raise the attachment to just above the travelling position.

!MWARNING If the machine starts to move during the following test, immediately apply the foot brake and reduce the engine speed. 2-2-5-1

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Section 3 - Routine Maintenance Maintenance Brakes Test the brake on a 20% gradient with a suitable, dry surface. Make sure your seat belt is securely fastened. 4

Test the park brake a

Drive the machine onto a 20% gradient.

Park Brake Adjustment 1

Disengage the park brake (lever horizontal).

Pull handle grip A forwards to release the twisting action. Turn handle grip A clockwise, half a turn. Push handle grip A back into place to lock the adjustment mechanism.

Test the park Brake ( T 3-31).

If the brake fails the test, repeat steps 1, 2 and 3. If there is no more adjustment and pin B is at the end of its travel get the brake checked by your JCB Dealer.

b With the foot pedal firmly pressed, fully engage the park brake. c

Set the forward/reverse lever to neutral (N).

d Slowly release the pressure from the foot brake pedal. If the machine starts to move, immediately re-apply the foot brake and remove the machine from the gradient. Adjust the park brake and repeat the test. e

brake.

K Testing

the

Park

With the foot brake fully released, the park brake should hold the weight of the machine on the gradient without any "creep".

Remove the machine from the gradient, lower the attachments to the ground and stop the engine.

If you have any queries concerning this procedure or the park brake adjustment, consult your local JCB Dealer.

B Fig 9.

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Section 3 - Routine Maintenance Maintenance Electrical System

Electrical System Battery

Checking the Electrolyte Level

Battery Disconnection/Connection

Low maintenance batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below.

T3-020_3

!MWARNING

T3-019_4

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

Get access to the battery. See Access Panels.

Disconnect and remove battery. See Battery Disconnection/Connection.

Disconnection

!MWARNING

Get access to the battery. See Access Panels.

If the machine has a battery isolator, move the switch to the OFF position then remove the key.

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

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

Connection 1

Remove covers A. Look at the level in each cell. The electrolyte should be 6 mm (1/4 in) above the plates. Top up if necessary with distilled water or de-ionized water.

Check the battery. a

If the terminal is dirty, clean the post.

Fig 10. b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper.

Refit battery.

Close and lock the access panels.

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

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

If the machine has a battery isolator, move the switch to the ON position.

Close and lock the access panels.

Battery Isolator (if fitted)

Fig 11. Typical Battery

battery isolator has been fitted.

To disconnect the battery from the machine electrics a

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Section 3 - Routine Maintenance Maintenance Electrical System

!MCAUTION

Jump Starting the Engine

Before carrying out arc welding on the machine, disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if a battery isolator is fitted. INT-3-1-13

At the end of a working cycle or if the machine is being left unattended, provided the lights are not required, the battery must be isolated. Before attempting to start the engine or use the machine electrics the battery isolator key must be fitted and switched on. Note: Wait at least 30 seconds after switching off the engine before isolating the battery. 1

To isolate the battery turn the battery isolator key in an anti-clockwise direction and remove. If the key is removable, keep it in a safe place and available for when the machine is next required. To connect the battery insert the key and turn in a clockwise direction.

!MWARNING

T3-021

Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery fully charged. Do not try to charge a frozen battery or jump-start and run the engine, the battery could explode. Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels. When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This prevents any chance of sparks near the battery. Set all the machine switches to their OFF positions before connecting the external power supply. Even with the starter switch set to off some circuits will be energised when the external power supply is connected. Do not connect the booster (slave) supply directly across the starter motor. Doing this by-passes the neutral gear safety switch. If the machine is in gear, it may 'runaway' and kill or injure bystanders. Use only sound jump leads with securely attached connectors. Connect one jump lead at a time. The machine has a negative earth electrical system. Check which battery terminal is positive (+) before making any connections. Keep metal watch straps and jewellery away from the jump lead connectors and the battery terminals - an accidental short could cause serious burns and damage equipment. Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine's electrical system.

Fig 12.

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 - Routine Maintenance Maintenance Electrical System 1

The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now. The engine will not start unless the park brake is on.

Set all switches in the cab to off.

Connect the booster cables as follows: a

Unlock and open the battery cover.

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

Connect the negative (-) booster cable to a good frame earth on the machine, away from and below the battery.

Note: A good frame earth is part of the main frame, free from paint and dirt. Do not use a pivot pin for an earth. d Connect the other end of this cable to the negative (-) terminal on the booster supply. 4

Do the Pre-Start Checks.

Start the engine.

!MWARNING When the engine is running, there are rotating parts in the engine compartment. Before disconnecting the cables, make sure that you have no loose clothing (cuffs, ties etc.) which could get caught in rotating parts. 2-2-4-3

Disconnect the negative booster cable from the machine frame earth. Then disconnect it from the booster supply. Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.

Close and lock the battery cover.

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Section 3 - Routine Maintenance Maintenance Electrical System

Fuses

Relay Identification

For information about fuses see Section C, Electrics, Fuses and Relays.

For information about relays see Section C, Electrics, Fuses and Relays.

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Section 3 - Routine Maintenance Maintenance Engine

Engine Oil and Filter B

Checking the Oil Level

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

Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites. INT-3-2-14

INT-3-2-3

Engine oil and oil filter change must be completed in accordance with the service schedules. Failure to change the oil and filter at the recommended interval could cause serious engine failure. 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Open the engine cover. K Engine Cover ( T 3-29).

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

If necessary, add recommended oil through one of the filler points B.

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Fig 13.

3-37

Section 3 - Routine Maintenance Maintenance Engine Changing the Oil and Filter

Operate the engine until the oil pressure low warning light has extinguished. Check for oil leakage. When the oil has cooled, check the oil level again, and if necessary top up with clean engine oil.

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Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil. 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Open the engine cover.

Place a container of suitable size beneath the drain plug C. K Fig 14. ( T 3-39).

!MCAUTION Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you. Keep to one side when you remove the plug. 13-3-1-15

Remove drain plug C and its 'O' ring D. Let the oil drain out, then clean and refit the drain plug with a new 'O' ring. Torque tighten the plug to 40 - 60 Nm (30 - 44 lbf ft).

Loosen and remove filter housing drain plug E. Let the oil fully drain. Refit the plug. Torque tighten the plug to 40 - 60 Nm (30 - 44 lbf ft).

Unscrew the filter canister F, using a chain wrench if necessary.

Clean the seal face of the filter head G.

Smear the seal H on the new filter canister with clean engine oil.

Screw in the new filter canister - hand tight only.

Through one of the filler points B, fill the engine with the recommended oil to the MAX mark on the dipstick A. Wipe off any spilt oil, refit the filler cap and make sure it is secure.

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Section 3 - Routine Maintenance Maintenance Engine

A Fig 14.

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Section 3 - Routine Maintenance Maintenance Engine

Cooling System Checking the Coolant Level The procedures below describes a typical coolant package installation.

A C

!MWARNING The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system. 9-3-3-1_2

Make sure the park brake is engaged and the transmission set to neutral. Lower the attachments to the ground, switch OFF the engine and remove the starter key.

Check the level of coolant in the expansion bottle A. If necessary remove the filler cap and top up to the level indicated. K Fig 15. ( T 3-40).

Refit the filler cap and make sure it is tight.

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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B Fig 15.

3-40

Section 3 - Routine Maintenance Maintenance Engine Changing the Coolant The procedures below describes a typical coolant package installation.

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Open the engine cover.

Carefully loosen cap A just enough to let any pressure escape. Remove the cap when all pressure is released. K Fig 15. ( T 3-40).

Disconnect the bottom radiator hose at B and allow the coolant to drain.

Flush the system by pouring clean water into filler port A.

Reconnect the radiator hose.

Fill the expansion bottle C, using the necessary antifreeze solution, to the level indicated.

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. Check the level in the expansion bottle and top up if necessary.

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Section 3 - Routine Maintenance Maintenance Engine

Front End Accessory Drive (FEAD) Belt

Inspecting the Drive Belt

Introduction

At the recommended service interval, visually inspect the belt for damage.

The front end accessory drive belt (FEAD) drives the alternator, water pump and the air conditioning compressor (if fitted).

Get access to the drive belt. Refer to Front End Accessory Drive Belt, Introduction.

Inspect the belt for cracks A, fraying B or missing pieces C. K Fig 16. ( T 3-42).

T3-029

The belt is automatically kept in tension so will not need to be adjusted.

Fit a new belt as required. Refer to Changing the Drive Belt.

!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

Fig 16.

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Section 3 - Routine Maintenance Maintenance Engine Changing the Drive Belt 1

Get access to the drive belt. Refer to Front End Accessory Drive Belt, Introduction.

Use a 16mm (5/8 in.) socket located on the hexagon spigot nut D, carefully rotate the tensioner against the spring force in direction E. Do not use excessive force or the tensioner will be damaged.

Keep holding the tensioner against the spring force and lift the belt off the tensioner pulley F.

Slowly release the spring force by rotating the tensioner unit in the opposite direction.

Before fitting a new belt, check that the tensioner roller and fan pulley rotate smoothly and that there is no play in the bearings.

Fit the new drive K Fig 16. ( T 3-42).

Use a 16mm (5/8 in.) socket located on the hexagon spigot nut D, carefully rotate the tensioner against the spring force in direction E. Do not use excessive force or the tensioner will be damaged.

Keep holding the tensioner against the spring force and lift the belt around the tensioner pulley F.

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belt

around

the

pulleys.

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Section 3 - Routine Maintenance Maintenance Engine

Engine Crankcase Ventilation

Lift out the filter element C and discard it.

Changing the Filter Element

Clean the inside of the filter housing D. Remove all oil and sludge contamination.

The filter element must be changed at the recommended interval. K Service Schedules ( T 3-7).

Make sure that the oil drain in the bottom of the filter housing is not blocked with sludge. If necessary remove the drain pipe E at the engine. Make sure that the drain pipe non return ball valve at the bottom of the filter housing is fitted and free to move.

Fit a new filter element C.

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Open the engine cover.

Undo the clips A and lift off the filter cover B. K Fig 17. ( T 3-44).

Important: Install the correct type of filter element. 8

Install the filter cover B.

A B D

C E Fig 17.

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Section 3 - Routine Maintenance Maintenance Engine

Engine Air Filter Changing the Filter Elements

)

* Fig 18.

Outer Element

Open the engine cover. K Fig 18. ( T 3-45).

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Undo clips A and lift of the cyclone block C.

Remove the filter outer element E and discard it.

Open the engine cover. 5

Remove the filter inner element F and discard it.

Undo clips A and lift off the cyclone block C. K Fig 18. ( T 3-45).

Clean the filter housing G, cyclone block C and the dust valve B. Replace the dust valve if it is damaged or cracked.

Fit a new filter inner element F and a new filter outer element E.

Refit the cyclone block C and secure with clips A.

Remove the filter outer element E and discard it.

Clean the filter housing G, cyclone block C and the dust valve B. Replace the dust valve if it is damaged or cracked.

Fit a new filter outer element E.

Refit the cyclone block C and secure with clips A.

Inner Element 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

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Section 3 - Routine Maintenance Maintenance Fuel System

Fuel System Introduction

!MWARNING Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of pressurised fluid and wear protective glasses. If fluid penetrates your skin, get medical help immediately. 0177

!MCAUTION Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. INT-3-3-12

!MCAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, the system must be bled to remove any air. 2-3-3-11

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Section 3 - Routine Maintenance Maintenance Fuel System

Water Separator and Fuel Filter Introduction To get access to the water separator A and engine fuel filter B for maintenance: 1

Open the engine cover. Refer to Access Panels, Engine Cover.

Draining the Water Separator and Engine Fuel Filter T3-075

If there is water in the fuel or if the cab warning light illuminates, drain the water separator and engine filter as detailed. 1

Get access to the Water Separator and Engine Fuel Filter. Refer to Water Separator and Engine Fuel Filter, Introduction.

Drain off any water in the element A by turning tap B.

Drain off any water in the water separator bowl C by turning tap D. Do not disconnect the electrical connector E (if fitted).

If there is sediment in the bowl after draining, support the bowl and release the locking ring F.

Wash the bowl in clean fuel.

Refit the bowl, secure in position with locking ring F.

Fig 19.

C040110-1

Important: Ensure the seal is seated correctly before refitting the bowl. Refer to Changing the Water Separator Pre-Filter. 7

Make sure that the electrical connector E is correctly fitted.

Fig 20.

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C048590-1

3-47

Section 3 - Routine Maintenance Maintenance Fuel System Changing the Filter Element 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Thoroughly clean the outside of the filter housing and around the filter head.

Loosen the drain tap B and allow the water/fuel to drain into a suitable container. K Fig 21. ( T 3-48).

Remove the low pressure fuel lines C and E. Mark the pipes prior to removal to ensure they are refitted in the correct position.

Release the filter strap retaining screw D and lift the filter clear.

Install new filter element A. Make sure that the filter is in the correct position to enable connection of the fuel lines. Torque tighten the filter strap retaining screw D to 24 Nm (17.7 lbf ft).

Reconnect the fuel lines C and E.

Bleed the fuel system.

Fig 21.

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3-48

Section 3 - Routine Maintenance Maintenance Fuel System Mechanical Fuel Injection System 1

Get access to the Engine Fuel Filter. Refer to Water Separator and Engine Fuel Filter, Introduction.

Thoroughly clean the outside of the filter housing and around the filter head.

Loosen the drain tap A and allow the fuel to drain into a suitable container. K Fig 22. ( T 3-49).

Mark the pipes prior to removal to ensure they are refitted in the correct position. Press fuel coupling release button B and disconnect fuel lines C and D.

Release the filter strap retaining screw E and lift the filter clear.

Install new filter element F. Make sure that the black dot G is aligned with the locating hole H in the strap. Torque tighten the filter strap retaining screw E to 24 Nm (17.7 lbf ft).

Reconnect the fuel lines C and D.

Bleed the fuel system. Refer to Bleeding the System.

3-49

9803/9520-9

Fig 22.

C007090

3-49

Section 3 - Routine Maintenance Maintenance Fuel System Changing the Water Separator Pre-Filter T3-076

Get access to the Water Separator. Refer to Water Separator and Engine Fuel Filter, Introduction.

Drain and remove the water separator bowl C. Refer to Draining the Water Separator and Engine Fuel Filter.

To remove the filter element A, release locking ring B and discard element.

Fit new element and secure in position with locking ring B.

Refit the bowl, secure in position with locking ring B.

Important: Ensure the seal D is seated correctly before refitting the bowl. 6

Make sure that the electrical connector E is correctly fitted.

Fig 23.

3-50

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C007030-5

3-50

Section 3 - Routine Maintenance Maintenance Fuel System Cleaning Water Separator Pump (if fitted) T3-077

If the priming pump does not operate or if a fuel blockage is suspected, the hand priming pump can be removed and the pump and sedimenter cleaned. Note: To carry out this procedure you will need a strap wrench to loosen and tighten locking ring A. 1

Get access to the Water Separator. Refer to Water Separator and Engine Fuel Filter, Introduction.

Thoroughly clean the outside of the filter housing and around the filter head.

To remove the pump assembly, using a suitable strap wrench release locking ring A, keep the assembly pressed down to contain the spring once the locking ring is free.

Carefully remove the pump assembly, take care not to lose spring B.

Pull out diaphragm C and clean as required using clean fuel.

Remove any debris in the water sedimenter and inlet connectors as required.

Make sure seal D is positioned correctly, lubricate diaphragm C with clean engine oil. Taking care not to damage diaphragm C, refit diaphragm and spring B.

Secure assembly in position, taking care not to cross thread locking ring A, tighten to finger tight.

With strap wrench, tighten locking ring A a further 1/4 of a turn.

Bleed the system and check for leaks. Refer to Bleeding the System.

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A B C D

Fig 24.

812300

3-51

Section 3 - Routine Maintenance Maintenance Fuel System Electronic Fuel Injection System T3-080

The engine installation features an electrically operated fuel lift pump A. The system is designed to bleed automatically when the lift pump is operated. Make sure that as much air is removed from the fuel as possible before starting the engine.

!MWARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. 13-3-2-16

Important: Do not attempt to bleed the high pressure fuel system by loosening high pressure pipe connections even when the engine is not running. To bleed the fuel system follow the correct procedure. Bleed the system as follows: 1

Turn on the starter switch to start the fuel lift pump A. Do not start the engine. Allow the pump to run for 30 seconds.

Turn off the starter switch to stop the fuel lift pump A. Wait 10 seconds and then turn the starter switch to start the pump. Do not start the engine. Allow the pump to run for 30 seconds.

Repeat step 2 twice more before starting the engine.

Start the engine and make sure it runs smoothly.

3-52

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Fig 25. Fig 26.

C048590

3-52

Section 3 - Routine Maintenance Maintenance Hydraulic System

Hydraulic System

!MCAUTION

Introduction

!MWARNING The temperature of the hydraulic oil will be high soon after stopping the engine. Wait until it cools (less than 40Â°C) before beginning maintenance. 8-3-4-10

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

Do not allow dirt to enter the system. Before disconnecting any part of the system, thoroughly clean around the connection. When a component has been disconnected, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the system. Dirt in the system will seriously damage the systems components and could be expensive to repair. INT-3-3-12

Release the Hydraulic Pressure 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Run the engine for one minute, then turn the starter key to O.

Turn the starter key to IGN. Do not start engine.

Push the auxiliary circuit switches on the servo control lever.

Make sure the pressure in the service hose line has been released before connecting or disconnecting the hoses.

INT-3-1-11_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

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Section 3 - Routine Maintenance Maintenance Hydraulic System

Checking the Fluid Level 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Look at the fluid level in the "Bulls-eye" sight glass A. the level should be in the centre of the sight glass. K Fig 27. ( T 3-54).

If necessary, top up with hydraulic fluid, through filler point A. For the correct grade of lubricant. K Fluids, Lubricants and Capacities ( T 3-14).

!MCAUTION If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately. 12-5-1-4

Fig 27.

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Section 3 - Routine Maintenance Maintenance Hydraulic System

Changing the Filter Element 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Raise the cover.

Undo the filter assembly cover A. Lift the handle attached to the top of the filter and pull the filter straight upwards from its housing. Discard the old element.

Replace the "O" ring on the cap, insert a new filter element into its tube and make sure it is fully home.

Note: The torque setting for the filter cap must not be exceeded. 5

Fold over the lifting handle and screw on the cover. Torque tighten the cap to 40 Nm (29.5 lbf ft).

Check the hydraulic fluid level and top up if necessary. K Checking the Fluid Level ( T 3-54)

Close and secure the cover.

Fig 28.

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3-55

Section 3 - Routine Maintenance Maintenance Transmission

Transmission Checking the Oil Level 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Open the engine cover.

Start and run the engine slowly for a period not exceeding five minutes. This allows the oil to fill filter, pump, torque converter, oil cooler and hoses.

Switch OFF the engine and remove the starter key, wait one minute.

Check that the oil level is between the end of the dipstick and maximum mark on the dipstick A.

Add oil as necessary. Fill through the dipstick tube to maximum dipstick level. Use only the recommended oil. K Fluids, Lubricants and Capacities ( T 3-14).

Fig 29.

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Section 3 - Routine Maintenance Maintenance Transmission

Changing the Oil and Filter

Important: On the recent models, access the filter through the cab floor by removing the bolts for the park brake mounting plate. The filter is directly below the access hole. The filter has a standard 'spin on' type connection direct to the transmission. Any spilt oil is collected below the machine in a suitable container. The filter is removed through the access hole and the new filter installed as a reverse procedure.

Fill the system with new oil through the dipstick/filler. Do not fill past the top mark on the dipstick.

Note: Fit only a genuine supplied JCB filter, otherwise damage to the system may be incurred through contamination.

3-Speed Transmission The transmission oil should be drained through the suction strainer aperture to flush out any particles which fall off the strainer during its removal. 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Disconnect the battery.

!MCAUTION When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer. 2-3-4-1

Place a container, of suitable size beneath the suction strainer. Remove bolts D. Pull out the strainer E and its gasket F. Allow the oil to drain into the container. Be aware that the oil may be hot.

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

Fit the strainer E and a new gasket F. Apply JCB Threadlocker and Sealer to bolts D before fitting and tightening them. Torque tighten the bolts to 10 Nm (7 lbf ft).

Unscrew and remove the filter B. Some machines feature a remote chassis mounted filter as shown at X. Fit the new filter: a

Smear seal C with transmission oil.

Fig 30.

b Screw the filter on until it just contacts the filter head. c

3-57

Turn the filter at least another 3/4 of a turn.

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Section 3 - Routine Maintenance Maintenance Transmission 6-Speed Transmission The transmission oil should be drained through the suction strainer aperture to flush out any particles which fall off the strainer during its removal. 1

Make sure the park brake is engaged and the transmission set to neutral. Lower the attachments to the ground, switch OFF the engine and remove the starter key.

Disconnect the battery.

F E

!MCAUTION

When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer. 2-3-4-1

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

Fit the strainer E and a new gasket F. Apply JCB Threadlocker and Sealer to bolts D before fitting and tightening them. Torque tighten the bolts to 10 Nm (7 lbf ft).

Unscrew and remove the filter B. Some machines feature a remote chassis mounted filter as shown at X. Fit the new filter:

C X

Smear seal C with transmission oil.

b Screw the filter on until it just contacts the filter head. c 7

Fig 31.

Turn the filter at least another 3/4 of a turn.

Fill the system with new oil through the dipstick/filler. Do not fill past the top mark on the dipstick.

Note: Fit only a genuine supplied JCB filter, otherwise damage to the system may be incurred through contamination.

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Section 3 - Routine Maintenance Maintenance Transmission Transmission (Filter and Strainer) Important: On the recent models, access the filter through the cab floor by removing the bolts for the park brake mounting plate. The filter is directly below the access hole. The filter has a standard 'spin on' type connection direct to the transmission. Any spilt oil is collected below the machine in a suitable container. The filter is removed through the access hole and the new filter installed as a reverse procedure.

The transmission oil should be drained through the suction strainer aperture to flush out any particles which fall off the strainer during its removal. 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

!MCAUTION When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer.

2-3-4-1

Place a container, of suitable size beneath the suction strainer. Remove bolts A. Carefully pull out the strainer with its gasket. Allow the oil to drain into the container. Be aware that the oil may be hot.

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

Fit the strainer with its gasket. Apply JCB Threadlocker and Sealer to bolts A before fitting and tightening them. Torque tighten the bolts to 10 Nm (7 lbf ft).

Unscrew and remove the filter B. To fit the new filter: a

Smear seal C with transmission oil.

Fig 32.

C029580-C1

b Screw the filter on until it just contacts the filter head. c 6

Turn the filter at least another 3/4 of a turn.

Fill the system with new oil through the dipstick/filler. Do not fill past the top mark on the dipstick. K Fluids, Lubricants and Capacities ( T 3-14).

Note: Fit only a genuine supplied JCB filter, otherwise damage to the system may be incurred through contamination.

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Section 3 - Routine Maintenance Maintenance Transmission

Transfer Gearbox

Changing the Oil

Checking the Oil Level

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Remove the fill/level plug A.

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

Remove the fill/level plug A, oil should flow from the hole.

If necessary, top up with recommended oil. K Fluids, Lubricants and Capacities ( T 3-14). Clean plug A and refit using a new bonded washer, tighten to 102 Nm (75 lbf ft).

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

Remove drain plug B, and drain the oil into a suitable container.

Clean plug B and refit using a new bonded washer, tighten to 102 Nm (75 lbf ft).

Fill with recommended oil through fill/level hole A.

Clean plug A and refit using a new bonded washer, tighten to 102 Nm (75 lbf ft).

Fig 33.

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Section 3 - Routine Maintenance Maintenance Transmission

Axles

Fill the axle with the specified quantity of oil through drive head casing fill/level plug A. If the machine has been set level, oil should just dribble out both hub fill/ level points.

Clean and refit both hub fill/level plugs C and fill/level plug A and their bonded washer.

Checking the Oil Level 1

Make the machine safe with the boom lowered. K Prepare the Machine for Maintenance ( T 3-20).

At the drive head casing remove fill/level plug A. Oil should be level with the bottom of the fill/level plug.

If necessary, top up with JCB recommended axle oil. Clean and refit fill/level plug A. K Fluids, Lubricants and Capacities ( T 3-14)

Note: It is essential that the machine is parked on level ground to ensure accurate oil level checking.

Fig 35.

Fig 34.

Changing the Oil 1

Set the machine level, with the machine tyres just clear of the ground. Manually rotate both wheels of the axle to bring the oil level mark on the hubs to the vertical position, with the fill/level plugs C at the bottom as shown at D.

Remove fill/level plugs C from the hubs and drain plug B from the drive head casing. Allow time for the oil to drain out.

Clean and refit drain plug and bonded washer B. Torque tighten to 79 Nm (58 lbf ft).

Set both hub OIL LEVEL marks to the horizontal as shown at E. There is a tolerance of 5 mm (0.2 in) above or below the horizontal.

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Fig 36.

3-61

Section 3 - Routine Maintenance Maintenance Tyres and Wheels

Tyres and Wheels Tyre Inflation

in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job.

Introduction

!MWARNING

T3-066

An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work. 2-3-2-7_2

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. K Fig 37. ( T 3-62).

Prepare the equipment. a

!MWARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury.

b Use an air hose fitted with a self-locking air chuck and remote shut-off valve.

13-3-1-7_1

Always try to maintain your tyre pressure to the recommended settings. Using your machine with underinflated tyres means:

Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 psi) above the recommended tyre pressure. For recommended tyres and pressures for your machine, see Specifications, Tyre Sizes and Pressures.

– Decreasing the machines stability – Higher tyre temperatures

Add the air. a

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.

– Excessive strain of the tyre fabric b Inflate the tyre to the recommended pressure. Do not over-inflate.

– More bulging of the sidewalls – Shortens the tyres life. Using the machine with over inflated tyres is dangerous: – It causes excessive tensile loads in the fabric: this makes a tyre more susceptible to cuts and punctures. Do not cut or weld on the rim of an inflated tyre. After checking or amending the tyre pressure always replace and secure the valve cap. Always deflate the tyre before removing foreign obstacles from the tread.

Procedure T3-067_2

These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call

3-62

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Fig 37.

A089570-1

3-62

Section 3 - Routine Maintenance Maintenance Tyres and Wheels Checking the Wheel Nut Torques T3-014_3

!MWARNING

If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. Every day, before starting work, check that the wheel nuts are tight. Tighten the wheel nuts (in a diagonal sequence) to the torque value shown. Table 17.

3-63

Front

Rear

Nm (lbf ft)

680 (500)

9803/9520-9

3-63

Section 3 - Routine Maintenance Maintenance Windscreen Washer

Windscreen Washer

Fig 38.

C051120-C2

Fill the windscreen washer bottle A with a suitable liquid. The liquid should contain a de-icing fluid to prevent it freezing. Do not use engine coolant anti-freeze.

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Section 3 - Routine Maintenance Maintenance Fire Extinguisher (if fitted)

Fire Extinguisher (if fitted) T3-022

Checking the Fire Extinguisher Check the fire extinguisher for damage, security and signs of leaking. Check that the gauge A indicates that the extinguisher is charged i.e. the needle is in the GREEN segment. Note: If the needle is in or very near the RED segment at either end of the gauge, the extinguisher must be serviced or replaced. Make sure the safety pin B is fitted and secure. The extinguisher should be serviced every 12 months by a suitably qualified person.

Fig 39.

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Section B Body and Framework Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-8

Section B - Body and Framework

Notes:

B-0

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B-0

Section B - Body and Framework Contents Page No. Technical Data Air Conditioning (Option) .......................................................................... B-1 Basic Operation Load Moment Indicator (LMI) ................................................................... B-3 Cooling Pack ............................................................................................ B-4 Fault Finding Air Conditioning ........................................................................................ B-5 Load Moment Indicator (LMI) ................................................................... B-8 Fault Codes .......................................................................................... B-8 General Fault Finding ......................................................................... B-10 Diagnostic Tests ................................................................................. B-12 Service Procedures Rivet Nuts ............................................................................................... B-19 Fitting Procedure ................................................................................ B-20 Slide Hammer Kit .................................................................................... B-21 Fitting Procedure ................................................................................ B-21 Air Conditioning (Option) ........................................................................ B-22 Service Checks .................................................................................. B-22 Leak Testing ....................................................................................... B-22 Tightening Leaking Hoses .................................................................. B-22 Refrigerant Charging and Discharging ............................................... B-24 Binary Pressure Switch Testing .......................................................... B-29 Compressor Drive Belt - Adjustment .................................................. B-29 Condenser Matrix Cleaning ................................................................ B-30 Cab ......................................................................................................... B-31 ROPS, FOPS Structure - Checks ....................................................... B-31 Direct Glazing ..................................................................................... B-31 Boom Fork Carriage Removal and Replacement ............................................. B-37 Removal ............................................................................................. B-37 Replacement ...................................................................................... B-38 Boom Removal and Replacement .......................................................... B-39 Removal ............................................................................................. B-39 Replacement ...................................................................................... B-40 Dismantling and Assembly ..................................................................... B-42 Dismantling ......................................................................................... B-42 Assembly ............................................................................................ B-45 Boom Shim Adjustment .................................................................................... B-47 Articulated Joint Removal and Replacement .................................................................... B-55 Load Moment Indicator (LMI) Removal and Replacement .................................................................... B-61 Transducer ......................................................................................... B-61

B-i

Section B - Body and Framework Contents Contents Page No. Instrument Panels EMS Unit and Front Console .................................................................. B-63 Removal ............................................................................................. B-63 Replacement ...................................................................................... B-64 Side Switch Panel ................................................................................... B-65 Removal ............................................................................................. B-65 Replacement ...................................................................................... B-65 Hydraulic Tank Removal and Replacement .................................................................... B-67 Removal ............................................................................................. B-67 Replacement ...................................................................................... B-69 Hose Connections .............................................................................. B-69 Fuel Tank Removal and Replacement .................................................................... B-71 Removal ............................................................................................. B-71 Replacement ...................................................................................... B-71 Fuel Level Sender .............................................................................. B-73 Cab Removal and Replacement .................................................................... B-75 Removal ............................................................................................. B-75 Replacement ...................................................................................... B-78 Hose Connections .............................................................................. B-78 Internal Components .............................................................................. B-80 Front Floor Mat ................................................................................... B-80 Variflow Pump Access Panel .............................................................. B-81 Front Blind .......................................................................................... B-82 Roof Blind ........................................................................................... B-82 Roof Liner ........................................................................................... B-83 External Components ............................................................................. B-84 Door Handle Removal and Replacement ........................................... B-84 Door Removal and Replacement ....................................................... B-84 Air Conditioning (Option) Removal and Replacement .................................................................... B-85 Pressure Switch ................................................................................. B-85 Condenser .......................................................................................... B-86 Mudguards Removal and Replacement .................................................................... B-89 Front Mudguard .................................................................................. B-89 Rear Mudguard .................................................................................. B-90 Pneumatic Fan General Information ................................................................................ B-91 LiveLink General Information ................................................................................ B-93

B-ii

Section B - Body and Framework

Technical Data Air Conditioning (Option) Pressure Switch Settings

Set Pressure

Reset Pressure

Low Pressure

15 PSI (1.03 bar) Increasing

4 PSI (0.27 bar) Decreasing

High Pressure

390 PSI (26.8 bar) Increasing

320 PSI (22 bar) Decreasing

Refrigerant R-134a

1200g

Oil Type Quantities - Recharge the system (1) Component Replacement Condenser Evaporator Hoses Receiver Drier Compressor (1) The quantity of oil replaced should be the same as that taken out during `Recovery' procedure.

B-1

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Section B - Body and Framework Technical Data Air Conditioning (Option)

Page left intentionally blank

B-2

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Section B - Body and Framework

Basic Operation Load Moment Indicator (LMI) A transducer measures the load exerted on the rear chassis and sends a signal to the indicator display box. The display box warns the operator when the machine is nearing its maximum working limit (i.e. when it could tip forward). The display box converts the signal from the transducer mounted on the rear chassis into a display of LEDs. Three green LEDs 1-C, and amber LED 1-D will illuminate progressively as the load increases. All LEDs will flash as the load nears the maximum working limit. If the load exceeds the maximum working limit, the red LED 1-E will illuminate and an audible warning will activate.

E D

100%

C G

Green LED 1-G remains on whenever power is supplied to the display box. If a system fault is detected, the audible alarm will sound and various combinations of LEDs will illuminate to indicate a fault code, see Fault Finding.

Fig 1. Typical Indicator Display Box

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Section B - Body and Framework Basic Operation Cooling Pack

Cooling Pack The cooling pack comprises of four radiators joined together. The cooling pack splits horizontally. From the bottom upwards the cooling sections are for: hydraulic oil, engine coolant, charge air and transmission oil.

Table 1. Key to Figure 4 Upper Mounting Points

Lower Mounting Points

Transmission Cooler

The cooling pack sections are bolted together, therefore a single section can be replaced.

Charge Air Cooler

Engine Cooler

Should the need arise to remove the cooling pack, the air conditioning condenser matrix can be hinged away without the need to disturb any of its pipework connections. Refer to K Air Conditioning (Option) ( T B-85)

Hydraulic Oil Cooler

Section Securing Bolts

4 5 6 C52600

Fig 2. Cooling Pack - Rear and Side Views

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Section B - Body and Framework

Fault Finding Air Conditioning 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. However, if a leak detector is not available an approximate source of leakage can be found by applying soap solution to suspect areas.

Table 2. General Fault Indications There are several indications that may help to determine the fault area on a system not working efficiently: a)

Poor performance

Low accumulator pressure

Repair or renew accumulator Evacuate and recharge

Plugged orifice tube

Renew orifice tube Evacuate and recharge

Blower does not operate on all speeds

Compressor clutch continually cuts out

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

B-5

System does not provide cool air Water temperature control valve to heater coil not fully closed

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Adjust cable

B-5

Section B - Body and Framework Fault Finding Air Conditioning CHECK 1

Table 3. No Air Conditioning ACTION

Are the controls set correctly, i.e. air conditioning selected, YES: and blower switched on? NO:

Is the air conditioning fuse blown? (See section 3 for fuse YES: number)

Check 2 Reset controls and retest Renew fuse and retest

NO:

Check 3

Does the compressor clutch operate with 12V

YES:

Check 4

connected directly to the clutch?

NO:

Change clutch assembly

Is the blower working?

YES:

Check 5

NO:

Check the electrical connections to the blower switch, resistor and blower motor. If connections are correct, replace blower switch and retest. If blower motor will still not function, replace blower motor assembly.

YES:

Replace pressure switch and retest. If still not working check the refrigerant system pressure. If pressure is very low, the refrigerant charge has leaked from the system. Call in a qualified refrigeration engineer or a suitably trained person to determine the fault and recharge the system. If pressure is high, go to check 6.

NO:

Renew the compressor clutch and retest

Bypass the thermostat switch (i.e. disconnect the

YES:

Replace thermostat switch and retest

electrical leads and connect them together). Does

NO:

Check all electrical connections

Does the compressor clutch engage with the pressure switch bypassed?

the clutch work? Table 4. Compressor clutch cycles frequently, air conditioning performance is only moderate Is the condenser coil contaminated with debris? YES: Clean the condenser and retest. NO:

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The refrigeration system has an internal blockage. Call in a qualified refrigeration engineer or a suitably trained person to determine the fault

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Section B - Body and Framework Fault Finding Air Conditioning 1

B-7

Table 5. Air conditioning performance poor Check the operation of the blower. Is the blower operating YES: Check 2. on all three speeds?

Check the temperature of the compressor suction hose manually. Is the hose warm to the touch?

NO:

If the blower will not operate on any speed, replace the blower switch and retest. If the blower still does not function, replace the blower motor assembly.

YES:

The orifice tube is being bypassed. Call in a trained refrigerant engineer to replace the orifice tube valve and recharge the system.

NO:

There is an internal blockage in the refrigerant circuit. Call in a qualified refrigeration engineer or a suitably trained person to locate the fault and carry out repairs.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI)

Load Moment Indicator (LMI)

!MWARNING

Fault Codes When the system detects a fault, the audible alarm will sound and various combinations of LEDs on the display box will illuminate to indicate a fault code for approximately 10 seconds. Note that the audible alarm and fault code cancel after 10 seconds, all the LEDs on the display box will then flash continuously as long as the fault remains. To show the fault code for a further 10 seconds, press and release button 3A.

If the Load Moment Indicator is faulty, contact your JCB Distributor. Do not try to repair it yourself. 12-2-1-1

Important: A new display box will not be calibrated. Always calibrate the system when fitting a new display box, see Service Procedures.

When the fault clears, the display will return to normal.

Fig 4. System Fault Codes Fault Description Code

E D

100%

C G

K Table 6. Transducer signal fault ( T B-9)

K Table 7. Calibration out of range ( T B-9)

K Table 8. Calibration required ( T B-9)

K Table 9. Indicator display box faulty ( T B-9)

K Table 10. Low battery voltage ( T B-9)

If any fault codes are displayed, turn the Ignition key switch to OFF and then ON again. If the fault does not clear, K Diagnostic Tests ( T B-12).

Fig 3. Typical Indicator Display Box

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI) Possible Cause

Table 6. Transducer signal fault Remedy

Transducer not connected.

Check transducer connection.

Faulty harness.

Check for trapped or damaged wires.

Faulty transducer.

Check for water ingress. Replace transducer.

Possible Cause

Table 7. Calibration out of range Remedy

System is incorrectly calibrated.

Re-calibrate the system, see Service Procedures.

Transducer not fixed down correctly.

â&#x20AC;&#x201C; Check mounting surfaces are clean and flat. Check mounting bolts are not bottoming-out. â&#x20AC;&#x201C; Check tightness of transducer mounting bolts, see Transducer, Removal and Replacement.

Faulty transducer.

Possible Cause

Replace transducer and re-calibrate the system. Table 8. Calibration required Remedy

System not calibrated.

Possible Cause

Calibrate the system, see Service Procedures. Table 9. Indicator display box faulty Remedy

The display box has detected an internal error.

Possible Cause Battery voltage is below 9 Volts.

B-9

Turn the Ignition key switch OFF and then ON again. Replace the display box if the fault does not clear.

Table 10. Low battery voltage Remedy Check battery voltage. Do 12V Supply and Fuse Test (V1), K Diagnostic Tests ( T B-12).

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI)

General Fault Finding

performing checks and where applicable, specific tests on the system.

The fault finding procedures are given in the form of tables. The tables are designed to identify possible causes by Fault: K Table 11. Display box does not work. ( T B-10) K Table 12. The display box seems to go out of calibration. ( T B-10) K Table 13. System not functioning correctly ( T B-11) Table 11. Display box does not work. Action

Possible Cause Blown fuse.

Check fuses.

Display box faulty.

Do Display Box Functional Test, K Diagnostic Tests ( T B-12)

Display box not receiving 12V supply.

Do 12V Supply and Fuse Test (V1), K Diagnostic Tests ( T B-12)

Possible Cause

Table 12. The display box seems to go out of calibration. Action

Transducer not fixed down correctly.

Check torque of transducer fixing screws. Check transducer fixing screws are not bottoming out in their holes. Check mounting surfaces are clean and flat, see Transducer, Removal and Replacement.

Faulty transducer.

Replace transducer and re-calibrate the system, see Service Procedures.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI) Action

Table 13. System not functioning correctly Yes

Do 12V Supply and Fuse Test (V1) and record voltage, Go to 2. K Diagnostic Tests ( T B-12). 12V Supply OK?

Is the transducer 12V supply OK?

Check Ignition ON, fuse condition, battery condition, test Done box connections. Repair as required. OK now?

Go to 2

Is the display box OK?

Go to 6

Go to 7

Do Transducer 12V Supply Test (V2) and record voltage, K Diagnostic Tests ( T B-12). OK now?

Done

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

Are the transducer output signals OK?

Go to 8

Go to 9

Do Display Box Functional Test and re-calibrate, K Diagnostic Tests ( T B-12). OK now?

Done

Replace display box.

Can the display box be re-calibrated?

Go to 10

Go to 11

Do Transducer Output Test (V3) and Transducer Output Test (V4), K Diagnostic Tests ( T B-12). OK now?

Done

Go to 12

Has frequent re-calibration been required?

Possible transducer slipping. Remove the transducer, clean surfaces and re-torque bolts, see Transducer, Removal and Replacement.

Do Transducer Output Test (V3) and Transducer Output Test (V4), K Diagnostic Tests ( T B-12). OK now?

Replace display box.

Go to 13

Do Harness Wiring Continuity and Short Circuit Tests and repair as required. K Diagnostic Tests ( T B-12). OK now?

Done

Check for uneven mounting surfaces or bolt not tightened correctly, see Transducer, Removal and Replacement.

Check transducer fixed securely. OK now?

Suspect faulty transducer.

Possible transducer slipping. Remove the transducer, clean surfaces and re-torque bolts.

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Go to 4

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Go to 3 Go to 5

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI)

Diagnostic Tests If the calibration procedure fails to rectify a problem, there are three main areas where faults can occur: – Indicator display box – Transducer – Machine electrical harness

(1) The black lead of the multimeter should be connected to TP1 (earth) when measuring voltages. (2) Measures the current signal in the transducer return wire and converts this to a voltage which can be read by the multimeter. (3) Is a direct connection to the transducer return wire. The test box also has three switches, TEST 1/TEST 2, TRANS/BOSS, RUN/CHECK to change settings for the various tests.

LMI Test Box The service engineer can use either the LMI Test Box 5-A (see Section1, Service Tools) or a suitably calibrated multimeter to diagnose faults in the system down to component level.

The test box is connected between the four-pin plug and socket, which connect the display box to the machine wiring harness behind the instrument panel in the cab. 1

Remove the instrument panel and connect test box 6A to harness connectors 6-B and 6-C as shown.

Fig 5. The test box has five test points, TP1 to TP5 which allow current signals (mA) in the circuit to be read as voltages by connecting a digital multimeter. The test points also allow continuity and open/short circuit tests to be made. Table 14. Test Box Test Points Test Point Function TP1

(1)

TP2

Earth

Before carrying out the tests make sure that: a

Display box 12V supply

TP3

Transducer 12V supply

TP4 (2)

Transducer output (Signal)

TP5 (3)

Transducer output (voltage)

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Fig 6.

The machine is on level ground with the boom horizontal.

b The forks are fitted, with no load. c

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The boom is fully retracted.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI)

Transducer 12V Supply Test (V2) 1

The ignition key switch is ON, but the engine is not running.

Expected reading: Battery voltage 11.0V to 15.0V

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

101

601

Display Box

Set the test box switches to RUN / TRANS / TEST 1, then measure the voltage between test points TP1 and TP2.

414

Fuse

000

12V Supply and Fuse Test (V1)

Set the test box switches to RUN / TRANS / TEST 1, then measure the voltage between test points TP1 and TP3.

413

d Two-wheel drive is engaged (if fitted) and the machine has been driven backwards and forwards several times with the wheels in the straight ahead position.

TP3

Expected reading: Battery voltage 11.0V to 15.0V

TP1

Transducer

Fig 8. Transducer Supply Test (V2)

If the test box is not available, measure the voltage between the feed wire to the transducer (TP3) and earth (TP1).

601

TP2

Display Box

414

413

101

000

Fuse

TP1

If the expected reading is not obtained, check that the ignition key switch is ON. Check the condition of the fuse, and the battery. Check the wiring harness connections. Rectify as required. If the expected reading is still not obtained after completing the above checks, the display box should be renewed.

Transducer

Fig 7. Display Box Supply Test (V1) If the test box is not available, measure the voltage between the feed wire to the display box (TP2) and earth (TP1). 2

If the expected reading is not obtained, check that the ignition key switch is ON. Check the condition of the fuse, and the battery. Check the wiring harness connections. Rectify as required. For details of the wiring harness and connections, see Electrical Connections.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI)

Transducer Output Test (V3) - with Transducer Fitted

Park the machine (unloaded) on level ground with the engine running. Apply the parking brake and place the forward/reverse lever in the neutral position. The green LED 9-G at the bottom of the display will illuminate to show that the indicator is receiving power.

Set the test box switches to RUN / TRANS / TEST 1, then measure the voltage between TP1 and TP4. Expected reading: 4.3V to 4.7V

Important: This voltage cannot be measured using a voltmeter directly on the wiring. This voltage can only be measured via the test box (see Section 1, Service Tools).

Fuse

Display Box

414

100%

TP4

C G

601

000

E D

101

413

Display Box Functional Test

Transducer

TP1

Fig 10. Transducer Output Test (V3) If the test box is not available, disconnect the transducer harness from the machine wiring 11-M. Connect test harness (see Section 1, Service Tools) between the two connectors 11-E and 11-F. Connect the pins of the test harness to a good quality multimeter capable of reading milli-amps (mA). The expected reading should be 45 to 55 mA.

Fig 9. Typical Indicator Display Box 2

Press and release button 9-A. All LEDs on the indicator will flash and the audible alarm will sound if the unit is functioning correctly.

Fig 11. 2

If the expected reading is not obtained, one of the following faults is most likely: a

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Poor earth connection.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI) 3

b Poor feed connection. c

Set the test box switches to CHECK / TRANS / TEST 1. Turn OFF the ignition switch and check for continuity between the following points on the test box and the two pin connector 13-E that was connected to the transducer.

Poor installation of transducer.

If the wiring is suspected, check for possible harness faults, K Harness Wiring Continuity and Short Circuit Test ( T B-15).

Continuity Test: Switch the multimeter to the Ohms scale and measure the electrical resistance between:

If a transducer fault or incorrect transducer mounting is suspected, test the transducer output with the transducer removed from the rear chassis. K Transducer Output Test (V4) - with Transducer Removed ( T B-16).

- Test point TP3 and pin 2 of connector 13-E. - Test point TP5 and pin 1 of connector 13-E. Expected reading: Less than 3 ohms.

Harness Wiring Continuity and Short Circuit Test 1

Short Circuit Test: Measure the electrical resistance between:

Disconnect the display box harness 12-C from the test box, but leave the test box connected to the machine wiring harness 12-B.

- Test points TP1 and TP5 - Test points TP3 and TP5 - Test points TP1 and TP3 Expected reading: Open Circuit.

Fuse

Fig 14. Harness Continuity and Short Circuit Tests If the test box is not available, disconnect the display box harness from the machine wiring harness, turn OFF the ignition switch and using a multimeter check for continuity or short circuits in the harness wiring between the display box and transducer electrical connectors.

Fig 12. 2

Disconnect the transducer harness from the machine wiring harness 13-M.

If the expected readings are not obtained, check for damaged wiring and faulty connections. If the expected readings are obtained, but the expected voltage reading from Transducer Output Test (V3) is not achieved, test the transducer output with the transducer removed from the rear chassis. K Transducer Output Test (V4) - with Transducer Removed ( T B-16)

Fig 13.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI) Transducer Output Test (V4) - with Transducer Removed

If the transducer is not distorted, then the voltage V4 should be between 4.48V and 4.52V. If it is outside this range, but within 4.40V to 4.60V, the transducer may still be serviceable, providing the result of Transducer Output Test (V3) is satisfactory.

Remove the transducer from the rear chassis, reconnect to the machine wiring harness 16-M and support the transducer under the machine.

Set the test box switches to RUN / TRANS / TEST 1, then measure the voltage between TP1 and TP4.

If the transducer passes this test, having failed Transducer Output Test (V3), the apparent failure may be due to uneven transducer mounting.

Expected reading: 4.48V to 4.52V

Important: This voltage cannot be measured using a voltmeter directly on the wiring. This voltage can only be measured via the test box (see Section 1, Service Tools).

Fuse

101

Check mounting surfaces are clean, flat and free from paint and rust etc.

b Refit the transducer to the rear chassis and torque tighten the fixing screws, see Transducer, Removal and Replacement.

601

413

414

000

Display Box

TP4 Transducer V4

TP1

Fig 15. Transducer Output Test (V4) If the test box is not available, disconnect the transducer harness from the machine wiring 16-M. Connect test harness (see Section 1, Service Tools) between the two connectors 16-E and 16-F. Connect the pins of the test harness to a good quality multi meter capable of reading milli-amps (mA). The expected reading should be 47 to 53 mA.

Fig 16.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI) Test Results The following table may be used to record the values and must be submitted in the event of a warranty claim. If applicable, any warranty parts must also be returned with any additional information such as: which lights are not illuminating, or if the display box function test is not successful.

Test

Table 15. Test Results Expected:

Supply and Fuse Test (V1)

11.0 to 15.0V

Transducer Supply Test (V2)

11.0 to 15.0V

Transducer Output Test (V3)

4.3 to 4.7V

Transducer Output Test (V4)

4.48V to 4.52V

Actual:

45 to 55 mA

47 to 53 mA Note: When returning equipment under warranty, the results of the above tests MUST be stated. Important: The system must always be re-calibrated after performing the above tests, and before operating the machine. See Service Procedures.

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Section B - Body and Framework Fault Finding Load Moment Indicator (LMI)

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Section B - Body and Framework

Service Procedures Rivet Nuts TB-001_2

A 'Rivet Nut' is a one piece fastener installed 'blind' from one side of the machine body/framework. The rivet nut 17A is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread 17-B.

Table 16. Specifications Rivet Nut Rivet Nut Material Rivet Thread Outside Thickness Length Diameter Diameter (Total)

Drill Hole Dia.

7.10

M10

0.25 - 3.00

14.00

3.00 - 5.50

17.00

0.50 - 3.00

16.00

3.00 - 5.50

19.00

0.50 - 3.00

18.00

3.00 - 5.50

21.00

1.00 - 3.50

23.00

3.50 - 6.00

26.00

9.10 11.10 13.10

Note: All dimensions in mm Fig 17. Rivet nuts are fitted to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and hydraulic valve retention etc. Various sized rivet nuts are available. K Table 16. Specifications ( T B-19) to determine the size of rivet nut to be used for particular applications. If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed. K Fitting Procedure ( T B-20). Note: In an emergency, and if no installation tool is available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.

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Section B - Body and Framework Service Procedures Rivet Nuts

Fitting Procedure

(smooth bulge) seating itself against the body/ framework 20-E.

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

Screw the rivet nut onto the mandrel of the installation tool. The bottom of the mandrel should be in line with the bottom of the rivet nut 18-A.

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

Fig 20. Fig 18. 3

Remove the installation tool.

Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut 19-B.

Fig 19. 4

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

Hold handle 20-C and at the same time draw the mandrel into the installation tool by turning nut 20-D. The rivet nut will contract in length and form an 'upset'

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Section B - Body and Framework Service Procedures Slide Hammer Kit

Slide Hammer Kit TB-003

Fig 21. Typical M/c. Installation The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be 'knocked through'. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins. The adaptors 21-A that form part of the kit have a screwed thread at each end. One of the threads will always be M20 size, this is to accommodate the end stops, items 21-B and 21-C. The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.

Fit an end stop 21-B onto the other end of the adaptor (M20 thread size), make sure that the adaptor threads are fully engaged.

Fit the 'slide bar' 21-E into the end stop. Again make sure that the threads are fully engaged.

Fit the 'slide hammer', item 21-F, onto the slide bar as shown.

Finally, fit another end stop, item 21-C, at the end of the slide bar, as shown. The slide hammer kit is now ready to use.

Fitting Procedure 1

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

Determine the thread size of the pivot pin and then fit the appropriate adaptor 21-A as shown. Use the spanner flats 21-D to securely fit the adaptor.

To extract the pivot pin, slide the hammer along the bar until it contacts end stop 21-C. Repeat this step until the pivot pin is released.

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

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Section B - Body and Framework Service Procedures Air Conditioning (Option)

Air Conditioning (Option) Service Checks

Leak Testing

!MWARNING

The air conditioning system needs to be checked regularly to ensure efficient and safe operation. Before commencing any service operations, carry out a basic service check as described below: 1

Start the engine and operate at fast idle speed (1000 RPM).

Switch on the air conditioning and set to maximum cooling.

Note: The cab temperature needs to be above 20°C. At low ambient temperatures it may be necessary to operate the heating system to prevent the air conditioning system switching off. 3

Operate the engine at operating temperature for five to ten minutes.

Close the cab door and windows and allow the internal temperature to stabilize.

Measure the temperature at the evaporator outlets. The temperature should change as the compressor clutch cycles in and out. The outlet temperature with the clutch engaged should be significantly below ambient (4°C to 10°C) rising by 6°C to 8°C when the clutch disengages.

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

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

Tightening Leaking Hoses

Stop the engine when the tests are complete.

!MWARNING

Off-Season Operation During the off-season, the air conditioning system should be operated for at least five minutes every month to circulate the oil in the system to lubricate the fittings and seals. When operating the system, ensure that: 1

Engine idle speed is greater than 1000 RPM.

Ambient temperature is greater than 0°C.

Cab temperature is greater than 20°C.

The engine is at normal operating temperature.

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TB-004

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

The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an 'O' ring seal which compresses when the connection is tight, creating an air tight seal. Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion

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Section B - Body and Framework Service Procedures Air Conditioning (Option) valve (the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes). If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector up and repeat the leakage test. If leakage is still evident, it will be necessary to discharge the system and renew the connector 'O' ring seal.

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Section B - Body and Framework Service Procedures Air Conditioning (Option)

Refrigerant Charging and Discharging TB-005

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

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

The 'Javac' unit 22-E will automatically switch off when a pressure balance exists between the system and the receiver bottle. Switch off 'Javac' at main switch, but leave the system connected. Switch on after 10 minutes, the 'Javac' will restart if residual pressure remains.

Close valves and remove equipment.

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

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

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

Connect the manifold to the system as shown, with the blue hose 22-A connected to the system low pressure port. Do Not connect the red hose 22-B. Make sure that both valves are closed.

Connect the yellow hose 22-C to the 'Javac' unit filter 22-D.

Connect the filter 22-D to the 'Javac' unit 22-E.

Connect the 'Javac' unit 22-E to an empty receiver bottle 22-F. Weigh the bottle before and after filling to assess system capacity.

Fig 22. Refrigerant Recovery

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

Switch on 'Javac' unit 22-E and open the low pressure manifold valve.

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

Recover all refrigerant from K Refrigerant Recovery ( T B-24).

the

system.

Close all valves and connect the manifold as shown. Connect the blue hose 23-A to the system low pressure port and the red hose 23-B to the high pressure port.

Connect the yellow hose 23-C to the vacuum pump 23-D.

Fig 23. Evacuating

Note: If the Electronic Vacuum Gauge 23-E is used Vacuum connected as shown. K Electronic Gauge ( T B-26), for further information. 4

Open manifold valves.

Switch on the vacuum pump 23-D until 740mm (29 in) mercury vacuum reads on both gauges.

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

Maintain suction for approximately 30 minutes.

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

Close valves and remove equipment.

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Section B - Body and Framework Service Procedures Air Conditioning (Option) Electronic Vacuum Gauge

ATM/BAT

Normal atmospheric pressure reading. Battery condition.

15"/510mbar

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

29"/980mbar

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

8000

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

1000

1.0mm (0.039 in)Hg. Deeper vacuum.

600

0.6mm (0.023 in)Hg. Deep vacuum.

400

0.4mm (0.015 in)Hg. Deep vacuum.

200

0.2mm (0.0078 in)Hg. Deep vacuum.

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

A396790

Fig 24. The CPS VG100 vacuum gauge is an electronic type using LED's to indicate various states of vacuum. It is used in place of or to supplement the gauge on the vacuum pump. Before connecting into the system switch on to check that the first LED lights to show that the battery is in good condition. Note: The indicator lights show pressure in inches of mercury (Hg) and vacuum in microns (0.001mm Hg).

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

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

Close all valves and connect the manifold as shown, with the blue hose 25-A connected to the oil injector 25-E and the red hose 25-B to the system high pressure port.

Connect the yellow hose 25-C to the vacuum pump 25-D.

Connect the other end of the oil injector 25-E to the system low pressure point 25-F.

Switch on the vacuum pump 25-D and open the high pressure side valve.

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

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

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

F Fig 25. Relubricating

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

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B-27

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

Close all valves and connect the manifold as shown. Connect the blue hose 26-A to system low pressure and the red hose 26-B to system high pressure. Connect the yellow hose 26-C to the refrigerant cylinder 26-D.

Invert single valve cylinder on the scales 26-E and zero the scale reading

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

Fig 26. Charging

Slowly open the high pressure valve and allow the vacuum to draw-in refrigerant to the specified weight for the system. Refer to Technical Data. Add refrigerant until the scales 26-E indicate the specified weight for the system or the weight obtained when the system refrigerant was previously recovered.

Note: To speed up the process a thermostatically controlled thermal blanket 26-F can be used around the replenishing cylinder. 4

Close all valves and remove the equipment.

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B-28

Section B - Body and Framework Service Procedures Air Conditioning (Option)

Binary Pressure Switch Testing

Compressor Drive Belt - Adjustment

If the fault finding table indicates that the binary pressure switch assembly is defective the fault may be electrical or due to incorrect system pressure.

The air conditioning compressor is driven by the front end accessory drive belt (FEAD).

Before testing the binary pressure switch 27-A it is important to check the refrigerant charge level. If the refrigerant charge level is satisfactory, test the switch as described below: 1

The belt is automatically kept in tension so will not need to be adjusted. At the recommended service interval, visually inspect the belt for damage, see Section 3, Routine Maintenance.

Switch OFF the engine and remove the harness connectors 27-B from the pressure switch 27-A.

B A

Fig 27. 2

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

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

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

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B-29

Section B - Body and Framework Service Procedures Air Conditioning (Option)

Condenser Matrix Cleaning It is likely that over a period of time, because of the machine's working environment, the airflow around the condenser matrix will become restricted due to a build up of airborne particles.

If the build up of particles is severe, heat dissipation from the refrigerant to the air will be significantly reduced, resulting in poor air conditioning performance. In extreme cases, over-pressurisation of the system occurs, causing the high pressure cut-out switch to operate and switch off the system. High pressure cut-out can also be caused by an internal blockage of the condenser matrix. 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

Raise the engine cover.

Release fastener 28-A and hinge condenser 28-B away from the radiator. Clean both sides of condenser 28-B and the front of the cooling pack. Swing the condenser back into position and close the fastener.

Lower the engine cover.

Run the air performance.

B-30

conditioning

and

check

C052680

cooling Fig 28.

9803/9520-8

B-30

Section B - Body and Framework Service Procedures Cab

Cab

!MWARNING

ROPS, FOPS Structure - Checks For the correct procedure, see Section 3, Routine Maintenance.

Direct Glazing TB-002_6

The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken. 1

Always wear safety glasses during both removal and replacement.

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.

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. BF-1-8_1

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 park brake. Stop the engine. Put protective covers over the cab seat and control pedestals.

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

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). 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. 3

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

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

B-31

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.

9803/9520-8

Pneumatic Knife. K Fig 29. ( T B-32). This provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.

B-31

Section B - Body and Framework Service Procedures Cab ii

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

iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass. Fig 29. Pneumatic Knife i

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

Press the handle to start the knife blade oscillating.

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

vi Secure the second end of the braided cutting wire in the special handle D.

Insert the knife blade into the sealant.

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

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. b Braided Cutting Wire and Handles. K Fig 30. ( T B-32). This method uses a 3-core wire, a wire starter tube and two handles. i

Slowly remove the steel tube A.

Cut-out Knife. K Fig 31. ( T B-32). The cut-out knife can be used as a left handed or right handed tool.

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

Fig 31. Cut-out Knife Insert the knife blade into the sealant.

Make sure that the blade of the knife is against the glass A. K Fig 31. ( T B-32).

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

Fig 30. Braided Cutting Wire and Handles

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B-32

Section B - Body and Framework Service Procedures Cab d Craft Knife. K Fig 32. ( T B-33). The blades A are replaceable. i

Insert the knife blade into the sealant.

Pull the knife along and cut out the old sealant.

Preparing the Cab Frame Aperture 1

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

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

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

Preparing the New Glass

!MWARNING Fig 32. Craft Knife 4

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

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 33. ( T B-33).

Make sure that the new glass correctly fits the frame aperture A. K Fig 34. ( T B-34). a

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

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

1-2 mm

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 33. 6

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.

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B-33

Section B - Body and Framework Service Procedures Cab

Fig 36.

Fig 34. 2

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

After checking for size, remove the new glass and place it on a purpose made glass stand. K Fig 35. ( T B-34).

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

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 37. ( T B-34).

Fig 35. Glass Stand Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board, sourced locally to fit the glass stand. K Fig 36. ( T B-34). It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an antiscratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

B-34

Fig 37. 5

9803/9520-8

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

B-34

Section B - Body and Framework Service Procedures Cab 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 38. ( T B-35). 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

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-33) - 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.

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'.

Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position. K Fig 40. ( T B-35).

Fig 38. 6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide A against the edge of the glass and make sure that the adhesive forms a continuous 'pyramid' shape. K Fig 39. ( T B-35)

Fig 40. Typical M/c. Installation b Sit the bottom edge of the glass on the spacer blocks. K Fig 41. ( T B-36)

Fig 39.

B-35

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B-35

Section B - Body and Framework Service Procedures Cab minutes, but it must not be used during the curing period of 30 minutes. c

Clean the glass using a purpose made glass cleaner

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

Remove all broken glass from the cab area.

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

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

Fig 41. 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. 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

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. 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

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B-36

Section B - Body and Framework

Boom Fork Carriage Removal and Replacement

INT-3-1-11_2

+ # #$ Fig 42. 4

Support the carriage 42-2.

!MWARNING

INT-3-3-7_1

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Removal 1

Position the boom so that the fork carriage 42-2 can be safely supported when it is disconnected from the boom assembly.

Stop the engine, apply the park brake and remove the starter key. Operate the hydraulic controls to release any remaining hydraulic pressure.

Put a label on the carriage hoses to identify them. Disconnect the hoses at 42-1.

B-37

BF-4-1_1

Remove the bolt, washer and spacer 43-4. Using a punch or a drift remove the tipping lever pivot 43-3.

Remove the bolt, washer and spacer 43-9. Using a punch or a drift remove the boom nose pivot 43-10.

Remove the fork carriage 42-2.

9803/9520-8

B-37

Section B - Body and Framework Boom Fork Carriage Removal and Replacement

2 3 4 1 5

9 6

Fig 43.

Replacement Replacement is the opposite of removal. Do a check of the condition of the pivot bushes 43-2 & 437. Replace if damaged. Use new seals 43-1, 43-6 & 43-8. Do a check of the condition of the grease nipple 43-5. Clean if blocked or replace if damaged. Grease the pivot pins, see Section 3 - Service Schedules.

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B-38

Section B - Body and Framework Boom Boom Removal and Replacement

Boom Removal and Replacement

!MWARNING

Removal

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

Note: The total boom assembly has a mass of approximately TBA. The lift ram has a mass of approximately 120kg (265lb). Make sure the ram is safely supported at all times to prevent personal injury and damage to the machine and equipment.

!MWARNING

INT-1-3-7_2

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

BF-4-1_1

Park the machine on firm level ground and apply the parkbrake.

Remove boom attachments, including the forks and fork bar.

Support the boom from above using a sling in the semi-raised position to get access to the lift ram rod end.

Support the lift ram then disconnect the lift ram rod end by removing the nut 45-8 and bolt 45-9.

Using the slide hammer kit, see Section 1 - Service Tools, remove the pivot pin 45-7. Lower the ram onto packing material to prevent damage to the piston rod.

Support the displacement rams then disconnect the rod end of the rams by removing nut 45-11 bolt 45-12.

Using the slide hammer kit, see Section 1 - Service Tools, withdraw the pivot pin 45-10. Lower the ram onto packing material to prevent damage to the piston rod.

Stop the engine and operate the hydraulic controls to release the remaining system pressure.

Loosen the filler cap to release remaining pressure in the hydraulic tank.

Remove the extension ram hose clamps 45-1A.

Put a label on the extension ram hoses to identify them and disconnect the hoses at 45-1B.

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B-39

INT-3-1-11_2

B-39

Section B - Body and Framework Boom Boom Removal and Replacement 12

Remove the boom strap bolts 45-3.

Remove the boom strap 45-2.

Remove the front pivot nut 45-5 and bolt 45-4.

Using the slide hammer kit, see Section 1 - Service Tools, remove the pivot pin 45-6.

Raise the boom.

Using a sling, support the boom in the raised position.

Make sure the boom is fully supported. Remove nuts 45-14, bolts 45-17 and the pivot pin 45-18.

Note: Make sure to keep the shims 45-19. 19

Using the lifting equipment gently move the boom towards the front of the machine to get access to the boom hose connections. Be careful not to strain or damage the hoses.

Disconnect the tilt ram hoses 45-22 and auxiliary hoses 45-23 at the manifold 45-21.

Make sure the extension ram hoses 45-20 & 45-24 will not get caught or damaged when lifting the boom away from the machine.

Carefully lift the boom away from the machine K Fig 44. ( T B-40), checking for any remaining connections. Lower the boom onto packing material.

C052720

Fig 44. Lifting the Boom

Replacement Replacement is the opposite of Removal. Do a check of the hydraulic oil level and add oil if necessary. Do a check of the condition of the pivot bushes 45-16 and seals 45-15. Replace if damaged. Do a check of the condition of the grease nipples 45-13. Clean if blocked or replace if damaged. Grease the pivot pins, see Section 3 -Service Schedules.

Item

Table 17. Torque Settings Nm

45-22 & 45-23

B-40

9803/9520-8

44-50

lbf ft

32.5-37

B-40

Section B - Body and Framework Boom Boom Removal and Replacement

22 23

24 16

19 17

15 13

3 12 10

9 5

6 7

8 Fig 45.

B-41

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B-41

Section B - Body and Framework Boom Dismantling and Assembly

Dismantling and Assembly Unless the boom fabrications are damaged it is not necessary to divide the boom sections. To divide the boom it must be first removed from the machine. Note: It is not necessary to divide or remove the boom to do the procedures that follow: – Extension ram removal and replacement. See Section E - Hydraulics.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Dismantling 1

Remove the fork carriage. K Fork Carriage Removal and Replacement ( T B-37).

Remove the boom from the machine K Boom Removal and Replacement ( T B-39)

Remove the hydraulic rams from the boom Section E - Hydraulic Rams.

Remove the telescopic hydraulic service hoses. To prevent hoses becoming damaged or tangled, remove the hoses before dividing the boom sections. See Section E - Boom Internal Pipes and Hoses.

Remove the inner boom 46-1

– Tilt ram removal and replacement. See Section E Hydraulics. – Front wear pads and shims. See Section B - Boom Shimming – Displacement ram removal and replacement. See Section E - Hydraulics.

INT-1-3-7_2

!MWARNING

b Put a label on all the wear pads and keep them together with their shims.

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.

Lift the front of the inner boom 46-1 clear of the lower wear pads 46-3 & 46-4 and then remove them.

d Make sure the front end of the inner boom 46-1 is supported and pull it out half way from the outer section 46-2. Attach suitable lifting equipment to the inner section and pull it out from the outer section.

INT-3-1-11_2

Make sure that the boom assembly is supported by the outer boom and then remove the front upper wear pads 46-6 and the side wear pads 465.

Remove the rear wear pads 46-7, 46-12 & 46-13. Put a label on all wear pads and keep them together with their shims.

INT-3-3-7_1

B-42

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B-42

Section B - Body and Framework Boom Dismantling and Assembly

11 10 9

12 8

2 3

Fig 46. 7

Remove the hose tray guides 46-10 by removing the screws 46-11 which attach them to the boom.

B-43

9803/9520-8

Undo the screws 46-8 and remove the hose tray guide wear pad 46-9.

B-43

Section B - Body and Framework Boom Dismantling and Assembly 9

Remove the tipping link and "Z" link assembly

Undo the bolt 47-16 and remove the spacer.

Support the "Z" link assembly 47-5 and pull out the pivot pin 47-17. (The thrust washers 47-1 & 47-15 may fall at this stage - make sure to keep them safe).

Undo the bolts 47-13 & 47-14 and keep the washers and spacers.

b Support the tipping link 47-7 and pull out the pivot pins 47-10 from the boom nose. c

g Remove the "Z" link 47-5 through the front of the boom nose.

Remove the tipping link 47-7 through the front of the boom nose.

h Remove the spacers 47-2 & 47-6 and seals 47-3. d Remove the seals 47-8 and spacers 47-9.

3 6

5 W 15

1 2

17 18 3 16

9 10 11 8

8 12

Fig 47.

B-44

9803/9520-8

B-44

Section B - Body and Framework Boom Dismantling and Assembly

Assembly

Item

Assembly is the opposite of dismantling but note the instructions that follow:

Table 18. Torque Settings68 Nm lbf ft

kgf m

46-8

3.05

46-11

6.11

Important: When the boom assembly has been removed from the machine make sure that it is securely supported. When the inner boom section is removed, forces may cause the whole assembly to move. 1

Do a check of the hose pair lengths. The hose lengths must be equal +/- 1 mm for each service pair (tilt ram pair, and auxiliary service pair).

DO NOT replace individual hoses. The hoses can stretch over time. It is possible that new hoses will not be the same length. Replace all four telescopic service hoses if one or more of the hoses are damaged.

Assemble the boom sections so that the boom is fully retracted.

Note: To align the rod end pivot of the extension ram, the hydraulic hoses must be fitted so that the boom can be extended. 4

Make sure that the hose routing is correct. DO NOT let the hoses go across each other.

When assembling the "Z" link 47-5 and tipping link 477 do an inspection of the items that follow: a

Examine the spacers 47-2, 47-6 & 47-9 for wear or damage. Replace as necessary.

b Use new seals 47-3 & 47-8. c

Examine the grease nipples 47-4, 47-11, 47-12 & 47-18 to make sure they are not blocked or damaged. Clean or replace as necessary.

d Examine the thrust washers 47-1 & 47-15 for wear Replace as necessary. e

Apply JCB High Strength threadlocker to the bolt 47-16.

Grease the pivot pins, see Section 3 -Service Schedules.

Measure the boom wear pad shimming to make sure it is correct see Section B - Boom Shimming.

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B-45

Section B - Body and Framework Boom Dismantling and Assembly

Page left intentionally blank

B-46

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B-46

Section B - Body and Framework

Boom Shim Adjustment This procedure gives the instructions for shimming the boom wear pads. If it is necessary to replace the shims in the rear of the boom, remove the boom from the machine. Below the pads are shims for the adjustment of the boom clearance. Partly worn pads may have shims added or removed to give the correct clearance.The pads must be replaced when or before they have worn down to a level as shown at 48-A. Front Lower Wear Pads 1

Park the machine on firm level ground and apply the parkbrake.

Chock both sides of all four wheels.

Lift the boom so that the forks / carriage are clear of the ground.

Measure the distance 48-B between the lower inner and outer boom faces. If this measurement is below the limits given K Table 19. Measurements ( T B-48) add or remove shims under the lower wear pads 49-2 & 49-3 to give the correct dimension.

Lower the forks / carriage to the ground so that there is no weight on the lower wear pads.

Remove the lower wear pad retaining bolts and add shims as necessary to give the correct dimension.

Measure the total thickness of the shims under each pad.

There must be 8-10 mm of thread engaged between the bolt thread and the wear pad assembly. This can be adjusted by adding or removing the wear pad retaining bolt washers. The bolt thread must not protrude beyond the surface of the wear pad insert.

Install the shims and torque tighten the bolts K Table 22. Torque Settings ( T B-53).

Note: On assembly of the carriage or bucket, check that the height of the left and right hand ends are equal. If there is a difference in height adjust the shims under the lower wear pads at section A-A K Fig 50. ( T B-52). The shims can be adjusted to a maximum shim difference of 3 mm. Make sure there is 8-10 mm of thread engaged between the bolt thread and the wear pad assembly. This can be adjusted by adding or removing the wear pad retaining bolt washers.

Note: At the initial vehicle build, two washers are installed below the head of the retaining bolt. 9

Apply a coating of JCB High Strength Threadlocker to the bolts before fitting.

B-47

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B-47

Section B - Body and Framework Boom Shim Adjustment

E A F

B Fig 48. Boom Shim Wear Pads

Dimension B

Table 19. Measurements Lower inside face of outer boom to underside of inner boom Standard 17 mm < 15 mm (0.59 in) add shims

Dimension E Vertical clearance (Front and rear) Max 2.0 mm (0.07 in) Dimension F

Total side clearance (Front and rear) Max 2.0 mm (0.07 in)

retaining bolt washers. The bolt thread must not protrude beyond the surface of the wear pad insert. 7

Apply a coating of JCB High Strength Threadlocker to the bolts 50-5 before fitting.

Install the shims and torque tighten the bolts K Table 22. Torque Settings ( T B-53).

Front Top Wear Pads 1

Park the machine on firm level ground and apply the parkbrake.

Chock both sides of all four wheels.

Lift the boom until the inner boom is resting on the lower wear pads.

Measure the distance 48-E between the upper inner and outer boom faces. If this measurement is below the limits given K Table 19. Measurements ( T B-48) add or remove shims under the top wear pads 49-5 to give the correct dimension.

Measure the total shim thickness of shims under each pad.

There must be 8-10 mm of thread engaged between the bolt thread and the wear pad assembly. This can be adjusted by adding or removing the wear pad

B-48

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B-48

Section B - Body and Framework Boom Shim Adjustment

4 3

Fig 49.

B-49

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B-49

Section B - Body and Framework Boom Shim Adjustment Front Side Wear Pads

Measure the total thickness of shims under each pad.

Park the machine on firm level ground and apply the parkbrake.

Chock both sides of all four wheels.

Lift the boom so that the forks / carriage are clear of the ground.

Pull the inner boom to one side and measure the total side clearance 48-F between the side wear pads 494 and the inner boom.

Note: At the initial vehicle build, two washers are installed below the head of the retaining bolt. 6

Apply a coating of JCB High Strength Threadlocker to the bolts before fitting.

Loosen the side wear pad bolts and shim as necessary. Divide the number of shims equally between both sides to make sure the inner boom runs centrally in the outer boom.

Install the shims and torque tighten the bolts K Table 22. Torque Settings ( T B-53).

Replace the boom.

Measure the total thickness of shims under each pad

Rear Lower Wear Pads

Remove the boom See Section B - Boom Removal and Replacement.

Position the inner boom so that it is resting on the lower wear pads.

Note: At the initial vehicle build, two washers are installed below the head of the retaining bolt.

Apply a coating of JCB High Strength Threadlocker to the bolts before fitting.

Refit the shims and torque tighten the bolts K Table 22. Torque Settings ( T B-53).

Wedge or lift the inner boom slightly to remove the load on the lower wear pads 49-6.

Note: For initial application of bolt sizes and their locations K Table 20. ( T B-52).

Remove the lower wear pad retaining bolts and add shims as necessary to give the correct dimension.

Rear Side Wear Pads

Measure the total thickness of the shims under each pad.

Remove the boom See Section B - Boom Removal and Replacement.

Pull the inner boom to one side and measure the total side clearance 48-F between the side wear pads 497 and the inner boom.

Loosen the side wear pad bolts and shim as necessary. Divide the number of shims equally between both sides to make sure the inner boom runs centrally in the outer boom.

B-50

Note: At the initial vehicle build, two washers are installed below the head of the retaining bolt. 8

9803/9520-8

Apply a coating of JCB High Strength Threadlocker to the bolts before fitting.

B-50

Section B - Body and Framework Boom Shim Adjustment 9

Install the shims and torque tighten the bolts K Table 22. Torque Settings ( T B-53).

Replace the boom.

Rear Upper Wear Pads 1

Remove the boom See Section B - Boom Removal and Replacement.

Make sure the inner boom is resting on the lower wear pads to take any load off the upper wear pads 49-8.

Measure the total shim thickness of shims under each pad.

Apply a coating of JCB High Strength Threadlocker to the bolts before fitting.

Install the shims and torque tighten the bolts K Table 22. Torque Settings ( T B-53).

Replace the boom.

B-51

9803/9520-8

B-51

Section B - Body and Framework Boom Shim Adjustment

8 6

4 2

6 1

A436520

Fig 50. Boom Shim Locations Table 20.

B-52

ITEM NO.

QUANTITY USED

DESCRIPTION

WEAR PAD

SHIM PLATE 1.6 mm

SCREW M10 X 25

SET SCREW M10 X 30

BOLT M10 X 40

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B-52

Section B - Body and Framework Boom Shim Adjustment ITEM NO.

QUANTITY USED

DESCRIPTION

M10 PLAIN WASHER

SHIM PLATE 0.5 mm

M8 SOCKET SCREW

BUTTON HEAD SCREW

SHIM PLATE 1.5 mm

SHIM PLATE

Table 21. Shims and Washers PAD POSITION

SHIM THICKNESS UNDER PAD (mm)

NUMBER OF WASHERS ITEM 6 UNDER BOLT HEAD

FRONT BOTTOM

1.5 (STANDARD)

FRONT TOP

1.5 (STANDARD)

FRONT SIDE

1.5 (STANDARD)

REAR BOTTOM

1.5 (STANDARD)

REAR TOP

1.5 (STANDARD)

REAR SIDE

1.5 (STANDARD)

Item

Table 22. Torque Settings Nm lbf ft

50-3,4,5 50-9

B-53

60 50

kgf m

44 36.9

6.11 5.1

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B-53

Section B - Body and Framework Boom Shim Adjustment

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B-54

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B-54

Section B - Body and Framework

Articulated Joint Removal and Replacement If wear is evident in the articulated joint the bushes and seals must be renewed. Worn bushes will cause a knocking noise from the area of the articulated joint, particularly when starting/stopping or changing steer direction of the machine. Note: Worn steer ram pivots may also cause knocking. Before removing the articulated joint check the condition of the steer ram pivot pins and bushes. To facilitate removal of the joint, the two halves of the machine must be separated. This procedure must be carried out in a workshop equipped with a suitable overhead crane. Prepare the Machine 1

Remove any attachments, lower the loader arm to the ground. Stop the engine and operate the controls to release any trapped hydraulic pressure.

Securely chock the front and rear wheels and then disconnect the propshaft from the front axle see Section F Front Axle.

K Fig 51. ( T B-56) Undo the 6 Verbus Ripp bolts 1 and remove the retaining plate 2. Retrieve any shims 3.

B-55

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B-55

Section B - Body and Framework Articulated Joint Removal and Replacement 3

5 6 7

2 23B 22

19 23A

24 20 21

9 25

4 26 21

A 11

10 18

27 17 16 14 13 12

C052420

Fig 51.

B-56

9803/9520-8

B-56

Section B - Body and Framework Articulated Joint Removal and Replacement

50mm (6 in)

Fig 52. Separating the Machine Halves 1

Remove the lock bolt(s) X and drive out the steer ram pivot pin(s) Y as shown at A.

Tag and disconnect the loader hydraulic hoses at their connections above the articulated joint.Disconnect the front chassis electrical harness multiplug from the main harness.Arrange slings to the two lifting points located on the front chassis K Fig 52. ( T B-57). Using an overhead crane lift the front of the machine until it is 150 mm (6 in) clear of the ground.Lower the machine onto suitable block supports under the rear chassis.Remove the chocks from the front wheels and operate the overhead crane to draw the loader end of the machine forward and at the same time down approximately 75 mm (3 in) until the oscillation pivot is disengaged from the rear chassis.Lower the loader (front) end of the machine on to suitable blocks placed under the chassis. Chock the front wheels.

Push and pull the articulated joint up and down to check for any play in the vertical pivot bushes 18 and 20 K Fig 51. ( T B-56). If any play is detected the bushes must be renewed.

K Fig 51. ( T B-56)Attach the overhead crane to the articulated joint 4 using a suitable sling. Remove the bolts 5, washers 6, 7 and remove the top pivot cover 8. Retrieve the `O' ring grease seal 9.Loosen the lock nut 10 K Fig 51. ( T B-56). Remove the lock bolt 11.Carefully remove the bolts 12K Fig 51. ( T B-56). If the pivot pin 15 is a loose fit it may drop out as the cover 16, O' ring grease seal 17 is removed. Be ready to support the pivot pin. If necessary use a suitable drift to drive out the pin from above.Using the overhead crane remove the articulated joint 4 from the chassis K Fig 51. ( T B-56).Check for wear in the oscillation bushes 22 as follows K Fig 51. ( T B-56):

Inspecting the Articulated Joint

B-57

9803/9520-8

Use the overhead crane to re-assemble the articulated joint 4 to the front chassis. Temporarily re-fit the shims 3 and retaining plate 2 using two original Verbus Ripp bolts 1.

B-57

Section B - Body and Framework Articulated Joint Removal and Replacement b Push and pull the articulated joint up and down and from side to side to check for any play in the bushes. If any play is detected the bushes must be renewed. c

The oscillation and vertical pivot bushes can be driven out of the chassis using suitable drifts.

When removing the top vertical pivot bush 20 retrieve any shim(s) 19 located between the shoulder and the chassis K Fig 51. ( T B-56).Fitting new vertical pivot bushes:

Remove the articulated joint from the rear chassis. Discard all 6 Verbus Ripp bolts.

Renewing the Bushes

K Fig 51. ( T B-56) Before renewing the bushes, carefully inspect pivot pin 15, articulated joint 4 and ring spacer 24 bearing faces for signs of wear or damage. Clean off all dirt, rust and grease from the relative areas of joint components and chassis. If maintenance has been neglected or the grease seals have been damaged, water ingress may have caused rust damage. If there are signs of wear or damage, components should be renewed as applicable. If necessary the ring spacer 24 can be removed from the articulated joint using a soft faced hammer. Bushes must be renewed as pairs.

b Using a suitable micrometer, measure the distances shown at D1 and D2 K Fig 53. ( T B-58). c

Using a suitable portable hydraulic press, pull in the bottom bush 18 K Fig 53. ( T B-58). As the bush is drawn in, blow any shards of bronze clear of the bush shoulder, making sure the bush seats correctly in the chassis.

Calculate the shim thickness as follows: Nominal dimension = 202 mm (7.953 in) Clearance required for articulated joint = min. 0.1 mm (0.004 in) max 0.3 mm (0.012 in) Shim thicknesses available - 0.25 (0.01 in) and 0.5 mm (0.02 in) Example D1 = 202.65 mm, D2 = 202.75 mm. Use smallest dimension i.e. D1 202.65 - 0.5 = 202.15 (inside tolerance) 202.65 - 0.25 = 202.4 (outside tolerance) Use one 0.5 mm shim.

d Place the required shim(s) 19 over the bush 20 and draw the bush up into the chassis using the press, blowing bronze shards clear as with the bottom bush. e

Fit new seals 21 around the shoulders of the bushes.

Fig 53.

B-58

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B-58

Section B - Body and Framework Articulated Joint Removal and Replacement 7

If ring spacer 24 has been removed or is to be renewed, locate it over the articulated joint and drive it home with a soft faced hammer.

Note: Make sure that the new grease seal 23A is in position between the articulated joint and the chassis. K Fig 51. ( T B-56) 8

Use the overhead crane to manoeuvre the loader (front) section of the machine onto the articulated joint. If difficulty is experienced, a 3/4 UNC bolt and suitable plate can be used in the end of the joint to draw the sections together.

When you are sure that the sections are fully together check the shim requirements between the rear chassis and articulated joint. a

b Measure the gap C between the shoulder of the bush and the retaining plate using suitable feeler gauges. If there is no gap, increase the shim stack until there is. Measure the gap.Calculate the total shim thickness required to give a gap of 0.1 mm (0.004 in) (min.) to 0.3 mm (0.012 in) (max). Select the required shims. Shims are available in 0.25 mm (0.01 in) and 0.5 mm (0.02 in) thickness.

Fig 54. 3

Fit a new grease seal 23B K Fig 55. ( T B-60). Fit the required shims together with retaining plate 3.Use new Verbus Ripp bolts 1 and progressively torque tighten to 120 Nm (88 lbf ft).If the articulated joint 4 has been renewed or the steer ram pivot castings 25 have been removed, replace the castings. K Fig 51. ( T B-56) Torque tighten the nuts 26/bolts 27 to 670 Nm (68.3 kgf m 494 lbf ft).

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B-59

Fitting new oscillation bushes K Fig 51. ( T B-56): a

Coat the outer diameter of new bushes 22 with JCB Threadlocker and Sealer.

b Using a suitable portable hydraulic press pull in the front and rear bushes into the front chassis simultaneously. 4

Fit a new grease seal 23A K Fig 51. ( T B-56).

K Fig 51. ( T B-56) Use the overhead crane to fit the articulated joint 4 to the front chassis. Orientate pivot pin 15 as shown. Fit the pin in the joint, aligning the lock bolt location hole Z with the threaded hole for lock bolt 11. Fit and tighten the lock bolt and then the lock nut 10.

Locate new `O' rings 9 and 17 and fit the top (8) and bottom (16) covers, orientating the grease points so that they are both accessible from one side of the machine.

B-59

Temporarily fit shims 3 of a known thickness together with retaining plate 2 as shown. K Fig 55. ( T B-60).

Section B - Body and Framework Articulated Joint Removal and Replacement

Fig 55.

B-60

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B-60

Section B - Body and Framework

Load Moment Indicator (LMI) Removal and Replacement Transducer Removal

Wait at least 30 minutes for the adhesive to cure before moving to the next step.

Calibrate and test the Load Moment Indicator system.

Carry out General Safety procedures. See Routine Maintenance (section 3). The Load Moment Indicator is bolted to the rear chassis frame, near the articulated joint.

C052690

Fig 56. TO MH 20/4/07

Disconnect the transducer harness connector.

Remove the transducer securing screws and washers. Lift off the transducer. (It may be adhering to the surface due to the Loctite used during fitment.)

Replacement 1

Thoroughly clean the mating faces of the transducer and chassis. If a degreasing agent is used ensure it is of the non-oily type which does not leave a residue. Ensure all traces of old sealant are removed.

Apply a thin film of Loctite 648 (JCB Part No. 4101/ 0600) to the flat metal surface of the transducer, ensuring that the adhesive is spread evenly and covers the entire surface.

Place the transducer in position, ensuring that the lead is on the correct side. Secure with the screws and washers.

Reconnect the harness connector.

B-61

Item Transducer securing screws(1)

Table 23. Torque Settings Nm kgf m 70

7.1

lbf ft 52

(1) Dry bolt (i.e. not lubricated).

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B-61

Section B - Body and Framework Load Moment Indicator (LMI) Removal and Replacement

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B-62

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B-62

Section B - Body and Framework

Instrument Panels EMS Unit and Front Console Removal

C 1

Remove the four screws 58-D that hold the EMS unit, unplug and remove the unit.

Mark the position of the steering wheel on the splined shaft.

Remove the steering wheel. K Fig 57. ( T B-63).

Fig 58.

D E

Fig 57. 4

Remove the two screws on the top of the steering column upper surround.

Remove the two button head screws 58-A, remove the steering column lower surround.

Remove the two button head screws 58-B and remove the steering column upper surround.

Remove the steering column switch retaining plate screw 59-D.

Lift of the switch retaining plate 59-E.

Remove the switch covers 59-F.

Disconnect the harness connectors at 59-J.

B-63

F F

J K Fig 59.

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B-63

Section B - Body and Framework Instrument Panels EMS Unit and Front Console 11

Unscrew the retaining screw 59-K from the switch collar 59-G.

Pull the column switches 59-H away from the column.

Prise out the air vents 60-L from the front console 60M.

Unscrew the four console retaining screws 60-N.

Pull the console 60-M up and away from the steering column.

M L

L N

Fig 60.

Replacement Replacement is the opposite of the removal procedure.

B-64

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B-64

Section B - Body and Framework Instrument Panels Side Switch Panel

Side Switch Panel Removal

G H

Unscrew the two securing screws 61-A and tilt the facia panel 61-B away from the shroud 61-C to unhook the lugs on the opposite side of the panel.

Disconnect the wiring connectors on the rear of the panel 61-B.

To remove the switches pull off the switch cover 61-G.

Prise out the switch assembly 61-H from the panel 61-B.

To remove the temperature control, fan or airconditioning switches, first pull the knob 61-D from the panel.

The control switch decals will lift away from the panel 61-B.

Remove the control switch assembly from the rear of the panel 61-B.

D D D

To remove the ignition switch 61-F, unscrew the bezel 61-E from the switch.

Remove the switch 61-F from the rear of the panel 61B.

B-65

Fig 61.

Replacement Replacement is the opposite of the removal procedure.

9803/9520-8

B-65

Section B - Body and Framework Instrument Panels Side Switch Panel

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B-66

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B-66

Section B - Body and Framework

Hydraulic Tank Removal and Replacement Removal

Disconnect the hydraulic feed and return hoses at the tank connectors B.

Park the machine and make it safe. Vent the hydraulic pressure. Obey the General Safety procedures, see Section 2 - General Procedures

Support the tank.

Remove the bolts from the front mountings C.

Working below the machine, remove the bolts A from the inner side of the chassis.

Remove the fuel tank from the machine.

K Fig 62. ( T B-68)

Lift the engine canopy. See Section 3 - Access Panels.

Remove the drain plug D and drain tank contents into a suitable clean container.

Remove the battery E, see Section C - Battery.

Disconnect the hydraulic hose to the filter F.

!MWARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Working below the machine, put a label on each hose before disconnecting to help identification when replacing. K Hose Connections ( T B-69)

B-67

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B-67

Section B - Body and Framework Hydraulic Tank Removal and Replacement

B B

A A B B A

B C C

D Fig 62.

B-68

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B-68

Section B - Body and Framework Hydraulic Tank Removal and Replacement

Replacement

Hose Connections

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Make sure the hydraulic hoses are connected to the correct connectors. K Fig 63. ( T B-69) Use a new seal when installing the drain plug 62-D.

Make sure all hose connections are tightened to the correct torque. K Table 24. Torque Settings ( T B-69)

Fill the tank with clean hydraulic fluid. See Section 3 Hydraulics. Bleed the hydraulic system, see Section E - Hydraulics. Start the engine and check for leaks.

Item

Table 24. Torque Settings Nm kgf m

63-A

44-50

4.48-5.09

lbf ft 32.4-36.8

63-B

58-65

5.91-6.62

42.7-48

63-C

102

10.4

75.2

63-D

102

10.4

75.2

63-E

44-50

4.48-5.09

32.4-36.8

63-F

2.75

63-G

33-40

3.36-4.07

24.3-29.5

B-69

G Fig 63. Hydraulic Tank Hose Connections Item

K Fig 63. ( T B-69)

Supply to SRS valve

Supply to main pump

To trailer brake valve (Longer hose connects to top port - N)

To trailer brake valve (Shorter hose connects to bottom port R)

From brake pedal

`T' Adaptor

Hydraulic return

9803/9520-8

B-69

Section B - Body and Framework Hydraulic Tank Removal and Replacement

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B-70

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B-70

Section B - Body and Framework

Fuel Tank Removal and Replacement Removal K Fig 64. ( T B-72) Carry out General Safety procedures, see Section 2 General Procedures.

!MWARNING

Working below the machine, remove the bolts E and G from the inner side of the chassis.

Remove the fuel tank from the machine.

Replacement Replacement is the opposite of the removal procedure.

Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels.

During the replacement procedure do this work also: Make sure to install the hoses A to the correct tank connectors. Use a new seal when installing the drain plug F.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

Lift the engine cover, see Section 3 - Engine Canopy.

Remove the cable tie and disconnect the fuel level sender unit connector B.

Remove the drain plug F and drain fuel tank contents into a suitable clean container.

Put a label on each hose before disconnecting to help identification when replacing. Disconnect fuel feed and return hoses A.

Remove the bolts D and lift hoses and clamps away from the tank.

Fill the tank with clean fuel. Make sure all connections are tight and check for leaks.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Support the tank.

Remove the bolts from the front mountings C.

B-71

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B-71

Section B - Body and Framework Fuel Tank Removal and Replacement

A A

G G

E C

D Fig 64.

B-72

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B-72

Section B - Body and Framework Fuel Tank Removal and Replacement

Fuel Level Sender

make sure the harness connector A is pointing to the engine compartment.

K Fig 65. ( T B-73)

Removal 1

Park the machine and make it safe, see Section 2 General Procedures.

Lift the engine cover, see Section 3 - Engine Canopy.

Remove the cable tie and disconnect the fuel level sender unit connector A.

Put marks on the sender unit B and the tank to show the position to help replacement.

Remove bolts C and carefully remove the fuel level sender from the tank.

C C

D Fig 65.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: Make sure to fit a new gasket D. Align the sender unit with the marks made on the tank during the removal procedure. If a new unit is installed

B-73

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B-73

Section B - Body and Framework Fuel Tank Removal and Replacement

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B-74

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B-74

Section B - Body and Framework Cab Removal and Replacement

Cab Removal and Replacement Removal

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-4-1_1

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Vent the hydraulic, steering and braking system, see Section 2 - General Procedures.

Lift the engine canopy and disconnect the battery, see Section 2 - General Procedures.

Working outside the cab remove the bolts B from the steer unit cover A. K Fig 66. ( T B-75).

Remove the front K Fig 66. ( T B-75).

Put a label on the steer unit hydraulic hoses to aid identification when replacing. Disconnect the hoses from steering unit. Cap all open ports to prevent loss of fluid and ingress of dirt. K Fig 71. ( T B-79)

steer

unit

cover

A. C076670

Make sure that all of the wheels are chocked and release parking brake. Disconnect parking brake cable 68, see Section G Brakes. K Fig 68. ( T B-77).

B-75

Fig 66. 8

Working on the right side below the cab loosen the hose clips C and disconnect the heater hoses B. K Fig 67. ( T B-76).

Disconnect the heater control cable.

Important: If the machine is fitted with air conditioning, Do not attempt to disconnect any air conditioning hoses until the refrigerant has been discharged. Charging and discharging the system requires special equipment and training. If necessary, use the services of a specialist refrigeration engineer.

9803/9520-8

B-75

Section B - Body and Framework Cab Removal and Replacement

front

floor

mat.

K Front

Floor

fitted).

Remove the Mat ( T B-80)

Disconnect the hitch K Fig 68. ( T B-77).

Attach appropriate lifting equipment to the ROPS and FOPS cage.

cable

(if

Important: When removing the cab mounts make sure to identify them as the front and rear mounts are different. 17

Remove cab mounting bolts E.

Lift the cab from the chassis a small distance to get access to the hoses on the bottom of the cab.

Put a label on the servo control hoses C to help identification when replacing. Disconnect the hoses. Cap all open hoses and pipes to prevent fluid loss and ingress of dirt. K Fig 69. ( T B-78)

Put a label on the brake valve hoses G to help identification when replacing. Disconnect the hoses. Cap all open hoses and pipes to prevent fluid loss and ingress of dirt. K Fig 70. ( T B-79)

Carefully lift the cab from the machine, making sure that all connections have been released and are clear of any obstruction.

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B-76

C B C

B A

C076400

Fig 67. 10

If applicable, once the system has been discharged, disconnect the air conditioning hoses A. K Fig 67. ( T B-76).

Disconnect the cab K Fig 68. ( T B-77).

Disconnect the washer tubing to the washer motor.

Disconnect the transmission ECU connector at the transmission ECU H.

B-76

electrical

connectors

electrical

Section B - Body and Framework Cab Removal and Replacement

C A

E E

H G

Fig 68.

B-77

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B-77

Section B - Body and Framework Cab Removal and Replacement

Replacement

Hose Connections

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: Make sure the servo, brake and steering hoses are connected to the correct connectors. K Hose Connections ( T B-78) Torque tighten the cab mounting bolts, see Section 3 Routine Maintenance.

A F D

Bleed the brakes, see Section G - Brakes. Bleed the hydraulic system, see Section E - Hydraulics.

E C

If applicable, recharge the air conditioning system, see Section B - Service Procedures.

Make sure that all cables are connected and correctly adjusted. Make sure that they are routed and secured correctly.

Make sure that all electrical and hydraulic services operate correctly.

Fig 69. Servo Hose Connections (view from rear of valve block) K Fig 69. ( T B-78)

B-78

Servo Pressure Supply

Crowd Servo Port

Lower servo Port

Dump Servo Port

Lift Servo Port

Tank Return

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B-78

Section B - Body and Framework Cab Removal and Replacement

A E

B A

D C

B Fig 70. Brake Hose Connections Item

K Fig 70. ( T B-79)

From Accumulator Block

Supply from Gear pump

To Brakes on Front Chassis

To Tank or Trailer Brake Valve (if fitted)

Tank Return

C D

F Fig 71. Steer Hose Connections

B-79

Item

K Fig 71. ( T B-79)

Tank Return

Steering Supply

To Steer Manifold (F)

Load Sense Line

Steering Manifold

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B-79

Section B - Body and Framework Cab Internal Components

Internal Components Front Floor Mat Removal

A A

B E E E E

Fig 72. 1

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Remove the nuts and bolts A from the cab kick plates B. K Fig 72. ( T B-80).

Lift the kick plate from the floor mat B.

Disconnect the throttle pedal electrical connectors C. These are located below the mat next to the front console on the right side. K Fig 73. ( T B-80).

Remove the throttle pedal securing bolts A.

Remove the throttle pedal B.

C076710

Fig 73. 7

B-80

9803/9520-8

Remove the foot brake pedal pivot pin A and remove the pedal B. K Fig 74. ( T B-81).

B-80

Section B - Body and Framework Cab Internal Components Replacement Replacement is the opposite of the removal procedure.

A A A

A B A

Fig 75.

Fig 74. 8

Remove the screws E from the securing strip D. K Fig 72. ( T B-80).

Remove the strip D from the cab.

Remove the floor mat C.

Replacement Replacement is the opposite of the removal procedure.

Variflow Pump Access Panel Removal 1

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Remove the Mat ( T B-80)

Remove the six K Fig 75. ( T B-81).

Lift the access panel B from the cab.

B-81

front

floor

mat.

K Front

securing

bolts

Floor

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B-81

Section B - Body and Framework Cab Internal Components

Front Blind

Removal and Replacement Removal 1

Make sure that the blind B is fully retracted. K Fig 76. ( T B-82).

Support the blind.

Remove the securing screws A.

Remove the blind from the cab.

B Fig 77.

Replacement Replacement is the opposite of the removal procedure.

Fig 76. Replacement Replacement is the opposite of the removal procedure.

Roof Blind Removal and Replacement Removal 1

Make sure that the blind B is fully retracted.

Support the blind.

Remove the securing screws A.

Remove the blind from the cab.

B-82

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B-82

Section B - Body and Framework Cab Internal Components

Roof Liner

Removal and Replacement

Note: Take care during the removal and replacement procedure. Make sure your hands and clothes are clean. The roof liner is easily damaged.

Removal 1

Remove the roof instrument panel. K Instrument Panels ( T B-63).

Remove the audio speaker securing screws D.

Note: Not all machines have audio speakers, some machines have a blanking plate in the speaker aperture. 3

Carefully pull the speaker C from the roof liner to get access to the electrical connector.

A Fig 78.

Disconnect the speaker electrical connector.

Prise out the interior light to get access to the electrical connector.

Disconnect the interior light electrical connector.

With the aid of one more person hold the roof liner B and remove the bolts A.

Remove the roof liner B.

Note: Put the roof liner into a clean plastic bag and keep it in a safe place. The roof liner is easily damaged. Replacement Replacement is the opposite of the removal procedure.

B-83

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B-83

Section B - Body and Framework Cab External Components

External Components Door Handle Removal and Replacement

Door Removal and Replacement

Removal

Remove the screws A from the inside of the door and remove the cover plate B.

Make sure the door D is supported.

2 2

Remove screws C and disconnect the latch assembly E from the handle unit G.

Using a thin punch and a hammer, tap securing pin G from the hinge assemblies B.

Knock hinge pin C from the hinge assemblies B.

Remove screws D whilst supporting the outer handle unit.

Repeat procedures 3 and 4 for all other hinges on door D.

Slightly tilt the handle unit G to unhook the unit from the door assembly. Retain gasket F.

Gently ease the door D from the hinge assembly B.

If necessary remove the hinge assembly B by removing the nuts from inside the cab.

If necessary the door catch assembly F can be removed by removing the nuts, bolts and locking plate.

D G B C

D Fig 79.

Replacement

Fig 80.

Replacement is the opposite of the removal procedure.

Replacement Replacement is the opposite of the removal procedure.

B-84

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B-84

Section B - Body and Framework

Air Conditioning (Option) Removal and Replacement Pressure Switch The binary pressure switch assembly is located in the engine compartment, adjacent to the air conditioning compressor.

Removal

!MWARNING Goggles and rubber gloves must be worn when pressure switches are removed or fitted. A small amount of refrigerant is released which can be harmful to the skin or eyes. BF-1-10

Park the machine and make it safe. Disconnect the battery. See Section 2 - General Procedures.

Remove the harness connectors.

Unscrew the pressure switch A.

Fig 81.

Replacement 1

Apply JCB Threadlocker to the pressure switch thread.

Install the pressure switch A into the threaded port and tighten sufficiently to make a gas-tight seal.

Reconnect the harness connectors.

Charge the air conditioning system. See K Service Procedures ( T B-19)

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

B-85

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B-85

Section B - Body and Framework Air Conditioning (Option) Removal and Replacement

!MWARNING

Condenser Note: Before removing the condenser matrix, discharge the system. Refer to Service Procedures, Air Conditioning - Refrigerant Charging and Discharging. The condenser matrix is mounted onto the cooling pack in the engine compartment. If the condenser is being removed only to get access to the cooling pack, this can be done without disconnecting the air conditioning hoses i.e. with the system fully charged. Having released the catch and removed the hinges the condenser can be carefully laid to one side, leaving the hoses still connected. Take care not to kink the hoses. Do not allow the condenser to hang on the hoses unsupported. Removal of the condenser matrix will require the assistance of a refrigeration engineer or suitably trained person, since the refrigerant needs to be drained from the system.

Removal 1

Note: To avoid damaging the condenser when removing or installing the hoses, it is essential that the hexagon flats on the pipe stubs G are held with a spanner whilst loosening or tightening the hose nuts.

Park the machine and make it safe. See Section 2 General Procedures.

When removing components or hoses, retain any lubricant within the component/hose and replenish the system with the same amount of clean lubricant (PAG Oil).

Lift the engine canopy, see Section 3 - Engine Canopy.

Disconnect and remove the battery.

Remove the nut A and bolt C. K Fig 82. ( T B-87).

Remove the hose clamp B from the condenser frame.

B-86

Make sure that the air conditioning system is fully discharged, refer to Service Procedures, Air Conditioning - Refrigerant Charging and Discharging. Put a label on the hoses before disconnecting to help identification when replacing. Disconnect the air conditioning hoses at the pipe stubs on the side of the condenser G. Plug the hose ends to prevent ingress of dirt and loss of fluid.

Support the condenser matrix H.

Remove nuts D and bolts E.

Carefully lift the condenser matrix H from the frame F.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: 1

After replacement recharge the system. Refer to Service Procedures, Air Conditioning Refrigerant Charging and Discharging.

Run the air conditioning and check the hose connections for leaks. In the cab, set the air conditioning to maximum cooling and check that cooled air is emitted from the vents.

9803/9520-8

B-86

Section B - Body and Framework Air Conditioning (Option) Removal and Replacement

G D D A

B C Fig 82.

B-87

9803/9520-8

B-87

Section B - Body and Framework Air Conditioning (Option) Removal and Replacement

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B-88

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B-88

Section B - Body and Framework Mudguards Removal and Replacement

Mudguards Removal and Replacement Front Mudguard

Support the mudguard A.

Removal

Remove the bolts and washers E.

Remove the headlight bracket D and the clamping plates F.

Remove the mudguard A from the mounting arm C.

If necessary remove the mounting arm securing bolts B and remove the arm C from the machine.

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures. Disconnect the headlight electrical connectors.

D E

E D

E F E

B A C

Fig 83.

Replacement Replacement is the opposite of the removal procedure.

B-89

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B-89

Section B - Body and Framework Mudguards Removal and Replacement

Rear Mudguard Removal 1

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Remove the road wheel to aid access if necessary, see Section F - Transmission.

Support the mudguard A.

Remove the bolts and washers B.

Remove the mudguard A from the machine.

B A

Fig 84.

Replacement Replacement is the opposite of the removal procedure.

B-90

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B-90

Section B - Body and Framework Pneumatic Fan General Information

Pneumatic Fan General Information 1

Reverse Fan

Control system bracket

Fan adapter

Capscrews

2 3 4

Fig 85.

B-91

332-W1824-2-1

9803/9520-8

B-91

Section B - Body and Framework Pneumatic Fan General Information

Page left intentionally blank

B-92

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B-92

Section B - Body and Framework LiveLink General Information

LiveLink General Information

Fig 86. Telematics

B-93

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332-U4420-4-1

B-93

Section B - Body and Framework LiveLink General Information

CONNECTOR 70 WAY MATING HALF PART N0 332/C8195 Pin Description 1 DIAG_TX 2 DIAG_RX 3 GW_CTS_232 4 GW_TX_232 5 GW_RX_232 6 GW_DTR_232 7 8 GW_DCD_232 9 GW_GND 10 AUX_BATT+ 11 1-WIRE GND 12 RUN_TERMINAL 13 BATTERY+ 14 DIAG_GND 15 GW_RTS_N 16 SEC_GND 17 18 GW_RTS_232 19 SOLAR_IN 20 AUX_BATT21 1-WIRE OUT 22 SEC_GND 23 BATTERY24 DIAG_DTR 25 GW_RTS_N 26 27 28 SOLAR_GND 29 FUTURE_GND 30 SENSOR INPUT3 31 SENSOR INPUT4 32 GW_DTR_422 33 GW_DCD_422 34 35 GW_GND

36 SENSOR1_GND 37 SENSOR2_GND 38 SENSOR INPUT1 39 SENSOR INPUT2 40 GW_TX_P 41 GW_TX_N 42 GW_RX_P 43 GW_RX_N 44 RELAY DRIVER 45 TAMPER 1 46 TAMPER 2 47 CHASSIS GND (PROTECTED) 48 GW_CTS_P 49 GW_CTS_N 50 TEST AUDIO_RET 51 TEST MIC_IN 52 TEST SPKR_OUT 53 54 RELAY_GND 55 MICRO LOADER_EN 56 J170857 J1708+ 58 59 CAN SHIELD 60 CAN_H 61 CAN_L 62 CABLE CUT+ 63 CABLE CUT64 65 66 67 68 69 70

Fig 87. ABI LiveLink Europe ROW

128-D0128

The system voltage is either 12 or 24V. CDMA is the mobile network.

B-94

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B-94

Section B - Body and Framework LiveLink General Information

GPS RP-TNC

CELL/PCS TNC

Fig 88. LiveLink Antenna

B-95

9803/9520-8

332-C8020

B-95

Section B - Body and Framework LiveLink General Information

Page left intentionally blank

B-96

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B-96

Section C Electrics Service Manual - TM310 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-9

Section C - Electrics

Notes:

C-0

9803/9520-9

C-0

Section C - Electrics Contents Page No. Technical Data General Electrical Data ............................................................................. C-1 Fuses and Relays ..................................................................................... C-2 Secondary Fuses ................................................................................. C-2 Relays .................................................................................................. C-3 Primary Fuses ...................................................................................... C-4 Fuses and Relays From 1314700 ............................................................ C-6 Introduction ........................................................................................... C-6 Primary Fuses ...................................................................................... C-6 Secondary Fuses ................................................................................. C-7 Relays .................................................................................................. C-8 Schematic Circuits TM310 ...................................................................................................... C-9 Overview .............................................................................................. C-9 Primary and Secondary Fuses, Ignition Switch and Relays ............... C-10 Engine ................................................................................................ C-12 Gearbox .............................................................................................. C-14 Instrumentation ................................................................................... C-16 SRS and Accessories ......................................................................... C-18 Front Wipe, Rear Wipe and Heater/Air Conditioning .......................... C-20 Front and Rear Worklights, Boom Light and Beacon ......................... C-22 Roadlights .......................................................................................... C-24 Auxiliary and Boom Hydraulics ........................................................... C-26 CAN Overview .................................................................................... C-28 Immobiliser and GPS ......................................................................... C-30 Earthing .............................................................................................. C-32 Service Procedures Using a Multimeter .................................................................................. C-35 Measuring DC Voltage ....................................................................... C-36 Measuring Resistance ........................................................................ C-36 Measuring Continuity .......................................................................... C-37 Measuring Frequency ......................................................................... C-37 Testing a Diode or a Diode Wire ......................................................... C-38 Battery .................................................................................................... C-39 Maintenance ....................................................................................... C-39 Testing ................................................................................................ C-39 Specific Gravity Testing ...................................................................... C-41 Alternator ................................................................................................ C-42 General Description ............................................................................ C-42 Service Precautions ........................................................................... C-42 Charging Circuit Test .......................................................................... C-42 Alternator Charging Test ..................................................................... C-43 Starter Motor ........................................................................................... C-45 Starting Circuit Test ............................................................................ C-45 Wire and Harness Number Identification ................................................ C-47 Introduction ......................................................................................... C-47 Wire Numbers and Functions ............................................................. C-48 Wiring Harness Repair ........................................................................... C-49 Introduction ......................................................................................... C-49 Repair Procedure ............................................................................... C-49

C-i

Section C - Electrics Contents

Contents Page No. Battery Removal and Replacement .................................................................... C-53 Removal ............................................................................................. C-53 Alternator Removal, Inspection and Replacement .................................................. C-55 Dismantle and Assemble ........................................................................ C-56 Renewing the Voltage Regulator and Brushes ................................... C-56 Renewing the Drive Pulley ................................................................. C-56 Starter Motor Removal, Inspection and Replacement .................................................. C-59 Dismantle and Assemble ........................................................................ C-60 Renewing the Brush Gear .................................................................. C-60 Renewing the Starter Solenoid ........................................................... C-60 Harness Data Drawings and Interconnection ................................................................ C-63 Harnesses .......................................................................................... C-63 TM310 ................................................................................................ C-66

C-ii

Section C - Electrics

Technical Data General Electrical Data System Type

12 Volt, negative earth

Battery (Single installation) - Cold crank Amps for 1 minute to 1.4 Volts per cell at - 850 18 0C (0 0F) - Reserve capacity (minutes) for 25 Amp load Alternator

C-1

95 Amp nominal output

9803/9520-8

C-1

Section C - Electrics Technical Data Fuses and Relays

Fuses and Relays

!MCAUTION

Fuse Circuit(s) Protected

Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the bay on the right hand side of the cab.

Front Worklights

Rating 20A

Front Worklights (Option)

15A

Rear Foglights

7.5A

Headlights

15A

Diagnostic

Hazard Indicators

15A

Beacon

7.5A

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

Interior Light, Radio

7.5A

Main Beam Flash

15A

Secondary Fuses

C10 GPS - Option

Fuse Circuit(s) Protected

Rating

Fuse Circuit(s) Protected

7.5A Rating

Brake Lights

15A

Power Hold Relay Coil

Instrumentation

7.5A

Engine Sensors

Horn, Front Wash/Wipe

10A

ECU4, Gearbox

Direction Indicators

10A

Gearbox ECU

10A

Rear Wash/Wipe

7.5A

Gearbox ECU

10A

Radio

Fuel Lift Pump

10A

Heater/Air Conditioning

30A

Engine1

7.5A

Air Conditioning Compressor, Boom Light

15A

Engine 2

7.5A

Engine 3

15A

Rear Worklights

15A

D10 Engine 4

15A

A10

Rear Worklights 2 (Option)

15A

Fuse Circuit(s) Protected

Rating

LH Sidelights

RH Sidelights

Spare

LLMC

7.5A

Gear lever

Auxiliary Solenoids

10A

Suspension Seat, Cigar Lighter

15A

SRS Suspension

7.5A

Front Quickhitch

7.5A

B10

Hydraulic Tow Hitch

7.5A

C-2

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C-2

Section C - Electrics Technical Data Fuses and Relays

Relays

Later models:

Relay Circuit

Ignition 3

Warning Buzzer

Direction Indicators

Neutral Start

Warning Buzzer

Ignition 4

Ignition 2

Ignition 3

Ignition 1

Ignition 2

Ignition 4

Ignition 1

Reverse

Fog Light

Fuel Lift Pump

Reverse

SRS 1

Fuel Pump

Brakelights

Front Quickhitch

SRS 1

Ignition 5

Auxiliary Quickhitch Diverter Valve

SRS 2

Quickhitch Isolator

Air Conditioning

Ignition 5

Air Conditioning

SRS 2

The engine ECU power hold relay is located adjacent to the primary fuses behind the battery.

" &

)

+ # & C051180-C1

Fig 1.

C-3

9803/9520-8

C-3

Section C - Electrics Technical Data Fuses and Relays

Primary Fuses

Fuse Circuit(s) Protected RH Sidelights

The primary fuses are located in fuse boxes mounted to the right of the battery. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Fuse Circuit(s) Protected PF1 Brake Lights

Rating

LH Sidelights Fuse Circuit(s) Protected PF7 Engine ECU

Rating 50A

Rating 40A

Fuse Circuit(s) Protected PF8 Engine ECU

Instrumentation

Rating 30A

Gearbox ECU

Front Wash/Wipe Direction Indicators Rear Wash/Wipe

PF4

PF1

PF3

PF2

Horn Fuse Circuit(s) Protected PF2 Aircon

Rating 50A

Heater Blower

Fig 2.

Boom Light Fuse Circuit(s) Protected PF3 SRS

Rating 50A

PF8

PF5

PF7

PF6

Cigar Lighter Auxiliary Solenoids Hydraulic Tow Hitch Gearlever

Fig 3. Fuse Circuit(s) Protected PF4 Rear Foglight

Rating 40A

Front Worklights Fuse Circuit(s) Protected PF5 Hazard Warning Lights

Rating 40A

Beacon Radio Interior Light Fuse Circuit(s) Protected PF6 Main Beam

Rating 40A

Dip Beam

C-4

9803/9520-8

C-4

Section C - Electrics Technical Data Fuses and Relays Table 1. Later Models PF1 Ignition, Neutral Start, Fuses: A1, A2, A3, A4, A5, A6 PF2 Ignition Relay 2, Fuses: A7, A8 PF3 Ignition Relay 1, Fuses: B5, B6, B7, B8, B9, B10 PF4 Ignition Relay 3, Fuses: C1, C2 PF5 Ignition Relay 4, Roadlights Relay, Fuses: A9, A10 PF6 Power Hold Relay, Fuses: D1 PF7 Engine ECU, LH Sidelights, RH Sidelights, PF8 Ignition Relay 5, Fuses: D2, D3, D4, D5

PF4

PF1

PF3

PF2 817-20798

Fig 4.

PF8

PF5

PF7

PF6 817-20799

Fig 5.

C-5

9803/9520-8

C-5

Section C - Electrics Technical Data Fuses and Relays From 1314700

Fuses and Relays From 1314700 Introduction

Primary Fuses

!MCAUTION

PF1 Ignition, Neutral Start, Fuses: A1, A2, A3, A4, A5, A6

Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

PF2 Ignition Relay 2, Fuses: A7, A8 PF3 Ignition Relay 1, Fuses: B5, B6, B7, B8, B9, B10 PF4 Ignition Relay 3, Fuses: C1, C2 PF5 Ignition Relay 4, Roadlights Relay, Fuses: A9, A10

The electrical circuits are protected by fuses. If a fuse blows, find out why and rectify the fault before fitting a new one.

PF6 Power Hold Relay, Fuses: D1 PF7 Engine ECU, LH Sidelights, RH Sidelights, PF8 Ignition Relay 5, Fuses: D2, D3, D4, D5

Before you access to the fuses, make the machine safe with the boom lowered. The Primary Fuses (PF) are located in fuse boxes mounted to the right of the battery.

PF4

PF1

PF3

PF2

The secondary fuses and relays are located in a fuse box A inside the bay on the right hand side of the cab.

817-20798

Fig 7.

PF8

PF5

PF7

PF6

817-20799

Fig 8. C087570

Fig 6.

C-6

9803/9520-8

C-6

Section C - Electrics Technical Data Fuses and Relays From 1314700

Secondary Fuses

333-U1513-1

Fig 9. Fuse Circuit(s) Protected

Rating

Fuse Circuit(s) Protected

Rating

Brakelights

15A

Front Work Lights

20A

Instrumentation

7.5A

Front Work Lights - Option

15A

Horn, Front Wash/Wipe

10A

Rear Foglights

7.5A

Direction Indicators

10A

Headlights

15A

Rear Wash/Wipe

7.5A

Diagnostics - Option

Radio

Hazard Indicators

15A

Heater/Air Conditioning

30A

Beacon

7.5A

Air Conditioning Compressor, Boom Light

15A

Interior Light, Radio, Instrument Cluster

7.5A

Main Beam Flash

15A

Rear Work Lights

15A

A10

Rear Work Lights (2) - Option

15A

C10 GPS - Option Fuse Circuit(s) Protected

Fuse Circuit(s) Protected

Rating

7.5A Rating

Power Hold Relay Coil

LH Sidelights

Engine Sensors

RH Sidelights

Gearbox, Throttle, Pump ECU

LLMC

7.5A

Gearbox ECU

10A

LLMC

Gearbox ECU

10A

Servo Isolator

Shutdown Relay

10A

Auxiliaries Circuit

10A

Engine1

7.5A

Suspension Seat, Cigar Lighter

15A

Engine 2

7.5A

SRS Suspension

7.5A

Engine 3

15A

Quickhitch Isolator

7.5A

D10 Engine 4

15A

B10

Auxiliary Circuit Diverter Valve

7.5A

C-7

9803/9520-8

C-7

Section C - Electrics Technical Data Fuses and Relays From 1314700

Relays Relay Circuit 1

Warning Buzzer

Direction Indicators

Power Hold Relay

Neutral Start

3a 3b

Ignition 4

Ignition 3

Ignition 2

Ignition 1

Foglight

Reverse

Fuel Pump

Brake Lights

SRS 1

Auxiliary Circuit Diverter Valve

Quickhitch Isolator

Ignition 5

Air Conditioning

SRS 2

T027350-C3

Fig 10.

The engine ECU power hold relay is located either adjacent to the primary fuses behind the battery or inside the cab 3a.

C-8

9803/9520-8

C-8

C-9

9803/9520-9

Production release.

Change to HVCS circuit.

Change to HVCS circuit and Extend and Retract.

Arm rest switch change.

Immobiliser and GPS fog circuit. Constant flow switch. Trailer indicator flasher.

Air conditioning pressure switch added.

Modifications:

K Earthing ( T C-32)

K Immobiliser and GPS ( T C-30)

K CAN Overview ( T C-28)

K Auxiliary and Boom Hydraulics ( T C-26)

K Roadlights ( T C-24)

The LLMC system has been modified. The recovery switch has been removed.

The LLMC system has been added. The auxiliary dump has been added. The reverse fan has been added.

Servo cut-off switch changed. Wires in cavities 9 and 10 swopped in fog switch.

K Front and Rear Worklights, Boom Light and Beacon ( T C-22)

K Front Wipe, Rear Wipe and Heater/Air Conditioning ( T C-20)

K SRS and Accessories ( T C-18)

K Instrumentation ( T C-16)

K Gearbox ( T C-14)

K Engine ( T C-12)

K Primary and Secondary Fuses, Ignition Switch and Relays ( T C-10)

Overview

TM310

Schematic Circuits

Section C - Electrics Schematic Circuits TM310

C-9

C-10

9803/9520-9

Mega Fuse

Ignition Switch

Neutral Start Relay

Ignition Relay 1

Ignition Relay 5

Ignition Relay 2

Ignition Relay 3

Ignition Relay 4

Primary Fuse 1

Primary Fuse 2

Primary Fuse 3

Primary Fuse 4

Primary Fuse 5

Primary Fuse 6

Primary Fuse 8

Primary Fuse 7

Starter Motor

Alternator

To Roadlight Switch

From Gearbox ECU

To Earth Splice

To Power Hold Relay

To Grid Heater Relay

Destinations

Battery Isolator

Table 3.

Battery

Table 2. Main Components K Fig 11. ( T C-11)

Primary and Secondary Fuses, Ignition Switch and Relays

To Flash To Earth Splice To Brake Light Relay To Instrumentation Splice To Front Wash/Wipe To Hazard Switch To Rear Wash/Wipe To Roof To Heater Switch To Air Conditioning

O P Q R S T U V W X Y

To HCVS ECU

To Engine ECU

To Water In Fuel

To Engine Oil Level

To Power Hold Relay - Coil

To Roadlight Switch (Dip/main)

To Rear Worklight 2

To Rear Worklight 1

To Lighting And Radio

To Instrument Pack

To Front Worklight 2

To Beacon

To Hazard Switch

To Boom Light

To Immobiliser

To Front Worklight 1

To Diagnostic Connector

To Transmission Dump Switch

To Power Hold Relay Coil

To Arm Rest Relay

To Reverse Fan Switch

To Reverse Fan

To Tracker

To Auxiliary Hydraulics

To Quickhitch Isolator

To Reverse Relay

To SRS

To Tow Mode

To Seat Suspension

To Cigar

To Servo switch

To Gear Lever - Select

To Joystick

To Gear Lever - FNR

To Gear Lever - Kickdown

To Instrument Panel

To Gearbox ECU

To Foot Throttle

Chassis Earth Cab Earth

Destinations

Section C - Electrics Schematic Circuits TM310

C-10

C-11

9803/9520-9 C

O N P XD

J K L

V W

S K T U

Fig 11. Primary Fuses, Secondary Fuses, Ignition Switch and Relays

X Y Z

AO AP

AH AI AJ I AJ AK AL AM AN

BD AR AS AT AU BG AV AW AX AY AZ XA XB XC

XF XE

853-10043-10-1

Section C - Electrics Schematic Circuits TM310

C-11

C-12

Water in Fuel Sensor

From Primary Fuse 7

From Fuse D1

From Primary Fuse 9

From Fuse D3

To Gearbox ECU - Overrun

From Brake Switch

From Speed Sensor

To Earth Splice

From Fuse D2

Table 5.

Fuel Lift Pump Relay

Destinations

Grid Heater Relay

Engine ECU Power Hold Relay

CAN Connector

Engine ECU

Foot Pedal

Engine ECU Ground

Fuel Lift Pump Relay

Grid Heater

Table 4. Main Components K Fig 12. ( T C-13)

Engine

Section C - Electrics Schematic Circuits TM310

9803/9520-9

C-12

Section C - Electrics Schematic Circuits

C-13

Fig 12. Engine

853-10043-10-9

TM310

9803/9520-9

C-13

C-14

9803/9520-9

Reverse Low Solenoid

Reverse High Solenoid

Layshaft Solenoid

Mainshaft Solenoid

Forward High Solenoid

Forward Low Solenoid

From Fuse B4

Table 7.

Destinations

To Instrument Pack

Transmission Oil Pressure Switch

Hydraulic Oil Temperature

Speed Sensor

Transmission Controller Gearbox Interface

Transmission Oil Temperature Switch

Hydraulic Vari-flow

Transmission Dump Field Mode

Vari-flow Control - HVCS

Transmission Dump Switch

Drive Mode Switch

HVCS Diode

DYB

6th Gear Solenoid

Park Brake Switch

TLCU Solenoid

Left Hand Column Switch

Transmission Controller Machine Interface

CAN Connector

Table 6. Main Components K Fig 13. ( T C-15)

Gearbox

From Joystick - Forward From Joystick - Reverse From Joystick - Dump To Neutral Start To Engine ECU To Reverse Lights and Alarm To Instrument Pack From Pedal Overrun From Fuse D3

L M N P Q R S T U V

From Fuse D5

From Joystick - Neutral

From Master Warning Lights

From Fuse D4

From Instrumentation

From Fuse D4

To Earth Splice

From Fuse B8

From Fuse C5 From Fuse B4

Destinations

Section C - Electrics Schematic Circuits TM310

C-14

C-15

V W X Y Y

R S

F F

V V

9803/9520-9

Fig 13. Gearbox

F 853-10043-10-8

Section C - Electrics Schematic Circuits TM310

C-15

C-16

9803/9520-9

Diode

Boom Retract Proximity Switch

Strain Gauge

Boom Lower Proximity Switch

Strain Gauge

Boom Angle Sensor

Air Filter Switch

Brake System Pressure Switch

Dump Limit Solenoid

LMI

Enter

Scroll

DXC

RXA

RXB

From Fuse B4

From Fuse A2

From Fuse C8

From Smooth Ride System

From Main Beam Switch

From Rear Fog

From 1st Trailer Turn

From Left Hand Indicators

From Alternator D+

From Right Hand Indicators

From Sidelights

Destinations

Buzzer

Table 9.

Instrument Cluster

Table 8. Main Components K Fig 14. ( T C-17)

Instrumentation

To Park Brake From HCVS To Earth Splice Wire Break To ECU To LMC ECU-4 To LMC ECU-7/3 To LMC ECU-6 To LMC ECU

T U V W X Y Y1 Y2 Y3

Blocked Air Filter SRS Brake Malfunction Park Brake Main Beam Rear Fog 1st Trailer DI Left Indicator Right Indicator

3 4 5 6 7 8 9 10 11

Hazard

Engine Coolant Level

Alternator Charge

Minor Components

To Hazard Switch

Table 10.

To Roadlight Switch

To CF Enable Switch

P From Fuse C5

To TX Dump Switch

To Fuse B3

To Reverse Fan Switch

Diagnostic Connector Dump Stop Diode

Fuel Sender

CAN Connector

Backlight

LCD

High Coolant Temperature

Coolant Temperature Gauge

Low Fuel

Fuel Gauge

Engine Pre-Heat

Low Oil Pressure

CAN Error

Water in Fuel

Engine ECU Fault

Transmission Oil Temperature

Transmission Oil Pressure

ECU4/HCVS

Destinations

Section C - Electrics Schematic Circuits TM310

C-16

C-17

9803/9520-9

N P Q S L

16 17 18 19 20

Fig 14. Instrumentation

12 13 14

9 10

7 8

1 2

Y2 V

V Y Y1

853-10043-10-2

Section C - Electrics Schematic Circuits TM310

C-17

C-18

9803/9520-9

SRS Relay 2

SRS Relay 1

Power Socket

SRS Switch

Reverse Fan Timer

Diode

Suspension Seat

SRS Pressure Switch

SRS Solenoid RAM

SRS Solenoid

Pressure Switch Top 1

Pressure Switch Top 2

Pressure Switch Bottom 1

Reverse Fan Relay

Radio Power

Left Hand Internal Light

Radio Speaker

Left Hand Speaker

Right Hand Speaker

DJa

DJb

DXD

RFA

From Fuse B8

From Sidelights

From Fuse B7

From Fuse C8

Table 12.

Reverse Fan Switch

Destinations

Reverse Fan Compressor

Table 11. Main Components K Fig 15. ( T C-19)

SRS and Accessories

To Beacon Switch From Alternator From Illumination Splice From Alternator W To Auxiliary Dump Switch Earth From Road Light

M N P Q R

J To Earth Splice

To Instrument Pack

To Hazard Earth

From Fuse A6 To Fan Earth

Destinations

Section C - Electrics Schematic Circuits TM310

C-18

C-19

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Fig 15. SRS and Accessories

853-10043-10-3

Section C - Electrics Schematic Circuits TM310

C-19

C-20

Heater Switch

Horn

Rear Washer Pump

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From Fuse A5

From Roof Switch Splice

From Fuse A7

From Fuse A3

To Earth Splice

From Fuse A8

Table 14.

Front Wiper

Destinations

Rear Wipe/Wash Switch

RH Rear Wiper Motor

NM Front Washer Pump

NB Compressor Clutch

MP Air Conditioning Low Pressure Switch

MN Air Conditioning High Pressure Switch

DM Air Conditioning Switch

DE Heater Air Conditioning Unit

DC Relay Air Conditioning

CM Right Hand Column Switch

Table 13. Main Components K Fig 16. ( T C-21)

Front Wipe, Rear Wipe and Heater/Air Conditioning

Section C - Electrics Schematic Circuits TM310

C-20

C-21

9803/9520-9

Fig 16. Front Wiper, Rear Wiper and Heater/Air Conditioning

853-10043-10-4

Section C - Electrics Schematic Circuits TM310

C-21

C-22

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Right Hand Rear Worklight 2

Beacon

Left Hand Rear Worklight

Left Hand Rear Worklight 2

Left Hand Front Worklight

Left Hand Front Worklight 2

Right Hand Front Worklight 2

Right Hand Front Worklight

Beacon Switch

Front Worklight Switch

Rear Worklight Switch

From Fuse C2

To CF Enable

From Fuse A9

From Fuse A10

To Auxiliary Dump Switch

From Fuse C1

To Roadlight

Table 16.

Right Hand Rear Worklight

Destinations

Diode

Boom Light Switch

Quickhitch Release

Quickhitch Isolator Switch

Boom Lamp 2

BL2

DXB

Boom Lamp 1

BL1

Table 15. Main Components K Fig 17. ( T C-23)

Front and Rear Worklights, Boom Light and Beacon From Fuse A6 From Fuse A8 From Fuse C7 To Earth Splice From Fuse B9

H J K L M

Destinations

Section C - Electrics Schematic Circuits TM310

C-22

C-23

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D G

Fig 17. Front and Rear Worklights, Boom Light and Beacon

BL2

BL1

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Section C - Electrics Schematic Circuits TM310

C-23

C-24

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Right Hand Column Switch (Main/Dip)

Right Hand Column Switch (Indicators)

Roadlight Switch

Brake Light

Flasher Unit

Diode

Reverse

Fog Latch

Flasher Unit - Trailer Only

Left Hand Front Headlight

Right Hand Front Headlight

Left Hand Reverse/Fog Lamp

Right Hand Reverse/Fog Lamp

Reverse Alarm

Right Hand Stop Tail Indicator Light

Left Hand Stop Tail Indicator Light

Trailer Socket

Right Hand Number Plate Light

Brake Light Switch

Left Hand Number Plate Light

CM1

CM2

DXA

From Primary Fuse 6

From Ignition Relay 4

From Fuse C6

From Instrumentation

Table 18.

Fog Light Switch

Destinations

Hazard Switch

Table 17. Main Components K Fig 18. ( T C-25)

Roadlights From Fuse A4 From Fuse C9 From Fuse B9 From Fuse A1 To Earth Splice From Front Worklight Switch To Engine ECU To Master Warning Lights From Gearbox ECU To Instruments To First Trail/Fog Indicator To Roadlight Switch Earth From Hazard Switch To SRS Switch To Fog Light Switch

E F G H J K L M N P Q R S T U

Destinations

Section C - Electrics Schematic Circuits TM310

C-24

C-25

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E D

Fig 18. Roadlights

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Section C - Electrics Schematic Circuits TM310

C-25

C-26

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Diode

Extend/Return Resistor

Auxiliary2 Relay

Arm Rest Relay

Voltage Regulator

Auxiliary Controller

Resistor

Second Auxiliary

Constant Auxiliary Flow Set

Transmission Dump

FNR

Extend/Retract Thumb Wheel

Auxiliary Thumb Wheel

Auxiliary B - Unlock

Auxiliary A - Lock

Boom Solenoid Retract

Boom Solenoid Extend

Diverter Valve Solenoid

Lower Sensor Relay

LLMC ECU

Constant Flow + Aux2

To Earth Splice

From Angle Sensor

To Earth Splice

To Earth Point

From Reverse Fan Switch

From Instrumentation Splice

From Fuse B10

To Transmission Controller - Reverse

To Transmission Controller - Dump

To Transmission Controller - Neutral

To Transmission Controller - Forward

From Fuse B6

To Boom Lights Switch

From Fuse B4

From Boom Lights Switch

From LMI

To Earth Splice

Auxiliary Resistor

Boom Extend/Retract Control

Constant Flow - Enable

Table 20.

Auxiliary Dump Solenoid

Servo Cut-Off Switch

Lower Limit Solenoid

Destinations

Arm Rest Switch

Servo Cut Off Solenoid

CR/DZ Joystick

Auxiliary Dump Switch

Table 19. Main Components K Fig 19. ( T C-27)

Auxiliary and Boom Hydraulics

Section C - Electrics Schematic Circuits TM310

C-26

C-27

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G H K

Fig 19. Auxiliary and Boom Hydraulics

Q Q

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Section C - Electrics Schematic Circuits TM310

C-27

C-28

The Shield is Connected to Ground

Gearbox ECU: Installed on the Left Hand Inner Chassis Rail)

Cab Front Bulkhead

Diagnostic Connector: Installed near the Fusebox

Instrument Pack

Connector

From Fuse C5

Note: To remove the cab, disconnect the gearbox connector A and CAN to the cab.

Engine ECU: Installed on the Engine

Table 21. Main Components K Fig 20. ( T C-29)

CAN Overview

Section C - Electrics Schematic Circuits TM310

9803/9520-9

C-28

Section C - Electrics Schematic Circuits

Fig 20. CAN Overview

853-10043-10-11

TM310

C-29

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C-29

C-30

Immobiliser

Qualcomm G-tracs

CAN

9803/9520-9

To Gear Lever

From Fuse C5

From Fuse A2

To Earth Splice

From Gear Lever

Note: BB: Either the immobiliser or link option.

Note: AA: Machine harness connector.

To Neutral Start Relay

From Fuse D2

To Engine

From Earth

From Gearbox ECU

From Alternator W

From Earth

From Battery

From Transmission Oil Temperature

From Brake System Pressure

From Blocked Air Filter

From Ignition

Table 23. Destinations K Fig 20. ( T C-29)

Immobiliser

IMM

DF-L DF-L Link

Antenna

Table 22. Main Components K Fig 20. ( T C-29)

Immobiliser and GPS

Section C - Electrics Schematic Circuits TM310

C-30

C-31

9803/9520-9

P Q

J K L M N

Fig 21. Immobiliser and GPS

E F G H

A B C D

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Section C - Electrics Schematic Circuits TM310

C-31

C-32

Cab Earth 2A

Cab Earth 1

Mainframe Earth

Cab Earth 2B

From Right Hand Rear Worklight

From Right Hand Rear Worklight 2

From Load Moment Indicator -A

From Right Hand Forward Worklight 2

From Left Hand Rear Worklight 2

From Left Hand Rear Worklight

From Right Hand Forward Worklight

From Radio Power

From Load Moment Indicator

From Rear Wipe Motor

From Beacon

From Left Hand Forward Worklight 2

From Left Hand Forward Worklight

From Left Hand Internal Light

From Front Worklight Switch

From Rear Wipe Switch

From Number Plate Light

From Beacon Switch

From Rear Worklight Switch

Destinations

Front Chassis Earth

Table 25.

Cab Roof Earth Point 1

Table 24. Main Components K Fig 22. ( T C-34)

Earthing

From Field Mode Switch From Servo Switch

AD AE

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From Diagnostic Connector

From Ignition Relay 5

From Ignition Relay 4

From Ignition Relay 3

From Ignition Relay 2

From Ignition Relay 1

From SRS Relay 2

From Air Conditioning Relay

From Flasher

From Reverse Relay

From Power Socket

From Dump Stop Circuit

From Quickhitch Switch

From Qualcomm

From Tow Mode Switch

From Relay EK

From Angle Sensor

From Immobiliser

ECU4 - Variflow

AW From Boom ECU4

From Fog Latch Relay

To Boom Light Switch

From Right Hand Headlight From Left Hand Headlight

Z AB

From LLMC ECU

Y AA

SRS Solenoid IRAM

From Left Hand Rear Reverse Light

From Left Hand Rear Combination

Reverse Alarm

To Auxiliary Hydraulic Solenoid

Trailer Socket

From Front Washer Motor

Instrument Pack

From Auxiliary Dump Solenoid

From Constant Flow Enable Switch

From Foot Brake Transmission Dump Switch

From Auxiliary Controller

Heater Air Conditioning Unit

From Park Brake Switch

Suspension Seat

Neutral Start Relay

From Gearbox ECU

From Air Conditioning Compressor

From Pressure Switch Bottom 2

From Oil Temperature Sender

From Rear Wash Pump

Water in Fuel

Servo Cut Off Solenoid

From Fuel Sender

From SRS Solenoid

From Right Hand Reverse Light

From Front Wash Pump

From Right Hand Rear Combination

From Brakelight Switch

From Air Filter Switch

BW From Brake Pressure Switch

From Horn Quickhitch/Boom Light

Destinations

Section C - Electrics Schematic Circuits TM310

C-32

C-33

From Fuel Lift Pump

From Reverse Low Solenoid

From Forward Low Solenoid

From TLCU Solenoid

From Gearbox ECU

Transmission Oil Pressure

From Transmission Temperature Switch

From Proximity Switch

CW From Gearbox ECU

From Mainshaft Solenoid

From Reverse High Solenoid

From 6th Gear Solenoid

To Forward High Solenoid

CM From Layshaft Solenoid

Destinations

Section C - Electrics Schematic Circuits TM310

9803/9520-9

C-33

C-34

T U Q R S L H V G N

A B C D E F K J M P

BA W X Y DD DD AC AA AB

9803/9520-9 BJ

AL AN AP AQ AR AS AT AU AF AM AG AJ BF BB AV

AD AH AK AZ BG BM AE BC

BK AY Z

BD BE AX AW BH

BP BQ

Fig 22. Earthing

CM CN CP CQ CR CS CT CU CX CY

BZ CA CB CC CD CE CF CG CH CK CJ CL BN

BR BS BT BU BV BW BX BY BL CV CW

853-10043-10-10

Section C - Electrics Schematic Circuits TM310

C-34

Section C - Electrics

Service Procedures Using a Multimeter TC-002

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

Fig 24. AVO 2003

Fig 23. FLUKE 85

Fig 25. A Typical Analogue Meter

C-35

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C-35

Section C - Electrics Service Procedures Using a Multimeter 1

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

Measuring Resistance 1

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

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

Select the correct range on the multimeter. a

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

Measuring DC Voltage 1

On the FLUKE 85. Turn the switch to position 23-B.

b On the AV0 2003.

Move the right hand slider switch to position 24-B, and the left hand slider switch to the appropriate Ohms (立) range.

On an analogue meter. i

Move the right slider switch to position 24-A, and the left hand slider switch to the appropriate range. c

Turn the switch to position 23-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 23-G to change the reading to 立. Touch the meter lead probes together and press the REL3 key on the meter to eliminate the lead resistance from the meter reading.

b On the AV0 2003.

Select the correct range on the multimeter. a

On the FLUKE 85.

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

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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C-36

Section C - Electrics Service Procedures Using a Multimeter

Measuring Continuity

Measuring Frequency

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

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

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

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

Insert the red probe into socket 23-J.

Turn the selector switch to position 23-A and depress 23-G repeatedly until 23-F is highlighted on the top row of the display.

Press button 23-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 23-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 23-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 24-B, and the left hand slider switch to position 24-C. If there is continuity (i.e. very low resistance) between two points the buzzer will sound. c

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

C-37

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C-37

Section C - Electrics Service Procedures Using a Multimeter

Testing a Diode or a Diode Wire

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

On an analogue meter. i

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

To test a Diode or a Diode Wire a

On the FLUKE 85. i

Turn the switch to position 23-D.

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

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

Select the Ohms 1000s (1k) range.

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

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

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

b On the AV0 2003. i

Move the right hand slider to position 24-A, and the left hand slider switch to position 24-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.

C-38

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C-38

Section C - Electrics Service Procedures Battery

Battery TC-001_4

!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:

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

– Never boost-charge a maintenance free battery.

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

– Never charge a maintenance free battery at a voltage in excess of 15.8 Volts.

5-3-4-12

– Never continue to charge a maintenance free battery after it begins to gas.

Testing This test is to determine the electrical condition of the battery and to give an indication of the remaining useful 'life'. Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27°C). Ensure that the battery is completely disconnected from the vehicle. Connect up the battery tester as follows:

C-39

Set the CHECK/LOAD switch 26-A to OFF.

Set rocker switch 26-B to the battery voltage (12V).

Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.

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C-39

Section C - Electrics Service Procedures Battery 4

Set the CHECK/LOAD switch 26-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts.

Set the CHECK/LOAD switch 26-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 26. Fault Diagnosis ( T C-40), if the foregoing tests are unsatisfactory.

Battery Tester Readings 1

Fig 26. Battery Tester

Table 26. 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

C-40

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C-40

Section C - Electrics Service Procedures Battery

Specific Gravity Testing The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15°C (60°F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing.

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. If the electrolyte temperature is other than 15°C (60°F) a 'correction factor' must be applied to the reading obtained. Add 0.07 per 10°C (18°F) if the temperature is higher than 15°C (60°F) and subtract the same if the temperature is lower.

Table 27. 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

C-41

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C-41

Section C - Electrics Service Procedures Alternator

Alternator TC-006

General Description

Charging Circuit Test

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

Ensure that all battery and alternator connections are in place, secure and making good metal - to - metal contact, especially the 'earth' connections to chassis and engine.

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

Turn the start switch to the ON position.

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

'Oil pressure' and 'No charge' warning lights should glow. If any light fails, K Check 1 ( T C-42). 4

If the 'No charge' warning light remains ON, K Check 2 ( T C-43).

Service Precautions 1

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

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

Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator. During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables). If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The slave battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.

C-42

Start the engine; all warning lights should extinguish rapidly.

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

Check 1 With start switch 'ON' try the heater motor and screen wiper. If they operate normally, check the warning light bulb for blown filament. Simultaneous failure of all items indicates a fault at the start switch. Check for cable disconnection before condemning the switch itself. If the 'No charge' warning bulb is in good order, withdraw the triple plug from the back of the alternator. Make a temporary connection between the SMALL terminal in the plug and earth as shown below. If the 'No charge' warning bulb still fails to light, check the cable for continuity. If the bulb now lights, check the alternator for a defective regulator. K Alternator Charging Test ( T C-43).

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C-42

Section C - Electrics Service Procedures Alternator

Alternator Charging Test

Fig 27.

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

Stop the engine and turn the starter switch to OFF.

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

Fig 29. 1

Ensure that all battery and alternator connections are in place, secure and making good metal - to - metal contact, especially the 'earth' connections to chassis and engine.

Make sure that the alternator drive belt tension is correctly adjusted.

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

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

Connect a multimeter positive lead to machine side of the shunt and negative lead to battery side of the shunt.

Connect the leads to the meter and set the meter to the relevant range as follows.

Fig 28. If the voltage is correct, check the alternator. K Alternator Charging Test ( T C-43).

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C-43

Section C - Electrics Service Procedures Alternator AVO 2002

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

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C-44

– Red lead to volts (middle) socket on meter. – Black lead to negative on meter. – RH slider to DC voltage. – LH slider. K Fig 29. ( T C-43).

AVO 2003

– Red lead to amps socket (marked A) on the meter. – Black lead to negative on meter. – RH slider to DC voltage – LH slider to 200 Shunt

FLUKE 85

– Red lead to volts socket (marked V ) on meter. – Black lead to COM socket on meter. – Set dial to mV.

Start the engine and run at maximum speed (see Technical Data). Meter should show maximum alternator output in Amps (see Technical Data).

Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly. 8

A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability. a

Defective suppression capacitor.

b Dirty slip rings or worn brushes. c

Defective regulator.

d Defective rectifier. e

Open or short - circuited field (rotor) windings.

Open or short - circuited power (stator) windings.

To check for fault a, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary.

To check for faults b and c, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the slip rings using extra-fine glass paper. The regulator may only be checked by substitution.

C-44

Section C - Electrics Service Procedures Starter Motor

Starter Motor TC-005

Starting Circuit Test

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

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

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

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

Connect the voltmeter across the battery terminals. K Fig 30. ( T C-45). Reading in 'start' position: 10.0V approximately. Minimum permissible reading in 'start' position 9.5V.

Fig 31. 3

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

Connect the voltmeter between the solenoid terminal 32-C and a good earth. Minimum permissible reading in 'start' position: 8.0V.

Fig 32.

Fig 30. 2

Connect the voltmeter between the starter main terminal 31-A and the commutator end bracket 31-B. In the 'start' position, the reading should not be more

C-45

9803/9520-8

If the reading is less than specified, connect the voltmeter between the neutral start relay terminal 33-D and earth. An increase in reading to 8.0V indicates a fault in the wiring from the start relay to the solenoid.

C-45

Section C - Electrics Service Procedures Starter Motor b If the reading between terminal 33-D and earth is below 8.0V, connect the voltmeter between terminal 33-E and earth. An increase in the reading to 8.0V indicates either a faulty start relay or a fault in the feed from the transmission selector switch to the relay solenoid. Check also the solenoid earth connection.

Connect the voltmeter between battery positive and the starter main terminal 35-A. With the starter switch 'off', the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to the 'on' position, maximum permissible reading 0.25V.

If the reading between 33-E and earth is less than 8.0V, the fault must be in either the starter switch or in the wiring between the solenoid, starter switch, and the start relay.

Fig 35. If the reading is above 0.25V, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive and solenoid connection 36-H. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.

Fig 33. 4

Connect the voltmeter between battery negative and starter earth connection 34-B. The reading in the 'start' position should be practically zero, maximum permissible reading 0.25V. If the reading is above 0.25V, a high resistance in the earth lead or connections is indicated.

Fig 36. 6

Finally refit the engine stop fuse.

Fig 34.

C-46

9803/9520-8

C-46

Section C - Electrics Service Procedures Wire and Harness Number Identification

Wire and Harness Number Identification TC-003_2

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

Fig 37. Typical Wire and Harness Number K Fig 37. ( T C-47). The illustration shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it's length.

The number stamped on the wire identifies the following:

Table 28. Wire and Harness Number Identification Ident. No.

Description

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

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

819

The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. K Wire Numbers and Functions ( T C-48).

9/371

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

C-47

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C-47

Section C - Electrics Service Procedures Wire and Harness Number Identification

Wire Numbers and Functions

Wires 800-999

Wires 000-199

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

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

Wires In Splices

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

The main input wire is allocated with a wire number and a suitable description, i.e. Wire 640 earth splice to earth. The additional wires in the splice are allocated the same wire number and a postfix, i.e. 640A, 640B, etc. K Fig 39. ( T C-48). Note: The letters I, O, Q and S are not used.

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

Wires 400-599 These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems. Fig 39.

Wires 600-799 General Points These numbers are used for earth wires. When the number is printed onto a wire A it is prefixed by the Earth symbol B. K Fig 38. ( T C-48). This symbol is printed onto the wire, it may however be omitted from harness drawings.

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

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

Fig 38. 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.

C-48

9803/9520-8

C-48

Section C - Electrics Service Procedures Wiring Harness Repair

Wiring Harness Repair TC-004

!MCAUTION

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

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

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

ELEC-2-3

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

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

Repair Procedure Part No.

Table 29. 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 29. ( T C-49), 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 40.

ELEC-2-2

C-49

9803/9520-8

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 40. ( T C-49). Note that each of the splices detailed is colour-coded to make size and range

C-49

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

With the Butane heater assembly, connection. K Fig 41. ( T C-50). a

seal

the

Remove the cap 42-A from the end of the disposable gas cartridge 42-B.

Fig 43. d Turn the small ring 44-E so that the air holes at 44F are completely closed. Fig 41. b Before assembling the gas cartridge to the reflector element 43-C, turn the red ring 43-D to the left, (in the direction of the minus sign marked on the ring).

Fig 44. e Fig 42. c

C-50

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 43. ( T C-50). A click will be heard.

Turn the red ring 45-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.

9803/9520-8

C-50

Section C - Electrics Service Procedures Wiring Harness Repair i

Side wings 47-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices).

Fig 45. f

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown. Fig 47. 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 46-E until the air holes at 46-F are completely open. The tool is ready for use.

Side wings 48-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 48. h To switch off the heater, turn the red ring 48-D to the left (in the direction of the minus sign). Fig 46. g The heater can be used in two modes:

C-51

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Section C - Electrics Service Procedures Wiring Harness Repair

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C-52

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C-52

Section C - Electrics Battery Removal and Replacement

Battery Removal and Replacement

!MCAUTION

!MWARNING

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

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

INT-3-1-14

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

Removal 1

Follow the procedure for disconnection of the battery. see Battery Disconnection - Section 3.

Ensure all battery connection wires are clear of battery top cover.

Disconnect battery clamp 49B by removing handnuts and washers 49A and lifting the clamp clear of the battery.

Lift the battery clear of the machine.

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

C050890

Fig 49.

Replacement Replacement is the reverse of the removal procedure and before reconnection see Battery Connection - Section 3.

C-53

9803/9520-8

C-53

Section C - Electrics Battery Removal and Replacement

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C-54

9803/9520-8

C-54

Section C - Electrics Alternator Removal, Inspection and Replacement

Alternator Removal, Inspection and Replacement

A 743750-C1

B Fig 50. Removal 1

Disconnect the negative (-) lead followed by the positive (+) lead from the battery terminals.

Torque tighten bolts 50-A and 50-B, K Table 30. Torque Settings ( T C-55).

Be sure to reconnect the electrical leads to the alternator in the correct positions.

Remove the alternator (accessory) drive belt, see Section 3, Routine Maintenance. Item

Disconnect the electrical leads from the alternator terminals. Label the leads to ensure they are refitted in the correct positions on assembly.

Undo the bolts 50-A and 50-B. Lift the alternator away from the cylinder block mounting.

50-A, 50-B

Table 30. Torque Settings Nm kgf m 47

4.8

lbf ft 34.7

Inspection 1

Check the brushes for wear. Renew the brushes if the length is less than 8 mm (0.3 in), see K Dismantle and Assemble ( T C-56)

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

It is not necessary to adjust the position of the alternator in order to tension the drive belt, as the accessory drive belt arrangement is self-tensioning.

C-55

9803/9520-8

C-55

Section C - Electrics Alternator Dismantle and Assemble

Dismantle and Assemble Renewing the Voltage Regulator and Brushes 1

The voltage regulator and brush set is a combined assembly. Renew the assembly as follows: a

Carefully remove the protective cover 51-A.

b Withdraw and discard the existing voltage regulator and brushes assembly 51-B and fit new assembly. c

Refit the protective cover 51-A.

Renewing the Drive Pulley 1

Renew the drive pulley as follows: a

Undo nut 51-D and remove washer 51-E. Using suitable pullers, withdraw the pulley 51-C from the shaft. Take care to retain the woodruff key 51-F.

b Fit new drive pulley onto shaft, locating the key 51-F. c

C-56

Refit the washer and tighten the nut 51-D.

9803/9520-8

C-56

Section C - Electrics Alternator Dismantle and Assemble

Fig 51. Alternator Component Key: A

Cover - brushes

Regulator and brush assembly

Drive pulley

Nut - drive pulley

Washer - drive pulley

Woodruff key -drive pulley

Tie bolts

C-57

9803/9520-8

C-57

Section C - Electrics Alternator Dismantle and Assemble

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C-58

9803/9520-8

C-58

Section C - Electrics Starter Motor Removal, Inspection and Replacement

Starter Motor Removal, Inspection and Replacement

A B

743720-C1

C Fig 52.

Removal 1

Disconnect the negative (-) lead followed by the positive (+) lead from the battery terminals. Disconnect the electrical leads 52-A and 52-B from the starter motor terminals. Label the leads to ensure they are refitted in the correct positions on assembly. Undo the 3 bolts 52-C and withdraw the starter motor from the flywheel housing.

Torque tighten bolts 52-C, K Table 30. Torque Settings ( T C-55).

Be sure to reconnect the electrical leads to the starter motor in the correct positions.

Item 52-C

Table 31. Torque Settings Nm kgf m 47

4.8

lbf ft 34.7

Inspection 1

Check the drive pinion splines for damage and excessive wear.

Check the brushes for wear. Renew the brushes if the length is less than 8 mm (0.3 in), see K Dismantle and Assemble ( T C-60).

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

Ensure that the flywheel housing and starter motor mating faces are clean.

Smear the drive pinion splines with JCB MPL Grease before assembly.

C-59

9803/9520-8

C-59

Section C - Electrics Starter Motor Dismantle and Assemble

Dismantle and Assemble Renewing the Brush Gear 1

Renew the brush gear as follows: a

Undo tie bolts 53-F and carefully separate the commutator end cover 53-G.

b Undo screws 53-H. Remove the brush holder and brushes 53-J. c

Check the brushes for wear. Renew the brushes if they are less than 8 mm (0.3 in) long. Refit or renew the brush set as required.

d Clean the commutator 53-K. e

Before refitting the commutator end cover, make sure that the sealing ring 53-L is undamaged and correctly fitted. Ensure wave washer 53-M is fitted inside the cover.

Carefully fit the commutator end cover, then tighten the tie bolts 53-F.

Renewing the Starter Solenoid 1

Renew the starter solenoid as follows: a

Disconnect the starter motor cable from the solenoid connector post 53-N.

b Undo screws 53-B and carefully withdraw the solenoid assembly 53-A. Discard the solenoid. c

Before fitting the new solenoid, make sure that the sealing ring 53-C is undamaged and correctly fitted.

d When fitting the new solenoid, be sure to engage the pinion lever arm 53-E through the hole in the solenoid actuator rod 53-D, then tighten the screws 53-B. e

C-60

Reconnect the starter motor cable to the solenoid connector post 53-N.

9803/9520-8

C-60

Section C - Electrics Starter Motor Dismantle and Assemble

B E

P N

H K M

J L

743740-C1

Fig 53. Starter Motor Component Key: A

Starter solenoid

Screws - starter solenoid (3 off)

Sealing ring - solenoid

Solenoid actuator rod

Pinion lever arm

Tie bolts (2 off)

Commutator end cover

Screws - commutator end cover (2 off)

Brush set

Commutator

Sealing ring - commutator end cover

Wave washer

Cable connector post

Pinion gear

C-61

9803/9520-8

C-61

Section C - Electrics Starter Motor Dismantle and Assemble

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C-62

9803/9520-8

C-62

Section C - Electrics

Harness Data Drawings and Interconnection Harnesses Drawings are reproduced from production electrical harness drawings.

Harness No. 1

Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness. To identify the correct harness drawing for a particular machine refer to the relevant Harness Interconnection page for the machine serial number range.

Issue Remarks

Drawing

Front Chassis 721/12325

K ( T C-66)

Main components connected to this harness:

Headlights Boom Lighting Horn SRS Solenoid

Cab Panel 332/R6766

Main components connected to this harness:

K ( T C-68)

4 Console Instruments Ignition Switch Diagnostic Socket Joystick Console Switches Boom ECU Transmission ECU Connector A Auxiliary ECU Console Warning Lamps Steering Column Switches Starter Switch Fuses and Relays Variflow Pump Control (HVCS) ECU Joystick (Hydraulic Control Lever) Diagnostic Socket Front Wiper Motor Air Conditioning and Heater Immobiliser

C-63

9803/9520-9

C-63

Section C - Electrics Harness Data Drawings and Interconnection 3

Rear Chassis 332/W2737

K ( T C-73)

Main components connected to this harness:

Transmission ECU Connector B Primary Fuses Rear Lights Reverse Alarm Buzzer Starter Solenoid Auxiliary Circuits 3 and 4 Fuel Sender Unit Grid Heater Relay Trailer Socket Front / Rear Washer Pumps Transmission Switches and Solenoids Alternator D+ Torque Converter Lockup Solenoid Servo Isolation Solenoid Brake Light Switch Power Hold Relay Fuel Lift Pump Engine ECU Engine ECU Earth Point HVCS Solenoid

Cab Roof 721/12324

3 Speed Transmission Only

K ( T C-84)

K ( T C-85)

K ( T C-86)

K ( T C-87)

K ( T C-88)

LiveLink 2 332/S9816

K ( T C-81)

Boom Work Light 332/R8501

Transmission Link 332/R0885

K ( T C-78)

Cab Roof (LLMC) 332/W2739

Boom Work Light (LLMC) 332/W5409

10 Boom Quickhitch (LLMC) 332/W5422 11 Cab Panel 333/U1396

C-64

Replaces 332/W5297

9803/9520-9

K ( T C-89)

C-64

Section C - Electrics Harness Data Drawings and Interconnection 12 Cab Panel 332/T5343

K ( T C-89)

K ( T C-100)

K ( T C-103)

K ( T C-104)

K ( T C-105)

13 Front Chassis 332/W2740 14 CAN Bus 332/U2659 15 Reverse Fan 332/W2375 16 Qualcomm Link Harness 332/W5456

C-65

9803/9520-9

C-65

C-66

Cab Connector

Horn

SRS Press Switch

SRS Solenoid

QH / Boom Light

L / H Headlight

R / H Headlight

Front Chassis Earth

Key to Connectors:

K Fig 54. ( T C-67)

Front Chassis- CAD 721/12325 Issue 2

TM310

Section C - Electrics Harness Data

Drawings and Interconnection

9803/9520-9

C-66

Section C - Electrics Harness Data

Fig 54.

Drawings and Interconnection

C-67

9803/9520-9

C-67

C-68

Diagnostic

CAN

Gearbox Controller A

Arm Rest Switch

E-Stop Switch

R / H Column Switch

9803/9520-9

Neutral Start Relay

Display CF and AUX 2

Ignition Relay 2 Diverter Valve Relay Reverse Relay

EG EH EH

Fuel Lift Pump Relay

Road Light Switch

ECU 4 - Boom

Ignition 5 Relay

Buzzer

CX EF

Quick Hitch Isolator Switch

CW Resistor Boom

Park Brake Switch

CV Recovery Switch

Instrument Pack

Mainframe Connector 1

Front Chassis Connector

Suspension Seat

Joystick 1

Diode Pack 2

L / H Column Switch

Mainframe Connector 3

Diode Pack 1

CN-3 Cigar Lighter 3

Diode Pack 4

Joystick Connector 2

Diode Pack 3

CN-2 Cigar Lighter 2

Mainframe Connector 2

Cab Earth 2

CN-1 Cigar Lighter 1

Cab Earth 1

SRS Switch Boom Light Switch

Ignition Relay 1

DN DP

DM-2 Air Conditioning 2

EU EV

Heater Switch

DM-1 Air Conditioning 1

Fog Light Switch

Indicator

Hazard Switch

SRS Relay

Ignition Switch Connector 2

Ignition Switch 1

Dallas Keypad 1

Roof Connector 1

CB Dallas Keypad 2

Immobiliser Control Unit

Roof Connector 2

CA DH

Heater Air Conditioning

Key to Connectors: DG

Brake Light Relay Sense Resistor HVCS

K Fig 55. ( T C-69) DD

Air Conditioning Relay

DC DC

Panel/Cab - CAD 332/R6766 Issue 4

Scroll

Enter

Resistor - Aux

Front Wiper Motor

CF Enable

CAN - Instrument

Gearbox CAN

Fusebox D

Fusebox C

Fusebox B

Fusebox A

ECU 4 Aux

Ignition Relay 4

Transmission Dump Switch

Variflow Control

Pedal Connector 2

Pedal Connector 1

Tow Mode Switch

Voltage Regulator

Armrest Relay

Ignition Relay 3

Section C - Electrics Harness Data

Drawings and Interconnection

C-68

Section C - Electrics Harness Data

Fig 55.

332-R6766-1-1

Drawings and Interconnection

C-69

9803/9520-9

C-69

Section C - Electrics Harness Data

Fig 56.

332-R6766-1-2

Drawings and Interconnection

C-70

9803/9520-9

C-70

Section C - Electrics Harness Data

Fig 57.

332-R6766-1-3

Drawings and Interconnection

C-71

9803/9520-9

C-71

Section C - Electrics Harness Data

Fig 58.

332-R6766-1-4

Drawings and Interconnection

C-72

9803/9520-9

C-72

C-73

Engine DCM Machine Connector

Transmission ECU Connector 2.2

Primary Fuse A

Primary Fuse B

Primary Fuse C

Primary Fuse D

Air Conditioning High Pressure Switch

Air Conditioning Low Pressure Switch

SRS Solenoid

L / H Fog / Reverse Lamp

R / H Fog / Reverse Lamp

Reverse Alarm

Speed Sensor

Starter Solenoid

Brake Pressure Switch

Aux 3 "B"

Aux 3 "A"

Air Conditioning Compressor Clutch

Transmission Oil Pressure Switch

Aux 4 / Boom Retract

Aux 4 / Boom Extend

9803/9520-9

Lower Limit Solenoid Power Hold Relay Fuel Lift Pump

Transmission Dump Pressure Switch

PL PN

Auxiliary Dump Solenoid

PK PM

Reverse Fan

Dump Limit Solenoid

Mainframe Earth 1

Pressure Switch 4

Pressure Switch 3

Servo Isolation Solenoid

Pressure Switch 2

Pressure Switch 1

Brake Light Switch

Diverter Solenoid

Forward Low Solenoid

6th Gear Solenoid

Forward High Solenoid

Torque Converter Lockup Solenoid

Mainshaft Solenoid

Layshaft Solenoid

Reverse Low Solenoid Reverse High Solenoid

NR SM5

Transmission Oil Temperature Switch

SM4

NP-W Alternator W

Air Filter Switch

SM3

Alternator D+

Cab Connector 3

NP-D

Engine ECU Earth Point

Fog Lights

Left Hand Indicators

Right Hand Indicators

Brake Lights

Right Hand Side Lights

Engine Earth

Earth Splice 2

Earth Splice 1

CAN Engine

Oil Temperature Sensor

HVCS Solenoid

Engine Oil Level Switch

Water In Fuel Sensor

SM14 Auxiliary Earth Splice

SM13 Earth Splice 3

SM12 Boom Earth Splice

SM11 Reverse Lights

SM10 Left Hand Side Lights

SM9

SM8

SM7

SM6

SM2

SM1

Rear Washer Pump

Cab Connector 2

Front Washer Pump

Trailer Socket

Cab Connector 1

Grid Heater Relay

Key to Connectors:

L / H Rear Lamp Fuel Sender

K Fig 59. ( T C-74) NH

R / H Rear Lamp

NF NG

Rear Chassis - CAD 332/W2737 Issue 4

Section C - Electrics Harness Data

Drawings and Interconnection

C-73

Section C - Electrics Harness Data

Fig 59.

332-W2737-4-1

Drawings and Interconnection

C-74

9803/9520-9

C-74

Section C - Electrics Harness Data

Fig 60.

332-W2737-4-2

Drawings and Interconnection

C-75

9803/9520-9

C-75

Section C - Electrics Harness Data

Fig 61.

332-W2737-4-3

Drawings and Interconnection

C-76

9803/9520-9

C-76

Section C - Electrics Harness Data

Fig 62.

332-W2737-4-4

Drawings and Interconnection

C-77

9803/9520-9

C-77

C-78

L / H Front Worklight 2

L / H Front Worklight

9803/9520-9

R / H Front Worklight 2

R / H Front Worklight

Beacon Switch

Cab Roof Earth

Front Worklight Switch

LMI

Rear Worklight Switch

Rear Wash / Wipe Switch

Radio Speaker

L / H Speaker

SB-1

RR-2 R / H Interior Light

RR-1 R / H Interior Light

RP-2 L / H Interior Light

RP-1 L / H Interior Light

L / H Rear Worklight 2

L / H Number Plate Light

Radio

Cab Connector 1

Beacon

Rear Wiper

R / H Number Plate Light

L / H Rear Worklight

R / H Rear Worklight 2

R / H Rear Worklight

Cab Connector 2

Key to Connectors:

K Fig 63. ( T C-79)

Cab Roof- CAD 721/12324 Issue 2 L / H Speaker

SC-2 R / H Speaker

SC-1 R / H Speaker

SB-2

Section C - Electrics Harness Data

Drawings and Interconnection

C-78

Section C - Electrics Harness Data

Fig 63.

721-12324-2-1

Drawings and Interconnection

C-79

9803/9520-9

C-79

Section C - Electrics Harness Data

Fig 64.

721-12324-2-2

Drawings and Interconnection

C-80

9803/9520-9

C-80

C-81 Left Hand Speaker

SB-2

Front Work Light 2 Earth 1 Earth 2 Interior Light Radio Rear Work Light 1 Rear Work Light 2 Roof Switch Wash Wipe

SR2 SR3 SR4 SR5 SR6 SR7 SR8 SR9

Right Hand Rear Work Light

Right Hand Rear Work Light 2

Right Hand Number Plate Light

Beacon

Cab Connector 1

Left Hand Number Plate Light

Rear Wiper

Left Hand Rear Work Light

Radio

Left Hand Rear Work Light 2

Left Hand Front Work Light 2

Left Hand Front Work Light

9803/9520-9

Right Hand Front Work Light 2

Right Hand Front Work Light

Beacon Switch

Cab Roof Earth

Front Work Light Switch

LLMC 1

LLMC 2

Rear Work Light Switch

Rear Wash / Wipe Switch

Radio Speaker

RXA

RXB

RR-2 Right Hand Interior Light

RR-1 Right Hand Interior Light

RP-2 Left Hand Interior Light

RP-1 Left Hand Interior Light

Front Work Light 1

SR1

Cab Connector 2

SR10 LLMC Feed

SC-2 Right Hand Speaker

SC-1 Right Hand Speaker

Left Hand Speaker

SB-1

Key to Connectors:

K Fig 65. ( T C-82)

Cab Roof (LLMC)- CAD 332/W2739 Issue 2

Section C - Electrics Harness Data

Drawings and Interconnection

C-81

Section C - Electrics Harness Data

Fig 65.

332-W2739-2-1

Drawings and Interconnection

C-82

9803/9520-9

C-82

Section C - Electrics Harness Data

Fig 66.

332-W2739-2-2

Drawings and Interconnection

C-83

9803/9520-9

C-83

C-84

K Fig 67. ( T C-84)

Transmission Link Harness - CAD 332/R0885 Issue 2

Fig 67.

Rear Chassis Harness Connector

MF-A Gearbox

Key to Connectors:

332-R0885-1

Section C - Electrics Harness Data

Drawings and Interconnection

9803/9520-9

C-84

C-85

Key to Connectors:

Boom Worklights - CAD 7332/R8501 Issue 1 R/H Boom Worklight

Fig 68.

L/H Boom Worklight

FP FR

Boom Worklight

32-R8501-1

Section C - Electrics Harness Data

Drawings and Interconnection

9803/9520-9

C-85

C-86

12-Way Socket

Key to Connectors:

LiveLink 2 - CAD 333/S9816-1-1

SCR

Fig 69.

CAN H CAN L

S! S2

12-Way Socket

AV C005 Resistor

C004 Harness Connector

C003 CAN Connector

333-S9816-1-1

Section C - Electrics Harness Data

Drawings and Interconnection

9803/9520-9

C-86

C-87

Key to Connectors:

Boom Worklight Harness (LLMC) - CAD 332/ W5409-3-1 Splice Splice Socket

BL1 BL2 BL3

Fig 70.

BL4 Splice

Socket

332-W5409-3-1

Section C - Electrics Harness Data

Drawings and Interconnection

9803/9520-9

C-87

C-88

Key to Connectors:

Boom Quickhitch Harness (LLMC) - CAD 332/ W5422-2-1

Fig 71.

C002 Boom Quickhitch Solenoid

C001 Front Chassis Connector

332-W5422-2-1

Section C - Electrics Harness Data

Drawings and Interconnection

9803/9520-9

C-88

C-89

9803/9520-9

Power Socket

Left Hand Column Switch

Joystick 1

Front Chassis Connector

Mainframe Connector 1

Instrument Pack

Park Brake Switch

Quick Hitch Isolator Switch

Buzzer

ECU 4 - Boom

Road Light Switch

Neutral Start Power Hold Relay

Right Hand Column Switch

Servo Cut-Off Switch

Diagnostic

Arm Rest Switch

Fog Light Switch

Hazard Switch

Gearbox ECU A

Ignition Switch Connector 2

Ignition Switch 1

CAN

Roof Connector 2

Roof Connector 1

Key to Connectors:

– Splices SC38 and SC39 removed.

– DA changed from a mini relay base to a twin micro relay base.

– DWC Dump stop diode removed.

Changes from 332/W5297:

Cab Panel Harness- CAD 333/U1396 Issue 1 DD

Auxiliary Dump Switch

LLMC ECU4

Heater Switch

Indicator

Auxiliary Diode B

Auxiliary Diode A

Lower Sense Resistor

Cab Earth 1

Cab Earth 2

Boom Light Switch

SRS Switch

Ignition Relay 1

DYC

DYB

DYA

DXD

DXC

DXB

DXA

Joystick Connector 2

Auxiliary 2 Diode

HVCS Diode

Auxiliary ECU Diode

SRS Diode

Alternator Diode

Worklight Diode

Brake Light Diode

DWC Dump Stop Diode

DWB Boom Retract Diode

DWA Boom Extend Diode

DVB

DVA

DM-2 Air Conditioning 2

DM-1 Air Conditioning 1

SRS Relay

Reverse Fan Switch

DG DJ

Immobiliser

Heater

Air Conditioning Brake Light Relay Cab Earth 2B

DC DE

Display CF and AUX 2

DZA

Options Plug

Auxiliary Resistor

Front Wiper

Instrument CAN

Gearbox CAN

68R Resistor

Front Chassis Earth

Trailer Flash

Fusebox D

Fusebox C

Fusebox B

Fusebox A

ECU 4 Auxiliary

Ignition Relay 4

Transmission Dump Switch

ECU 4 Pump Control

Pedal Connector 2

Pedal Connector 1

Transmission Mode Switch

5 Volt Supply

Armrest Fog Latch Relay

Ignition Relay 3

Diverter Valve Reverse Relay

Ignition Relay 2

Ignition 5 Fuel Pump Relay

Extend/Retract Resistor

Recovery Switch

Suspension Seat

Mainframe Connector 3

Mainframe Connector 1

Section C - Electrics Harness Data

Drawings and Interconnection

C-89

Section C - Electrics Harness Data

Fig 72.

333-U1396-1-1

Drawings and Interconnection

C-90

9803/9520-9

C-90

Section C - Electrics Harness Data

Fig 73.

333-U1396-1-2

Drawings and Interconnection

C-91

9803/9520-9

C-91

Section C - Electrics Harness Data

Fig 74.

333-U1396-1-3

Drawings and Interconnection

C-92

9803/9520-9

C-92

Section C - Electrics Harness Data

Fig 75.

333-U1396-1-4

Drawings and Interconnection

C-93

9803/9520-9

C-93

Section C - Electrics Harness Data

Fig 76.

333-U1396-1-5

Drawings and Interconnection

C-94

9803/9520-9

C-94

C-95

9803/9520-9

Display CF and AUX 2

ECU 4 - Boom

Buzzer

Quick Hitch Isolator Switch

Park Brake Switch

Neutral Start Relay

Instrument Pack

DZA

Mainframe Connector 1

Front Chassis Connector

L / H Column Switch

Joystick 1

CN-3 Power Socket 3

R / H Column Switch

LLMC ECU4

Heater Switch

Indicator

Diverter Valve Reverse Relay

Ignition Relay 2

Ignition 5 Fuel Pump Relay

Extend/Retract Resistor

Recovery Switch

Suspension Seat

Mainframe Connector 3

Mainframe Connector 2

Joystick Connector 2

Diode Pack 4

Diode Pack 3

Diode Pack 2

Diode Pack 1

Lower Sense Resistor

M10 Ring

Cab Earth 1

Boom Light Switch

SRS Switch

Ignition Relay 1

DM-2 Air Conditioning 2

CN-2 Power Socket 2

Servo Cut-Off Switch

Auxiliary Dump Switch SRS Relay

DM-1 Air Conditioning 1

CN-1 Power Socket 1

Arm Rest Switch

Diagnostic

CAN

Fog Light Switch

Gearbox ECU A

Hazard Switch

Ignition Switch Connector 2

Ignition Switch 1

Roof Connector 1

Reverse Fan Switch

Immobiliser Control Unit

DF DG

Heater Air Conditioning

Roof Connector 2

Cab Earth 2B

Air Conditioning Brake Light Relay

Key to Connectors:

K Fig 55. ( T C-69)

Cab Panel Harness- CAD 332/T5343 Issue 3 (JCB444 T3)

Options Plug

Scroll

Enter

Auxiliary Resistor

Front Wiper

Instrument CAN

Gearbox CAN

68R Resistor

Front Chassis Earth

Trailer Flash

Fusebox D

Fusebox C

Fusebox B

Fusebox A

ECU 4 Auxiliary

Ignition Relay 4

Transmission Dump Switch

Variflow Control

Pedal Connector 2

Pedal Connector 1

Tow Mode Switch

Voltage Regulator

Armrest Fog Latch Relay

Ignition Relay 3

Section C - Electrics Harness Data

Drawings and Interconnection

C-95

Section C - Electrics Harness Data

Fig 77.

332-T5343-3-1

Drawings and Interconnection

C-96

9803/9520-9

C-96

Section E Hydraulics Service Manual - TM310 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-9

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

Section E - Hydraulics

Notes:

E-0

9803/9520-9

E-0

Section E - Hydraulics Contents Page No. Technical Data Main Hydraulic Pump ............................................................................... E-1 Variable Flow ........................................................................................ E-1 Auxiliary Pump ..................................................................................... E-1 Control Valve Block .................................................................................. E-2 Maximum RPM Cycle Times ................................................................ E-2 Smooth Ride System (SRS) ..................................................................... E-3 Accumulator ......................................................................................... E-3 Basic Operation Flowshare ................................................................................................. E-5 Component Location and Identification ................................................ E-6 Oil Pump ............................................................................................... E-8 Load Sensing ....................................................................................... E-8 Pressure Compensation (Flowshare) ................................................... E-8 Hydraulic Circuit Operation .................................................................. E-8 Circuit Descriptions Variable Displacement Pump Operation ................................................. E-13 Hydraulic Variable Control System (HVCS) ....................................... E-15 Pulse Width Modulation (PWM) .............................................................. E-18 Schematic Circuits TM310 .................................................................................................... E-19 Service Procedures Flow and Pressure Tests ........................................................................ E-21 Checking Pump Flow ......................................................................... E-21 System Pressures .............................................................................. E-22 Checking the Servo Pilot Pressure ..................................................... E-25 `Positional Type' Hydraulic Adaptors ...................................................... E-26 Fitting Procedure ................................................................................ E-26 Bleeding the Hydraulic System ............................................................... E-27 Hand Control Valve (Servo) Hand Control Valve ................................................................................. E-29 Removal and Replacement ................................................................ E-29 Dismantling, Inspection and Assembly ............................................... E-30 Main Hydraulic Pump Removal and Replacement .................................................................... E-33 Removal ............................................................................................. E-33 Replacement ...................................................................................... E-34 Dismantle and Assemble ........................................................................ E-36 Control Valve Block Handling ................................................................................................. E-37 Removal ................................................................................................. E-38 Replacement .......................................................................................... E-39 Hose Connections .............................................................................. E-39 Boom Internal Pipes and Hoses Removal and Replacement .................................................................... E-41 Removal ............................................................................................. E-41 Assembly ............................................................................................ E-44

E-i

Section E - Hydraulics Contents

Contents Page No. Hydraulic Rams Precautions During Use .......................................................................... E-45 Installation .......................................................................................... E-45 Caution During Use ............................................................................ E-45 Maintenance, Inspection Points ......................................................... E-45 Lift Ram .................................................................................................. E-47 Removal ............................................................................................. E-47 Replacement ...................................................................................... E-47 Displacement Rams ............................................................................... E-49 Removal ............................................................................................. E-49 Replacement ...................................................................................... E-49 Extension Ram ....................................................................................... E-51 Removal ............................................................................................. E-51 Replacement ...................................................................................... E-51 Tilt Ram .................................................................................................. E-53 Removal ............................................................................................. E-53 Replacement ...................................................................................... E-55 Dismantle and Assemble ........................................................................ E-56 Typical Ram ........................................................................................ E-56 Tilt Ram .............................................................................................. E-59 Lift Ram .............................................................................................. E-60 Extension Ram ................................................................................... E-61 Displacement Ram ............................................................................. E-62 Smooth Ride System (SRS) Technical Data ........................................................................................ E-63 Description .............................................................................................. E-64 Hydraulic Schematic ........................................................................... E-65 Fault Finding ........................................................................................... E-66 Accumulators .......................................................................................... E-67 Charging and Discharging .................................................................. E-67 Removal and Replacement ................................................................ E-68 Dismantling and Assembly ................................................................. E-70 Anti-Cavitation Valve Removal and Replacement .................................................................... E-73 Removal ............................................................................................. E-73 Replacement ...................................................................................... E-73 Hose Connections .............................................................................. E-74 Basic Hydraulic and Electrical System Information Longitudinal Load Moment ..................................................................... E-75 System Overview ............................................................................... E-75 Setting the Volume and Brightness .................................................... E-77 Warm Up Procedure ........................................................................... E-78 Daily Functional Check ....................................................................... E-78

E-ii

Section E - Hydraulics Contents

Contents Page No. Longitudinal Load Moment Control ......................................................... E-79 Principal of Operation ......................................................................... E-79 Groundworks Mode and Pick and Place Mode .................................. E-80 System Flow Diagram ........................................................................ E-81 LMI Transducers ................................................................................. E-84 Angle Sensors .................................................................................... E-87 LMI Output Signal (PWM) .................................................................. E-87 Groundworks Mode Enable ................................................................ E-87 End-Damping ..................................................................................... E-88 Diagnostic Fault Codes ...................................................................... E-89 Blink Error Codes ............................................................................... E-91 Test Weight ......................................................................................... E-93 LLMI, LLMC Calibration Check .......................................................... E-93 Machine Stability Check ..................................................................... E-93 System Checks .................................................................................. E-93 Calibration .......................................................................................... E-94

E-iii

Section E - Hydraulics Contents

Contents

E-iv

Page No.

E-iv

Section E - Hydraulics Technical Data Main Hydraulic Pump

Technical Data Main Hydraulic Pump Variable Flow Type:

Variable Displacement

Reference:

A10VO-63EKXDX/53R

Mounting:

Gearbox

Load Sense Pressure Margin to Pump Pressure (Delta-P)

15 bar

217 lbf/in2

Pump Stand-by Pressure (in neutral position)

25 bar

362.5 lbf/in2

Pressure Cut Off

250 bar

3626 lbf/in2

Maximum Displacement

63cc/rev

3.85in3/rev

Maximum Flow at 2350 rpm

140 L/min

30.7 gal/min

Flow in Load Sense Line

1-5 L/min

0.22-1.1 UK gal/min

35 kg

77 lb

Weight

bar

kg/cm2

lbf/in2

Brake Charge Valve Cut In Pressure

86.6

1232

Cut Out Pressure

115

117.2

1668

Maximum Brake Line Pressure

870

Service Flows Boom

130 L/min

28.5 gal/min

Extension

125 L/min

27.5 gal/min

Tilt

125 L/min

27.5 gal/min

Auxiliary

90 L/min

20 gal/min

6 cc/rev

22 L/min

Note: The auxiliary and the extension solenoid operated services only require 15 bar internal pilot pressure. The other services require 30 bar external pilot pressure.

Auxiliary Pump Flow at 2420 x 1.625 rev/min

E-1

9803/9520-8

E-1

Section E - Hydraulics Technical Data Control Valve Block

Control Valve Block Type:

4 Spool, load sense - pressure compensated, double acting spools.

Spool 1

Boom Raise & Lower Service

Solenoid Operated

Spool 2

Extend Service

Pilot Operated

Spool 3

Carriage Tilt Service

Solenoid Operated

Spool 4

Auxiliary Service

Pilot Operated

Relief Valve Pressures: K Fig 1. ( T E-2). bar

kgf/cm2

lbf/in2

215

219.2

3118.3

230

234.5

3335

J - Carriage Tilt Ram Head Side

240

244.7

3480.9

H - Carriage Tilt Ram Rod Side

240

244.7

3480.9

C - Load Sense Relief Valve (1) (2)

P - Valve Block Inlet Pressure

Auxiliary Relief Valves (ARV's)

M - Pressure Reducing Valve

35.6

507.6

Load Sense Pressure at Steer Relief

180

183.5

2610

Pump Pressure at Steer Relief

195

198.8

2828

(1) Before testing the Load Sense Relief Valve pressure, allow the hydraulic system to warm up to 50 Â°C (122 Â°F) to ensure an accurate reading. (2) This value is always 15 bar higher than the Load Sense Pressure Relief Valve pressure. Dump

2.6 Seconds

Extend

4.0 Seconds

Retract

2.6 Seconds

Fig 1.

Maximum RPM Cycle Times The cycle times below are the figures with an unladen boom. Lift

6.0 Seconds

Lower

4.4 Seconds

Crowd

3.0 Seconds

E-2

9803/9520-8

E-2

Section E - Hydraulics Technical Data Smooth Ride System (SRS)

Smooth Ride System (SRS) Accumulator

A Important: Upon installation of new accumulator the correct decal stating charge pressure must be attached. Remove original decal which states a zero charge pressure. Decals may be in the form of a large plate K Fig 2. ( T E-3) or a smaller plate K Fig 3. ( T E-3). A piston type accumulator operates as a liquid spring absorbing displaced fluid from the lift ram. Selectable from a switch in the cab. Charging Gas

Air Free Dry Nitrogen

Accumulator Capacity

1.0 litre (58 cu/in)

Accumulator Weight

4.4 kg (9.75 lb)

Charge Pressures Although identical in appearance, the accumulators are charged to different pressures. When renewing an accumulator make sure that it is charged to the correct pressure. Note: Replacement accumulators will only be supplied in an uncharged, non pressurised condition to meet Health and Safety, and Air freight hazardous goods requirements. Accumulator Charge Pressure

Bar

Psi

- Accumulator 1 (0.5L)

362

- Accumulator 2 (0.24 L)

218

- Accumulator 1 (1.0 L)

34.5

500

- Accumulator 2 (1.0 L)

1200

Boom Suspension System (Option)

Important: When replacing the lift ram or hose burst check valve on machines fitted with SRS, it is important that all the hydraulic pressure in the accumulators is vented, see Smooth Ride System (SRS), Accumulators. Failure to do this may result in the valve being forced out of the cavity as it is unscrewed.

Fig 2.

Fig 3.

E-3

9803/9520-8

E-3

Section E - Hydraulics Technical Data Smooth Ride System (SRS)

Page left intentionally blank

E-4

9803/9520-8

E-4

Section E - Hydraulics Basic Operation Flowshare

Basic Operation Flowshare The following explains the basic operation of Flowshare machines with a variflow pump driven hydraulic system. The JCB Flowshare variflow hydraulic system differs in many important aspects to that of the normal parallel hydraulic system. Before attempting to service or fault find the system ensure that you read and understand all the descriptions in this section.

E-5

9803/9520-8

E-5

Section E - Hydraulics Basic Operation Flowshare

Component Location and Identification Table 1. Component Key

E-6

Item

Description

Oil Cooler

Mounted on the machine cooling pack.

Hydraulic Oil Filter

Positioned in hydraulic tank

Pump Assembly

A variflow pump mounted in the cab floor.

Control Lever

Servo control lever.

Pump Control Solenoid (HVCS)

Located on the variflow pump 3.

Control Valve Block

Flowshare valve with solenoid and servo control spools.

Load Sense Relief Valve

Controls maximum system pressure.

Hydraulic Tank

Mounted on the rear of the machine.

Pump Control ECU (HVCS)

Positioned behind the fuse and relay panel.

PWM ECU's

Positioned behind the fuse and relay panel.

Accumulator Valve Block (Servo and brake pressure)

Positioned at the front right of the chassis to the right of the valve block.

Anti Cavitation Valve

Positioned at the front right of the chassis below the valve block.

9803/9520-8

E-6

Section E - Hydraulics Basic Operation Flowshare

5 3 1

9 9 8 1

11 C080220

Fig 4. Component Location

E-7

9803/9520-8

E-7

Section E - Hydraulics Basic Operation Flowshare

Oil Pump

Pressure Compensation (Flowshare)

Oil is drawn from the hydraulic tank 4-7 by the hydraulic pump assembly 4-3. The pump assembly is mounted on the rear of the gearbox and is driven by the engine.

Each service spool incorporates a pressure compensator valve. When services are operated simultaneously the system ensures consistent operating speed for all services, even when the limit of the hydraulic pump performance is approached.

The hydraulic pump 4-3 is a variable displacement axial piston type. The pump output flow is controlled by varying the angle of the internal tilting swashplate mechanism.

Hydraulic Circuit Operation

The angle of the swashplate is regulated automatically by the hydraulic load sense pressure, so that the pump only delivers the amount of oil that is needed to satisfy the hydraulic system demand.

Note that to make the description as clear as possible the diagrams show only part of the complete hydraulic system. For the complete hydraulic schematics, see Schematic Circuits.

The angle of the swashplate is also controlled by the pump control solenoid 4-5. The solenoid is controlled by the pump controller ECU (HVCS) 4-8.

No Services Operated: K Fig 5. ( T E-10).

The ECU monitors the load on the engine by comparing the throttle pedal position with the actual engine speed. If the engine is overloaded the ECU responds with a signal to the solenoid and the swashplate angle is reduced. The ECU also monitors the hydraulic oil temperature. When the oil reaches a pre-determined value the pump controller ECU responds with a signal to the solenoid and the swashplate angle is reduced. The resultant reduction in oil flow allows the oil to cool.

With all the services in neutral, there is no demand for flow from the hydraulic pump P, and consequently the pump internal tilting swashplate is at its minimum angle. In this condition the pump delivers only the minimum flow that is needed to satisfy normal system internal leakage, and to generate a system standby pressure. A small amount of oil from the pump P flows to the inletoutlet section of the control valve 3.

Oil from the pump 4-3 flows to the control valve block 4-6.

When the main system pressure reaches around 15 bar the spring 3a in flushing valve 3b is overcome and oil is returned back to tank.

The hydraulic oil cooler 4-1 in the return line from the valve block 4-6 cools the system hydraulic oil.

Note: The pump also supplies the steer circuit via the steer priority valve 1.

Load Sensing

Oil from the pump P also flows through the chassis mounted filter assembly to the servo pressure supply valve 5. The valve supplies servo pilot oil pressure regulated at 35 bar to the valve spools.

When a service is operated, the system senses the demand and responds by increasing the pump operating pressure to a value slightly above that required to move the load. The load sense feature also incorporates the main pressure relief function, which is controlled by the load sense relief valve 4-6A. This replaces the Main Relief Valve (MRV) used in the normal system.

Service Operation: K Fig 6. ( T E-11). When a service is operated, boom lift for example, movement of the joystick controller supplies pilot oil to actuate the service spool 3f. The controller supplies pilot oil at a pressure proportional to the joystick movement, thus controlling how far the service spool is displaced. Oil passes across the service spool to the applicable pressure compensator valve 3d.

E-8

9803/9520-8

E-8

Section E - Hydraulics Basic Operation Flowshare The valve opens and diverts oil to the load sense gallery and load hold check valve 3e.

only the minimum flow needed to maintain the system pressure at the maximum setting.

Pressure in the load sense gallery increases and the flushing valve 3b begins to close. At the same time, the pump P responds to the load sense pressure by increasing the angle of the tilting swashplate.

Since the main system pressure required to open the flushing valve is around 15 bar above the load sense pressure it follows that the main system pressure will be limited to 215 bar + 15 bar, a total of 230 bar.

As the swashplate angle increases, the output flow from the pump increases proportionally, and the main system pressure continues to rise until load hold check valve 3e opens and the boom lift ram 7 operates.

Note: The pressure values given are examples for the purpose of explanation only. Actual values may be different depending on the machine variant. All pressure relief valves are factory set. No adjustment is normally required.

The main system pressure will now be equal to the load sense pressure (load from the boom lift ram) + the force of flushing valve spring 3a (around 15 bar). Oil from the other side of the ram 4 flows across the service spool and returns back to tank in the normal way. Multiple Service Operation: In the normal hydraulic system the services are connected in parallel, this means that when multiple services are operated simultaneously, the speed of one service can be affected by the operating pressure of another service. This is not the case with precision control.

Table 2. Colour Key to Oil Flow and Pressure Full Pressure Load Sense Line Servo Neutral Exhaust

The pressure compensator valves for each service react to the differing load pressures. For example, when a pressure compensator valve is subjected to a higher load sense pressure from another service, it reacts to reduce the flow to its service, ensuring that the associated ram operates at a constant speed, regardless of the increase in the main system pressure. Main System Pressure Relief: K Fig 7. ( T E-12). The maximum main system pressure is controlled by limiting the maximum load sense pressure. When a service ram reaches the end of its stroke, or the service meets resistance and generates pressure above 215 bar in the load sense line, the load sense relief valve 3c opens and load sense oil is dumped to tank, preventing further pressure rise. Some of the system oil passes across the flushing valve 3b as normal. At the same time, the pump P responds to the load sense pressure by decreasing the angle of the tilting swashplate towards its minimum angle. As the swashplate angle decreases, the output flow from the pump reduces accordingly so that the pump delivers

E-9

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E-9

E-10

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Fig 5. No Services Operated (Neutral)

3f 3g

1 2 3 4

C080250-C1

Section E - Hydraulics Basic Operation Flowshare

E-10

E-11

3d 3e

Fig 6. Service Operation

3f 3g

1 2 3 4

C080250-C2

Section E - Hydraulics Basic Operation Flowshare

9803/9520-8

E-11

E-12

9803/9520-8

3d 3e

Fig 7. Main System Pressure Relief

3f 3g

1 2 3 4

C080250-C3

Section E - Hydraulics Basic Operation Flowshare

E-12

Section E - Hydraulics

Circuit Descriptions Variable Displacement Pump Operation

Fig 8. Sectioned View The pump output flow and operating pressure are controlled by varying the angle of the tilting swashplate A. The swashplate is moved in one direction by the force of the spring B, and in the opposite direction by control pressure (orange) acting behind the swash control piston C. The control pressure is derived from the pump operating pressure (red) by the action of the flow compensator spool D.

E-13

The flow compensator spool regulates the angle of the swashplate automatically in response to changes in the hydraulic load sense pressure (yellow) from the hydraulic service. Flow Compensator Valve: When a hydraulic service is operated, boom lift for example, a pressure signal (demand) is generated in the load sense line LS from the control valve block.

9803/9520-8

E-13

Section E - Hydraulics Circuit Descriptions Variable Displacement Pump Operation The increase in the load sense pressure, combined with the force of the spring E pushes the flow compensator spool D to the right, this in turn, allows some control pressure (orange) acting on the swash control piston C to vent back to tank via the case drain (green). The force of the spring B increases the angle of the swashplate A and the pump output flow increases proportionally. When the output flow is enough to satisfy the flow demanded by the service, the pump operating pressure P (red) increases sufficiently to start to move the service ram. The increase in the pump operating pressure pushes the flow compensator spool D back to the left, against the force of the spring E and hydraulic load sense pressure; this in turn increases the control pressure acting on the swash control piston C, which decreases the angle of the swashplate A against the force of spring B. As the swashplate angle decreases, the output flow from the pump decreases. In this way, the pump delivers only the minimum flow needed to maintain the system pressure required to operate the service. Note: The flow compensator spool D is moving constantly, thereby regulating the pump swashplate to balance the pressures acting on each end of the spool. The additional force of spring E is factory set to be equivalent to 25 bar (360 lbf/in2), therefore the pump operating pressure (i.e. main system pressure) will always be maintained at 25 bar above the load sense pressure. This is sometimes referred to as the `Delta-P' pressure setting.

Hydraulic Variable Control Solenoid Valve: The proportional solenoid valve X is part of the hydraulic variable control system (HVCS). The system automatically adjusts the pump performance (power curve characteristic) to limit the hydraulic power available to the hydraulic services under conditions of high engine load or high hydraulic fluid temperature. The solenoid valve is controlled by a current signal output from a pump controller electronic control unit (ECU). The solenoid valve works as a separate pressure regulating valve and increases the control pressure acting on the swash control piston C by a set amount, according to the valve current signal. Because the control pressure is regulated by the solenoid valve independently (down stream) of the flow compensator spool D, this means that when it is operating, it will alter the way that the pump swashplate normally responds to changes in the hydraulic load sense pressure. In this way, the hydraulic power curve of the pump can be adjusted electrically by the current signal from the pump controller ECU. For details of the HVCS electrical circuit and connections K Hydraulic Variable Control System (HVCS) ( T E-15).

Pressure Cut-Off Valve: The pressure cut-off valve is a secondary safety device to limit the maximum operating pressure, and thereby protect the pump from over pressurisation. If the pump operating pressure P (i.e. main system pressure) ever reaches the setting of the valve springs F, the pressure cut-off spool G will be pushed to the left, this in turn, increases the control pressure acting on the swash control piston C, which decreases the angle of the swashplate, and reduces the pump output flow to minimum. While the pressure cut-off valve is operating, the pump will remain hydraulically stalled i.e. maintaining maximum operating pressure at minimum flow.

E-14

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E-14

Section E - Hydraulics Circuit Descriptions Variable Displacement Pump Operation

This section explains how the HVCS electrical system works.

Central to the system is the pump controller electronic control unit (ECU) ER mounted in the engine compartment. The ECU receives an engine load signal (actual engine torque) from the engine ECU (not shown) via the Gearbox ECU CJ, and also a hydraulic fluid temperature signal from the variflow pump temperature switch PY.

609M

609N

Hydraulic Variable Control System (HVCS)

E.C.U 4

452

1906

When the HVCS system is operating, the pump controller ECU shows a pump symbol on the instrument panel CU.

For a detailed explanation of PWM current signal output, see K Pulse Width Modulation (PWM) ( T E-18).

E-15

FUSE 35

FUSE 34

304 FUSE 28

FUSE 33

111

Note: The Gearbox ECU CJ converts the existing engine load CANbus protocol signal from the engine ECU, into a corresponding LINbus protocol signal to the pump controller ECU ER. For details of the wires and connectors K Wires and Connectors ( T E-16).

112A

113A

113B

The solenoid valve operates to adjust the pump performance (power curve characteristic) and thereby limits the hydraulic power available to the hydraulic services.

112B

1903A

1904

When the pump controller ECU senses that the engine is being overloaded, or when the hydraulic fluid temperature reaches a set limit, it sends a corresponding pulse width modulated (PWM) current signal output to the variflow pump proportional solenoid valve PX.

450

603J

Fig 9. Electrical Schematic Component Key: ER

Pump Controller ECU

Gearbox ECU

Instrument panel - HVCS `Active' warning light

HVCS Proportional solenoid valve (Variflow pump)

Hydraulic fluid temperature switch (Variflow pump - suction port)

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E-15

Section E - Hydraulics Circuit Descriptions Variable Displacement Pump Operation Wires and Connectors

Connectors (h1)

Wires and connectors K Fig 10. ( T E-17) as applicable. On the electrical diagram the electrical connectors (example, EA) are shown looking on the mating face of each connector when they are disconnected.

The wire numbers and colours, where appropriate, are shown as an aid to identification while fault finding. Before fault finding make sure that you understand how the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and solenoid coils.

Sense Resistor HVCS

Connectors (h2) PX

HVCS Proportional solenoid valve (Variflow pump)

Hydraulic fluid temperature switch (Variflow pump - suction port)

h2 - h1

Earth Point 1

Splices (h1) Note: When fault finding do not use a multimeter on the ECU pins. Only test the associated wiring. Uncouple the connector ER and then use a multimeter at the pins inside the connector as applicable. The ECU is inherently more reliable than its associated wiring and components. Before renewing the ECU be sure to check all the related equipment first.

SC12

Earth Splice D

SC13 SC29 SC30 SC33 SC34

Splices (h2) SM13

Rear Chassis Earth Splice

Component Key: The following key identifies the component connectors on the electrical diagram. For harness drawings, see Section C, Harness Data. h1

Harness - 332/R6766 Panel

Harness - 721/12544 Rear Chassis

Connectors (h1) EA

h1 - h2

Pump controller ECU

Fusebox C

Instrument Panel

Transmission ECU Connector A

Cab Earth Point 2

Diode Pack 2

E-16

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E-16

Section E - Hydraulics Circuit Descriptions

450

20 19 18 17 16

15 14 13 12 11

30 29 28 27 26

25 24 23 22 21

40 39 38 37 36

35 34 33 32 31

EA 24

22 27

SC13

1904A 1904

111

SC33 1

FUSE 33

621A

4 9

12 11 10

19 17 15 13 11 9 7 5 3 1

20 18 16 14 12 10 8 6 4 2

E.C.U.

5 8 8 5

6 7 7 6

E-17

12 11 10

111AA

SC30 1903

111AB

450

1904B

452

1906

SC34

SC12 609N

609M

1903B

SC29

1903A

Fig 10. Wires and Connectors - Hydraulic Variable Control System

35 34 33 32 31 25 24 23 22 21 15 14 13 12 11

40 39 38 37 36 30 29 28 27 26 20 19 18 17 16 10

2 1

1904 1903A

603J

SM13

Variable Displacement Pump Operation

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E-17

Section E - Hydraulics Circuit Descriptions Pulse Width Modulation (PWM)

Pulse Width Modulation (PWM) Ohms law states that, the amount of current flow in a circuit is determined by the voltage, and the resistance. A 12v circuit with a resistance of 6 ohms, would draw a current of 2 amps. This would be the case for a standard solenoid, which is either on or off.

The graph A although unstable would give a current rating of 1.5 amps. To stabilise the current in the circuit, the frequency would need to be increased. If the time scale on the graph A was one second, the frequency would be 4Hz (Hertz (cycles per second)).

Once the voltage is applied to the circuit, it is present 100% of the time. This would be known as a 100% duty cycle. Therefore the circuit will draw 2 amps constantly.

The graph B shows the same duty cycle, but at a higher frequency of 32 Hz. Note that the proportional solenoids can operate at a frequency of 250 Hz.

A 3

Current

Time ON

75% Duty cycle

1 cycle 3

Voltage

Current Time

Fig 11. A proportional solenoid requires differing amounts of current, depending on its condition. As the coil has a fixed resistance, changing the current rating can be done in either of two ways, 1

Having lots of different resistors switched in and out of the circuit at different times to change the current flowing.

To change the duty cycle of the solenoid.

Fig 12.

It is easier, more economical, and more reliable to change the duty cycle of the circuit, especially using today's computer - controller technology. The duty cycle is the amount of time a component is switched on compared to the time it is switched off. If a solenoid is on for three seconds, then off for one second, on for three, off for one etc. this would be a 75% duty cycle.

E-18

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E-19

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Priority Pressure Regulating Valve

Load Sensing Relief Valve

Servo Cut-off Valve

Pressure Relief Valve

Auxiliary Relief Valve

Lift Control Spool

High Pressure Relief Valve

Loader Control Valve

Accumulator Charge Valve

Brake Modulating Valve

Auxiliary Pump

Accumulator Block

Trailer Brake (Option)

Front Axle Brakes

Suction Strainer

Main Pump

Filter

Oil Cooler

Hydraulic Tank

Filler/Breather

Steer Shock Valves

Load Sensing Steer Unit

Steer Manifold Block

Table 3. Component Key Steer Rams

K Fig 13. ( T E-20).

Tilt Ram (Crowd) Compensating Rams Lift Ram

39 40

Anti-Cavitation (Overcentre) Valve

35 Extension Ram

Hose Burst Check Valve

Quick Release Couplings

Quick Hitch Lock/Auxiliary Diverter Valve

Boom Suspension System (Option)

Quick Hitch Rams

Hydraulic Tow Hitch (Option) Servo Control Valve

Auxiliary Control Spool

28 30

Tilt Control Spool

27 29

Extension Control Spool

TM310

Schematic Circuits

Section E - Hydraulics Schematic Circuits TM310

E-19

E-20

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L2 L1 L

OUT N

12 X

19 26

2A 2B

Fig 13.

1A 1B

23 3A 3B 24

4A 4B

3 2

32 33

Section E - Hydraulics Schematic Circuits TM310

E-20

Section E - Hydraulics

Service Procedures Flow and Pressure Tests Checking Pump Flow It is not possible to measure maximum flow at system pressure because the pump swashplate will return to minimum angle (minimum flow) when the system reaches full pressure. A practical method to determine the hydraulic pump performance is to measure the cycle times for the main hydraulic services. See K Technical Data ( T E-1)

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E-21

Section E - Hydraulics Service Procedures Flow and Pressure Tests

System Pressures

B Note: This procedure describes the correct method to check the main system pressure, load sense pressure, pump standby pressure, steering pressure and delta-P pressure. A multi-channel digital pressure test set will be required to measure the pressures accurately (see Service Tools).

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

C076620

!MWARNING

Fig 14.

Push button 15-D to switch the test set ON, then push button 15-E to set the screen to display delta-P between channels 1 and 2.

INT-3-1-11_2

Park the machine and make it safe. Vent the hydraulic system. See Section 2 - General Procedures.

Working below the RH side of the machine, connect a 0 - 400 bar (5801 lbf/in2) pressure transducer to the pump pressure test point on the valve block 14-A. Connect this transducer to `Channel 1' on the test set.

Connect another 0 - 400 bar (5801 lbf/in2) pressure transducer to the load sense test point on the valve block 14-B. Connect this transducer to `Channel 2' on the test set.

Fig 15. 5

E-22

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Start the engine. Make sure that the hydraulic oil is at working temperature, i.e. 500C (1220F).

E-22

Section E - Hydraulics Service Procedures Flow and Pressure Tests 6

Record the pressure figures in a table as shown below:

Standby

Main System

Table 4. Load Delta-P Sense

b Turn the steering wheel and hold machine against steer stops. c

Steering

Record the pressure shown on channel 1. This is the steering pressure.

Compare the recorded pressures to those specified in Section E- Technical Data. 7

Measure the standby pressure: a

Release the throttle pedal to let the engine idle.

If necessary the pressures can be adjusted. K Pressure Adjustment ( T E-24).

b Do not operate hydraulic services. c

Record the pressure shown on channel 1. This is the pump standby pressure.

Note: A higher than recommended standby pressure shows a fault in the system. 8

Measure the main system pressure and load sense pressure: a

Push the throttle pedal fully to the floor.

b Push the auxiliary thumbwheel towards the front of the machine. c

Record the pressure shown on channel 1. This is the main system pressure.

d Note the pressure shown on channel 2. This is the load sense pressure. 9

Measure the delta-P pressure: a

Use the main system pressure and load sense pressure readings obtained in step 8. Subtract the Load sense pressure reading from the main system pressure reading. This value is the deltaP pressure. Example:

Main system Pressure 240 bar 10

Load Sense Pressure -

220.5 bar

Delta-P Pressure =

19.5 bar

Measure the Steering pressure: a

E-23

Push the throttle pedal fully to the floor.

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E-23

Section E - Hydraulics Service Procedures Flow and Pressure Tests Pressure Adjustment If necessary the hydraulic system pressures can be adjusted. Make sure the test equipment is connected as described in the test procedures. K System Pressures ( T E-22) 1

Adjust the Main System pressure:

To adjust the main system pressure, loosen the locknut 16-B and turn the adjuster screw 16-A (at the valve block as shown).

B Fig 17. 4

Adjust the Steering pressure: a

Switch OFF the engine and vent residual hydraulic pressure.

b The steering pressure is adjusted using the load sense relief valve in the hydraulic steer unit. Once adjusted tighten the locknut and check the pressure again. K System Pressures ( T E-22) C076730

Fig 16. After adjustment also check the load sense pressure and main system pressure. K Flow and Pressure Tests ( T E-21) 2

Tighten the locknut 16-B.

Adjust the load sense pressure: a

Switch OFF the engine and vent residual hydraulic pressure.

Note: The load sense pressure is adjusted using the Load Sense MRV located on the variflow pump. To get access to the pump remove the pump access panel, see Section B - Cab. b Loosen the locknut 17-A and turn the adjuster screw 17-B clockwise to increase pressure and counter-clockwise to decrease the pressure. Once adjusted tighten the locknut and check the pressure again. K System Pressures ( T E-22)

E-24

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E-24

Section E - Hydraulics Service Procedures Flow and Pressure Tests

Checking the Servo Pilot Pressure

Make sure that the hydraulic oil is at working temperature, i.e. 500C (1220F). 1

Working under the machine, connect a 0 - 70 bar (0 1000 lbf/in2) pressure gauge to the servo pressure test point 18-A.

Fig 19.

Note: The servo pressure test point is the test point at the front end of the accumulator block. The rear pressure test point is for testing the brake pressure.

C076550

Fig 18. 2

With the engine running at 1500 rpm, hold the auxiliary thumbwheel to raise system pressure until the relief valve cuts in.

Check the reading on the pressure gauge. The servo pressure should be as stated in K Technical Data ( T E-1)

If the servo pilot pressure is incorrect, adjust the pressure using the adjustable cartridge valve mounted on the valve block outlet slice 19-B.

E-25

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E-25

Section E - Hydraulics Service Procedures `Positional Type' Hydraulic Adaptors

`Positional Type' Hydraulic Adaptors Fitting Procedure On a typical machine, some hydraulic components may utilise `Positional Type' SAE Hydraulic Adaptors. When fitting `Positional Type' Hydraulic Adaptors it is important to adopt the following procedure. If this procedure is not followed correctly, damage to the `O' ring seal 20- A can occur, resulting in oil leaks. 1

Ensure the locknut 20-B is screwed back onto the body of the adaptor as far as possible as shown.

Check the `O' ring backing washer 20-C is a tight fit on the adaptor. Note that the washer should not move freely, if the washer is slack do not use the adaptor.

Check the `O' ring 20-A is fitted and that it is free from damage or nicks. Before fitting the adaptor, smear the `O' ring with clean hydraulic fluid.

Fig 20.

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

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

Set the angular position of the adaptor as required, then secure by tightening the locknut 20-B.

Note: When fitted correctly no more than one thread should be visible at 21-Z as shown. 6

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

Fig 21.

E-26

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E-26

Section E - Hydraulics Service Procedures Bleeding the Hydraulic System

Bleeding the Hydraulic System Whenever any hydraulic component is disconnected or removed the system must be bled as follows:

Important: Before starting the engine the variflow pump body must be filled with hydraulic fluid. If the engine is started with no fluid in the pump, damage to the pump can occur. Obey the replacement procedures. 1

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Vent the hydraulic pressure, see Section 2 - General Procedures.

If the pump has been removed or replaced it must be "primed" before starting the engine. a

Remove the variflow pump access cover, see Section B - Cab.

A Fig 22.

b Remove the pump case drain hose 22-A and adaptor 22-B. c

Fill the pump case with clean hydraulic fluid through the drain adaptor port 22-C until the fluid is level with the port.

d Reconnect the hose 22-A and adaptor 22-B. 4

Fill the hydraulic tank to the correct level with clean hydraulic fluid.

Start the engine and let it run at idle speed (i.e. do not push the accelerator).

Turn the steering wheel a minimum of 10 times in both directions.

Operate the main hydraulic services until the air is removed from the pump. The pump will be noisy until the air has been evacuated.

E-27

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E-27

Section E - Hydraulics Service Procedures Bleeding the Hydraulic System

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E-28

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E-28

Section E - Hydraulics

Hand Control Valve (Servo) Hand Control Valve Removal and Replacement

Replacement

Before attempting to remove a pilot control valve the pilot circuit accumulator pressure must be vented.

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

!MWARNING

Bleed the hydraulic Procedures ( T E-21)

system,

see

K Service

INT-3-1-11_2

Park the machine on firm level ground, extend and lower the boom to rest on the ground, install the articulation lock, switch off engine and operate the hydraulic controls to vent system pressures. Release hydraulic tank filler cap to reduce tank pressure.

Removal Fig 23. 1

Undo the four fasteners positioned on the side of the arm rest moulding (two on either side).

The bottom moulding can now be removed.

Slacken the hose connections at the valve.

Disconnect the electrical connection at the wiring connector.

Undo the four fasteners (positioned around the joystick) holding the valve block to the servo arm. This will now allow the joystick and valve to be removed from the arm without removing the top moulding.

If the hoses are not already tagged, tie on your own tags. Make sure you have recorded the connections correctly, enabling correct re-connection when replacing the valve. Disconnect the hoses at the valve. Cap all open hoses and ports.

E-29

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E-29

Section E - Hydraulics Hand Control Valve (Servo) Hand Control Valve

Dismantling, Inspection and Assembly K Fig 24. ( T E-31).

Dismantling 1

Undo the cap screws 1. Lift off the joint mechanism assembly 2.

position, check the dimension X. The wobble plate 5 must be positioned so that it makes contact with the top of the valve plungers. If there is a gap at X, or if the plate is depressing the plungers adjust as follows: Hold the collar 11 using a suitable rod located in hole Y. Slacken the lock nut 10 and then screw the collar 11 up or down as required. Tighten the lock nut 10.

Item

Pull out the four valve capsule assemblies 3.

Remove the six adaptors 16 from the ports. Note that the adaptors incorporate seals.

Table 5. Torque Settings Nm kgf m

lbf ft

Inspection 1

Inspect the underside of the wobble plate 5 for signs of excessive wear. If wear is evident the complete assembly 2 must be renewed.

Inspect the universal joint for signs of excessive play. If wear is evident the complete assembly 2 must be renewed.

Inspect the mating faces of plungers 6 and bushes 7 for signs of excessive wear. If wear is evident the value capsule must be renewed as a complete assembly.

If the value has been contaminated with debris be sure to remove it from all internal drillings. Carefully inspect the mating faces of spools 8 and body 9. If scoring is evident the complete valve must be renewed.

Assembly Assembly is the reverse of dismantling but note the following: 1

The valve assembly is susceptible to malfunction and damage if it is contaminated with debris or dirt. Make sure that all components are clean and free from debris.

Renew all `O' rings 14 and seals 15.

Apply JCH HP Grease to the mating faces of wobble plate 5 and plungers 6.

If the joint mechanism assembly 2 is to be renewed it must be adjusted correctly. With the assembly fixed in

E-30

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E-30

Section E - Hydraulics Hand Control Valve (Servo) Hand Control Valve

1 3 15 6

14 7

9 8

10 11

CABLE EXIT HOLE

Fig 24.

E-31

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E-31

Section E - Hydraulics Hand Control Valve (Servo) Hand Control Valve

Page left intentionally blank

E-32

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E-32

Section E - Hydraulics

Main Hydraulic Pump Removal and Replacement Carry out General Safety procedures, see Section 2 General Procedures.

open port and cap the hose to prevent loss of fluid and ingress of dirt.

Before removing the variable displacement pump, make sure the exterior of the pump and working area are thoroughly cleaned and free of possible sources of contamination.

Remove flange bolts 25-K (4 off) and remove the outlet hose 25-L from the pump body. Plug the open port and cap the hose to prevent loss of fluid and ingress of dirt.

Removal

Disconnect the load sense hose 25-J at the pump. Plug the open port and cap the hose to prevent loss of fluid and ingress of dirt.

Disconnect the case drain hose 25-F at the pump. Plug the open port and cap the hose to prevent loss of fluid and ingress of dirt.

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Secure the pump assembly using a sling around the pump body. With the pump suitably supported, remove the two mounting bolts 25-G and carefully lift the pump out through the cab floor.

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E-33

INT-3-1-11_2

Vent the hydraulic system, see Section 2 - General Procedures.

Drain the hydraulic fluid from the hydraulic tank into a suitable clean container.

Remove the floor mat, see Section B - Cab.

Remove the pump access panel, see Section B Cab.

Disconnect the electrical connector at the pump control solenoid (HVCS) 25-E.

Disconnect the electrical connector at the hydraulic fluid temperature switch 25-D.

Loosen the clip 25-B and disconnect the suction hose 25-C from the pump inlet manifold 25-A. Plug the

E-33

Section E - Hydraulics Main Hydraulic Pump Removal and Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure so this work also: Important: Before starting the engine the pump body must be filled with hydraulic fluid. If the engine is started with no fluid in the pump, damage to the pump can occur. Obey the replacement procedures. 1

Make sure that the pump flange and gearbox mating face are clean and free from oil and grease before assembly.

Install new O ring seals to the pump to gearbox casing mating face and inlet and outlet hose flanges. Lubricate the O rings with clean hydraulic fluid.

Apply JCB threadlocker and sealer to the flange bolts and tighten to the correct torque. K Table 6. Torque Settings ( T E-34)

Reconnect the hydraulic hoses and suction hose at the pump.

Connect the electrical connectors at the hydraulic fluid temperature switch 25-D and the pump control solenoid 25-E.

Fill the hydraulic tank to the correct level with clean hydraulic fluid.

Loosen cap 25-K and allow any trapped air to escape from the pump body and drain hose. Tighten the cap.

Bleed the system. K Bleeding the Hydraulic System ( T E-27)

Item

Table 6. Torque Settings Nm kgf m

lbf ft

25-G

125

Large adapter

Small adapter

E-34

12.7

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E-34

Section E - Hydraulics Main Hydraulic Pump Removal and Replacement

G F H

E C B A J L D

C076660

Fig 25.

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E-35

Section E - Hydraulics Main Hydraulic Pump Dismantle and Assemble

Dismantle and Assemble Do not attempt to dismantle the variable displacement pump. If the pump is defective it must be renewed.

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Section E - Hydraulics

Control Valve Block Handling Incorrect handling will result in permanent damage to the valve assembly. The valve block should be lifted by holding either end of the valve body. Do not use the electric solenoids to the lift the valve. Extreme care should be taken to avoid damaging the electric solenoids when handling the valve assembly.

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E-37

Section E - Hydraulics Control Valve Block Removal

Removal

!MWARNING

Disconnect the electrical connectors from the valve block solenoids 26-B and the servo cut off solenoid 26-C.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

BF-4-1_1

GEN-4-1_1

With the valve block suitably supported, undo the mounting bolts 26-A. Pull the valve block away from the chassis a small amount to get access to the servo hoses at the rear of the block.

Disconnect and blank the servo control hoses. K Fig 27. ( T E-39)

Carefully lift out the valve block clear of the machine. K Handling ( T E-37).

Park the machine and make it safe. Obey the General Safety procedures, see Section 2 - General Procedures.

INT-3-1-11_2

Vent the hydraulic and steering pressure, see Section 2 - General Procedures.

Remove the hydraulic filler cap.

Working below the right side of the machine, get access to the valve block.

Put a label on all of the hydraulic hoses to help with identification when replacing.

Disconnect the hydraulic hoses on the front face of the valve block.

B Fig 26.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Put a label on the valve block solenoid electrical connectors to help with identification when replacing.

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E-38

Section E - Hydraulics Control Valve Block Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: 1

Make sure that the servo and service hoses are connected to the correct connectors. K Hose Connections ( T E-39)

Operate the machines hydraulic system. Check for correct operation and leaks.

A F D

Fill the hydraulic system with the recommended hydraulic fluid as required, see Section 3 - Routine Maintenance. Bleed the hydraulic Procedures ( T E-21)

system,

see

E C

K Service

After replacement, check MRV and ARV pressures, see Section E - Service Procedures.

Hose Connections

K Fig 27. ( T E-39) A

Servo Pressure Supply

Crowd Servo Port

Lower servo Port

Dump Servo Port

Lift Servo Port

Tank Return

Fig 27. Servo Hose Connections (view from rear of valve block)

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E-39

Section E - Hydraulics Control Valve Block Replacement

Fig 28. Service Hose Connections K Fig 28. ( T E-40) A

Lower Service

Extend Service

Crowd Service

Auxiliary Service Port B

Lift Service

Retract Service

Dump Service

Auxiliary Service Port A

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E-40

Section E - Hydraulics

Boom Internal Pipes and Hoses Removal and Replacement K Boom Supply Pipework ( T E-43). The hydraulic pipes and hoses that supply the tilt ram and the auxiliary connections are located inside the inner boom. Flexible hoses connect the valve block to the boom distribution manifold. The hoses from the manifold to the boom are held in the flexible track which prevents damage to the hoses during boom extension. The internal steel pipes are attached to a steel support tray. This tray is held in place by the wear pad retaining bolts. Note: The threads of the wear pad retaining bolts must not protrude through the wear pad insert as this may cause chafing and damage to the pipes / hoses.

Put a label on the tilt ram and auxiliary hoses to identify them.

Undo the front and rear lower wear pad retaining screws and remove the pads and shims 31-3 & 31-8.

Move the hose support tray towards the rear of the boom and disconnect the hoses at 31-5A.

Disconnect the track hoses at 31-4A.

Remove the securing clamp bolts 29-1 and clamp from the hose track and lift the track away from the hose support tray.

Undo the pipe securing bolts 29-2 and lift the pipes away from the hose support tray.

Remove the hose track retaining straps by removing the circlip and washer.

Table 7. Boom Internal Pipework Key. 1

Tilt ram pipes

Auxiliary connection pipes

Hose tray mounting point to inner boom front wear pad

Hose retaining track

Hose support tray

Support tray guide bracket screws

Support tray guide bracket

Hose tray mounting point to inner boom rear wear pad

Extend ram supply hoses

Boom distribution manifold

Auxiliary supply hoses

Tilt ram supply hoses

Removal

1 C052710

Before removing the hoses complete the operations that follow: â&#x20AC;&#x201C; Remove the boom from the machine see Section B Boom. â&#x20AC;&#x201C; Remove the hydraulic rams see Section E Hydraulic Rams.

E-41

Fig 29. Flexible Hose Track Clamps 8

Undo the pipe clamp bolts 30-2 & 30-5 and remove the clamps 30-1 & 30-4.

Pull the hoses 30-3 and pipes 30-6 through the front of the boom

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E-41

Section E - Hydraulics Boom Internal Pipes and Hoses Removal and Replacement

1 2 C052580

Fig 30. Boom Nose Hoses

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E-42

Section E - Hydraulics Boom Internal Pipes and Hoses

E-43

Fig 31. Boom Supply Pipework

Removal and Replacement

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E-43

Section E - Hydraulics Boom Internal Pipes and Hoses Removal and Replacement

Assembly Item Assembly is the opposite of dismantling but note the instructions that follow: 1

Do a check of the hose pair lengths. The hose lengths must be equal +/- 1 mm for each service pair (tilt ram pair, and auxiliary service pair).

Bleed the hydraulic Procedures ( T E-21)

Make sure that the hose routing is correct. DO NOT let the hoses go across each other.

Measure the boom wear pad shimming to make sure it is correct see Section B - Boom Shimming.

E-44

system.

Table 8. Torque Settings Nm

lbf ft

Lift Ram Hoses

44-50

32.5-37

Extension Ram Hoses

44-50

32.5-37

Tilt and Auxiliary hoses

44-50

32.5-37

K Service

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E-44

Section E - Hydraulics

Hydraulic Rams Precautions During Use TE-006

Installation 1

Special seal materials are necessary so check to see if the ram that you are using is suitable or not.

Precautions when installing the ram on the machine. a

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

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

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

When painting the machine, mask the ram.

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

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

Welding after installing the ram may result in damage. a

Warm up sufficiently before beginning work. a

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

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

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

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

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

Install the ram only when it is clean.

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

Caution During Use

Maintenance, Inspection Points

Use only under designated conditions. a

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

b In high temperature environments (approx. 90Â°C and above) or low temperature environments (below -20Â°C), seals quickly become damaged.

E-45

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Carry out daily maintenance and inspection. a

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

E-45

Section E - Hydraulics Hydraulic Rams Precautions During Use minimum. If leaving for more than one week, apply a light coating of suitable grease or petroleum jelly to the exposed part of the ram piston rod. 2

Use genuine JCB parts when replacing parts. a

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

Caution during dismantling and reassembly. a

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

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

E-46

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

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E-46

Section E - Hydraulics Hydraulic Rams Lift Ram

Lift Ram Removal

Remove all attachments from the carriage.

Remove the boom See Section B - Boom Removal and Replacement.

Carry out the General Safety Procedures, see Section C - Machine Safety.

Put a label on each lift ram hose to identify them.

Disconnect and plug the lift ram hydraulic hoses at 32-2 & 32-3.

Remove the nut 32-6, bolt 32-5 and the pivot pin 324 from the head end of the lift ram.

Attach the correct lifting equipment to the ram rod eye end and lift away from the vehicle.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: 1

Grease the pivot pins. See Section 3 - Service Schedules.

Do a check of the hydraulic oil level and add oil if necessary. See Section 3 - Routine Maintenance.

Bleed the hydraulic system. Hydraulic System ( T E-27)

Do a check of the condition of the grease nipples 321. Clean if blocked or replace if damaged.

E-47

K Bleeding

the

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E-47

Section E - Hydraulics Hydraulic Rams Lift Ram

5 6

C052480

Fig 32. Lift Ram Removal

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Section E - Hydraulics Hydraulic Rams Displacement Rams

Displacement Rams Removal

During the replacement procedure do this work also:

Lower the boom and carriage to the ground.

Grease the pivot pins. See Section 3 - Service Schedules.

Carry out the General Safety procedures, see Section C - Machine Safety

Do a check of the hydraulic oil level and add oil if necessary. See Section 3 - Routine Maintenance.

Bleed the hydraulic system. Hydraulic System ( T E-27)

K Bleeding

the

INT-3-1-11_2

Stop the engine, apply the park brake and remove the starter key.

Operate the hydraulic controls to release the remaining hydraulic pressure in the system.

Put a label on each displacement ram hose to identify them.

Disconnect and plug the displacement ram hydraulic hoses at 33-7.

Support the displacement ram 33-8.

!MWARNING This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Remove the nut 33-2, bolt 33-3 and pivot pin 33-1 from the rod end of the ram.

Remove the nut 33-4, bolt 33-6 and pivot pin 33-5 from the cylinder end of the ram. Remove the ram from the machine.

Replacement Replacement is the opposite of the removal procedure.

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Section E - Hydraulics Hydraulic Rams Displacement Rams

8 56

3 1

Fig 33. Displacement Ram Removal

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Section E - Hydraulics Hydraulic Rams Extension Ram

Extension Ram

!MWARNING

Removal 1

Remove all attachments from the carriage.

This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Lower the boom to the ground.

BF-4-1_1

Carry out the General Safety procedures, Section C - Machine Safety

!MWARNING

Prepare suitable lifting equipment and remove the extension ram from the boom.

Replacement

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: 1

Grease the pivot pins. See Section 3 - Service Schedules.

Do a check of the hydraulic oil level and add oil if necessary. See Section 3 - Routine Maintenance.

INT-3-1-11_2

K Bleeding

Stop the engine, apply the park brake and remove the starter key.

Bleed the hydraulic system. Hydraulic System ( T E-27)

the

Operate the hydraulic controls to release the remaining hydraulic pressure in the system.

Do a check of the condition of the pivot bushes 34-8 and shims 34-4. Replace if damaged.

Remove the boom strap bolts 34-2A.

Use new seals 34-9.

Remove the boom strap 34-2.

Do a check of the condition of the grease nipples 343. Clean if blocked or replace if damaged.

Remove the extension ram hose clamps 34-1A. 7

Make sure that the shims 34-4 are installed.

Put a label on the extension ram hoses to identify them and disconnect the hoses at 34-1B.

Remove the front pivot nut 34-10 and bolt 34-11.

Using the slide hammer kit, see Section 1 - Service Tools, remove the pivot pin 34-12.

Remove the nuts 34-7 and bolts 34-6.

Pull out the main pivot pin 34-5 sufficiently to remove the extension ram.

Note: Remember that the extension ram pivot pin 34-5 is also the main pivot for the boom. Use a dummy pivot pin to drive out the pivot pin 34-5 and to support the other side of the boom.

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Section E - Hydraulics Hydraulic Rams Extension Ram

4 1B

6 3

5 7

Fig 34. Extension Ram Removal

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Section E - Hydraulics Hydraulic Rams Tilt Ram

Tilt Ram Removal 1

Remove any attachments from the carriage.

Extend the tilt ram fully.

Fig 35. 3

Extend the boom sufficiently to get access to the tilt ram cylinder end pivot pin 35-1.

Lower the boom and carriage to the ground.

Fig 36. 7

Stop the engine, apply the park brake and remove the starter key.

Remove the boom nose cover bolts 36-1 and remove the nose cover 36-2 from the machine.

Operate the hydraulic controls to release the remaining hydraulic pressure in the system.

Carry out the General Safety procedures, Section C - Machine Safety

Support the tilt ram 37-6.

!MWARNING

This component is heavy. It must only be removed or handled using a suitable lifting method and device. BF-4-1_1

Remove the bolt 37-1, washer 37-2, spacer 37-3 and pivot pin 37-4 from the rod end of the ram 37-6.

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INT-3-1-11_2

E-53

Section E - Hydraulics Hydraulic Rams Tilt Ram

4 5 1

2 3

Fig 37. Tilt Ram Removal 11

Remove the hose clamping plate screw 38-2 and plate 38-1.

Remove the screw, washer and spacer 39-3, and the pivot pin 39-2 from the cylinder end of the ram.

1 2 Fig 38.

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Section E - Hydraulics Hydraulic Rams Tilt Ram During the replacement procedure do this work also:

Grease the pivot pins. See Section 3 - Service Schedules.

Do a check of the hydraulic oil level and add oil if necessary. See Section 3 - Routine Maintenance.

Bleed the hydraulic system Hydraulic System ( T E-27).

Do a check of the condition of the grease nipples 375 & 39-1. Clean if blocked or replace if damaged.

K Bleeding

the

3 1 Fig 39. 13

Pull the tilt ram 40-3 out from the boom slightly to get access to the hose connections 40-1.

1 2 C052610

Fig 40. 14

Put a label on the tilt ram hoses to identify them and disconnect the hoses at 40-1.

Pull the tilt ram 40-3 out through the nose of the boom 40-2.

Replacement Replacement is the opposite of the removal procedure.

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Section E - Hydraulics Hydraulic Rams Dismantle and Assemble

Dismantle and Assemble Typical Ram Note: For detailed illustrations and torque settings for Ram ( T E-59), K Lift each ram see K Tilt Ram ( T E-60), K Extension Ram ( T E-61), K Displacement Ram ( T E-62).

Dismantle See K Fig 43. ( T E-58) and K Fig 44. ( T E-58). The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Place ram assembly on a locally manufactured strip and rebuild bench as shown in K Fig 41. ( T E-56).

Extract dowel 6 from the piston head using a metric screw (M3, M4, or M6 depending on ram size) threaded into the extractor hole. Remove piston head from rod using special spanner (see Service Tools). Remove gland bearing and end cap 1 from piston rod and remove the `O' ring 9, wiper seal 10 and rod seal 11. Check the end cap bearing for damage, scores or nicks. If damaged, the bearing must be replaced as part of the end cap assembly. Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals. Check the bore of the ram cylinder for damage.

Assemble Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying JCB Threadlocker and Sealer (High Strength). Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High Strength).

Fig 41. Slacken end cap 1 using special spanner (see Service Tools), and remove the piston rod assembly 2 from the cylinder.

!MWARNING

For the correct method of fitting seals to the end cap and piston head. Apply JCB Activator to threads of end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with the JCB Threadlocker and Sealer (High Strength).

If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted. Severe injury can be caused by a suddenly released piston rod.

Note: Neither the JCB Threadlocker and Sealer (High Strength) nor Activator must be allowed to contact seals, bearing rings, or 'O' rings.

HYD-1-2

Fit locking dowel 6 to piston head and rod as follows:

Position piston rod assembly on bench in place of ram cylinder. Remove seal 4 and wear rings 3 and 5 from piston head.

Fit 'O' ring 8 into piston head 7.

Fit piston head to piston rod and torque tighten, K Table 9. Torque Settings ( T E-57).

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E-56

Section E - Hydraulics Hydraulic Rams Dismantle and Assemble 3

New ram Shaft and piston head fitted. If both are required, the following procedure should be followed: a

Drill through piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit, see K Fig 42. ( T E-57) and K Table 10. Drill Diameters and Depths ( T E-57).

b Remove all swarf and contamination. Insert dowel 6 into drilled hole, make sure tapped extractor hole is to outside. 4

New piston head fitted on a pre-drilled piston rod. Re-drill and dowel BOTH the piston head and piston rod at 90° from the existing drilled dowel hole in the piston rod. Follow the procedures described in step 3.

New piston rod fitted to a pre-drilled piston head. Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head. a

Item

Table 9. Torque Settings Nm kgf m

Use the correct size diameter drill to suit the dowel and drill to the required depth, K Table 10. Drill Diameters and Depths ( T E-57).

d Remove all swarf and contamination, insert the dowel. Position cylinder on bench and install rod assembly into cylinder.

678

69.2

500

405

41.3

300

Fig 42. Table 10. Drill Diameters and Depths All Dimensions are in mm Ram Size

Dowel Size

80 x 50

6Ø x 20

6.02-6.1

22-23

Guide Guide Dowel Drill Drill Ø Drill ØX Depth

Dowel Drill Depth Y

8Ø x 25

8.02-8.1

27-28

110 x 60 12Ø x 30

12.02-12.1

32-33

12.02-12.1

37-38

70 x 40 90 x 50 100 x 60 110 x 65 120 x 65 12Ø x 35

Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the end cap, K Table 9. Torque Settings ( T E-57).

lbf ft

Use a drill the same diameter as the pre-drilled hole in the piston head to make a 'centre mark' in the piston rod. DO NOT drill the piston rod at this stage.

b Use an undersized diameter drill as a guide and drill into the piston rod to the required depth, K Table 10. Drill Diameters and Depths ( T E-57). Make sure the drill has centred correctly on the 'centre mark' made at step 5a. c

Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.

130 x 75

Note: If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

E-57

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E-57

Section E - Hydraulics Hydraulic Rams Dismantle and Assemble

Fig 43.

5 6

11 10

Fig 44. Typical Ram Assembly Note that on boom and bucket rams, pivot pin grease seals are fitted.

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Section E - Hydraulics Hydraulic Rams Dismantle and Assemble

Tilt Ram

2 3

5 6

10 Fig 45. Item

Item

E-59

Grease Nipple

Piston Head Assembly

Counter Balance Cartridge

Dowel

Wear Ring

Item

Piston Seal

405

298.7

Wear Ring

678

500

Piston Rod

Cylinder

End Cap Assembly

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Table 11. Torque Settings Nm

lbf ft

E-59

Section E - Hydraulics Hydraulic Rams Dismantle and Assemble

Lift Ram

5 6

Fig 46. Item

Item

Grease Nipple

Piston Head Assembly

Dowel

Wear Ring

Piston Seal

Wear Ring

Piston Rod

Cylinder

End Cap Assembly

Grease Nipple

Plug Table 12. Torque Settings Nm

405

9 11

E-60

298.7

678 33.4

lbf ft 500

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E-60

Section E - Hydraulics Hydraulic Rams Dismantle and Assemble

Extension Ram

2 3

4 5 6

Fig 47. Item

Item

Grease Nipple

Piston Head Assembly

Dowel

Wear Ring

Piston Seal

Wear Ring

Piston Rod

Cylinder

End Cap Assembly Table 13. Torque Settings Nm

lbf ft

405

298.7

678

500

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Section E - Hydraulics Hydraulic Rams Dismantle and Assemble

Displacement Ram

4 5 6

1 Fig 48. Item

E-62

Grease Nipple

Piston Head Assembly

Dowel

Wear Ring

Piston Seal

Wear Ring

Piston Rod

Cylinder

End Cap Assembly

Item

Table 14. Torque Settings Nm

lbf ft

405

298.7

678

500

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E-62

Section E - Hydraulics

Smooth Ride System (SRS) Technical Data Gas:

Air Free Dry Nitrogen

Accumulator Charge Pressure Acc. No.

bar (psi)

83 (1200)

35 (500)

Note: The accumulators are charged to Different Pressures. It makes no difference which accumulator contains which pressure. Note: Accumulators fitted to machines will have a label on the accumulator body specifying the charge pressure. Note: Replacement accumulators will only be supplied in an uncharged, non pressurised condition to meet Health and Safety/Air freight hazardous goods requirements. Note: When replacing the lift ram or hose burst check valve on machines fitted with SRS, it is important that all the hydraulic pressure in the accumulators is vented (see Accumulators - Removal and Replacement). Failure to do this may result in the valve being forced out of the cavity as it is unscrewed.

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Section E - Hydraulics Smooth Ride System (SRS) Description

Description Smooth Ride System (SRS) will enhance the comfort of the ride by damping the forces imposed on the machine by the movement of the boom as the machine travels over uneven surfaces.

4 7 4 3

In order to engage the system, the lift ram must be fully closed or the weight of the boom must be supported. This is sensed by a pressure switch built into the head end of the main lifting ram. Note: It is only intended for use whilst travelling. The system will be automatically disabled when the loader control servo is operated.

The boom will move up and down independently of the machine with SRS selected. Make sure there is adequate ground clearance below the boom and attachments to allow for this movement. When a switch in the cab is operated, a solenoid built into the head end of the lift ram is energised and opens. Hydraulic oil from the head end of the lift ram is channelled through internal galleries to act against the pressurised pistons in the accumulators. The rod side of the ram, again via internal galleries is connected to the tank to make up or dissipate oil as required.

6 2

Fig 50.

Table 16. Component Key Main Lift Ram

Accumulators

Operating Solenoid

Internal Operation Spool Valve Location

Link Pipe, Ram Head to Accumulators

Rod Side Link Pipe to Spool Valve and Tank

Pressure Switch

Fig 49.

Table 15. Component Key Operating Switch

Warning Light

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Section E - Hydraulics Smooth Ride System (SRS) Description

Hydraulic Schematic

Item

The Smooth Ride Systems's hydraulic schematic diagram is contained in the main hydraulic schematic. The section of the schematic showing the SRS controls is shown below.

Rod Side Drain Valve

Counterbalance Valve

Accumulators

Accumulator Select Valve

Pressure Switch

Lift Ram

A F E

Fig 51.

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Section E - Hydraulics Smooth Ride System (SRS) Fault Finding

Fault Finding Fault

Probable Cause

Action

System will not activate.

Excessive pressure in lift ram.

Ensure weight of boom is fully supported when activating system.

Faulty pressure switch.

Check switch. Replace as necessary.

Unable to lower the boom.

Rod side (drain) solenoid valve open.

Check if solenoid operating, replace as required. Check electrical feed to solenoid/switch.

Restricted boom suspension movement when system switched ON.

Rod side solenoid valve closed.

Check if solenoid operating, replace as required. Check electrical feed to solenoid/switch built into the head of the main lift ram.

Springy boom operation with system switched OFF.

Head side (accumulator) solenoid valve open.

Check if solenoid operating, replace as required.

No suspension when system switched ON.

Electrical supply problem.

Check Fuse. Check for continuity in wiring.

Head side solenoid valve closed.

Check if solenoid operating, replace as required. Check electrical feed to solenoid/switch built into the head end of the main lift ram.

Suspension feels `hard' (gas charge pressure increase).

Oil to gas leak across accumulator piston.

Discharge, drain and recharge. If frequent, replace seals in accumulator.

Suspension feels `soft' (gas charge pressure decrease).

Leak across accumulator piston.

Recharge. If frequent, replace seals in accumulator.

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Section E - Hydraulics Smooth Ride System (SRS) Accumulators

Accumulators Charging and Discharging

Discharging

Charging

Remove the accumulator(s) from the machine.

Remove the gas valve guard A and gas valve cap B.

Screw valve C all the way out (counter clockwise) before attaching charging tool (part no. 892/00948) to accumulator gas valve.

Close bleed valve D.

Do not twist the hose, connect the charging tool to the gas valve. Tighten to 1.36 Nm (1.0 lbf ft).

Either connect charging tool to a bottle of compressed nitrogen gas which is turned off or remove hose F and fit a suitable blank on charging tool.

Connect charging tool to a bottle of compressed nitrogen gas.

Screw valve C all the way in (clockwise), this will depress the core in the gas valve.

Screw valve C all the way in (clockwise), this will depress the core in the gas valve. Check charge pressure which should be set to suit the boom and the attachment fitted to the machine. For recommended pressures K Technical Data ( T E-63).

Open bleed valve D until all the gas charge is relieved from the accumulators. Remove the charging tool.

Install the accumulator(s) to the machine.

Note: The accumulators are charged to Different Pressures. It makes no difference which accumulator contains which pressure. 8

If charge pressure is low, release hand valve E on the nitrogen bottle and slowly fill the accumulators. Close valve E when the charge pressure is reached on the gauge.

Let the pressure settle for 10 to 15 minutes. This will allow the gas temperature to stabilise. If the charge pressure is exceeded, with the gas bottle closed, open bleed valve D. Reduce pressure as required, the close bleed valve.

!MCAUTION

Fig 52.

To reduce pressure use the recommended charging tool or the charge valve could be damaged which may result in rapid discharge of the accumulator. HYD-2-4

When complete screw valve C all the way out (counter clockwise) then open the bleed valve D to vent the hose.

Hold the gas valve to keep from turning, loosen the nut and remove the charging tool.

Refit gas valve and valve guard.

Install the accumulator(s) to the machine.

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Section E - Hydraulics Smooth Ride System (SRS) Accumulators

Removal and Replacement Removal

Park the machine on level ground, lower the boom onto a workstand. (The workstand should be of sufficient height to allow access to the lift ram and accumulators.) Switch off the engine and chock all four wheels. Release all hydraulic pressure in the accumulator by selecting the starter key to the ON position without the engine running, SRS ON and operating the boom hydraulic control lever.

!MCAUTION You must vent all the hydraulic pressure from the accumulators before disconnecting them from the hydraulic system. 0043

Disconnect hydraulic connections 1 and plug the ends of the pipes and the accumulator ports.

Slacken the securing nuts 2 on both "U" clamps 3.

Remove one of the "U" clamps 3 securing the accumulators to the lift ram. Further slacken the nuts securing the second "U" clamp sufficiently to allow the accumulator to be removed from its mounting.

Replacement Replacement is a reverse of removal. Charge the system. Check for correct operation and leaks. Replenish the hydraulic system with the recommended hydraulic fluid as required.

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Section E - Hydraulics Smooth Ride System (SRS) Accumulators

4 3 W

5 2

Fig 53.

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Section E - Hydraulics Smooth Ride System (SRS) Accumulators

Dismantling and Assembly

Note: This procedure tells you how to dismantle, inspect and assemble one of the accumulators. The other accumulator is maintained in the same way.

Inspection

Dismantle

!MDANGER Discharge all gas pressure before dismantling the accumulators. Failure to comply can cause rapid discharge of gas and/or hydraulic fluid which can result in death, personal injury and damage to the machine. 0044

Minor nicks, scratches or light scoring of the body bore may be removed by using a very fine paper. Dress the bore until all apparent imperfections have been removed. All seals and `O' rings must be discarded and new ones fitted.

Assembly 1

Coat all internal components with clean hydraulic oil.

Secure the accumulator in horizontal position.

Fit piston seal 9, teflon back up rings 10 and seals 11.

Fit piston assembly into bore 1 with hollow side towards the gas end. Do not let piston seal drag on threads, the piston must go into the bore exactly square and very slowly. The piston is a tight fit, use a hammer and a block of wood to tap the piston until all of the piston is 2 in. (50 mm) below the beginning of honed bore.

The gas end cap (cap with gas valve) must be removed before the hydraulic end cap. This allows any residual pressure to escape through the safety vent holes. If the hydraulic end cap is removed first the piston will cover the safety vent holes which could result in the piston being forced out under pressure. HYD-2-6

Inspect piston for cracks, burrs around the `O' ring grooves, or damage. Examine the body bore 1, using a light, for scratches or scoring. Inspect end caps for damaged threads or burrs on `O' ring grooves.

Check that the accumulator you are working on has been discharged.

!MCAUTION

Remove piston seal and `O' rings.

Fit three pins into the holes in gas end cap 4, using a long bar working against the pins, unscrew the end cap. Fit three pins into the holes in hydraulic end cap 5, using a long bar working against the pins, unscrew the end cap.

Remove and discard `O' rings and back up rings from end caps.

Remove the piston 6 by pushing from the hydraulic end with a bar.

!MCAUTION Do not remove the piston by applying compressed air at the opposite end. HYD-2-7

E-70

Note: Keep pressure on the piston while tapping through the bore chamfer, otherwise the piston will bounce back, damaging the piston ring. 4

Fit end cap back up seal 7. Make sure the seal is fitted with leading edge A pointing in a counter clockwise direction otherwise the seal will bind when the end cap is fitted.

Fit end cap `O' rings 8, it is important that seals 7 and 8 are fitted in the correct position in relation to each other to prevent leaks.

Fit end caps 4 and 5, use pins and a long bar. Make sure the gas end cap is fitted to the correct end, piston hollow end to gas side.

Note: The end caps will stop against the chamfer leading into the honed bore, `O' ring sealing is not dependent upon cap tightness. 7

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Use new `O' ring 13 and fit the gas valve 12.

E-70

Section E - Hydraulics Smooth Ride System (SRS) Accumulators

Fig 54.

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Section E - Hydraulics Smooth Ride System (SRS) Accumulators

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Section E - Hydraulics Anti-Cavitation Valve Removal and Replacement

Anti-Cavitation Valve Removal and Replacement Removal B The anti-cavitation valve in located on the inner side of the chassis under the right side of the machine. 1

Carry out the General Safety Procedures, see Section 2 - General Procedures.

!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.

G C076450

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

Fig 55.

GEN-1-1

Replacement

Vent the hydraulic pressure, see Section 2 - General Procedures.

Replacement is the opposite of the removal procedure.

Put a label on each hose before disconnecting to help identification when replacing.

Disconnect and plug the hydraulic hoses 55-A, B, C and G.

Undo bolts 55-E and remove the anti-cavitation valve 55-D.

During the replacement procedure do this work also: 1

When installing adaptors, do not overtighten as this distorts the body and the valve may fail to operate correctly. K Table 17. Torque Settings ( T E-74) 2

Reconnect the hoses in the correct positions as labelled during removal. K Hose Connections ( T E-74)

Make sure that the flow check valve is replaced with the flow direction arrow 55-H pointing towards the valve.

Check the hydraulic fluid level, see Section 3 Routine Maintenance.

Bleed the hydraulic Procedures ( T E-21)

If the anti-cavitation valve is being renewed, remove the adaptors.

E-73

Discard the old seals and fit new seals and `O' rings.

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system.

K Service

E-73

Section E - Hydraulics Anti-Cavitation Valve Removal and Replacement 6

After replacement, check that there are no hydraulic leaks.

Item

K Fig 57. ( T E-74)

To valve block lift connection

To valve block tilt connection

Fig 56. Table 17. Torque Settings Nm kgf m

Item 56-A

lbf ft

1.42

124

56-B

1.42

124

56-C

8.26

717

56-D

8.26

717

56-E

102

10.40

902.7

56-F

102

10.40

902.7

Hose Connections

B A

Fig 57. Hose Connections Item

K Fig 57. ( T E-74)

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Section E - Hydraulics

Basic Hydraulic and Electrical System Information Longitudinal Load Moment System Overview

!MWARNING The Load Moment Indicator shows forward machine stability only. Do not use it as a guide to the weight being lifted. Refer to the load charts in the cab. The maximum working load indicated by the load moment indicator does not correspond to the SWL specified on the load charts in the cab. 5-2-4-15

!MWARNING Look at the indicator lights frequently while lifting or handling loads. As more lights show, take extra care with control lever movements. Do not jerk the levers or make sudden changes of direction. 5-2-4-4

!MWARNING The readout display will be affected by extreme chassis articulation. Before lifting a load, always ensure that the machine is not fully articulated. 4-2-4-2

The Longitudinal Load Moment (LLM) is a product of the load on the boom and the distance the load is moved forward from the centre of gravity of the machine. As the load is moved forward so the load moment increases to a point where the machine will tip forwards. The Longitudinal Load Moment Indicator (LLMI) A warns the operator when the machine is near its maximum forward longitudinal load moment. The Longitudinal Load Moment Control (LLMC) isolates the controls to prevent the operator exceeding the maximum forward longitudinal load moment. The LEDs B on the display illuminate progressively as the load increases. All the LEDs will flash as the load nears the maximum working limit. If the load exceeds the maximum working limit, the red LED C illuminates and an audible warning activates. If a system fault is detected, different combinations of LEDs will light to give a diagnostic fault code. K Diagnostic Fault Codes ( T E-89). Note: The LLMI and LLMC systems must only be calibrated by your JCB Dealer.

!MWARNING If the Load Moment Indicator is faulty, contact your JCB Distributor. Do not try to repair it yourself. 12-2-1-1

!MWARNING Do not tamper, modify or try to disable the LLMC as this can damage the operation of both the LLMI and LLMC permanently. A defective LLMI or LLMC may allow the operator to exceed the limits of stability and can cause the machine to overturn, serious injury or death. 5-2-7-9

The load charts, the boom extension markers and the display supply the primary sources of information for the operator to operate the machine safely.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment

A C

The machine is on firm, level ground.

The machine is doing a loading or a positioning function.

The boom is not fully retracted.

The LLMI/LLMC is activated. (Not overridden).

100%

The LLMI and LLMC systems are only an enhancement to the devices that JCB currently fit as a standard. For example load charts and boom extension markers. The LLMI and LLMC systems must not to be relied upon as the primary source of protection for the machine. Duty of care is still with the operator/site agent to: – Know the mass and load centre of the loads being handled. – Know the boom angle and extension that is required to position the load. (To check this, do a practice run first without the load). – Obey the LLMI indications, lift charts and boom extension markers when they move the load. t052390

Fig 1.

The systems are designed to help you to work more safely. They are not a substitute for skill and common sense!

The LLMI and LLMC systems are intended to work even when the machine is fully articulated. However, the stability of the machine changes with chassis articulation. Take extra care when operating the machine at extreme chassis articulation. The LLMI and LLMC systems do not warn the operator of tipping or overturning the machine when: 1

Subjected to sudden overloading.

The machine is travelling/operating on unsuitable ground. (Must be hard level ground)

It is at risk of tipping or overturning sideways or rearwards.

Travelling with the load in an elevated position.

Travelling across or turning on a slope.

Driving into bends too fast or too sharp.

The LLMI/LLMC will only operate when: 1

The machine is static.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment

Setting the Volume and Brightness The volume of the audible alarm, and the brightness of the display LEDs can be set by the operator using display button E. This allows the volume and brightness to be reduced for night time use. The possible options are: 1

Full volume and full brightness (default setting)

Reduced volume and full brightness

Full volume and reduced brightness

Reduced volume and reduced brightness

Setting Procedure 1

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

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

Press and hold the display button E.

Fig 2.

The display will cycle through the volume and brightness options, pausing for approximately three seconds to demonstrate each option. 4

Release the button during the required demonstration to select the option.

Note: The system will reset to the default setting when the starter key is switched to the off position.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment

Warm Up Procedure

For the machine hydraulic system to work efficiently, the hydraulic oil should be at a temperature of 10째C (50째F) or above.

Push then hold the display/test button B. Make sure that all of the LEDs flash and the alarm sounds. Do not release the display/test button B. a

If the air temperature is above freezing (0째C, 32째F), the oil will reach this temperature during start up without any special warm up procedure.

Try to extend then lower the boom. Make sure that the boom does not move.

b Lift the boom. (The boom must be able to move in this direction).

If the air temperature is below freezing, do the following warm up procedure:

Stop the machine (unloaded) on level ground with the engine running.

d Release the display/test button B.

Apply the park brake and put the forward/reverse lever in the neutral position.

With the engine at about half throttle, about 1500rpm: a

Raise and lower the boom - 5 times

Retract, then lower the boom.

The functional test is complete.

Note: If a system fault is detected, different combinations of LEDs will light to give a diagnostic fault code. K Diagnostic Fault Codes ( T E-89). Note: During operation the system continuously self checks for faults.

b Extend and retract the boom - 5 times c

Retract the boom. (The boom must be able to move in this direction).

Dump and crowd the forks - 5 times.

Daily Functional Check At the start of each shift you must complete a functional check of the LLMI/LLMC system.

100%

!MWARNING If the system is faulty, contact your JCB distributor. Do not try to repair it yourself.

0206

Park the machine (unloaded) on level, solid ground. Do not stop the engine. Apply the park brake, then move the transmission lever to the neutral position. T052390-1

Fig 3.

Check the display: Make sure the green LED A at the bottom of the display is ON, (this indicates that the display is receiving power). Push the display/test button B and release. If the unit is functioning correctly, all the LEDs in section C of on the display will flash and an audible alarm sounds.

Put the boom in the horizontal position, then extend it to the 1 metre (3 foot) position.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

Longitudinal Load Moment Control Principal of Operation The LLMC system is designed to stop movements of the boom geometry that increase the longitudinal load moment beyond the limits determined in the 'Load Chart'. (EN15000). This typically means an interaction with:

– Boom lower

– Boom extend. The LLMI provides all the information about the stability of the machine: – Visual (A progressive LED scale from 50-100% stability). – Audible (A warning alarm at and beyond 100% stability). The LLMC system is controlled primarily by an input signal from the LLMI: – The boom functions will begin to slow down as the number of lights increase. – The boom functions will stop with a flashing Amber or Red LED. To further improve the speed control at high boom angles, an additional sensor on the side of the boom provides an angle signal.

Red LED

Amber LED (Flashing)

All functions are disabled

Amber LED (lit)

Green LEDs (x3 lit)

Caution - approaching the machine stability limits, the machines hydraulic functions slow down

Power ON indicator

Remains ON when the machine ignition is ON

Display button

Pick and Place LED

D E

F G H

T055490

Fig 4.

Table 1. Danger when lit - the machine is at the limit of stability

G Override switch

LLMC is active Refer to System Override for more details

Groundworks LED LLMC inactive

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

Groundworks Mode and Pick and Place Mode Introduction When the ignition is ON, the LLMI/LLMC system is permanently ON. Dependant on the status of the machine, the LLMC system automatically switches between the Pick and Place and the Groundworks modes. The LLMI system functions as normal in both modes. A Green or Amber LED in a machine symbol indicates the machines operating mode:

â&#x20AC;&#x201C; Pick and Place mode, the green LED A is ON. The machine will respond to the display to restrict its movements within the load chart envelope.

â&#x20AC;&#x201C; Groundworks mode, the amber LED B is ON. Allows the machine to operate without the interaction of the LLMC. The visual and audible display will still indicate the stability of the machine. T055490-1

When the boom is fully retracted, the system is engaged into the Groundworks mode. When the machine is moving faster than 2kph, (1.24mph) the system is engaged into the Groundworks mode. In all other conditions the system will revert to Pick and Place mode. Note: For machines in Australia (AS 1418.19) an additional sensor is used to make sure that the boom is below 10O and fully retracted before the Groundworks mode can be enabled.

Fig 5.

System Override The LLMC system can be temporarily overridden. Important: Make sure it is safe to recover the load before overriding the LLMC system. Refer to the Load Charts. 1

Push and hold the buttons A and B for 40 seconds. When all the of LEDs flash and the audible alarm sounds, the override function is enabled for a maximum of 60 seconds.

Do not release the buttons A and B, the override system will only function when the buttons remain pushed.

Operate the controls to recover the load, then release the buttons A and B. The override function can not be selected again until five seconds have elapsed.

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In override mode the boom lower, extend and tilt functions are available at a restricted speed.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

System Flow Diagram

T055490-4

Fig 6. A

Override switch - display mounted

Display switch - display mounted

Strain gauge transducers (x2)

Boom lower switch

Boom retract switch

LMI display - includes visual (LEDs) and audible (buzzer) stability indication. LLMI and LLMC fault display.

Boom angle sensor

ECU, LLMC

Lower speed control solenoid

ECU, extend - retract

Extend solenoid

Retract solenoid

Blink code LED

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control 1

The boom switches and the input speed supply the override signals to change between the ‘Pick and Place’ and the ‘Groundworks’ modes.

The LMI display processes the strain-gauge transducers to provide a proportional visual and audible display against the changing machine stability. Diagnostic checks are run on the Groundworks switches. Any detected fault is shown on the LMI and appropriate action occurs, refer to K Table 10. ( T E-90).

The ECU proportionally controls the boom lower solenoid. The input to the LMI is modified based on the angle sensor for full speed calibration when lowering the boom. An onward PWM signal output for a proportional reduction of the boom extend function and for enddamping control of the boom retract function.

The input speed is used to develop alternative boom speed limits under dynamic conditions, (still termed as Groundworks mode).

The ECU is primarily used for the thumbwheel control of the boom extend and boom retract functions. Additional input is used to restrict the boom extend function in response to an LMI signal and to boom retract in response to an end-damping signal.

An onward PWM signal through the ECU4 for the proportional control of the boom lower function. Table 2. TM180/220

TM310/320

Boom lower

Measured in series using a link harness at the control 0-1500mA supply valve

control valve

Creates a related variable control pressure at the valve 570-1250mA control 550-1250mA outlet port range control range Creates a related minimum control pressure at the valve outlet port

Boom lower solenoid Measure across the pins with a multimeter sense resistor

0-1500mA supply

50-200mA stand-by 50-200mA stand-by 2.2ohm 1% tolerance

2.2ohm 1% tolerance

TM180/220

TM310/320

Table 3. Boom extend/retract

Measured in series using a link harness at the control 0-1500mA supply valve

control valve

Creates a related variable control pressure at the valve 750-1200mA control 7000-1200mA outlet port range control range Creates a related minimum control pressure at the valve outlet port

Boom lower solenoid Measure across the pins with a multimeter sense resistor

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0-1500mA supply

700mA stand-by

750mA stand-by

3.3 ohm 1% tolerance

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control Table 4. TM180/220

TM310/320

Boom is fully lowered - a safe LMI signal and no green, amber or red LEDs (except the 760mA power LED at the bottom)

750mA

Boom is fully raised and fully retracted - a safe LMI signal and no green, amber or red 1250mA LEDs (except the power LED at the bottom)

1250mA

Boom is fully raised and extended by a minimum of 150mm - a safe LMI signal and no 790mA green, amber or red LEDs (except the power LED at the bottom)

825mA

Boom pivots horizontally (maximum reach) and extended by a minimum of 150mm - a 1250mA safe LMI signal and no green, amber or red LEDs (except the power LED at the bottom)

1250mA

The system does not have a feedback loop from the solenoid pressure output. The system depends on an accurate solenoid current to give the correct pilot pressure. A sense-resistor feedback circuit accurately maintains the coil current. Make sure that the sense-resistor is within specification, this is essential if the ECU is to pass the correct current to the coil. The current at the boom lower control solenoid continuously changes because of the inputs from the LMI and the angle sensor. The system does have some setpoints for reference that can be used as a guide for system conformance.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

LMI Transducers

load on the boom. The clearance slot in the chassis between the mounting pads magnifies the strain.

Introduction The two LMI transducers installed on the rear of the loader tower registers the bend in the chassis in response to the

The two LMI transducers remove the effects of lateral twist from the steer inputs and the offset chassis loads, as the pressure balance changes between the lift and compensation cylinders.

Table 5. The LMI dual transducers installed on the front chassis compensate for the loads on the chassis through the steering and compensation cylinder.

Datum position:

A 45-55mA current when a single LMI transducer is installed.

The boom has no attachment on the front and is fully retracted with the boom lowered A 90-110mA current when a dual (100mm clear of ground). transducer is installed. Measured in a series circuit with the transducers using a link harness. 100% position: An amber flashing LED when the boom is raised to the pivots level.

A current of the datum recorded value (dual transducers) +13mA (+/-1) TM180/220 or +10mA (+/-1) TM310/320. Measured in a series circuit with the LMI transducers using a link harness

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control Installation 1

can pick up debris on its surface that could be attached to the chassis.

Make sure that the LMI transducer mounts (A) and the wear-pad mounts (B) are free from paint and rust. If there is rust, remove with emery paper. Clean the LMI transducer mounts and the wear-pad mounts surface on the inside and outside of the chassis with a de-greasing solution and clean cloths / paper towels. Let the surfaces dry.

Connect an LMI transducer tester C (or use a test lead) to each LMI transducer and check the output.

The output readings on each LMI transducer must read between 49 and 50mA. Replace the LMI transducer if the readings are incorrect.

A C

LMI TRANSOUCER TESTER

T059000-1 T059000-7

Fig 7. TM220

Fig 9.

Apply a thin, even layer of Loctite 638 to the base of each LMI transducer.

Apply Loctite 242 to the M10x40 bolts, then use the bolts to attach the LMI transducers (D) and wear-pads (E) to the front chassis.

Finger tighten all the bolts, then torque tighten the LMI transducer bolts to 60Nm.

Note: Always fully torque tighten the top bolt first before the bottom bolt. Never tighten the bolts in stages (repeatedly moving between the top and bottom bolts). Note: The transducer tester device number is 332/H1950. T059000-2

Fig 8. TM220 3

Carefully remove the LMI transducer from its packing.

Important: This must only be done before testing and installation. Do not put the LMI transducer down where it

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control 9

Connect an LMI transducer tester to each LMI transducer and check the output. The output on each LMI transducer must read between 45 and 55mA, if not refer to Adjustment.

Apply a bead of clear silicon F around the outside of each LMI transducer to create a seal. Remove any excess silicon.

T059000-4

Fig 10. TM220

D T059000-6

Fig 13.

Adjustment Note: The following procedure is only applicable within two minutes of the installation of the LMI transducer. If the Loctite has cured, go to step three. How to adjust an out of range LMI transducer:

T060950-1

Fully loosen, then re-torque the top bolt on the LMI transducer. If its still out of range do step 2.

Fully loosen both of the bolts, then re-torque in the opposite order to the fist installation (bottom bolt first). If its still out of range do step 3.

Remove and clean both the LMI transducer and the chassis. Check the chassis with a suitable straight edge:

Fig 11. TM310/320

If uneven contact JCB.

b If okay replace the sensor. 4

Install a new LMI transducer, refer to Installation.

T060950-1

Fig 12. TM220

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

Angle Sensors

LMI Output Signal (PWM)

An angle sensor (a rotating potentiometer) is connected by linkage to the boom assembly provides the LLMC system with the exact boom angle. This information is used to make sure that the correct speed is used at the right angle.

A digital signal that is related to the chassis loading is transmitted from the LMI display unit to the LMC ECU.

An open or closed circuit is registered as a fault code. The angle sensor linkage is adjustable for calibration purposes. Make sure that locked-off and tamper evident patches are installed on locking nuts.

Boomchassis angle sensor linkage

Table 6. 90O sensor range

The LMC ECU processes this signal, with the angle sensor and the retract switch to calculate the permitted boom speed. Note: Use a meter that can show the PWM information.

LMI output PWM As installed:

0-5V supply voltage 0.7V +/-0.4 when with a 0.5-4.5V fully lowered control range 4.3V +/-0.1 when fully raised

Table 7. Red LED on 10% PWM duty Measured as a PWM duty at Pin 7 LMC ECU Amber flashing 20% - 80% PWM duty LED - first control range Green LED Measured as a PWM duty at Pin 7 LMC ECU

Measured at pin 2 on the angle sensor, or Pin 5 at the LMC ECU

Groundworks Mode Enable When the boom is fully retracted, the boom retract switch enables the Groundworks mode. The system uses a 4-pin changeover switch to supply a parity signal to self-check for a valid switching-signal. Measure as a voltage at pins 4 and 9 of the LMI 14-way connector. When the machine speed is above 2kph (1.24mph), a speed signal provided by a frequency relay enables the Groundworks mode. TM180/220: When the speed sensor frequency is above 25Hz, a switching-output occurs. Measure as a voltage at pin 10, of the LMI 14-way connector.

T060950

Fig 14. TM310/320 - Angle Sensor

TM310/320: A CAN Bus signal is processed in the front console and broadcast as an ON/OFF signal. Measure as a voltage at pin 10, of the LMI 14-way connector.

T059000-3

Fig 15. TM220 - Angle Sensor

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

End-Damping The boom angle sensor and the boom retract sensor are used to provide a cushioned end-stop to the lift and telescopic cylinders. (Boom lower and boom retract only). At the end of the boom lower stroke, a signal is sent from the boom angle sensor to the LLMC ECU. This signal will override the servo-control lever command and slow the boom down to provide a cushioned stop.

At the beginning of the boom lower stroke, a signal is sent from the boom angle sensor to the LLMC ECU. This signal will override the servo-control lever command to give a slow start of control to enhance the stability of the machine. At the end of the boom retract stroke, a signal is sent from the boom angle sensor to the LLMC ECU. This signal will override the servo-control lever command and slow the boom down to provide a cushioned stop.

Table 8. TM180/ 220

TM310/ 320

Boom lower end-damping 0.7 - 1.3V control range through the angle sensor input

Start of reduction at 1.3V Full speed reduction at 0.7V (mA at the boom lower control valve)

760mA

750mA

Boom retract enddamping using the retract switch input

Control current (maximum) at the retract solenoid when the retract switch is closed

960mA

750mA

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A step change in the maximum control current when retracted

Measured in series using a link harness at the main valve block solenoid

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

Diagnostic Fault Codes

Error Code 4 - Display unit faulty

LLMI Diagnostic Fault Codes

The display box has detected an internal error.

These are the primary fault messages related to the display unit and transducer. The audible alarm and the fault code display cancel after 10 seconds and all LEDs on the display will flash continuously as long as the fault remains. Push, then release the display button to show the fault code for a further 10 seconds.

Error Code 5 - Low battery voltage Battery voltage is below 9 Volts.

All fault codes will either disable the LLMC system or put it in load recovery mode only (low speed control of retract and lower - no extend) until the error is cleared. With the exception of an LLMC fault all other faults do not require the status Pick and Place or Groundworks LEDs to be acknowledged.

Error Code 6- LLMC fault Refer to the Pick and Place/Groundworks LED status for more information.

Error Code 1 - Transducer signal fault Transducer disconnected or wiring damaged.

Error Code 2 - Calibration out of range System is incorrectly calibrated.

Error Code 3 - Calibration required System not calibrated.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control LLMC Diagnostic Fault Codes When the upper LED scale is as shown, (K Table 9. ( T E-90)) the related LLMC fault codes are indicated through the status of the Pick and Place G and Groundworks H LEDs.

All fault codes will either disable the LLMC system or put it in load recovery mode only (low speed control of retract and lower - no extend) until the fault is cleared.

Table 9. On

Red

Amber

Off

Green

Off

Green

Pick and Place

Amber

Groundwork

A B C

Pick and Place

Table 10. Groundwork Fault Type s

Off

D E F

Dump Solenoid Open/Closed circuit fault on the output to the dump cut solenoid

Off

Flash

Boom Retract 1/1 or 0/0 error on the switch inputs

Flash

Off

Boom Lower Switch 1/1 or 0/0 error on the switch inputs

Flash

Supply Voltage

The LEDs flash together - not Secondary supply voltage alternately fault On

Flash

T055490-2

Fig 16.

Flyback Ground Output ground not valid

Off

System Internal LMI display fault

PWM Output Fault Open/Closed circuit fault of the output to the ECU4

Flash

ECU4 Error

Blink code sequence

K Blink Error Input error code from the Codes ( T E- machine system ECU 91)

Note: The boom retract and boom lower faults initially report the error with the Groundworks and Pick and Place LEDs solid instead of flashing. Then when you push the display/test button the Groundworks and Pick and Place LEDs flash and the top display no longer shows an error but reports the current SWL.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

Blink Error Codes The blink error codes are shown in the format of long and short flashes of the: – Pick and Place LED on the display unit, when in the ECU4 Error condition. K Table 11. LLMC ECU4 ( T E-91). – Auxiliary LED on the side console, when in the Ext/ Ret ECU4 condition. K Table 12. Ext/Ret ECU4 ( T E-92). – Constant Flow LED on the side console, when in the Ext/Ret ECU4 condition. K Table 13. Auxiliary ECU4 ( T E-92).

A long flash is followed by short flashes to determine which is the relevant code (count the short flashes). The flash sequence will repeat indefinitely until the fault is cleared. The repeat sequence is indicated by a long flash at the start of each sequence. Note: When the blink error code is shown, push the button A to return the bar graph display to the current load moment value. It does not cancel the alarm, this is permitted to allow a guided recovery of the load. Note: A ‘’key cycle’’ is when the starter key is set to the OFF position, then back to the ON position, it resets the fault detection system.

Table 11. LLMC ECU4 Action

Blink Code ID

Fault

Pin 10 (lower valve) fault (open circuit or short circuit)

When the blink codes are activated, the lower valve is closed and isolated until a key cycle.

Pin 11 (PWM interlink signal) fault (open circuit or short circuit)

Not implemented because this fault is detected in the Extend/Retract ECU.

Pin 7 LMI PWM control signal duty cycle is out of range (<5% or >95

Closes and isolates the lower valve until the boom is retracted, then allows the boom to lower at a decreased speed. The boom extend function is disabled, but the boom retract function is allowed at a slow speed. (This allows a recovery of the load).

Pin 7 LMI PWM Control signal time period is out of range (<8333us or >1000ms) = (>120Hz or <100Hz)

Closes and isolates the lower valve until the boom is retracted, then lets allows boom to lower at a decreased speed. The boom extend function is disabled, but the boom retract function is allowed at a slow speed. (This allows a recovery of the load).

Pin 9 angle sensor is too high (>4.75V)

The boom lower, retract and extend functions operate at a decreased speed. The LMI Display / control is still active.

Pin 9 angle sensor voltage is too low The boom lower, retract and extend functions operate at a decreased (<0.255V) speed. The LMI Display / control is still active.

Pin 9 current sense voltage is too high (> 4.51V)

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Closes and isolates the lower valve until a key cycle.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control Table 12. Ext/Ret ECU4 Action

Blink Code ID

Fault

Pin 10 (retract valve) fault (open circuit or short circuit))

When the blink codes are triggered, close and inhibit this output until the thumbwheel returns to the neutral position.

Pin 11 (extend valve) fault (open circuit or short circuit)

When the blink codes are triggered, close and inhibit this output until the thumbwheel returns to the neutral position.

Pin 8 LCS PWM control signal duty cycle is out of range (<5% or >95%)

Boom extend is disabled but retract is allowed in "Soft Stop" mode. If the blink codes are triggered when extending the boom, then the thumbwheel must be returned to the neutral position before you try again.

Pin 8 LCS PWM control signal time period is out of range (<18ms or >22ms) = (>111Hz or <91Hz)

Boom extend is disabled but retract is allowed in "Soft Stop" mode. If the blink codes are triggered when extending the boom, then the thumbwheel must be returned to neutral to try again.

Pin 6 thumbwheel voltage is too high Close both of the Ext/Ret valves and isolate until the thumbwheel (>4.8V) returns to neutral.

Pin 6 thumbwheel voltage is too low (<0.2V)

Pin 9 current sense voltage is too high Close both of the Ext/Ret valves and isolate until the thumbwheel (> 4.51V) returns to neutral.

Blink Code ID

Fault

Pin 10 (retract valve) fault (open circuit or short circuit))

When the blink codes are triggered, close and inhibit this output until the thumbwheel returns to the neutral position.

Pin 11 (extend valve) fault (open circuit or short circuit)

When the blink codes are triggered, close and inhibit this output until the thumbwheel returns to the neutral position.

N/A

Pin 6 thumbwheel voltage is too high Close both of the Ext/Ret valves and isolate until the thumbwheel (>4.8V) returns to neutral.

Pin 6 thumbwheel voltage is too low (<0.2V)

Pin 9 current sense voltage is too high Close both of the Ext/Ret valves and isolate until the thumbwheel (> 4.51V) returns to neutral.

E-92

Close both of the Ext/Ret valves and isolate until the thumbwheel returns to neutral.

Table 13. Auxiliary ECU4 Action

Close both of the Ext/Ret valves and isolate until the thumbwheel returns to neutral.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control

Test Weight

System Checks

The machines test weights are:

LLMC Cut Out of Telescopic and Lower

– TM180/220: 1.8-2.2t

Lift the test weight.

– TM310/320: 2.6-2.9t. Extend the boom, the boom should extend a short distance to clear the retract sensor before coming to a stop. The display will change into 'Pick and Place' mode

LLMI, LLMC Calibration Check Fully retract the boom and lift the forks 100mm (4in.) clear of the ground, this is the DATUM position. Connect both of the transducers into a Y-splitter lead, and then through the link harness and back into one of the machine harness connectors. Measure using a multimeter set to mA and make a record of the output. Lift the test weight until the boom is horizontal (Quickhitch pivot at same height as load tower pivot), extend the boom slowly until there is an amber flashing LED on the LMI display. This is the 100% capacity point.

T058820-9

Fig 17. There may be sufficient boom speed and movement to trigger the red LED, or it may stop at the amber flashing LED. – Boom lower function should be prevented

Make a record of the transducer mA output.

– Boom extend function should be prevented 100% capacity - Datum = transducer swing.

– Boom raise function will continue to operate – Boom retract function will continue to operate

The transducer swing should be:

– Fork tilt function will continue to operate – TM180/220: 13 +/- 1mA.

– Fork crowd function will continue to operate

– TM310/320: 10 +/- 1mA.

– Auxiliary function will continue to operate in both directions.

Machine Stability Check With a load positioned at the 100% stability point, the machine should remain stable when steered from left to right.

Retract the boom, the retract sensor should be triggered, and the lower display will change into 'Groundworks' mode

A momentary lifting of the outer rear tyre can be expected due to the centre joint 'wind up' when carrying heavy loads that can prevent chassis oscillation without a significant opposing force. T058820-10

Fig 18. Despite the display retaining a high stability warning (potentially still a red LED) the boom functions should all work again. Change the position of the weight.

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Section E - Hydraulics Basic Hydraulic and Electrical System Information Longitudinal Load Moment Control Boom Retract End-Damping

Enter the calibration mode on the LMI display: Push and hold the upper LMI display button while simultaneously starting the engine.

With no load on the boom, retract the boom at maximum speed. Just before reaching full retract the boom speed should automatically reduce (end-damping) to cushion the impact.

Hold the button for around 40seconds after start up to enter the calibration mode.

It is normal for the system to be at its most effective at around 50% of full speed, particularly on the TM310/320 the reaction times of the ECU and valves means at full speed there may still be a small bang.

The display will have a Red LED only (bottom LED Green, on at all times to indicate power 'on') 4

Set the machine to the tip point:

Boom Lower End-Damping Extend the boom until the load is resting on the ground and both of the rear tyres are clear of the ground, the machines balance point.

With no load on the boom, lower the boom at maximum speed, just before reaching the ground the boom speed should automatically reduce (end-damping) to cushion the impact.

Push the upper LMI button once to set the tip point. The display will change to a red LED and an amber LED.

Speed Change of LLMC Mode With the boom partially extended (until the display shows 'Pick and Place' mode LED), drive the machine forwards until the speed is above 2kph (1.24mph).Make sure the display changes into 'Groundworks' mode and vice versa when slowing down.

Set the machine to the 100% point: Retract the boom by 475mm TM180/220 (975mm TM310/320), make sure the load is still approximately 400mm from the ground.

Calibration

Push the upper LMI button once to set the 100% point.

Service Calibration Process

The display will change to all green LEDs and the amber LEDs are flashing.

Introduction The relatively short boom extension available on TM products means only a narrow band of weights are suitable for calibration.

The calibration procedure is complete.

The test load should be: â&#x20AC;&#x201C; Sufficiently heavy to make sure that at least one of the machines rear wheels will rise from the ground before the boom is fully extended. â&#x20AC;&#x201C; Sufficiently light enough to ensure 100% capacity can be made before full retract. Calibration Procedure 1

Fully retract and raise the load approximately 400mm from the ground.

Fully steer the machine to right hand lock.

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Section F Transmission Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-8

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

Section F - Transmission

Notes:

F-0

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F-0

Section F - Transmission Contents Page No. Technical Data Tyre Pressures and Sizes .......................................................................... F-1 TM310 and TM310S ..............................................................................F-1 TM-W .....................................................................................................F-1 Front Axles ................................................................................................ F-2 Unit Identification ...................................................................................F-2 Rear Axles ................................................................................................. F-4 Unit Identification ...................................................................................F-4 Powershift Gearboxes ............................................................................... F-6 PS763 3-Speed .....................................................................................F-6 PS766 6-Speed .....................................................................................F-9 Basic Operation General Description ................................................................................. F-13 Transmission Assembly ........................................................................... F-15 PS760 Transmission ...........................................................................F-15 Dual Control Forward, Neutral and Reverse (F/N/R) ............................... F-16 Operation Characteristics ....................................................................F-16 PS763 and PS766 Powershift Gearboxes ............................................... F-17 Component Identification .....................................................................F-17 Principle of Operation ..........................................................................F-19 Hydraulic and Electrical Operation ......................................................F-20 Operation Characteristics - PS760 Gearbox .......................................F-24 Drivepaths - 3 Speed ...........................................................................F-27 Drivepaths - 6 Speed ...........................................................................F-31 Torque Converter ..................................................................................... F-36 Component Identification .....................................................................F-36 Principle of Operation ..........................................................................F-36 Lock-Up Torque Converter ...................................................................... F-37 Principle of Operation ..........................................................................F-37 Component Identification .....................................................................F-37 Systems Description PS763 and PS766 Powershift Gearboxes ............................................... F-43 Forward and Reverser Clutch Operation .............................................F-43 Mainshaft, Layshaft and 6-Speed Clutch Operation ............................F-43 Electrical Connections Powershift Gearbox (PS 760 3 Speed) .................................................... F-45 Introduction ..........................................................................................F-45 Quick Reference ..................................................................................F-47 Wires and Connectors .........................................................................F-49 Powershift Gearbox (PS766 ECU 2.3 6 Speed) ...................................... F-53 Introduction ..........................................................................................F-53 Quick Reference ..................................................................................F-55 Wires and Connectors .........................................................................F-57 Transmission ECU ................................................................................... F-61 ECU Location ......................................................................................F-61 ECU Electrical Connections ................................................................F-62 ECU Feeds and Earths .......................................................................F-65 Lock Up Torque Converter ....................................................................... F-72 Introduction ..........................................................................................F-72 Quick Reference ..................................................................................F-74 Wires and Connectors .........................................................................F-77

F-i

Section F - Transmission Contents Contents Page No. Fault Finding Powershift Gearbox ................................................................................. F-81 Introduction ..........................................................................................F-81 Fault Finding Tables ............................................................................F-81 Powershift Gearbox Dismantling and Assembly ...................................................................... F-93 Front Axle Removal and Replacement ..................................................................... F-95 When Removing ..................................................................................F-95 When Replacing ..................................................................................F-95 Dismantle and Assemble ......................................................................... F-97 Rear Axle Removal and Replacement ..................................................................... F-99 When Removing ..................................................................................F-99 When Replacing ..................................................................................F-99 Dismantle and Assemble ....................................................................... F-101 Driveshafts Removal and Replacement ................................................................... F-103 When Removing ................................................................................F-103 When Replacing ................................................................................F-103 Transfer Gearbox Removal and Replacement ................................................................... F-105 Removal ............................................................................................F-105 Replacement .....................................................................................F-105

F-ii

Section F - Transmission

Technical Data Tyre Pressures and Sizes TM310 and TM310S FRONT

REAR Bar

lbf/in2

2.0

3709

1.8

3881

2.9

2.5

3836

460/70 R24

2.6

2.0

3760

500/70 R24

2.2

2.0

3917

Manufacturer

Size

Bar

lbf/in

Michelin XMCL

460/70 R24

2.3

Michelin XMCL

500/70 R24

2.0

Goodyear SGI

15.5/80 R24

Goodyear IT520 Goodyear IT520

Note: The maximum pressure embossed on the tyre may differ from the pressure stated in the table. Inflate to the pressures in the table, these are agreed with the tyre manufacturer(s) in accordance with European Tyre and Rim Technical Organisation (ETRTO) standards to satisfy machine and stability performance. If the tyres fitted to

Rolling Circumference (mm)

your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures. Important: Refer to the Operator Handbook for the tyre sizes applicable to your machine. Ensure that the correct tyres are fitted and they are inflated to the correct pressures.

TM-W FRONT Manufacturer

Size

REAR

Bar

lbf/in

Bar

lbf/in2

Rolling Circumference (mm)

Michelin XHA

15.5 R25

2.5

2.0

3795

Michelin X-Mine D2

12 R24

4.25

3.0

3881

MIchelin XSM D2+

12 R24

4.25

3.0

3837

Michelin XTLA

15.5 R25

2.5

2.0

3785

Goodyear IT520

500/70 R24

2.2

2.0

3917

Goodyear IT530

500/70 R24

2.2

2.0

3917

F-1

Important: Refer to the Operator Handbook for the tyre sizes applicable to your machine. Ensure that the correct tyres are fitted and they are inflated to the correct pressures.

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F-1

Section F - Transmission Technical Data Front Axles

Front Axles Unit Identification The axle serial number is stamped on the unit identification plate 1-A or as applicable. When ordering replacement parts, always quote the details on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

Fig 1.

Designation PD70 Axle Hubs

70 series

Hub swivels and drive shafts

70 series

Drive head

80 Series

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Section F - Transmission Technical Data Front Axles Specifications Type

3 piece, JCB spiral bevel input with epicyclic hub reduction, and inboard braking

Installation

Rigid Pad Mount

Weight (dry, with no steer rams and without wheels)

386 kg (851 lb) approx.

Half (Axle) Shaft Braking/Type

5 friction plate, 6 counter plate (each half shaft)

Input Type

Yoke

Overall Gear Ratio

13.7 : 1

Crownwheel and Pinion Ratio

2.538 : 1 Standard

Hub Reduction

5.4 : 1

Number of Teeth

F-3

Crownwheel

Pinion

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F-3

Section F - Transmission Technical Data Rear Axles

Rear Axles Unit Identification The axle serial number is stamped on the unit identification plate 1-A or as applicable. When ordering replacement parts, always quote the details on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

Fig 2.

Designation PD70 Axle Hubs

70 series

Hub swivels and drive shafts

70 series

Drive head

80 Series

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F-4

Section F - Transmission Technical Data Rear Axles Specifications Type

3 piece, JCB spiral bevel input with epicyclic hub reduction

Installation

Rigid Pad Mount

Weight (dry, with no steer rams and without wheels)

386 kg (851 lb) approx.

Input Type

Yoke

Overall Gear Ratio

13.7 : 1

Crownwheel and Pinion Ratio

2.538 : 1 Standard

Hub Reduction

5.4 : 1

Number of Teeth

F-5

Crownwheel

Pinion

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F-5

Section F - Transmission Technical Data Powershift Gearboxes

Powershift Gearboxes PS763 3-Speed Unit Identification The gearbox serial number is stamped on the unit identification plate 3-A as shown. When ordering replacement parts, always quote the details on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

Fig 3.

Designation PS763 (2 wheel drive) - Integral brake

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Section F - Transmission Technical Data Powershift Gearboxes Specifications Description

Table 1. PS763 3-Speed Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft, and 2 wheel drive clutch packs giving 4 forward and 4 reverse speeds. Electrically (relay) controlled gear selection. Integral wet multi-plate park brake.

Weight (dry) 2WD

227 kg (500 lb)

Gear Ratios

Forward 1st

7.967:1

2nd

4.290:1

3rd

1.857:1

4th

Electronically blanked.

Torque Converter Torque Converter Dia.

310 mm (12.2 in.)

Torque Converter Identification

W300

Torque Multiplication at Stall

2.02:1

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Section F - Transmission Technical Data Powershift Gearboxes Converter Pressures (in neutral) Converter In at 50 C 0

Converter In at 100 C 0

Converter Out at 50 0C Converter Out at 100 C 0

Table 2. PS763 3-Speed bar

kgf/cm2

lbf/in2

1000 rev/min.

1.4 - 2.2

20.3 - 31.9

2000 rev/min.

5.8 - 6.9

5.9 - 7.0

84.1 - 100.0

1000 rev/min.

0.5 - 1.3

7.2 - 18.9

2000 rev/min.

2.5 - 3.5

2.5 - 3.7

36.2 - 50.8

1000 rev/min.

0.6 - 1.6

8.7 - 23.2

2000 rev/min.

2.8 - 3.8

2.9 - 3.9

40.6 - 55.1

1000 rev/min.

0.2 - 1.0

2.9 - 14.5

2000 rev/min.

1.0 - 1.9

14.5 - 27.6

7.1

7.2

103.0

1000 rev/min.

0.2 - 0.9

2.9 - 13.1

2000 rev/min.

1.1 - 2.1

16.0 - 30.5

1000 rev/min.

0.1 - 0.4

1.5 - 5.8

2000 rev/min.

0.4 - 1.4

5.8 - 20.3

1000 rev/min.

11.0 - 13.0

11.2 - 13.3

159.5 - 188.5

2000 rev/min.

13.0 - 15.2

13.3 - 15.5

188.5 - 220.5

1000 rev/min.

10.2 - 12.2

10.4 - 12.4

147.9 - 176.9

2000 rev/min.

11.4 - 14.5

11.6 - 14.8

165.3 - 210.3

Converter Inlet Relief Pressure (max.) Lubrication Pressure (in neutral) Oil at 50 0C Oil at 100 C 0

Main Line Pressure (in neutral) Oil at 50 0C Oil at 100 0C Clutch Pressure

All clutch pressures should be the same as mainline pressure to within 0.7 bar (10 lbf/in2)

Flow Rates (in neutral) Cooler oil flow at 50 C 0

Cooler oil flow at 100 C 0

Pump oil flow at 100 0C

L/min.

US gal/min.

UK gal/min.

1000 rev/min.

8.5 - 11.0

2.1 - 2.9

1.9 - 2.4

2000 rev/min.

17.0 - 25.1

4.5 - 6.6

3.7 - 5.5

1000 rev/min.

6.2 - 9.5

1.6 - 2.5

1.4 - 2.1

2000 rev/min.

15.0 - 19.5

4.0 - 5.2

3.3 - 4.3

1000 rev/min.

11.5 - 15.6

3.0 - 4.1

2.5 - 3.4

2000 rev/min.

24.0 - 33.0

6.3 - 8.7

5.3 - 7.3

Control Solenoid Valves

3 way, 2 position, normally closed, integral suppression diode.

Initial coil current draw

1.68 amps @ 12 volts & 20 0C

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F-8

Section F - Transmission Technical Data Powershift Gearboxes

PS766 6-Speed Unit Identification The gearbox serial number is stamped on the unit identification plate 4-A as shown. When ordering replacement parts, always quote the details on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

Fig 4.

Designation PS766 (2 wheel drive) - Integral brake

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F-9

Section F - Transmission Technical Data Powershift Gearboxes Specifications Description

Table 3. PS766 6-Speed Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft, 6 speed and 2 wheel drive clutch packs giving 6 forward and 4 reverse speeds. Electronically controlled gear selection. Integral wet multi-plate park brake.

Weight (dry) 2WD

270 kg (595 lb)

Gear Ratios

Forward 1st

8.17:1

2nd

4.90:1

3rd

3.62:1

4th

2.25:1

5th

1.35:1

6th

1.00:1

Lock Up Torque Converter Torque Converter Dia.

310 mm (12.2 in.)

Torque Converter Identification

W300 LUC

Torque Multiplication at Stall

2.52:1

Converter Pressures (in neutral) Converter In at 50 C 0

Converter Out at 50 C 0

Lock Up Converter Inlet Relief Valve Pressure (max.)

F-10

bar

kgf/cm2

lbf/in2

1000 rev/min.

2.0 - 4.95

2.0 - 5.0

29 - 72

2000 rev/min.

4.0 - 6.8

4.1 - 6.9

58 - 99

1000 rev/min.

0.6 - 2.25

0.6 - 2.3

8.7 - 33

2000 rev/min.

1.25 - 2.50

1.3 - 2.6

18 - 36

8.5

8.67

123

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F-10

Section F - Transmission Technical Data Powershift Gearboxes Table 4. PS766 6-Speed Lubrication Pressures (in neutral) At 50 0C

1000 rev/min.

0.25 - 1.0

0.26 - 1.0

3.6 - 14.5

2000 rev/min.

0.50 - 1.0

0.51 - 1.0

7.3 - 14.5

1000 rev/min.

11.4 - 15.7

11.6 - 16.0

165 - 228

2000 rev/min.

12.4 - 17.0

12.6 - 17.3

180 - 246

L/min.

US gal/min.

UK gal/min.

1000 rev/min.

14.0 MIN

3.7 MIN

3.1 MIN

2000 rev/min.

17.0 MIN

4.5 MIN

3.7 MIN

1000 rev/min.

16.0 MIN

4.2 MIN

3.5 MIN

2000 rev/min.

34.0 MIN

9.0 MIN

7.5 MIN

Main Line Pressure (in neutral) At 50 0C

Flow Rates (in neutral) Cooler at 50 0C Pump at 50 C 0

Control Solenoid Valves

3 way, 2 position, normally closed, integral suppression diode.

Coil Resistance

7.5 Ohm @ 20 0C

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Section F - Transmission Technical Data Powershift Gearboxes

Page left intentionally blank

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F-12

Section F - Transmission

Basic Operation General Description

F E

B K

C063610

Fig 5. The rear mounted engine F drives a torque converter E which is mounted to the engine flywheel. The output from the torque converter drives an electro hydraulically controlled `Powershift' gearbox H. Drive from the gearbox is transmitted via the transfer box C to the front axle A and rear axle D by driveshafts B and J. The driveshaft from the gearbox to the transfer gearbox (upper driveshaft) K varies in length depending on machine variant. The driveshafts B and J which transfer drive to the axles (lower driveshafts) are standard on all variants. A slip joint is included to allow for the movement of the articulated front chassis.

F-13

The transfer gearbox C (or drop box) allows drive to be transmitted from the gearbox which is mounted high on the chassis to the lower drive centres of the axles. This is the same for all variants. The transmission hydraulic oil flows to an air blast oil cooler mounted within the cooling pack G at the rear of the machine. There are two variants of gearbox a 3 speed and a 6 speed with lock up torque converter. Both are controlled by a transmission ECU. The transmission features dedicated oil filtering and cooling systems.

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F-13

Section F - Transmission Basic Operation General Description Machines with PS763 and PS766 Powershift gearboxes feature an integral wet multi-plate parking brake. The engine incorporates a vibration damper bolted to the flywheel. There are 3 combinations of axles these being – A standard Maxtrack Axle front and rear – A limited slip differential axle front and rear – A limited slip differential axle at the front and a standard Maxtrack rear axle.

F-14

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F-14

Section F - Transmission Basic Operation Transmission Assembly

Transmission Assembly PS760 Transmission

Fig 6. PS760

Table 5. Key to Components Transmission Mounting

Handbrake

Dipstick

Transmission Cooler Hoses

Breather

Vibration Damper

Filter

Column Switch

Transmission Oil Pressure Switch

Bevel Gearbox

Torque Converter

F-15

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F-15

Section F - Transmission Basic Operation Dual Control Forward, Neutral and Reverse (F/N/R)

Dual Control Forward, Neutral and Reverse (F/N/R) Operation Characteristics

and column switch 7-B must both be set to neutral to activate the joystick switch.

B N

Fig 7. Column F/N/R Switch

In addition to the column direction switch, a joystick mounted drive direction switch 8-A is also fitted. The switch enables the operator to select F, N or R from the joystick for more efficient machine operation. The column mounted drive direction switch 7-B always takes priority and this switch must be set to "N" to enable the joystick drive selection switch to operate. On engine start-up the column switch must be set to the "N" position, but the joystick switch position is ignored. After the engine has been started the joystick switch 8-A

Column F/N/R Switch Position Forward

Neutral

Reverse

The table shows the switch logic for the combinations of column switch 7-B and joystick switch 8-A.

Table 6. F/N/R Switch Logic Joystick F/N/R Switch Position Engine Start Forward Neutral Reverse Enabled?

z z

z z z z

z z

z z z

F-16

Fig 8. Joystick F/N/R Switch

z z

9803/9520-8

Machine Direction

Yes

Neutral

Forward

Reverse

Forward

Reverse

F-16

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

PS763 and PS766 Powershift Gearboxes Component Identification A

Torque converter

Forward/input clutch assembly

Reverse clutch assembly

Mainshaft assembly

Layshaft assembly

Torque converter relief valve

Oil pressure maintenance valve

Transmission oil pump

Park brake actuator

Park brake pack

Hose connection - to oil cooler

Hose connection - from oil cooler

6-Speed assembly (if fitted)

Oil filter

Gear drive to reverse unit clutch assembly

Solenoid control valves

Transmission oil pressure switch

Speed sensor

F-17

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F-17

F-18

G 9803/9520-8

Section F - Transmission Basic Operation

C003460-C3

F-18

Fig 9. Component Identification

M V P C

U T

PS763 and PS766 Powershift Gearboxes

E L K

S B

A J

N H

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

Principle of Operation K Fig 9. ( T F-18) The JCB Powershift is an electro-hydraulic transmission unit. Gear shifting and direction selection are controlled using multi-disc clutch packs. Electrically operated solenoid valves T divert pressurised oil (provided by pump J) to the selected clutch packs.

C022260-C2

A combined lever/swivel switch W on the steering column actuates both gear ratio and direction solenoids. K Fig 10. ( T F-19). Also a joystick drive direction switch X is fitted. For more information on the operation of this please see K Dual Control Forward, Neutral and Reverse (F/N/ R) ( T F-16). The Powershift unit consists of a torque converter A, forward clutch assembly B, reverse clutch assembly C, layshaft assembly E, mainshaft assembly D, 2/4 wheel drive clutch assembly F.

Fig 10.

X F N R

6-speed gearboxes incorporate a `6-speed' shaft and clutch assembly P. The forward clutch assembly B is driven by the torque converter A. The reverse clutch assembly C is permanently driven via constant meshing of spur gears S. On 6-speed gearboxes the 6-speed assembly is also driven via meshing gears S.

Fig 11.

Filter Q is used to prevent potential system contamination by filtering dirt particles. Intercooled engines. Gearbox oil is cooled transmission oil cooler W. K Fig 12. ( T F-19).

The cooler is part of the machine `cooling pack' and utilises air blast as a means of cooling the gearbox oil. The gearbox incorporates an integral multiplate park brake L. The brake is housed inside the gearbox casing and is wet (immersed in gearbox oil). The brake is mechanically operated via a cable attached to actuator K and acts on the layshaft E.

F-19

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Fig 12.

F-19

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

Hydraulic and Electrical Operation Key to Oil Flow & Pressure

Speed sensor

Solenoid valve manifold block

Gearbox oil cooler

Full Pressure Pressure Lubrication Exhaust

Component Key A

Torque converter

Forward clutch assembly

Reverse clutch assembly

Mainshaft assembly

Layshaft assembly

Torque converter relief valve

Oil pressure maintenance valve

Transmission oil pump

6-speed assembly (if fitted)

Output yoke

Hose connection - to oil cooler

Hose connection - from oil cooler

Oil strainer

Oil filter

Forward low ratio clutch

Forward low ratio clutch solenoid

Forward high ratio clutch

Forward high ratio clutch solenoid

Reverse high ratio clutch

Reverse high ratio clutch solenoid

Reverse low ratio clutch

Reverse low ratio clutch solenoid

6-speed clutch (6-speed gearbox only)

6-speed clutch solenoid (6-speed gearbox only)

Mainshaft clutch

Mainshaft clutch solenoid

Layshaft clutch

Layshaft clutch solenoid

F-20

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F-20

F-21

6 Ws

9803/9520-8

L Ys

M B 1 Us

J Ts

Basic Operation

Section F - Transmission

C003470-C2

Fig 13. Electrical and Hydraulic Operation

F-21

PS763 and PS766 Powershift Gearboxes

P Zs

A Q C 1

Xs 5

3 3 2

1 2

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes Hydraulic and Electrical Operation K Fig 13. ( T F-21)

directs pressurised oil to the layshaft clutch Z. Solenoid valve Ys, when energised, directs pressurised oil to the mainshaft clutch Y.

Oil pump J is directly driven by the engine via the torque converter.

On 6-speed gearboxes, the 6-speed clutch X is controlled via solenoid valve Xs

Oil from the pump J is fed through an internal passage via the filter Q to the pressure maintenance valve H, which maintains pressure to the solenoid valve block for clutch selection.

Note: All the clutches work on the same principle. For a full description of operation see Systems Description, Powershift Gearbox.

Excess oil from the maintenance valve flows back through the casing to the torque converter A. Pressure in the converter is controlled by a relief valve G which dumps oil from the converter line back to the sump. Oil from the torque converter A flows out of the gearbox at position M to the external oil cooler 6, retur ning to the solenoid valve manifold block 5 at position N. The oil then flows through internal oilways providing lubrication for clutches and bearings before returning to the gearbox sump. The torque converter A is a fluid coupling bolted to a drive plate which in turn is bolted to the engine flywheel. As the engine starts to rotate, the converter gives smooth power take off gradually increasing the torque transmitted. This torque is transferred from the converter assembly to the clutch/gear assemblies via input shaft on the forward clutch assembly B. Forward clutch assembly B contains two hydraulically operated clutches; one clutch (T) provides a forward low ratio drive and the other (U) a forward high ratio drive. Each clutch is controlled by a 2-position solenoid valve. When the applicable solenoid is energised, pressurised oil is directed to either the forward low (solenoid Ts) or forward high (solenoid Us) clutch. The reverse clutch assembly C is similar to the forward clutch assembly. It contains two hydraulically operated clutches; one clutch (W) provides a reverse low ratio drive and the other (V) a reverse high ratio drive. 2-position solenoid valves when energised, direct pressurised oil to either the reverse low (solenoid Ws), or reverse high (solenoid Vs) clutch.

When a gear is selected via the control switch in the cab, 2 clutches are always engaged. By selecting different pairs of clutches different gear ratios are engaged. The solenoids are controlled by an electronic control unit (ECU) mounted beneath the cab. Speed sensor 1 is used to enable the gear selection to be managed automatically as required. Example - 2nd gear forward (6-speed gearbox) In the schematic, the gearbox is shown with 2nd gear forward engaged. 2nd gear forward requires the forward low clutch T and layshaft clutch Z to be engaged. When the gear selection switch is moved to 2nd gear forward, the electrical control system energises solenoid valves Ts and Zs. Pressurised oil is diverted to the back of pistons in both clutches to engage the drive. At the same time all other solenoids are de-energised, diverting oil from the back of the other clutch pistons to the gearbox sump. Clutches and solenoids engaged for each gear selection are shown in tabular format as follows: K Table 7. 3-Speed Powershift ( T F-23) K Table 8. 6-Speed Powershift ( T F-23) Note: Solenoid valve Xs controls clutch X, solenoid valve Zs controls clutch Z and so on.

Both the mainshaft and the layshaft assemblies have a single clutch each. Solenoid valve Zs, when energised,

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F-22

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes Table 7. 3-Speed Powershift Clutches engaged

Gear

Forward

Reverse

1st

T, Z

W, Z

2nd

U, Z

V, Z

3rd

T, Y

W, Y

Table 8. 6-Speed Powershift Clutches engaged

Gear

Forward

Reverse

1st

X, Z

W, Z

2nd

T, Z

V, Z

3rd

U, Z

W, Y

4th

X, Y

V, Y

5th

T, Y

6th

U, Y

Ts Us Ws Vs

5 Xs

A390510-C3

Fig 14. Solenoids

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F-23

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

Operation Characteristics - PS760 Gearbox

depending on which `mode' is selected. K Mode Operation (6 Speed Machines Only) ( T F-26).

Central to the system is the gearbox ECU (Electronic Control Unit) A. The unit receives `inputs' from electrical devices such as the gear select switch B. Depending on the input signals the ECU `outputs' energise electrical devices such as gearbox solenoid control valves C. For a full description of how the gearbox electrical system works see Electrical Connections - PS760 Gearbox.

Start Up When the starter switch is set to the ON position the ECU performs a series of self checks. If the checks are valid three beeps sound. After the checks the ECU selects neutral even if forward or reverse is selected on the column lever. To select forward or reverse the operator must cycle the lever through neutral. If the checks fail, 1 or 2 beeps will sound and the ECU will enter an appropriate limp mode (see K Limp Modes ( T F-25).

`Manual' Gear Select (6 Speed Machines Only) The operator can `manually' select some gear ratios using the column switch. It is important to remember that the numbers on the column switch DO NOT indicate the actual gear ratio selected, for example, position 1 may select F1, F2 or F3 gear ratios depending which `mode' is selected. K Mode Operation (6 Speed Machines Only) ( T F-26).

The ECU checks to see if the machine road speed is suitable before down shifting the gearbox. If the road speed is too high a single double beep is sounded. Pressing the kick down switch a second time causes the ECU to select the previous gear. An indicator light will illuminate until the operator selects another gear position using the column switch.

`Automatic' Gear Selection (6 Speed Machines Only) When A (auto) is selected on the column switch, the ECU selects 3rd, 4th, 5th or 6th gears, depending on which `Mode' is selected. K Mode Operation (6 Speed Machines Only) ( T F-26). The gearbox will automatically up shift and down shift in response to road speed. To enable up shifts the accelerator pedal must be pressed, this prevents up shifting when coasting down hill for example, thus ensuring maximum machine control. Note that the ECU does not automatically shift gears in response to engine load.

Park Brake ON When the park brake is on, the ECU will hold the gearbox in neutral even if forward or reverse are selected. A warning light illuminates only when forward or reverse is selected.

When down shifting (say from 3rd to 2nd) the ECU checks to see if the machine road speed is suitable before down shifting the gearbox. If the road speed is too high a single double beep is sounded. When the road speed reduces to a pre-set value the ECU down shifts the gearbox and the beeps will stop. The gearbox ECU also prevents direction change if the road speed is too high.

Kick Down Operation (6 Speed Machines Only) The column lever incorporates a kickdown switch which enables the operator to down shift to the next lowest gear,

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F-24

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes Transmission Dump When the operator presses the dump switch the ECU selects neutral by de-energising one clutch only. This enables smooth re-engagement of gears when the dump button is released.

Joystick Direction Switch See the section on Dual Control F/N/R K Dual Control Forward, Neutral and Reverse (F/N/R) ( T F-16).

Limp Modes When necessary the ECU will provide alternative gear selection should faults occur. This enables the machine to be moved (`limped') under its own power. For full details of the limp modes see Fault Finding - Powershift Gearbox.

B A

Fig 15.

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F-25

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes Mode Operation (6 Speed Machines Only) To ensure selection of the most applicable gear ratios and shift points for a given machine application the operator can select one of three `modes'. The modes are selected using a cab mounted switch. See the Operator Handbook for switch identification. The modes configure the gearbox as follows: Field Mode Configures the gearbox for field applications such as straw bale clearance. Gear Select Position

Forward

Reverse

F4, F5

Gears selectable with kick down

F2, F3, F4

Forward

Reverse

F4, F5, F6

R3, R4

Gears selectable with kick down

F1, F2, F3, F4(1)

Kick down is not available for reverse gears

Road Mode - Power (Laden) Configures the gearbox for optimum shift points when the machine is laden and/or towing a laden trailer. When `A' is selected up shifts only occur when the engine is producing maximum power and down shifts when the engine is producing maximum torque.

R3, R4 (1)

Gear Select Position

In this way the engine is always operating at its optimum r.p.m. for maximum performance.

Kick down is not available for reverse gears

(1) Only selected as a result of an up shift, (kick down button pressed a second time). Road Mode - ECO (Unladen) Configures the gearbox for optimum road performance and fuel economy, typically when the machine is unladen, including towing an unladen trailer. When `A' is selected shifts occur at lower road speeds, ensuring that the machine is operating in the highest practical gear at all times.

Gear Select Position

Forward

Reverse

F3, F4, F5, F6

R3,R4

Gears selectable with kick down

F1, F2, F3

Kick down is not available for reverse gears

(1)

Lock Up Torque Converter Operation The lock up torque converter operates automatically between preset parameters when F5 or F6 gears are selected. When field mode is selected the lock up torque converter can be disabled. For a full explanation see K Lock-Up Torque Converter ( T F-37).

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Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

Drivepaths - 3 Speed Forward 1F K Fig 17. ( T F-28) 1st GEAR FORWARD Clutches Engaged

Solenoids Energised

Forward Low

Layshaft

2F K Fig 19. ( T F-28) 2nd GEAR FORWARD Clutches Engaged

Solenoids Energised

Forward High

Layshaft

3F K Fig 18. ( T F-28) 3rd GEAR FORWARD Clutches Engaged

Solenoids Energised

Forward Low

Mainshaft

Ts Us

Ws Vs

Ys Zs A396740-C2

Fig 16.

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F-27

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

W V

W V T U

T U Y

Y Z

A396670-C3

Fig 19. 2F A396660-C3

Fig 17. 1F

W V

T U

A396680-C3

Fig 18. 3F

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F-28

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes Reverse 1R K Fig 21. ( T F-30) 1st GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse Low

Layshaft

2R K Fig 23. ( T F-30) 2nd GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse High

Layshaft

3R K Fig 22. ( T F-30) 3rd GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse Low

Mainshaft

Ts Us

Ws Vs

Ys Zs A396740-C2

Fig 20.

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F-29

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

W V

T U

A396710-C3

A396700-C3

Fig 23. 2R

Fig 21. 1R

W V

T U

A396720-C3

Fig 22. 3R

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F-30

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

Drivepaths - 6 Speed

5F K Fig 29. ( T F-33) 5th GEAR FORWARD

Forward

Clutches Engaged

Solenoids Energised

1F K Fig 25. ( T F-32)

Forward Low

1st GEAR FORWARD

Mainshaft

Clutches Engaged

Solenoids Energised

`6 Speed'

6F K Fig 30. ( T F-33)

Layshaft

6th GEAR FORWARD Clutches Engaged

Solenoids Energised

2F K Fig 27. ( T F-32)

Forward High

2nd GEAR FORWARD

Mainshaft

Clutches Engaged

Solenoids Energised

Forward Low

Layshaft

Ts Us Ws Vs

3F K Fig 26. ( T F-32) 3rd GEAR FORWARD Clutches Engaged

Solenoids Energised

Forward High

Layshaft

4F K Fig 28. ( T F-32) 4th GEAR FORWARD

Clutches Engaged

Solenoids Energised

`6 Speed'

Mainshaft

Xs A390510-C4

Fig 24.

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F-31

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

W V

T U

A387850-C3

A387860-C3

Fig 25. 1F

Fig 27. 2F

W V

T U

A387870-C3

A387880-C3

Fig 26. 3F

F-32

Fig 28. 4F

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F-32

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

W V

T U

A387890-C3

Fig 29. 5F

W V

T U

A387900-C3

Fig 30. 6F

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F-33

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes Reverse

Ts Us Ws

1R K Fig 32. ( T F-35) 1st GEAR REVERSE

Clutches Engaged

Solenoids Energised

Reverse Low

Layshaft

2R K Fig 34. ( T F-35) 2nd GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse High

Layshaft

3R K Fig 33. ( T F-35)

A390510-C4

Fig 31.

3rd GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse High

Mainshaft

4R K Fig 35. ( T F-35) 4th GEAR REVERSE Clutches Engaged

Solenoids Energised

Reverse High

Mainshaft

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F-34

Section F - Transmission Basic Operation PS763 and PS766 Powershift Gearboxes

W V

T U

A387920-C3

A387910-C3

Fig 32. 1R

Fig 34. 2R

W V

T U

A387940-C3

A387930-C3

Fig 35. 4R

Fig 33. 3R

F-35

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F-35

Section F - Transmission Basic Operation Torque Converter

Torque Converter Component Identification

Principle of Operation The torque converter is similar to a fluid coupling, which utilises the centrifugal force exerted in the transmission oil to transmit power from the engine to the gearbox. It multiplies the torque from the engine and functions as a combined clutch and infinitely variable reduction gearbox.

Impeller

Turbine

Reaction member

Drive plate

Drive to gearbox input shaft

Spline location for reaction member

Direct drive from the engine to the gearbox oil pump

Direction of oil flow

The torque converter is enclosed in a casing and consists of three basic parts, the impeller A, reaction member C, and turbine B. Impeller A is driven by the engine. Reaction member C does not rotate. Its hub engages with a splined tube on the gearbox oil pump and is held stationary. Turbine B is engaged with the splined end of the gearbox input shaft. The impeller A, driven by the engine, forms one set of shaped blades, it can be likened to a centrifugal pump imparting energy to the transmission oil. This energy is transferred to another set of shaped blades, which form the turbine B The turbine is connected to the gearbox and converts the energy back to a mechanical torque. When the impeller A is rotating faster than the turbine B, the fixed reaction member C causes some of the energy in the oil to be transferred back to the impeller A. This has the effect of multiplying the torque available. When the impeller A (input) is running much faster than the turbine B (output) there is a substantial circulation of transmission oil around the blades. The oil circulation is maximum when the turbine (output) is stalled, and is almost zero when the impeller and turbine speeds are equal i.e. the ratio is near 1:1. If the turbine (output) is stalled whilst the impeller (input) is revolving, all the power is dissipated as heat. Because of the absence of a direct mechanical connection between the engine and the gearbox therefore, the flexibility of the torque converter drive greatly reduces wear on the transmission, absorbing shocks and torsional vibration from the engine. The engine cannot be stalled due to overload, as the fluid coupling slips.

Fig 36.

F-36

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F-36

Section F - Transmission Basic Operation Lock-Up Torque Converter

Lock-Up Torque Converter The lock up torque converter incorporates a clutch which, when engaged, enables a direct mechanical connection between the engine and the gearbox.

Component Identification A

Lock up clutch

This eliminates any slippage in the drive line and results in improved efficiency. The system is only available on 6 speed Powershift machines.

Clutch friction material

Torque converter casing

Turbine

Principle of Operation

Gearbox input drive shaft

Solenoid control valve

Speed sensor, gearbox output shaft

Speed sensor, engine flywheel

ECU (electronic control unit)

Gear select lever

Lubrication bypass valve (part of item F)

The lock up clutch assembly A is fixed to the turbine D (output section) of the torque converter. The turbine is connected to the gearbox input shaft E via a splined hub. For a description of how the turbine is driven see Torque Converter, Principle of Operation. The clutch is engaged and disengaged hydraulically by utilising the normal oil flow through the torque converter. Solenoid control valve F changes the direction of oil the flow to engage or disengage the clutch as applicable. The solenoid control valve F is energised via an electrical output from the gearbox ECU J (electronic control unit) The ECU J receives inputs from the gear select lever K, engine speed sensor H and gearbox output shaft speed sensor G. An output from the ECU energises the solenoid control valve F (enabling torque converter lock up) under the following conditions: â&#x20AC;&#x201C; 6-Speed gearbox: Auto, 5th or 6th must be selected, AND the speed difference between the engine flywheel and gearbox output drive shaft must be within pre-determined values.

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F-37

Section F - Transmission Basic Operation Lock-Up Torque Converter

B A

C025160

Fig 37. Component Identification

F-38

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F-38

Section F - Transmission Basic Operation Lock-Up Torque Converter State 1: Torque Converter Unlocked When inputs to the ECU J from the gear select lever K and speed sensors G and H are outside pre-determined values, solenoid control valve F is not energised and oil enters the converter casing nearest the flywheel via the centre of the gearbox input shaft E. Oil then flows past the front of the clutch assembly A. This causes the clutch assembly A to move on its splined hub away from the torque converter casing C. Oil leaves the torque converter via ports in the oil pump assembly and then passes through the oil cooler M via the control valve F. The torque converter operates in the normal way. Note: Although the torque converter operates in the normal way, it should be noted that the oil flow to and from the converter is opposite to the normal system.

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F-39

Section F - Transmission Basic Operation Lock-Up Torque Converter

M L

B A

F C

E H

F1,2,3 / R C003710-C2

Fig 38. Torque Converter Unlocked

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F-40

Section F - Transmission Basic Operation Lock-Up Torque Converter State 2: Torque Converter Locked When inputs to the ECU J from the gear select lever K and speed sensors G and H are within pre-determined values, an output from the ECU energises solenoid control valve F. Oil enters the converter via ports in the oil pump assembly and into the converter casing nearest the gearbox. Oil pressure forces the clutch assembly A to move on its splined hub, engaging the clutch friction material B with the inside of the torque converter casing C. Drive from the engine is now transmitted from the converter casing, through clutch A and directly to the gearbox input shaft E via the turbine D. Small bleed holes allow a small flow of oil past the clutch assembly A through the converter, providing oil cooling and preventing hydraulic locks. Lubrication bypass valve L is pushed of its seat and oil flows through the cooler M and into the gearbox lubrication system in the normal way.

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F-41

Section F - Transmission Basic Operation Lock-Up Torque Converter

M L

B A

F C

E H

A (5,6) C003720-C2

Fig 39. Torque Converter Locked

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F-42

Section F - Transmission Systems Description PS763 and PS766 Powershift Gearboxes

Systems Description PS763 and PS766 Powershift Gearboxes Forward and Reverser Clutch Operation The forward and reverse clutch units are very similar in design and operate in the same way. The following description refers to one unit and can be applied to either the forward or reverse clutch units. The clutch 1 transfers drive from the input shaft A3 to either gear G1 or gear G2 depending on which of the two clutches (A1 or A2) is engaged, transferring drive to the mainshaft. When neither clutch is engaged, neutral is selected. The clutches are of the wet, multi plate type. The clutch housings and input shaft are a one piece assembly A3. The assembly is permanently driven by the engine via the torque converter. Clutch counter plates 3 are also permanently driven via meshing teeth inside the clutch housings.

from clutch A2 is vented to the sump via the solenoid valve spool E2. Oil is prevented from leaking by seals 6 on the pistons and ring seals 7 on the input shaft A3. The valve E is shown using symbols. For an explanation of how the symbols work, see Section E, Introduction to Hydraulic Schematic Symbols.

Mainshaft, Layshaft and 6-Speed Clutch Operation The mainshaft, layshaft and 6-speed units all incorporate one clutch and not two, as in the forward and reverse units. The operation of the single clutches is the same as for one clutch in the forward or reverse units.

Clutch friction plates 4 are meshed with the gear/plate carriers (G1 and G2). In the diagram, clutch A1 is engaged. The counter plates 3 and friction plates 4 are pressed together by hydraulically actuated piston 5. Drive is then transmitted from the input shaft to the gear G1. Clutch A2 is disengaged and no drive is transmitted to gear/plate carrier G2. The gear is also free to rotate on the input shaft assembly. Actuation of the hydraulic pistons 10 and 5 is controlled via two position solenoid valves E1 and E2. When neutral is selected, solenoids E1 and E2 are deactivated and the flow of pressurised oil to the clutches is blocked. Springs 8 and 9 move the pistons away from the clutch plates and oil from both pistons is vented to the sump. When for example clutch A1 is selected to be engaged, solenoid valve E1 is energised and solenoid valve E2 is de-energised. Pressurised oil is diverted via cross drillings inside the input shaft A3 to the clutch piston 5. Pressure

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F-44

E1 1

7 9803/9520-8

Section F - Transmission Systems Description

A396830-C1

Fig 40. Forward and Reverser Clutch Operation

F-44

PS763 and PS766 Powershift Gearboxes

3 4

9 8

G2 A2 A1 6 5 6 10

G1 A3

Section F - Transmission

Electrical Connections Powershift Gearbox (PS 760 3 Speed) Introduction

Component Key

This section explains how the electrical system works when the following gearbox functions are operated:

Item

Description

Column Forward/Neutral/Reverse Lever (FNR)

1st, 2nd, and 3rd gears forward

Transmission dump switch

Park brake switch

Solenoid control valves

Joystick FNR Lever

Transmission ECU

Kickdown Switch

Column Gear Selection Switch

Transmission Oil Temperature Switch

Transmission Speed Sensor

Transmission Oil Pressure Switch

Neutral 1st, 2nd, and 3rd gears reverse Transmission dump Park brake switch For relevant electrical K Fig 41. ( T F-46).

components,

see

The 3-speed power shift gearbox is controlled using a transmission ECU. For details of the ECU please see the relevant part of this section K Transmission ECU ( T F-61). The ECU receives a signal from the column mounted gear and column forward/reverse lever B or at the Joystick FNR lever G. The transmission dump switch C or park brake switch D also transmit a signal to the ECU. The ECU also transmits signals to energise the gearbox mounted solenoid control valves E.

F-45

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F-45

Section F - Transmission Electrical Connections Powershift Gearbox (PS 760 3 Speed)

H A

U W V

J K S Y Z X

Fig 41. Electrical Components

F-46

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F-46

Section F - Transmission Electrical Connections Powershift Gearbox (PS 760 3 Speed)

Quick Reference Electrical connectors K Fig 42. ( T F-48). The information is intended as an aid when checking for faulty wires or connectors by means of continuity tests using a multimeter. DO NOT use a multimeter on the ECU connector pins (connectors A and B). Only test the associated wiring, uncouple connectors CJ and MH and then use a multimeter at the pins inside these connectors as applicable. Use the JCB Diagnostics system to identify possible faults with the ECU See Powershift Gearbox JCB Diagnostics - User Guide.

Electrical Connections Illustration showing the location of relevant electrical components and their connectors. Note: Interconnecting harness connectors are not shown here. For full details see the relevant expanded harness schematic in this section.

Component Key Item

Description

Park brake switch

Joystick Connector

Column switch connector

Dump switch

Transmission ECU connector A (40 pin)

Transmission ECU connector B (24 pin)

Gearbox Solenoids NV

Forward high (U)

Forward low (T)

Reverse low (W)

Reverse high (V)

Mainshaft (Y)

Layshaft (Z)

F-47

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Section F - Transmission Electrical Connections Powershift Gearbox (PS 760 3 Speed)

6 5

18 17 16

88 17 16

24 23 22

E.C.U. B 3

9 8

21 20 19

15 14 13

NW NV NR NS CJ

10 9 8 7 6

20 19 18 17 16

40 39 38 37 36

30 29 28 27 26

E.C.U. A 5 4 3 2 1

15 14 13 12 11

35 34 33 32 31

25 24 23 22 21

NU NT

12 1 9

2 3

1 4 8

2 5

9 10 11 12 13 14

10 R

F 4

R 5 7

F N

DZ 8

13 4

D 3

CV 3

C025280-C4

Fig 42. Electrical Connectors

F-48

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F-48

Section F - Transmission Electrical Connections Powershift Gearbox (PS 760 3 Speed)

Wires and Connectors Although the system is straight forward in design it is never the less fairly complex in practice. For this reason schematics are divided into 2 parts - ECU inputs and solenoid activation.

Tow Mode Switch

Pedal Connector 1

Hydraulic Variflow Control (HVCS) ECU

Transmission Dump Switch

Fusebox A

On the electrical diagram the electrical connectors (example, MD to EB) are shown looking on the mating face of each connector when they are disconnected.

Fusebox B

Fusebox D

Transmission CANbus Connector

The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding.

Connectors (h2)

Before fault finding make sure that you understand how the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and solenoid coils. Gearbox solenoid coils can be checked for the correct resistance value as given in Technical Data. See Section C, Service Procedures, Using a Multimeter for more details.

Rear Chassis Harness to Panel Harness Connector

Rear Chassis Harness to Transmission Link Harness Connector

Transmission ECU Connector B

Speed Sensor

Transmission Oil Pressure Switch

Reverse low solenoid (W)

Reverse high solenoid (V)

Faults may be caused by poor earth connections. Although earth connections are shown, it must be remembered that the cab assembly is earthed via further earth strap and cable connections.

Layshaft solenoid (Z)

Mainshaft solenoid (Y)

Forward high solenoid (U)

Forward low solenoid (T)

The following key identifies the component connectors. K Fig 44. ( T F-51) and K Fig 43. ( T F-50), K Fig 45. ( T F-52). Note that the wires coloured green show the electrical `feed to earth' for the gearbox mounted solenoids.

PC1

Mainframe Earth

Transmission Dump Pressure Switch

Earth Points

Component Key

Connectors (h3) MF

Transmission Link Harness to Rear Chassis Harness Connector

MF-A Transmission Oil Temperature Switch

Harness - 332/R6766 Panel/Cab

Splices (h1)

Harness - 721/12544 Rear Chassis

SC8

Fuse

Harness - 332/R0885 Transmission Link

SC9

Cab Earth 2

Note: For harness drawings see Section C.

SC10 Earth C SC12 Earth D

Connectors (h1)

SC16 Parkbrake Relay

Ignition Switch 1

SC33 Fuse

Ignition Switch 2

Splices (h2)

Transmission ECU Connector A

SM1

L/H Column Switch

Park Brake Switch

Brake Light Relay

Immobiliser Control Unit

Cab Earth 2

Joystick Connector 2

Panel Harness to Rear Chassis Harness Connector 3

Reverse Relay

F-49

Earth Splice 1

Electrical connector locations. Earth point locations. Section C, Earth Points

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F-49

F-50

113A

113B

112A

112B

SC33 111B

SC10

4 3 1807

ZE 9

872

111C

883

1807

502X

503X

872

607B

607C

811

444A

445

12 1

812

37 32

35 34 33 32 31

879 1906

25 24 23 22 21

15 14 13 12 11

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SC16

876

818

2903

SC8

107J

40 39 38 37 36

35 34 33 32 31

817E

30 29 28 27 26

878

2805

20 19 18 17 16

2805

873

874

873

874

5 8

810

871

810

871

25 24 23 22 21

15 14 13 12 11

808

40 39 38 37 36

809

808

30 29 28 27 26

809

20 19 18 17 16

10 R

120B

811

609A

818

444

817D

445

F 4

609M

8 7 5

875 879

5 4 3

6 7

2 1

F-50

004

001

999A

Fig 43. ECU Inputs Connector A

DA 842

3 2

12 11 10

6 5

3 2 1

12 11 10

2904

609N

E.C.U.

Electrical Connections

19 17 15 13 11 9 7 5 3 1

CV 444

107AV

20 18 16 14 12 10 8 6 4 2

8 9 10

SC12

SC9

876

F15

F19

Section F - Transmission

F35 F34 F33

19 17 15 13 11 9 7 5 3 1

Powershift Gearbox (PS 760 3 Speed)

20 18 16 14 12 10 8 6 4 2

8 7 9

EW 19 17 15 13 11 9 7 5 3 1

EH 10

13 A 4

20 18 16 14 12 10 8 6 4 2

120B

817

21 20 19

601J

601K

24 23 22

15 14 13

18 17 16

88 17 16

PC1

9803/9520-8

SM1

601M

404 601M

21 20 19

1 2

MF MF

15 14 13

7 2827

18 17 16

404

88 17 16

2 882

TB MH SC9

24 23 22

h3 MF-A

601N

F-51

3 404 2

2867 1

601P

880 30 30 2820

11 6

9 413 607A

2820 7

MD EB EM

601L

h2 h1

Fig 44. ECU Inputs Connector B

Section F - Transmission Electrical Connections Powershift Gearbox (PS 760 3 Speed)

F-51

F-52 T 2860

601G

Y 2

2865

601D

NW U 2861 601B

Z 2

2866

601A

9803/9520-8

h2 2863 601F

1 2

601J

5 4

18 17 16

88 17 16

24 23 22

18 17 16

88 17 16

NR 2865

2866

2862

2863

601E

2862 2860

2861

601K

21 20 19

15 14 13

21 20 19

15 14 13

Section F - Transmission

F-52

Electrical Connections

Fig 45. Solenoid Actuation

Powershift Gearbox (PS 760 3 Speed)

601

SM1

T.B.A.

Transmission Dump Operation

Section F - Transmission Electrical Connections Powershift Gearbox (PS766 ECU 2.3 6 Speed)

Powershift Gearbox (PS766 ECU 2.3 6 Speed) Introduction

Component Key

This section explains how the Powershift PS766 6 speed electrical system works.

Item

Description

Column Forward/Neutral/Reverse Lever (FNR)

For relevant electrical K Fig 46. ( T F-54).

Transmission dump switch

Park brake switch

The 6-speed power shift gearbox is controlled using a transmission ECU. For details of the ECU please see the relevant part of this section K Transmission ECU ( T F-61).

Solenoid control valves

Joystick FNR Lever

Transmission ECU

Kickdown Switch

The ECU receives a signal from the column mounted gear and column forward/reverse lever B or at the Joystick FNR lever G.

Column Gear Selection Switch

Transmission Oil Temperature Switch

Transmission Speed Sensor

The transmission dump switch C or park brake switch D also transmit a signal to the ECU. The ECU also transmits signals to energise the gearbox mounted solenoid control valves E.

Transmission Oil Pressure Switch

Transmission Mode Selector

F-53

components,

see

9803/9520-8

F-53

Section F - Transmission Electrical Connections Powershift Gearbox (PS766 ECU 2.3 6 Speed)

H A

U W V

J K S Y Z X

Fig 46. Electrical Components

F-54

9803/9520-8

F-54

Section F - Transmission Electrical Connections Powershift Gearbox (PS766 ECU 2.3 6 Speed)

Quick Reference The information is intended as an aid when checking for faulty wires or connectors by means of continuity tests using a multimeter. DO NOT use a multimeter on the ECU connector pins (connectors A and B). Only test the associated wiring, uncouple connectors CJ and MH and then use a multimeter at the pins inside these connectors as applicable. Use the JCB Diagnostics system to identify possible faults with the ECU See Powershift Gearbox - JCB Diagnostics - User Guide.

Electrical Connections Illustration showing the location of relevant electrical components and their connectors. K Fig 47. ( T F-56). Note: Interconnecting harness connectors are not shown here. For full details see the relevant expanded harness schematic in this section. Component Key A

Gearbox solenoids

Park brake switch

C076

Transmission dump switch. Forward, neutral, reverse switch. (Joystick)

Column switch - forward, neutral, reverse, gear select and kick down functions

Harness connector - ECU - A

Harness connector - ECU - B

Transmission mode selector switch(1)

Torque Converter Lock Up Solenoid (If Fitted)

Transmission speed sensor(2) K Transmission ECU ( T F-61) K Transmission ECU ( T F-61)

(1) Located in the cab, see the Operator handbook for location. (2) For speed sensor testing procedure see Service Procedures, Speed Sensors.

F-55

9803/9520-8

F-55

Section F - Transmission Electrical Connections Powershift Gearbox (PS766 ECU 2.3 6 Speed)

6 5 4

18 17 16

88 17 16

24 23 22

E.C.U. B 9

21 20 19

15 14 13

A 10 9 8

20 19 18 17 16

40 39 38 37 36

30 29 28 27 26

E.C.U. A 5 4 3 2 1

15 14 13 12 11

35 34 33 32 31

25 24 23 22 21

CV EM 3

CV CP 3

12 1

1 1 2

13 A

3 6

9 10 11

10 R

12 13 14

DZ NW NV NR NS F

F 4

5 7

D A B

NT NU PD Fig 47. Electrical Components and Connectors

F-56

9803/9520-8

F-56

Section F - Transmission Electrical Connections Powershift Gearbox (PS766 ECU 2.3 6 Speed)

Tow Mode Switch

Pedal Connector 1

Hydraulic Variflow Control (HVCS) ECU

Transmission Dump Switch

Fusebox A

On the electrical diagram the electrical connectors (example, MD to EB) are shown looking on the mating face of each connector when they are disconnected, K Fig 48. ( T F-58).

Fusebox B

Fusebox D

Transmission CANbus Connector

The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding.

Rear Chassis Harness to Panel Harness Connector

Rear Chassis Harness to Transmission Link Harness Connector

Transmission ECU Connector B

Earth Points Faults may be caused by poor earth connections. Although earth connections are shown, it must be remembered that the cab assembly is earthed via further earth strap and cable connections. The following key identifies the component connectors. K Fig 49. ( T F-59) and K Fig 48. ( T F-58), K Fig 50. ( T F-60). Note that the wires coloured green show the electrical `feed to earth' for the gearbox mounted solenoids. Component Key

Connectors (h2)

Speed Sensor

Transmission Oil Pressure Switch

Reverse low solenoid (W)

Reverse high solenoid (V)

Layshaft solenoid (Z)

Mainshaft solenoid (Y)

Forward high solenoid (U)

Forward low solenoid (T)

PC1

Mainframe Earth

6th Gear Solenoid

Torque Convertor Lock Up Solenoid (if Fitted)

Transmission Dump Pressure Switch

Splices (h1) SC8

Fuse

SC9

Cab Earth 2

SC1 0

Earth C

Note: For harness drawings see Section C.

SC1 2

Earth D

Connectors (h1)

SC1 6

Parkbrake Relay Fuse

Harness - 332/R6766 Panel/Cab

Harness - 721/12544 Rear Chassis

Ignition Switch 1

Ignition Switch 2

SC3 3

Transmission ECU Connector A

Splices (h2)

L/H Column Switch

SM1

Park Brake Switch

Brake Light Relay

Electrical connector locations.

Immobiliser Control Unit

Earth point locations. Section C, Earth Points

Cab Earth 2

Joystick Connector 2

Panel Harness to Rear Chassis Harness Connector 3

Reverse Relay

F-57

9803/9520-8

Earth Splice 1

F-57

F-58

113A

113B

112A

112B

SC33 111B

SC10

4 3 1807

ZE 9

872

111C

883

1807

502X

503X

872

607B

607C

811

10 R

120B

811

609A

818

444

817D

445

F 4

609M

8 7 5

875 879

F-58

004

001

999A

Fig 48. ECU Inputs Connector A

DA 842

3 2

12 11 10

6 5

3 2 1

12 11 10

2904

609N

20 18 16 14 12 10 8 6 4 2

19 17 15 13 11 9 7 5 3 1

E.C.U.

Electrical Connections

2 1

CV 444

107AV

5 4 3

6 7

8 9 10

SC12

SC9

876

F15

F19

Section F - Transmission

F35 F34 F33

19 17 15 13 11 9 7 5 3 1

8 7 9

20 18 16 14 12 10 8 6 4 2

EH 10

13 A 4

EW 19 17 15 13 11 9 7 5 3 1

Powershift Gearbox (PS766 ECU 2.3 6 Speed)

444A

445

12 1

812

37 32

35 34 33 32 31

879 1906

25 24 23 22 21

15 14 13 12 11

9803/9520-8

SC16

876

818

2903

SC8

107J

40 39 38 37 36

35 34 33 32 31

817E

30 29 28 27 26

878

2805

20 19 18 17 16

2805

873

874

873

874

5 8

810

871

810

871

25 24 23 22 21

15 14 13 12 11

808

40 39 38 37 36

809

808

30 29 28 27 26

809

20 19 18 17 16

20 18 16 14 12 10 8 6 4 2

120B

817

601J

21 20 19

601K

24 23 22

15 14 13

18 17 16

88 17 16

21 20 19

15 14 13

9803/9520-8

Section F - Transmission Electrical Connections

F-59

Powershift Gearbox (PS766 ECU 2.3 6 Speed)

Fig 49. ECU Inputs Connector B

PC1 SM1

7 2827

18 17 16

601M

88 17 16

404 2

2 882

TB MH SC9

24 23 22

601N

F-59

3 404 2

2867 1

601P

880 30 30 2820

11 6

9 413 607A

2820 7

MD EB EM

601L

h2 h1

F-60 LUC 2802 601H

1 2

PE T 2860

601G

Y 2

2865

601D

U 2861 601B

1 2

2866

601A

9803/9520-8

h2 2863 601F

601J

2802

2864

601C

2863

601E

2862 2860

2861

2864

601K

F-60

Electrical Connections

Fig 50. Solenoid Actuation

Section F - Transmission

2862

601

T.B.A.

Powershift Gearbox (PS766 ECU 2.3 6 Speed)

2866

21 20 19

15 14 13

21 20 19

15 14 13

2865

18 17 16

88 17 16

24 23 22

18 17 16

88 17 16

SM1

Transmission Dump Operation

Section F - Transmission Electrical Connections Transmission ECU

Transmission ECU ECU Location The ECU is located within the rear chassis at the front left corner.

Fig 51. ECU Location

F-61

9803/9520-8

F-61

Section F - Transmission Electrical Connections Transmission ECU

ECU Electrical Connections

ECU Connector TA

Electrical connections at the ECU K Fig 52. ( T F-64). Note: When fault finding DO NOT use a multimeter on the ECU connector pins. Only test the associated wiring, uncouple connectors at TA and TB and then use a multimeter at the pins inside the harness connectors as applicable. Use the JCB Diagnostics system to identify possible faults with the ECU See Powershift Gearbox JCB Diagnostics - User Guide.

Component Key ECU Connector TA

TA28

Column lever neutral switch

TA29

Reverse Relay

TA30

Parkbrake switch (Normally Open)

TA31

Not Used

TA32

Hydraulic Variflow Control (HVCS) ECU

TA33

Not Used

TA34

Neutral Start Relay

TA35

Parkbrake switch (Normally Closed)

TA36

ECU Earth

TA37

Transmission dump switch

TA38

Column lever reverse switch

TA39

Kickdown switch

TA40

Not Used

TA1

ECU Feed

TA2

Bank 2 12V Feed

TA3

Not Used

TA4

Bank 1 12V Feed

ECU Connector TB

TA5

Bank 1 12V Feed

TB1

Lock up torque converter solenoid (if fitted)

TA6

CANbus High

TB2

TA7

Column lever forward switch

Transmission Dump Pressure Switch (Normally Open)

TA8

2nd gear switch

TB3

Gearbox speed sensor

TA9

Control lever (joystick) forward switch

TB4

Output - Z solenoid

TA10

Not Used

TB5

Not Used

TA11

Not Used

TB6

Output - U solenoid

TA12

Footbrake Pressure Dump Enable

TB7

Gearbox speed sensor Earth

TA13

Not Used

TB8

TA14

Speed Output to Engine ECU

Transmission Dump Pressure Switch (Normally Closed)

TA15

Control lever (joystick) neutral switch

TB9

TA16

CANbus Low

Power / ECO / Field mode changeover signal (6 Speed Machines Only)

TA17

4th - Auto gear switch (6 Speed Machines Only)

TB10

Gearbox speed sensor

TA18

1st gear switch

TB11

Switch low transmission oil pressure

TA19

Throttle switch

TB12

Output - X solenoid

TA20

Not Used

TB13

ECU Bank 1 Earth

TA21

Not Used

TB14

Not Used

TA22

Not Used

TB15

Output - Y solenoid

TA23

Control lever (joystick) reverse switch

TB16

Not Used

TA24

CANbus Shield

TB17

Not Used

TA25

Not Used

TB18

Not Used

TA26

ECU Earth

TB19

ECU Bank 2 Earth

TA27

3rd gear switch

TB20

Output - V solenoid

TB21

Switch - transmission oil temperature

F-62

9803/9520-8

F-62

Section F - Transmission Electrical Connections Transmission ECU ECU Connector TB TB22

Not Used

TB23

Output - W solenoid

TB24

Output - T solenoid

ECU Input Devices B

Gear select switch

Column Forward/Neutral/Reverse select switch

Gearbox oil temperature switch

Park brake switch

Speed sensor - gearbox mounted

Kick down switch

Throttle switch

Gearbox oil pressure switch

Transmission dump switch

Transmission mode select switch

HVCS ECU

Control lever (joystick) Forward / Neutral / Reverse select switch

ECU Output - Activated Devices 1

LMS ECU and display

S-Z

Gearbox solenoid control valves

F-63

9803/9520-8

F-63

Section F - Transmission Electrical Connections Transmission ECU 12V IGNITION BANK 1 FEED TA 4 TA 5

BANK 2 FEED TA 2 TA 1 FEED

B1 FEED

B2 FEED

FEED

12V

C B

TA 7

FORWARD

N R

NEUTRAL

TA 28

REVERSE

TA 38

1 2

GEAR 1

TA 18

GEAR 2

TA 8

GEAR 3

TA 27

GEAR A

TA 17

FEED

FNR GEARSHIFT LEVER

OUT

IN IN

OUT OUT OUT

THROTTLE

TA 19

DUMP

TA 37

FOOTBRAKE DUMP TA 12

J Q

KICKDOWN

TA 39

HVCS

TA 32

SPEED

TA 14

OUT

GND RTN IN

GND RTN

IN FREQ 2

OUT

ECU 2.3

OUT

GND RTN

IN TA 9

N NEUTRAL

TA 15

R REVERSE

TA 23

TB 6 ’U’ SOLENOID TB 12 ’X’ SOLENOID TB 15 ’Y’ SOLENOID TB 18 4WD SOLENOID TB 20 ’V’ SOLENOID TB 23 ’W’ SOLENOID TB 24 ’T’ SOLENOID TB 13 BANK 1 GROUND RETURN TB 19 BANK 2 GROUND RETURN

IN IN

TB 3

TRANS SPEED

SPEED SENSOR

TB 7 TRANS SPEED GROUND RETURN TB 10 TRANS SPEED SUPPLY

TB 11 LOW TRANS OIL PRESSURE

TB 21 HIGH OIL TEMPERATURE

TB 2 TRANSMISSION DUMP PRESSURE SW

FNR JOYSTICK LEVER

F FORWARD

S-Z

OUT

TB 1 LUC SOLENOID TB 4 ’Z’ SOLENOID

TB 8 TRANSMISSION DUMP PRESSURE SW

TB 9 THREE MODE MOMENTARY SWITCH

IN IN

CAN SH

HANDBRAKE NC TA 35

CANL

HANDBRAKE NO TA 30

ECU GND

F F

OUT

CANH

REVERSE RELAY TA 29

OUT

ECU GND

NEUTRAL START RELAY TA 34

12V

TA 24 CAN SHIELD

CAN HIGH

TA 16 CAN LOW

TA 6

TA 36 ECU GROUND

TA 26 ECU GROUND

DIAGNOSTICS CONNECTOR

Fig 52. ECU Connections

F-64

9803/9520-8

F-64

Section F - Transmission Electrical Connections Transmission ECU

ECU Feeds and Earths ECU Power Supply and Earths Fuse

Table 9. ECU Feeds and Earths ECU Connector TA ECU Connector TB

POWER FEED I

POWER FEED II

F37

EARTH I

EARTH II

Earth Point(1)

DT DT

EARTH III

EARTH IV

(1) For earth point locations refer to Section C.

Gearbox Function

Table 10. Transmission Dump Dump Switch E.C.U. TA

TRANSMISSION DUMP

Gearbox Function

Table 11. Park Brake ON Park Brake Switch CV

E.C.U. TA

PARK BRAKE ON

2-3

F-65

9803/9520-8

F-65

Section F - Transmission Electrical Connections Transmission ECU Column Switch Position

Table 12. ECU Inputs, Direction and Gear Selection Column Switch CP

E.C.U. TA (Inputs)

Position F (Forward)

7-4

Position N (Neutral)

7-6

Position R (Reverse)

7-10

Position 1

14-12

Position 2

14-9

Position 3

14-5

Position A

14-13

FNR Switch Position (joystick)

Joystick Switch DZ

F N R

Position F (Forward)

8-4

Position N (Neutral)

7-8

Position R (Reverse)

8-5

Column Switch Position

Table 13. ECU Inputs, Kick Down Column Switch CP

E.C.U. TA (Inputs)

Kick down button pressed

11-8

F-66

9803/9520-8

F-66

Section F - Transmission Electrical Connections Transmission ECU Mode Switch Position

Table 14. ECU Inputs, Mode Selection Mode Switch EM E.C.U. TB (Inputs)

Mode change selected

2-3

9, 16(1)

(1) When the ignition is ON there is a permanent 12v input at Pin 16

F-67

9803/9520-8

F-67

Section F - Transmission Electrical Connections Transmission ECU Gearbox Function

Table 15. ECU Outputs, Forward Gears E.C.U. TB (Outputs) Solenoid Connectors

1st GEAR

4(Z), 12(X)

Gearbox Solenoid

SM1

FORWARD

X,Z Z X

2nd GEAR

4(Z), 24(T) SM1

FORWARD

T,Z Z

3rd GEAR

4(Z), 6(U) SM1

FORWARD

U,Z Z

4th GEAR (6 Speed Machines Only)

15(Y), 12(X) SM1

FORWARD

X,Y Y

5th GEAR (6 Speed Machines Only)

15(Y), 24(T) SM1

FORWARD

T,Y Y

6th GEAR (6 Speed Machines Only)

15(Y), 6(U) SM1

FORWARD

U,Y Y

F-68

9803/9520-8

F-68

Section F - Transmission Electrical Connections Transmission ECU Gearbox Function

Table 16. ECU Outputs, Reverse Gears E.C.U. TB (Outputs) Solenoid Connectors

1st GEAR

4(Z), 23(W)

Gearbox Solenoid

SM1

REVERSE

W,Z Z

2nd GEAR

4(Z), 20(V) SM1

REVERSE

2R V,Z Z

3rd GEAR

15(Y), 23(W) SM1

REVERSE

4th GEAR (6 Speed Machines Only)

W,Y

15(Y), 20(V) SM1

REVERSE 4R(A) V,Y Y

F-69

9803/9520-8

F-69

Section F - Transmission Electrical Connections Transmission ECU

CU 11

815

444D

P/BRAKE SWITCH 2

445

7 9

FUSE 19 EW18

EH REVERSE ALARM

FUSE 25 609P

EX 10

FUSE 15 EW 10

TB3 810

6 FOR / REV SWITCH 818

CP 7

811 445

TA35

PARKBRAKE OFF

TA7 TA28 TA38

809

R 10

REVERSE ALARM

TA30

444A

F 4 N 6

TA29

808

PARKBRAKE ON FORWARD NEUTRAL REVERSE

817B

1 12 2 9

817E

3 5 A 13

CP 8

F 4

TA18

871

TA8

872

TA27

873

TA17

874

2867

2802

’TCLU’ SOLENOID

3rd GEAR

TA39

2805

TB6

TB20

KICKDOWN

ECU

GEAR SELECTOR - JOYSTICK SWITCH

’T’ SOLENOID

2861

’U’ SOLENOID

TB23

2862

2863

’V’ SOLENOID

’W’ SOLENOID

875

TA9 TA15 TA23

876

FORWARD NEUTRAL REVERSE

TB12

TB15

2864

2865

’X’ SOLENOID

’Y’ SOLENOID

878

2860

2nd GEAR

TB24

1st GEAR

AUTOMATIC

TB1

A 601P

GEAR SELECTOR

TB7 TB10

C 2867

TB4

2866

’Z’ SOLENOID

1903B

TA32

1906

607B 607C

HVCS

TA26 TA36

EARTH

Fig 53. Electrical Schematic, Neutral Selected - Park Brake ON.

F-70

9803/9520-8

F-70

Section F - Transmission Electrical Connections Transmission ECU

CU 11

815

444D

P/BRAKE SWITCH 2

445

7 9

FUSE 19 EW18

EH REVERSE ALARM

FUSE 25 609P

EX 10

FUSE 15 EW 10

TB3

6 FOR / REV

811

SWITCH

445

818

CP 7

TA35

PARKBRAKE OFF

TA7 TA28 TA38

809

R 10

REVERSE ALARM

TA30

444A

F 4 N 6

TA29

808

PARKBRAKE ON FORWARD NEUTRAL REVERSE

817B

1 12 2 9

817E

3 5 A 13

CP 8

F 4

TA18

871

TA8

872

TA27

873

TA17

874

2867

2802

’TCLU’ SOLENOID

3rd GEAR

TA39

2805

TB6

TB20

KICKDOWN

ECU

GEAR SELECTOR - JOYSTICK SWITCH

TB23

875

TA9 TA15 TA23

876

FORWARD NEUTRAL REVERSE

TB12

TB15 878

2860

’T’ SOLENOID

2nd GEAR

TB24

1st GEAR

2861

’U’ SOLENOID

AUTOMATIC

TB1

A 601P

GEAR SELECTOR

TB7 TB10

C 2867

TB4 1903B

TA32

1906 607B 607C

TA26

2862

2863

2864

2865

2866

’V’ SOLENOID

’W’ SOLENOID

’X’ SOLENOID

’Y’ SOLENOID

’Z’ SOLENOID

HVCS EARTH

TA36

Fig 54. Electrical Schematic - 1st Gear Reverse Selected.

F-71

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F-71

Section F - Transmission Electrical Connections Lock Up Torque Converter

Lock Up Torque Converter Introduction This section explains how the Lock Up Torque Converter electrical system works. Central to the system is the ECU (Electronic Control Unit) 1. The unit receives `inputs' from electrical devices such as the engine speed sensor B. Depending on the input signals an ECU `output' energises the lock up torque converter solenoid control valve 2. The ECU can be connected to diagnostics software loaded on a laptop PC. The communications link is facilitated via diagnostics socket 3 K Fig 55. ( T F-73). See also Powershift Gearbox - JCB Diagnostics - User Guide.

Component Key 1

ECU

ECU Input Devices A

Gear select switch

Engine speed sensor

Transmission speed sensor

ECU Output - Activated Devices D

Lock up torque converter solenoid control valve

In-cab warning light(1) - torque converter lock up

(1) For identification of in-cab warning lights see the machine Operator Handbook.

F-72

9803/9520-8

F-72

Section F - Transmission Electrical Connections Lock Up Torque Converter

D B

E A

Fig 55. Electrical Components

F-73

9803/9520-8

F-73

Section F - Transmission Electrical Connections Lock Up Torque Converter

Quick Reference

Component Key

Electrical connectors K Fig 56. ( T F-75)

Column switch

Electrical circuit for lock up torque converter control. Shown with torque converter LOCKED. `Live feed' wires are coloured red and feed to earth are green K Fig 57. ( T F-76).

Instruments

Harness connector - ECU - A

Harness connector - ECU - B

Transmission speed sensor

The information is intended as an aid when checking for faulty wires or connectors by means of continuity tests using a multimeter. DO NOT use a multimeter on the ECU connector pins (connectors A and B). Only test the associated wiring, uncouple connectors CJ and MH and then use a multimeter at the pins inside these connectors as applicable. Use the JCB Diagnostics system to identify possible faults with the ECU See Powershift Gearbox JCB Diagnostics - User Guide.

Torque converter lock up solenoid control valve

Note: Interconnecting harness connectors are not shown here. For full details see the relevant expanded harness schematic in this section.

F-74

ECU Connector TA TA7

Column Forward switch

TA17

4th - Auto gear switch

TB14

Engine speed sensor - input

ECU Connector TB TB3

Transmission speed sensor - input

TB1

Lock up torque converter control valve solenoid - output

9803/9520-8

F-74

Section F - Transmission Electrical Connections Lock Up Torque Converter

6 5 4

18 17 16

88 17 16

24 23 22

E.C.U. B 3

9 8

21 20 19

15 14 13

12 1

13 A

20 19 18 17 16

40 39 38 37 36

30 29 28 27 26

E.C.U. A

5 4 3

9 10 11

12 13 14

10 R

1 B

2 1

15 14 13 12 11

35 34 33 32 31

25 24 23 22 21

MW 1

C B

Fig 56. Electrical Components - Connectors

F-75

9803/9520-8

F-75

Section F - Transmission Electrical Connections Lock Up Torque Converter

815

444D

P/BRAKE SWITCH 2

445

7 9

FUSE 19 EW18

EH REVERSE ALARM

FUSE 25 609P

EX 10

FUSE 15

EW 10

6 FOR / REV

811

SWITCH

445

818

CP 7

PARKBRAKE OFF

TA7 TA28 TA38

809

R 10

REVERSE ALARM

TA35 TA30

444A

F 4 N 6

TA29

808

PARKBRAKE ON FORWARD NEUTRAL REVERSE

817B

TB3

GEAR SELECTOR 1 12

TA8

872

817E

3 5

TA27

873

A 13

TA17

874

CP FUSE 34

112A

EY 8 FUSE 35

3rd GEAR

TB1

KICKDOWN

TA2

BANK 2 +VE

2802

’TCLU’ SOLENOID

ECU

BANK 1 +VE

TA19

THROTTLE

875

876

TA9 TA15 TA23

FORWARD NEUTRAL REVERSE

TB13 TB19

601J

-VE

601K

-VE -VE

878

2867

GEAR SELECTOR - JOYSTICK SWITCH

TA1

111B 1807

TB10

A 601P

TA5

113A

EY 6

2nd GEAR

TA39

TA4

113B

EY 10

TB7

TA3

112B

FUSE 33

1st GEAR

AUTOMATIC

2805

TA18

871

2 9

C 2867

TB9

1903B

TA32

1906

FUSE 15

TA37

879

817C

EW 10

TA34

812

7 9

607B 607C

HVCS DUMP NEUTRAL START

TB11 TB21

EM -VE

2820

NC -VE

413

MF 404

-VE

TA26 TA36

EARTH -VE

607D

Fig 57. Electrical Schematic - Torque Converter `Locked'

F-76

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F-76

Section F - Transmission Electrical Connections Lock Up Torque Converter

Wires and Connectors On the electrical diagram the electrical connectors (example, EB to MD) are shown looking on the mating face of each connector when they are disconnected K Fig 59. ( T F-79). The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding. Before fault finding make sure that you understand how the the electrical circuits work. The most effective method of fault finding is by means of JCB Diagnostics software and a laptop PC, see Service Procedures, Powershift Gearbox - JCB Diagnostics - User Guide. Having identified a faulty system, use the schematics to identify the relevant wires and connectors, continuity checks can then be carried out using a multimeter. Gearbox solenoid coils can be checked for the correct resistance value as given in Technical Data. See Section C - Service Procedures, for more details.

Transmission Speed Sensor

TCLU Solenoid

Earth point

Splices (h1) SC9

Earth Splice 2

Splices (h2) SM1

Earth Splice

Electrical Diagram Earth Points Faults may be caused by poor earth connections. Although earth connections are shown, it must be remembered that the cab assembly is earthed via further earth strap and cable connections. For details of these connections see Section C, Earth Points. Component Key The following key identifies the component connectors, K Fig 58. ( T F-78) and K Fig 59. ( T F-79). Note that the wires coloured red show the electrical `live feed' and wires coloured green show the electrical `feed to earth' for the relevant components. h1

Harness - 332/R6766 Panel

Harness - 721/12544 Rear Chassis

Note: For harness drawings see Section C. Connectors (h1) DT

Earth point

h1 to h2

Tow Mode Control Switch

Connectors (h2) MD

h2 to h1

ECU Connector B

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F-77

Section F - Transmission Electrical Connections Lock Up Torque Converter

6 5 4

18 17 16

88 17 16

24 23 22

E.C.U. B 9

21 20 19

15 14 13

A 10 9 8

12 1

20 19 18 17 16

40 39 38 37 36

30 29 28 27 26

E.C.U. A 5

13 A

4 3 2

9 10 11

10 R

15 14 13 12 11

35 34 33 32 31

25 24 23 22 21

12 13 14

EM F

F 4

R 2

5 7 6

D 3

MW A B

Fig 58. Electrical Connectors

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F-78

Section F - Transmission Electrical Connections Lock Up Torque Converter h1

h2 DT

21 20 19

24 23 22

15 14 13

18 17 16

88 17 16

601H 19

601J

601K

601H

LUC

2802

2 2

2867

2827

1 2

601P

21 20 19

15 14 13

2820

9 1

18 17 16

2820 413

88 17 16

607A

24 23 22

SC9

B C

SM1

PC1

Fig 59. Electrical Diagram

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F-79

Section F - Transmission Electrical Connections Lock Up Torque Converter

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Section F - Transmission

Fault Finding Powershift Gearbox Introduction

Fault Finding Tables

The fault finding procedures are given in the form of tables. The tables are designed to identify possible causes by performing checks and where applicable, specific tests on the gearbox. Having identified a cause the suggested remedy is given. The tables are designed to identify causes through a process of elimination, starting with the simplest, most easily rectified faults. Gearbox faults may be caused by faulty electrical connectors or components as indicated in the fault finding tables. Due to the time and effort involved in removing, dismantling, assembling and replacing a gearbox, it is recommended that fault finding procedures are carried out until a fault can be identified with a good degree of certainty. Full details of the test procedures referred to in the tables are given in Service Procedures, PS763 and PS766 Powershift Gearboxes and PS766 Powershift Gearbox as applicable.

F-81

Fault Descriptions 1

Machine drives but lacks power in all K Table 17. ( T F-82). gears. Gearbox oil may also be overheating.

Machine does not drive in any gear. K Table 18. ( T F-84).

Some gears fail to engage or lack power.

K Table 19. ( T F-85).

Gearbox overheating.

K Table 20. ( T F-86).

Noisy operation.

K Table 21. ( T F-87).

Gearbox oil contaminated with water.

K Table 22. ( T F-88).

Machine does not achieve maximum K Table 23. ( T F-90). speed when travelling on the highway (lock-up torque converter variants only).

Gear shifts fail to function normally or shifts occur at incorrect road speed. Fails to autoshift (PS766 gearbox only).

K Table 24. ( T F-91).

Gearbox fails to change into the selected mode (Field, Road `ECO', Road `Power', PS766 gearbox only).

K Table 25. ( T F-92)

9803/9520-8

F-81

Section F - Transmission Fault Finding Powershift Gearbox Fault Machine drives but lacks power in all gears. Gearbox oil may also be overheating.

Table 17. Possible Cause

Action

Gearbox oil level low.

Check for leaks and top up oil level as required.

Gearbox oil contaminated or wrong grade.

Investigate the reason for the contamination and rectify as required. Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil.

Suction strainer restricted or blocked.

Remove the suction strainer and clean or renew as applicable, refer to Section3, Routine Maintenance.

Pressure maintenance valve defective. Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Mainline Pressure. Remove the pressure maintenance valve and inspect for signs of damage or excessive wear. Clean or renew as applicable. Torque converter relief valve defective. Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Converter IN Pressure. Remove the torque converter relief valve and inspect for signs of damage or excessive wear. Clean or renew as applicable. Oil cooler lines restricted or blocked. Internal blockage within the oil cooler matrix due to contamination.

Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Converter OUT Pressure and Lubrication Pressure. Clear the restriction. Inspect the hose routing and renew the hoses or oil cooler matrix as applicable.

Faulty torque converter.

Carry out torque converter stall tests to confirm stall speeds are within specification, refer to Torque Converter Stall Tests. Remove the gearbox and renew the torque converter. Note that the torque converter assembly is a non serviceable item.

Failure of oil pump assembly.

F-82

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Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Pump Flow.

F-82

Section F - Transmission Fault Finding Powershift Gearbox Fault

Possible Cause

Action Remove the gearbox and inspect the oil pump for signs of damage or excessive wear. Renew oil pump as applicable.

Gearbox internal leakage fault.

Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Converter OUT Pressure. Remove and dismantle the gearbox. Inspect all components for signs of damage or excessive wear. In particular, check the seals and renew as applicable.

K Fault Finding Tables ( T F-81).

F-83

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F-83

Section F - Transmission Fault Finding Powershift Gearbox Fault

Table 18. Possible Cause

Machine does not drive in any gear. Gearbox oil level low. Park brake switch or transmission dump switch defective.

Action Check for leaks and top up oil level as required. Check the function of the park brake switch and transmission dump switch. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C Electrics.

Gear selector column switch defective. Check the function of the gear selector column switch, see Section C Electrics. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C Electrics. Low mainline oil pressure.

Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Mainline Pressure.

Failure of oil pump assembly.

Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Pump Flow. Remove the gearbox and inspect oil pump for signs of damage or excessive wear. Renew oil pump as applicable.

K Fault Finding Tables ( T F-81).

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F-84

Section F - Transmission Fault Finding Powershift Gearbox Fault Some gears fail to engage or lack power.

Table 19. Possible Cause

Action

Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C Electrics.

Solenoid coil faulty.

Check the solenoid for open or short circuits. Measure the solenoid coil resistance. Renew the solenoid coil.

Clutch operating oil pressure low.

Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Isolating a Suspect Clutch.

Failure of clutch assembly.

Check for clutch internal leakage. Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Individual Clutch Leakage Test. Check for clutch slippage. Carry out torque converter stall tests to confirm stall speeds are within specification, refer to Torque Converter Stall Tests. Remove and dismantle gearbox. Inspect relevant clutch components for signs of damage or excessive wear. Renew as applicable.

K Fault Finding Tables ( T F-81).

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F-85

Section F - Transmission Fault Finding Powershift Gearbox Fault Gearbox oil overheating.

Table 20. Possible Cause

Action

Gearbox oil level incorrect i.e. Too low Adjust the oil level to the correct level, or too high. refer to Section3, Routine Maintenance. Gearbox oil contaminated or wrong grade.

Investigate the reason for the contamination and rectify as required. Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil.

Suction strainer restricted or blocked.

Remove the suction strainer and clean or renew as applicable, refer to Section3, Routine Maintenance.

Oil cooler hoses kinked or trapped.

Clear the restriction. Inspect the hose routing and reroute or renew the hoses as applicable.

Machine being operated incorrectly i.e. Educate the operator. Incorrect gear range. Torque converter relief valve defective. Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Converter IN Pressure. Failure of oil pump assembly.

Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Pump Flow. Remove the gearbox and inspect oil pump for signs of damage or excessive wear. Renew oil pump as applicable.

K Fault Finding Tables ( T F-81).

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F-86

Section F - Transmission Fault Finding Powershift Gearbox Fault Noisy operation.

Table 21. Possible Cause

Action

Gearbox oil level low.

Check for leaks and top up oil level as required.

Gearbox oil contaminated or wrong grade.

Investigate the reason for the contamination and rectify as required. Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil.

Suction strainer restricted or blocked.

Remove the suction strainer and clean or renew as applicable, refer to Section 3, Routine Maintenance.

Low lubrication oil pressure.

Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Lubrication Pressure.

Gearbox components damaged or excessively worn.

Remove and dismantle the gearbox. Inspect all components for signs of damage or excessive wear. In particular, check shaft seals and bearings. Renew as applicable.

K Fault Finding Tables ( T F-81).

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F-87

Section F - Transmission Fault Finding Powershift Gearbox Fault Gearbox oil contaminated with water. (1)

Table 22. Possible Cause

Action

Water ingress during filling or topping- Drain the oil and flush the gearbox, up. refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil. Missing or incorrect dipstick. Damaged Renew missing, incorrect or damaged filler tube. parts. Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil. Machine operated in deep water.

Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil.

Gearbox oil cooler faulty, gearbox oil contaminated with engine coolant.(2)

Remove and test oil cooler, Refer to Oil Cooler, Testing.

Gearbox casings damaged.

Inspect the gearbox casing. Renew missing or damaged parts. Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil.

Gearbox oil circuit pipework or hoses damaged.

Inspect the pipework and hoses. Renew missing or damaged parts. Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil.

Consequential Faults. (3) a Pressurisation of gearbox casing. Water in the oil combined with heat Dipstick blows out and oil escapes from torque converter causes steam. from dipstick tube.

Replace or renew the dipstick.

Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil. b Clutch failure due to friction lining Water ingress. separation.

c Badly worn or noisy bearings.

F-88

Remove and dismantle gearbox. Inspect relevant clutch components for signs of damage or excessive wear. Renew as applicable.

Overheating transmission oil.

K Table 20. ( T F-86)

Water ingress.

Remove and dismantle the gearbox. Inspect all components for signs of damage or excessive wear. Renew components as applicable.

9803/9520-8

F-88

Section F - Transmission Fault Finding Powershift Gearbox Fault

Possible Cause Insufficient lubrication.

Action Drain the oil and flush the gearbox, refer to Service Procedures Powershift Gearbox, Flushing the Transmission Oil. Carry out oil pressure and flow tests, refer to Pressure and Flow Tests Lubrication Pressure.

(1) Carefully inspect the gearbox oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum permissible water content of the oil is 0.10%. If the gearbox oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before remedying, thoroughly investigate and rectify the cause of the water contamination. (2) Machines with non intercooled engines only. Machines with intercooled engines are fitted with an air blast type gearbox oil cooler. (3) Gearbox faults caused typically by water contamination and other factors related to the gearbox oil. K Fault Finding Tables ( T F-81).

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F-89

Section F - Transmission Fault Finding Powershift Gearbox Fault

Table 23. Possible Cause

Machine does not achieve Operator error. maximum speed when travelling on the highway (Lock-up torque converter variants only).

Action Educate the operator. Ensure operator fully understands the characteristics of the lock up function.

Lock up torque converter solenoid not Inspect the condition of the associated being energised. electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C, Electrics. Lock up torque converter solenoid coil Check the solenoid for open or short faulty. circuits. Measure the solenoid coil resistance. Renew the solenoid coil. Engine or transmission speed sensor faulty.

Use the applicable JCB Diagnostics software to check the ECU inputs and outputs. Refer to Service Procedures - PS766 Powershift Gearbox, Diagnostics User Guide. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C, Electrics. Renew the speed sensor.

Faulty lock up torque converter.

Remove the gearbox and renew the lock up torque converter. Note that the torque converter assembly is a non serviceable item.

K Fault Finding Tables ( T F-81).

F-90

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F-90

Section F - Transmission Fault Finding Powershift Gearbox Fault

Table 24. Possible Cause

Action

Gear shifts fail to function normally Gear selector column switch faulty or shifts occur at incorrect road speed. (PS766 gearbox only)(1)

Check the function of the gear selector column switch.

Fails to autoshift (PS766 gearbox only) (2)

Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C Electrics. Transmission speed sensor faulty.

Check the function of the speed sensor. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C Electrics. Renew the speed sensor. Refer to Service Procedures - PS766 Powershift Gearbox, Speed Sensor.

Gearbox electronic control unit (ECU) defective. (3)

Use the ECU Diagnostics software to check the ECU inputs and outputs. See Section C Electrics. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Section C Electrics. Renew the ECU.(4)

(1) The simplest and best way to fault find the ECU controlled gearbox electrical system is by using the applicable JCB Diagnostics software and a laptop PC, refer to `Service Procedures - PS766 Powershift Gearbox, Diagnostics User Guide'. This diagnostics system enables the engineer to quickly identify faults with specific electrical circuits or devices. The devices electrical connections, locations and wire identifications are given in `Electrical Connections PS766 Powershift Gearbox. See also `Section C Harness Data'. (2) Note that on 6 speed gearboxes, 4th, 5th and 6th gears utilise clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th gears fail to engage, check that the lower 3 gears function correctly before investigating a possible Shiftmaster fault, refer to `Fault Table - Some gears fail to engage or lack power'. (3) In response to certain faults the ECU will enter a `Limp Mode'. For a detailed description of the Limp Modes, refer to `Service Procedures - Powershift Gearbox, Electronic Control Unit'. (4) The ECU is inherently reliable. It is protected internally from electrical damage. It is housed in a rugged case for protection from mechanical damage and ingress of dirt and moisture. Faults with associated systems are more likely to be caused by wiring or other input and output device failure. Before renewing the ECU make sure beyond reasonable doubt that it is faulty. K Fault Finding Tables ( T F-81).

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F-91

Section F - Transmission Fault Finding Powershift Gearbox Fault Gearbox fails to change into the selected mode (Field, Road `ECO', Road `Power', PS766 gearbox only).

Table 25. Possible Cause

Action

Mode switch faulty

Check the function of the mode switch. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Electrical Connections, Powershift Gearbox (PS766 6 speed). Renew the switch if it is faulty.

Mode relay faulty.

Check the function of the mode relay. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Electrical Connections, Powershift Gearbox (PS766 6 speed). Renew the relay if it is faulty.

IFT electronic control unit (ECU) faulty Check the relevant electrical input and output form the IFT ECU for the transmission mode function. Inspect the condition of the associated electrical wiring, plugs and connectors for damage and check that the relevant fuses are intact. See Electrical Connections, Powershift Gearbox (PS766 6 speed). Renew the ECU if it is faulty.(1) Gearbox electronic control unit (ECU) defective.

Check the relevant ECU inputs and outputs. See Electrical Connections, Powershift Gearbox (PS766 6 speed). Renew the ECU if it is faulty.(1)

(1) The ECU is inherently reliable. It is protected internally from electrical damage. It is housed in a rugged case for protection from mechanical damage and ingress of dirt and moisture. Faults with associated systems are more likely to be caused by wiring or other input and output device failure. Before renewing the ECU make sure beyond reasonable doubt that it is faulty. K Fault Finding Tables ( T F-81).

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F-92

Section F - Transmission

Powershift Gearbox Dismantling and Assembly The procedures for dismantling, inspection and assembly are described in a separate publication, see Transmissions Service Manual (publication No. 9803/ 8610 for full details). Make sure that you identify the gearbox correctly, see Technical Data - Designation in this section for details.

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F-93

Section F - Transmission Powershift Gearbox Dismantling and Assembly

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Section F - Transmission

Front Axle Removal and Replacement When Removing Before commencing, set machine in straight ahead position on firm level ground (preferably a concrete surface), with boom retracted and lowered to the ground, transmission in neutral, and parking brake applied. Install articulation locks and block wheels both sides. 'Crack' wheel nuts to aid subsequent removal. Raise machine by means of a trolley jack placed under the axle half casing and position stands or blocks securely under front module chassis, as shown at A. Lower trolley jack until the stands take machine weight. Remove wheels. Disconnect brake lines on axle housing. Remove four bolts C to disconnect driveshaft flange at axle half coupling. Place a trolley jack under the axle for support before unscrewing self-locking nuts D from securing bolts, and removing axle from frame for servicing elsewhere.

When Replacing The procedure for replacing an axle is the reverse of that for removal. Bleed the brakes before attempting to move the machine. See Bleeding the Brakes, Section G.

Item

Table 26. Torque Settings Nm kgf m lbf ft

7.9

822

83.8

606

F-95

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F-95

Section F - Transmission Front Axle Removal and Replacement

C Fig 60.

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F-96

Section G Brakes Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-8

Section G - Brakes

Notes:

G-0

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G-0

Section G - Brakes Contents Page No. Park Brake Gearbox Integral ....................................................................................... G-1 Dismantle, Inspection and Assemble ................................................... G-1 Brake Pump Removal and Replacement ...................................................................... G-9 Removal ............................................................................................... G-9 Replacement ........................................................................................ G-9 Brake Valve Removal and Replacement .................................................................... G-11 Removal ............................................................................................. G-11 Replacement ...................................................................................... G-11 Service Procedures Service Brakes ....................................................................................... G-13 Bleeding the Braking System ............................................................. G-13

G-i

Section G - Brakes Contents

G-ii

Page No.

G-ii

Section G - Brakes Park Brake Gearbox Integral

Park Brake Gearbox Integral Dismantle, Inspection and Assemble The integral park brake consists of a wet multi plate friction pack and a mechanical actuator assembly. A separate dismantling procedure is given for each sub-assembly.

!MWARNING Before working on the park brake, park on level ground and put blocks on each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. BRAK-8-8

Dismantle the Multi-Plate Brake Pack K Fig 3. ( T G-2). 1

Working inside the cab, disengage the parking brake (lever horizontal). Rotate the park brake lever to fully slacken the cable.

Remove the rear propshaft, see Section F, Propshafts. Position the output yoke 2-A as shown.

Working beneath the machine at the gearbox, undo 2 off bolts 3-A at positions 3-X and screws 3-B. Using a flat bladed screwdriver located in the cover cutout, lever off cover plate 3-C.

Undo the remaining 4 off bolts 3-A and carefully pull off cover 3-D, keeping it square to the mating face on the gearbox (Note that the park brake cable is still attached at this stage).

Fig 1.

Note: If the cover does not come free one or more reaction pins 3-F will have remained in the cover. Use a pair of long nosed pliers to push the pins back into the gearbox casing. Be sure not to damage the surface of the pins. 5

Remove the needle roller thrust bearing 3-E, thrust plate 3-G, friction plates 3-H (5 off) and counter plates 3-J (5 off).

Fig 2.

Note: If the brake actuator is to be dismantled, or the cable renewed, then remove the park brake cable 1-A. Undo screw 1-C, remove circlip 1-B and withdraw the cable from the housing.

G-1

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G-1

Section G - Brakes Park Brake Gearbox Integral

J D H G E

C C002180-C5

A Fig 3. Multi-Plate Brake Pack

G-2

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G-2

Section G - Brakes Park Brake Gearbox Integral Dismantle the Brake Actuator 1

Carefully undo screw 4-A, note that the screw is under tension from springs 4-B and 4-C.

Remove washers 4-D and 4-E, followed by springs 4B and 4-C.

Lift out the brake actuator plate 4-F followed by balls 4-G (5 off).

Fig 4.

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G-3

Section G - Brakes Park Brake Gearbox Integral Inspection Before inspecting the brake components carefully remove all traces of sealing compound from component mating faces. Using a suitable degreaser clean the brake components including the brake housing in the gearbox rear casing. 1

Carefully inspect the friction plates 6-A and counter plates 6-B. If any of the plates show signs of damage or distortion, renew the complete friction pack.

Assemble the friction and counter plates (including the thrust plate 6-C) on a suitable datum table. Measure the overall thickness of the assembled friction pack. The thickness 5-X must be between 39.6 mm and 37.1mm. If the pack is out side these limits the complete friction pack assembly must be renewed.

Note: The friction pack may be outside the maximum thickness value if the plates are distorted, typically after the brake has performed an emergency stop.

Fig 5. 3

Inspect the following components for signs of excessive wear or damage: Balls 6-D and their tapered locating slots (cover 6-E and actuator plate 6F), needle roller thrust bearing 6-G and the corresponding bearing surfaces (actuator plate 6-F and thrust plate 6-C).

Note: Some discolouration of the needle rollers is acceptable providing the surface of the rollers is otherwise undamaged. 4

Make sure that the park brake cable is smooth and free in operation. Inspect the cable outer for signs of damage. Renew the cable if it is damaged or stiff to operate. Fig 6.

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G-4

Section G - Brakes Park Brake Gearbox Integral Assemble the Brake Actuator 1

Apply a little grease to the ball locating slots in cover 7-H and actuator plate 7-F. Locate balls 7-G in their slots in cover 7-H.

Fit actuator plate 7-F followed by springs 7-B and 7C.

Locate washers 7-D and 7-E. Compress the springs 7-B and 7-C, then fit screw 7-A and tighten.

Item

Table 1. Torque Settings Nm kgf m

7-A

1.6

lbf ft 12

Fig 7.

G-5

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G-5

Section G - Brakes Park Brake Gearbox Integral Assemble the Multi-Plate Brake Pack

casing as shown at 9-Y. Fit the cover and 4 off bolts 9-A. Torque tighten bolts 9-A. K Table 2. Torque Settings ( T G-6). Note that 2 off bolts at position 9X are not fitted at this stage. Carefully feed the park brake cable up into the cab, through the aperture in the cab floor.

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

Working beneath the machine, assemble the reaction pins 9-F followed by the friction pack into the gearbox casing. Note that a counter plate 9-J is fitted first, followed by a friction plate 9-H and so on. Fit the thrust plate 9 last.

Note: If removed during the dismantling, fit the park brake cable 8-A. Feed the cable into the housing and connect the fork end to the brake actuator 8-F with screw 8-E. Make sure that `O' ring 8-D is undamaged and correctly fitted on collar 8-B. Locate the collar inside the brake housing and retain with circlip 8-C.

Working inside the cab, reconnect the park brake cable to the park brake lever and adjust the lever, see Service Procedures, Park Brake, Adjustment. Working under the machine view the brake friction pack through the housing aperture and check its operation. Play in the plates will be easily felt when the brake is off.

Before fitting cover plate 9-C, apply a bead of JCB Multigasket sealant to the mating face on the cover 9D as shown at 9-Z. Fit screws 9-B (5 off) and remaining bolts 9-A (2 off). K Table 2. Torque Settings ( T G-6).

If any brake components have been renewed it must be assumed that the gearbox oil will be contaminated. Change the gearbox oil and filter, see Section 3, Maintenance.

Note: Screw 8-E is a special clevis pin. DO NOT fit a normal bolt or screw. 2

Make sure that the needle roller thrust bearing 9-E is correctly located on the brake actuator assembly, if necessary use some grease to help retain the bearing.

Note: A small quantity of gearbox oil will be transferred from the sump to fill the brake cavity when the engine is started. Check the gearbox oil level and top up if necessary, see Section 3, Maintenance.

Item

Table 2. Torque Settings Nm kgf m

lbf ft

8-E

0.9

6.6

9-A

5.7

9-B

1.6

Fig 8. 3

Before fitting the cover 9-D, apply a bead of JCB Multigasket sealant to the mating face on the gearbox

G-6

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G-6

Section G - Brakes Park Brake Gearbox Integral

J D

H G

C002180-C6

A Fig 9. Multi-Plate Brake Pack

G-7

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G-7

Section G - Brakes Park Brake Gearbox Integral

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G-8

Section G - Brakes

Brake Pump Removal and Replacement The brake pump is located on the right side of the engine.

During the replacement procedure do this work also:

Before removing the pump, make sure the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination.

Make sure that the pump flange and engine mating face are clean and free from oil and grease prior to assembly.

Removal

Install new O ring seals to the pump to engine mating face and inlet and outlet hose flanges. Lubricate the O rings with clean hydraulic fluid.

Reconnect the inlet and outlet hoses to the pump.

Fill the hydraulic tank to the correct level with clean hydraulic fluid.

Bleed the braking Procedures ( T G-13)

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

system.

A B

INT-3-1-11_2

Vent the braking system pressure, see Section 2 General Procedures.

Lift the engine canopy, see Section 3 - Engine Canopy.

Put a label on the inlet and outlet hoses B to help identification when replacing.

Disconnect the inlet and outlet hoses B. Plug the open port and cap the hose to prevent loss of fluid and ingress of dirt.

Drain the hydraulic fluid from the hydraulic tank into a suitable clean container.

Remove the four mounting bolts A and remove the pump C from the engine.

K Service

C A A

B C076510

Fig 10.

Replacement Replacement is the opposite of the removal procedure.

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G-9

Section G - Brakes Brake Pump Removal and Replacement

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Section G - Brakes

Brake Valve Removal and Replacement Removal

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-4-1_1

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Vent the braking system pressure, see Section 2 General Procedures.

Working below the cab put a label on the brake hoses D to help identification when replacing.

Disconnect the hoses D. Cap all open hoses and pipes to prevent fluid loss and ingress of dirt.

Disconnect the brake light switch F and brake pressure switch E electrical connectors.

Remove the pedal pivot pin B.

Remove the pedal.

With the aid of one more person support the brake valve C from below the cab.

A D D D

D E Fig 11.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: 1

Bleed the braking system, see Section G - Brakes.

Remove the pedal assembly securing bolts A from inside the cab.

Check the hydraulic fluid level, see Section 3 Hydraulics.

The pedal assembly B and brake valve C can be removed from the machine.

Make sure that the hoses are connected to the correct connectors. K Fig 12. ( T G-12)

Bleed the braking Procedures ( T G-13)

G-11

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system.

K Service

G-11

Section G - Brakes Brake Valve Removal and Replacement

E A

D C

B Fig 12. Brake Hose Connections Item

K Fig 12. ( T G-12)

From Accumulator Block

Supply from Gearpump

To Brakes on Front Chassis

To Tank or Trailer Brake Valve (if fitted)

Tank Return

G-12

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G-12

Section G - Brakes

Service Procedures Service Brakes Bleeding the Braking System

Note: As the brake system uses hydraulic fluid there may be small traces of air in suspension in the fluid that can be discounted.

!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.

Make sure all of the bleed screws are tight.

Check the hydraulic fluid level, see Section 3 Routine Maintenance.

BRAK-1-2

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Operate the engine for a minimum of 2 minutes and occasionally operate the brake pedal. This makes sure that the brake system charge valve has filled the accumulator and removed any air from the charge circuit.

!MWARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. BRAK-1-1

Check the hydraulic fluid level, see Section 3 Routine Maintenance.

Important: .Make sure that during the bleeding procedure the level is not allowed to fall below the MINIMUM mark. Important: Make sure to keep the engine running whilst bleeding the system. 4

Attach a tube to the appropriate bleed screw, making sure that the free end of the tube is immersed in fluid in a suitable container.

Open the bleed screw and push the brake pedal.

Continue bleeding normally until all air is dispelled, closing the bleed screw with the pedal fully depressed.

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G-13

Section G - Brakes Service Procedures Service Brakes

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G-14

Section H Steering Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-8

Section H - Steering

Notes:

H-0

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H-0

Section H - Steering Contents Page No. Service Procedures Bleeding the System ................................................................................. H-1 Hydraulic Pressure Tests .......................................................................... H-2 Standby and Steering Pressure ............................................................ H-2 Steer Rams Removal and Replacement ...................................................................... H-3 Dismantle and Assemble .......................................................................... H-5 Hydraulic Steer Unit Removal and Replacement ...................................................................... H-7 Removal ............................................................................................... H-7 Replacement ........................................................................................ H-8 Hose Connections ................................................................................ H-8 Steering Manifold Removal and Replacement ...................................................................... H-9 Removal ............................................................................................... H-9 Replacement ........................................................................................ H-9 Hose Connections .............................................................................. H-10

H-i

Section H - Steering Contents

H-ii

Page No.

H-ii

Section H - Steering

Service Procedures Bleeding the System The steer circuit is integrated with the variflow pump and the main hydraulic system. For bleed procedures see Section E - Service Procedures.

H-1

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H-1

Section H - Steering Service Procedures Hydraulic Pressure Tests

Hydraulic Pressure Tests Standby and Steering Pressure The steer circuit pressure is integrated with operation of the variflow pump and the main hydraulic system pressures. See Section E - Service Procedures.

H-2

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H-2

Section H - Steering

Steer Rams Removal and Replacement A C

C A

Fig 1. Park the machine and make it safe. Obey general safety procedures, see Section 2 - General Procedures.

Removal

Before commencing work clean the area around the steer ram. The following procedure applies to each of the front steering rams. 1

Vent the hydraulic and steering pressure, see Section 2 - General Procedures.

Put a label on each steer ram hydraulic hose to help identification when replacing.

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-4-1_1

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H-3

Section H - Steering Steer Rams Removal and Replacement 3

Disconnect the hoses at the connectors C. Blank off the hoses and plug the ram ports to prevent loss of fluid and ingress of dirt.

Support the ram D.

Remove bolts and nuts B.

Remove the pivot pins A at each end of the ram and lift the ram away from the machine.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: 1

Check the hydraulic fluid level. See Section 3 Routine Maintenance.

Before driving the machine, bleed the steering system. K Bleeding the System ( T H-1)

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H-4

Section H - Steering Steer Rams Dismantle and Assemble

Dismantle and Assemble Refer to Section E - Rams, Dismantle and Assemble, Typical Ram.

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H-5

Section H - Steering Steer Rams Dismantle and Assemble

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H-6

Section H - Steering Hydraulic Steer Unit Removal and Replacement

Hydraulic Steer Unit Removal and Replacement Removal

Remove the steering unit 3-A.

GEN-4-1_1

Park the machine and make it safe. Obey general safety procedures, see Section 2 - General Procedures.

B A

Before commencing work clean the area around the steering unit. 1

Vent the hydraulic and steering pressure, see Section 2 - General Procedures.

Remove the cab front cover bolts 2-B.

Remove the cab front cover 2-A to get access to the steer unit.

Remove the Panels ( T B-62)

Put a label on each steering hydraulic hose to help identification when replacing.

front

console.

K Instrument

Disconnect the hydraulic hoses to steering unit 3-A, labelling them to aid reconnection. Plug the ports and hoses to prevent the ingress of dirt and excessive loss of hydraulic oil.

Mark the orientation of steering unit 3-A to splined shaft 3-B.

Remove bolts 3-C (4 off) from inside the cab. At the same time have an assistant support steering unit 3A at the front of the cab.

H-7

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C076670

Fig 2.

H-7

Section H - Steering Hydraulic Steer Unit Removal and Replacement

Fig 3.

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Torque tighten fixing bolts 3-C.

Make sure the steering hoses are connected to the correct connectors. K Hose Connections ( T H-8)

Check the hydraulic fluid level. See Section 3 Routine Maintenance.

Before driving the machine, bleed the steering system, see K Bleeding the System ( T H-1)

If a new steering unit has been fitted then the system relief valve must be tested for correct pressure setting, see Section E - Service Procedures.

Hose Connections Item

K Fig 4. ( T H-8)

Tank Return

Steering Supply

To Steer Manifold (F)

Load Sense Line

Steering Manifold

H-8

C C

F Fig 4. Steer Hose Connections

9803/9520-8

H-8

Section H - Steering

Steering Manifold Removal and Replacement D

E A

Fig 5.

Removal

Disconnect the left steer ram hoses at the connectors A. Blank off the hoses and plug the ports to prevent loss of fluid and ingress of dirt.

Disconnect the right steer ram hoses at the connectors E. Blank off the hoses and plug the ports to prevent loss of fluid and ingress of dirt.

Disconnect the steer valve hoses at the connectors C and D. Blank off the hoses and plug the ports to prevent loss of fluid and ingress of dirt.

Support the manifold block F.

Remove the bolts B.

Remove the manifold block F.

Park the machine and make it safe. Obey general safety procedures, see Section 2 - General Procedures. Before commencing work clean the area around the steering manifold.

Replacement

Vent the hydraulic and steering pressure, see Section 2 - General Procedures.

Replacement is the opposite of the removal procedure.

Put a label on each steering hydraulic hose to help identification when replacing.

During the replacement procedure do this work also:

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H-9

Section H - Steering Steering Manifold Removal and Replacement 1

Make sure the steering hoses are connected to the correct connectors. K Hose Connections ( T H-10)

Item

K Fig 6. ( T H-10)

Left Steer Ram

Check the hydraulic fluid level. See Section 3 Routine Maintenance.

Right Steer Ram

To Steer Valve

Before driving the machine, bleed the steering system, see K Bleeding the System ( T H-1)

To Steer Valve

Steer Valve

Hose Connections

C D A

C B B

Fig 6. Steering Manifold Hose Connection

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H-10

Section K Engine Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

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Section K - Engine

Notes:

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K-0

Section K - Engine Contents Page No. Technical Data Basic Engine Data .................................................................................... K-1 Introduction Engine Types ............................................................................................ K-3 Unit Identification .................................................................................. K-3 Silencer Removal and Replacement ...................................................................... K-5 Removal ............................................................................................... K-5 Replacement ........................................................................................ K-5 Cooling Pack Removal and Replacement ...................................................................... K-7 Removal ............................................................................................... K-7 Replacement ...................................................................................... K-10 Dismantle and Assemble .................................................................... K-10 Coolant Expansion Tank Removal and Replacement ..................................................................... K-11 Removal ..............................................................................................K-11 Replacement ...................................................................................... K-12 Circuit Descriptions Engine ECU - SE Engines ...................................................................... K-13 Machine Electrical Interface ............................................................... K-13 Engine ECU Power-Up ....................................................................... K-16 Cold Start Heater ................................................................................ K-17 Fuel Lift Pump .................................................................................... K-18 Electronic Fault Codes ....................................................................... K-18 Throttle Position Sensor ..................................................................... K-19 Engine Installation .............................................................................................. K-21 Procedure ........................................................................................... K-21 Engine Assembly ................................................................................................ K-29 Procedure ........................................................................................... K-29

K-i

Section K - Engine Contents

K-ii

Page No.

K-ii

Section K - Engine Technical Data Basic Engine Data

Technical Data Basic Engine Data Engine Variants: TM310, TM-W: 97 kW (130 bhp); TM310S/TM320: 108 kW Turbocharged with Intercooler (145 bhp) Emission compliance

US-EPA Tier 3, EU Stage IIIA

Rated speed

2200 rpm

Weight (Dry):

457 kg (1007 lb)(1)

Number of cylinders

Nominal bore size

103 mm (4.055 in)

Stroke

132 mm (5.16 in)

Cylinder arrangement

In line

Combustion Cycle

4-stroke

Firing order

1-3-4-2

Displacement

4.40 litres

Compression ratio

17.1 : 1

Engine Compression

see Note (2)

Direction of rotation (viewed from front {crankshaft pulley} end)

Clockwise

Valves

4 per cylinder

Valve clearances measured at the tappet end of the rockers (measured cold): - Inlet

0.15 to 0.20 mm (0.006 to 0.008 in)

- Exhaust Lubricating oil pressure

0.43 to 0.50 mm (0.017 to 0.020 in) 4.3 bar (62lb in2)

(3)

Combustion system

Common rail direct Injection

High pressure fuel pump

Rotary mechanical, high pressure with electronically controlled fuel metering

Idle speed

850 r.p.m. (nominal)

Recommended fuel specifications

Refer to Section 1, General Information, Diesel Fuel

JCB Engine Service Manual

9803/3030

(1) Dry weight. No cooling fan drive. (2) Compression variance between each cylinder should be no greater than 3.5 bar (50 lb in2) (3) Engine at normal operating temperature and maximum revs.

K-1

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K-1

Section K - Engine Technical Data Basic Engine Data

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K-2

Section K - Engine Introduction Engine Types

Introduction Engine Types The engine in this machine is the JCB Dieselmax, type SE, as defined below. Type

Group

Engines with electronically controlled common rail fuel injection

Unit Identification

D B

Engine data labels 1A are located on the cylinder block at position 1C and rocker cover 1D (if fitted). The data label contains important engine information and includes the engine identification number 1E. A typical engine identification number is explained as follows: SE

320/40001

00001

C Fig 1.

Engine Type

Note: When ordering replacement parts, always quote the complete engine identification number.

S = 4.4 litre series. E = electronic common rail turbocharged and intercooled. 2

Engine part number

Country of manufacture

fuel

injection,

U = United Kingdom 4

Engine Serial Number

Year of Manufacture

The last three parts of the engine identification number are stamped on the cylinder block at position 1B. U

K-3

00001

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Section K - Engine Introduction Engine Types

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K-4

Section K - Engine

Silencer Removal and Replacement Removal

Examine the studs C on the engine exhaust manifold. If they are defective replace them with new ones.

Park the machine and make it safe. Obey the general safety procedures. Make sure that the engine cannot be started. See Section 2 - General Procedures.

If the engine is hot let it cool for one hour.

Note: Do not use a defective silencer. If the silencer is defective replace it with a new one.

Lift the engine canopy, see Section 3 - Engine Canopy.

Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:

Remove the exhaust manifold nuts A.

Support the silencer F. Remove the two bolts E and lift the clamping straps D.

Lift off the silencer F.

Remove and discard the gasket B.

Replacement

â&#x20AC;&#x201C; Use a new gasket B. â&#x20AC;&#x201C; Torque tighten the bolts E. Table 1. Torque Settings Nm kgf m

Item 2-E

2.2

lbf ft 16

D F D

B E

A C Fig 2.

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K-5

Section K - Engine Silencer Removal and Replacement

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K-6

Section K - Engine

Cooling Pack Removal and Replacement Removal The engine cooling pack is designed as a sub assembly which incorporates the following components: K Fig 5. ( T K-9) A

Engine coolant radiator matrix

Radiator top hose connection

Radiator bottom hose connection

Hydraulic oil cooler

Hydraulic oil cooler inlet hose

Hydraulic oil cooler outlet hose

Transmission liquid to liquid oil cooler

Transmission oil cooler hoses

Intercooler (Charge Air Cooler - CAC)

Intercooler inlet hose

Intercooler outlet hose

Fixing points

Cooling pack stabiliser bar

Fan Cowling

Important: For some service procedures it may be possible to remove the air conditioning condenser without disconnecting any hoses, thus negating the need to discharge the system. Be sure to support the condenser out of harms way. If any air conditioning hoses are to be disconnected make sure the air conditioning system is discharged by a qualified person. See Section B - Service Procedures Before attempting to remove the cooling pack allow the engine and hydraulic system to cool. 1

Although it is possible to remove individual components it will often be quicker and easier to remove the complete sub assembly, particularly if access is required for engine overhaul or removal and replacement for example.

Remove the engine canopy, see Section B - Access Panels.

4-3-4-1_2

Park the machine and make it safe. Obey the care and safety procedures. See Section 2 - General Procedures

C076500

Fig 3.

K-7

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K-7

Section K - Engine Cooling Pack Removal and Replacement 2

Release the catch 3-A on the condenser frame assembly and swing the condenser 3-C away from the cooling pack 3-B.

Put a label on the condenser air conditioning hoses before disconnection to aid identification when replacing.

Disconnect the intercooler inlet 5-D1 and outlet 5-D2 hoses.Cap all open hoses and pipes.

Disconnect the transmission oil cooler inlet and outlet hoses 5-C1. Cap all open hoses and pipes.

Disconnect the hydraulic oil cooler inlet 5-B1 and outlet 5-B2 hoses. Cap all open hoses and pipes.

Loosen the locknut 5-H on the cooling pack stabiliser bar 5-F.

Support the cooling pack assembly, unscrew bolts 5E and carefully lift the assembly away from the machine.

9803/9520-8

K-8

Disconnect the condenser air conditioning hoses.

Support the condenser frame and disconnect the frame hinges.

Remove the condenser frame from the cooling pack.

Disconnect the reverse alarm electrical connector (if fitted).

Disconnect the air filter electrical connector 4-B.

Loosen the clip 4-C and disconnect the air filter inlet hose 4-B.

C076700

B Fig 4. 10

Drain the engine coolant by disconnecting the radiator bottom hose at 5-A2. Cap all open hoses and pipes.

Disconnect the radiator top hose at 5-A1. Cap all open hoses and pipes.

K-8

Section K - Engine Cooling Pack Removal and Replacement

F H

C F

E H D

E A E B E C1

C1 E C D2

D1 F

A A2

B B1

G E

B2 E

Fig 5.

K-9

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K-9

Section K - Engine Cooling Pack Removal and Replacement

Replacement

Dismantle and Assemble

Replacement is the opposite of the removal procedure.

With the cooling pack removed from the machine dismantle components as required.

During the replacement procedure do this work also: – After replacement fill the engine cooling system with the correct coolant. See Section 3 - Engine. – Check the hydraulic fluid level. See Section 3 Hydraulics. – Check the transmission oil level and top up as necessary. See Section 3 - Transmission.

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K-10

Section K - Engine

Coolant Expansion Tank Removal and Replacement

F G

D E Fig 6.

Removal

Park the machine and make it safe. Obey the general safety procedures, see Section 2 - General Procedures.

Make sure that the engine cannot be started.

If the engine is hot let it cool for one hour.

Open the engine canopy, see Section 3 - Engine Canopy.

Release the hose clip B and remove the hose C at the expansion tank.

Release the hose clip D and remove the hose E at the expansion tank.

Remove the bolt F from the centre of the expansion tank.

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Lift off the expansion tank A. Remove washer G.

K-11

Section K - Engine Coolant Expansion Tank Removal and Replacement

Replacement Replacement is the opposite of the removal procedure. During the replacement procedure do this work also: â&#x20AC;&#x201C; Fill the engine cooling system with the correct type of coolant. Refer to Section 3 - Routine Maintenance. â&#x20AC;&#x201C; When the replacement procedure is complete start the engine and check for coolant leaks.

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K-12

Section K - Engine

Circuit Descriptions Engine ECU - SE Engines Machine Electrical Interface K Fig 7. ( T K-14). The components shown connected to the engine ECU are not part of the engine assembly. For details of engine electrical devices refer to the engine Service Manual 9806/3030. Component Key: 01

Engine ECU to machine harness connector

Grey connector ECU signal type:

Power hold relay drive

Output

Foot throttle position sensor

Input

Inlet manifold heater relay drive 1

Output

Brake pedal switch

Input

Vehicle speed sensor

Input

Fuel lift pump relay drive

Output

Key switch (engine start/shut off)

Input

Water in fuel switch

Input

See also K ECU Connector 01 - Pin Details ( T K-15).

K-13

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K-13

Section K - Engine Circuit Descriptions Engine ECU - SE Engines

01 + 12V

+ 12V + 12V

+ 12V

21 17 38 7 29 34

B 1 2

D 48

+ 12V

62 61 59 58

+ 12V

49 53 57 60

+ 12V

+ 12V CAN LO CAN HI

55 23 27

01 01

4 8 12 16 20 24 28 32 36 40 44 48 52 56 59 62

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 60

4 8 12 16 20 24 28 32 36 40 44 48 52 56 59 62

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 60

Fig 7. Machine Electrical Interface

K-14

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K-14

Section K - Engine Circuit Descriptions Engine ECU - SE Engines ECU Connector 01 - Pin Details Pin Number

Description

Not Used

Power hold relay drive

Not Used

Throttle pedal sensor track 2 supply

Not Used

Throttle pedal sensor track 1 supply

Not Used

Throttle pedal sensor track 1 supply

Speed sensor

CANbus low

Not Used

CANbus High

Not Used

Throttle pedal sensor track 2 supply

Not Used

Brake pedal switch

Throttle pedal sensor track 2 return

Not Used

K-15

Pin Number

Description

Not Used

Throttle pedal sensor track 1 return

Not Used

Fuel lift pump relay drive

Not Used

Key switch (engine start / shut off)

Not Used

Grid heater relay

Power hold relay drive fuse

Not Used

Power hold relay drive fuse

Not Used

Water in fuel switch

Not Used

Power hold relay drive fuse

Controller ground

Power hold relay drive fuse

Controller ground

9803/9520-8

K-15

Section K - Engine Circuit Descriptions Engine ECU - SE Engines

Engine ECU Power-Up

Component Key:

This section explains how the ECU power-up electrical system works.

Battery

Electronic control unit (ECU)

ECU power fuse 1

ECU power fuse 2

ECU power fuse 3

ECU power fuse 4

ECU Power relay

Engine fuse

Starter switch

620

The engine ECU B is enabled via a signal from the starter key switch J. When the starter switch is turned, the ECU completes the return to earth circuit for the power relay G, which then energises. The relay contacts connect a `live' feed to the ECU via power fuses C, D, E and F to allow engine starting.

309

44 107

315

49 60

312

313

57 53

314

E F 305

G 2

FUSE 001

FUSE

311

310

PRIMARY FUSE

Fig 8. Electrical Schematic

K-16

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K-16

Section K - Engine Circuit Descriptions Engine ECU - SE Engines

Cold Start Heater 620

This section explains how the cold start electrical system works.

The system aids engine starting by heating the air in the induction manifold via electrical `grid heater' A. Operation of the system is fully automatic and is controlled by the engine ECU C. The ECU monitors the temperature and enables the heating sequence if required. The ECU illuminates a warning light on the instrument panel to show when the grid heater is on.

403

Note: The temperature signal comes from sensors on the engine. The sensors (not shown) are connected to the engine ECU via the engine assembly harness. For more details, see the applicable Engine Service Manual.

D E

001

FUSE

105

PRIMARY FUSE

310

Fig 9. Electrical Schematic Component Key:

K-17

Grid heater

Battery

Electronic control unit (ECU)

Relay - grid heater

Primary fuse - grid heater

Starter switch

9803/9520-8

K-17

Section K - Engine Circuit Descriptions Engine ECU - SE Engines

Fuel Lift Pump

Electronic Fault Codes

This section explains how the fuel lift pump electrical system works.

The engine ECU will log system faults as a fault code. These fault codes can be accessed with the correct diagnostics software tool, using a laptop computer connected to the machine CAN system, see Section M Electronic Data Systems.

620

The fuel lift pump C is operated via a relay D. When the starter key switch E is turned, the engine ECU B completes the return to earth circuit for the fuel lift pump relay which then energises. The relay contacts connect a `live' feed to the lift pump electric motor.

B M

590

100 FUSE 001

FUSE

105

PRIMARY FUSE

310

Fig 10. Electrical Schematic Component Key: A

Battery

Electronic control unit (ECU)

Fuel lift pump

Fuel lift pump relay

Starter switch

K-18

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K-18

Section K - Engine Circuit Descriptions Engine ECU - SE Engines

Throttle Position Sensor 620

This section explains how the throttle position sensor electrical system works. The sensor unit converts movement of the throttle pedal into electrical signals to the engine ECU C. The pedal operates the sensor via a link arm and roller wheel. The sensor incorporates two variable resistors D and E, which produce two signal outputs (Track 1 and Track 2) according to the position of the pedal.

Note: Signal track 2 is the inverse of signal track 1. Therefore the sum of both signals is always approximately 5 volts. K Table 2. ( T K-19).

Mid travel

2.5V

Fully down (engine maximum 4.5V speed)

0.5V

107

433

432

439

B C 1

2 3 4

107 FUSE

4.5V

001

0.5V

21 17 38

Table 2. Sensor Output (+/- 0.1 volts) Pedal Position Track 1 Track 2 Fully up (engine idle speed)

5V 29 34 436

435

431

1807

PRIMARY FUSE

310

Fig 11. Electrical Schematic Component Key:

K-19

Switch - Overrun signal to transmission electronic control unit (ECU)

Battery

Engine electronic control unit (ECU)

Throttle Inverse - Track 2 signal

Throttle Overrun - Track 1 signal

Starter switch

9803/9520-8

K-19

Section K - Engine Circuit Descriptions Engine ECU - SE Engines

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K-20

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K-20

Section K - Engine Engine Installation

Engine Installation Procedure

Collect the crane and chains.

Use plates to hold the top of the axle bolts 1 in position, then tighten the axle bolts to a torque of 600 Nm.

Attach the chains to the engine sub-assembly 4, as shown. K Fig 3. ( T K-21).

Use the crane 5 to lift the engine sub-assembly.

Attach the locknuts K Fig 1. ( T K-21).

the

axle

bolts

1 P012670

Fig 1. 3

Put a rebound washer on each of the gearbox mounts 2 and the engine mounts 3 on the chassis. K Fig 2. ( T K-21).

3 2 6

3 Fig 3.

2 7

Fig 2.

K-21

P012680

P012690

Lower the engine sub-assembly onto the mounts on the chassis. K Fig 4. ( T K-22).

Note: Make sure that rebound washers are installed between the engine/gearbox mounts 6 and the mounts (2 and 3) on the chassis. K Fig 2. ( T K-21).

9803-9520-8

K-21

Section K - Engine Engine Installation 8

Disconnect the chains from the engine sub-assembly, then move the crane and the chains to a safe area.

Loosely install the fixing-bolts 7, locknuts 8, spacers 9 and washers to the engine and the gearbox mounts on the chassis. K Fig 4. ( T K-22).

Put an M16 washer 10 between the engine mounts and the rebound washers on the chassis.

Put an M16 hardened-washer on the underside 11 of the gearbox mounts.

Tighten the engine and gearbox fixing-bolts 7 (x4) to a torque of 184 Nm.

Tighten the locknuts 8.

Tighten the cap-screws 12 (x2) into the gearbox to a torque of 297 Nm.

K Fig 5. ( T K-22). For more information, refer to Section F, Transmission, Driveshafts.

Fig 5. 16

s157510-c2

Connect the hoses 14 (x2) between the steer-block 15 and the steer-ram 16, then tighten them to a torque of 40 Nm. K Fig 6. ( T K-22).

Note: Make sure that the hoses 14 do not touch each other.

7 16

8 9

10 Fig 4.

Fig 6. P012700

Connect the top driveshaft 13 to the dropbox, then tighten the set-screws to a torque of 77 Nm.

K-22

P012710

Note: Attach the push-on cable ties to the weld-studs on the rear chassis. Note: The mainframe harness is comprised of several breakout cables which are routed to different components

9803-9520-8

K-22

Section K - Engine Engine Installation on the machine. For more information on the mainframe harness, refer to Section C, Harnesses, 332/W2737. g

Note: The main â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; 17 of the mainframe harness is known as the start point and must be secured in the position shown. K Fig 7. ( T K-23). 17

l h

Route the mainframe harness to the engine and the rear chassis, as shown. K Fig 7. ( T K-23). Use the push-on cable ties to attach the mainframe harness to the chassis. Cable tie the mainframe harness at its multi-breakout point to the bracket 18 on the rear chassis.

c a

Route the mainframe harness below the dipstick tube and behind the gearbox mount. Route the mainframe harness behind the harness plates over the top of the gearbox, then cable tie in position.

d e f

20 18 P012720

Fig 7. a

To cab connectors

To valve block

Route the mainframe harness around the off side of the engine.

To hydraulic pump

To fuel lift pump and CAN engine cables

Note: Make sure the breakout cable from the mainframe harness to the hydraulic pump, is at the bottom of the bracket 18 next to the chassis. This makes sure that the breakout cable to the three cab connections is long enough.

To A/C switches

To washer pumps and rear

To alternator and earth point

To solenoids

To brakes and gear ECU

To primary fuses and and power-hold relay cables To air filter switch and rear

When the breakout cables have been connected, cable tie them in position.

Route the breakout cable to the hydraulic pump 19.

Connect the breakout cable to the gearbox speed sensor 20, hydraulic pump 19 and the oil temperature sensor 21.

Route the breakout cables to the top 22 and bottom rows 23 of connectors on the valve block. K Fig 8. ( T K-24).

Make sure the plugs from the breakout cable to the top row 22 of the valve block are connected in the order:- Aux 3, SRS, Aux 4 then SRS. If the machines does not have the Smooth Ride System (SRS) option, connect blank plugs to the SRS connectors on the top row of the valve block and to the .breakout cable.

K-23

Connect the breakout cable to the connectors on the bottom row on the valve block 23.

9803-9520-8

K-23

Section K - Engine Engine Installation Note: For machines with 3/4 speed gearbox, connect a bank plug to the transmission oil temperature lead. Note: For machines with 3/4 speed gearbox, install a blank to the first connector.

23 Fig 8. 24

P012750

Route, then connect the breakout cable to the connectors 24 and 25 on the LLMC valve. K Fig 9. ( T K-24).

Note: Connect the long leg of the breakout cable to the front connector 25 on the LLMC valve. Fig 10.

Fig 9. 25

P012730

Machines which have a 3/4 speed gearbox, install a link harness 27 between the mainframe harness and the gearbox link harness. K Fig 11. ( T K-24).

Re-phase the T-adaptor on the top of the gearbox when the link harness is connected to prevent contact with the cab. Tighten the hose to a torque of 60 Nm.

P012810

Route, then connect its breakout cable to the bottom row of connectors on the gearbox solenoids 26. There is no connection to the end solenoid. K Fig 10. ( T K-24).

Note: For machines with 3/4 speed gearbox,connect a blank plug to the spare connector. 26

Route, then connect its breakout cable to the top row of connectors on the gearbox solenoids 26.

K-24

9803-9520-8

Fig 11.

P012760

K-24

Section K - Engine Engine Installation 29

Route, then connect its breakout cable to the water in fuel sensor and the fuel lift pump connections.

Route, then connect its breakout cable to the engine ECU, A/C compressor and the CAN engine connections.

Route, then connect its breakout cable to the fuel sender and the A/C high and low pressure switches.

Route, then connect the longest branch on the washer pump harness to the front motor on the washer bottle. Connect the breakout cable to the rear motor on the washer pump.

Route the breakout cable to the rear lights.

Route, then connect its breakout cable to the SRS valve. The breakout cable start point is at 17.

Connect the harness to the earth point on the near side of the engine.

Route, then connect its breakout cable to the starter motor 28 and the alternator 29. K Fig 12. ( T K-25).

Route the breakout cable to the rear lights.

Route, then connect its breakout cable to the transmission dump pressure switch and the brake pedal switches.

If applicable, connect the breakout cable to the diverter valve and the auxiliary dump solenoid. Only do the diverter valve step on the machines which have the rear hydraulics option.

Note: The diverter connector is on the same breakout as the auxiliary solenoid connector. The diverter valve is installed near the gearbox ECU 30 on machines with rear hydraulics. K Fig 13. ( T K-25). 41

If necessary, put a blank plug in the auxiliary dump solenoid and the diverter valve connectors.

Route, then connect its breakout cable to the gearbox ECU 30.

29 Fig 12.

P012770-2

Route, then connect its breakout cable to the primary fuses, power-hold relay and the grid heater relay.

Note: The primary fuses are in fuse boxes mounted to the right of the battery. The engine ECU power-hold relay is adjacent to the primary fuses.

K-25

P012780

Fig 13. 43

Connect a Y-connector 31 to each end of the CAN harness 32. K Fig 14. ( T K-26).

Install a resistor 33 in one of the Y-connectors.

Note: The resistor will only install into one of the empty positins on the Y-connectors.

9803-9520-8

K-25

Section K - Engine Engine Installation 45

Connect the CAN harness 32 (the resistor end) to the off side of the mainframe harness next to the engine ECU.

Route the CAN harness to the gearbox, then along the near side of the machine to the gear box ECU.

35 35

Note: Use new cable ties to attach the CAN harness to the mainframe harness.

33 32 Fig 14.

38 37

P012790

P012820

Fig 15.

No light option:-Install all the blanking grommets to the rear light brackets 34. K Fig 15. ( T K-26).

Attach the left and right hand combination lights to rear light brackets. Make sure the drain hole is at the bottom of the light.

Note: Tow hitches (optional): 1

Hydraulic tow hitch 35: a

Lift the tow hitch into position, then install and torque its bolts 36 to 621 Nm.

Attach the fog/reverse lights to the rear light brackets Make sure the drain hole is at the bottom of the light.

b Sub-assemble the quick release couplings (to 102 Nm) and hoses (to 27 Nm).

Move rear light sub-assemblies to the rear chassis, be careful not to damage the paint on the body.

Connect their breakout cables to the left and right hand rear lights and the reverse/fog lights.

Connect the breakout cable to the reverse alarm.

Connect the breakout cable to the air filter switch.

If necessary, connect the breakout cable to the trailer socket.

Remove the two adaptors from the hydraulic tow hitch and install new adaptors. Torque the adaptors to 34 Nm.

d Attach the hose sub assemblies to the tow hitch. Phase the hoses at 90 degrees to the tow hitch. Torque the hoses to 27 Nm. 2

Rockinger tow hitch 37: Make M24 and M16 holes in a spacer plate 38. Put the spacer plate in position against the rear chassis and tighten the bolts 39 to a torque of 621 Nm Put the Rockinger tow hitch against the spacer plate and tighten the bolts 39 to a torque of 184 Nm.

K-26

9803-9520-8

K-26

Section K - Engine Engine Installation 3

Recovery tow hitch: There is a cut-out for the wire rope at the top of the tow hitch. Hold the tow hitch in position, then install its bolts to a torque of 621 Nm. Sub-assemble, then install a recovery hitch pin and a retaining clip. Route the retaining wire rope through the cut-out in the recovery hitch

K-27

9803-9520-8

K-27

Section K - Engine Engine Installation

Page left intentionally blank

K-28

9803-9520-8

K-28

Section K - Engine

Engine Assembly Procedure 1

Collect the crane and the chains from the engine subassembly area.

Collect and set-up the engine stand.

Lower the engine onto the engine stand. Put a small support between the bell housing and the engine stand, then secure the engine in position.

Remove the chains from the engine.

Attach the lifting-jig to the torque converter 2. (6speed or 3-speed option). K Fig 2. ( T K-29).

Note: When the engine stand is used, make sure the brakes are applied. 3

Collect the engine and its stand.

Attach the chains to the crane and engine.

Use the crane to support the engine.

Remove the engine securing bolts.

Lift the engine to a working height.

Attach the adapter K Fig 1. ( T K-29).

plate

2 4 3

the

engine. Fig 2. 12

Move the crane into position, then attach its chains to the lifting-jig.

Lift the torque converter and move it into position near the engine.

Apply Loctite242 to the bolts, then put the bolts in their positions 3 and tighten to attach the torque converter to the engine. Torque the bolts to 44 Nm. K Fig 2. ( T K-29).

Remove the crane, chains and lifting-jig.

Move the lugs 4 on the torque converter until they are vertical.

Use a small file to remove any sharp edges from the torque converter.

Remove any remaining oil and swarf from the torque converter.

9803-9520-8

K-29

Fig 1.

K-29

P013510-1

P013500

Section K - Engine Engine Assembly 27

Put the gearbox support strut between the engine stand and the gearbox.

Remove the crane, chains and lifting bracket.

Attach the driveshaft 9 to the gearbox 6 (6-speed or 3-speed option). Torque the bolts to 72 Nm. K Fig 4. ( T K-30).

For more information, refer Transmission, Driveshafts, Replacement.

to Section F, Removal and

13 7

6 Fig 3.

P013520-1

Attach a lifting bracket 5 to the gearbox 6 (3-speed or 6-speed option). K Fig 3. ( T K-30).

Move the crane and attach its chains to the lifting bracket.

Move the gearbox near to the engine.

Align the drive-dogs 7 on the transmission drive shaft, they must be horizontal, opposite to the torque converter lugs.

Fig 4.

Slide the gearbox onto the torque converter/engine. Move the gearbox carefully from side to side to help join the components together.

Install a bearing 10 (6-speed or 3-speed option) onto the gearbox pump driveshaft 11: K Fig 5. ( T K-31).

Make sure the bearing is flush to the flat face of the driveshaft. Put a seal 12 in the groove to the driveshaft. Make sure the seal is seated correctly. 31

Use its bolts 8, washers and the harness plates to attach the gearbox to the engine. Torque the bolts to 51 Nm.

K-30

P013530-1

Put the bearing onto a spacer, then use a plastic or copper mallet from above to tap the driveshaft into the bearing.

Remove any remaining oil and swarf from the gearbox splines. Spray P80 lubricating-fluid onto the splines.

9803-9520-8

Insert the driveshaft assembly into the gearbox. Make sure the driveshaft and bearing are fully inserted into the gearbox, if necessary use a plastic mallet.

K-30

Section K - Engine Engine Assembly

28 12

10 13 14

27 20 26

23 Fig 5. 32

P013530-2

Attach the main hydraulic pump to the gearbox. Make sure the gasket remains flat against the pump and gearbox. Torque the bolts 16 to 125 Nm. K Fig 4. ( T K-30).

Fig 6.

P012690-1

Slide the 32T gear into position on the gear pump.

Use a screwdriver to bend the tabs on the lockingwasher 21 upwards, then slide it into position. K Fig 6. ( T K-31).

Apply Loctite242, then tighten the nut 22 in position.

Put an O-ring 23 into the gear pump. Make sure the O-ring is seated correctly.

Apply Loctite242, then use the cap screws 24 to attach the gear pump to the engine.

Connect the bottom adapter 25 to the gear pump. Torque the adapter to 122 Nm.

Connect the top adapter 26 to the gear pump. Torque the adapter to 48 Nm.

Attach the support bracket for the hydraulic breather pipe at position 27.

Loosely install a bolt ready for the mainframe harness at position 28.

9803-9520-8

K-31

Align the 32T gear 19 with the key on the gear pump 20. K Fig 6. ( T K-31).

K-31

25 22

Put the gasket 14 between the gearbox 6 and the main hydraulic pump 15. K Fig 5. ( T K-31).

For more information, refer to Section E, Hydraulics, Main Pump. 35

Put the circlip 13 into the groove on the driveshaft. Make sure the circlip fits fully into its groove. K Fig 5. ( T K-31).

Section K - Engine Engine Assembly 45

Put the hydraulic filler tube into the gearbox 29. Make sure the filler tube is pushed fully into the gearbox. Make sure the seal is in position, then tighten the nut to secure the filler tube in position.

Attach the support P-clip and bracket to the filler tube, then attach the P-clip to the support bracket 27.

Use the cap screws 32, full nuts and spacers to attach the support bracket to the gearbox. (6-speed or 3speed option). Install the spacer on the engine side of the gearbox.

Put the dipstick into the filler tube. Make sure the dipstick fits over the filler tube.

Connect the breather hose to the top of the filler tube.

Attach the breather hose to the filler tube. Do not over tighten the cable ties.

Attach the mounts 17 to the gearbox support bracket 30. K Fig 7. ( T K-32).

Note: Put a drip tray under the gearbox to catch any excess oil. 54

Remove the filter cover and the seal from the gearbox.

Note: Before you install the transmission oil filter, apply a layer of oil to its seal. 55

Install hand-tight the transmission oil filter 33 to the gearbox.

Remove the remaining oil from the gearbox.

Install the sump drain plug 34 into the engine. K Fig 8. ( T K-33).

9803-9520-8

K-32

31 30 32 18

17 33 Fig 7.

P013560

Turn the support bracket upside down, then install the bolts 18, washers and locknuts to secure the mount in position.

Turn the support bracket over, then install hand tight the rebound washers and bolts 31 in the support bracket 30.

Note: The cut-out portion of the support bracket faces towards the engine.

K-32

Section K - Engine Engine Assembly

42 38 37

Put the exhaust gasket 40 in position.

When tightening the nuts 41 on the manifold, hold the opposite end of the exhaust up.

Attach the exhaust strap 42, do not over-tighten.

Tighten the support bracket 37.

Apply hose lubricant, then push the connector tubes into the heater hose.

Connect an elbow to the heater hose.

Attach the wormdrive clips to the heater hose. Torque the clips to 6 Nm.

Attach the heater hose 43 to the engine. Torque the clips to 6 Nm.

Attach a support clip to the heater hose.

Remove a bolt 44 from the side of the engine, then replace it when the support clip is attached.

36 43 44

Make sure the heater hose does not catch the engine.

35 Fig 8.

Attach the left hand engine mount 35. Apply Loctite242, then torque the bolts to 74 Nm. K Fig 8. ( T K-33).

Attach the right hand engine mount. Apply Loctite242, then torque the bolts to 74 Nm.

Put the engine fixing bolts in the left and right engine mounts.

Remove the lifting eye 36 from the engine.

Attach the support bracket 37 for the exhaust to the engine.

50 45 49

Loosely attach the exhaust cradle bracket 38 to the engine.

Put the exhaust 39 in position.

K-33

P013570

46 Fig 9.

P013580

Install the A/C idler pulley 45. Torque the pulley bolt to 48 Nm. K Fig 9. ( T K-33).

9803-9520-8

K-33

Section K - Engine Engine Assembly 76

Install the A/C compressor 46 or the non A/C idler pulley to the engine.

Put the fan hub 47 in position, then apply Loctite242 and install the bolts.

Standard fan: a

Apply Loctite242 to the fan studs, then put them into the holes 50 in fan hub.

The ends with the least amount of thread will fit into the fan pulley.

b Install the fan pulley 48 and spacer. c

Fig 10.

Install the A/C fan belt 49. Put the fan belt around the pulleys.

Use a ratchet on the adjuster nut 51 and remove the locking-pin with the long nosed pliers.

Note: Do not over-tighten the nut on the starter.

P012770-1

Connect the battery and alternator leads to the starter motor 53.

Connect the alternator lead to the alternator 54.

Check the condition and security of the engine and transmission.

9803-9520-8

K-34

d Put the fan onto the fan studs. Put the concave side of the blades towards the engine. e

Tighten the bolt to secure the fan in position.

Reverse fan option: a

Install the fan pulley and the reverse fan adapter. Torque the cap screws to 36 Nm.

b Install the non A/C fan belt: Install the fan belt around the pulleys. Use a ratchet on the adjuster nut and remove the locking-pin with the long nosed pliers. c

Put Loctite242 on the bolts, then put the reverse fan in position and tighten the bolts.

d Connect the air hose. The air hose is a push-fit into the elbow. 80

Attach the breather hose to the top of the engine. Cable tie the breather hose to the bracket on the side of the engine near the exhaust manifold.

Attach the cover plate 52 to the engine. HDPTO engines only. K Fig 10. ( T K-34).

K-34

Section M Network Systems Service Manual - TM310, TM320 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems

Publication No.

9803/9520-8

Section M - Network Systems

Notes:

M-0

9803/9520-8

M-0

Section M - Network Systems Contents Page No. Network Systems Description ................................................................................................ M-1 What is the Network System? ..............................................................M-1 CANbus Communications System .......................................................M-1 Wires and Connectors ..........................................................................M-2 Electronic Monitoring System Description ................................................................................................ M-5 EMS Display .........................................................................................M-5 EMS Set-up ..........................................................................................M-5 Connected Devices .................................................................................. M-8 Electronic Fault Codes Fault Code Displays ............................................................................... M-13 CAN Enabled Display .........................................................................M-13 CANbus Connected Computer ...........................................................M-13 Electronic Monitoring System ECU Fault Codes .................................... M-14 Operator Warnings .............................................................................M-14 Fault Code Log ...................................................................................M-14 Fault Code List ...................................................................................M-16 Servicemaster Why Use Servicemaster? ....................................................................... M-23 Introduction .........................................................................................M-23 Fault Finding .......................................................................................M-23 Identify Poor Maintenance ..................................................................M-23 Access Machine Set Up Data .............................................................M-23 Re-Programming ECUs ......................................................................M-23 Summary ............................................................................................M-23 What is Servicemaster? .......................................................................... M-24 Introduction .........................................................................................M-24 CANbus Communications System .....................................................M-24 Servicemaster Structure .....................................................................M-24 How to Set Up Servicemaster ................................................................ M-25 Install Servicemaster ..........................................................................M-26 Start Servicemaster ............................................................................M-27 Load the DLA Laptop Driver Software ................................................M-28 Configure the DLA Type and Communications Port ...........................M-29 Check the DLA Firmware File ............................................................M-30 Connect Servicemaster to the Machine CANbus ...............................M-32 Servicemaster Tools Summary ................................................................................................ M-33

M-i

Section M - Network Systems Contents Contents Page No. JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide ................................ M-34 Introduction .........................................................................................M-34 Care and Safety .................................................................................M-34 Connecting 4.4L Tier 3 Diagnostics ....................................................M-35 Starting 4.4L Tier 3 Diagnostics ..........................................................M-35 4.4L Tier 3 Diagnostics Overview .......................................................M-36 Navigating within Diagnostics .............................................................M-37 Menu Bar - File Menu .........................................................................M-37 Menu Bar - Options Menu ..................................................................M-38 Menu Bar - Window Menu ..................................................................M-39 Menu Bar - Help Menu .......................................................................M-39 Start and Stop Buttons ........................................................................M-40 Page List ............................................................................................M-40 Status bar ...........................................................................................M-41 LED Status Key ..................................................................................M-41 Engine Connector Page .....................................................................M-42 Machine Connector Page ...................................................................M-44 Actuator Tests Page ...........................................................................M-46 Fault Codes Page ...............................................................................M-47 ShiftMaster Diagnostics 2.3 - User Guide .............................................. M-48 Introduction .........................................................................................M-48 Care and Safety .................................................................................M-49 Installing ShiftMaster Diagnostics .......................................................M-49 Connecting Shiftmaster Diagnostics ..................................................M-49 Starting ShiftMaster Diagnostics ........................................................M-50 ShiftMaster Diagnostics Overview ......................................................M-51 Navigating within ShiftMaster Diagnostics .........................................M-52 Menu Bar - File Menu .........................................................................M-52 Menu Bar - Options Menu ..................................................................M-53 Menu Bar - Window Menu ..................................................................M-54 Menu Bar - Help Menu .......................................................................M-55 Start and Stop Buttons ........................................................................M-55 Page List ............................................................................................M-56 Status bar ...........................................................................................M-56 ECU Setup Page ................................................................................M-57 Dashboard Page ................................................................................M-58 ECU Status Page ...............................................................................M-59 Torque Converter Lock Up (TCLU) Page ...........................................M-61 Solenoid Test Mode Page ..................................................................M-63 Solenoid Identification Page ...............................................................M-64 ECU Block Diagram Page ..................................................................M-64 Connection Problems .........................................................................M-65 General Information ............................................................................M-66

M-ii

Section M - Network Systems Contents Contents Page No. TM310 / TM320 Setup - User Guide ...................................................... M-67 Introduction .........................................................................................M-67 Care and Safety .................................................................................M-67 Installing .............................................................................................M-67 Connection .........................................................................................M-67 Starting TM310 / TM320 Setup ..........................................................M-68 Navigating within TM310 /TM320 Setup ............................................M-69 Menu Bar - File Menu .........................................................................M-69 Menu Bar - Utilities Menu ...................................................................M-70 Menu Bar - Help Menu .......................................................................M-70 Vehicle Setup .....................................................................................M-71 Options ...............................................................................................M-71 Language ...........................................................................................M-72 Write ...................................................................................................M-72 Read ...................................................................................................M-73 Connection Problems .........................................................................M-74 Engine Setup - User Guide ..................................................................... M-75 Introduction .........................................................................................M-75 Care and Safety .................................................................................M-75 Installing .............................................................................................M-75 Connection .........................................................................................M-75 Starting Engine Setup .........................................................................M-76 Navigating within Engine Setup ..........................................................M-77 Menu Bar - File Menu .........................................................................M-77 Menu Bar - Utilities Menu ...................................................................M-78 Menu Bar - Help Menu .......................................................................M-78 General ...............................................................................................M-79 Injector Calibration .............................................................................M-80 Write ...................................................................................................M-80 Read ...................................................................................................M-81 Connection Problems .........................................................................M-82

M-iii

Section M - Network Systems Contents Contents

M-iv

Page No.

M-iv

Section M - Network Systems

Network Systems Description What is the Network System?

The engine ECU can communicate with other machine ECUs using a CANbus network system.

Modern machines use electronic control units (ECUs) to control machine systems such as hydraulics, transmission and engine.

CANbus Communications System

In much the same way as office computers can be `networked' to communicate with each other the machine ECUs can be `networked'. Some advantages of networking are:

and

reliable

Controller

Area

Network

An electronic communications system that connects all the machine ECUs to one pair of data wires called the CANbus. Coded data is sent to and from the ECUs on the CANbus.

– Improved more intelligent control systems – More comprehensive instrumentation

in-cab

By connecting Servicemaster diagnostic software to the CANbus, data is seen and decoded for use by a service engineer.

– Service software tools can be used for fault finding and machine control set up.

C E Fig 1. CANbus System Example A

CANbus wires

Engine ECU

Transmission ECU

Electronic Monitoring System (EMS) ECU

Diagnostics socket

M-1

9803/9520-8

M-1

Section M - Network Systems Network Systems Description

Wires and Connectors Wires and connectors for the EMS ECU K Fig 2. ( T M-3) and for the CANbus system as applicable. On the electrical diagram the electrical connectors (example, CU) are shown looking on the mating face of each connector when they are disconnected.

Fusebox A

Fusebox C

CAN Transmission ECU connector

CAN EMS connector

"Enter" button

"Scroll" button

The wire numbers and colours, where appropriate, are shown as an aid to identification while fault finding. Most potential faults can be traced using a multimeter to carry out continuity checks on the CAN wiring. If the CAN wiring is not at fault, check the relevant ECU power and earth connections.

Connectors (h2)

Note: CANbus signals cannot be measured on a multimeter. Note: When fault finding do not use a multimeter on the ECU pins. Only test the associated wiring. Uncouple the connector CU and then use a multimeter at the pins inside the connector as applicable. The ECU is inherently more reliable than its associated wiring and components. Before renewing the ECU be sure to check all the related equipment first.

Earth Points Faults may be caused by poor earth connections. For details of these connections, see Section C, Electrics Machine Earth Connections.

Harness - 721/12543 Panel

Harness - 721/12325 Front Chassis

Harness - 721/12544 Rear Chassis

Harness - 727/00012 CANbus

Harness - 727/00013 CANbus

SRS Solenoid

L/H Headlight

R/H Headlight

Front Chassis Earth point

Connectors (h3) Engine ECU earth point.

Rear chassis harness to panel harness connector

Air filter vacuum switch

Engine ECU Connector

Brake pressure switch

Fuel level sender unit

Alternator

Mainframe earth point

Engine oil level switch

CAN Engine ECU Connector

SC1 SC12 SC3 SC15 SC4 SC16 SC6 SC18 SC1 SC27 0

Note: For harness drawings see Section C - Electrics. Connectors (h1)

Splices (h2) SF1 SF3

Fog light switch

Diagnostic Connector

CAN Connector

Transmission ECU connector A

Panel harness to front chassis harness connector

Instrument pack (EMS)

Buzzer relay

Direction indicator relay

Cab earth point 1

Cab earth point 2

Panel harness to rear chassis harness connector 3

HVCS ECU

M-2

front chassis harness to panel harness connector

Splices (h1)

Component Key h1

Splices (h3) SM2 SM3 SM1 3

9803/9520-8

M-2

FK 830D

806E

FA CS

600F

600C

805E

14 19

400

502

442B

503

601Z

805G

SC4

806H

602

ME 603

SC18 830AB

602G

402

602F

421

SC3

SC1

SM2 24

SC27

606

552C

24 1

28 13

13 2

408 27

603E

SC16 444A

603E

19 17 15 13 11 9 7 5 3 1

FUSE 28 16

304D

SC12

E.C.U. 609

608

CF ZP 608D

609B

480

106E

479

106D

442B 106C

SC6

EV FUSE 2 106B

20 18 16 14 12 10 8 6 4 2

19 17 15 13 11 9 7 5 3 1

835C

M-3

Description

Fig 2. EMS ECU Wires and Connectors

Network Systems

SC10

Section M - Network Systems

SM13 1

20 18 16 14 12 10 8 6 4 2

452

9803/9520-8

407

444D

421

418

837A

408

SC15

402

837B

805E

830D

806E

552A

606B

552A

SF1

837BB

304D

452

106B

600E

479

835C

837BA

600

837B

SF3

480

M-3

M-4

CJ CU 36

35 34

h5 A B

h4 h3

503

601Z

CAN S

502 502X

E.C.U.

503X

601X

CAN L

CAN H

B C

9803/9520-8

502

A B

B A B

601Y

SM3

B A

601Y

502

503

601Z

MC1

M-4

Description

Fig 3. CANbus Network Wires and Connectors

Network Systems

Section M - Network Systems

503

Section M - Network Systems

Electronic Monitoring System Description EMS Display

EMS Set-up

Machines fitted with digital display systems feature a Electronic Monitoring System (EMS) control unit (ECU). The ECU is part of the instrument cluster console.

Using JCB Servicemaster 2

The ECU monitors data from electrical and electronic devices on the machine. Data is received via dedicated wires and from the machine CANbus, depending on the type of device.

Refer to the Servicemaster Tools topic in this section for information regarding the use of the TM310/TM320 Set-up tool.

The ECU processes the data and controls devices in the graphical user interface (GUI) such as the engine coolant temperature gauge and system status indicator lamps. The EMS ECU also monitors machine usage in the form of engine run hours and service events. If the ECU receives electronic fault codes or electrical signals to be interpreted as faults the ECU activates visual and, when applicable, audible warnings. Fault codes are also logged by the ECU.

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Section M - Network Systems Electronic Monitoring System Description Using EMS Display Panel Enter Set-up Mode

a g

c o

p n

q m

e l

d g

c d

R C050710-2-C1

Fig 4. Press buttons 4-R and 4-L simultaneously then turn on ignition but do not start the engine to select "Set-up Mode".

Press button L to select the required item.

Clock Adjustment Display

Description

CLOCK

To set up the date and clock.

SERIAL NUMBER

To display the machine serial number (CANbus set up only)

ROLLING RADIUS

To set up the rolling radius of the tyres.

SERVICE INTERVALS

To set up the service intervals.

UNIT

To set up the units (mph or km/h).

EXIT

To exit from this menu.

Access set-up mode. K Enter Set-up Mode ( T M-6)

Day digits will flash. a

b Press button L. 3

Month digits will flash. a

Button L is used to confirm a selection.Button R is used to change a selection. 1

The line selection arrow is displayed to the left of CLOCK.

Press button R to go to the next selection.

M-6

Press button R until the required numbers are displayed.

b Press button L. 4

Year digits will flash. a

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Press button R until the required numbers are displayed.

M-6

Section M - Network Systems Electronic Monitoring System Description b Press button L. 5

b Press button L.

Hour digits will flash.

Note: If button R is pressed, the adjustment sequence will start again.

Press button R until the required numbers are displayed.

Rolling radius is set.

b Press button L.

Minutes digits will flash.

Units adjustment

Access set-up mode. K Enter Set-up Mode ( T M-6)

METRIC units (km/h) are displayed.

Press button R until the required numbers are displayed.

Press button L to go to the set-up menu.

b Press button L. a 7

Press button R to select IMPERIAL units (mph).

Clock is set. b Press button L to confirm METRIC units.

Note: If button R is pressed, the adjustment sequence will start again. 8

IMPERIAL units (mph) are displayed. a

Press button L to go to the set-up menu.

Press button R to select METRIC units (km/h).

b Press button L to confirm IMPERIAL units.

Serial Number Display 1

Access set-up mode. K Enter Set-up Mode ( T M-6)

Units are set.

The serial number is displayed.

Press button L to go to the set-up menu.

Exit Set-up Mode

Rolling Radius Adjustment

Access set-up mode. K Enter Set-up Mode ( T M-6)

Left digit will flash.

Set-up menu is displayed. a

Press button R until the line selection arrow is to the left of EXIT.

b Press button L to return to the pre-start mode. a

Press button R until the required number is displayed.

Note: If button R is pressed, the line selection arrow will move to the left of CLOCK again.

b Press button L. 3

Centre digit will flash. a

Press button R until the required number is displayed.

b Press button L. 4

Right digit will flash. a

M-7

Press button R until the required number is displayed.

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M-7

Section M - Network Systems Electronic Monitoring System Connected Devices

Connected Devices The tables show how the monitoring system ECUs respond to inputs from connected devices. Note: Some of the warning and indicator light signals are sent through the CANBus system and do not have a dedicated input.

Device

Not Used

Input/Output

Important: The connector pin numbers are for the harness connectors, NOT the pins on the ECUs. The connectors are viewed from the front. DO NOT TOUCH the pins on the ECUs.

Table 1. Function

Sidelight

Input

Fused Power Supply

+12V

Fused Power Supply

+12V

Not Used

Left Direction Indicator

High Side Digital Input

Operate warning light when direction indicator active.

Right Direction Indicator

High Side Digital Input

Operate warning light when direction indicator active.

Earth

Cab Earth

SRS

High Side Digital Input

Operate warning light when SRS system is active or transmitting a fault.

Not Used

Park Brake Sensor

High Side Digital Input

Operate warning light when parkbrake applied.

Not Used

Air Filter Vacuum Switch

Low Side Digital Input

Operate warning light when air filter is blocked

M-8

Display

Trigger for display backlight.

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M-8

Section M - Network Systems Electronic Monitoring System Connected Devices Pin

Device

Input/Output

Function

Trailer Direction Indicator

High Side Digital Input

Operate warning light when trailer direction indicator active.

Not Used

Fuel Level Sender

Analog Input

Display fuel level, operate low fuel level warning light.

Not Used

"Scroll" button

Digital Input

Operate menu and scrolling of LCD display messages

Not Used

Main Beam

High Side Digital Input

Operate warning light when main beam switched on.

Not Used

"Enter" button

Digital Input

Operate menu and acknowledgement of LCD display messages

Not Used

Hydraulic Speed Control

Digital Input

Operate warning light when instructed by HVCS ECU

Engine Oil Level Switch

Digital Input

Operate warning light when engine oil level is low.

Not Used

Rear Fog Light Switch

High Side Digital Input

Operate warning light when for light is active.

Brake Pressure Switch

Low Side Digital Input

Operate warning light when a brake malfunction

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Display

M-9

Section M - Network Systems Electronic Monitoring System Connected Devices Pin

Device

Input/Output

Function

Buzzer

Low Side Output

D+ Alternator Terminal

Low Side Analog Input

CAN Shield

CAN Low

Communication Low Side Input/ Output

Receive and transmit CANbus data

CAN High

Communication High Side Input/ Output

Receive and transmit CANbus data

Display

Operate warning light when alternator not charging.

Provide an earth shield for CAN wires

The following warning lights are operated through the CANbus system and do not therefore have a dedicated input.

Device

Table 2. CANbus Devices Input/Output Function

Engine ECU

CANbus Input from Engine ECU

Operate gauge and warning light when instructed by the engine ECU.

Engine ECU

CANbus Input from Engine ECU

Operate warning light when instructed by the engine ECU

Engine ECU

CANbus Input from Engine ECU

Operate warning light when instructed by the engine ECU

Engine ECU

CANbus Input from Engine ECU

Operate warning light when instructed by the engine ECU

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Display

M-10

Section M - Network Systems Electronic Monitoring System Connected Devices Device

Input/Output

Function

Engine ECU

CANbus Input from Engine ECU

Operate warning light when no signal received from the engine ECU

Transmission ECU

CANbus Input from Transmission ECU

Operate warning light when instructed by the transmission ECU

Transmission ECU

CANbus Input from Transmission ECU

Operate warning light when instructed by the transmission ECU

Transmission ECU

CANbus Input from Transmission ECU

Operate warning light when instructed by the transmission ECU

Transmission ECU

CANbus Input from Transmission ECU

Operate warning light when no signal received from the transmission ECU

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Display

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Section M - Network Systems Electronic Monitoring System Connected Devices

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Section M - Network Systems

Electronic Fault Codes Fault Code Displays Depending on the machine specification fault codes recorded by the engine ECU can be accessed and displayed in several ways:

CAN Enabled Display The machine may be equipped with a CAN enabled display. Such a display will be capable of displaying all recorded codes, for example E127. All logged codes will be displayed. The operator may also have a facility to erase the fault code log. See the applicable machine documentation for further information.

CANbus Connected Computer Error codes logged can be accessed via a suitable laptop computer running the applicable diagnostics software, JCB Shiftmaster Diagnostics for example. The computer must be connected to the machine CANbus socket using a data link adapter (DLA). Once connected all recorded codes can be displayed, for example E127. The engineer also has a facility to erase the fault code log.

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes

Electronic Monitoring System ECU Fault Codes Operator Warnings

The electronic monitoring ECU receives fault data from devices and other ECU's via dedicated wires or from the machine CANbus. Should faults occur related to the electrical devices connected to it the ECU responds as follows.

Since the electronic monitoring ECU controls the machine instrumentation (Graphical User Interface) the relevant operator warnings are activated in response to faults. These warnings can include display of fault codes in addition to warning lamps and audible warnings.

2 3 4 5

Fig 5. EMS Display Item 1

LCD Display Panel

Engine Speed

Engine Hours

Service Needed

Normally Current Time. Replaced by an Error Code in the event of certain Engine, Transmission or ECU errors.

ERROR: E098 Fig 6. EMS LCD With Error Code Displayed

Fault Code Log The monitoring system electronic control unit (ECU) incorporates a `data logging' feature for recording fault codes.

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes The log enters the fault code together with the current time and date. The fault code log can be read on the LCD. Alternatively use the JCB diagnostics tool.

Reading the Fault Code Log on the LCD TBA

Reading the Fault Code Log with JCB Servicemaster Use JCB Servicemaster and a laptop computer connected to machine CANbus to see the codes. The diagnostics tool will also enable fault finding options.

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes

Fault Code List Engine ECU Fault Codes Fault Code

Description

Warning Displays

E001

CANbus communication failure between LMS ECU and Engine ECU.

Message displayed on LCD.

E001

E002

Engine RPM - data erratic, intermittent or incorrect.

Message displayed on LCD

E002

E008

Inlet manifold pressure sensor fault - voltage above normal or shorted high.

Message displayed on LCD

E008

E009

Inlet manifold pressure sensor fault - voltage below normal or shorted low.

Message displayed on LCD

E009

E010

Accelerator Pedal Position sensor fault - voltage Message displayed on above normal or shorted high. LCD

E010

E011

Accelerator Pedal Position sensor fault - voltage Message displayed on below normal or shorted low. LCD

E011

E012

Hand Throttle Position sensor fault - voltage above normal or shorted high.

Message displayed on LCD

E012

E013

Hand Throttle Position sensor fault - voltage below normal or shorted low.

Message displayed on LCD

E013

E014

Engine Oil Pressure sensor fault - voltage above Message displayed on normal or shorted high. LCD

E014

E015

Engine Oil Pressure sensor fault - voltage below Message displayed on normal or shorted low. LCD

E015

E017

Engine Coolant Temperature sensor fault voltage above normal or shorted high.

Message displayed on LCD

E017

E018

Engine Coolant Temperature sensor fault voltage below normal or shorted low.

Message displayed on LCD

E018

E023

Intake Manifold Temperature sensor fault voltage above normal or shorted high.

Message displayed on LCD

E023

E024

Intake Manifold Temperature sensor (TMAP) fault - voltage below normal or shorted low.

Message displayed on LCD

E024

E027

Sensor Supply Voltage 3 fault - voltage above or Message displayed on below normal or shorted low or high. LCD

E027

E036

Sensor Supply Voltage 3 - data erratic, intermittent or incorrect.

Message displayed on LCD

E036

E040

Ground Speed Sensor circuit fault - data erratic, Message displayed on intermittent or incorrect. LCD

E040

E041

Ground Speed Sensor circuit fault - data abnormal rate of change.

Message displayed on LCD

E041

E047

Fuel Temperature Sensor fault - voltage above normal or shorted high.

Message displayed on LCD

E047

E048

Fuel Temperature Sensor fault.

Message displayed on LCD

E048

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes Fault Code

Description

Warning Displays

E049

Fuel Temperature Sensor fault - voltage below normal or shorted low.

Message displayed on LCD

E049

E051

High pressure fuel solenoid valve number 1 fault Message displayed on - voltage below normal or shorted low LCD

E051

E052

High pressure fuel solenoid valve number 1 fault Message displayed on - voltage above normal or shorted high, current LCD below normal or open circuit.

E052

E068

Engine Control Module Temperature sensor fault - voltage above normal or shorted high.

Message displayed on LCD

E068

E069

Engine Control Module Temperature sensor fault - voltage below normal or shorted low.

Message displayed on LCD

E069

E076

Injector solenoid valve fault, cylinder 1 - current Message displayed on above normal or grounded circuit. LCD

E076

E078

Injector solenoid valve fault, cylinder 3 - current Message displayed on above normal or grounded circuit. LCD

E078

E080

Injector solenoid valve fault, cylinder 2 - current Message displayed on above normal or grounded circuit. LCD

E080

E082

Injector solenoid valve fault, cylinder 4 - current Message displayed on above normal or grounded circuit. LCD

E082

E083

Injector solenoid valve fault, cylinder 1 - current Message displayed on below normal or open circuit. LCD

E083

E085

Injector solenoid valve fault, cylinder 3 - current Message displayed on below normal or open circuit. LCD

E085

E089

Injector solenoid valve fault, cylinder 2 - current Message displayed on below normal or open circuit. LCD

E089

E090

Injector solenoid valve fault, cylinder 4 - current Message displayed on below normal or open circuit. LCD

E090

E091

Engine Control Module fault - data erratic, intermittent or incorrect.

Message displayed on LCD

E091

Calibration Memory fault.

Message displayed on LCD

E091

E095

Sensor Supply Voltage 1 fault - voltage below normal or shorted low.

Message displayed on LCD

E095

E096

Fuel pump control module fault - voltage above Message displayed on normal or shorted high. LCD

E096

E097

Fuel pump control module fault - voltage below normal or shorted low.

Message displayed on LCD

E097

E104

Fuel pump control module idle fault - data erratic, intermittent or incorrect.

Message displayed on LCD

E104

E111

Intake air heater 2 - relay enable fault.

Message displayed on LCD

E111

E113

Sensor Supply Voltage 2 fault - voltage above normal or shorted high.

Message displayed on LCD

E113

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes Fault Code

Description

Warning Displays

E114

Sensor Supply Voltage 1 fault - voltage above normal or shorted high.

Message displayed on LCD

E114

E119

Water in fuel detected - data above normal operating range.

Message displayed on LCD

E119

E122

Water in fuel indicator fault - voltage above normal or shorted high

Message displayed on LCD

E122

E126

Intake manifold pressure sensor fault - data erratic, intermittent or incorrect

Message displayed on LCD

E126

E127

Power supply fault - data erratic

Message displayed on LCD

E127

E129

Battery voltage fault - data below normal level

Message displayed on LCD

E129

E130

Battery voltage fault - data above normal level

Message displayed on LCD

E130

E133

Fuel pump delivery pressure fault - data above normal level

Message displayed on LCD

E133

E134

Injector metering rail 1 pressure sensor fault voltage above normal or shorted high

Message displayed on LCD

E134

E135

Injector metering rail pressure sensor fault voltage below normal or shorted low

Message displayed on LCD

E135

E138

Fuel pump calibration trim circuit fault calibration fault

Message displayed on LCD

E138

E142

Fuel metering solenoid fault

Message displayed on LCD

E142

E159

Cylinder power imbalance - data erratic

Message displayed on LCD

E159

E183

Injector metering rail 1 pressure sensor fault data erratic, intermittent or incorrect

Message displayed on LCD

E183

E700

High pressure fuel pump delivery pressure low - Message displayed on data below normal level LCD

E700

E701

High fuel pressure solenoid valve 1 fault - data erratic, intermittent or incorrect.

Message displayed on LCD

E701

E702

High pressure fuel pump delivery pressure fault Message displayed on - data below normal level LCD

E702

E703

High pressure fuel pump delivery pressure low. Message displayed on LCD

E703

E704

Engine knock sensor fault - abnormal pulse width or frequency

Message displayed on LCD

E704

E705

Minimum Drive Pulse Drift (Injector 1) Mechanical system not responding or out of adjustment.

Message displayed on LCD

E705

E706

Minimum Drive Pulse Drift (Injector 2) Mechanical system not responding or out of adjustment.

Message displayed on LCD

E706

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes Fault Code

Description

Warning Displays

E707

Minimum Drive Pulse Drift (Injector 3) Mechanical system not responding or out of adjustment.

Message displayed on LCD

E707

E708

Engine control module main relay fault - relay not responding correctly

Message displayed on LCD

E708

E709

Engine coolant temperature sensor fault.

Message displayed on LCD

E709

E710

Intake air heater 1- relay enable fault - voltage above normal or shorted high

Message displayed on LCD

E710

E711

Intake air heater 1- relay enable fault - voltage below normal or shorted low

Message displayed on LCD

E711

E712

Intake air heater 1- relay enable fault - current below normal or open circuit

Message displayed on LCD

E712

E713

Intake air heater 1- relay enable fault - current above normal or grounded circuit

Message displayed on LCD

E713

E714

Cruise control set speed- mechanical system not responding or out of adjustment

Message displayed on LCD

E714

E715

Boost pressure validity - no fault, air pressure sensor data is plausible

Message displayed on LCD

E715

E716

Throttle pedal position sensor fault - data erratic Message displayed on LCD

E716

E717

Injector metering rail 1 pressure sensor fault

Message displayed on LCD

E717

E718

Engine position sensor fault (camshaft sensor) - Message displayed on abnormal pulse width or frequency LCD

E718

E719

Engine speed (crankshaft position) sensor fault Message displayed on - no signal, data erratic (target disc gap signal LCD missing)

E719

E720

Engine speed (crankshaft position) sensor - data Message displayed on erratic, intermittent or incorrect. LCD

E720

E722

Auxiliary Output 1 (temperature gauge/lamp) fault - voltage below normal or shorted low

Message displayed on LCD

E722

E723

Auxiliary Output 1 (temperature gauge/lamp) fault - current below normal or open circuit.

Message displayed on LCD

E723

E724

Auxiliary Output 1 (temperature gauge/lamp) Message displayed on fault - current above normal or grounded circuit. LCD

E724

E725

Wiring harness resistance too high or too low, cylinder 4

Message displayed on LCD

E725

E726

Wiring harness resistance too high or too low, cylinder 2

Message displayed on LCD

E726

E727

Wiring harness resistance too high or too low, cylinder 1

Message displayed on LCD

E727

E728

Wiring harness resistance too high or too low, cylinder 3

Message displayed on LCD

E728

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes Fault Code

Description

E729

Engine injector bank 1 (cylinders 2 and 4) - Bad Message displayed on device or component LCD

E729

E730

Engine injector bank 2 (cylinders 1 and 3) - Bad Message displayed on device or component LCD

E730

E731

High fuel pressure solenoid valve 1 fault - data above normal level.

Message displayed on LCD

E731

E732

High fuel pressure solenoid valve 1 fault

Message displayed on LCD

E732

E733

Maintenance Lamp fault - voltage below normal Message displayed on or shorted low LCD

E733

E734

Maintenance Lamp fault - current below normal Message displayed on or open circuit LCD

E734

E735

Maintenance Lamp fault - current above normal Message displayed on or grounded circuit LCD

E735

E736

Engine injector bank 1 (cylinders 2 and 4) Voltage below normal or shorted low.

Message displayed on LCD

E736

E737

Engine injector bank 2 (cylinders 1 and 3) Voltage below normal or shorted low

Message displayed on LCD

E737

E738

Hand throttle position sensor fault - data erratic Message displayed on LCD

E738

E745

Minimum Drive Pulse Drift (Injector 0) Mechanical system not responding or out of adjustment.

Message displayed on LCD

E745

E746

Auxiliary Output 2 (oil pressure gauge/lamp) fault - voltage below normal or shorted low

Message displayed on LCD

E746

E747

Engine Gaseous Fuel Correction Factor - out of Message displayed on calibration. LCD

E747

E748

Engine Gaseous Fuel Correction Factor - data erratic, intermittent or incorrect.

Message displayed on LCD

E748

E749

Auxiliary Output 2 (oil pressure gauge/lamp) fault - current below normal or open circuit

Message displayed on LCD

E749

E750

Auxiliary Output 2 (oil pressure gauge/lamp) Message displayed on fault - current above normal or grounded circuit LCD

E750

E751

Malfunction Indicator Lamp (MIL) fault - voltage Message displayed on above normal or shorted high. LCD

E751

E752

Maintenance Lamp fault - voltage above normal Message displayed on or shorted high LCD

E752

E753

Engine Electrical Lift Pump - voltage above normal or shorted high.

Message displayed on LCD

E753

E755

Engine position sensor fault (camshaft sensor) - Message displayed on mechanical system not responding or out of LCD adjustment.

E755

E756

Ground Speed Sensor circuit fault - voltage below normal or shorted low.

E756

M-20

Warning Displays

Message displayed on LCD

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes Fault Code

Description

Warning Displays

E757

ECU Power Output Supply 2 fault - current below normal or open circuit.

Message displayed on LCD

E757

E758

ECU Power Output Supply 2 fault - current above normal or grounded circuit.

Message displayed on LCD

E758

E759

Engine speed sensor fault - mechanical system Message displayed on not responding or out of adjustment. LCD

E759

E760

Engine Electrical Lift Pump - voltage below normal or shorted low.

Message displayed on LCD

E760

E761

Engine Electrical Lift Pump - current below normal or open circuit.

Message displayed on LCD

E761

E762

Engine Electrical Lift Pump - current above normal or grounded circuit.

Message displayed on LCD

E762

E763

Intake Manifold Temperature sensor fault

Message displayed on LCD

E763

E773

Malfunction Indicator Lamp (MIL) fault - current Message displayed on above normal or grounded circuit. LCD

E773

E774

Injector metering rail 1 pressure sensor fault out of calibration

Message displayed on LCD

E774

E775

Sensor Supply Voltage 1 fault - data erratic, intermittent or incorrect.

Message displayed on LCD

E775

E776

Fuel pump control valve (IMV) fault - current below normal or open circuit.

Message displayed on LCD

E776

E777

Fuel pump control valve (IMV) fault - current above normal or grounded circuit.

Message displayed on LCD

E777

E778

Fuel pump control valve (IMV) fault - data above Message displayed on normal operating range. LCD

E778

E779

Fuel pump control valve (IMV) fault - data above Message displayed on normal operating range. LCD

E779

E780

Fuel pump control valve (IMV) fault

Message displayed on LCD

E780

E781

Sensor Supply Voltage 3 fault - data erratic, intermittent or incorrect.

Message displayed on LCD

E781

E782

Malfunction Indicator Lamp (MIL) fault - voltage Message displayed on below normal or shorted low. LCD

E782

E783

Malfunction Indicator Lamp (MIL) fault - current Message displayed on below normal or open circuit. LCD

E783

E784

Intake Manifold Temperature sensor fault abnormal rate of change.

Message displayed on LCD

E784

E785

Ground Speed Sensor circuit fault - current below normal or open circuit.

Message displayed on LCD

E785

E786

Intake air heater 2- relay enable fault - voltage below normal or shorted low

Message displayed on LCD

E786

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Section M - Network Systems Electronic Fault Codes Electronic Monitoring System ECU Fault Codes Fault Code

Description

Warning Displays

E787

Intake air heater 2- relay enable fault - current below normal or open circuit

Message displayed on LCD

E787

E788

Intake air heater 2- relay enable fault - current above normal or grounded circuit

Message displayed on LCD

E788

E789

Ground Speed Sensor circuit fault - current above normal or grounded circuit.

Message displayed on LCD

E789

E790

Ground Speed Sensor circuit fault - mechanical Message displayed on system not responding or out of adjustment. LCD

E790

E791

Ground Speed Sensor circuit fault - voltage above normal or shorted high.

Message displayed on LCD

E791

E792

Auxiliary Output 1 (temperature gauge/lamp) fault - voltage above normal or shorted high.

Message displayed on LCD

E792

E793

Auxiliary Output 2 (oil pressure gauge/lamp) fault - voltage above normal or shorted high.

Message displayed on LCD

E793

E794

Intake air heater 2- relay enable fault - voltage above normal or shorted high.

Message displayed on LCD

E794

E795

Sensor Supply Voltage 2 fault - data erratic, intermittent or incorrect.

Message displayed on LCD

E795

E796

ECU Power Output Supply 2 fault - voltage below normal or shorted low.

Message displayed on LCD

E796

E797

ECU Power Output Supply 1 fault - voltage below normal or shorted low.

Message displayed on LCD

E797

E798

ECU Power Output Supply 1 fault - current below normal or open circuit.

Message displayed on LCD

E798

E799

ECU Power Output Supply 1 fault - current above normal or grounded circuit.

Message displayed on LCD

E799

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Section M - Network Systems Servicemaster Why Use Servicemaster?

Servicemaster Why Use Servicemaster? Introduction

Re-Programming ECUs

JCB machines now use the latest developments in electronic management of machine systems. This means that machine systems such as service hydraulics, engine, transmission and steering are controlled using electronic control units (ECU's).

The ECU's use pre-loaded data to compute responses to inputs from sensors. If an ECU is replaced the correct data files must be programmed (`flashed') into the ECU memory.

The ECU's process inputs from electrical sensors and then output signals to electrical actuators on the applicable devices. The ECU's are also connected to the machine CANbus electronic communication system.

New data files may also be issued by JCB Service to improve machine operation. This will also require the ECU to be re-programmed. This can only be done with Servicemaster.

Fault Finding

Summary

Faults with ECU controlled systems can be difficult or impossible to trace using traditional methods.

With the latest Servicemaster software loaded on your laptop and you can:

In addition to the primary function of machine control the ECUs are also able to detect possible faults with sensors and actuators. The faults are `logged' using a code system.

– Fault find

Use Servicemaster to see and understand these codes.

– View and change machine set up data

In addition Servicemaster has direct links to relevant onscreen help information about relevant devices. This information is designed to help you identify, test, and if applicable, remove and replace devices.

– For fast, effective fault finding. – Check maintenance standards – See if the machine has been abused. – This can only be done with Servicemaster. – Flash ECUs with the correct data files – This can only be done with Servicemaster.

Identify Poor Maintenance System faults that are present, or have happened in the past can be seen. This is not only useful when fault finding but can also identify poor standards of maintenance. For example a log showing a history of water in fuel detected. Use Servicemaster to see and understand these codes.

Access Machine Set Up Data Machine parameters such as tyre sizes, gear shift points and engine injector calibration codes are all stored and used by the relevant control ECU's. During the life of the machine it will be necessary to change some of these parameters. Without the correct data the machine will not operate correctly. This can only be done with Servicemaster.

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Section M - Network Systems Servicemaster What is Servicemaster?

What is Servicemaster? Introduction JCB Servicemaster is software for use with Microsoft Windows and a laptop personal computer. The laptop computer is connected to the machine `diagnostic socket' using special cables and an adapter. Use Servicemaster software to:

The DVD includes all the software tools for all applicable JCB machines. A selector window 7B is used to choose the correct software tool set 7C for each machine range.

Tool Sets Tool sets 7C are different for each machine range. A typical tool set includes:

â&#x20AC;&#x201C; Display data from machine ECUs â&#x20AC;&#x201C; Change data stored in ECUs

CANbus Communications System C

Controller

Area

Network

Vehicle Setup tool

Diagnostics tool

Flash Programmer tool

Data Logger tool

Service History

Instrument Cluster Setup

Servicemaster software communicates with the machine ECUs using the CAN. CAN is an electronic communications system that connects compatible machine ECUs to one pair of data wires called the CANbus. Coded data is sent to and from the ECUs on the CANbus. By connecting Servicemaster software to the CANbus this data is seen and decoded for use by an engineer.

Servicemaster Structure Servicemaster software is supplied as part of the JCB Service data DVD 7A issued to JCB dealers.

Each tool is specific to the chosen machine range. The tool icons are `shortcuts' to the tool software files. Detailed information about how to use the tools is given in the applicable machine documentation.

C Fig 7.

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Section M - Network Systems Servicemaster How to Set Up Servicemaster

How to Set Up Servicemaster Note: The procedures that follow describe how to set up Servicemaster for USB compatible equipment. There are other procedures and options. These are described in detail in the Servicemaster help files contained on the JCB Service Information DVD.

Configure the DLA type and communications port

Make sure that the DLA flash memory contains the latest firmware file

Connect Servicemaster to the machine CANbus

Before you set up Servicemaster make sure you have: – A Microsoft Windows compatible laptop computer with a DVD drive and a USB port (8A) Note: Servicemaster is compatible with Windows 98, 2000, ME and XP. – The latest Servicemaster software (JCB Service Information DVD) (8B) – A JCB compatible data link adapter (DLA) (8C)

K Install Servicemaster ( T M-26) K Start Servicemaster ( T M-27) K Load the DLA Laptop Driver Software ( T M-28) K Configure the DLA Type and Communications Port ( T M-29) K Check the DLA Firmware File ( T M-30) K Connect Servicemaster to the Machine CANbus ( T M-32)

– The correct connection cables (8D) Important: DO NOT connect any cables at the laptop, DLA or machine now.

A C

D B Fig 8. To set up Servicemaster for the first time: 1

Install Servicemaster

Start Servicemaster

Load the DLA laptop driver software

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Section M - Network Systems Servicemaster How to Set Up Servicemaster

Install Servicemaster 1

Exit all open programs on your laptop computer.

Insert the `JCB Service Information Pack DVD' into the DVD drive. The chooser screen will open. Click on the `S4' icon. K Fig 9. ( T M-26)

Fig 11. a

At the `installer' K Fig 12. ( T M-26)

screen

click

`Next'.

Fig 9. 3

The S4 chooser screen will open. Click on the Servicemaster Icon. K Fig 10. ( T M-26)

Fig 12. b At the `destination location' screen click `Next'. c

At the `installation type' screen click `Next'. (A full installation is recommended.)

d At the `installation complete' screen, click `Finish'. Fig 10. 4

The Servicemaster set up screen will open. Click on the `Install' button. K Fig 11. ( T M-26). The installation process now starts:

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Section M - Network Systems Servicemaster How to Set Up Servicemaster

Start Servicemaster 1

Double click on the Servicemaster icon. K Fig 13. ( T M-27). (The icon is found on the desktop or in the `Start' menu -`Programs' - 'JCB'.)

Fig 13. 2

The Servicemaster chooser window will open. K Fig 14. ( T M-27)

Fig 15.

Fig 14. 3

Open the drop down menu to see the machines and components supported by Servicemaster tools. K Fig 15. ( T M-27)

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Section M - Network Systems Servicemaster How to Set Up Servicemaster

Load the DLA Laptop Driver Software To use Servicemaster for the first time you must load the DLA driver software. You will not have to do the procedure again. Important: DO NOT connect the DLA or cables at the laptop or machine now. 1

Start the Servicemaster software on your laptop computer. K Start Servicemaster ( T M-27)

Select `DLA' from K Fig 16. ( T M-28)

the

drop

down

menu.

Fig 18.

Fig 16. 3

Double click on icon.K Fig 17. ( T M-28)

the

USB

driver

Fig 17. Note: Drivers are also available for computers with serial ports (no USB) and other versions of Microsoft Windows. If your laptop does not have a USB port, double click on the correct driver icon. 4

The driver installer window will open. Follow the on-screen K Fig 18. ( T M-28). installation instructions to complete the installation.

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Section M - Network Systems Servicemaster How to Set Up Servicemaster

Configure the DLA Type and Communications Port

Note: Older DLAs and laptop computers may not be compatible with USB ports. Choose the `Parallel/Serial DLA' device in the DLA chooser.

To use Servicemaster for the first time you must make sure that the correct DLA and laptop port is selected to communicate with the DLA. You will not have to do the procedure again. 1

Start the Servicemaster software on your laptop computer. K Start Servicemaster ( T M-27)

Select `DLA' from the Servicemaster drop down menu. K Fig 16. ( T M-28)

Double click the K Fig 19. ( T M-29)

COM

Port

Chooser

icon.

Fig 19. 4

The DLA Chooser window will open. Select the `USB/ Serial DLA' device and then click `Apply'. K Fig 20. ( T M-29)

Fig 20.

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Section M - Network Systems Servicemaster How to Set Up Servicemaster

Check the DLA Firmware File Important: Do not connect the DLA to the machine until this procedure has been completed. The DLA has software embedded in its own flash memory. This file must be replaced with a new one when new firmware is released. You will only have to Check the DLA firmware file version if you receive a new Servicemaster version or use a different DLA. 1

Make sure that the DLA is connected to the laptop computer. K Connect the 'USB PC Cable' 25A to the DLA and a free port on your laptop computer. ( T M-32)

Start the Servicemaster software on your laptop computer. K Start Servicemaster ( T M-27)

Select `DLA' from K Fig 16. ( T M-28)

Double click on the USB DLA Flash Loader icon. K Fig 21. ( T M-30)

the

drop

down

A Fig 22. 6

menu.

Check for a new firmware file: Click on the browse button 22A and locate the file stored within the JCB_Servicemaster directory on your laptop hard drive. a

Click the `Open' button. The selected file appears in the `Firmware File Name' field together with its release date and application version, for example 2.01.K Fig 24. ( T M-30)

Fig 21. Note: Older DLAs and laptop computers may not be compatible with USB ports. Double click the `Flash loader for Serial/Parallel DLA' icon. 5

The device flash update tool window opens. The details of the firmware in the DLA are displayed including the application version, for example 1.04.

Fig 23.

A Fig 24.

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Section M - Network Systems Servicemaster How to Set Up Servicemaster 7

Load a new firmware file: If the firmware in the DLA is not up to date, load the new file. Click the `Start' button 24A and follow the on-screen instructions.

When the update is complete disconnect the DLA and close the servicemaster application.

Important: The computer must be restarted before the updated software can be used.

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Section M - Network Systems Servicemaster How to Set Up Servicemaster

Connect Servicemaster to the Machine CANbus To use Servicemaster connect your laptop computer to the machine CANbus. Connection is made using Data Link Adapter (DLA) 25C and the applicable cables.

Make sure the machine ignition system is OFF.

Connect the 'USB PC Cable' 25A to the DLA and a free port on your laptop computer.

Note: Connect the USB cable directly to the laptop computer. DO NOT connect the cable via a USB hub. Note: Older DLAs and laptop computers may not be compatible with USB ports. Use the serial PC cable 25B to connect the DLA to the laptop serial port.

C D Fig 26.

Connect the 'Machine Cable' 25D to the DLA. The 'Machine Cable' has a 15-way D-type connector on one end and a 9-way CAN connector on the other. Plug the 15-way connector into the DLA and tighten the thumb-screws.

Connect the 9-way CAN connector into the machines' Diagnostics Connector 26A as follows:

Fig 25.

Table 3. Component Key USB PC Cable 718/20235

Serial PC Cable

718/20236

USB DLA

728/26500

Machine Cable

718/20237

Position the CAN connector 26B to align the centre pin location tab 26C with the diagnostics connector. 26A.

b Couple the connectors. Turn the locking ring 26D clockwise to secure the connectors.

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

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Section M - Network Systems

Servicemaster Tools Summary Tool

Icon

Description

User Guide

JCB 4.4L Tier 3 SE Engine Diagnostics

View engine operating parameters in K JCB 4.4L Tier 3 SE Diagnostics Tool - User real time. Perform engine electrical Guide ( T M-34) actuator tests. View, save or clear engine ECU fault code log.

PS760 ShiftMaster Transmission Diagnostics

View gearbox operating parameters in real time. Perform gearbox electrical actuator tests.

JCB 4.4L Tier 3 SE Engine Help

Comprehensive information about engine related sensors, actuators and ECU fault codes.

TM310/TM320 Setup Tool

Configure the machine options and EMS display.

K TM310 / TM320 Setup - User Guide ( T M-67)

Engine Setup

Configure engine type, settings and calibration of injectors.

K Engine Setup - User Guide ( T M-75)

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Introduction

Care and Safety

The 4.4L Tier 3 diagnostics software tool is part of the JCB Servicemaster software suite. See Section M Servicemaster for servicemaster installation details. The diagnostics software is designed to be an easy to use fault finding tool for 444 T3 series electronically controlled engines.

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Connecting 4.4L Tier 3 Diagnostics

To use Engine Diagnostics your laptop computer must be connected to the machine CANbus. See Section M Servicemaster for servicemaster connection details.

Select `Engine Tools' from the drop down list K Fig 27. ( T M-35) and then start the diagnostics tool running by clicking on the Engine Diagnostics icon K Fig 29. ( T M-35).

Starting 4.4L Tier 3 Diagnostics 1

Turn ON the machine ignition and additionally start the engine if required (taking normal precautions).

Start JCB Servicemaster on the laptop computer.

Fig 29. 5

The JCB 444 Engine Diagnostics tool will then open up displaying the main window K Fig 30. ( T M-35). Select the correct engine, click on JCB 4.4L Tier3

Fig 27. 3

Make sure that the correct DLA is selected in the chooser. Click on `Utilities', DLA Setup. The DLA Chooser window opens. Check the button to match to the Current Device. Click `Apply' K Fig 28. ( T M-35).

Fig 30.

Fig 28.

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

4.4L Tier 3 Diagnostics Overview There are several key elements to the diagnostics tool. These can be seen labelled below. Each element is explained in detail in later sections.

5 6 7 8

2 1 3

10 11 12

4 Fig 31.

Key: 1

Menu Bar

K ( T M-37)

Start and Stop Buttons

K ( T M-40)

Engine Selection Buttons

Main Window

CAN communication status LEDs K ( T M-41)

Engine Connector Page

K ( T M-42)

Machine Connector Page

K ( T M-44)

Actuator Test Page

K ( T M-46)

Fault Codes Page

K ( T M-47)

M-36

Page List

K ( T M-40)

LED Status Key

K ( T M-41)

Status Bar

K ( T M-41)

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Navigating within Diagnostics

Menu Bar - File Menu

Navigation is designed to be via a mouse. On Laptop PCs this may take the form of a small joystick or touch sensitive pad and some buttons, usually located near to the keyboard.

The File Menu contains an Exit option to close down the program K Fig 32. ( T M-37).

As with most Windows based programs, it is possible to navigate the diagnostics software using the keyboard by pressing certain combinations of keys. Note: This can be particularly useful for certain Laptop computers where the mouse/joystick can be oversensitive. Try out the following, it may come in useful one day.

Fig 32. On exiting the program communications with both ECU and DLA are shut down.

There are two main methods of navigation described below; â&#x20AC;&#x201C; Pressing the ALT key will cause the File option on the Menu Bar to be highlighted. You can then use the arrow keys to navigate the menus. â&#x20AC;&#x201C; Notice that all the menu items on the Menu Bar have a letter that is underlined (e.g. the 'F' in File). Holding down the ALT key and pressing the required letter key will activate that option (i.e. either open the menu or execute a function). For example, if you wish to open the Preferences Dialogue this can be done by pressing ALT + O (to open the Options menu) then ALT + P (to execute the Preferences option).

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Menu Bar - Options Menu

Language support is not available for the text within the page displays. Once your preferences have been selected either: Click on the OK button to apply them or click on the Cancel button to leave them unchanged.

Fig 33. – Start Diagnostics to commence communications with the engine ECU K Fig 33. ( T M-38). – Stop Diagnostics K Fig 33. ( T M-38).

cease

communications

– Controller Status Click on the buttons to toggle ON or OFF the diagnostics connection with the machine CAN system

Fig 34. – Preferences option opens up the Preference Dialogue K Fig 34. ( T M-38). – From the Preferences Dialogue there is support for multiple languages. Use the drop-down menu and scroll bar to chose the required language. Languages available are – English (United Kingdom) – French (France) – German (Germany) – Spanish (International Sort) Note: The language option only effects text within the Main Window (e.g. Page List, LED Status Key, etc.).

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Menu Bar - Window Menu

Menu Bar - Help Menu

K Fig 35. ( T M-39)

K Fig 36. ( T M-39)

Fig 36. Fig 35. Like most other Windows based programs where there are multiple sub-windows or Pages used, there are usually options to organise how they are laid-out. JCB Engine Diagnostics software is no different and offers the following options;

– About: Opens a window showing the part number and the version number of the installed copy of the Diagnostics software. – Help: Opens a help file about the software. – Engine Help: Opens a help file containing information about the engine sensor and actuator devices for engine control.

– Cascade – Tile Horizontally – Tile Vertically

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Start and Stop Buttons

Page List

These offer the same function as the Start Diagnostics and Stop Diagnostics options within the Options Menu.To start the Diagnostics tool communicating with the gearbox ECU simply click on the Start Button (large green LED) at the top of the Main Window.Similarly, click on the Stop Button (large red LED) to cease communications K Fig 37. ( T M-40).

In the top left corner of the main window is displayed a list of pages which can be displayed K Fig 38. ( T M-40).

Fig 38.

Fig 37.

M-40

Clicking in the box next to the required page will make that page appear in the main window display area. (A tick will also appear in the box to show it is being displayed.) At any time the user may swap between displayed pages simply by clicking in the check box of the required page in the page list. The function keys, F2, F3 etc. can also be used to select pages as required.

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Status bar

LED Status Key

There are 2 items of interest displayed on the Status Bar, which is located along the bottom of the Diagnostics main window.

Displays a key for the colour status of the LEDs shown on the diagnostics pages. The LED's change colour dependant on the electrical signal.

Fig 39. Connected ECU: The type of ECU connected to the Diagnostics tool is indicated on the far left side of the Status bar. CAN communications: Two small LEDs indicate data being transmitted (red) and received (green) over the CAN communications link. These LEDs can be seen to be flashing rapidly as data is transported. This can be another useful aid to determining the state of any established communications. Connection Status: Indicates if the diagnostics software is connected, connecting or not connected to the engine ECU.

Fig 40. LED Colour

Electrical signal status

Red

Off

Green

On/Active

Blue

Open circuit

Yellow

Short Circuit

Grey

No data

Information Window: Displays information about data on the diagnostics pages when the mouse is rolled over the fields.

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Engine Connector Page

A B C

D H E

Fig 41. This page displays data about the devices connected to the ECU engine harness. Sensor values being received by the ECU are displayed in data windows in real time. K Fig 41. ( T M-42).

Engine speed (RPM)

Engine coolant temperature (degrees C)

Fuel Temperature

214

Note: To see the data in real time start the engine. – Engine Hours: Shows total hours the engine has run in the window 41A.

Data Window Key: K Fig 41. ( T M-42) Value

No signal default value (fault condition)

Engine run hours

Inlet manifold air pressure 5.1 bar (bar)

Inlet manifold air temperature (degrees C)

Common rail fuel pressure 1305 (bar)

Engine oil pressure (bar)

M-42

Note: If a new ECU is fitted the engine hours data will be lost. The new ECU will log the hours starting at zero. – Boost Pressure: The sensor device electrical schematic is shown. A real time sensor value is shown in the window 41 B. In the event of no signal a default value is displayed. To link to more information about the device click on Boost Pressure. – Air Temperature: The sensor device electrical schematic is shown. A real time sensor value is shown in the window 41C. In the event of no signal a

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide default value is displayed. To link to more information about the device click on Air Temperature. – Fuel Rail Pressure: The sensor device electrical schematic is shown. A real time sensor value is shown in the window 41D. In the event of no signal a default value is displayed. To link to more information about the device click on Fuel Rail Pressure. – Inlet Metering Valve: The actuator device electrical schematic is shown. To link to more information about the device click on Inlet Metering Valve. – High Pressure Fuel Valve: The actuator device electrical schematic is shown. To link to more information about the device click on High Pressure Fuel Valve. – Oil Pressure: The sensor device electrical schematic is shown. A real time sensor value is shown in the window 41E. In the event of no signal a default value is displayed. To link to more information about the sensor click on Oil Pressure. – Oil Level: The sensor device electrical schematic is shown. The light indicates the status of the level switch signal to the ECU – Coolant Temperature: The sensor device electrical schematic is shown. A real time sensor value is shown in the window 41H. In the event of no signal a default value is displayed. To link to more information about the device click on Coolant Temperature. – Crankshaft Sensor: The sensor device electrical schematic is shown. To link to more information about the device click on Crankshaft Sensor. – Camshaft Sensor: The actuator device electrical schematic is shown. To link to more information about the device click on Camshaft Sensor. – Combustion Noise Sensor 1 (Knock Sensor): The sensor device electrical schematic is shown. To link to more information about the device click on Combustion Noise Sensor 1. – Combustion Noise Sensor 2 (Knock Sensor): The sensor device electrical schematic is shown. To link to more information about the device click on Combustion Noise Sensor 2. – Fuel Temperature: The sensor device electrical schematic is shown. A real time sensor value is shown in the window 41J. To link to more information about the device click on Fuel Temperature. – Engine Speed (RPM): The engine speed is shown in the window 41G in real time as revs per minute.

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Machine Connector Page

3 F

5 E

1 2

Fig 42. This page displays data about the devices connected to the ECU machine harness. Sensor values being received by the ECU are displayed in data windows in real time.

Speed Limiter set value

Machine ground speed

Important: The actual devices connected to the ECU by means of the machine connector are specific to a given application. For details of the devices fitted refer to the relevant machine technical documentation. Note: To see the data in real time start the engine. Data Window Key: K Fig 42. ( T M-44) Value

No signal default value (fault condition)

Engine run hours

Engine speed (RPM)

Foot throttle position %

102%

Hand throttle position %

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide – Engine Hours: Shows total hours the engine has run in the window 42A. – Earth: Electrical schematic showing ECU earth connections. – CAN Bus: Electrical schematic showing ECU controller area network (CAN) connections. – Check Engine lamp: Electrical schematic showing the engine check lamp ECU connection. – Malfunction Indicator Lamp (MIL): Electrical schematic showing the malfunction indicator lamp ECU connection. – Fuel Pump: Electrical schematic showing the electric fuel pump solenoid ECU connection. – Grid Heater: Electrical schematic showing the inlet manifold heater (grid heater) solenoid ECU connection. – Water in Fuel Switch: Electrical schematic showing water in fuel switch ECU connection. LED indicator 42-1 shows the signal status. To link to more information about the device click on Water in Fuel Switch. – Fuel Level Switch: Electrical schematic showing fuel level switch ECU connection. LED indicator 42-2 shows the signal status. – Power Supply: Electrical schematic showing ECU power supply connections. – Ignition Key Switch: Electrical schematic showing the ignition key switch ECU connection. LED indicator 42-3 shows the signal status. – Brake Pedal Switch: Electrical schematic showing the brake pedal switch ECU connection. LED indicator 42-4 shows the signal status – Engine Speed Control: Electrical schematic showing the engine speed control switch ECU connection. LED indicator 42-5 shows the signal status. – Hand Throttle: Electrical schematic showing the hand throttle ECU connections. To link to more information about the device click on Hand Throttle. – Foot Pedal Throttle: Electrical schematic showing the foot pedal throttle ECU connections. To link to more information about the device click on Foot Pedal Throttle.

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Actuator Tests Page

Fig 43. Important: Set the machine ignition to ON but DO NOT start the engine during the actuator test procedures. This page allows the engineer to `force' on an output from the ECU to a device. This is useful when fault finding because each device can be tested individually. After each test the ECU fault code log will display fault codes specific to the device. – Injector 1, 2, 3, 4: All four injectors can be tested individually. Click the Start button to energise the injector solenoid coil. The Start button changes to Stop. If the injector coil is working a buzz will be audible. If there is no sound audible the injector, its electrical connection or the engine ECU is defective. Click the button to de-energise the injector coil.

button changes to Stop. Click the button to switch off the MIL output. – Grid Heater: Click the Start button to switch on the grid heater relay output. The Start button changes to Stop. Click the button to switch off the relay output. – MIV Toggle: Click the Start button to switch on the metering inlet valve (MIV) output. The Start button changes to Stop. Click the button to switch off the MIV output. – Current Status: The window displays information showing the ECU output status.

If a fault is indicated check the fault code log. K Fault Codes Page ( T M-47) Note: You must de-energise one injector coil before energising another. – MI Lamp Toggle: Click the Start button to switch on the malfunction indicator lamp (MIL) output. The Start

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Section M - Network Systems Servicemaster Tools JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide

Fault Codes Page

Fig 44. This page allows the engineer to access fault codes logged by the ECU. The ECU logs a fault code if sensor or actuator signals are not valid. These codes are useful when fault finding. – Active Fault Codes: Displays fault codes for active faults in real time. To link to information about the fault code click on the code.

necessarily active. To link to information about the fault code click on the code. – Save Faults: Click the button to save the fault code lists as a file to a computer location. – Link to Fault Code List: Click to link to a complete list of possible fault codes. – Erase Fault Codes: Click the button to erase logged fault codes from the ECU memory.

Note: Start the engine to see all the active fault codes. Note: To check if a fault code is no longer active set engine ignition system to OFF and then restart the engine. The Servicemaster log display will not delete codes that are no longer active until the engine ignition system is set to OFF. – Previously Active Fault Codes: Displays fault codes for faults that have occurred but are not

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

ShiftMaster Diagnostics 2.3 - User Guide

Introduction

not compatible with either earlier versions of Windows 3.x. Ideally the computer should be a laptop type.

The ShiftMaster Diagnostics software tool is part of the JCB Service Master software suite. The diagnostics software is designed to be an easy to use fault finding tool for Powershift PS760 series electronically controlled gearboxes. ShiftMaster Diagnostics employs the graphical strengths of the Microsoft Windows operating environment to simplify electrical fault finding within the gearbox ECU control system. ShiftMaster Diagnostics is only intended for use with ECU 2, ECU 2.2 & ECU 2.3 controlled PS760 gearboxes. The system is not compatible with relay controlled gearboxes. Older versions of Powershift Controllers used on the PS750 series gearboxes are not supported. Note: This software guide is universal and some functions may not be available on particular machine variants. This software is intended for use on IBM Compatible Personal Computers (PCs) running Windows 9x, Windows2000 and WindowsXP operating systems but is

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Care and Safety

!MWARNING Be sure to read and follow any on screen instructions. Failure to follow correct procedure could result in death or injury. 2-4-5-5

Fig 45.

Installing ShiftMaster Diagnostics The ShiftMaster Diagnostics tool is fully integrated within JCB Service Master. To use ShiftMaster diagnostics you must install JCB Service Master onto a suitable laptop computer. For full instructions on how to install JCB Service Master software please refer to the documentation which accompanies JCB Service Master.

Connecting Shiftmaster Diagnostics To use Shiftmaster Diagnostics your laptop computer must be connected to the machine CANbus. See Section M Servicemaster for servicemaster connection details.

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Starting ShiftMaster Diagnostics 1

Turn ON the machine ignition and additionally start the engine if required (taking normal precautions).

Start JCB Service Master on the laptop computer.

Fig 48. 5

Warning message appears K Fig 49. ( T M-50). Read and understand the Warning message. If you can comply with the requirements press the `Accept' button.

Fig 46. 3

Fig 49. 6

The ShiftMaster Diagnostics tool will then open up displaying the main window K Fig 30. ( T M-35).

Fig 47. 4

Select `Compact Wheeled Loading Shovels' from the drop down list K Fig 27. ( T M-35) and then start the diagnostics tool running by clicking on the ShiftMaster Diagnostics icon K Fig 29. ( T M-35).

Fig 50.

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

ShiftMaster Diagnostics Overview There are several key elements to the Diagnostics tool. These can be seen labelled below. Each element is explained in detail in later sections.

Fig 51. Key: 1

Menu Bar

K ( T M-37)

Solenoid Test Mode Page

K ( T M-63)

Start and Stop Buttons

K ( T M-40)

Solenoid Identification Page

K ( T M-64)

Main Window

ECU Block Diagram Page

K ( T M-64)

ECU Setup Page

K ( T M-42)

Page List

K ( T M-40)

Dashboard Page

K ( T M-58)

LED Status Key

K ( T M-59)

ECU Status Page

K ( T M-59)

Page Display Area

LUC Page(2)

K ( T M-61)

Status Bar

(1)

K ( T M-41)

(1) The page list differs depending on the type of ECU connected (ECU 2 or ECU 2.2 / ECU 2.3) (2) Lock up torque converter page. Some gearboxes are not fitted with a lock up torque converter. The diagnostics software always displays the page even if it is not applicable.

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Navigating within ShiftMaster Diagnostics

Menu Bar - File Menu

Navigation is designed to be via a mouse. On Laptop PCs this may take the form of a small joystick or touch sensitive pad and some buttons, usually located near to the keyboard.

The File Menu contains an Exit option to close down the program K Fig 32. ( T M-37).

As with most Windows based programs, it is possible to navigate the ShiftMaster Diagnostics software using the keyboard by pressing certain combinations of keys. Note: This can be particularly useful for certain Laptop computers where the mouse/joystick can be oversensitive. Try out the following, it may come in useful one day.

Fig 52.

There are two main methods of navigation described below;

On exiting the program communications with both ECU and DLA are shut down.

â&#x20AC;&#x201C; Pressing the ALT key will cause the File option on the Menu Bar to be highlighted. You can then use the arrow keys to navigate the menus. â&#x20AC;&#x201C; Notice that all the menu items on the Menu Bar have a letter that is underlined (e.g. the 'F' in File). Holding down the ALT key and pressing the required letter key will activate that option (i.e. either open the menu or execute a function). For example, if you wish to open the Preferences Dialogue this can be done by pressing ALT + O (to open the Options menu) then ALT + P (to execute the Preferences option).

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Menu Bar - Options Menu

Fig 53. – Start Diagnostics to commence communications with the ShiftMaster ECU K Fig 33. ( T M-38). – Stop Diagnostics K Fig 33. ( T M-38).

cease

communications Fig 55. – Preferences option opens up the Preference Dialogue K Fig 34. ( T M-38).

Fig 54. – Road Speed Settings (ECU 2.2/2.3 only) Opens up the Road Speed Settings window K Fig 54. ( T M-53). – Press the `Load' button to upload the data from the ECU. – If the rolling radius of the wheel has been changed (due to a tyre fitment change for example) input the rolling radius and the associated axle ratio. – To change the speed units displayed by the diagnostics software check the required button on the Display Units panel. – Press the `OK' button to save the settings and close the window.

Fig 56. – From the Preferences Dialogue there is support for multiple languages. Use the drop-down menu and scroll bar to chose the required language K Fig 56. ( T M-53). Languages presently on offer are – English (Canada) – English (United Kingdom) – French (France) – German (Germany) – Italian (Italy) – Portuguese (Portugal) – Spanish (International Sort)

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide Note: The language option only effects text within the Main Window (e.g. Page List, LED Status Key, etc.). Language support is not available for the text within the page displays.

Menu Bar - Window Menu K Fig 35. ( T M-39)

Fig 57. – The Preferences Dialogue also offers the ability to change the background colour of the Page displays. Select the required background colour using the radio buttons K Fig 57. ( T M-54). Note: When using a laptop PC it can often be difficult to see the screen in bright sunlight. Changing the background colour can help improve the contrast (especially with the different LED colours) and so make viewing the screen easier. Once your preferences have been selected either:

Fig 58. Like most other Windows based programs where there are multiple sub-windows or Pages used, there are usually options to organise how they are laid-out. ShiftMaster Diagnostics software is no different and offers the following options; – Cascade – Tile Horizontally – Tile Vertically

Click on the OK button to apply them or click on the Cancel button to leave them unchanged.

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Menu Bar - Help Menu

Start and Stop Buttons

K Fig 36. ( T M-39)

Fig 59. â&#x20AC;&#x201C; About: Opens a window showing the part number and the version number of the installed copy of the Diagnostics software K Fig 60. ( T M-55). Fig 61.

Fig 60.

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Page List

Status bar

In the top left corner of the main window is displayed a list of pages which can be displayed K Fig 38. ( T M-40).

There are 2 items of interest displayed on the Status Bar, which is located along the bottom of the Diagnostics main window.

Note: The page list differs depending on the type of ECU connected (ECU 2 or ECU 2.2/2.3).

Connected ECU: The type of ECU connected to the Diagnostics tool is indicated on the far left side of the Status bar K Fig 39. ( T M-41).

Fig 63. CAN communications: Two small LEDs indicate data being transmitted (red) and received (green) over the CAN communications link K Fig 64. ( T M-56).

Fig 64. These LEDs can be seen to be flashing rapidly as data is transported. This can be another useful aid to determining the state of any established communications. Fig 62. Clicking in the box next to the required page will make that page appear in the main window display area. (A tick will also appear in the box to show it is being displayed.) At any time the user may swap between displayed pages simply by clicking in the check box of the required page in the page list. The function keys, F2, F3 etc. can also be used to select pages as required.

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

ECU Setup Page

a) `'NO DLA COMMS' if there are problems in communication with the DLA, or

This page displays crucial information about the ECU configuration K Fig 41. ( T M-42).

b) `'NO ECU COMMS' if the DLA is working but the ShiftMaster ECU is not responding. Note: For help on fixing communication problems, see K Connection Problems ( T M-65). Hardware Version: The hardware version is a reference to the build level of the electronics. Future developments may mean that hardware upgrades are required. This may effect which software can be used. Software Version: The software version refers to the issue level of the ECU operating software. Again, future developments may require software revisions.

ETS Function The ETS function provides a means of loading and uploading gearbox ECU software setup files between the ECU and the computer. On earlier versions of servicemaster a separate program was required to perform this function. This is now incorporated within shiftmaster diagnostics 2.3. The setup files have a file name extension of.ets. Fig 65. It is always useful to confirm that this is the correct configuration for the machine before commencing any fault finding. The ECU Setup Page displays the following information; ECU Setup Description: As well as its' operating software, the gearbox ECU also stores a group of Setup Data (or Settings). This Setup Data is used to tailor how a certain ECU part number functions. The Setup Data is loaded during the manufacturing process and has been approved for use in the intended application. Contained as part of the Setup Data is a Description. This Description is what is displayed here. The engineer can use this description to verify that the correct Setup Data is being used.

Load ETS File: A revision to the gearbox ECU software file may be supplied by JCB for installation on particular ECU models. Store the file on the computer which is to be connected to the gearbox ECU. The shiftmaster diagnostic program needs to open this file and obtain the software version and other applicable information to make sure it is compatible with the ECU connected to the computer. Send ETS Data: This allows the computer to send a software setup file to the gearbox ECU. Receive ETS Data: This reads the existing setup file from the gearbox ECU. Save ETS File: This saves the data received from the ECU onto the computer.

The ShiftMaster Setup software tool is designed to view and update current setup data. Application Code Part Number: During normal operation the application code is displayed. If there are communications errors present then this will contain either:

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Dashboard Page K Fig 66. ( T M-58)

Fig 66. – Requested Gear: This is the demand from the operator. – Selected Gear: This is the actual gear being selected by the ECU. Note: The operator Requested Gear is not always the same as the Selected Gear, e.g. when the ECU blocks shifts when offering protection. – Transmission Speed: This is the current transmission output speed which is directly related to the road speed (through axle ratio and tyre size). The transmission speed sensor is located next to the output gear and detects the passing of the gear teeth. The sensor has a fixed installation, no adjustment is necessary. This signal is used by the ECU to determine gear-shifting and protection strategies. – ECU 2.2/2.3 only. The speed may be displayed as a frequency value or, alternatively, road speed in MPH or KPH. Use the Options Menu, Road Speed Settings to select the required units. K Menu Bar - Options Menu ( T M-38).

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

ECU Status Page

Gears

This page gives a detailed picture of how the ECU is operating.

– Inputs: The items on the left show the signal lines connected to the gear selection lever and where fitted the selection switch on the hydraulic control lever (Joystick). The gear selection lever is the left hand half of the control lever assembly mounted on the steering column. The hydraulic control lever (Joystick ECU 2.3 machines) has a selection switch for forward, neutral and reverse gears. The input status is indicated by a coloured LED, grey - input OFF, green - input ON. – Outputs: The items on the right are the power outputs to the transmission solenoid valves. The output status is indicated by a coloured LED, grey output OFF, red - output ON (solenoid energised). The ECU and Diagnostics software proactively scans the solenoids for electrical open and short circuits. In the event of a circuit problem the corresponding solenoid output LED will be coloured yellow when ON, or blue when OFF.

Fig 67. Information in this display is constantly updated in realtime. The status of the ECU electrical inputs and outputs is displayed using simulated LED's. The LED's change colour depending on the status of the inputs and outputs. A key in the bottom left corner of the main window explains the colours.

Note: During certain gear-shifts the gearbox ECU will perform electrical Modulation to improve gear-shift quality. The ECU does this by adding delays to off-going and/or on-coming clutches and so overlapping energised outputs. These delays are in the order of a few hundred milli-seconds but it is sometimes long enough to be observed on the status LEDs. Thus, during certain shifts it is quite normal to observe more than 2 outputs ON at any one time.

4WD – Direct 4WD: An ECU input which is usually derived from the machine footbrake switch (which also controls the brake lights). Whenever this signal is present the 4WD Solenoid output is energised. – Indirect 4WD: An ECU input which is usually derived from a command from a console mounted '4WD selector' switch. (However, this switch arrangement may change between machines.)

Fig 68. The following is a brief explanation of each feature.

Transmission Speed This is exactly the same signal as explained in the previous section.

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– 4WD Solenoid (Bank 2): An ECU output to the transmission 4WD solenoid. The output status is indicated by a coloured LED, grey - output OFF, red output ON (solenoid energised). The ECU and Diagnostics software proactively scans the solenoids for electrical open and short circuits. In the event of a circuit problem the corresponding solenoid output

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide LED will be coloured yellow when ON, or blue when OFF. – 4WD Configuration: Depending on the type of 4WD clutch fitted 4wheel drive OR 2 wheel drive may be selected when the `4WD' solenoid is energised. The clutch may be a `Spring Applied' or `Pressure Applied' type. – 4WD Status: Indicates if 4WD is `Engaged' or `Disengaged'.

Misc Inputs These inputs are derived from the remaining operator controls. The input status is indicated by a coloured LED, grey - input OFF, green - input ON.

data depending on the machines mode of operation. The operator is able to preselect different transmission modes using a selector switch in the cab. – Bit 0: An ECU input signal derived from a mode selection switch. – Bit 1: An ECU input signal derived from a mode selection switch. – Set #: Indicates the transmission shift pattern data sets selected. There can be upto three different data set combinations selected by the ECU depending on the combination of inputs at Bit 0 and Bit 1. – Enable Footbrake Dump: If fitted.

– Handbrake Switch: Signal derived from the Parkbrake switch. Used to hold the transmission in Neutral if the parkbrake is applied. Two types of switch may be fitted NO (Normally Open) or NC (Normally Closed). – Footbrake Switch: If fitted. Two types of switch may be fitted NO (Normally Open) or NC (Normally Closed). – Dump Switch: (or Transmission Disconnect) Signal usually derived from a momentary switch. Temporarily selects Neutral when pressed (usually to divert engine power to hydraulics). – Throttle Switch: Signal derived from a switch fitted to the machine throttle pedal. Used to interact with the Automatic Mode of gear-shifting. – Pressure Switch: Signal derived from the transmission mounted Low Oil Pressure Switch. – Kickdown Switch: Signal derived from a momentary button used to temporarily select the next lowest gear. – Oil Temp Switch: Signal derived transmission oil temperature switch.

from

the

Misc Outputs These are the additional ECU outputs, generally used to control cab instrumentation such as a Driver Indicator (lamp and buzzer where fitted), low Oil Pressure Lamp and Kickdown Indicator. The output status is indicated by a coloured LED, grey - output OFF, red - output ON.

Load Mode (ECU 2.2/2.3 only) Some machines utilise transmission `modes'. The transmission can be configured to change the shift pattern

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Torque Converter Lock Up (TCLU) Page The TCLU control page displays information relating to the torque converter lock up operation K Fig 69. ( T M-61).

5 10 9 2

12 13

Fig 69. Key

Lock up clutch solenoid valve symbol

Engine speed sensor

Engine speed - lock up clutch `OFF' value

Engine speed r.p.m. (real time)

Engine speed - lock up clutch `ON' value

Engine speed sensor input status LED

Lock up clutch system `active' or `inactive'

Transmission output speed sensor

Transmission speed r.p.m. (real time)

Reference value - engine, transmission speed differential

Transmission speed sensor input status LED

Engine, transmission speed differential (real time)

Lock up clutch solenoid status LED

Current gear selected

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide For operation of the lock up clutch two speed references are required by the E.C.U.

Engine speed (n/min) is read from the input side of the transmission. The engine speed input is connected to the E.C.U. (pin 31A) and a green input LED 69-3 indicates the signal status.

Fig 70. Transmission output speed is taken from the same signal source described in Dashboard K ( T M-58). The transmission output speed is connected to the E.C.U. (pin 03B) and a green input LED 69-6 indicates the signal status. Two padlock symbols can be seen above the engine speed display. The locked padlock indicates the speed at which the lock up clutch (LUC) is switched `ON' and the unlocked padlock indicates when the LUC is switched `OFF'.

Fig 71. The circular graphic represents the torque converter and its elements K Fig 72. ( T M-62). 1

Stator

Turbine

Impeller

Lock up clutch

1 Fig 72. The central graphic 69-8 attached to E.C.U. output 01B depicts the lock up clutch solenoid. The red LED 69-7 indicates its status. Reference in brackets 69-11 displays as (active) if the gear selected is valid for LUC operation, or (inactive) if gear selected is not valid. The current gear selected is shown under the label `Gear'. A maximum differential speed reference value 69-12 is indicated next to a padlock symbol. If all the other interlocks are observed and the differential speed 69-13 is below that of the reference value, in this case 360 then the LUC is enabled.

Real time engine and transmission output speed are also displayed on the graphic K Fig 69. ( T M-61).

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Solenoid Test Mode Page

Fig 73. The Solenoid Test Mode page allows testing of each transmission solenoid individually. Since gear selection always requires two solenoid valves to be energised the tests can be carried out with the transmission in neutral. For electrical tests the engine does not have to be running. For hydraulic clutch pressure testing the engine must be running, before using the Test Mode facility disconnect the drive shafts at the gearbox. Important: It is possible that the gearbox may have developed a fault causing a clutch to be permanently engaged. If a second clutch is engaged (by using the Test Mode facility for instance) the gearbox will engage a gear unexpectedly. Before using the Test Mode facility disconnect the drive shafts at the gearbox. – Initial Conditions: To enable the test mode the handbrake must be ON, the FNR lever set to NEUTRAL and the road speed must be ZERO. The conditions are displayed in the Initial Conditions panel. – Start/Stop Button: Press the button to toggle the test mode either on or off as required. `TEST MODE READY' or `TEST MODE ACTIVE' is displayed as applicable. If the initial conditions are not compatible with the test mode the Start/Stop button is disabled and `NOT ALLOWED' is displayed.

output OFF, red - output ON (solenoid energised). The ECU and Diagnostics software proactively scans the solenoids for electrical open and short circuits. In the event of a circuit problem the corresponding solenoid output LED will be coloured yellow when ON, or blue when OFF. – To test the Driver, Kickdown and reverse Indicators: Click the appropriate button using the mouse. While the button is held down the ECU is `forced' to output power to the indicator and or warning devices. The output status is indicated by a coloured LED, grey - output OFF, red - output ON. If the devices are working they will illuminate and, or sound, as applicable. – To test the Neutral Start and Low Oil Pressure switches: Click the appropriate button using the mouse. While the button is held down the ECU is `forced' to output power to the switch. The output status is indicated by a coloured LED, grey - output OFF, red - output ON. Note: If the test mode is not enabled make sure that the START button is pressed (large green `LED' at the top left corner of the screen).

– To test a solenoid: If tests are being carried out with the engine running, make sure that the drive shafts are disconnected at the gearbox. Click the appropriate button using the mouse. The ECU is `forced' to output power to the selected solenoid. The output status is indicated by a coloured LED, grey -

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Solenoid Identification Page

ECU Block Diagram Page

The solenoid identification page is for reference only K Fig 74. ( T M-64).

The ECU block diagram page is for reference only K Fig 75. ( T M-64).

Fig 75. Fig 74.

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide

Connection Problems In general, whenever there are problems communicating with the DLA there will be an error message displayed.The following section although not exhaustive attempts to identify the more common ECU communication problems. ShiftMaster PC Service Tools must use the authorised Data Link Adaptor (DLA) contained in the Electronic Service Tool Kit. The latest versions of both the hardware and software can be obtained through authorised suppliers. ShiftMaster software has been designed to run on the Windows 9.X, Windows 2000 and Windows XP operating systems. A number of reasons can generate software problems and assistance from an Information Technology engineer is advised. In particular, laptop PCs can suffer serial communications conflicts were the PC hardware does not allow the Diagnostic software access to the communication ports. In the majority of cases conflicts are caused by either software already running on the PC, or by certain 'driver' files not releasing the COM port(s). The PC Service Tools for example ShiftMaster Diagnostics indicate the existence of an ECU communication problem that can reside in two areas indicated in the type of displayed error message. The first message is generated when the problem exists between the PC and DLA then the `Error Connecting to DLA' will be displayed. K Fig 76. ( T M-65)

Fig 77. The second is generated when no communications can be established with the DLA and the ECU usually through a hardware problem. No power supply from the machine, indicated by the DLA's power LED will display the 'NO ECU COMMS' message. K Fig 78. ( T M-66). Another source could be related to resistance of the two data communication wires making up the machine's harness for the ECU's CAN connection to the Deutsch 9 way round diagnostic connector. The wiring must have two 120 Ohm resistors fitted to either end of this run of cable to give a 60 Ohm impedance. If the impedance is incorrect then `NO ECU COMMS' message will displayed. K Fig 78. ( T M-66)

Fig 76. Confirmation of this error can be found in the `ECU Setup Page' with "NO DLA COMMS' being displayed in the `ECU Part Number' box. K Fig 77. ( T M-65)

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Section M - Network Systems Servicemaster Tools ShiftMaster Diagnostics 2.3 - User Guide establish if the software is conflicting with the port may establish this source. If the aforementioned information fails to resolve the situation then the following contacts may be able to provide further assistance; – Information Technology (IT) engineer. – Authorised machine dealer or agent. – Machine OEM. The Original Equipment Manufacturer (OEM) will make the relevant enquires.

General Information For all enquiries about the ShiftMaster Diagnostics tool please follow your normal channels of enquiry. This ensures that useful information can filter through to JCB personnel at all levels.

Fig 78. Note: The ECU must be powered for communications to work, i.e. the machine ignition must be ON (but the engine need not be running). If a problem is experienced it can take one of three forms, a constant failure to establish communications, drop out during communications or intermittent communication connection. However, the source has a tendency to be of the `NO DLA COMMS' type and thus related to the user's PC. Contributory factors to communication errors could be related to the following items: – DLA Drivers. The DLA and PC are programmed with software `drivers' which handle communications. Ensure the latest drivers are installed on the PC and DLA (contained in the latest version of Service Master). – PC Power Management. Previous experiences have shown that some laptops' Power Management software can disrupt the COM ports. Turning off the power management software may resolve the problem. – IR Drivers. If the PC has an InfraRed (IR) communications port then disabling the driver may help. – Modem Drivers. Modem drivers could cause communication conflicts and temporary disabling to

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

TM310 / TM320 Setup - User Guide

Introduction

Installing

The TM310 / TM320 Setup software tool is part of the JCB Service Master software suite. The software is designed to allow software updates and to configure the Electronic Instrument cluster to match machine parameters.

The TM310 / TM 320 Setup tool is fully integrated within JCB Service Master 2 Version 7.1. To use the setup program you must install JCB Service Master 2 Version 7.1 onto a suitable laptop computer.

Note: This software guide is universal and some functions may not be available on particular machine variants.

For full instructions on how to install JCB Service Master software see Section M - Servicemaster.

This software is intended for use on IBM Compatible Personal Computers (PCs) running Windows 9x, Windows2000 and WindowsXP operating systems but is not compatible with either earlier versions of Windows 3.x. Ideally the computer should be a laptop type.

Connection To use the setup program your laptop computer must be connected to the machine CANbus. See Section M Servicemaster for servicemaster connection details.

Care and Safety

!MWARNING Be sure to read and follow any on screen instructions. Failure to follow correct procedure could result in death or injury. 2-4-5-5

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

Starting TM310 / TM320 Setup

Turn ON the machine ignition and additionally start the engine if required (taking normal precautions).

Start JCB Service Master on the laptop computer.

The TM310 / TM320 Setup tool will then open up displaying the vehicle setup window. K Fig 82. ( T M-68).

Fig 79. 3

Fig 82. 6

Enable the connection between the PC/Laptop by pressing the "Connect" button K Fig 83. ( T M-68) or select "Connect" from the "File" Menu. K Fig 84. ( T M-68)

Fig 83.

Fig 80. 4

Select `Compact Wheeled Loading Shovels' from the drop down list K Fig 79. ( T M-68) and then start the setup tool running by clicking on the TM310 / TM320 Setup icon K Fig 81. ( T M-68).

Fig 84.

Fig 81.

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

Navigating within TM310 /TM320 Setup

Menu Bar - File Menu

Navigation is designed to be via a mouse. On Laptop PCs this may take the form of a small joystick or touch sensitive pad and some buttons, usually located near to the keyboard.

K Fig 85. ( T M-69).

As with most Windows based programs, it is possible to navigate the cluster setup software using the keyboard by pressing certain combinations of keys. Note: This can be particularly useful for certain Laptop computers where the mouse/joystick can be oversensitive. Try out the following, it may come in useful one day. There are two main methods of navigation described below; – Pressing the ALT key will cause the File option on the Menu Bar to be highlighted. You can then use the arrow keys to navigate the menus. – Notice that all the menu items on the Menu Bar have a letter that is underlined (e.g. the 'F' in File). Holding down the ALT key and pressing the required letter key will activate that option (i.e. either open the menu or execute a function). For example, if you wish to open the Preferences Dialogue this can be done by pressing ALT + O (to open the Options menu) then ALT + P (to execute the Preferences option).

M-69

Fig 85. – Connect: to connect the PC/laptop to the instrument cluster to enable communication. – Disconnect: to disconnect the PC/laptop and the instrument cluster and cease communication. – Read: to read the existing configuration of the instrument cluster. – Write: used to update the instrument cluster configuration. – Exit: to close down the program. On exiting the program communications with both ECU and DLA are shut down.

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

Menu Bar - Utilities Menu

Menu Bar - Help Menu K Fig 36. ( T M-39)

Fig 86. – Select Language: - to select the language of the setup program. K Fig 87. ( T M-70) – Controller Status: to show that the ECU is online.When the ECU is online the machine codes are displayed. This diagram shows the actual settings read from a test machine.K Fig 88. ( T M-70)

Fig 89. – Help: opens the help program K Fig 90. ( T M-70) – About: Opens a window showing the version number of the installed copy of the software K Fig 91. ( T M-70).

Fig 90.

Fig 87.

Fig 91.

Fig 88.

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

Vehicle Setup

Options

K Fig 92. ( T M-71)

K Fig 95. ( T M-71)

This screen is used to configure the instrument cluster ECU machine model.

This screen is used to configure the instrument cluster ECU machine options. The options available will vary depending on machine model selected.

Fig 92.

Configure Electronic Instrument Cluster Vehicle Setup 1

Click "Connect" to begin communication with the ECU.

Fig 93.

Fig 95.

Configure Electronic Instrument Cluster Options

Fig 94. 2

Using the "Model" Drop down menu select the machine model.

Enter the machine serial number into the VIN box.

Click "Next" to be taken to the options Screen.

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Using the "Tyre Type and Manufacturer" drop down menu select the tyres that are fitted to the machine.

Type the rolling radius size into the "rolling radius" box.

Select the service interval to be used by the EMS in the "Service Hours Alarm" box.

Configure which units the EMS will use by checking the box next to metric or imperial.

Click "Next" to be taken to the language screen.

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

Language K Fig 95. ( T M-71) This screen is used to configure the instrument cluster ECU language. The options available will vary depending on machine model selected.

Fig 97.

Fig 98. If the "Write" function is disabled make sure the communication connection is enabled by pressing the "Connect" button K Fig 99. ( T M-72) or select "Connect" from the "File" Menu. K Fig 100. ( T M-72)

Fig 99.

Fig 96.

Configure Electronic Instrument Cluster Options 1

Click on the "Country" drop down menu to select the country the machine will be supplied to.

A list of available languages will be displayed below.

The settings can now be written the machine electronic instrument cluster ECU. K Write ( T M-72)

Fig 100.

Write The User can program the machine Electronic Instrument Cluster connected using the write function. Several programming checks are made to ensure all required values are made (Model Type, Languages etc.) to ensure the data written will not make any invalid conditions in the vehicle system. Press the "Write" button K Fig 97. ( T M-72) or select "Write" from the "File" menu K Fig 98. ( T M-72).

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

Read K Fig 66. ( T M-58) On occasion it may be necessary for the software and setup information to be read back from the ECU to check settings or preload current settings ready for updating because of new options being fitted to the vehicle. Press the "Read" button K Fig 101. ( T M-73) or select "Read" from the "File" menu. K Fig 102. ( T M-73)

Fig 101.

Fig 103.

Fig 102. The progress of the read operation is shown in the status window. When the data has been read from the ECU the data is stored back into the data entry boxes on the options screen. K Fig 103. ( T M-73)

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Section M - Network Systems Servicemaster Tools TM310 / TM320 Setup - User Guide

Connection Problems In general, whenever there are problems communicating with the DLA there will be an error message displayed.The following section although not exhaustive attempts to identify the more common ECU communication problems. The setup program must use the authorised Data Link Adaptor (DLA) contained in the Electronic Service Tool Kit. The latest versions of both the hardware and software can be obtained through authorised suppliers. Servicemaster software has been designed to run on the Windows 9.X, Windows 2000 and Windows XP operating systems. A number of reasons can generate software problems and assistance from an Information Technology engineer is advised. In particular, laptop PCs can suffer serial communications conflicts were the PC hardware does not allow the software access to the communication ports. In the majority of cases conflicts are caused by either software already running on the PC, or by certain 'driver' files not releasing the COM port(s). An error is generated K Fig 104. ( T M-74) when no communications can be established with the DLA and the ECU usually through a hardware problem. Another source could be related to resistance of the two data communication wires making up the machine's harness for the ECU's CAN connection to the Deutsch 9 way round diagnostic connector.

Ensure the latest drivers are installed on the PC and DLA (contained in the latest version of Service Master). – PC Power Management. Previous experiences have shown that some laptops' Power Management software can disrupt the COM ports. Turning off the power management software may resolve the problem. – IR Drivers. If the PC has an InfraRed (IR) communications port then disabling the driver may help. – Modem Drivers. Modem drivers could cause communication conflicts and temporary disabling to establish if the software is conflicting with the port may establish this source. If the aforementioned information fails to resolve the situation then the following contacts may be able to provide further assistance; – Information Technology (IT) engineer. – Authorised machine dealer or agent. – Machine OEM. The Original Equipment Manufacturer (OEM) will make the relevant enquires.

Fig 104. Note: The ECU must be powered for communications to work, i.e. the machine ignition must be ON (but the engine need not be running). If a problem is experienced it can take one of three forms, a constant failure to establish communications, drop out during communications or intermittent communication connection. Contributory factors to communication errors could be related to the following items: – DLA Drivers. The DLA and PC are programmed with software `drivers' which handle communications.

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

Engine Setup - User Guide

Introduction

Installing

The Engine Setup software tool is part of the JCB Service Master software suite. The software is designed to allow software updates and to configure the Electronic Instrument cluster to match machine parameters.

The Engine Setup tool is fully integrated within JCB Service Master 2 Version 7.1. To use the setup program you must install JCB Service Master 2 Version 7.1 onto a suitable laptop computer.

Note: This software guide is universal and some functions may not be available on particular machine variants.

For full instructions on how to install JCB Service Master software see Section M - Servicemaster.

Connection To use the setup program your laptop computer must be connected to the machine CANbus. See Section M Servicemaster for servicemaster connection details.

Care and Safety

!MWARNING Be sure to read and follow any on screen instructions. Failure to follow correct procedure could result in death or injury. 2-4-5-5

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

Starting Engine Setup

Turn ON the machine ignition and additionally start the engine if required (taking normal precautions).

Start JCB Service Master on the laptop computer.

The Engine Setup tool will then open up displaying the vehicle setup window. K Fig 108. ( T M-76).

Fig 105. 3

Fig 106. 4

Enable the connection between the PC/Laptop by pressing the "Connect" button K Fig 109. ( T M-76) or select "Connect" from the "File" Menu. K Fig 110. ( T M-76)

Fig 109.

Select `Compact Wheeled Loading Shovels' from the drop down list K Fig 105. ( T M-76) and then start the setup tool running by clicking on the Engine Setup icon K Fig 107. ( T M-76).

Fig 110. Fig 107.

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

Navigating within Engine Setup

Menu Bar - File Menu

Navigation is designed to be via a mouse. On Laptop PCs this may take the form of a small joystick or touch sensitive pad and some buttons, usually located near to the keyboard.

K Fig 111. ( T M-77).

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Fig 111. – Connect: to connect the PC/laptop to the ECU to enable communication. – Disconnect: to disconnect the PC/laptop and the ECU and cease communication. – Read: to read the existing configuration of the ECU. – Write: used to update the ECU configuration. – Exit: to close down the program. On exiting the program communications with both ECU and DLA are shut down.

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

Menu Bar - Utilities Menu

Menu Bar - Help Menu K Fig 115. ( T M-78)

Fig 112. – Select Language: - to select the language of the setup program. K Fig 113. ( T M-78) – Controller Status: to show that the ECU is online.When the ECU is online the machine codes are displayed. This diagram shows the actual settings read from a test machine.K Fig 114. ( T M-78)

Fig 115. – Help: opens the help program K Fig 116. ( T M-78) – About: Opens a window showing the version number of the installed copy of the software K Fig 117. ( T M-78).

Fig 116.

Fig 113.

Fig 117.

Fig 114.

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

General K Fig 118. ( T M-79)

Using the "Machine Type" Drop down menu select the machine model.

Enter the engine serial number into the "Engine Serial Number" box.

Enter the engine power rating into the "Engine Power Rating" box.

Using the "Cold Start Kit" drop down box, select whether a cold start kit is fitted or not.

The settings can now be written the engine ECU. K Write ( T M-80)

This screen is used to configure the engine model.

Fig 118.

Configure Engine Setup 1

Click "Connect" to begin communication with the ECU.

Fig 119.

Fig 120.

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

Injector Calibration

Write

K Fig 121. ( T M-80)

The User can program the ECU using the write function. Several programming checks are made to ensure all required values are made (Model Type, Languages etc.) to ensure the data written will not make any invalid conditions in the vehicle system.

This screen is used to calibrate the injectors using the code printed on the injector body.

Press the "Write" button K Fig 122. ( T M-80) or select "Write" from the "File" menu K Fig 123. ( T M-80).

Fig 122.

Fig 123. If the "Write" function is disabled make sure the communication connection is enabled by pressing the "Connect" button K Fig 124. ( T M-80) or select "Connect" from the "File" Menu. K Fig 125. ( T M-80)

Fig 121.

Configure Injector Setup 1

Type the injector calibration codes into the boxes provided.

The settings can now be written the engine ECU. K Write ( T M-80) Fig 124.

Fig 125.

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

Read K Fig 128. ( T M-81) On occasion it may be necessary for the software and setup information to be read back from the ECU to check settings or preload current settings ready for updating because of new options being fitted to the vehicle. Press the "Read" button K Fig 126. ( T M-81) or select "Read" from the "File" menu. K Fig 127. ( T M-81)

Fig 126.

Fig 128.

Fig 127. The progress of the read operation is shown in the status window. When the data has been read from the ECU the data is stored back into the data entry boxes on the options screen. K Fig 128. ( T M-81)

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Section M - Network Systems Servicemaster Tools Engine Setup - User Guide

Connection Problems In general, whenever there are problems communicating with the DLA there will be an error message displayed.The following section although not exhaustive attempts to identify the more common ECU communication problems. The setup program must use the authorised Data Link Adaptor (DLA) contained in the Electronic Service Tool Kit. The latest versions of both the hardware and software can be obtained through authorised suppliers. Servicemaster software has been designed to run on the Windows 9.X, Windows 2000 and Windows XP operating systems. A number of reasons can generate software problems and assistance from an Information Technology engineer is advised. In particular, laptop PCs can suffer serial communications conflicts were the PC hardware does not allow the software access to the communication ports. In the majority of cases conflicts are caused by either software already running on the PC, or by certain 'driver' files not releasing the COM port(s). An error is generated K Fig 129. ( T M-82) when no communications can be established with the DLA and the ECU usually through a hardware problem. Another source could be related to resistance of the two data communication wires making up the machine's harness for the ECU's CAN connection to the Deutsch 9 way round diagnostic connector.

Fig 129. Note: The ECU must be powered for communications to work, i.e. the machine ignition must be ON (but the engine need not be running). If a problem is experienced it can take one of three forms, a constant failure to establish communications, drop out during communications or intermittent communication connection. Contributory factors to communication errors could be related to the following items: – DLA Drivers. The DLA and PC are programmed with software `drivers' which handle communications.

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