JCB 3CX, 4CX Backhoe Loader Repair Service Manual

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(S/N: 2000000 onwards)

This service manual PDF download for the 3CX, 4CX JCB Backhoe Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Backhoe Loader 3CX
JCB Backhoe Loader 4CX
(S/N: 2000000 onwards)

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine
Section M – Electronic Network

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9813/0250-01
Total Pages : 1620

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9813-0250

Section 1
General Information
Use
Introduction
Scope
Personnel
Newest Data
Machine Applications
Format
Left and Right Sides
Left Side, Right Side
Hydraulic Schematic Codes
Colour Codes
Machine Identification
Introduction
Machine Identification Plate
Typical Product Identification Number (PIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Numbers
ROPS/FOPS Certification plate
FOPS Data Plate
Torque Settings
Introduction
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
`Positional Type’ Hydraulic Adaptors
Fitting Procedure
Service Tools
Introduction
Numerical List
Tool Detail Reference
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Metric Test Points
Introduction
Parts Information
Service Consumables
Introduction
Sealing and Retaining Compounds
Fuel
Introduction
Acceptable and Unacceptable Fuels
Additives
Service Requirements for use of B20 Biodiesel
Warranty
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
Stall Speed Combinations
Introduction
Specifications

Section 2
Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Introduction
Safety Label Identification
General Procedures
Introduction
Parking the Machine and Making it Safe
Tools
Toolbox (If fitted)
Carrying Tools onto the Machine
Loader Arm Safety Strut
Installing
Removing
Venting Hydraulic Pressure
Venting the Brake System Pressure
Lowering a Load
Boom and Dipper Hose Burst Protection Valve (HBPV)
Loader Hose Burst Protection Valve (HBPV)
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hoses
Disconnecting the Hoses
Quick Release Couplings
Connecting and Disconnecting
`Quick-Connect’ Pilot Hoses
Disconnecting
Connecting
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Battery Disconnection/Connection
Disconnection
Connection
Removing and Replacing Components
Battery Charging System Precautions
Hydraulic Rams
Installation
Caution During Use
Maintenance, Inspection Points

Section 3
Maintenance
Routine Maintenence
Health and Safety
Lubricants
Battery
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuels
Prepare the Machine for Maintenance
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
Checking The ROPS/FOPS Structure
Greasing
Introduction
Preparing the Machine for Greasing
Loader Arms
Backhoe and Quickhitch
Front Axle (2 Wheel Drive Machines)
Front Axle (4 Wheel Drive Machines)
Front Axle (All Wheel Drive Machines)
Rear Axle (All Wheel Drive Machines)
Extending Dipper
Driveshafts
6-in-1 Clamshovel
Stabilisers (Centremount Machines)
Loader Quickhitch
Power Sideshift
Kingpost
Knuckle (If Fitted)
Backhoe Quickhitch (Hydraulic)
Access Panels
Engine Cover
Front Grille
Heater and Air Conditioning
Cleaning the Cab Heater Fresh Air Filter
Changing the Cab Air Conditioning Recirculation Filters (If Fitted)
Brakes
Park Brake
Electrical System
Battery
Jump Starting The Engine
Fuses and Relays
Engine
Oil and Filter
Cooling System
Front End Accessory Drive Belt
Air Filter
Fuel System
Introduction
Water Separator and Engine Fuel Filter
Bleeding the System
Hydraulic System
Introduction
Releasing the Hydraulic Pressure
Hydraulic Tank Filler Cap
Oil and Filter
Hose Burst Protection Valves (If fitted)
Transmission
Gearbox
Axles (All Wheel Steer Machines)
Axles (Two Wheel Steer Machines)
Tyres and Wheels
Tyre Inflation
Wheel Nuts
Wheel Alignment
Introduction
Electronic Steer Mode Selector
Wear Pads
Extradig Dipper Wear Pads
Stabiliser Legs (Sideshift Machines Only)
Windscreen Washer
Checking the Level
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A
Attachments
Hi-Flow Rockbreaker Circuit
Introduction
Operation Overview
Gearpump Machines
Gearpump Machines with Hi Flow Bi- Direction Auxiliary
Advanced EasyControl Machines
Changing the Return Line Filter – if fitted

Section B
Body and Framework
Cab Air Conditioning SYSTEM
Introduction
Related Topics
Specifications
R134a Refrigerant
PAG Type Refrigerant Oil
Operation Overview
System Operation
System Control
Electrical Operation and Schematics
Electrical Description
Wires and Connectors
Safety Procedures
Service Checks
Off-Season Operation
Fault Finding
Fault Indications
System Diagnosis using Test Gauges
Test Procedures
Leak Testing
Tightening Leaking Hoses
Refrigerant Charge Level
Binary Pressure Switch
Refrigerant
Refrigerant Charging and Discharging
Cleaning the Cab Filter
Compressor Drive Belt – Adjustment
Overload Warning SYSTEM
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Description
Wires and Connectors
Pressure Switch Renewal
Stabiliser Leg Alarm SYSTEM
Introduction
Related Topics
Operation Overview
Electrical Operation and Schematics
Electrical Description
Wires and Connectors
Leg Alarm Switch – Adjustment (Sideshift)
Leg Alarm Switch – Adjustment (Centremount)
Cab
Introduction
Related Topics
ROPS, FOPS Structure – Checks
Removal and Replacement
Direct Glazing
Cab Mountings
Side Console
Front Steering Console
Column Switches
B Post Covers
Roof Lining
Cab Roof Moulding
Seat – Manual Controls Machines
Air Conditioning Condenser
Introduction
Related Topics
Cleaning
Removal and Replacement
Removal
Replacement
Cab HVAC Unit
Introduction
Related Topics
Heater Unit Control Cables
Removal
Replacement
Adjustment
Air Conditioning Unit (HVAC)
Removal
Replacement
Evaporator Matrix
Removal
Replacement
Binary Pressure Switch
Removal
Replacement
Blower Unit
Removal
Replacement
Freeze Protection Thermostat
Removal
Replacement
Heater Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Fuel Tank
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Fuel Level Sender
Removal and Replacement
Engine Cover
Introduction
Related Topics
Removal and Replacement
Engine Cover
Engine Cover Release Cable
Front Grille Housing
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Engine Bay Support Frame
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Stabiliser Legs
Introduction
Related Topics
Sideshift
Wear Pads
Wear Pad – Adjustment
Removal and Replacement
Sideshift
Centremount
Boom and Dipper
Introduction
Related Topics
Extending Dipper
Wear Pad Adjustment
Removal and Replacement
Boom
Dipper
Kingpost & Carriage
Introduction
Related Topics
Sideshift
Hydraclamp Clearance Setting
Powered Sideshift
Wear Pad Renewal
Chain Adjustment
Removal and Replacement
Power Sideshift Ram
Kingpost
Sideshift Carriage
Loader Arms
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Boom Lock Cable
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Boom Stop Setting
Hydraulic Tank
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Fluid Level Sight Glass
Cover Plates
Front Bumper / Counterweight
Introduction
Related Topics
Removal and Replacement
Shovel Reset
Introduction
Related Topics
Operation and Adjustment

Section C
Electrics
Fuses and Relays
Introduction
Related Topics
Fuses (Manual Controls)
Fuses (Easy Controls / Advanced Easy Controls)
Link Box Fuses
Relays (Manual Controls)
Relays (Easy Controls / Advanced Easy Controls)
Relays – Gearbox/Steer Control
4 speed Powershift, Synchro Shuttle Machines
Shiftmaster Machines
Schematics
Manual Control Machines
Sheets
Component Keys
EasyControl Machines
Sheets
Component Keys
Advanced EasyControl Machines
Sheets
Component Keys
Electrical Harness SYSTEM
Introduction
Related Topics
Earth Points
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Harness Interconnections and Drawings
Harnesses – Manual Controls Machines
Harnesses – Joystick Controls (Servo) Machines
Drawings
Test Procedures
How to Use a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Introduction
Related Topics
Specifications
Testing
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Electrical Operation and Schematics
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Battery
Introduction
Related Topics
Specifications
Maintenance
Test Procedures
High Rate Discharge Test
Specific Gravity Testing
Disconnection and Connection
Removal and Replacement
Removal
Replacement

Section E
Hydraulics
Systems and Schematics
Introduction
Systems
Schematics – Parallel System – Manual Controls
Schematics – Parallel System – EasyControls
Schematics – Closed Centre System – Advanced EasyControls
Manual Controls Hydraulic SYSTEM
Introduction
Related Topics
Specifications
Loader Valve – Basic (Including Float)
Loader Valve – (Including Float, Reset and SRS)
Excavator Valve
Auxiliary Valve – if fitted
Hydraulic Pump – Gearbox Mounted
Hydraulic Pump – Engine Mounted
Operation Overview
Component Location and Identification
Operation
Hydraulic Operation and Schematics
No Services Operated
Service Operation
Unloader Operation
Main System Pressure Relief
Hydraulic Flow Mode Control
Schematics
Pilot Operated Main Relief Valve (MRV) Operation
Gearpump
Loader Valve
Excavator Valve
Electrical Operation and Schematics
Hydraulic Flow Mode Control
Hydraclamp Valve Operation
Shovel Reset Operation
Fault Finding
Tables
Test Procedures
Pump Flow and Pressure Testing
Main Relief Valve (MRV)
Unloader Valve
Auxiliary Relief Valves – Using Hand Pump
Ram Creep Tests – All Services
EasyControl Hydraulic SYSTEM
Introduction
Related Topics
Specifications
Loader Valve
Loader Valve – (Including SRS)
Excavator Valve
Pilot Pressure Valve
Auxiliary Valve
Hydraulic Pump – Gearbox Mounted
Hydraulic Pump – Engine Mounted
Operation Overview
Pump Systems
Excavator Servo Controls
Auxiliary Service Thumbwheel Controls
Joystick Enable and Seat Interlock Switches
Excavator Bucket Thumb Ram – if fitted
Excavator Auxiliary Service
Hydraulic Operation and Schematics
No Services Operated
Service Operation
Unloader Operation
Main System Pressure Relief
Hydraulic Flow Mode Control
Schematics
Pilot Operated Main Relief Valve (MRV)
Gearpump
Loader Valve
Excavator Valve
Pilot Pressure Valve
Electrical Operation and Schematics
Joysticks Enable Circuit
Hydraulic Flow Mode Control
Excavator/Loader Auxiliary Changeover Circuit
Excavator/Loader Auxiliary Service Controls
Thumbwheel Controls
Fault Finding
Tables
Thumbwheel Diagnostic `Blink’ Codes
Test Procedures
Checking the Servo Pressure
Checking the Main System Pressure
Advanced EasyControl Hydraulic SYSTEM
Introduction
Related Topics
Specifications
Loader Valve
Excavator Valve
Auxiliary Valve
Pilot Pressure Valve
Hydraulic Pump
Operation Overview
Loader and Excavator Servo Controls
Variflow Pump
Load Sense and Pressure Compensator Function
Auxiliary Service Thumbwheel Controls
Joystick Enable and Seat Interlock Switches
Hydraulic Operation and Schematics
No Services Operated
Service Operation
Multiple Service Operation
Main System Pressure
Schematics
Loader Valve
Excavator Valve
Hydraulic Variflow Pump
Pilot Pressure Valve
Electrical Operation and Schematics
Joysticks Enable Circuit
Excavator/Loader Changeover Circuit
Excavator/Loader Auxiliary Service Controls
Thumbwheel Controls
Fault Finding
Tables
Thumbwheel Diagnostic `Blink’ Codes
Test Procedures
Checking the Servo Pressure
Checking the Main System Pressures
Hydraulic Services Cycle Times
Checking for Internal Leakage Fault in Load Sense Line
Pressure Compensator Network – Testing
Smooth Ride SYSTEM (SRS)
Introduction
Related Topics
Specifications
Accumulator
Operation Overview
Hydraulic Operation and Schematics
Hose Burst Protection Valves (HBPV) Option
Electrical Operation and Schematics
Hose Burst Protection (HBPV) Option
Fault Finding
Accumulator Removal and Replacement
Integral Type
Remote Type
Accumulator Charging and Discharging
Charging
Discharging
Excavator Valve – Parallel type
Introduction
Related Topics
Removal and Replacement
Hoses and Pipes (Sideshift Valve)
Hoses and Pipes (Centremount Valve)
Valve Block
Valve Block Dismantling and Assembly
Load Hold Check Valves
Service Spools
Auxiliary Relief Valves
Spool Assembly
Auxiliary Relief Valves (ARV’s)
Hydraclamp Valve (Sideshift Machines)
Excavator Valve – Closed Centre Type
Introduction
Related Topics
Removal and Replacement
Dismantle and Assemble
Valve Block Sections
Servo Operated Spool
External Auxiliary Relief Valves (ARV’s)
Internal Auxiliary Relief Valves (ARV’s) – if fitted
Pressure Compensator Valves
Load Hold Check Valves
Loader Valve – Parallel Type
Introduction
Related Topics
Removal and Replacement
Dismantle and Assemble
Main Relief Valve (MRV)
Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV)
Unloader Valve
Standard Spool
Float Spool
Electric Detent Spool
Loader Valve – Closed Centre Type
Introduction
Related Topics
Removal and Replacement
Dismantle and Assemble
Valve Block Sections
Servo Operated Spool
Manually Operated – Electric Detent Spool
Manually Operated – Mechanical Detent Spool
Load Sense Relief Valve
External Auxiliary Relief Valves (ARV’s)
Internal Auxiliary Relief Valves (ARV’s) – if fitted
Flow Regulator Valve
Pressure Compensator Valves
Load Hold Check Valves
Pilot Pressure Supply Valve
Introduction
Related Topics
Removal and Replacement
Hose Burst Protection Valves – Manual Controls
Introduction
Related Topics
Hydraulic Operation and Schematics – Loader HBPV
Load Raise
Load Lower
Relief Valve
Hose Burst
Smooth Ride System (SRS) – Option
Hydraulic Operation and Schematics – Boom HBPV
Load Raise
Load Lower
Relief Valve
Hose Burst
Hydraulic Operation and Schematics – Stabiliser HBPV
Twin Check Valves
Single Check Valve
Test Procedures
Checking Hose Burst Protection Valve
Lowering a Load
Pilot Valve Setting Procedure – Loader HBPV
Removal and Replacement
Dismantle and Assemble
Loader HBPV
Boom HBPV
Main Pump – Gear Type (Pump 1/2)
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assemble
Dismantle
Inspection
Assemble
Main Pump – Gear Type (Pump 3)
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle, Inspection and Assemble
Main Pump – Variflow Type
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Rams
Introduction
Related Topics
Removal and Replacement
Loader Shovel Ram
Loader Lift Ram
Slew Ram
Stabiliser Ram (Sideshift)
Stabiliser Ram (Centremount)
Bucket Crowd Ram
Dipper Ram
Boom Ram
Dismantle and Assemble
Typical Ram
Slew Ram
Dipper Ram
Power Sideshift Ram
JCB Ram Sealing Procedure
Excavator Control Levers
Introduction
Related Topics
Dismantle
Assemble
Adjustment
Loader Control Levers
Introduction
Related Topics
Dismantle and Assembly
Dismantling
Assembly
Joystick and Stabiliser Controls
Introduction
Related Topics
Operation Overview
Joystick Controllers
Stabiliser Controls
ISO and SAE Control Pattern Changeover Valve – if fitted
Joystick/Auxiliary Control Changeover Valve – if fitted
Removal and Replacement
Dismantle and Assemble
Auxiliary Foot Pedal Control
Introduction
Related Topics
Dismantle
Assemble
Adjustment
Oil Cooler Matrix
Introduction
Related Topics
Removal and Replacement

Section F
Transmission
Wheels and Tyres
Introduction
Related Topics
Specifications
Tyre Sizes and Pressures
Front Axles
Introduction
Related Topics
Specifications
All Wheel Steer Machines
2 Wheel Steer Machines (4 Wheel Drive)
2 Wheel Steer Machines (2 Wheel Drive)
Component Identification
Renewing the Pinion Oil Seal
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Rear Axles
Introduction
Related Topics
Specifications
All Wheel Steer Machines
2 Wheel Steer Machines
Component Identification
Renewing the Pinion Oil Seal
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
SS700 Gearbox SYSTEM
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Start Up
Drive Select
‘Manual’ Gear Select
Park Brake ON
Transmission Dump
2/4 Wheel Drive Select
Hydraulic Operation and Schematics
Solenoid Operation
Electrical Operation and Schematics
Introduction
Quick Reference
Wires and Connectors
Fault Finding
Introduction
Fault Finding Tables
Test Procedures
Torque Converter Stall Test
Pressure and Flow Tests
Flushing the Transmission Oil
PS764 Gearbox SYSTEM
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Start Up
Pump Drive
Drive Select
‘Manual’ Gear Select
Park Brake ON
Transmission Dump
2/4 Wheel Drive Select
Hydraulic Operation and Schematics
Electrical Operation and Schematics – Relay Control
Introduction
Quick Reference
Wires and Connectors
Electrical Operation and Schematics – ECU Control
Introduction
ECU Electrical Connections
ECU Feeds and Earths
Forward Gears
Reverse Gears
Transmission Dump
Park Brake ON, Neutral Select
Drivepaths
Forward
Reverse
Fault Finding
Introduction
Tables
Test Procedures
Torque Converter Stall Test
Pressure and Flow Tests
Clutch Leakage Tests
Flushing the Transmission Oil
PS766 Gearbox SYSTEM
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Start Up
Pump Drive
Drive Select
`Manual’ Gear Select
`Automatic’ Gear Selection
Kick Down Operation
2/4 Wheel Drive Select
Transmission Dump
Park Brake ON
Limp Modes
Hydraulic Operation and Schematics
Hydraulic Operation
Electrical Operation and Schematics
Introduction
ECU Electrical Connections
ECU Feeds and Earths
Forward Gears 1,2,3
Forward Gears, 4,5,6 (A)
Reverse Gears
Transmission Dump
Park Brake ON, Neutral Select
Wires and Connectors
Drive Paths
Forward
Reverse
Fault Finding
Introduction
Gearbox `Limp Modes’
Transmission Technical Data Check List
Tables
Test Procedures
Torque Converter Stall Test
Pressure and Flow Tests
Flushing the Transmission Oil
Torque Converter Lock Up SYSTEM
Introduction
Related Topics
Operation Overview
Component Identification
State 1, Torque Converter Unlocked
State 2, Torque Converter Locked
Electrical Operation and Schematics
Introduction
Quick Reference
Wires and Connectors
Test Procedures
Shiftmaster ECU
Introduction
Related Topics
Component Identification
Renewing the ECU
SS700 Gearbox
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Forward and Reverser Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Spring ON) Operation
Synchromesh (Blocking Pin Type)
Synchromesh (Cone Type)
Removal and Replacement
Gearbox Assembly
Forward and Reverse Solenoid Control Valve – Solenoid Coil
Oil Pressure Switch
Dismantle, Inspection and Assembly
Gearbox Assembly
Forward and Reverse Solenoid Control Valve
PS760 Gearbox
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Forward and Reverser Clutch Operation
Mainshaft, Layshaft and 6 Speed Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Spring ON) Operation
Solenoid Control Valve Cartridge – Solenoid Coil
Removal and Replacement
Solenoid Control Valve Cartridge – Twin Fixing Type
Removal and Replacement
Oil Pressure Switch
Removal and Replacement
Oil Temperature Switch – Non Lock Up Torque Converter Variants
Removal and Replacement
Oil Temperature Switch – Lock Up Torque Converter Variants
Removal and Replacement
Removal and Replacement
Dismantle, Inspection and Assembly
Torque Converter
Introduction
Related Topics
Specifications
Component Identification
Operation Overview
Removal and Replacement
Removal
Replacement
Oil Cooler Matrix
Introduction
Related Topics
Removal and Replacement
Propshafts
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Speed Sensors
Introduction
Related Topics
Gearbox Speed Sensor
Testing
Engine Speed Sensor
Testing
Speedometer
Introduction
Related Topics
Calibration Procedure

Section G
Brakes
Service Brakes SYSTEM
Introduction
Related Topics
Specifications
Service Brakes
Brake Valve
Priority/Charge Valve (Gearpump)
Priority/Charge Valve (Variflow)
Operation Overview
General Description
2 and 4 Wheel Braking Modes
Hydraulic Operation and Schematics – Gear Pump System
Charge
Standby
Brake Opertion
Schematics
Hydraulic Operation and Schematics – Variflow System
Charge
Standby
Brake Operation
Schematics
Electrical Operation and Schematics – Relay Control Gearboxes
Brake Pressure Warning
Brake Mode
Electrical Operation and Schematics – ECU Control Gearboxes
Brake Pressure Warning
Brake Mode
Fault Finding
Introduction
Fault Finding Tables
Test Procedures
Checking the Brake Pressure
Checking the Charge Pressure
Checking the Brake Accumulator
Checking the Brake Low Pressure Switch Operation
Brake Piston Seal Leakage Test
Axle Breather (Braked Axles) – Inspection
Bleeding
Dismantle and Assemble
Brake Light Switch – Adjustment
Internal Park Brake SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Test Procedures
Adjustment
Lever Adjustment
Switch Adjustment
Renewing the Parkbrake Cable
Removal
Replacement
Dismantle, Inspection and Assemble
Dismantle the Multi-Plate Brake Pack
Dismantle the Brake Actuator
Inspection
Assemble the Brake Actuator
Assemble the Multi-Plate Brake Pack
External Park Brake SYSTEM
Introduction
Related Topics
Specifications
Operation Overview
Test Procedures
Adjustment
Lever Adjustment
Cable Adjustment
Switch Adjustment
Renewing the Brake Pads
Pad Removal
Pad Inspection
Pad Replacement
Renewing the Parkbrake Cable
Removal
Replacement
Brake Valve
Introduction
Related Topics
Hydraulic Operation and Schematics
Brake Operation
Removal and Replacement
Dismantle and Assemble
Accumulator Removal and Replacement
Combined Priority/Charge Valve
Introduction
Related Topics
Removal and Replacement
Gearpump Machines
Variflow Machines
Dismantle and Assemble
Park Brake Calliper
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Torque Figures
Dismantle, Inspection and Assemble
Dismantle
Inspection
Assemble
Park Brake Disc
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Park Brake Switch
Introduction
Related Topics
Removal and Replacement
Removal
Replacement

Section H
Steering
Steering SYSTEM
Introduction
Related Topics
Specifications
Hydraulic Steer Unit
Priority Valve
Operation Overview
4 Wheel Steer System
2 Wheel Steer System
Steer Modes
Hydraulic Operation and Schematics – Steer Unit
Neutral
Left Turn
Right Turn
Right turn, Unassisted
Shock Valve
2 Wheel Steer Mode – Right Turn
Crab Steer Mode – Right Turn
Priority Valve Operation
Hydraulic Operation and Schematics – Priority Valve – Gearpump Type
Charge Valve Open – No Steer Demand
Turning
Hydraulic Operation and Schematics – Priority Valve – Variflow Type
Accumulator Charged – No Steer Demand
Turning
Electrical Operation and Schematics
ECU Controlled Steer Mode
Wires and Connectors
Fault Finding
Tables
Diagnostic `Blink’ Codes – All Wheel Steer Machines
Test Procedures
Checking Components for Internal Hydraulic Leakage
Hydraulic Pressure Tests
Steer Mode Valve – Checking Solenoid Operation
Re-phasing the Road Wheels
Bleeding the System
4 Wheel Steer Machines
2 Wheel Steer Machines
Proximity Switch – Setting
Hydraulic Steer Unit
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Dismantle
Assemble
Priority Valve
Introduction
Related Topics
Removal and Replacement
Dismantle and Assemble
Power Track Rod
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Link Arms
Dismantle and Assemble
Rams
Steering Column
Introduction
Related Topics
Removal and Replacement
Dismantle and Assemble
Auto Steer Mode Valve
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Dismantle and Assemble
Dismantle
Assemble

Section K
Engine
Cold Start Heater SYSTEM
Introduction
Related Topics
Operation Overview
Component Location
Electrical Operation and Schematics
Starter Motor
Introduction
Related Topics
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Renewing the Brush Gear
Renewing the Starter Solenoid
Coolant Expansion Tank
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
Cooling Pack (Non Intercooled)
Introduction
Related Topics
Component Location
Removal and Replacement
Dismantle and Assemble
Cooling Pack (Intercooled Mechanical F.I. Engines)
Introduction
Related Topics
Component Location
Removal and Replacement
Dismantle and Assemble
Cooling Fan Viscous Coupling
Introduction
Related Topics
Operation Overview
Removal and Replacement
Throttle Cable
Introduction
Related Topics
Removal and Replacement
Removal
Replacement
JCB Dieselmax
Introduction
Related Topics
Specifications
Component Identification
Removal and Replacement
Removal
Replacement

Section M
Electronic Network
Servicemaster SYSTEM
Introduction
Related Topics
Why Use Servicemaster?
Introduction
Fault Finding
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECU’s
Summary
What is Servicemaster?
Introduction
CANbus Communications System
Servicemaster Structure
How to Set Up Servicemaster
Install Servicemaster
Start Servicemaster
Load the DLA Laptop Driver Software
Configure the DLA Type and Communications Port
Check the DLA Firmware File
Connect Servicemaster to the Machine CANbus
Servicemaster Tools
Introduction
Related Topics
Summary
ShiftMaster Diagnostics 2.3 – User Guide
Introduction
Care and Safety
Installing ShiftMaster Diagnostics
Connecting ShiftMaster Diagnostics
Starting ShiftMaster Diagnostics
ShiftMaster Diagnostics Overview
Navigating within ShiftMaster Diagnostics
Menu Bar – File Menu
Menu Bar – Options Menu
Menu Bar – Window Menu
Menu Bar – Help Menu
Start and Stop Buttons
Page List
Status bar
ECU Setup Page
Dashboard Page
ECU Status Page
Torque Converter Lock Up (TCLU) Page
Solenoid Test Mode Page
Solenoid Identification Page
ECU Block Diagram Page
Connection Problems
General Information
Pulse Width Modulation Theory
Introduction
Related Topics
Operation Overview
Electronic Control Unit Theory
Introduction
Related Topics
Operation Overview
ECU Inputs
ECU Outputs

 

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