JCB 434S Wheeled Loading Shovel Repair Service Manual

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(S/N: 1244000 Onwards)

This service manual PDF download for the 434S JCB Wheeled Loading Shovel 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 Wheeled Loading Shovel 434S – from S/N: 1244000 Onwards

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes –
P/N : 9803/9420-02
Total Pages : 572

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9803-9420-2
Service Manual
Service Manual
Wheeled Loading Shovel – 434S
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
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Section 1 – General Information
Section 1
Section 1
General Information
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
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Introduction
Introduction
About this Publication
About this Publication
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.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course…
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 General Information – includes torque settings and service tools.
1 General Information – includes torque settings and service tools.
2 Care & Safety – includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 Routine Maintenance – includes service schedules and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
<TABLE
<TABLE
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<TABLE ROW
A
A
Attachments
<TABLE ROW
B
B
Body & Framework…etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.
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.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
This Service Manual covers the following machines:
434S Wheeled Loading Shovel from machine serial number 1244000
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Identifying your Machine
Identifying your Machine
Identification Plates
Identification Plates
Identification Plate
Identification Plate
Your machine has an identification plate
1X
1
<GRAPHIC
<GRAPHIC
Fig 1.
Explanation of Vehicle Identification Number (VIN)
Explanation of Vehicle Identification Number (VIN)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
1
2
3
4
5
<TABLE BODY
<TABLE ROW
SLP
43400
6
E
1244000
1 World Manufacturer Identification, SLP = JCB
1 World Manufacturer Identification, SLP = JCB
2 Machine Model, 43400 = 434
3 Year of Manufacture 6, ( W = 1998, X = 1999 , Y = 2000, 1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7 = 2007, etc.)
4 Manufacturing Location (E = England)
5 Machine Serial Number (1244000)
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 nu…
The machine and engine serial numbers can help identify exactly the type of equipment you have.
Unit Identification
Unit Identification
The engine serial number is stamped on a plate
2Y
2
<GRAPHIC
<GRAPHIC
Fig 2.
Typical Engine Identification Number
Typical Engine Identification Number
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<TABLE HEADING
<TABLE ROW
1
2
3
4
5
<TABLE BODY
<TABLE ROW
YB
50457
U
576887
6
1 Engine Type, YB = 6 cylinder turbo
1 Engine Type, YB = 6 cylinder turbo
2 Build Number
3 Country of Origin
4 Engine Sequence Number
5 Year of Manufacture
The Transmission serial number is stamped on plate
3Z
3
<GRAPHIC
<GRAPHIC
Fig 3.
Torque Settings
Torque Settings
Zinc Plated Fasteners (golden finish)
Zinc Plated Fasteners (golden finish)
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.
UNF Grade `S’ Bolts
UNF Grade `S’ Bolts
<TABLE
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Bolt size
Torque Settings
<TABLE BODY
<TABLE ROW
Dia.
(mm)
Hexagon
Nm
kgf m
lbf ft
<TABLE ROW
(A/F) mm
<TABLE ROW
1/4
6.3
7/16
14
1.4
10
<TABLE ROW
5/16
7.9
1/2
28
2.8
20
<TABLE ROW
3/8
9.5
9/16
49
5.0
36
<TABLE ROW
7/16
11.1
5/8
78
8.0
58
<TABLE ROW
1/2
12.7
3/4
117
12.0
87
<TABLE ROW
9/16
14.3
13/16
170
17.3
125
<TABLE ROW
5/8
15.9
15/16
238
24.3
175
<TABLE ROW
3/4
19
1 1/8
407
41.5
300
<TABLE ROW
7/8
22.2
1 5/16
650
66.3
480
<TABLE ROW
1
25.4
1 1/2
970
99.0
715
<TABLE ROW
1 1/4
31.7
1 7/8
1940
198.0
1430
<TABLE ROW
1 1/2
38.1
2 1/4
3390
345.0
2500
Metric Grade 8.8 Bolts
Metric Grade 8.8 Bolts
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt size
Torque Settings
<TABLE BODY
<TABLE ROW
Dia.
(mm)
Hexagon
Nm
kgf m
lbf ft
<TABLE ROW
(A/F) mm
<TABLE ROW
M5
(5)
8
7
0.7
5
<TABLE ROW
M6
(6)
10
12
1.2
9
<TABLE ROW
M8
(8)
13
28
3.0
21
<TABLE ROW
M10
(10)
17
56
5.7
42
<TABLE ROW
M12
(12)
19
98
10
72
<TABLE ROW
M16
(16)
24
244
25
180
<TABLE ROW
M18
(18)
27
350
36
258
<TABLE ROW
M20
(20)
30
476
48
352
<TABLE ROW
M24
(24)
36
822
84
607
<TABLE ROW
M30
(30)
46
1633
166
1205
<TABLE ROW
M36
(36)
55
2854
291
2105
Rivet Nut Bolts/Screws
Rivet Nut Bolts/Screws
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt size
Torque Settings (for steel rivet nuts)
<TABLE BODY
<TABLE ROW
Dia.
(mm)
Nm
kgf m
lbf ft
<TABLE ROW
<TABLE ROW
M3
(3)
1.2
0.12
0.9
<TABLE ROW
M4
(4)
3.0
0.3
2.0
<TABLE ROW
M5
(5)
6.0
0.6
4.5
<TABLE ROW
M6
(6)
10.0
1.0
7.5
<TABLE ROW
M8
(8)
24.0
2.5
18.0
<TABLE ROW
M10
(10)
48.0
4.9
35.5
<TABLE ROW
M12
(12)
82.0
8.4
60.5
All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
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Service Tools
Service Tools
Numerical List Section B – Body and Framework
Numerical List Section B – Body and Framework
The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.
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.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
Tool Detail Reference
<TABLE BODY
<TABLE ROW
825/99849
Dummy Bush
K Fig 15. ( T 1-10)
K Fig 15. ( T 1-10)
<TABLE ROW
825/99851
Bearing Locator
K Fig 15. ( T 1-10)
K Fig 15. ( T 1-10)
<TABLE ROW
826/01179
M6 x 16mm Rivet Nut
K Fig 4. ( T 1-8)
K Fig 4. ( T 1-8)
<TABLE ROW
826/01106
M6 x 19mm Rivet Nut
K Fig 4. ( T 1-8)
K Fig 4. ( T 1-8)
<TABLE ROW
826/01177
M8 x 18mm Rivet Nut
K Fig 4. ( T 1-8)
K Fig 4. ( T 1-8)
<TABLE ROW
826/01176
M10 x 23mm Rivet Nut
K Fig 4. ( T 1-8)
K Fig 4. ( T 1-8)
<TABLE ROW
826/01333
M10 x 26mm Rivet Nut
K Fig 4. ( T 1-8)
K Fig 4. ( T 1-8)
<TABLE ROW
892/00842
Glass Lifter
K Fig 6. ( T 1-8)
K Fig 6. ( T 1-8)
<TABLE ROW
892/00843
Glass Stand
K Fig 5. ( T 1-8)
K Fig 5. ( T 1-8)
<TABLE ROW
892/00844
Long Knife
K Fig 14. ( T 1-10)
K Fig 14. ( T 1-10)
<TABLE ROW
892/00846
Glass Extractor (Handles)
K Fig 11. ( T 1-9)
K Fig 11. ( T 1-9)
<TABLE ROW
892/00847
Nylon Spatula
K Fig 7. ( T 1-8)
K Fig 7. ( T 1-8)
<TABLE ROW
892/00848
Wire Starter
K Fig 9. ( T 1-9)
K Fig 9. ( T 1-9)
<TABLE ROW
892/00849
Braided Cutting Wire
K Fig 13. ( T 1-10)
K Fig 13. ( T 1-10)
<TABLE ROW
926/15500
Rubber Spacer Blocks
K Fig 8. ( T 1-9)
K Fig 8. ( T 1-9)
<TABLE ROW
992/12800
Cut-Out Knife
K Fig 10. ( T 1-9)
K Fig 10. ( T 1-9)
<TABLE ROW
992/12801
‘L’ Blades
K Fig 12. ( T 1-10)
K Fig 12. ( T 1-10)
Tool Detail Reference Section B – Body and Framework
Tool Detail Reference Section B – Body and Framework
<TABLE
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<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 4.
<TABLE ROW
Note: 826/01179 M6 x 16mm Rivet Nut, 826/01106 M6 x 19mm Rivet Nut, 826/01177 M8 x 18mm Rivet Nut, 826/01176 M10 x 23mm Rivet Nut, 826/01333 M10 x 26mm Rivet Nut
826/01179 M6 x 16mm Rivet Nut, 826/01106 M6 x 19mm Rivet Nut, 826/01177 M8 x 18mm Rivet Nut, 826/01176 M10 x 23mm Rivet Nut, 826/01333 M10 x 26mm Rivet Nut
<TABLE ROW
Installation Tool Available from:
<TABLE ROW
Bollhoff Fastenings Ltd.
<TABLE ROW
Midacre
<TABLE ROW
The Willenhall Estate
<TABLE ROW
Rose Hill
<TABLE ROW
Willenhall
<TABLE ROW
West Midlands, WV13 2JW
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 5. 892/00843
<TABLE ROW
Note: essential for preparing new glass prior to installation.
essential for preparing new glass prior to installation.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 6. 892/00842
<TABLE ROW
Note: – minimum 2 off – essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.
– minimum 2 off – essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 7. 892/00847
<TABLE ROW
Note: – general tool used for smoothing sealants – also used to re-install glass in rubber glazing because metal tools will chip the glass edge.
– general tool used for smoothing sealants – also used to re-install glass in rubber glazing because metal tools will chip the glass edge.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 8. 926/15500
<TABLE ROW
Note: – used to provide the correct set clearance between glass edge and cab frame. (unit quantity = 500 off)
– used to provide the correct set clearance between glass edge and cab frame. (unit quantity = 500 off)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 9. 892/00848
<TABLE ROW
Note: – used to access braided cutting wire (below) through original polyurethane seal.
– used to access braided cutting wire (below) through original polyurethane seal.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 10. 992/12800
<TABLE ROW
Note: – used to remove broken glass.
– used to remove broken glass.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 11. 892/00846
<TABLE ROW
Note: – used with braided cutting wire (below) to cut out broken glass.
– used with braided cutting wire (below) to cut out broken glass.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 12. 992/12801
<TABLE ROW
Note: – 25 mm (1 in) cut – replacement blades for cut-out knife (above), (unit quantity = 5 off)
– 25 mm (1 in) cut – replacement blades for cut-out knife (above), (unit quantity = 5 off)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 13. 892/00849
<TABLE ROW
Note: – consumable heavy duty cut-out wire used with the glass extraction tool (above), (approx 25 m length)
– consumable heavy duty cut-out wire used with the glass extraction tool (above), (approx 25 m length)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 14. 892/00844
<TABLE ROW
Note: – used to give extended reach for normally inaccessible areas.
– used to give extended reach for normally inaccessible areas.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 15. 825/99849
<TABLE ROW
Note: – used with bearing locator to set up Upper Centre Pivot.
– used with bearing locator to set up Upper Centre Pivot.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 16. 825/99851
<TABLE ROW
Note: – used with dummy bush to set up Upper Centre Pivot.
– used with dummy bush to set up Upper Centre Pivot.
Numerical List Section C – Electrics
Numerical List Section C – Electrics
The tools listed in the table are special tools required for testing electrics. These tools are available from JCB Service.
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.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
Tool Detail Reference
<TABLE BODY
<TABLE ROW
718/20237
Interrogation Lead
K Fig 21. ( T 1-13)
K Fig 21. ( T 1-13)
<TABLE ROW
892/00282
Shunt
K Fig 17. ( T 1-12)
K Fig 17. ( T 1-12)
<TABLE ROW
892/00283
Tool Kit Case
K Fig 17. ( T 1-12)
K Fig 17. ( T 1-12)
<TABLE ROW
892/00284
Digital Tachometer
K Fig 17. ( T 1-12)
K Fig 17. ( T 1-12)
<TABLE ROW
892/00285
Hyd. Oil Temperature Probe
K Fig 17. ( T 1-12)
K Fig 17. ( T 1-12)
<TABLE ROW
892/00286
Surface Temperature Probe
K Fig 17. ( T 1-12)
K Fig 17. ( T 1-12)
<TABLE ROW
892/00298
Fluke Meter
K Fig 17. ( T 1-12)
K Fig 17. ( T 1-12)
<TABLE ROW
892/01066
Interrogation Lead
K Fig 19. ( T 1-12)
K Fig 19. ( T 1-12)
<TABLE ROW
892/01174
Data Link Adaptor
K Fig 20. ( T 1-13)
K Fig 20. ( T 1-13)
<TABLE ROW
993/85700
Battery Tester
K Fig 18. ( T 1-12)
K Fig 18. ( T 1-12)
Tool Detail Reference Section C – Electrics
Tool Detail Reference Section C – Electrics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 17.
<TABLE ROW
1
892/00283 Tool Kit Case
<TABLE ROW
2
892/00298 Fluke Meter
<TABLE ROW
3
892/00286 Surface Temperature Probe
<TABLE ROW
4
892/00284 Venture Microtach Digital Tachometer
<TABLE ROW
5
892/00282 100 amp Shunt – open type
<TABLE ROW
6
892/00285 Hydraulic Temperature Probe
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 18. 993/85700
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 19. 892/01066
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 20. 892/01174
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 21. 718/20237
Numerical List Section E – Hydraulics
Numerical List Section E – Hydraulics
The tools listed in the table are special tools required for testing, removing and replacing hydraulics. These tools are available from JCB Service.
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.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
Tool Detail Reference
<TABLE BODY
<TABLE ROW
1406/0011
Bonded Washer
K Fig 24. ( T 1-17)
K Fig 24. ( T 1-17)
<TABLE ROW
1406/0014
Bonded Washer
K Fig 24. ( T 1-17)
K Fig 24. ( T 1-17)
<TABLE ROW
1406/0018
Bonded Washer
K Fig 24. ( T 1-17)
K Fig 24. ( T 1-17)
<TABLE ROW
1406/0021
Bonded Washer
K Fig 24. ( T 1-17)
K Fig 24. ( T 1-17)
<TABLE ROW
1406/0029
Bonded Washer
K Fig 24. ( T 1-17)
K Fig 24. ( T 1-17)
<TABLE ROW
1604/0006
Adapter
K Fig 25. ( T 1-17)
K Fig 25. ( T 1-17)
<TABLE ROW
1612/0006
Adapter
K Fig 25. ( T 1-17)
K Fig 25. ( T 1-17)
<TABLE ROW
816/00189
Blanking Cap
K Fig 27. ( T 1-18)
K Fig 27. ( T 1-18)
<TABLE ROW
816/00190
Blanking Cap
K Fig 27. ( T 1-18)
K Fig 27. ( T 1-18)
<TABLE ROW
816/00193
Blanking Cap
K Fig 27. ( T 1-18)
K Fig 27. ( T 1-18)
<TABLE ROW
816/00196
Blanking Cap
K Fig 27. ( T 1-18)
K Fig 27. ( T 1-18)
<TABLE ROW
816/00197
Blanking Cap
K Fig 27. ( T 1-18)
K Fig 27. ( T 1-18)
<TABLE ROW
816/00294
Blanking Cap
K Fig 27. ( T 1-18)
K Fig 27. ( T 1-18)
<TABLE ROW
816/15118
Pressure Test Adapter
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
816/20008
Adapter
K Fig 25. ( T 1-17)
K Fig 25. ( T 1-17)
<TABLE ROW
816/55038
Pressure Test Adapter
K Fig 23. ( T 1-17)
K Fig 23. ( T 1-17)
<TABLE ROW
816/55040
Pressure Test Adapter
K Fig 23. ( T 1-17)
K Fig 23. ( T 1-17)
<TABLE ROW
892/00039
Spool Clamp
K Fig 31. ( T 1-19)
K Fig 31. ( T 1-19)
<TABLE ROW
892/00055
Blanking Plug
K Fig 26. ( T 1-18)
K Fig 26. ( T 1-18)
<TABLE ROW
892/00056
Blanking Plug
K Fig 26. ( T 1-18)
K Fig 26. ( T 1-18)
<TABLE ROW
892/00057
Blanking Plug
K Fig 26. ( T 1-18)
K Fig 26. ( T 1-18)
<TABLE ROW
892/00058
Blanking Plug
K Fig 26. ( T 1-18)
K Fig 26. ( T 1-18)
<TABLE ROW
892/00059
Blanking Plug
K Fig 26. ( T 1-18)
K Fig 26. ( T 1-18)
<TABLE ROW
892/00060
Blanking Plug
K Fig 26. ( T 1-18)
K Fig 26. ( T 1-18)
<TABLE ROW
892/00074
Female Connector
K Fig 29. ( T 1-18)
K Fig 29. ( T 1-18)
<TABLE ROW
892/00075
Female Connector
K Fig 29. ( T 1-18)
K Fig 29. ( T 1-18)
<TABLE ROW
892/00076
Female Connector
K Fig 29. ( T 1-18)
K Fig 29. ( T 1-18)
<TABLE ROW
892/00077
Female Connector
K Fig 29. ( T 1-18)
K Fig 29. ( T 1-18)
<TABLE ROW
892/00137
Micro-Bore Hose
K Fig 32. ( T 1-19)
K Fig 32. ( T 1-19)
<TABLE ROW
892/00223
Hand Pump
K Fig 32. ( T 1-19)
K Fig 32. ( T 1-19)
<TABLE ROW
892/00239
Charging Tool
K Fig 33. ( T 1-19)
K Fig 33. ( T 1-19)
<TABLE ROW
892/00253
Pressure Test Kit
K Fig 22. ( T 1-17)
K Fig 22. ( T 1-17)
<TABLE ROW
892/00255
Pressure Test Adaptor
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
892/00256
Pressure Test Adaptor
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
892/00257
Pressure Test Adaptor
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
892/00258
Pressure Test Adaptor
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
892/00259
Pressure Test Adaptor
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
892/00260
Pressure Test Adaptor
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
892/00261
Pressure Test Adaptor
K Fig 28. ( T 1-18)
K Fig 28. ( T 1-18)
<TABLE ROW
892/00262
Pressure Test Adaptor
K Fig 32. ( T 1-19)
K Fig 32. ( T 1-19)
<TABLE ROW
892/00263
Pressure Test Adaptor
K Fig 23. ( T 1-17)
K Fig 23. ( T 1-17)
<TABLE ROW
892/00264
Pressure Test Adaptor
K Fig 23. ( T 1-17)
K Fig 23. ( T 1-17)
<TABLE ROW
892/00265
Pressure Test Adaptor
K Fig 23. ( T 1-17)
K Fig 23. ( T 1-17)
<TABLE ROW
892/00268
Flow Monitoring Unit
K Fig 25. ( T 1-17)
K Fig 25. ( T 1-17)
<TABLE ROW
892/00269
Sensor Head
K Fig 25. ( T 1-17)
K Fig 25. ( T 1-17)
<TABLE ROW
892/00270
Load Valve
K Fig 25. ( T 1-17)
K Fig 25. ( T 1-17)
<TABLE ROW
892/00274
Adapter
K Fig 32. ( T 1-19)
K Fig 32. ( T 1-19)
<TABLE ROW
892/00275
Adapter
K Fig 25. ( T 1-17)
K Fig 25. ( T 1-17)
<TABLE ROW
892/00279
Gauge
K Fig 32. ( T 1-19)
K Fig 32. ( T 1-19)
<TABLE ROW
892/00309
A.R.V. Pressure Test Kit
K Fig 34. ( T 1-19)
K Fig 34. ( T 1-19)
<TABLE ROW
892/00335
A.R.V. Cartridge Removal Tool
K Fig 34. ( T 1-19)
K Fig 34. ( T 1-19)
<TABLE ROW
892/00340
Test Block Body
K Fig 34. ( T 1-19)
K Fig 34. ( T 1-19)
<TABLE ROW
892/00341
Setting Body
K Fig 34. ( T 1-19)
K Fig 34. ( T 1-19)
<TABLE ROW
892/00343
Spanner
K Fig 34. ( T 1-19)
K Fig 34. ( T 1-19)
<TABLE ROW
892/00345
Anti-cavitation Lock Out Bung
K Fig 34. ( T 1-19)
K Fig 34. ( T 1-19)
<TABLE ROW
892/00706
Test Probe
K Fig 32. ( T 1-19)
K Fig 32. ( T 1-19)
<TABLE ROW
892/00948
Charging Tool
K Fig 33. ( T 1-19)
K Fig 33. ( T 1-19)
<TABLE ROW
892/01042
Charging Tool
K Fig 33. ( T 1-19)
K Fig 33. ( T 1-19)
<TABLE ROW
892/01043
Adapter
K Fig 33. ( T 1-19)
K Fig 33. ( T 1-19)
<TABLE ROW
992/09300
Spanner
K Fig 30. ( T 1-18)
K Fig 30. ( T 1-18)
<TABLE ROW
992/09400
Spanner
K Fig 30. ( T 1-18)
K Fig 30. ( T 1-18)
<TABLE ROW
992/09500
Spanner
K Fig 30. ( T 1-18)
K Fig 30. ( T 1-18)
<TABLE ROW
992/09600
Spanner
K Fig 30. ( T 1-18)
K Fig 30. ( T 1-18)
<TABLE ROW
992/09700
Spanner
K Fig 30. ( T 1-18)
K Fig 30. ( T 1-18)
<TABLE ROW
992/10000
Spanner
K Fig 30. ( T 1-18)
K Fig 30. ( T 1-18)
<TABLE ROW
992/10100
Spool Clamp
K Fig 31. ( T 1-19)
K Fig 31. ( T 1-19)
<TABLE ROW
993/68300
Adjusting Pin
K Fig 34. ( T 1-19)
K Fig 34. ( T 1-19)
The following parts are replacement items for kits and would normally be included in the kit numbers above.
Replacement items for kit no. 892/00253
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
Tool Detail Reference
<TABLE BODY
<TABLE ROW
892/00201
Replacement Gauge
K Fig 22. ( T 1-17)
K Fig 22. ( T 1-17)
<TABLE ROW
892/00202
Replacement Gauge
K Fig 22. ( T 1-17)
K Fig 22. ( T 1-17)
<TABLE ROW
892/00203
Replacement Gauge
K Fig 22. ( T 1-17)
K Fig 22. ( T 1-17)
<TABLE ROW
892/00254
Replacement Hose
K Fig 22. ( T 1-17)
K Fig 22. ( T 1-17)
Tool Detail Reference Section E- Hydraulics
Tool Detail Reference Section E- Hydraulics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 22. Hydraulic Circuit Pressure test Kit
<TABLE ROW
892/00253 Pressure Test Kit
<TABLE ROW
892/00201 Replacement gauge 0-20 bar (0-300 lbf/in2)
2
<TABLE ROW
892/00202 Replacement gauge 0-40 bar (0-600 lbf/in2)
2
<TABLE ROW
892/00203 Replacement gauge 0-400 bar (0-6000 lbf/ in2)
2
<TABLE ROW
892/00254 Replacement Hose
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 23. Pressure Test `T’ Adapters
<TABLE ROW
892/00262 1/4 in BSP x 1/4 in F BSP x Test Point
<TABLE ROW
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point
<TABLE ROW
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
<TABLE ROW
892/00263 5/8 in BSP x 5/8 in F BSP x Test Point
<TABLE ROW
892/00264 3/4 in BSP x 3/4 in F BSP x Test Point
<TABLE ROW
892/00265 1 in M BSP x 1 in F BSP x Test Point
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 24. Bonded Washers
<TABLE ROW
1406/0011 1/4 in BSP
<TABLE ROW
1406/0018 1/2 in BSP
<TABLE ROW
1406/0014 5/8 in BSP
<TABLE ROW
1406/0021 3/4 in BSP
<TABLE ROW
1406/0029 1.1/4 in BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 25. Flow Test Equipment
<TABLE ROW
892/00268 Flow Monitoring Unit
<TABLE ROW
892/00269 Sensor Head 0 to 100 l/min. (0 to 22 UK gal/min)
<TABLE ROW
892/00270 Load Valve
<TABLE ROW
1406/0021 Bonded Washer
<TABLE ROW
1604/0006 Adapter 3/4 in M x 3/4 M BSP
<TABLE ROW
1612/0006 Adapter 3/4 in F x 3/4 M BSP
<TABLE ROW
816/20008 Adapter 3/4 in F x 1/2 M BSP
<TABLE ROW
892/00275 Adapter 1/2 in F x 3/4 M BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 26. Female Cone Blanking Cap
<TABLE ROW
892/00055 1/4 in BSP
<TABLE ROW
892/00056 3/8 in BSP
<TABLE ROW
892/00057 1/2 in BSP
<TABLE ROW
892/00058 5/8 in BSP
<TABLE ROW
892/00059 3/4 in BSP
<TABLE ROW
892/00060 1 in BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 27. Male Cone Blanking Cap
<TABLE ROW
816/00294 1/4 in BSP
<TABLE ROW
816/00189 3/8 in BSP
<TABLE ROW
816/00190 1/2 in BSP
<TABLE ROW
816/00197 5/8 in BSP
<TABLE ROW
816/00196 3/4 in BSP
<TABLE ROW
816/00193 1 in BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 28. Pressure Test Adapters
<TABLE ROW
892/00255 1/4 in BSP x Test Point
<TABLE ROW
892/00256 3/8 in BSP x Test Point
<TABLE ROW
892/00257 1/2 in BSP x Test Point
<TABLE ROW
892/00258 5/8 in BSP x Test Point
<TABLE ROW
816/15118 3/4 in BSP x Test Point
<TABLE ROW
892/00259 1 in BSP x Test Point
<TABLE ROW
892/00260 1.1/4 in BSP x Test Point
<TABLE ROW
892/00261 5/8 in UNF x Test Point
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 29. Female Connectors
<TABLE ROW
892/00074 3/8 in BSP x 3/8 in BSP
<TABLE ROW
892/00075 1/2 in BSP x 1/2 in BSP
<TABLE ROW
892/00076 5/8 in BSP x 5/8 in BSP
<TABLE ROW
892/00077 3/4 in BSP x 3/4 in BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 30. Hexagon Spanners for Ram Pistons and End Caps
<TABLE ROW
992/09300 55 mm
<TABLE ROW
992/09400 65 mm
<TABLE ROW
992/09500 75 mm
<TABLE ROW
992/09600 85 mm
<TABLE ROW
992/09700 95 mm
<TABLE ROW
992/10000 125 mm
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 31. Spool Clamps
<TABLE ROW
892/00039 Spool Clamp
<TABLE ROW
992/10100 Spool Clamp
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 32. Hand Pump Equipment
<TABLE ROW
892/00223 Hand Pump
<TABLE ROW
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
<TABLE ROW
892/00274 Adapter 1/4 in. M BSP x 3/8 in. M BSP Taper
<TABLE ROW
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
<TABLE ROW
892/00706 Test Probe
<TABLE ROW
892/00279 Gauge 0 – 400 bar (0 – 6000 lbf/in2)
2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 33. Accumulator Charge Equipment
<TABLE ROW
892/00239 Charging Tool (Diaphragm Accumulators)
<TABLE ROW
892/01042 Charging Tool (Diaphragm Accumulators)
<TABLE ROW
892/01043 Adaptor (use with 892/01042)
<TABLE ROW
892/00948 Charging Tool (Piston Accumulators)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 34. Components for Valve Block A.R.V. Testing
<TABLE ROW
892/00309 A.R.V. Pressure Test Kit
<TABLE ROW
1 892/00340 Test Block Body
<TABLE ROW
2 892/00341 Setting Body
<TABLE ROW
3 993/68300 Adjusting Pin
<TABLE ROW
4 892/00343 Spanner
<TABLE ROW
5 892/00345 Anti-cavitation Lock Out Bung
<TABLE ROW
6 892/00335 A.R.V. Cartridge Removal Tool
Numerical List Section F – Transmission
Numerical List Section F – Transmission
The tools listed in the table are special tools required for removal and replacement of Transmission parts. These tools are available from JCB Service.
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.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
Tool Detail Reference
<TABLE BODY
<TABLE ROW
892/00817
Heavy Duty Socket
K Fig 36. ( T 1-21)
K Fig 36. ( T 1-21)
<TABLE ROW
892/00818
Heavy Duty Socket
K Fig 36. ( T 1-21)
K Fig 36. ( T 1-21)
<TABLE ROW
892/00819
Heavy Duty Socket
K Fig 36. ( T 1-21)
K Fig 36. ( T 1-21)
<TABLE ROW
892/00859
Spanner Stake Nut
K Fig 39. ( T 1-22)
K Fig 39. ( T 1-22)
<TABLE ROW
892/00860
Bearing Shim Remover
K Fig 42. ( T 1-22)
K Fig 42. ( T 1-22)
<TABLE ROW
892/00861
Bearing Remover Base Tool
K Fig 42. ( T 1-22)
K Fig 42. ( T 1-22)
<TABLE ROW
892/00862
Tab Washer Fitting Tool
K Fig 39. ( T 1-22)
K Fig 39. ( T 1-22)
<TABLE ROW
892/00863
Blanking Plate Fitting Tool
K Fig 43. ( T 1-22)
K Fig 43. ( T 1-22)
<TABLE ROW
892/00865
Computer Test Harness
K Fig 38. ( T 1-21)
K Fig 38. ( T 1-21)
<TABLE ROW
892/00866
Computer Test Indicator Box
K Fig 38. ( T 1-21)
K Fig 38. ( T 1-21)
<TABLE ROW
892/00867
Computer Test Interrogator Box
K Fig 38. ( T 1-21)
K Fig 38. ( T 1-21)
<TABLE ROW
892/01000
Bearing Puller
K Fig 44. ( T 1-22)
K Fig 44. ( T 1-22)
<TABLE ROW
892/01001
Bearing Tool
K Fig 45. ( T 1-23)
K Fig 45. ( T 1-23)
<TABLE ROW
892/01002
Spring Compressor
K Fig 46. ( T 1-23)
K Fig 46. ( T 1-23)
<TABLE ROW
892/01003
Bearing Puller
K Fig 44. ( T 1-22)
K Fig 44. ( T 1-22)
<TABLE ROW
892/01004
Bearing Tool
K Fig 45. ( T 1-23)
K Fig 45. ( T 1-23)
<TABLE ROW
892/01005
Bearing Tool
K Fig 45. ( T 1-23)
K Fig 45. ( T 1-23)
<TABLE ROW
892/01006
110 Volt Heater
K Fig 47. ( T 1-23)
K Fig 47. ( T 1-23)
<TABLE ROW
892/01007
Pipe Swaging Tool
K Fig 48. ( T 1-23)
K Fig 48. ( T 1-23)
<TABLE ROW
892/01008
Pipe Swaging Tool
K Fig 48. ( T 1-23)
K Fig 48. ( T 1-23)
<TABLE ROW
892/01009
Pipe Swaging Tool
K Fig 48. ( T 1-23)
K Fig 48. ( T 1-23)
<TABLE ROW
892/01010
Pipe Swaging Tool
K Fig 48. ( T 1-23)
K Fig 48. ( T 1-23)
<TABLE ROW
892/01013
Lifting Eye
K Fig 49. ( T 1-23)
K Fig 49. ( T 1-23)
<TABLE ROW
892/01014
Retainer
K Fig 50. ( T 1-23)
K Fig 50. ( T 1-23)
<TABLE ROW
892/01015
Lifting Eye
K Fig 49. ( T 1-23)
K Fig 49. ( T 1-23)
<TABLE ROW
892/00909
Puller
K Fig 41. ( T 1-22)
K Fig 41. ( T 1-22)
<TABLE ROW
992/04000
Torque Multiplier
K Fig 37. ( T 1-21)
K Fig 37. ( T 1-21)
<TABLE ROW
992/07603
Replacer – Bearing Cup
K Fig 35. ( T 1-21)
K Fig 35. ( T 1-21)
Tool Detail Reference Section F – Transmission
Tool Detail Reference Section F – Transmission
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 35. 992/07603
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 36. Heavy Duty Socket for Durlock Bolts
<TABLE ROW
892/00817 17 mm A/F x 3/4 in. Square Drive
<TABLE ROW
892/00818 22 mm A/F x 3/4 in. Square Drive
<TABLE ROW
892/00819 15 mm A/F x 1/2 in. Square Drive
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 37. 992/04000
<TABLE ROW
Note: Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.
Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 38.
<TABLE ROW
<GRAPHIC
<GRAPHIC
<TABLE ROW
<GRAPHIC
<GRAPHIC
<TABLE ROW
892/00865 Computer test harness
<TABLE ROW
892/00866 Computer test indicator box
<TABLE ROW
892/00867 Computer test interrogator box
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 39. 892/00859
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 40. 892/00862
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 41. 892/00909
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 42.
<TABLE ROW
1 892/00860 Bearing Remover Shim
<TABLE ROW
2 892/00861 Bearing Remover Base Tool
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 43. 892/00863
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 44.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 45.
<TABLE ROW
892/01001 Bearing Tool
<TABLE ROW
892/01004 Bearing Tool
<TABLE ROW
892/01005 Bearing Tool
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 46. 892/01002
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 47. 892/01006
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 48.
<TABLE ROW
892/01007 Pipe Swaging Tool
<TABLE ROW
892/01008 Pipe Swaging Tool
<TABLE ROW
892/01009 Pipe Swaging Tool
<TABLE ROW
892/01010 Pipe Swaging Tool
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 49.
<TABLE ROW
892/01013 Lifting Eye
<TABLE ROW
892/01015 Lifting Eye
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 50. 892/01014
Numerical List Section K – Engine
Numerical List Section K – Engine
The tools listed in the table are special tools required for refurbishment of Engine parts. These tools are available from JCB Service.
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.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
Tool Detail Reference
<TABLE BODY
<TABLE ROW
892/00041
De-glazing Tool
K Fig 51. ( T 1-25)
K Fig 51. ( T 1-25)
Tool Detail Reference Section K – Engine
Tool Detail Reference Section K – Engine
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 51. 892/00041
<TABLE ROW
Note: De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings)
De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings)
For details of other engine service tools refer to Perkins Service Manual P/N
Page left intentionally blank
Service Consumables
Service Consumables
Sealing and Retaining Compounds
Sealing and Retaining Compounds
Table 1.
Table 1.
<TABLE
<TABLE HEADING
<TABLE ROW
Type
Description
Part No.
Quantity
<TABLE BODY
<TABLE ROW
JCB Multi-Gasket
A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
4102/1212
50 ml
<TABLE ROW
JCB High Strength Threadlocker
A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.
4102/0551
50 ml
<TABLE ROW
JCB Retainer (High Strength)
For all retaining parts which are unlikely to be dismantled.
4101/0651
50 ml
<TABLE ROW
JCB Threadlocker and Sealer
A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
4101/0250
10 ml
<TABLE ROW
4101/0251
50 ml
<TABLE ROW
JCB Threadlocker and Sealer (High Strength)
A high 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.
4101/0550
10 ml
<TABLE ROW
4101/0552
200 ml
<TABLE ROW
JCB Threadseal
A medium strength thread sealing compound.
4102/1951
50 ml
<TABLE ROW
JCB Activator
A cleaning primer which speeds the curing rate of anaerobic products.
4104/0251
200 ml (Aerosol)
<TABLE ROW
4104/0253
1 ltr (Bottle)
<TABLE ROW
JCB Cleaner/Degreaser
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/1557
400 ml (Aerosol)
<TABLE ROW
Direct Glazing Kit
For one pane of glass; comprises of:
– 1 x Ultra Fast Adhesive (310 ml)
– 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.
993/55700
<TABLE ROW
Ultra Fast Adhesive
For direct glazing.
4103/2109
310 ml
<TABLE ROW
Active Wipe 205
For direct glazing.
4104/1203
250 ml
<TABLE ROW
Black Primer 206J
For direct glazing.
4201/4906
30 ml
<TABLE ROW
Clear Silicone Sealant
To seal butt jointed glass.
4102/0901
<TABLE ROW
Plastic to Metal Bonder
To seal plastic to metal joints.
4103/0956
50 g
<TABLE ROW
Black Polyurethane Sealant
To finish exposed edges of laminated glass.
4102/2309
310 ml
Section 2 – Care and Safety
Section 2
Section 2
Care and Safety
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
Page left intentionally blank
Safety Notices
Safety Notices
Introduction
Introduction
In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.
Study the Operator Manual before starting the machine. You must understand and follow the instructions in the Operator Manual. Y…
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.
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.
Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.
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.
Safety Check List
Safety Check List
Safety – Yours and Others
Safety – Yours and Others
All machinary can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.
In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards a…
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 CAREFUL
BE ALERT
BE SAFE
General Safety
General Safety
Operator Manual
You and others can be injured if you operate or maintain the machine without first studying the Operator Manual. Read the safety…
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.
Clothing
You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective cloth…
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.
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.
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.
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that li…
Raised Equipment
Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported.
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.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
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.
Operating Safety
Operating Safety
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.
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.
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.
Engine
The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.
Exhaust Gases
Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making s…
If the machine is fitted with a Roll Over Protection Structure (ROPS) and/or a Falling Objects Protection Structure (FOPS), you …
Work Sites
Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for …
Communications
Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with o…
Parking
An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly.
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.
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.
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.
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.
Hazardous Atmospheres
This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without ad…
Regulations
Obey all laws, work site and local regulations which affect you and your machine.
Practice
You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away fr…
Reversing
Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions.
Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate wit…
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.
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.
Electrical Power Cables
You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables.
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.
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.
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.
Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
The use of non-approved attachments could invalidate your warranty.
Controls
You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.
Entering/Leaving
Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when ent…
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 diox…
Engine Panels
The engine has exposed rotating parts.
Do not open the bonnet while the engine is running. Keep other people clear while you raise the engine cover using the boom. Do not use the machine with the bonnet open or the cover raised.
Maintenance Safety
Maintenance Safety
Communications
Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the ot…
Repairs
If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result…
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.
Electrical Circuits
Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.
Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.
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.
Battery Gases
Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure t…
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.
Battery Terminals
The machine is negatively earthed. Always connect the negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead first.
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 prot…
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure…
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.
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants…
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.
Soft Ground
A machine can sink into soft ground. Never work under a machine on soft ground.
Hot Coolant
The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the syst…
Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out.
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.
Cleaning
Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.
When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer’s instructions and safety precautions.
‘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.
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the hoses regularly for:
– Damaged hose ends
– Damaged hose ends
– Chafed outer covers
– Ballooned outer covers
– Kinked or crushed hoses
– Embedded armouring in outer covers
– Displaced end fittings.
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.
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.
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel …
New fluoroelastomeric components at ambient temperature require no special safety precautions.
Used fluoroelastomeric components whose temperatures have not exceeded 300˚C (572˚F) require no special safety precautions. If e…
Used fluoroelastomeric components subjected to temperatures greater than 300˚C (572˚F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:
1 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
1 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
2 Thoroughly wash contaminated area with detergent and water.
3 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately.
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.
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.
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), moni…
Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage …
Counterweights
Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them.
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.
Accumulators
The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating …
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.
Jacking
A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of t…
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.
Wheels and tyres are heavy. Take care when lifting or moving them.
Store with care to ensure that they cannot fall and cause injury.
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.
Safety Decals
Safety Decals
Decals on the machine warn you of particular hazards. Each decal is attached close to a part of the machine where there is a possible hazard. Read and make sure you understand the safety message before you work with or on that part of the machine.
Keep all decals clean and readable. Replace lost or damaged decals. The decals and their attachment points are as illustrated. Each decal has a part number printed on it, use this number to order a new decal from you JCB dealer.
<GRAPHIC
Decals
Decals on the machine warn you of particular hazards. You can be injured if you do not obey the decal safety instructions.
Each decal is attached close to a part of the machine where there is a possible hazard. Make sure replacement parts include warning decals where necessary.
Keep all decals clean and readable. Replace lost or damaged decals. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor.
<GRAPHIC
If you need eye-glasses for reading, make sure you wear them when reading the safety decals. Decals are strategically placed aro…
<GRAPHIC
<GRAPHIC
Fig 1.
Section 3 – Routine Maintenance
Section 3
Section 3
Routine Maintenance
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Section 1 – General Information
Section 1 – General Information
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Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
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Routine Maintenance
Routine Maintenance
Health and Safety
Health and Safety
Lubricants
Lubricants
Introduction
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
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.
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
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
Waste Disposal
Waste Disposal
All waste products should be disposed of in accordance with all the relevant regulations.
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.
All waste products should be disposed of in accordance with all the relevant regulations.
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
Handling
New Oil
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 Oil
Used engine crankcase lubricants contain harmful contaminants.
Here are precautions to protect your health when handling used engine oil:
1 Avoid prolonged, excessive or repeated skin contact with used oil.
1 Avoid prolonged, excessive or repeated skin contact with used oil.
2 Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin:
a Wash your skin thoroughly with soap and water.
a 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.
3 Avoid skin contact with oil soaked clothing.
4 Don’t keep oily rags in pockets.
5 Wash dirty clothing before re-use.
6 Throw away oil-soaked shoes.
First Aid – Oil
First Aid – Oil
Eyes
Eyes
In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.
Swallowing
Swallowing
If oil is swallowed do not induce vomiting. Get medical advice.
Skin
Skin
In the case of excessive skin contact, wash with soap and water.
Spillage
Spillage
Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.
Fires
Fires
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.
Battery
Battery
Warning Symbols
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 c…
Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.
Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.
When reconnecting, fit the positive (+) lead first.
First Aid – Electrolyte
First Aid – Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get medical help.
IS SWALLOWED
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.
GETS ONTO YOUR SKIN
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.
Warning Symbols
Warning Symbols
The following warning symbols may be found on the battery.
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Symbol
Meaning
<TABLE BODY
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Keep away from children.
<TABLE ROW
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Shield eyes.
<TABLE ROW
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No smoking, no naked flames, no sparks.
<TABLE ROW
<GRAPHIC
<GRAPHIC
Explosive Gas.
<TABLE ROW
<GRAPHIC
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Battery acid.
<TABLE ROW
<GRAPHIC
<GRAPHIC
Note operating instructions.
Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.
Electrical Circuits
Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.
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.
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.
Battery Gases
Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure t…
Service Schedules
Service Schedules
A Badly Maintained Machine Is A Danger To The Operator And The People Working Around Him. Make Sure That The Regular Maintenance And Lubrication Jobs Listed In The Service Schedules Are Done To Keep The Machine In A Safe And Efficient Working Condition.
Apart From The Daily Jobs, The Schedules Are Based On Machine Running Hours. Keep A Regular Check On The Hourmeter Readings To C…
Maintenance
Maintenance must be done by suitably qualified personnel. Before attempting any maintenance work, make sure the machine is safe….
Apart From The Daily Jobs, The Schedules Are Based On Machine Running Hours. Keep A Regular Check On The Hourmeter Readings To C…
<TABLE
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<TABLE ROW
Calendar equivalents:
<TABLE BODY
<TABLE ROW
Every 10 Hours
=
Daily
<TABLE ROW
Every 50 Hours
=
Weekly
<TABLE ROW
Every 100 Hours
=
Monthly
<TABLE ROW
Every 500 Hours
=
Six Months
<TABLE ROW
Every 1000 Hours
=
Yearly
<TABLE ROW
Every 2000 Hours
=
2 Years
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Owner or Operator Tasks
First 100 hrs only (to be completed by JCB Distributor)
Regular Service
Table 1. Engine
Table 1. Engine
<TABLE
<TABLE HEADING
<TABLE ROW
Pre-start Cold Checks, Service Points and Fluid Levels
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Oil Level and Condition
Check
<TABLE ROW
Oil and Filter
Change
In arduous conditions change the oil and filter after every 250 Hours or three months (whichever comes first).
<TABLE ROW
Coolant
Change
<TABLE ROW
Coolant Level
Check
<TABLE ROW
Coolant strength and Condition
Check
<TABLE ROW
Air Cleaner Dust Valve
Clean
Clean more often when working in dusty environments
<TABLE ROW
Air Cleaner Outer Element
Change
Change outer element more frequently in dusty operating environments.
<TABLE ROW
Air Cleaner Inner Element
Change
<TABLE ROW
Fuel System For Leaks and Contamination
Check
<TABLE ROW
Fuel Filter
Drain
<TABLE ROW
Fuel Filter
Change
<TABLE ROW
Fuel Sedimenter
Check
<TABLE ROW
Fan Belt Tension/Condition
Check
<TABLE ROW
Fan Belt
Change
<TABLE ROW
Valve Clearances
Check/Adjust
<TABLE ROW
External Oil Leaks
Check
Table 2. Transmission and Axles
Table 2. Transmission and Axles
<TABLE
<TABLE HEADING
<TABLE ROW
Pre-start Cold Checks, Service Points and Fluid Levels
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Transmission Oil Level
Check
<TABLE ROW
Transmission Strainer/Filter
Change
<TABLE ROW
Differential Oil Level
Check
<TABLE ROW
Differential Oil
Change
<TABLE ROW
Hub Oil
Check
<TABLE ROW
Hub Oil
Change
<TABLE ROW
Axle Breathers
Clean
<TABLE ROW
Tyre Pressures/Condition
Check
<TABLE ROW
Wheel Nut Security
Check
<TABLE ROW
Axle Mount Security
Check
<TABLE ROW
Propshaft Security
Check
<TABLE ROW
Bevel Ring Gear Deflection Plunger
Check
<TABLE ROW
Propshaft and Universal Joints
Grease
Table 3. Hydraulics
Table 3. Hydraulics
<TABLE
<TABLE HEADING
<TABLE ROW
Pre-start Cold Checks, Service Points and Fluid Levels
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Oil Level
Check
<TABLE ROW
Oil Filter
Change
<TABLE ROW
Oil
Change and Sample
<TABLE ROW
Servo Filter
Change
<TABLE ROW
Tank Filler Cap
Change
<TABLE ROW
Tank Suction Strainers (2 off)
Clean
<TABLE ROW
Hoses, Rams and Pipework for Damage or Leaks
Check
Table 4. Brakes
Table 4. Brakes
<TABLE
<TABLE HEADING
<TABLE ROW
Pre-start Cold Checks, Service Points and Fluid Levels
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Parkbrake Operation
Check
Table 5. Electrics
Table 5. Electrics
<TABLE
<TABLE HEADING
<TABLE ROW
Pre-start Cold Checks, Service Points and Fluid Levels
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Instrument Panel Operation
Check
<TABLE ROW
Battery Electrolyte Level (if applicable)
Check
<TABLE ROW
Battery Charge and Condition
Check
<TABLE ROW
Battery Terminals for Condition & Tightness
Check
<TABLE ROW
Wiring for Chaffing and Routing
Check
Table 6. Bodywork and Cab
Table 6. Bodywork and Cab
<TABLE
<TABLE HEADING
<TABLE ROW
Pre-start Cold Checks, Service Points and Fluid Levels
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Machine Condition Generally
Check
<TABLE ROW
Wing Mirrors Condition & Security
Check
<TABLE ROW
All Pivot Pins
Grease
<TABLE ROW
Propshaft Joints
Grease
Grease more frequently when operating in arduous conditions.
<TABLE ROW
Windscreen Washer Fluid Level
Fill
<TABLE ROW
Cab Heater Intake Filter(s)
Clean
Clean more frequently in dusty operating environments.
<TABLE ROW
Seat Belt Condition and Security
Check
<TABLE ROW
Hinges
Grease
<TABLE ROW
ROPS/FOPS Structure
Check
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
First 100 hrs only (to be completed by JCB Distributor)
Regular Service
Table 7. Engine
Table 7. Engine
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Idle Speed
Check and Adjust
<TABLE ROW
Torque Converter Stall Speed
Check
<TABLE ROW
Combined Stall Speed
Check
<TABLE ROW
Max. No Load Speed
Check and Adjust
<TABLE ROW
Throttle System
Check
<TABLE ROW
Exhaust Smoke
Check
<TABLE ROW
Fuel System for Leaks and Contamination
Check
<TABLE ROW
Exhaust System Security
Check
<TABLE ROW
Air Inlet System Security
Check
<TABLE ROW
Coolant System for Leaks
Drain
Table 8. Transmission and Axles
Table 8. Transmission and Axles
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Clutch Pack Pressures
Check
<TABLE ROW
Clutch Disconnect/Dump Button
Check
<TABLE ROW
Clutch Pack Calibration
Check
<TABLE ROW
Speed Change and Selection
Check
<TABLE ROW
Forward/Reverse Selection/ Operation
Check
<TABLE ROW
Neutral Start Operation
Check
<TABLE ROW
Reverse Alarm (if fitted)
Check
<TABLE ROW
Oil Cooler and Pipework
Check
Table 9. Hydraulics
Table 9. Hydraulics
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
MRV Pressure
Check and Adjust
<TABLE ROW
Steer Circuit MRV Pressure
Check and Adjust
<TABLE ROW
ARV Pressure
Check and Adjust
<TABLE ROW
Operation of All Services
Check
<TABLE ROW
Hoses for Damage and Leaks
Check
<TABLE ROW
Pipework for Damage and Leaks
Check
<TABLE ROW
Piston Rods and Gland Seals
Check
Table 10. Electrics
Table 10. Electrics
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Starter Motor
Check
<TABLE ROW
Alternator
Check
<TABLE ROW
Gauges and Warning Lights
Check
<TABLE ROW
Proximity Sensor Function
Check
<TABLE ROW
Cab Switches
Check
<TABLE ROW
Wiper Motors
Check
<TABLE ROW
Heater
Check
Table 11. Cab
Table 11. Cab
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Glazing for Correct Fit
Check
<TABLE ROW
Doors and Hinges
Check
<TABLE ROW
Toolkit and Handbook
Check
<TABLE ROW
Locks and Keys
Check
<TABLE ROW
Seat/Seat Belts
Check
Table 12. Paintwork
Table 12. Paintwork
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Condition
Check
Table 13. Attachments
Table 13. Attachments
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Attachment Circuit Pressures
Check
<TABLE ROW
Operation
Check
Table 14. Registration/Certification
Table 14. Registration/Certification
<TABLE
<TABLE HEADING
<TABLE ROW
Functional Test and Final Inspection
Operation
Daily 10 Hr
Weekly 50 Hr
Monthly 100 Hr
First 100 Hr
6 Monthly 500 Hr
Yearly 1000 Hr
2 Yearly 2000 Hr
<TABLE BODY
<TABLE ROW
Form 2530(F91) (UK Requirement) – Lift
Check
<TABLE ROW
Form 2531(F96/F97) (UK Requirement)
Check
<TABLE ROW
SWL Stickers (UK)
Renew as Required
Lubricants and Capacities
Lubricants and Capacities
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of…
Table 15. 434S Machines
Table 15. 434S Machines
<TABLE
<TABLE HEADING
<TABLE ROW
ITEM
ITEM
CAPACITY
FLUID/LUBRICANT
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
INTERNATIONAL SPECIFICATION
<TABLE BODY
<TABLE ROW
Engine Oil
Engine Oil
<TABLE ROW
-10 to 50˚ C
If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.
17.5 litres (3.9 UK gal)
JCB Extreme Performance Engine Oil 15W/40
ACEA E3/B3/A3 API CH-4A3
<TABLE ROW
Gearbox
Gearbox
27 litres (5.9 UK gal)
The figure quoted is TOTAL system capacity. Use the ‘MAX’ and ‘MIN’ marks on the dipstick when refilling the system.
JCB HP Universal ATF
ZF TE-ML 06, 11, 12, 14
<TABLE ROW
Axles
Axles
39 litres (8.6 UK gal)
JCB LS Gear Oil
API GL4, MIL-L- 2105B
Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
<TABLE ROW
Hydraulic System
Hydraulic System
210 litres (46.2 UK gal)
The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and watch the level indicator.
JCB HP Hydraulic Fluid
ISO VG46
<TABLE ROW
Cooling System
Cooling System
35 litres (7.7 UK gal)
Water/Anti-freeze ( K Coolant Mixtures ( T 3-33))
K Coolant Mixtures ( T 3-33)
ASTM D3306-74
<TABLE ROW
Fuel System (Main)
Fuel System
230 litres (50.6 UK gal)
Diesel Oil ( K Types of Fuel ( T 3-37))
K Types of Fuel ( T 3-37)
ASTM D975-66T Nos. 1D, 2D.
<TABLE ROW
Fuel System (Aux.)
Fuel System
140 litres (31.0 UK gal)
Diesel Oil ( K Types of Fuel ( T 3-37))
K Types of Fuel ( T 3-37)
ASTM D975-66T Nos. 1D, 2D.
<TABLE ROW
Grease Points
Grease Points
JCB HP Grease
If JCB Special MPL Grease is used for normal greasing, all 100 hour greasing operations must be carried out at TEN (10) HOUR intervals.
Lithium based
<TABLE ROW
Autolube System (if fitted)
JCB MPL EP Grease
Lithium based
Biodegradeable Hydraulic Fluid is a factory option ONLY. Replenish with JCB Biodegradeable Multigrade Hydraulic fluid. For further information, contact Wheeled Loader Technical Service.
Seat Belt
Seat Belt
Checking the Seat Belt Condition and Security
Checking the Seat Belt Condition and Security
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.
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.
Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.
Check that the belt mounting bolts are undamaged, correctly fitted and tightened.
Articulation Lock
Articulation Lock
Installing the Articulation Lock
Installing the Articulation Lock
The articulation lock is stowed in the machine’s tool box. The articulation lock is fitted, as illustrated, with the machine in the ‘straight ahead’ position.
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
The articulation lock is stowed in the machine’s tool box. The articulation lock is fitted, as illustrated, with the machine in the ‘straight ahead’ position.
1 Steer the machine to bring the front and rear wheel in a straight line.
1 Steer the machine to bring the front and rear wheel in a straight line.
2 Apply the park brake, put the transmission in neutral and stop the engine.
3 Remove the articulation lock bar
C
4 Position the articulation lock bar. Fit pins
A
B
A
B
<GRAPHIC
<GRAPHIC
Fig 1.
Removing the Articulation Lock
Removing the Articulation Lock
1 Remove locking pins
Always make sure the articulation safety lock has been removed before attempting to drive the machine. The machine cannot be steered with the articulation lock fitted.
1 Remove locking pins
1 Remove locking pins
A
B
2 Stow locking bar
C
Loader Arm Safety Strut
Loader Arm Safety Strut
Installing the Safety Strut
Installing the Safety Strut
1 Empty the bucket and raise the loader arm enough to fit the safety strut
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
1 Empty the bucket and raise the loader arm enough to fit the safety strut
You could be killed or seriously injured if the loader control is accidentally operated. Make sure that no- one goes near the machine whilst you fit the safety strut.
1 Empty the bucket and raise the loader arm enough to fit the safety strut
1 Empty the bucket and raise the loader arm enough to fit the safety strut
2A
2
2 Apply the parking brake, put the transmission in neutral and stop the engine.
3 Fit the strut:
a Remove the strut from its stowage position.
a Remove the strut from its stowage position.
b Place the strut around the ram.
c Secure the strut into position using strap
2B
2
4 Start the engine.
5 Slowly lower the loader arm onto the safety strut. Stop the movement immediately the weight of the arm is supported by the strut.
Extreme care must be taken when lowering the loader arm onto the safety strut. ‘Feather’ the lever to lower the loader arm slowly.
Removing the Safety Strut
Removing the Safety Strut
1 Make sure the parking brake is on, and that the transmission is in neutral.
You could be killed or injured if the loader control is accidentally operated. Make sure no-one comes near the machine while you remove the safety strut.
1 Make sure the parking brake is on, and that the transmission is in neutral.
1 Make sure the parking brake is on, and that the transmission is in neutral.
2 Raise the loader arm to take the weight off the safety strut
2A
2
3 Remove the strut:
a Release securing strap
a Release securing strap
2B
2
b Remove safety strut.
c Return the safety strut to its stowage position.
<GRAPHIC
<GRAPHIC
Fig 2.
Engine Covers
Engine Covers
Opening the Engine Covers
Opening the Engine Covers
Opening the Engine Covers
Opening the Engine Covers
1 Apply the parking brake, put the transmission in neutral and stop the engine.
Engine
1 Apply the parking brake, put the transmission in neutral and stop the engine.
1 Apply the parking brake, put the transmission in neutral and stop the engine.
2 Pull handle
3D
3
3 Pull handle
3E
3
Closing the Engine Covers
Closing the Engine Covers
1 Pull handle
1 Pull handle
3E
3
2 Make sure the panel is latched.
<GRAPHIC
<GRAPHIC
Fig 3.
Rear Grille
Rear Grille
Opening the Rear Grille
Opening the Rear Grille
1 Apply the parking brake, put the transmission in neutral and stop the engine.
1 Apply the parking brake, put the transmission in neutral and stop the engine.
2 Open the left side engine cover
K Engine Covers ( T 3-16)
A
3 Open the rear grille by pulling the bottom of the grille out and up, the grille will be lifted by the gas struts.
Closing the Rear Grille
Closing the Rear Grille
1 Close the rear grille by pulling the bottom of the grille down against the pressure of the gas struts. Keep a firm hold on the grille.
1 Close the rear grille by pulling the bottom of the grille down against the pressure of the gas struts. Keep a firm hold on the grille.
2 Make sure the rear grille is latched. Close and lock the engine cover.
<GRAPHIC
<GRAPHIC
Fig 4.
Heater Door
Heater Door
Opening the Heater Door
Opening the Heater Door
1 Apply the parking brake, put the transmission in neutral and stop the engine.
1 Apply the parking brake, put the transmission in neutral and stop the engine.
2 Unlock and press catch
A
Closing the Heater Door
Closing the Heater Door
1 Close the heater door by pushing on the area surrounding the catch.
1 Close the heater door by pushing on the area surrounding the catch.
2 Make sure the heater door is latched. It is recommended that the door is kept locked.
<GRAPHIC
<GRAPHIC
Fig 5.
Greasing
Greasing
For interval
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.
For interval
K Service Schedules ( T 3-5)
The machine must be greased regularly to keep it working efficiently. Regular greasing will also increase the machine’s working life.
Grease should be applied with a grease gun, normally two strokes of the gun should be sufficient. Stop the greasing procedure when fresh grease appears at the joint. Use the recommended grease,
K Lubricants and Capacities ( T 3-12)
In the following illustrations, the grease points are numbered. Count off the grease points as you apply grease to each one. Refit the dust caps after greasing.
In arduous conditions the shovel pivot pins should be greased at least every ten (10) hours.
Shovel Pivot Pins (HT)
Shovel Pivot Pins (HT)
Total of 6 grease points. (
1
6
Loader Arm Pivot Points (HT)
Loader Arm Pivot Points (HT)
Total of 18 grease points (
7
24
<GRAPHIC
<GRAPHIC
Fig 6.
Centre Pivot
Centre Pivot
Total of 3 grease points
<GRAPHIC
<GRAPHIC
Fig 7.
Rear Axle Pivots
Rear Axle Pivots
Total of 2 grease points (
4
5
Steer Rams
Steer Rams
Total of 4 grease points (
6
9
<GRAPHIC
<GRAPHIC
Fig 8.
Propshafts
Propshafts
Total of 7 grease points
<GRAPHIC
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.
<GRAPHIC
<GRAPHIC
Fig 9.
Cab Door Hinges
Cab Door Hinges
When greasing the cab door hinges, open the door and stand as shown.
<GRAPHIC
<GRAPHIC
Fig 10.
Automatic Greasing System
Automatic Greasing System
When the ignition is ON, the greasing system performs all operations automatically.
Grease Points
Grease Points
The following points are greased by the automatic system (when fitted):
1 Shovel Pivot Pins
1 Shovel Pivot Pins
2 Loader Arm Pivot Points
3 Centre Pivot and Steering Rams
All other grease points must continue to be greased as per the Service Schedules
Filling the Reservoir
Filling the Reservoir
It is essential that the correct grease is used in this system.
1 Remove the dust cap from the filler coupling
1 Remove the dust cap from the filler coupling
A
2 Carefully clean the area around the filler coupling and the coupling on the filler hose.
3 Attach the filler hose to the coupling
A
4 Fill the reservoir
C
D
5 Remove the filler hose, clean the coupling and refit the dust cap.
Any air introduced during filling will exit via the reservoir vent. If large amounts of air are present, carry out a continuous greasing cycle for one minute.
<GRAPHIC
<GRAPHIC
Fig 11.
Testing the System
Testing the System
In order to test the correct operation of the system, carry out a single greasing cycle.
Single Greasing Cycle
Single Greasing Cycle
1 Turn starter switch to IGN.
1 Turn starter switch to IGN.
2 Press test button
B
3 The system will perform a single cycle test.
In order to prime the system after cleaning the machine or to vent the system; a continuous should be carried out.
Continouous Greasing Cycle
Continouous Greasing Cycle
1 Turn starter switch to IGN.
1 Turn starter switch to IGN.
2 Press test button
B
3 The system will perform a continuous cycle run.
The continuous greasing cycle will continue to run until the starter switch is turned to OFF.
Replacing the Fill Point Filter
Replacing the Fill Point Filter
1 Clean the area around the filler coupling
1 Clean the area around the filler coupling
A
2 Remove the filler coupling
A
F
3 Loosen locknut
E
4 Remove filter
F
Grease may flow from the housing
G
<GRAPHIC
<GRAPHIC
Fig 12.
5 Screw the new filter into the filter housing, hand-tight only, until the O ring contacts the filter housing
Pressurised grease may flow from the filter housing as the filter is loosened.
5 Screw the new filter into the filter housing, hand-tight only, until the O ring contacts the filter housing
5 Screw the new filter into the filter housing, hand-tight only, until the O ring contacts the filter housing
G
6 Tighten locknut
E
7 Refit the filler coupling.
System Display Unit
System Display Unit
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Indication
Description
<TABLE BODY
<TABLE ROW
A
A
Yellow Lamp
Low Level
Reservoir requires replenishing.
<TABLE ROW
B
B
Red Lamp
Error
System not operating due to insufficient grease.
<TABLE ROW
C
C
Green Lamp
Light Duty Greasing Mode
Long interval between grease cycles.
<TABLE ROW
D
D
Green Lamp
Normal Duty Greasing Mode
Standard interval between grease cycles.
<TABLE ROW
E
E
Green Lamp
Heavy Duty Greasing Cycle
Short interval between grease cycles.
<TABLE ROW
F
F
Greasing Mode Selection Switch

Press the mode switch repeatedly until the desired mode lamp (C, D or E) illuminates.
<GRAPHIC
<GRAPHIC
Fig 13.
Electrical System
Electrical System
Battery
Battery
Before commencing work on the battery you must read
Section c – Electrics – Service Procedures.
Checking the Electrolyte Level
Checking the Electrolyte Level
Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditi…
1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.
Do not disconnect the alternator, the battery, or any part of the charging circuit with the engine running.
1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.
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.
1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.
1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.
2 Remove the battery cell covers and check the electrolyte level in each cell. The electrolyte should be 6 mm (0.25 in) above the plates.
3 Top-up if necessary with distilled water or de-ionised water.
Do not top the battery up with acid. The electrolyte could boil out and burn you.
3 Top-up if necessary with distilled water or de-ionised water.
4 Check the Connections. Make sure that the terminals are tight and clean. Coat them with petroleum jelly to prevent corrosion.
<GRAPHIC
<GRAPHIC
Fig 14.
Jump Starting The Engine
Jump Starting The Engine
1 The parking brake should have been engaged when the machine was last parked. If it is not engaged, engage it now.
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.
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.
1 The parking brake should have been engaged when the machine was last parked. If it is not engaged, engage it now.
1 The parking brake should have been engaged when the machine was last parked. If it is not engaged, engage it now.
2 Set all switches in the cab to off.
3 Lower the shovel to the ground, if it is not already there. It will lower itself under its own weight when you operate the lev…
Before lowering the attachments to the ground, make sure that the machine and the area around it are clear of other people. Anyone on or close to the machine could fall and be crushed by the attachments, or get caught in the linkages.
3 Lower the shovel to the ground, if it is not already there. It will lower itself under its own weight when you operate the lev…
4 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.
5 Connect the negative (-) booster cable to a suitable point on the engine. Connect the other end of this cable to the negative (-) terminal of the booster supply.
6 Start the engine.
7 Disconnect the negative booster cable from the engine. Then disconnect it from the booster supply.
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.
7 Disconnect the negative booster cable from the engine. Then disconnect it from the booster supply.
8 Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.
Fuses and Relays
Fuses and Relays
For fuse, primary fuse and relay information please refer to
Section C – Electrics – Technical Data.
Engine
Engine
Checking the Oil Level
Checking the Oil Level
1 Park the machine on level ground and lower the attachments to the ground.
Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.
1 Park the machine on level ground and lower the attachments to the ground.
1 Park the machine on level ground and lower the attachments to the ground.
2 Stop the engine. Put the transmission in neutral and remove the starter key.
3 Open the right side engine cover.
4 Check that the oil level is between the two marks on the dipstick
15A
15
5 If necessary, add the recommended oil through the filler point
15B
15
K Lubricants and Capacities ( T 3-12)
6 Make sure the filler cap and the dipstick are secure. Close and lock the engine cover.
<GRAPHIC
<GRAPHIC
Fig 15.
Changing the Oil and Filter
Changing the Oil and Filter
1 Park the machine on level ground and lower the attachments to the ground.
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.
1 Park the machine on level ground and lower the attachments to the ground.
Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.
1 Park the machine on level ground and lower the attachments to the ground.
1 Park the machine on level ground and lower the attachments to the ground.
2 Stop the engine. Put the transmission in neutral and remove the starter key.
3 Open the left side engine cover.
4 Place a suitable container beneath the drain plug (to catch the oil).
5 Remove the self-sealing drain plug outer threaded cover
16A
16
6 Fit the self-sealing drain kit threaded union (with attached drain pipe) and drain the sump oil.
7 Remove the self-seal drain kit, clean and refit the outer cover. (Do not over tighten the cover.)
8 Clean the area around the filter head. Unscrew the filter canister
18C
18
9 Clean filter head
18D
18
<GRAPHIC
<GRAPHIC
Fig 16.
10 Add clean engine oil to the new filter canister. Allow time for the oil to pass through the filter element.
11 Smear the seal
18E
18
12 Screw in the new filter canister until it just contacts the filter head.
13 Turn the filter a further 3/4 of a turn.
14 Fill the engine with the recommended oil, to the
MAX
15 Make sure the engine will not start and turn the engine using the starter key until the oil pressure warning light is extinguished.
To make sure the engine will not start, remove the engine shut-off solenoid fuse (see
Section C – Electrics
16 Refit the engine shut-off solenoid fuse and start the engine. Check for leaks. When the engine has cooled, check the oil level.
<GRAPHIC
<GRAPHIC
Fig 17.
<GRAPHIC
<GRAPHIC
Fig 18.
Air Filter
Air Filter
Changing the Elements
Changing the Elements
In a dusty working environment, the outer element may have to be renewed more frequently than the service schedule recommendatio…
1 Apply the park brake, put the transmission in neutral and stop the engine.
The outer element must be renewed immediately if the warning light on the instrument panel illuminates.
1 Apply the park brake, put the transmission in neutral and stop the engine.
Do not run the engine when the outer element has been removed.
1 Apply the park brake, put the transmission in neutral and stop the engine.
1 Apply the park brake, put the transmission in neutral and stop the engine.
2 Open the engine cover on the right side of the machine.
3 If changing the inner element, disconnect the filter induction hose
19J
19
4 Release latches
19A
19
19
19
B
19C
19
19D
19
5 Clean inside canister
19E
19
19F
19
6 Check the new elements before fitting, discard if damaged. Smear the seals
19G
19
19H
19
7 Refit cover
19B
19
19A
19
19F
19
8 Connect the induction hose
19J
19
<GRAPHIC
<GRAPHIC
Fig 19.
Cooling System
Cooling System
Coolant Mixtures
The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before checking the coolant level or checking the system.
Coolant Mixtures
Coolant Mixtures
To prevent the coolant freezing in cold conditions, antifreeze must be added. JCB Universal Antifreeze will give protection down to the temperatures shown in the table.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Antifreeze Solution
Starts to freeze at
<TABLE BODY
<TABLE ROW
55%
-36˚C (-33˚F)
Never use less than 50% solution otherwise there will not be enough corrosion protection.
Never use more than 60% solution otherwise the cooling system may be damaged.
Leave the antifreeze in all the year round as it gives protection against corrosion.
Check the strength of antifreeze solution at least once a year, preferably at the start of the cold period. Always renew the antifreeze every two years.
A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant’s boiling point.
Anti-Corrosion Additives
Antifreeze can be harmful. Obey the manufacturer’s instructions when handling full strength or diluted antifreeze.
Anti-Corrosion Additives
Anti-Corrosion Additives
To provide sufficient corrosion protection, supplemental coolant additive (SCA) must be added to the coolant mixture. The coolant filter provides the required amount of SCA, provided the filter is replaced at regular intervals.
Checking the Coolant Level
Checking the Coolant Level
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Stop the engine and let it cool down. Open the rightside engine cover.
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Stop the engine and let it cool down. Open the rightside engine cover.
2 Check that the coolant is visible in the header tank
20A.
20
3
5
3 Close the engine cover. Top up the coolant system through the filler cap. Access to the filler cap is through a hole in the engine cover above the filler cap.
4 Refit the filler cap and make sure it is tight.
5 Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and check for leaks.
<GRAPHIC
<GRAPHIC
Fig 20.
Draining and Refilling the Coolant
Draining and Refilling the Coolant
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Stop the engine and let it cool down. Open the leftside engine cover.
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Stop the engine and let it cool down. Open the leftside engine cover.
2 Access to the filler cap is through a hole in the engine cover above the filler cap. Carefully loosen cap. Let any pressure escape. Remove the cap.
Hot Coolant
The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the syst…
2 Access to the filler cap is through a hole in the engine cover above the filler cap. Carefully loosen cap. Let any pressure escape. Remove the cap.
3 Remove drain plug from the radiator drain extension and drain the coolant.
Keep your face away from the drain hole when removing the drain plug.
3 Remove drain plug from the radiator drain extension and drain the coolant.
4 Flush the system using clean water.
5 Refit drain plug.
6 Prepare a mixture of water and sodium carbonate.
Use 1.0 lb (0.5 kg) of sodium carbonate for every 23 litre (5.0 UKGal).
7 Fill the system slowly with the mixture to prevent air locks. Wait 2 to 3 minutes to allow air to be vented and top up the header tank to 1/3 full.
Do not
8 Run the engine for 5 minutes at the normal running temperature. Stop the engine and allow to cool.
9 Drain the cooling system, checking that the coolant is not dirty. If it is, repeat the flushing process (steps
6
9
10 Refill the system as described at step
7
K Coolant Mixtures ( T 3-33)
A 50% antifreeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant’s boiling point.
11 Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and check for leaks.
Make sure the heater control is in the hot position before running the engine. This will ensure that the coolant mixture circulates through the entire cooling system.
Engine Drive Belt
Engine Drive Belt
Checking the Engine Drive Belt
Checking the Engine Drive Belt
Tension and Condition
Tension and Condition
1 Park the machine on level ground.
Make sure the engine cannot be started. Disconnect the battery before doing this job.
1 Park the machine on level ground.
1 Park the machine on level ground.
2 Apply the park brake, put the transmission in neutral and stop the engine.
3 Open the engine cover.
4 Inspect the belt for the damage as follows:-
a Cracks across the belt width
a Cracks across the belt width
A
b Cracks across the belt which intersect those in the direction of the belt length
B
c Renew the belt if it has unacceptable cracks or if it is frayed or has pieces of material missing as at
C
5 Check the belt tension. The maximum deflection on the longest run of the belt as at
D
6 Close and `latch’ the engine cover.
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Fig 21.
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Fig 22.
Fuel System
Fuel System
Types of Fuel
Types of Fuel
Use good quality diesel fuel to get the correct power and performance from your engine.
Recommended Fuel Specification
Recommended Fuel Specification
– EN590 Diesel Fuel Types – Auto/Co/C1/C2/C3/C4.
– EN590 Diesel Fuel Types – Auto/Co/C1/C2/C3/C4.
– BS2869 Class A2.
– ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA.
– JIS K2204 (1992) Grades 1, 2, 3, and Special Grade 3.
Where low sulphur/low aromatic fuels are used it is important that lubricity additives are used. The additives listed below are …
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 – 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels.
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 – 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels.
2 Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm.
3 Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%).
Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of.
Acceptable Fuel Specification
Acceptable Fuel Specification
– ASTM D975-91 Class 1-1DA.
The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also affect the engine performance.
– ASTM D975-91 Class 1-1DA.
– ASTM D975-91 Class 1-1DA.
– JP7, MIL T38219 XF63.
– NATO F63.
Sulphur Content
Sulphur Content
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.
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.
High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently.
Table 16.
Table 16.
<TABLE
<TABLE HEADING
<TABLE ROW
Percentage of sulphur in the fuel (%)
Oil Change Interval
<TABLE BODY
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Less than 0.5
Normal
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0.5 to 1.0
0.75 of normal
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More than 1.0
0.50 of normal
Aviation Kerosene Fuels
Aviation Kerosene Fuels
Aviation kerosene fuels are not approved and their use may cause damage to components. Warranty will not be allowed on any component where damage is found to have been caused by the use of aviation kerosene.
Low Temperature Fuels
Low Temperature Fuels
Special winter fuels may be available for engine operation at temperatures below 0˚C (32˚F). These fuels have a lower viscosity….
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Fuel resources such as Rape Methyl Ester and Soybean Methyl ester, collectively known as Fatty Acid Methyl Esters are being used as alternatives and extenders for mineral oil.
Fatty Acid Methyl Esters must conform to certain standards to be of acceptable quality, just as mineral oils do at present.
Consult your JCB distributor for advice about the use of Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.
Petrol
Petrol
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.
Filling the Tank
Filling the Tank
At the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel.
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.
At the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel.
We recommend that, if possible, you lock the fuel cap to prevent theft and tampering.
Draining the Fuel Filter
Draining the Fuel Filter
1 Apply the parking brake, put the transmission in neutral and stop the engine.
1 Apply the parking brake, put the transmission in neutral and stop the engine.
2 Open the right side engine cover.
3 Drain off any water in the bowl
25B
25
25A
25
4 Push up valve and turn clockwise until closed. Do not over tighten.
5 Close and lock the engine cover.
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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.
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Fig 23.
Changing the Suction Side Fuel Filter Element
Changing the Suction Side Fuel Filter Element
1 Apply the park brake, put the transmission in neutral and stop the engine.
1 Apply the park brake, put the transmission in neutral and stop the engine.
2 Open the engine cover.
3 Disconnect the `Water in Fuel’ sensor connector
C
4 Unscrew the filter element
A
5 To assist with priming, fill the filter element with fuel before fitting. Install filter element, hand tight only. Check for leaks.
6 Reconnect connector(s) mentioned in step 3.
7 Close and lock the engine cover.
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Fig 24.
Changing the Pressure Side Fuel Filter Element
Changing the Pressure Side Fuel Filter Element
1 Apply the park brake, put the transmission in neutral and stop the engine.
1 Apply the park brake, put the transmission in neutral and stop the engine.
2 Open the engine cover.
3 Unscrew the filter element
B
4 DO NOT fill the filter element with fuel before fitting. Install filter element, hand tight only.
5 Close and lock the engine cover.
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Fig 25.
This engine fuel system is self-priming, do not attempt to bleed the fuel system manually.
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.
Priming the Fuel System
Priming the Fuel System
Priming the fuel system is required only after changing the fuel filter elements:
1 Apply the park brake, put the transmission in neutral and stop the engine.
1 Apply the park brake, put the transmission in neutral and stop the engine.
2 Make sure that there is enough fuel in the fuel tank.
3 Release priming handle
A
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Fig 26.
4 Pump priming handle until pressure has built up in the system.
5 Lock priming handle
A
6 Start the engine. Slowly increase the engine speed while any remaining air is vented from the system.
Hydraulic System
Hydraulic System
Checking the Fluid Level
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 prot…
Checking the Fluid Level
Checking the Fluid Level
1 Apply the parking brake, put the transmission in neutral, lower the shovel/attachment to the ground. Make sure it is flat on the ground. Stop the engine.
1 Apply the parking brake, put the transmission in neutral, lower the shovel/attachment to the ground. Make sure it is flat on the ground. Stop the engine.
2 The level should be visible in the sight glass
27A
27
3 If necessary, top up with hydraulic fluid.
4 Open the right side engine cover. Open filler cap
28B
28
5 Top up the system with hydraulic fluid,
K Lubricants and Capacities ( T 3-12)
6 Refit filler cap
28B
28
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Fig 27.
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If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately.
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Fig 28.
Changing the Filter Element
Changing the Filter Element
1 Open the right side top step.
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.
1 Open the right side top step.
1 Open the right side top step.
2 Remove hydraulic tank cap.
3 Unscrew and remove nuts
29C
29
29D
29
29E
29
4 Pull out the complete element assembly
29F
29
5 Remove the nut and spring
29K
29
29L
29
29J
29
6 Fit the new element
29L
29
29G
29
29H
29
7 Replace the cover plate
29D
29
29C
29
8 Top up the system with hydraulic fluid,
K Lubricants and Capacities ( T 3-12)
9 Refit filler cap. Make sure it is secure. Close the right side top step.
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Fig 29.
Transmission
Transmission
Checking the Oil Level (Engine Running)
Checking the Oil Level (Engine Running)
The transmission oil level should be checked only when the oil is at the correct working temperature.
1 Park the machine on level ground.
1 Park the machine on level ground.
2 Apply the parking brake, put the transmission in neutral.
3 Open the left side engine cover. Remove, wipe and replace the dipstick
The procedure below must be carried out with the engine running. Apply the park brake, block the wheels and ensure that no-one enters the cab.
3 Open the left side engine cover. Remove, wipe and replace the dipstick
30A
30
Turn `T’ handle
30D
30
30D
30
4 Make sure the oil is at the correct mark on the dipstick.
5 If necessary, add recommended oil at dipstick/filler point
30A
30
The transmission may overheat if the oil level is above the HOT mark.
6 Close and lock the engine cover.
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Fig 30.
Changing the Oil and Filter
Changing the Oil and Filter
1 Place a suitable container beneath the transmission (to catch the oil).
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.
1 Place a suitable container beneath the transmission (to catch the oil).
1 Place a suitable container beneath the transmission (to catch the oil).
2 Remove the dipstick
30A
30
31B
31
3 Drain the oil. Clean and refit drain plug
31B
31
4 Unscrew and discard old filter
31C
31
5 Fit the new filter
31C
31
6 Fill the system with new oil at dipstick/filler point /
30A
30
Do not fill past the top mark on the dipstick.
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Fig 31.
Front and Rear Axles
Front and Rear Axles
Checking the Differential Oil Level
Checking the Differential Oil Level
1 Clean the area around fill/level plug
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.
1 Clean the area around fill/level plug
The axle oil level must be checked with the machine level, otherwise a false indication of the amount of oil in the axle will be given.
1 Clean the area around fill/level plug
1 Clean the area around fill/level plug
32A
32
2 Remove fill/level plug
32A
32
3 Top up with the recommended oil if necessary.
4 Clean and refit fill/level plug
32A
32
The 436 axle is shown, the 426 axle filler plug is at the opposite side.
Draining and Refilling the Differential Oil
Draining and Refilling the Differential Oil
1 Clean the area around fill/level plug
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.
1 Clean the area around fill/level plug
1 Clean the area around fill/level plug
32A
32
2 Remove fill/level plug
32A
32
3 Place a suitable container beneath the drain plug
32B
32
4 Remove drain plug
32B
32
5 Clean and refit drain plug
Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.
5 Clean and refit drain plug
32B
32
32B
32
6 Fill the axle with the recommended oil through fill/ level plug
32A
32
7 Clean and refit fill/level plug
32A
32
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Fig 32.
Checking the Hub Oil Level
Checking the Hub Oil Level
1 Make sure the
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.
1 Make sure the
1 Make sure the
OIL LEVEL
33B
33
2 Clean the area around fill/drain plug
33A
33
3 Remove fill/drain plug
33A
33
4 Top up with the recommended oil if necessary.
5 Clean and refit fill/drain plug
33A
33
The hubs must be treated separately, a total of four hubs.
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Fig 33.
Draining and Refilling the Hub Oil
Draining and Refilling the Hub Oil
1 Make sure both fill/drain plug
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.
1 Make sure both fill/drain plug
1 Make sure both fill/drain plug
33A
33
33C
33
2 Clean the area around fill/drain plug
33A
33
3 Remove fill/drain plug
33A
33
4 Drive the machine slowly forward to bring the
There will be no oil in the hub when the machine is driven forward. Only drive the machine forward one quarter revolution of the wheel. Do not drive the machine more than is necessary.
4 Drive the machine slowly forward to bring the
OIL LEVEL
33B
33
5 Fill the hub with the recommended oil through fill/ drain plug
33A
33
6 Clean and refit fill/drain plug
33A
33
The hubs must be treated separately, a total of four hubs.
Cab Heater Filters
Cab Heater Filters
Cleaning the Intake Filter
Cleaning the Intake Filter
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Lower the attachments to the ground. Stop the engine. Remove the starter key.
The filter may be filled with dust. Wear goggles and a face mask when removing the filter.
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Lower the attachments to the ground. Stop the engine. Remove the starter key.
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Lower the attachments to the ground. Stop the engine. Remove the starter key.
2 To gain access to the cab heater air filter
34A
34
K Opening the Heater Door ( T 3-18)
3 Open fasteners at
34
34
B
34C.
34
4 Remove filter
A
An additional filter
D
A
D
5 Refit filter
A
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Fig 34.
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Fig 35.
Windscreen Washer
Windscreen Washer
Replenishing
Replenishing
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Fig 36.
To gain access to the washer bottle
A
K Opening the Heater Door ( T 3-18)
Fill the windscreen washer bottle with a suitable liquid. The liquid should contain a de-icing fluid to prevent it freezing.
Do not use engine coolant antifreeze
On completion, close and lock the access cover.
Section A – Attachments
Section A
Section A
Attachments
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Section 1 – General Information
Section 1 – General Information
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Section 2 – Care and Safety
Section 2 – Care and Safety
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Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
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Section C – Electrics
Section C – Electrics
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Section E – Hydraulics
Section E – Hydraulics
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Section F – Transmission
Section F – Transmission
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Section G – Brakes
Section G – Brakes
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Section H – Hydraulic Steering
Section H – Hydraulic Steering
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Section K – Engine
Section K – Engine
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Optional Attachments
Optional Attachments
Quick Release Couplings
Quick Release Couplings
Connecting and Disconnecting
Connecting and Disconnecting
Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will have female couplings
A
B
K Fig 1. ( T A-2)
The quick release couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly. The recommendations listed below should always apply when using flat face quick release couplings.
Finally, please read the correct fitting and releasing procedures before installing or removing any optional attachment fitted with quick release couplings.
Quick Release Couplings – Do’s and Don’ts
Quick Release Couplings – Do’s and Don’ts
– Do wipe the two faces of the coupling and make sure they are clean before connecting.
– Do wipe the two faces of the coupling and make sure they are clean before connecting.
– Do make sure the outside sleeve (female coupling) is pulled back when disconnecting.
– Do connect and disconnect a new coupling two or three times to ‘work’ the PTFE seals – sometimes a new coupling will stick if the seals have not been ‘worked’.
– Do use a spanner on the hexagon flats of the coupling when fitting adaptors.
– Do use a rubber or hide hammer to disconnect a coupling if it sticks – sticking may occur if there is dirt present in the coupling.
– Don’t attempt to re-connect a damaged half coupling – this will destroy the seals and necessitate replacing both half couplings.
– Don’t leave the coupling where it may be run over by a machine or otherwise crushed – this will distort the coupling sleeve and prevent correct connection and disconnection.
– Don’t clamp on the smooth diameter of the coupling when fitting adaptors – always use the hexagon.
– Don’t try to turn the sleeve (female coupling) when the coupling has been disconnected – the locking ball will wedge underneath the sleeve and destroy the coupling.
– Don’t damage the faces of the couplings – this can prevent connection and disconnection, or damage seals and cause leakage.
– Don’t try to dismantle the couplings – they are non serviceable parts. If a coupling is damaged it should be replaced with a new one.
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.
Hydraulic fluid at pressure can injure you. Make the machine safe before connecting or disconnecting quick release couplings; stop the engine and then operate the attachment control a few times to vent residual hydraulic pressure in the attachment hoses
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.
The external surfaces of the couplings must be clean before connecting or disconnecting. Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or seriously injured by faulty Quick Release Couplings.
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.
Connecting Quick Release Couplings
Connecting Quick Release Couplings
1 Remove any residual hydraulic pressure trapped in the service line hose.
1 Remove any residual hydraulic pressure trapped in the service line hose.
2 Wipe the two faces of the male and female couplings and make sure they are clean.
3 Make sure that ball
1-C
1
4 Fit the male coupling into the female coupling; To ensure that the coupling is not accidentally released, rotate sleeve
1-E
1
1-C
1
1-D
1
Disconnecting Quick Release Couplings
Disconnecting Quick Release Couplings
1 Remove any residual hydraulic pressure trapped in the service line hose.
1 Remove any residual hydraulic pressure trapped in the service line hose.
2 Align the slot
1-D
1
1-C
1
3 Pull back sleeve
1-E
1
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Fig 1.
Section B – Body and Framework
Section B
Section B
Body and Framework
<TABLE
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<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
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Section G – Brakes
Section G – Brakes
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Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
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Technical Data
Technical Data
Air Conditioning Option
Air Conditioning Option
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Binary Switch Settings
Binary Switch Settings
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Low pressure
2.05 bar (29.8 lbf/ in. 2.1Kg/cm)
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High pressure
23.5 bar (341 lbf/ in, 24Kg/cm)
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Thermostatic Switch Settings
Thermostatic Switch Settings
<TABLE ROW
Cut out
32.0˚F to 34.0˚F (0˚C to 1.1˚C)
<TABLE ROW
Cut in
44.0˚F to 46.0˚F (6.6˚C to 7.7˚C)
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Refrigerant
Refrigerant
<TABLE ROW
1.3 Kg of R134a Gas
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Oil
Oil
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Type
Pag oil
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Quantities:
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– Recharge the system
1.5 fluid oz. (42.6 millilitres)
<TABLE ROW
– Condenser replacement
2.0 fluid oz (56.8 millilitres)
<TABLE ROW
– Evaporator replacement
3.0 fluid oz. (85.2 millilitres)
<TABLE ROW
– Hoses replacement
2 to 4 fluid oz. (56.8 to 113.6 millilitres)
<TABLE ROW
– Receiver Drier replacement
2.0 fluid oz. (56.8 millilitres)
<TABLE ROW
– Compressor replacement
None – pre charged
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Fig 1. Typical Condenser
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Fault Finding
Fault Finding
Air Conditioning
Air Conditioning
Visual Inspection
Make the machine safe before working underneath it. Park the machine on level ground and lower the attachments, (If it is necess…
Visual Inspection
Visual Inspection
The following checks are visual inspection items that can be carried out without the need for specialist equipment or the need to open the air conditioning circuit.
The visual checks are to be carried out without the engine running unless specifically stated.
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
The visual checks are to be carried out without the engine running unless specifically stated.
Condenser
Condenser
The condenser is located at the rear of the machine.
1 Raise the rear grille and engine covers.
1 Raise the rear grille and engine covers.
2 Check that the condenser is free of leaves, debris, mud or built up dirt deposits. The condenser needs to be relatively clean in order to function efficiently as a heat exchanger. If the condenser obviously needs cleaning refer to
K Condenser ( T B-28)
3 While inspecting the condenser, check the hose connections. Condenser failure can be caused by loose hoses. Hose movement can cause a fatigue failure of the condenser tubing adjacent to the fittings. Make sure the hoses are securely clamped.
Receiver Drier
Receiver Drier
The receiver drier is located under the engine cover attached to the radiator cowl
1 Clean the sight glass on the top housing of the receiver drier.
1 Clean the sight glass on the top housing of the receiver drier.
2 Check the sight glass, in a normal operating system the sight glass should be clear. (See
K Sight Glass Indications ( T B-5)
3 Check the hose connections to the receiver drier for signs of cracks or wear due to being insecurely clamped. Any suspect hoses should be noted and rectified
only
K Service Procedures ( T B-17)
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
Compressor and Drive Belt
Compressor and Drive Belt
The compressor is mounted to a bracket secured to the engine.
1 Check that the compressor is securely mounted to the its bracket and that the bracket is securely mounted to the engine.
1 Check that the compressor is securely mounted to the its bracket and that the bracket is securely mounted to the engine.
2 Check that the compressor clutch assembly and drive pulley are secure.
3 Check that the drive belt is in good condition. The belt should not show signs of excessive wear or be frayed and should be co…
Section 3 – Routine Maintenance – Belt Adjustment
4 Check the belt run between the compressor clutch pulley and the belts engine drive pulley. The belt run should form a straight line parallel to the engine timing cover.
Hoses and Fittings
Hoses and Fittings
1 Check all visible hoses and fitting. Look for places where the hoses flex or are fastened, clamped, connected, bent or pass through panels. All these places are potential wear and damage points. Any suspect hoses should be noted and rectified
1 Check all visible hoses and fitting. Look for places where the hoses flex or are fastened, clamped, connected, bent or pass through panels. All these places are potential wear and damage points. Any suspect hoses should be noted and rectified
only
K Service Procedures ( T B-17)
2 For any hoses that may appear to require tightening See
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
2 For any hoses that may appear to require tightening See
K Tightening Leaking Hoses ( T B-20)
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 pre…
General Fault Indications
General Fault Indications
There are several indications that may help to determine the fault area on a system not working efficiently:
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a)
Poor performance.
Low system pressure –
Evacuate and recharge system.
<TABLE ROW
Condenser matrix air flow restricted –
Remove debris from around matrix using compressed air or low pressure water.
<TABLE ROW
Air filter blocked –
Remove and replace.
<TABLE ROW
Compressor drive belt too slack –
Adjust to correct tension.
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b)
Warm or slightly cool air emitted from unit.
Expansion valve stuck open or closed –
Renew expansion valve.
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c)
Blower operates on fan speed 3 only.
Blower resistor failed –
Renew resistor.
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Blower motor failed –
Renew complete blower unit.
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Blower does not operate.
Fuse blown –
Replace fuse and retest.
<TABLE ROW
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d)
Compressor clutch continually cuts out.
Condenser matrix blockage –
Remove debris from around matrix/renew condenser.
<TABLE ROW
Overcharging of refrigerant system –
Evacuate and recharge system.
<TABLE ROW
Blocked expansion valve/condenser –
Clear blocked component.
Sight Glass Indications
Sight Glass Indications
An approximate indication of the condition of the refrigerant can be seen through the receiver/drier sight glass when the compressor is running. Refer also to
K Checking Refrigerant Charge Level ( T B-19)
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Clear – No fault indicated unless the system is unable to provide cool air. The indication then is that the system is completely discharged of refrigerant.
<TABLE ROW
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Foam or bubbles – Refrigerant low and in need of charging. (Some slight bubbling is to be expected when R134a refrigerant is used.)
<TABLE ROW
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Clouded – Desiccant breakdown in the receiver-drier.
Sight glass indications cannot always give a positive identification of a problem. Further diagnosis, preferably by a refrigeration engineer using pressure gauges, is advisable before reaching a definite conclusion.
No Air Conditioning
No Air Conditioning
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on?
YES:
Check 2
<TABLE ROW
NO:
Reset controls and retest.
<TABLE ROW
2
Is the air conditioning (evaporator) blower working?
YES:
Check 3.
<TABLE ROW
NO:
Check 4.
<TABLE ROW
3
Is the compressor running (visual check of pulley/ clutch)?
YES:
Check 9.
<TABLE ROW
NO:
Check 5.
<TABLE ROW
4
Is the air conditioning fuse(s) blown?
YES:
Renew fuse(s) and retest.
<TABLE ROW
NO:
Check 8.
<TABLE ROW
5
Is there a 12V supply to the pressure switch harness?
YES:
Check 6.
<TABLE ROW
Refer to K Pressure Switch Assembly (Two Switch System) ( T B-26)
K Pressure Switch Assembly (Two Switch System) ( T B-26)
NO:
Check 7.
<TABLE ROW
6
Does the compressor clutch engage with pressure switch assembly bypassed?
YES:
Replace pressure switch assembly.
<TABLE ROW
Refer to K Pressure Switch Assembly (Two Switch System) ( T B-26)
K Pressure Switch Assembly (Two Switch System) ( T B-26)
NO:
Renew the compressor clutch and retest.
<TABLE ROW
7
Does the clutch engage with thermostat switch bypassed?
YES:
Renew thermostat switch and retest.
<TABLE ROW
NO:
Check all electrical connections.
<TABLE ROW
8
Are blower switch and wiring OK?
YES:
Renew blower unit complete.
<TABLE ROW
NO:
Renew switch or wiring.
<TABLE ROW
9
Is sight glass indication OK?
YES:
Check 10.
<TABLE ROW
NO:
Charge check required by refrigeration engineer or suitably trained person.
<TABLE ROW
10
Is condenser air flow blocked?
YES:
Clean condenser and radiator.
<TABLE ROW
NO:
Check 11.
<TABLE ROW
11
Is evaporator air flow blocked?
YES:
Clean filter and, if necessary the evaporator.
<TABLE ROW
NO:
Call in refrigeration engineer or suitably trained person.
System Diagnosis
System Diagnosis
Normally Functioning A/C System
Normally Functioning A/C System
Gauge Readings:
Gauge Readings:
Low Side Gauge – Normal.
High Side Gauge – Normal.
Other symptoms:
Other symptoms:
Sight Glass – Clear.
Discharge Air – Cold.
Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are closed and the readings are stable and that the system has a full charge.
The pressures on the manifold at 25 ˚C with the engine at 1500 RPM, the blower on maximum and the thermostat set to maximum, should be approximately:
Typically, the high pressure is 6 – 8 times the low pressure.
LOW SIDE – 2.0 bar (2.0 kgf/cm
2
2
HIGH SIDE – 14.8 bar (15.1 kgf/cm
2
2
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Fig 2.
Low R-134a Charge
Low R-134a Charge
Gauge Readings:
Gauge Readings:
Low Side Gauge – Low.
High Side Gauge – Low.
Other symptoms:
Other symptoms:
Sight Glass – Bubbles continuously visible.
Diagnosis:
Diagnosis:
System slightly low on R-134a, due to leak or incorrect charge.
Correction:
Correction:
1 Leak test system.
1 Leak test system.
2 Evacuate A/C system.
3 Repair system leaks.
4 Charge system with R-134a.
5 Operate system and check performance.
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Fig 3.
Poor Refrigerant Circulation
Poor Refrigerant Circulation
Gauge Readings:
Gauge Readings:
Low Side Gauge – Zero to negative.
High Side Gauge – Low.
Other symptoms:
Other symptoms:
Receiver-Drier – Frost on tubes from receiver-drier to evaporator unit.
Diagnosis:
Diagnosis:
Refrigerant flow obstructed by dirt, receiver-drier clogged.
Correction:
Correction:
1 Evacuate A/C system.
1 Evacuate A/C system.
2 Replace receiver-drier.
3 Charge system with R-134a.
4 Operate system and check performance.
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Fig 4.
No Refrigerant Circulation
No Refrigerant Circulation
Gauge Readings:
Gauge Readings:
Low Side Gauge – Zero to negative.
High Side Gauge – Low.
Other symptoms:
Other symptoms:
Receiver-Drier – Frost or moisture on tubes before and after receiver-drier.
Diagnosis:
Diagnosis:
Refrigerant flow obstructed by dirt, moisture or gas leakage from expansion valve heat sensing tube.
Correction:
Correction:
1 Evacuate A/C system.
1 Evacuate A/C system.
2 Check heat sensing tube at expansion valve. Replace expansion valve if necessary.
3 Remove expansion valve and attempt removal of dirt. If dirt cannot be removed, replace expansion valve.
4 Replace receiver-drier.
5 Charge system with R-134a.
6 Operate system and check performance.
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Fig 5.
Insufficient Cooling of Condenser or Refrigerant Overcharge
Insufficient Cooling of Condenser or Refrigerant Overcharge
Gauge Readings:
Gauge Readings:
Low Side Gauge – High.
High Side Gauge – High.
Other symptoms:
Other symptoms:
Sight Glass – No bubbles visible even at lower engine RPM.
Diagnosis:
Diagnosis:
Refrigerant overcharge, condenser cooling fins clogged with dirt or cooling fans malfunctioning.
Correction:
Correction:
1 Clean condenser cooling fins.
1 Clean condenser cooling fins.
2 Check cooling fan operation.
3 Evacuate A/C system.
4 Charge system with R-134a.
5 Operate system and check performance.
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Fig 6.
Air in System
Air in System
Gauge Readings:
Gauge Readings:
Low Side Gauge – High.
High Side Gauge – High.
Other symptoms:
Other symptoms:
Sight Glass – Bubbles visible during system operation.
Pipes – Low pressure pipes are hot to the touch.
Diagnosis:
Diagnosis:
Air is present in the system, possibly from inadequate evacuation procedure.
Correction:
Correction:
1 Evacuate A/C system.
1 Evacuate A/C system.
2 Check compressor oil for contamination. Check compressor for proper oil amount. Correct if necessary.
3 Charge system with R-134a.
4 Operate system and check performance.
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Fig 7.
Expansion Valve Improperly Mounted or Heat Sensing Tube Defective (Opening Too Wide)
Expansion Valve Improperly Mounted or Heat Sensing Tube Defective (Opening Too Wide)
Gauge Readings:
Gauge Readings:
Low Side Gauge – High.
High Side Gauge – High.
Other symptoms:
Other symptoms:
Pipes – Large amount of frost or moisture on low side pipes.
Diagnosis:
Diagnosis:
Excessive refrigerant in low side pipes possibly from expansion valve being opened too wide.
Correction:
Correction:
1 Leak test system.
1 Leak test system.
2 Evacuate A/C system.
3 Repair system leaks.
4 Charge system with R-134a.
5 Operate system and check performance.
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Fig 8.
Compressor Malfunction
Compressor Malfunction
Gauge Readings:
Gauge Readings:
Low Side Gauge – High.
High Side Gauge – Low.
Diagnosis:
Diagnosis:
Internal compressor leak or compressor mechanically broken.
Correction:
Correction:
1 Evacuate A/C system.
1 Evacuate A/C system.
2 Repair or replace compressor.
3 Charge system with R-134a.
4 Operate system and check performance.
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Fig 9.
Some Moisture in the System
Some Moisture in the System
Gauge Readings:
Gauge Readings:
Low Side Gauge – Normal, then sometimes drops to below zero.
High Side Gauge – Normal, then sometimes goes high.
Diagnosis:
Diagnosis:
Moisture in system freezes, temporarily stopping cycle, normal system operation returns when ice melts.
Correction:
Correction:
1 Evacuate A/C system.
1 Evacuate A/C system.
2 Replace receiver-drier.
3 Remove moisture by repeatedly evacuating system.
4 Charge system with R-134a.
5 Operate system and check performance.
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Fig 10.
Service Procedures
Service Procedures
Rivet Nuts
Rivet Nuts
A ‘Rivet Nut’ is a one piece fastener installed ‘blind’ from one side of the machine body/framework. The rivet nut
11- A
11
11-B
11
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Fig 11.
Rivet nuts are fitted to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and hydraulic valve retention etc.
Various sized rivet nuts are available.
K Table 1. Specifications ( T B-17)
If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed.
K Fitting Procedure ( T B-18)
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.
Table 1. Specifications
Table 1. Specifications
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<TABLE HEADING
<TABLE ROW
Rivet Nut Thread Diameter
Rivet Nut Outside Diameter
Material Thickness
Rivet Length (Total)
Drill Hole Dia.
<TABLE BODY
<TABLE ROW
M5
7
0.25 – 3.00
14.00
7.10
<TABLE ROW
3.00 – 5.50
17.00
<TABLE ROW
M6
9
0.50 – 3.00
16.00
9.10
<TABLE ROW
3.00 – 5.50
19.00
<TABLE ROW
M8
11
0.50 – 3.00
18.00
11.10
<TABLE ROW
3.00 – 5.50
21.00
<TABLE ROW
M10
13
1.00 – 3.50
23.00
13.10
<TABLE ROW
3.50 – 6.00
26.00
All dimensions in mm
Fitting Procedure
Fitting Procedure
1 Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.
1 Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.
2 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
12-A
12
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<GRAPHIC
Fig 12.
3 Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut
13-B
13
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<GRAPHIC
Fig 13.
4 Insert the rivet nut (assembled to the tool) into the hole drilled in step
1
5 Hold handle
14-C
14
14-D
14
14-E
14
The thread of the rivet nut must not be stripped, take care when ‘upsetting’ the rivet nut.
<GRAPHIC
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Fig 14.
6 Remove the installation tool.
Air Conditioning
Air Conditioning
Checking Refrigerant Charge Level
Checking Refrigerant Charge Level
The pressure in the system, i.e. the refrigerant charge level can be determined by checking the state of refrigerant at the rece…
If the level of charge is correct the sight glass will be clear. If the charge is low bubbles will be seen. Bubbles may also be …
When
R143a
K Fault Finding ( T B-3)
1 Park the machine on firm, level ground. Lower the loader arms to the ground. Engage the parking brake.
1 Park the machine on firm, level ground. Lower the loader arms to the ground. Engage the parking brake.
2 Chock the wheels, to prevent movement.
3 Raise the right-side engine cover.
4 Start the engine and run at idle. Switch air conditioning ON to circulate refrigerant.
5 Check refrigerant charge level at sight glass
15A
15
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Fig 15.
Leak Testing
Leak Testing
The refrigerant is heavier than air and will leak downwards from the defective component. Check in still conditions but in a well ventilated area.
Leak testing in Air Conditioning systems should be carried out only in a well ventilated area.
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
Tightening Leaking Hoses
The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an ‘O’ ring seal which compresses when the connection is tight, creating an air tight seal.
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
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 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 connect…
Refrigerant Charging and Discharging
Refrigerant Charging and Discharging
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.
Refrigerant Recovery
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
Refrigerant Recovery
Refrigerant Recovery
The recovery process clears the system refrigerant prior to servicing or for refrigerant renewal.
Do not re-use refrigerant unless you are aware of its purity.
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.
1 Ensure that the engine is OFF and the starter key removed.
2 Connect the manifold to the system as shown, with the blue hose
16-A
16
16-B
16
3 Connect the yellow hose
16-C
16
16-D
16
4 Connect the filter
16-D
16
16-E
16
5 Connect the ‘Javac’ unit
16-E
16
16-F
16
Do not fill the receiver bottle to more than 80% by weight.
6 Switch on ‘Javac’ unit
16-E
16
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
16-E
16
8 Close valves and remove equipment.
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Fig 16. Refrigerant Recovery
Evacuating (Vacuuming)
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 the system.
1 Recover all refrigerant from the system.
K Refrigerant Recovery ( T B-21)
2 Close all valves and connect the manifold as shown. Connect the blue hose
17-A
17
17-B
17
3 Connect the yellow hose
17-C
17
17-D
17
If the Electronic Vacuum Gauge
17-E
17
K Electronic Vacuum Gauge ( T B-23)
4 Open manifold valves.
5 Switch on the vacuum pump
17-D
17
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.
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.
<GRAPHIC
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Fig 17. Evacuating
Electronic Vacuum Gauge
Electronic Vacuum Gauge
<GRAPHIC
<GRAPHIC
Fig 18.
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.
The indicator lights show pressure in inches of mercury (Hg) and vacuum in microns (0.001mm Hg).
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ATM/BAT
ATM/BAT
Normal atmospheric pressure reading. Battery condition.
<TABLE ROW
15″/510mbar
15″/510mbar
381mm (15 in)Hg. Partial vacuum – Vacuum system is operating.
<TABLE ROW
29″/980mbar
29″/980mbar
736mm (29 in)Hg. No vacuum drawn – Possible system leakage.
<TABLE ROW
8000
8000
8.0mm (0.31 in)Hg. Partial vacuum – If the reading does not progress the system may have a slow leak.
<TABLE ROW
1000
1000
1.0mm (0.039 in)Hg. Deeper vacuum.
<TABLE ROW
600
600
0.6mm (0.023 in)Hg. Deep vacuum.
<TABLE ROW
400
400
0.4mm (0.015 in)Hg. Deep vacuum.
<TABLE ROW
200
200
0.2mm (0.0078 in)Hg. Deep vacuum.
<TABLE ROW
25
25
0.025mm (0.00098 in)Hg. Pump Test. Maximum sustainable vacuum.
Relubricating
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.
1 Ensure that the engine is OFF and the starter key is removed.
2 Close all valves and connect the manifold as shown, with the blue hose
19-A
19
19-E
19
19-B
19
3 Connect the yellow hose
19-C
19
19-D
19
4 Connect the other end of the oil injector
19-E
19
19-F
19
5 Switch on the vacuum pump
19-D
19
6 Unscrew the oil injector cap and add the specified quantity of refrigerant oil.
7 When 740mm (29 in) mercury shows on the vacuum gauge, open the oil injector valve to allow the oil into the system.
8 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.
Use only PAG oil in R-134a systems.
<GRAPHIC
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Fig 19. Relubricating
Charging
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
1 Close all valves and connect the manifold as shown. Connect the blue hose
20-A
20
20-B
20
20-C
20
20-D
20
2 Invert single valve cylinder on the scales
20-E
20
Some refrigerant cylinders have separate valves for gas and liquid. Be sure to connect to the liquid port when following the above procedure.
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 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
20-E
20
To speed up the process a thermostatically controlled thermal blanket
20-F
20
4 Close all valves and remove the equipment.
<GRAPHIC
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Fig 20. Charging
Pressure Switch Assembly (Two Switch System)
Pressure Switch Assembly (Two Switch System)
The pressure switch assembly comprises a low pressure switch designed to open at approximately 2 bar (30 lbf/in
2
2
When the refrigerant pressure is within the 2 and 24 bar limits the switches will be closed and providing the thermostat and on/…
If the fault finding table indicates that the pressure switch assembly is defective the fault may be electrical or due to incorrect system pressure.
Follow the procedure for checking the refrigerant charge level (
K Checking Refrigerant Charge Level ( T B-19)
Pressure Switch Testing
Pressure Switch Testing
1 Switch the engine off so that the air conditioning system cannot operate.
1 Switch the engine off so that the air conditioning system cannot operate.
2 Disconnect the pressure switch harness, FS, from the side console harness and connect an external 24V power supply between the…
If the compressor clutch does not operate with the external power supply, one of the pressure switches in the assembly is faulty or the level of refrigerant charge is insufficient to close the low pressure switch.
3 Replace the pressure switch assembly. If the clutch still fails to operate check all electrical connections.
Binary Pressure Switch Testing (Single Switch System)
Binary Pressure Switch Testing (Single Switch System)
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.
Before testing the binary pressure switch
21-A
21
1 Switch OFF the engine and remove the harness connectors
1 Switch OFF the engine and remove the harness connectors
21-B
21
21-A
21
<GRAPHIC
<GRAPHIC
Fig 21.
2 Connect a link wire between the two harness connectors (effectively bypassing the pressure switch).
3 Switch on the engine and air conditioning system. If the system operates, one of the switches inside the binary pressure switch assembly is faulty.
4 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
Condenser
Condenser
It is likely that over a period of time, because of the machines working environment, the airflow around the condenser coil 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 coil.
Condenser Coil Cleaning
Condenser Coil Cleaning
Take care not to damage the condenser fins or tubes. Damaged fins must be straightened out to ensure a good air flow through the coil.
The condenser is located at the rear of the machine.
1 Park the machine on firm level ground. Lower the loader arms to the ground.
1 Park the machine on firm level ground. Lower the loader arms to the ground.
2 Remove the stater key.
3 Chock both front and rear wheels
4 Swing out and raise the grille at the rear of the machine.
5 Use compressed air or low pressure water to backflow through the coil fins. Take care not to damage the fins.
6 Run the air conditioning and check cooling performance.
Air Conditioning
Air Conditioning
Air Conditioning Components
Air Conditioning Components
The Air Conditioning Unit
The Air Conditioning Unit
The air conditioning unit (a/c) contains a blower unit; evaporator; heater radiator; filters and thermostat. It is located on the right side of the cab behind a hinged panel.
Unlike the earlier models supplied by this manufacturer, the binary pressure switch is now located on the receiver drier.
Removal
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
Removal
Removal
K Fig 23. ( T B-31)
K Fig 23. ( T B-31)
The removal of the unit will require the assistance of a refrigeration engineer or suitably qualified person since the refrigerant will need to be discharged from the system
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
2 Open the access panel on the right hand side of the machine.
3 Remove the electrical harnesses
1
2
When facing the cabinet, the upper left hand wiring harness connector is for the heater motor, the right hand connector is for the air conducting.
4 Reach under the side of the cab and remove the two air conditioning unit drain hoses from the unit by pulling them from the units welded drain tubes. (Not shown.)
There are no clips fitted to these hoses during production. If the hoses are stretched to a point where they are not a snug push fit they should be replaced when refitting the unit.
5 Allow the engine to cool down. Slowly release the filler cap to release any residual pressure. Refit the cap once the pressure has been released.
The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before checking the coolant level or checking the system.
5 Allow the engine to cool down. Slowly release the filler cap to release any residual pressure. Refit the cap once the pressure has been released.
6 Loosen the coolant hose clips
3
5
7 Release the clips securing the control cables
4
9
8 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
When working on the Air Conditioning System, gloves, eye protection and protective clothing must be worn. Do not smoke or expose refrigerant to naked flames or hot surfaces.
8 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
K Refrigerant Charging and Discharging ( T B-21)
9 With the system fully discharged, disconnect the high and low pressure hoses
6
7
8
10 Remove the seven bolts
22A
22
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Fig 22.
Replacement
Replacement
K Fig 23. ( T B-31).
K Fig 23. ( T B-31)
Replacement is the reverse of the removal procedure, however, note of the following:
1 When refitting the unit care must be taken to ensure the condensation drain hoses are correctly routed. There must be no kinks…
1 When refitting the unit care must be taken to ensure the condensation drain hoses are correctly routed. There must be no kinks…
If the cooling system has been drained, when refilling, do not exceed the maximum fill rate of 10 litres per minute.
2 When refilling the cooling system use the correct water/antifreeze mixture. A 50% mixture should be maintained even if frost protection is not required. Refer to
Section 3 – Routine Maintenance – Coolant Mixtures.
3 The air conditioning system will need to be recharged with refrigerant by a refrigeration engineer or suitably trained and qualified person.
K Refrigerant Charging and Discharging ( T B-21)
<GRAPHIC
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Fig 23.
Filters
Filters
Alongside the paper element filter fitted as standard, an additional filter can be fitted should operating conditions dictate.
K Fig 26. ( T B-34).
K Fig 26. ( T B-34)
Removal
Removal
1 Open the access panel on the right hand side of the machine.
1 Open the access panel on the right hand side of the machine.
2 Release the two ‘1/4 turn fasteners’
24A
24
There is no need to remove the ventilation flap control cable as there is sufficient flexibility in the cable to allow the removal of the cover.
3 Remove the standard filter element
Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.
3 Remove the standard filter element
24B
24
4 If fitted, remove the secondary filter
24C
24
Replacement
Replacement
Replacement is the reverse of the removal procedure, however, note the following:
– The secondary filter, regardless of its type, is secured in position by two magnets. These magnets are a part of the filter element, therefore care must be taken to ensure the filter is installed the correct way round.
– The secondary filter, regardless of its type, is secured in position by two magnets. These magnets are a part of the filter element, therefore care must be taken to ensure the filter is installed the correct way round.
<GRAPHIC
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Fig 24.
Blower Motor
Blower Motor
For component layout see,
K Fig 26. ( T B-34)
The blower motor is located inside the air conditioning unit. The only user serviceable component being the resistor which gover…
The blower motor can be removed from the air conditioning cabinet with the air conditioning assembly in situ.
Removal
Removal
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
2 Open the access panel on the right hand side of the machine.
3 Remove the filter housing and filter(s),
K Filters ( T B-32)
4 Remove the eight screws
25A
25
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Fig 25.
5 Withdraw the blower motor assembly
26-5
26
6 Remove the thermostat from the heater blower support tray
26-4
26
K Thermostat ( T B-35)
7 Fully withdraw the blower motor assembly.
Replacement
Replacement
Replacement is the reverse of the removal procedure.
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<TABLE
<TABLE HEADING
<TABLE ROW
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Fig 26.
<TABLE BODY
<TABLE ROW
Component Key:
Component Key:
<TABLE ROW
1
1
Filter Cover
<TABLE ROW
2
2
Standard Air Filter Element
<TABLE ROW
3
3
Secondary Filter Element (HEPA/ Carbon)
<TABLE ROW
4
4
Blower Motor Support Tray
<TABLE ROW
5
5
Blower Motor Assembly
<TABLE ROW
6
6
Air Conditioning Cabinet
<TABLE ROW
7
7
Heater Matrix
<TABLE ROW
8
8
Expansion valve
<TABLE ROW
9
9
Evaporator
Thermostat
Thermostat
The thermostat monitors the external temperature of the evaporator and is located within the air conditioning cabinet alongside of the blower motor.
Removal
Removal
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
2 Open the access panel on the right hand side of the machine.
3 Remove the filter housing and filter(s).
K Filters ( T B-32)
4 Remove the eight screws
27A
27
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Fig 27.
5 Withdrawn the temperature probe
28A
28
6 Withdraw the heater motor sufficiently to secure access to the thermostat securing bolts
.
K Fig 26. ( T B-34)
7 Disconnect the harness connection
28B
28
8 Remove the securing bolts
28C
28
Replacement
Replacement
Replacement is the reverse of the removal procedure.
Care must be taken when inserting the thermostat probe into the evaporator coil to ensure the evaporator is not damaged.
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Fig 28.
Evaporator
Evaporator
The evaporator is located in the air conditioning cabinet. Its removal will require the assistance of a refrigeration engineer or suitably qualified person since the refrigerant will need to be discharged from the system
Refer to
K Fig 23. ( T B-31)
K Fig 26. ( T B-34)
Removal
Removal
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
2 Open the access panel on the right hand side of the machine.
3 Remove the filter housing and filter(s).
K Filters ( T B-32)
4 Remove the eight screws
29A
29
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Fig 29.
5 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
When working on the Air Conditioning System, gloves, eye protection and protective clothing must be worn. Do not smoke or expose refrigerant to naked flames or hot surfaces.
5 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
5 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
K Refrigerant Charging and Discharging ( T B-21)
6 With the system fully discharged, disconnect the high (
23-7
23
23-6
23
23-8
23
7 Remove the bolt
30A
30
30B
30
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Fig 30.
8 Carefully withdraw the evaporator unit
26-
26
9
26-
26
8
Replacement
Replacement
Replacement is the reverse of the removal procedure, however note the following:
1 The air conditioning system will need to be recharged with refrigerant by a refrigeration engineer or suitably trained and qualified person.
1 The air conditioning system will need to be recharged with refrigerant by a refrigeration engineer or suitably trained and qualified person.
K Refrigerant Charging and Discharging ( T B-21)
Expansion Valve
Expansion Valve
The expansion valve is located on the air conditioning cabinet.
Refer to
K Fig 23. ( T B-31)
K Fig 26. ( T B-34)
Removal
Removal
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine
2 Open the access panel on the right hand side of the machine.
3 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
When working on the Air Conditioning System, gloves, eye protection and protective clothing must be worn. Do not smoke or expose refrigerant to naked flames or hot surfaces.
3 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
3 Ensure that the air conditioning system has been fully discharged of its refrigerant by a refrigeration engineer or a suitably trained and qualified person.
K Refrigerant Charging and Discharging ( T B-21)
4 With the system fully discharged, disconnect the high (
23-
23
7
23-
23
6
23-
23
8
5 Peel back the insulation
31E
31
6 Disconnect the pipes
31C
31
D
31B
31
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Fig 31.
7 Remove the bolt
31A
31
8 Remove and discard the O-rings from the pipes
31C
31
D
Replacement.
Replacement.
Replacement is the reverse of the removal procedure, however, note the following:
1 Always replace the pipe fittings O-rings with new.
1 Always replace the pipe fittings O-rings with new.
2 The air conditioning system will need to be recharged with refrigerant by a refrigeration engineer or suitably trained and qualified person.
K Refrigerant Charging and Discharging ( T B-21)
Heater Radiator
Heater Radiator
The heater radiator is located in the air conditioning cabinet.
Refer to
K Fig 23. ( T B-31)
K Fig 26. ( T B-34)
Removal
Removal
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
1 Park the machine on firm level ground, apply the park brake and put the transmission in neutral. Stop the engine and remove the stater key to prevent the engine being started while you are working on the machine.
2 Open the access panel on the right hand side of the machine.
3 Allow the engine to cool down. Slowly release the filler cap to release any residual pressure. Refit the cap once the pressure has been released.
The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before checking the coolant level or checking the system.
3 Allow the engine to cool down. Slowly release the filler cap to release any residual pressure. Refit the cap once the pressure has been released.
4 Loosen the coolant hose clips
23-3
23
23-5
23
5 Release the clips securing the control cable
23-4
23
6 Remove the upper hose clip
32A
32
32B
32
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Fig 32.
7 Remove the four screws
33A
33
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Fig 33.
8 Withdraw the heater radiator
26-7
26
Replacement.
Replacement.
Replacement is the reverse of the removal procedure, however, note the following:
If the cooling system has been drained, when refilling, do not exceed the maximum fill rate of 10 litres per minute.
1 When refilling the cooling system use the correct water/antifreeze mixture. A 50% mixture should be maintained even if frost protection is not required. Refer to
1 When refilling the cooling system use the correct water/antifreeze mixture. A 50% mixture should be maintained even if frost protection is not required. Refer to
Section 3 – Routine Maintenance – Coolant Mixtures.
Binary Pressure Switch
Binary Pressure Switch
The binary pressure switch assembly is located in the engine compartment, screwed into the receiver drier unit.
Removal
Removal
1 Disconnect the battery.
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.
1 Disconnect the battery.
1 Disconnect the battery.
2 Remove the harness connectors
34A
34
34B
34
Replacement
Replacement
1 Screw the pressure switch
1 Screw the pressure switch
34B
34
2 Reconnect the harness connectors
34A
34
3 If the system is in an un-charged condition, charge the air conditioning system.
K Refrigerant Charging and Discharging ( T B-21)
4 Operate the air conditioning system and check around the pressure switch for leaks. If any leaks are found, tighten the pressure switch further until the leaking stops.
Leak testing in Air Conditioning systems should be carried out only in a well ventilated area.
4 Operate the air conditioning system and check around the pressure switch for leaks. If any leaks are found, tighten the pressure switch further until the leaking stops.
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Fig 34.
Cab
Cab
Glazing
Glazing
Direct Glazing
Direct Glazing
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.
1 Always wear safety glasses during both removal and replacement.
2 Use protective gloves – heavy duty leather gauntlet type gloves when cutting out the broken glass; ‘non- slip’ type gloves when handling/moving panes of glass; surgical type gloves when using the polyurethane adhesives.
3 Wear protective overalls.
4 Do not smoke – the activators and primers used in the procedures are highly flammable.
5 Do not attempt to handle or move panes of glass unless you are using glass lifters.
Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service (see
Service Tools
The work must only be carried out in a dry, frost free environment. A protective canopy may be required or the machine/frame mus…
Glass should not be replaced at temperatures below 5˚C (41˚F).
Removing the Broken Glass and Old Sealant
Laminated glass must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitu…
Removing the Broken Glass and Old Sealant
Removing the Broken Glass and Old Sealant
1 Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.
Always wear safety glasses when removing or installing screen glass. Never use a power operated knife when removing the sealant …
1 Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.
1 Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.
2 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.
a 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.
a 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.
b Toughened glass – remove as much of the shattered glass as possible prior to cutting out the old sealant.
3 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 Pneumatic Knife.
a Pneumatic Knife.
K Fig 35. ( T B-43)
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Fig 35. Pneumatic Knife
i Press the handle to start the knife blade oscillating.
This tool must not be used on toughened glass.
ii Insert the knife blade into the sealant.
iii Slowly move the knife along the sealant with the blade positioned as close to the glass as possible. Do not allow the knife blade to overheat or the sealant will melt.
b Braided Cutting Wire and Handles.
K Fig 36. ( T B-43)
i Insert the steel tube
i Insert the steel tube
36-A
36
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Fig 36. Braided Cutting Wire and Handles
ii Insert the braided cutting wire
36-B
36
iii Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass.
iv Secure each end of the braided cutting wire in the special handles
36-C
36
v 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.
c Cut-out Knife.
K Fig 37. ( T B-44)
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Fig 37. Cut-out Knife
i Insert the knife blade into the sealant.
ii Make sure that the blade of the knife is against the glass
37-A
37
iii Use the ‘pull-handle’ to pull the knife along and cut out the old sealant.
d Craft Knife.
K Fig 38. ( T B-44)
38-A
38
i Insert the knife blade into the sealant.
i Insert the knife blade into the sealant.
ii Pull the knife along and cut out the old sealant.
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Fig 38. Craft Knife
There are other tools available to cut out the old sealant. For example, there is a long handle type craft knife to give extended reach. Refer to
Service Tools
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.
5 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 39. ( T B-44)
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Fig 39.
6 Apply a coat of ‘Black Primer 206J’ to the paintwork if:
a Paintwork was damaged or scratched during the glass/sealant removal procedures.
a Paintwork was damaged or scratched during the glass/sealant removal procedures.
b The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures.
Preparing the Cab Frame Aperture
Preparing the Cab Frame Aperture
1 If damp or wet, dry the aperture area using a hot air gun (sourced locally).
1 If damp or wet, dry the aperture area using a hot air gun (sourced locally).
2 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.
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
Preparing the New Glass
1 Make sure that the new glass correctly fits the frame aperture
Laminated glass must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitu…
1 Make sure that the new glass correctly fits the frame aperture
1 Make sure that the new glass correctly fits the frame aperture
40-A
40
a Put two spacer blocks
a Put two spacer blocks
40-B
40
b Install the new glass on the spacer blocks – Always use glass lifters
40-C
40
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.
The glass edges must not touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass.
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Fig 40.
2 After checking for size, remove the new glass and place it on a purpose made glass stand.
K Fig 41. ( T B-45)
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Fig 41. Glass Stand
Small panes of glass will need locating on a 600 x 700 mm x 15 to 19 mm thick plywood board
42-A
42
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Fig 42.
3 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.
4 Clean the glass
a Use ‘Active Wipe 205’ to thoroughly clean and ‘prime’ the black ceramic ink band printed on the glass (see
a Use ‘Active Wipe 205’ to thoroughly clean and ‘prime’ the black ceramic ink band printed on the glass (see
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 43. ( T B-46)
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Fig 43.
5 Install the Ultra Fast Adhesive cartridge (see
Sealing and Retaining Compounds
Note
a Remove the aluminium disc cover from the base of the cartridge and discard the ‘dessicant capsule’.
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 44. ( T B-46)
e Install the cartridge in the applicator gun.
Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven for 1 hour to a temperature…
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Fig 44.
6 Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide
45-A
45
K Fig 45. ( T B-46)
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Fig 45.
Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. After approximately 10 minutes the sealant will form a ‘skin’, this will prevent the glass from bonding.
7 After applying the adhesive, leave a small amount of sealant protruding from the nozzle. This will prevent any adhesive left in the cartridge from ‘curing’.
Installing the New Glass
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.
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-45)
1
2 Install the glass in the frame aperture:
a Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position.
a Always use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position.
K Fig 46. ( T B-47)
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Fig 46. Typical M/c. Installation
b Sit the bottom edge of the glass on the spacer blocks.
K Fig 47. ( T B-47)
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Fig 47.
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.
3 Make the inside seal smooth:
a Wearing surgical gloves, dip your finger in a soapy water solution.
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
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’.
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.
On completion of the glass replacement procedures, the sealant ‘curing’ time is 30 minutes. This means that the machine can be driven and used after 30 minutes, but it must not be used during the curing period of 30 minutes.
c Clean the glass using a purpose made glass cleaner
6 On completion of the glass installation procedures tidy the work area:
a Remove all broken glass from the cab area.
a Remove all broken glass from the cab area.
b Remove the protective covers from the cab seat and control pedestals.
c Renew all ‘warning’ and ‘information’ decals so that the new installation conforms with the original cab installation.
ROP/FOPS Structure
ROP/FOPS Structure
Checking the Structure
Checking the Structure
1 Check the structure for damage.
If the machine is fitted with a Roll Over Protection Structure (ROPS) and/or a Falling Objects Protection Structure (FOPS), you …
1 Check the structure for damage.
1 Check the structure for damage.
2 Make sure that all the ROPS/FOPS mounting bolts
48A
48
3 Make sure that the ROPS/FOPS mounting bolts
48A
48
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Fig 48.
Bodywork
Bodywork
Removal and Replacement of the Rear Bodywork
Removal and Replacement of the Rear Bodywork
It will be necessary to remove the rear bodywork section covering the engine and cooling pack to carry out certain essential maintenance tasks.
To remove the bodywork proceed as follows:
Removal
Removal
1 Park the machine on firm level ground, lower the attachments to the ground, apply the park brake and set the transmission to neutral. Stop the engine. Block both sides of all four wheels.
1 Park the machine on firm level ground, lower the attachments to the ground, apply the park brake and set the transmission to neutral. Stop the engine. Block both sides of all four wheels.
The procedure detailed below must be followed to correctly vent the residual hydraulic pressure.
2 Vent the hydraulic pressure as detailed in
Section E – Hydraulics – Service Procedures – Venting the System Pressure.
3 Disconnect the batteries to prevent the engine being started whilst carrying out this procedure.
4 Open the left and right-hand side engine covers. From inside the right-hand side cover pull the release cable
49A
49
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Fig 49.
5 Remove the six bolts securing the fan grille to the fan housing. (The lower three are fitted on the under side of the grille.)
6 Label and disconnect the hoses to the cooling fan motor
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
6 Label and disconnect the hoses to the cooling fan motor
50A
50
50B
50
50C
50
Section E – Hydraulics – Service Procedures – Connecting and Disconnecting Hydraulic Hoses.
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Fig 50.
7 Remove the plastic body panel fitted above the fan housing covering the upper rear bodywork support panel.
8 Feed the released fan hydraulic hoses up through the top of the fan housing, through the upper bodywork support panel and rest over the right-hand side chassis.
9 Raise the fan housing fully on its gas struts, attach a suitable sling to the motor and connect the sling to a overhead crane.
K Fig 51. ( T B-50)
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Fig 51.
10 With the weight of the fan motor and housing assembly held by the overhead crane, release the two gas struts from the fan housing.
11 Working from inside the fan housing aperture, remove the four bolts securing the fan housing top hinges to the upper rear bod…
12 Disconnect the charge air cooler steel pipe at the hose connections each side of the rear engine bulkhead. Plug the open ports and hoses and remove the steel pipe from the rear bulkhead.
Access to the cooling pack sections drain plugs is via holes machined into the rear panel beneath the batteries accessed from the rear.
13 Drain the coolant from the cooling pack radiator section into a suitable container. (Cover the container to prevent dirt ingr…
14 Disconnect the coolant top hose from its connections at the cooling pack and the engine and remove the hose from the bulkhead. Plug the open ports to prevent dirt ingress.
15 Disconnect the two small bore coolant hoses
52A
52
52B
52
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Fig 52.
16 Disconnect the exhaust flexi-pipe at the silencer and the engine and remove. Plug the open ports to prevent any ingress of dirt or debris. The silencer should be left secured to the bodywork.
17 Disconnect the air cleaner hose between the filter housing and the engine. Plug the open ports to prevent any ingress of dirt or debris. The air cleaner assembly can be left secured to the bodywork.
18 Label and disconnect the harness from the air filter restriction switch. Release the harness from its securing at the bulkhead
19 Disconnect the large bore coolant hose from the header tank. Plug the open hose to prevent the ingress of dirt or debris. The header tank can be left secured to the bodywork.
20 Label and disconnect the grid heater harness cable
53A
53
53B
53
53C
53
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Fig 53.
21 Label and disconnect the emergency steer positive feed cable
54A
54
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Fig 54.
22 label and disconnect the emergency steer motor feed cable
55A
55
55B
55
C
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Fig 55.
23 Remove the bolts securing the emergency steering motor/pump and electrical units to the front bulkhead. Secure the components to the engine so that the weight of the assembly is not hanging on the electrical harness or the hydraulic hoses.
24 Label and disconnect the rear and engine harness connections at their connections through the front bulkhead on the right-hand side of the machine.
K Fig 56. ( T B-52)
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Fig 56.
25 Remove the two bolts securing the fuel sedimenter bowl to the rear bulkhead and temporarily secure the sedimenter to the engine. There is no need to disconnect the fuel pipes to the sedimenter.
26 Remove the two bolts securing the air conditioning receiver drier to the rear bulkhead and secure the receiver drier to the chassis or engine. DO NOT release the air conditioning hoses at the receiver drier.
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
26 Remove the two bolts securing the air conditioning receiver drier to the rear bulkhead and secure the receiver drier to the chassis or engine. DO NOT release the air conditioning hoses at the receiver drier.
27 Securely fit the lifting eyes to the threaded holes provided in the rear bodywork and attach suitable lifting slings. Securely attach the slings to an overhead crane.
28 Remove the four bolts
57A
57
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Fig 57.
29 Remove the four bolts
58A
58
It will be necessary to simultaneously feed the main transmission hydraulic hose and the two smaller engine fan hydraulic hoses
58B
58
58C
58
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Fig 58.
30 Remove the four bolts
59A
59
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Fig 59.
31 Using the overhead crane and, whilst checking for unreleased connections, slowly lift the complete rear bodywork section from the machine. Once clear of the machine lower the bodywork section to the ground and secure.
Replacement
Replacement
Replacement is the reverse of the removal procedure, however note the following:
1 Remember to feed the two fan hydraulic hoses and the transmission hose up through the apertures in the lower corners of the rear bulkhead as the bodywork is lowered into place.
1 Remember to feed the two fan hydraulic hoses and the transmission hose up through the apertures in the lower corners of the rear bulkhead as the bodywork is lowered into place.
2 All hydraulic hose sealing O-rings must be replaced. Do not over tighten the Allen bolts
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 prot…
2 All hydraulic hose sealing O-rings must be replaced. Do not over tighten the Allen bolts
60A
60
K Table 2. Torque Settings ( T B-54)
3 Top up all fluids as necessary using the correct grade of fluid for each system. Refer to
Section 3 – Routine Maintenance
4 The correct concentration of coolant antifreeze is to be added to the cooling system. A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolants boiling point.
Antifreeze can be harmful. Obey the manufacturer’s instructions when handling full strength or diluted antifreeze.
4 The correct concentration of coolant antifreeze is to be added to the cooling system. A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolants boiling point.
5 To provide sufficient corrosion protection, Supplemental Coolant Additive (SCA) must be added to the coolant mixture. The cool…
It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate is any higher than this there is a possibility of air becoming trapped in the system.
6 When refitting the batteries, make sure they are connected in the correct manner by connecting the earth lead last.
Table 2. Torque Settings
Table 2. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
A
A
Allen Bolt
25
2.5
18
<TABLE ROW
Coolant drain plug
Coolant drain plug
55
5.6
40
<GRAPHIC
<GRAPHIC
Fig 60.
Cooling Pack
Cooling Pack
Cooling Pack
Cooling Pack
Introduction
Introduction
The 434S cooling pack has individual sections for Charge Air Cooling, Engine Coolant, Transmission Fluid and Hydraulic Oil Cooling, though only the engine cooling fan is piped into the hydraulic oil cooler.
The pack sections are positioned vertically. When viewed from the rear of the machine the sections from left to right are, Charge Air Cooling, Transmission Fluid Cooling, Engine Coolant Radiator and Hydraulic oil cooler.
The sections can be replaced individually by unbolting them from their top and bottom mounting plates although, in order for a section to be replaced, the whole cooling pack will need to be removed from the machine.
Removal
Removal
1 Remove the rear bodywork as detailed in
1 Remove the rear bodywork as detailed in
K Removal and Replacement of the Rear Bodywork ( T B-49)
Do not undo the hoses to the air conditioning condenser. If the hoses are of insufficient length to allow the condenser to be sa…
The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be discon…
Do not undo the hoses to the air conditioning condenser. If the hoses are of insufficient length to allow the condenser to be sa…
2 Release the catch on the left-hand side of the cooling pack holding the air conditioning condenser in the closed position.
3 Remove the two bolts
61A
61
61B
61
61C
61
<GRAPHIC
<GRAPHIC
Fig 61.
4 Lift the condenser forwards away from the cooling pack and place securely inside the chassis.
5 Disconnect the lower charge air cooler hose, plug the open port and cap the hose to prevent the ingress of dirt or debris.
6 Disconnect the hoses to the transmission cooler. Plug the open ports and cap the hoses to prevent fluid loss and the ingress of dirt or debris.
7 Remove the lower coolant hose being careful to collect any coolant still in the hoses.
8 Disconnect the hoses to the hydraulic cooler. Plug the open ports and cap the hoses to prevent fluid loss and the ingress of dirt or debris.
Do not lift the cooling pack by any points other than the designated lifting eyes, to do so could cause damage to the cooling pack.
9 Attach a suitable sling to the lifting eyes incorporated into the top of the cooling pack and attach to a overhead crane.
10 Remove the lower cooing pack to chassis mounting bolts.
11 Take the weight of the cooling pack on the crane. Remove the upper mounting bolts
62A
62
<GRAPHIC
<GRAPHIC
Fig 62.
12 Using the crane slowly lift the cooling pack from the machine and stow safely on the ground.
Replacement
Replacement
Replacement is the reverse of removal but note the following:
1 All hydraulic hose sealing O-rings must be replaced. Do not over-tighten the Allen bolts
1 All hydraulic hose sealing O-rings must be replaced. Do not over-tighten the Allen bolts
63A
63
K Table 3. Torque Settings ( T B-57)
2 The correct concentration of coolant antifreeze is to be added to the cooling system. A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant boiling point.
3 To provide sufficient corrosion protection, Supplemental Coolant Additive (SCA) must be added to the coolant mixture. The cool…
It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate is any higher than this there is a possibility of air becoming trapped in the system.
4 When refitting the batteries, make sure they are connected in the correct manner by connecting the earth lead last.
Antifreeze can be harmful. Obey the manufacturer’s instructions when handling full strength or diluted antifreeze.
4 When refitting the batteries, make sure they are connected in the correct manner by connecting the earth lead last.
Table 3. Torque Settings
Table 3. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
A
A
Allen Bolt
25
2.5
18
<TABLE ROW
Coolant drain plug
Coolant drain plug
55
5.6
40
<GRAPHIC
<GRAPHIC
Fig 63.
Page left intentionally blank
Centre Pivot
Centre Pivot
Removal and Replacement
Removal and Replacement
Removal
Removal
Park the machine in the straight-ahead position on firm, level ground. Lower the shovel flat onto sliders resting on the ground….
1 Securely block all wheels on both sides.
1 Securely block all wheels on both sides.
2 Remove the cab, refer to
K Removal and Replacement ( T B-59)
3 Remove the pin from each steering ram rod end. Move the steering rams clear of the front chassis.
4 Disconnect the driveshaft at the brake disc flange. Mark all four flanges to ensure correct re-assembly.
5 Separate the two halves of the hydraulic pipe clamp to release the hydraulic pipework.
There should be sufficient slack in the hydraulic pipework to allow the front and rear chassis to be separated without the pipework having to be disconnected. When separating the chassis, take care not to put undue strain on the hydraulic pipework.
6 Using suitable blocks, support the rear chassis at front and rear.
7 Place a trolley jack under the lower pivot flange of the front chassis after putting a piece of timber between the contact points.
8 Remove the lower pivot pin as follows:
a Remove screw
a Remove screw
64-3
64
64-4
64
64- 31
64
b Drive out pivot pin
64-2
64
64-30
64
64-20
64
64- 6
64
9 Remove the upper pivot as follows:
a Remove split pin
a Remove split pin
64-22
64
64-21
64
64-17
64
64-28
64
b Remove bolts
64-23
64
64-24
64
64-5
64
c Drive out pivot pin
64-1
64
64-9
64
64-14
64
64-26.
64
d Remove and discard bearings
64-18
64
64-7
64
10 Remove the blocks from under the front wheels.
11 Release the parking brake and manually separate the front and rear chassis just sufficiently to enable work to be carried out on the centre pivot.
<GRAPHIC
<GRAPHIC
Fig 64.
Replacement
Replacement
Fit new bearings
18
9
14
K Numerical List Section B – Body and Framework ( T 1-7)
1 Grease the face of the bottom end cap
1 Grease the face of the bottom end cap
5
23
24
2 Pack the bottom bearing with grease and fit into the new bearing cup.
Ensure that the bearing is completely filled with grease.
3 Position dummy boss
A
4 Position the top bearing on top of dummy boss
A
5 Position bearing locator
B
6 Measure gap d between the top of bearing locator
B
X
<GRAPHIC
<GRAPHIC
Fig 65.
7 Add dimension
d
t
d
t
8 Select shims from the table corresponding to dimension (
d
t
B
If no dimension
t
t
zero
9 Bearing locator
X
t
10 Remove bearing locator
B
A
11 Fit new lip seals
7
12 Position the top bearing cone on pivot pin
1
Y
<GRAPHIC
<GRAPHIC
Fig 66.
13 Smear the bottom portion of the rear module pivot bore with locking fluid.
14 Remove bottom end cap
5
26
23
15 Carefully mate the front and rear chassis.
16 Assemble the lower pivot pin
2
30
20
6
31
4
3
17 Smear locking fluid onto the top portion of pivot pin
1
18 Pack the top bearing with grease and fit the bearing cup.
Ensure that the bearing is completely filled with grease.
19 Fit the shim pack and washer
26
20 Grease the face of the top end cap
5
24
23
21 Fit bolt
17
28
21
22
If necessary, the castellated nut can be further tightened until the next castellation lines up with the split pin drilling in the bolt.
22 Manoeuvre lip seals
7
23 Apply grease through each of the nipples until it is emitted through the lip seals.
The remainder of the procedure is a reversal of the removal procedure.
Table 4. Torque Settings
Table 4. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
3
3
244
24.9
180
<TABLE ROW
21
21
68
6.9
50
<TABLE ROW
23
23
98
10.0
72
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Shim
Part No.
Nominal Thickness mm (in)
<TABLE BODY
<TABLE ROW
A
A
819/00029
1.0
(0.039)
<TABLE ROW
B
B
819/00030
0.25
(0.010)
<TABLE ROW
C
C
819/00031
0.15
(0.006)
<TABLE ROW
D
D
819/00035
0.6
(0.024)
<TABLE ROW
E
E
819/00037
0.9
(0.035)
<TABLE ROW
F
F
819/00036
0.7
(0.028)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Dimension (d + t)
Shims
<TABLE ROW
mm (in)
<TABLE BODY
<TABLE ROW
0.83 – 0.87 (0.033 – 0.034)
D + B
<TABLE ROW
0.88 – 0.92 (0.035 – 0.036)
E
<TABLE ROW
0.93 – 0.97 (0.037 – 0.038)
F + B
<TABLE ROW
0.98 – 1.02 (0.039 – 0.040)
A
<TABLE ROW
1.03 – 1.07 (0.040 – 0.042)
E + C
<TABLE ROW
1.08 – 1.12 (0.042 – 0.044)
D + 2 x B
<TABLE ROW
1.13 – 1.17 (0.044 – 0.046)
A + C
<TABLE ROW
1.18 – 1.22 (0.046 – 0.048)
2 x D
<TABLE ROW
1.23 – 1.27 (0.048 – 0.050)
A + B
<TABLE ROW
1.28 – 1.32 (0.050 – 0.052)
D + F
<TABLE ROW
1.33 – 1.37 (0.052 – 0.054)
2 x D + C
<TABLE ROW
1.38 – 1.42 (0.054 – 0.056)
2 x F
<TABLE ROW
1.43 – 1.47 (0.056 – 0.058)
F + D + C
<TABLE ROW
1.48 – 1.52 (0.058 – 0.060)
D + E
<TABLE ROW
1.53 – 1.57 (0.060 – 0.062)
2 x F + C
<TABLE ROW
1.58 – 1.62 (0.062 – 0.064)
A + D
<TABLE ROW
1.63 – 1.67 (0.064 – 0.066)
D + E + C
<TABLE ROW
1.68 – 1.72 (0.066 – 0.068)
A + F
<TABLE ROW
1.73 – 1.77 (0.068 – 0.070)
E + F + C
<TABLE ROW
1.78 – 1.82 (0.070 – 0.072)
2 x E
<TABLE ROW
1.83 – 1.87 (0.072 – 0.074)
B + E + F
<TABLE ROW
1.88 – 1.92 (0.074 – 0.076)
A + E
<TABLE ROW
1.93 – 1.97 (0.076 – 0.078)
A + B + F
<TABLE ROW
1.98 – 2.02 (0.078 – 0.079)
2 x A
<TABLE ROW
2.03 – 2.07 (0.080 – 0.081)
A + C + E
<TABLE ROW
2.08 – 2.12 (0.082 – 0.083)
2 x D + E
<TABLE ROW
2.13 – 2.17 (0.084 – 0.085)
2 x A + C
<TABLE ROW
2.18 – 2.22 (0.086 – 0.087)
D + E + F
<TABLE ROW
2.23 – 2.27 (0.088 – 0.089)
2 x A + B
<TABLE ROW
2.28 – 2.32 (0.090 – 0.091)
2 x F + E
Page left intentionally blank
Section C – Electrics
Section C
Section C
Electrics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
Page left intentionally blank
Technical Data
Technical Data
General Electrical Data
General Electrical Data
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
System Type
System Type
24 Volts, negative earth
<TABLE ROW
Battery
Battery
<TABLE ROW
Cold Crank Amps for 1 minute to 1.4VPCat -18 ˚C (0 ˚F)
410 Amps
<TABLE ROW
Reserve Capacity (minutes) for 25 Amp load
180
<TABLE ROW
Alternator
Alternator
0120-488-206
<TABLE ROW
Starter Motor
Starter Motor
42-MT/400
Bulbs
Bulbs
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Bulb
Rating (Watts)
<TABLE BODY
<TABLE ROW
Headlights – main
75 W
<TABLE ROW
Headlights – dip
70 W
<TABLE ROW
Indicators
21 W
<TABLE ROW
Indicator repeater
5 W
<TABLE ROW
Instruments
1.2 W
<TABLE ROW
Work lights
70 W Halogen
<TABLE ROW
Number plate light
5 W
<TABLE ROW
Tail lights
5 W
<TABLE ROW
Front sidelights
4 W
<TABLE ROW
Interior lights
10 W
<TABLE ROW
Stop lights
21 W
<TABLE ROW
Beacon
70 W Halogen
<TABLE ROW
Rear fog
21 W
<TABLE ROW
Warning lights
1.2 W
<TABLE ROW
Master Warning Light
5W
Fuses and Relays 434S Machines
Fuses and Relays 434S Machines
Fuses and Relays
Fuses and Relays
The electrical circuits are protected by fuses. The fuses are located in a fuse box (shown with the lid removed) behind the drivers seat.
Fuses
Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
The electrical circuits are protected by fuses. The fuses are located in a fuse box (shown with the lid removed) behind the drivers seat.
K Fig 1. ( T C-3)
If a fuse ruptures, find out why and rectify the fault before fitting a new one.
Secondary Fuses
Secondary Fuses
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
A1
Front Work Lights Relay, Ign 1 Relay
20A
<TABLE ROW
A2
Additional Front Work Lights (2 Total)
10A
<TABLE ROW
A3
Rear Work Lights (2 Total)
10A
<TABLE ROW
A4
Additional Rear Work Lights (2 Total)
10A
<TABLE ROW
A5
Roadlight Switch (Headlights)
15A
<TABLE ROW
A6
Main Beam
10A
<TABLE ROW
A7
Rear Fog Light
5A
<TABLE ROW
A8
Grid Heater Relay
3A
<TABLE ROW
A9
Blank

<TABLE ROW
A10
Blank

<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
B1
RH Sidelights
3A
<TABLE ROW
B2
LH Sidelights
3A
<TABLE ROW
B3
Heated Rear Screen
15A
<TABLE ROW
B4
EMS Battery Feed
3A
<TABLE ROW
B5
ZF Computer Battery Feed
7.5A
<TABLE ROW
B6
Hazard Indicators
10A
<TABLE ROW
B7
Beacon/Interior Light
7.5A
<TABLE ROW
B8
Radio (24 volt)
10A
<TABLE ROW
B9
Headlight Flash
15A
<TABLE ROW
B10
Ignition Relays/Roadlight Illumination
5A
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
C1
Starter Relay
3A
<TABLE ROW
C2
Cigar Lighter (24 volt)
10A
<TABLE ROW
C3
Loader Auxiliaries, Quickhitch, Servo Isolator
7.5A
<TABLE ROW
C4
Rear Wash/Wipe
7.5A
<TABLE ROW
C5
Front Wash/Wipe, Horn
10A
<TABLE ROW
C6
Heater Motor
20A
<TABLE ROW
C7
Air Conditioning Compressor
5A
<TABLE ROW
C8
Heated Mirrors/Seat, Suspension Seat
20A
<TABLE ROW
C9
Direction Indicators
5A
<TABLE ROW
C10
Trailer Electrics (12 volt)
10A
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
D1
EMS Ignition Feed
3A
<TABLE ROW
D2
ZF Computer Ignition Feed, SRS Solenoid
7.5A
<TABLE ROW
D3
Reversing Camera
5A
<TABLE ROW
D4
Emergency Steer System
1A
<TABLE ROW
D5
Shutdown relay, Immobiliser
5A
<TABLE ROW
D6
Reverse Alarm and Lights
5A
<TABLE ROW
D7
24/12 volt Dropper (Radio, Cigar/ Lighter, Auxiliary)
10A
<TABLE ROW
D8
Reverse Fan
5A
<TABLE ROW
D9
Brake Lights, Tow Hitch Solenoids
7.5A
<TABLE ROW
D10
Shovel and Arm Reset
7.5A
Relays
Relays
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Relay
Circuit
<TABLE BODY
<TABLE ROW
1
Ignition 1
<TABLE ROW
2
Ignition 2
<TABLE ROW
3
Brake Lights
<TABLE ROW
4
Reverse Light
<TABLE ROW
5
Engine Shutdown
<TABLE ROW
6
Transmission Reverse
<TABLE ROW
7
Emergency Steer
<TABLE ROW
8
Air Conditioning
<TABLE ROW
9
Transmission Dump
<TABLE ROW
10
Ignition 3
<TABLE ROW
11
Front Work Lights
<TABLE ROW
12
Lights
<TABLE ROW
13
Flasher Unit
<TABLE ROW
14
Heated Rear Screen
<TABLE ROW
15
Neutral Start
<TABLE ROW
16
Blank
<TABLE ROW
17
Blank
Diagnostic Connectors
Diagnostic Connectors
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
X
ZF Transmission
<TABLE ROW
Y
EMS
<GRAPHIC
<GRAPHIC
Fig 1.
Primary Fuses
Primary Fuses
K Fig 2. ( T C-4).
K Fig 2. ( T C-4)
The primary fuses are located in a fuse box mounted at the right side of the battery bay inside the rear grille.
If a fuse ruptures, find out why and rectify the fault before fitting a new one.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF1
Front Work Lights
60A
<TABLE ROW
Ignition 1
<TABLE ROW
EMS (Ignition Feed)
<TABLE ROW
ZF Computer (Ignition Feed)
<TABLE ROW
ACCS
<TABLE ROW
Reversing Camera
<TABLE ROW
Emergency Steer System
<TABLE ROW
ESOS and Immobiliser
<TABLE ROW
Reverse Alarm and Lights
<TABLE ROW
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF2
Hazard Indicators
40A
<TABLE ROW
Beacon and Interior Light
<TABLE ROW
Radio (24 volt)
<TABLE ROW
Headlight Flash
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF3
Ignition
60A
<TABLE ROW
Roadlight Illumination
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF4
Cigar Lighter
60A
<TABLE ROW
Loader Auxiliaries, Quickhitch and Servo Isolator
<TABLE ROW
Rear Wash/Wipe
<TABLE ROW
Front Wash/Wipe and Horn
<TABLE ROW
24/12 volt Dropper (Radio, Cigar Lighter and Aux.)
<TABLE ROW
Reverse Fan
<TABLE ROW
Brake Lights and Tow Hitch Solenoids
<TABLE ROW
Shovel and Arm Reset
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF5
Rear Work Lights
40A
<TABLE ROW
Roadlight Switch (Headlights)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF6
Heater Motor
60A
<TABLE ROW
Air Conditioning Compressor
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF7
RH Sidelights
30A
<TABLE ROW
LH Sidelights
<TABLE ROW
Heated Rear Screen
<TABLE ROW
EMS (Battery Feed)
<TABLE ROW
ZF Computer (Battery Feed)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
PF8
Engine ECU
30A
<GRAPHIC
<GRAPHIC
Fig 2.
Service Procedures
Service Procedures
Using a Multimeter
Using a Multimeter
In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician…
These instructions are intended to cover the use of the recommended multimeters.
<GRAPHIC
<GRAPHIC
Fig 3. FLUKE 85
<GRAPHIC
<GRAPHIC
Fig 4. AVO 2003
<GRAPHIC
<GRAPHIC
Fig 5. A Typical Analogue Meter
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 “
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 “

E
COMMON
COM
+
V
2 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.
3 When measuring voltage: Make sure that the correct range is selected, that is set the selector to a value equal to or greater …
Measuring DC Voltage
Measuring DC Voltage
1 Select the correct range on the multimeter.
1 Select the correct range on the multimeter.
a On the FLUKE 85.
a On the FLUKE 85.
Turn the switch to position
3-B
3
b On the AV0 2003.
Move the right slider switch to position
4-A
4
c On an analogue meter.
Turn the dial to the appropriate DC Volts range.
2 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.
Measuring Resistance
Measuring Resistance
1 Make sure there is no power to the part of the circuit you are about to measure.
1 Make sure there is no power to the part of the circuit you are about to measure.
2 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.
3 Select the correct range on the multimeter.
a On the FLUKE 85.
a On the FLUKE 85.
i Turn the switch to position
i Turn the switch to position
3-C
3
F
3-G
3
REL
3
b On the AV0 2003.
i Move the right hand slider switch to position
i Move the right hand slider switch to position
4- B
4
c On an analogue meter.
i Move the dial to the appropriate Ohms (W) range.
i Move the dial to the appropriate Ohms (W) range.
Measuring Continuity
Measuring Continuity
1 Make sure there is no power to the part of the circuit you are checking for continuity.
1 Make sure there is no power to the part of the circuit you are checking for continuity.
2 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.
3 Select the correct range on the multimeter.
a On the FLUKE 85.
a On the FLUKE 85.
Turn the switch to position
3-C
3
3-F
3
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
4-B
4
4-C
4
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 (W) 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.
Measuring Frequency
Measuring Frequency
The AVO 2003 and the analogue meter are not capable of measuring frequency, therefore a Fluke 85 digital multimeter must be used.
1 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.
1 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.
2 Insert the red probe into socket
3-J
3
3 Turn the selector switch to position
3-A
3
3-G
3
3-F
3
4 Press button
3-H
3
5 Touch or connect the red probe to the frequency source to be measured. Press and hold button if an average reading is required.
Testing a Diode or a Diode Wire
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 To test a Diode or a Diode Wire
1 To test a Diode or a Diode Wire
a On the FLUKE 85.
a On the FLUKE 85.
i Turn the switch to position
i Turn the switch to position
3-D
3
ii Press the
HOLD
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.
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.
v Press the HOLD button and check that the
H
b On the AV0 2003.
i Move the right hand slider to position
i Move the right hand slider to position
4-A
4
4-C
4
ii 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. If the Avometer does not buzz the diode is faulty.
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 On an analogue meter.
i Select the Ohms 1000s (1k) range.
i Select the Ohms 1000s (1k) range.
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 sh…
ii 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 sh…
Battery
Battery
Maintenance
Maintenance
To ensure that the battery provides optimum performance the following steps should be observed:
1 Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.
1 Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.
2 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.
3 Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) – this condition makes recharging the battery very difficult.
Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery:
– Never boost-charge a maintenance free battery.
– Never boost-charge a maintenance free battery.
– Never charge a maintenance free battery at a voltage in excess of 15.8 Volts.
– Never continue to charge a maintenance free battery after it begins to gas.
Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery c…
Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.
Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.
When reconnecting, fit the positive (+) lead first.
First Aid – Electrolyte
First Aid – Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get medical help.
IS SWALLOWED
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.
GETS ONTO YOUR SKIN
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.
Testing
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:
1 Set the CHECK/LOAD switch
1 Set the CHECK/LOAD switch
6-A
6
2 Set rocker switch
6-B
6
3 Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.
4 Set the CHECK/LOAD switch
6-A
6
5 Set the CHECK/LOAD switch
6-A
6
Do not hold the switch in the LOAD position for more than 10 seconds.
6 K Table 1. Fault Diagnosis ( T C-10), if the foregoing tests are unsatisfactory.
6 K Table 1. Fault Diagnosis ( T C-10)
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Fig 6. Battery Tester
Table 1. Fault Diagnosis
Table 1. Fault Diagnosis
<TABLE
<TABLE HEADING
<TABLE ROW
Battery Tester Readings
Remedy
<TABLE BODY
<TABLE ROW
1 CHECK: 0 – 12.6 Volts
1 CHECK: 0 – 12.6 Volts
1 CHECK: 0 – 12.6 Volts
LOAD: less than 6 Volts
Renew battery
<TABLE ROW
2 CHECK: 6 – 12.4 Volts
2 CHECK: 6 – 12.4 Volts
2 CHECK: 6 – 12.4 Volts
LOAD: less than 9 Volts and falls steadily but remains in yellow zone.
Recharge and re-test. If tests still unsatisfactory renew battery.
<TABLE ROW
3 CHECK: less than 10 Volts
3 CHECK: less than 10 Volts
3 CHECK: less than 10 Volts
LOAD: less than 3 Volts
Indicates battery has been over-discharged and unlikely to recover. Renew battery.
<TABLE ROW
4 CHECK: more than 11 Volts
4 CHECK: more than 11 Volts
4 CHECK: more than 11 Volts
LOAD: 6 – 10 Volts steady
Charge battery which will probably recover.
Specific Gravity Testing
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 hy…
Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15˚C (60˚F) a ‘correction factor’ must be applied to the reading obtained. Add 0.07 per 10˚C (18˚F) if the temperature is higher than 15˚C (60˚F) and subtract the same if the temperature is lower.
Table 2. Specific Gravity at 15˚C (60˚F)
Table 2. Specific Gravity at 15˚C (60˚F)
<TABLE
<TABLE HEADING
<TABLE ROW
Fully Charged
Half Discharged
Fully Discharged
<TABLE BODY
<TABLE ROW
Ambient temperature up to 27˚C (80˚F)
1.270 – 1.290
1.190 – 1.210
1.110 – 1.130
<TABLE ROW
Ambient temperature above 27˚C (80˚F)
1.240 – 1.260
1.170 – 1.190
1.090 – 1.110
Alternator
Alternator
General Description
General Description
The alternator is a three phase generator having a rotating field winding and static power windings.
When the start switch is turned on, current from the battery flows by way of the ‘No Charge’ warning light to the field winding….
Servicing is restricted to periodic inspection of slip ring brushes. Bearings are ‘sealed for life’.
Service Precautions
Service Precautions
1 Ensure that the battery negative terminal is connected to the earthing cable.
1 Ensure that the battery negative terminal is connected to the earthing cable.
2 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.
3 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.
4 During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables).
5 If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the char…
Charging Circuit Test
Charging Circuit Test
1 Ensure that all battery and alternator connections are in place, secure and making good metal – to – metal contact, especially the ‘earth’ connections to chassis and engine.
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.
2 Adjust the alternator drive belt tension if necessary and make sure that the battery is well charged.
3 Turn the start switch to the ON position.
‘Oil pressure’ and ‘No charge’ warning lights should glow. If any light fails,
K Check 1 ( T C-12)
4 Start the engine; all warning lights should extinguish rapidly.
If the ‘No charge’ warning light remains ON,
K Check 2 ( T C-13)
If the oil pressure warning remains on stop engine Immediately and investigate the engine lubrication system.
Check 1
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 con…
K Alternator Charging Test ( T C-13)
<GRAPHIC
<GRAPHIC
Fig 7.
Check 2
Check 2
The following checks should be made using an analogue (moving pointer) type meter.
1 Stop the engine and turn the starter switch to OFF.
1 Stop the engine and turn the starter switch to OFF.
2 Withdraw the alternator plug and connect the test meter between the large terminals and ‘earth’. With the meter set to measure…
<GRAPHIC
<GRAPHIC
Fig 8.
If the voltage is correct, check the alternator.
K Alternator Charging Test ( T C-13)
Alternator Charging Test
Alternator Charging Test
<GRAPHIC
<GRAPHIC
Fig 9.
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.
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.
2 Make sure that the alternator drive belt tension is correctly adjusted.
3 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
4 Install a 100 amp open – type shunt between the battery positive lead and the battery positive terminal.
5 Connect a multimeter positive lead to machine side of the shunt and negative lead to battery side of the shunt.
6 Connect the leads to the meter and set the meter to the relevant range as follows.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
AVO 2002
AVO 2002
– Red lead to volts (middle) socket on meter.
– Red lead to volts (middle) socket on meter.
– Red lead to volts (middle) socket on meter.
– Black lead to negative on meter.
– RH slider to DC voltage.
– LH slider.
K Fig 9. ( T C-13)
<TABLE ROW
AVO 2003
AVO 2003
– Red lead to amps socket (marked A) on the meter.
– Red lead to amps socket (marked A) on the meter.
– 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
<TABLE ROW
FLUKE 85
FLUKE 85
– Red lead to volts socket (marked V ) on meter.
– Red lead to volts socket (marked V ) on meter.
– Red lead to volts socket (marked V ) on meter.
– Black lead to COM socket on meter.
– Set dial to mV.
7 Start the engine and run at maximum speed (see
7 Start the engine and run at maximum speed (see
Technical Data
Technical Data
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.
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.
f Open or short – circuited power (stator) windings.
9 To check for fault
a
10 To check for faults
b
c
11 Faults
d
e
f
Starter Motor
Starter Motor
Starting Circuit Test
Starting Circuit Test
Before carrying out the voltmeter tests, check the battery condition and ensure that all connections are clean and tight.
To prevent the engine starting during the tests ensure that the engine stop fuse is removed, (refer to
Fuse Identification
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.
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.
1 Connect the voltmeter across the battery terminals.
K Fig 10. ( T C-15)
A low reading probably indicates a fault in the starter motor.
<GRAPHIC
<GRAPHIC
Fig 10.
2 Connect the voltmeter between the starter main terminal
11-A
11
11-B
11
1
If the reading is within this limit, continue to Step
3
4
5
<GRAPHIC
<GRAPHIC
Fig 11.
3 Connect the voltmeter between the solenoid terminal
12-C
12
<GRAPHIC
<GRAPHIC
<GRAPHIC
Fig 12.
a If the reading is less than specified, connect the voltmeter between the neutral start relay terminal
13-D
13
b If the reading between terminal
13-D
13
13-E
13
If the reading between
13-E
13
<GRAPHIC
<GRAPHIC
Fig 13.
4 Connect the voltmeter between battery negative and starter earth connection
14-B
14
If the reading is above 0.25V, a high resistance in the earth lead or connections is indicated.
<GRAPHIC
<GRAPHIC
Fig 14.
5 Connect the voltmeter between battery positive and the starter main terminal
15-A
15
<GRAPHIC
<GRAPHIC
Fig 15.
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
16-H
16
<GRAPHIC
<GRAPHIC
Fig 16.
6 Finally refit the engine stop fuse.
Wire and Harness Number Identification
Wire and Harness Number Identification
Introduction
Introduction
This section details the allocation of wire numbers and the identification of wires in the wiring harness.
<GRAPHIC
<GRAPHIC
Fig 17. Typical Wire and Harness Number
K Fig 17. ( T C-17) shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it’s length.
K Fig 17. ( T C-17)
The number stamped on the wire shown in
K Fig 17. ( T C-17)
Table 3. Wire and Harness Number Identification
Table 3. Wire and Harness Number Identification
<TABLE
<TABLE HEADING
<TABLE ROW
Ident. No.
Description
<TABLE BODY
<TABLE ROW
B
B
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
B
B
<TABLE ROW
819
819
The wire’s unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products.
<TABLE ROW
9/371
9/371
The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).
9/371
Wire Numbers and Functions
Wire Numbers and Functions
Wires 000-199
Wires 000-199
These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:
– Wires
– Wires
000 – 099
– Wires
100 – 199
Feeds via ignition relays are classed as ignition feeds.
Wires 200-399
Wires 200-399
These numbers are reserved for battery feeds, They can be further categorised by:
– Wires
– Wires
200 – 299
– Wires
300 – 399
Wires 400-599
Wires 400-599
These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems.
Wires 600-799
Wires 600-799
These numbers are used for earth wires. When the number is printed onto a wire
18-A
18
18-B
18
<GRAPHIC
<GRAPHIC
Fig 18.
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.
Wires 800-999
Wires 800-999
These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc.
Wires In Splices
Wires In Splices
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.
The letters I, O, Q and S are not used.
General Points
General Points
1 Wires continue to have the same number even after passing through a connector block to another harness.
1 Wires continue to have the same number even after passing through a connector block to another harness.
2 If all the numbers in a category have been allocated, then the category is re-used with an additional prefix ‘1’, i.e. 1832.
Wiring Harness Repair
Wiring Harness Repair
Introduction
Introduction
Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, a…
To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an accepta…
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.
When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular ci…
In addition to the warnings incorporated into this procedure, extreme care should be taken when handling the gas heating tool to…
When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not t…
Repair Procedure
Repair Procedure
Table 4. Tools Required
Table 4. Tools Required
<TABLE
<TABLE HEADING
<TABLE ROW
Part No.
Description
Qty
<TABLE BODY
<TABLE ROW
892/00350
Butane Heater assembly
1
<TABLE ROW
892/00349
Crimp tool
1
<TABLE ROW
892/00351
Splice 0.5-1.5 mm (Red)
50
<TABLE ROW
892/00352
Splice 1.5-2.5 mm (Blue)
50
<TABLE ROW
892/00353
Splice 3.0-6.0 mm (Yellow)
50
1 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
1 Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in
K Table 4. ( T C-19)
<GRAPHIC
<GRAPHIC
Fig 19.
2 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 19. ( T C-19)
3 With the Butane heater assembly, seal the connection.
K Fig 20. ( T C-20)
a Remove the cap
a Remove the cap
21-A
21
21-B
21
<GRAPHIC
<GRAPHIC
Fig 20.
b Before assembling the gas cartridge to the reflector element
b Before assembling the gas cartridge to the reflector element
b Before assembling the gas cartridge to the reflector element
22-C
22
22-D
22
<GRAPHIC
<GRAPHIC
Fig 21.
c 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.
c 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.
c 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 22. ( T C-20)
<GRAPHIC
<GRAPHIC
Fig 22.
d Turn the small ring
d Turn the small ring
d Turn the small ring
23-E
23
23- F
23
<GRAPHIC
<GRAPHIC
Fig 23.
e Turn the red ring
e Turn the red ring
e Turn the red ring
24-D
24
Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartr…
<GRAPHIC
<GRAPHIC
Fig 24.
f Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
f Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
f Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red. Then turn the small ring
25-E
25
25-F
25
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.
<GRAPHIC
<GRAPHIC
Fig 25.
g The heater can be used in two modes:
g The heater can be used in two modes:
g The heater can be used in two modes:
i Side wings
i Side wings
26-G
26
<GRAPHIC
<GRAPHIC
Fig 26.
ii Side wings
27-G
27
<GRAPHIC
<GRAPHIC
Fig 27.
h To switch off the heater, turn the red ring
h To switch off the heater, turn the red ring
h To switch off the heater, turn the red ring
27-D
27
Electronic Monitoring System (EMS)
Electronic Monitoring System (EMS)
C164 Display Panel
C164 Display Panel
Ignition On
Ignition On
During the first second after switching on, all LCD segments and warning lights are illuminated then the software version is displayed on the top line.
Pre-Start Mode
Pre-Start Mode
<GRAPHIC
<GRAPHIC
Fig 28.
The following warning lights are checked:
<GRAPHIC
<GRAPHIC
Fig 29.
1 Battery Voltage
1 Battery Voltage
Illuminated if the battery voltage is low.
2 Hydraulic Fluid Temperature
Illuminated if the temperature is high.
3 Transmission Oil Temperature
Illuminated if the temperature is high.
4 Fuel Level
Illuminated if the temperature is high.
5 Coolant Temperature
Flashes when only 10% of fuel is left in tank.
6 CAN-Bus Error
Illuminated if EMS receives a CAN bus error from the ZF Computer.
The following warning lights will also Illuminate and the buzzer will sound:
<GRAPHIC
<GRAPHIC
Fig 30.
7 Engine Oil Pressure Low
7 Engine Oil Pressure Low
8 Parking Brake On
9 Alternator No Charge
10 Brake Pressure Low (unless accumulators are still charged)
11 Steering Pressure Low
Setting Up
Setting Up
1 Turn on the power by turning the starter key to IGN.
1 Turn on the power by turning the starter key to IGN.
2 Pressing the SETUP/SELECT button while in Pre- Start Mode will allow the display to be set up as follows:
Use the up and down arrows to adjust display as required.
a CLK FORMAT
a CLK FORMAT
a CLK FORMAT
a CLK FORMAT
The clock format (12/24 Hour) is shown in the top right corner.
b HOUR
c AM/PM
With 12 Hour selected, AM or PM is selected and is displayed in the top left corner.
d MINUTE
e YEAR
f MONTH
g DATE (Day)
h LANGUAGE
English is the default language, there is one alternative language. Certain languages are not available.
i Returns the display to Pre-Start Mode.
Start Inhibit
Start Inhibit
<GRAPHIC
<GRAPHIC
Fig 31.
The following warnings will also cause the “START INHIBIT” message to be displayed. The engine will not start until the fault is cleared
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
3
3
Transmission Oil Temperature
<TABLE ROW
4
4
Coolant Temperature
<TABLE ROW
12
12
Emergency Steer Pump
If Neutral is not selected, the panel will display the message “IN GEAR” and the buzzer will sound.
If the parking brake is on and the transmission is not in neutral, the message “PARK BRAKE” will also be displayed.
If there is a fault with the emergency steering, the message “STEER SW FAULT” will be displayed and the buzzer will sound.
START INHIBIT can be overridden by pushing the MANUAL button once.
Warning Lights
Warning Lights
Visual Warnings Only
Visual Warnings Only
<GRAPHIC
<GRAPHIC
Fig 32.
1 Direction Indicators
1 Direction Indicators
Left or Right flashes with the direction indicators. Both flash when Hazard Warning Lights are on. Use the indicators to signal before turning.
2 Hazard Warning
Flashes with the hazard warning lights (even with the starter switch at O). Switch the flashers on whenever your machine is a possible hazard.
3 Side Lights On
Lights up when the side lights are switched on.
4 Main Beam On
Lights up when the headlight main beams are switched on. Switch the main beams off for on- coming traffic.
5 Dip Beam On
Lights up when the headlight dipped lights are switched on.
6 Front Work Lights On
Lights up when the front work lights are switched on.
7 Rear Work Lights On
Lights up when the rear work lights are switched on.
8 Rear Fog Light On
Lights up when the rear fog light is switched on.
9 Parking Brake Engaged
Lights up when the parking brake is engaged.
10 Emergency Steer Pump
Lights up when the emergency steering system is operating, ie, When the machine is moving.
Flashes when system fails to pressurise due to system fault.
“EM STEER FAULT”.
Visual Warnings plus Buzzer and Message
Visual Warnings plus Buzzer and Message
The messages associated with these warnings will be displayed on the top line of the display panel.
<GRAPHIC
<GRAPHIC
Fig 33.
11 Battery Voltage Low
11 Battery Voltage Low
Lights up when the battery voltage is low.
“BATTERY LOW”
12 Engine Oil Pressure Low
Operates if the engine oil pressure drops too far. The light should go out when the engine is started.
13 Hydraulic Fluid Temperature High
Operates if the hydraulic fluid temperature rises too high.
“HYD OIL TEMP”
14 Transmission Oil Temperature High
Operates if the transmission oil temperature rises too high.
“TRANS OIL TEMP”
15 No Charge
Operates when the battery charging circuit fails while the engine is running. The light should go out a few seconds after the engine is started.
“ALTERNATOR”
“ENG OIL PRESS”
16 Brake System Pressure Low
Lights up when the brake system pressure is low.
“BRAKE FAILURE”
17 Main Steer System
Lights up if the main hydraulic system pressure fails. Stop the machine as soon as it is safe to do so and rectify the fault.
“STEERING PRESS”
18 Water Temperature High
Operates if the engine coolant temperature rises too high.
“COOLANT TEMP”
19 Air Filter Blocked
Operates if the engine air filter clogs up.
“AIR FLTER BLKD”
Visual Warning and Message
Visual Warning and Message
The messages associated with these warnings will be displayed on the top line of the display panel.
<GRAPHIC
<GRAPHIC
Fig 34.
1 Service Required
1 Service Required
If lit, contact your JCB Dealer.
“SERVICE REQD”
The “SERVICE REQD” message is displayed in Pre-Start Mode only.
If diagnostic option is fitted, the Service Requires warning and message will be displayed at pre-set intervals and also if the diagnostic computer memory is full. The Service Required is reset when data is down loaded by your JCB Dealer.
Automatic Engine Shut Down
Automatic Engine Shut Down
The following warnings will also initiate the automatic engine shut down system.
<GRAPHIC
<GRAPHIC
Fig 35.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
1
1
Engine Oil Pressure Low
<TABLE ROW
2
2
Transmission Oil Temperature High
<TABLE ROW
3
3
Brake System Pressure Low
<TABLE ROW
4
4
Main Steer System
<TABLE ROW
5
5
Coolant Temperature
<TABLE ROW
6
6
Air Filter Blocked
A 30 second count down to engine shut down starts as soon as the warning symbol is illuminated.
The count down time is displayed on the top line of the display alternating with the appropriate warning dialogue.
In an emergency, the MANUAL button will reset the counter to 30 seconds; this will allow the machine to be moved if necessary.
In an emergency
Although there is no limit to the number of times the button may be pressed, each press of the MANUAL button is remembered in the diagnostic data logger.
The ignition switch must be switched OFF after a shut down to enable the system to reset.
Segmented Displays
Segmented Displays
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Speedometer
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates the road speed. The road speed in miles per hour (mph) is shown in black and kilometres (kph) are shown in red.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fuel Gauge
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates the level of fuel in the tank. SeeK Types of Fuel ( T 1-109) for the fuel to be used. Do not let the tank run dry, or air will enter the fuel system.
The message “LOW FUEL” is displayed on the panel when only 10% of fuel is left in the tank.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Water Temperature
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates the working temperature of the engine coolant. Do not let the indicator rise to the red danger zone of the gauge.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Transmission Oil Temperature
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates the working temperature of the transmission oil. Do not let the indicator rise to the red danger zone of the gauge.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Hydraulic Fluid Temperature
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates the working temperature of the hydraulic fluid. Do not let the indicator rise into the red danger zone of the gauge.
Transmission Fault
Transmission Fault
In the event of the transmission developing a fault, the EMS will display a fault code to aid diagnosis.
A fault code will be displayed on the top line of the display panel. An example of a fault code is shown below.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ZFCB ERROR ??
ZFCB ERROR ??
A list of the fault codes is given in the Service Manual.
Indications (Engine Off)
Indications (Engine Off)
<GRAPHIC
<GRAPHIC
Fig 36.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates that machine hours are displayed top left of the display.
All the warning lights should go out when the engine is started. Rectify any faults immediately.
Indications (Engine Running)
Indications (Engine Running)
<GRAPHIC
<GRAPHIC
Fig 37.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates that Transmission information is displayed top left of the display.
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indicates that time is displayed top right of the display.
The gear in use is indicated top left of the display.
Neutral (N) is displayed until the parking brake is disengaged when ranges 1 or 2 are selected.
Warning Light Test (Daily)
Warning Light Test (Daily)
1 Turn on the power by turning the starter key to IGN.
1 Turn on the power by turning the starter key to IGN.
2 All the fault warning lights should illuminate during the start up cycle.
3 If any of the fault warning lights fail to illuminate, contact your JCB Dealer.
Do not use the machine if any of the warning lights do not illuminate. Have the fault rectified immediately.
Fault Finding
Fault Finding
Introduction to Fault – Finding Techniques
Introduction to Fault – Finding Techniques
The fault-finding procedures detailed in this manual rely on the correct use of a Fluke 85 digital multimeter for measuring voltage, current, continuity and frequency.
Instructions on the use of this meter are provided on
K Using a Multimeter ( T C-5)
K Measuring Frequency ( T C-7)
Fault diagnosis could involve the measurement of continuity between certain points in a circuit. Whilst the location of these points may look straightforward on the schematic diagram, the reality is somewhat different.
The wiring in your machine is not laid out as shown in the schematic diagram. For a variety of reasons associated with safety, r…
<GRAPHIC
<GRAPHIC
Fig 38. Schematic Diagram
Harness Routing
Harness Routing
As a major aid to fault-finding we have detailed the point to point wiring throughout the machine.
The machines have individual harnesses as follows:
1 front chassis harness
1 front chassis harness
2 rear chassis harness
3 side console harness
4 rear cab harness
5 cab roof harness
6 controller harness
7 rear grille harness
8 hydraulic mode harness
9 under bonnet light
Their approximate locations are shown in
K Harnesses: 434S Machines ( T C-59)
<GRAPHIC
<GRAPHIC
Fig 39. Wiring Harness
<GRAPHIC
<GRAPHIC
Fig 40.
Example of Wire Tracing
Example of Wire Tracing
This section contains information for each harness in the form of a diagram showing the actual wire harness and tables detailing the harness connections and wire identification.
The diagram shows how wiring can be traced from point to point using the harness information. With the knowledge gained from this worked example it should be straightforward to trace any wire through the machine.
Two way connector FE is connected to the front washer motor. Wire 819 is the live wire and 600 AG, the chassis connection. (All …
K Fig 56. ( T C-69)
Using the wiring information for the five harnesses all wires can be traced from source to destination. It should be noted, however, that, unlike in the example, some wires undergo a number change particularly when switched through a relay.
Connectors are identified by a two letter code, eg. FE.
Splices are also identified by a two letter code of which the first letter is always S, eg SA.
On the Side Console Harness, (
K Fig 58. ( T C-72)
K Fig 60. ( T C-76)
Splices are identified on the page by showing them in a dotted line box.
Circuit Diagrams
Circuit Diagrams
Basic Circuit
Basic Circuit
The basic circuit shows a `standard’ machine.
Table 5.
K Fuses and Relays 434S Machines ( T C-2)
Table 5.
Table 5.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 41. ( T C-35)
Main Components
K Fig 41. ( T C-35)
<TABLE ROW
1
Battery isolator
<TABLE ROW
2
Battery
<TABLE ROW
3
Start relay
<TABLE ROW
4
Starter motor
<TABLE ROW
5
Ignition switch
<TABLE ROW
6
Alternator
<TABLE ROW
7
Grid heater relay
<TABLE ROW
8
HVAC relay
Heating Ventilation Air Conditioning
<TABLE ROW
9
Ignition relay 1
<TABLE ROW
10
Front work lights relay
<TABLE ROW
11
Lighting relay
<TABLE ROW
12
Ignition relay 2
<TABLE ROW
13
Ignition relay 3
Table 6.
Table 6.
<TABLE
<TABLE BODY
<TABLE ROW
Primary Fuses K Fig 41. ( T C-35)
K Fig 41. ( T C-35)
<TABLE ROW
PF1
Ignition relay 1/front work light circuits
<TABLE ROW
PF2
Hazard indicators, beacon, Interior light, radio (24v), head light flash
<TABLE ROW
PF3
Ignition/starter circuits
<TABLE ROW
PF4
Grid heater relay
<TABLE ROW
PF5
Lighting
<TABLE ROW
PF6
HVAC circuit
<TABLE ROW
PF7
Right and left hand sidelights, heated rear screen, Battery feed for EMS and ZF computer.
<TABLE ROW
PF8
Engine ECU
<TABLE ROW
PF9
Emergency steering circuit
<TABLE ROW
PF10
Engine grid heater circuit
Table 7.
Table 7.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C1
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C2
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C3
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C4
C4
K Fig 41. ( T C-35)
K Fig 41. ( T C-35)
<TABLE ROW
C5
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C6
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C7
C7
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C8
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C9
C9
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C10
K Fig 44. ( T C-41)
K Fig 44. ( T C-41)
<TABLE ROW
C11
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C12
K Fig 45. ( T C-43)
K Fig 45. ( T C-43)
<TABLE ROW
C13
K Fig 45. ( T C-43)
K Fig 45. ( T C-43)
<TABLE ROW
C14
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C15
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C16
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C17
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
C18
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C19
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C20
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C21
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C22
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C23
K Fig 46. ( T C-45)
K Fig 46. ( T C-45)
<TABLE ROW
C24
K Fig 46. ( T C-45)
K Fig 46. ( T C-45)
<TABLE ROW
C25
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C26
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C27
K Fig 46. ( T C-45)
K Fig 46. ( T C-45)
<TABLE ROW
C28
K Fig 46. ( T C-45)
K Fig 46. ( T C-45)
<TABLE ROW
C29
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C30
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C31
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C32
K Fig 51. ( T C-55)
K Fig 51. ( T C-55)
<TABLE ROW
C33
K Fig 45. ( T C-43)
K Fig 45. ( T C-43)
<TABLE ROW
C34
K Fig 45. ( T C-43)
K Fig 45. ( T C-43)
<TABLE ROW
C35
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C36
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C37
K Fig 46. ( T C-45)
K Fig 46. ( T C-45)
<TABLE ROW
C38
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C39
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C40
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C41
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C42
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C43
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C44
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C45
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C46
K Fig 45. ( T C-43)
K Fig 45. ( T C-43)
<TABLE ROW
C47
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C48
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
C49
K Fig 44. ( T C-41)
K Fig 44. ( T C-41)
<GRAPHIC
<GRAPHIC
Fig 41. Primary Fuses, Ignition Switch and Relays: Sheet 1 of 13
For component key
K Table 5. ( T C-33)
For key to connecting circuits
K Table 7. ( T C-33)
Table 8.
Table 8.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 42. ( T C-37)
Main Components
K Fig 42. ( T C-37)
<TABLE ROW
14
EMS Connector A
<TABLE ROW
a
Buzzer
<TABLE ROW
b
Emergency steer switch
<TABLE ROW
c
Brake pressure switch
<TABLE ROW
d
Brake pressure switch (engine mounted)
<TABLE ROW
e
Steer pressure switch
<TABLE ROW
f
Engine oil pressure switch
<TABLE ROW
g
Air filter blocked switch
<TABLE ROW
h
Hydraulic oil temperature switch
<TABLE ROW
j
Charge air cooler temperature switch
<TABLE ROW
15
EMS Diagnostic port
<TABLE ROW
16
CAN J1939 Connector
<TABLE ROW
17
CAN Terminating resistor
<TABLE ROW
18
Vari-flow fan solenoid
<TABLE ROW
19
EMS Connector B
<TABLE ROW
a
Fuel level sensor
<TABLE ROW
b
Water temperature sender (Tier II Engine only)
All the items listed here are not necessarily fitted to all machines in the range.
Table 9.
Table 9.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C50
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C51
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C52
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C53
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C54
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C55
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C56
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C57
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C58
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C59
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C60
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C61
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C62
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C63
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C64
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C65
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C66
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C67
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C68
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
CB1
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
CB2
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
CB3
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<GRAPHIC
<GRAPHIC
Fig 42. Instrumentation – EMS display, Sheet 2 of 13
For component key
K Table 8. ( T C-36)
For key to connecting circuits
K Table 9. ( T C-36)
Table 10.
Table 10.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 43. ( T C-39)
Main Components
K Fig 43. ( T C-39)
<TABLE ROW
20
Speed sensor
<TABLE ROW
21
Left hand column switch
<TABLE ROW
22
Joystick
<TABLE ROW
23
SRS Solenoid
Smooth Ride System
<TABLE ROW
24
SRS Switch
<TABLE ROW
25
Auto/manual ON/OFF switch
<TABLE ROW
26
Dump switch
<TABLE ROW
a
Transmission disconnect pressure switches
<TABLE ROW
27
Handbrake lever switch
<TABLE ROW
28
E-stop type switch (456 only)
<TABLE ROW
29
ZF Computer
<TABLE ROW
a
Diagnostic port
<TABLE ROW
b
Internal gear chain speed sensor
<TABLE ROW
c
Turbine speed sensor
<TABLE ROW
d
Engine speed sensor
<TABLE ROW
e
Hand brake solenoid
<TABLE ROW
f
Gearbox controller
<TABLE ROW
g
Torque converter out temperature sensor
Table 11.
Table 11.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C69
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C70
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C71
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C72
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C73
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C74
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C75
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C76
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C77
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
CB1a
K Fig 44. ( T C-41)
K Fig 44. ( T C-41)
<TABLE ROW
CB2a
K Fig 44. ( T C-41)
K Fig 44. ( T C-41)
<TABLE ROW
CB3a
K Fig 44. ( T C-41)
K Fig 44. ( T C-41)
<GRAPHIC
<GRAPHIC
Fig 43. ZF Computer and Gearbox Controller, Sheet 3 of 13
For component key
K Table 10. ( T C-38)
For key to connecting circuits
K Table 11. ( T C-38)
Table 12.
Table 12.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 44. ( T C-41)
Main Components
K Fig 44. ( T C-41)
<TABLE ROW
30
Electronic foot throttle
<TABLE ROW
31
Engine ECU connector (Engine harness)
<TABLE ROW
a
Coolant level sense resistor
<TABLE ROW
32
Engine ECU J1 connector
<TABLE ROW
a
Crankshaft speed sensor
<TABLE ROW
b
Camshaft position sensor
<TABLE ROW
c
Fuel rail pressure sensor
<TABLE ROW
d
Water in fuel sensor (WIF)
<TABLE ROW
e
Intake manifold pressure/air temperature sensor
<TABLE ROW
f
Engine oil pressure sensor
<TABLE ROW
g
Barometric
<TABLE ROW
h
Engine coolant temperature sensor
<TABLE ROW
j
Fuel lift pump
<TABLE ROW
k
Engine oil pressure switch
<TABLE ROW
l
Fuel pump actuator
<TABLE ROW
m
CAN bus data link
<TABLE ROW
n
Injector 1
<TABLE ROW
p
Injector 2
<TABLE ROW
q
Injector 3
<TABLE ROW
r
Injector 4
<TABLE ROW
s
Injector 5
<TABLE ROW
t
Injector 6
<TABLE ROW
33
Engine ECU power connector
<TABLE ROW
34
CAN Terminating resistor
Table 13.
Table 13.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C78
K Fig 41. ( T C-35)
K Fig 41. ( T C-35)
<TABLE ROW
C79
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<GRAPHIC
<GRAPHIC
Fig 44. Tier 3 Engine ECU, Sheet 4 of 13
For component key
K Table 12. ( T C-40)
For key to connecting circuits
K Table 13. ( T C-40)
Table 14.
Table 14.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 45. ( T C-43)
Main Components
K Fig 45. ( T C-43)
<TABLE ROW
35
Right hand column switch
<TABLE ROW
36
Wiper motor
<TABLE ROW
37
Front washer motor
<TABLE ROW
38
Horn
<TABLE ROW
39
Wash/wipe switch
<TABLE ROW
40
Rear wiper motor
<TABLE ROW
41
Rear washer motor
<TABLE ROW
42
Heater motor switch
<TABLE ROW
43
HVAC Unit
<TABLE ROW
44
Air conditioning relay
<TABLE ROW
45
Air conditioning switch
<TABLE ROW
46
Hi/low binary switch
<TABLE ROW
47
Compressor clutch
Table 15.
Table 15.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C80
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C81
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C82
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C83
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C84
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C85
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C86
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C87
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C88
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<GRAPHIC
<GRAPHIC
Fig 45. Front Wiper, Rear Wiper and Heater/AC, Sheet 5 of 13
For component key
K Table 14. ( T C-42)
For key to connecting circuits
K Table 15. ( T C-42)
Table 16.
Table 16.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 46. ( T C-45)
Main Components
K Fig 46. ( T C-45)
<TABLE ROW
48
Front work light switch
<TABLE ROW
49
Left hand front work light
<TABLE ROW
50
Right hand front work light
<TABLE ROW
51
Left hand front auxiliary work light
<TABLE ROW
52
Right hand front auxiliary work light
<TABLE ROW
53
Rear work light switch
<TABLE ROW
54
Left hand rear work light
<TABLE ROW
55
Right hand rear work light
<TABLE ROW
56
Left hand rear auxiliary work light
<TABLE ROW
57
Right hand rear auxiliary work light
<TABLE ROW
58
Left hand rear auxiliary work light (bonnet)
<TABLE ROW
59
Right hand rear auxiliary work light (bonnet)
<TABLE ROW
60
Beacon switch
<TABLE ROW
61
Beacon
<TABLE ROW
62
Interior light right hand
<TABLE ROW
63
Interior light left hand
Table 17.
Table 17.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C89
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C90
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C91
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C92
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C93
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C94
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C95
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C96
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C97
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C98
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C99
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C100
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C101
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C102
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C103
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C104
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C105
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C106
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C107
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C108
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<GRAPHIC
<GRAPHIC
Fig 46. Front and Rear Beacons, Auxiliary Work Lights, Sheet 6 of 13
For component key
K Table 16. ( T C-44)
For key to connecting circuits
K Table 17. ( T C-44)
Table 18.
Table 18.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 47. ( T C-47)
Main Components
K Fig 47. ( T C-47)
<TABLE ROW
64
Roadlight switch
<TABLE ROW
65
Left hand number plate light (roof)
<TABLE ROW
66
Right hand number plate light (roof)
<TABLE ROW
67
Right hand column switch
<TABLE ROW
68
Left hand front headlight
<TABLE ROW
69
Right hand front headlight
<TABLE ROW
70
Rear fog light switch
<TABLE ROW
71
Reverse relay
<TABLE ROW
72
Reverse alarm
<TABLE ROW
73
Left hand rear combination lamp
<TABLE ROW
74
hazard switch
<TABLE ROW
75
Flasher unit
<TABLE ROW
76
Right hand column switch
<TABLE ROW
77
Right hand combination lamp
<TABLE ROW
78
Brake light relay
<TABLE ROW
79
Brake light switch
<TABLE ROW
80
Brake light switch (mainframe)
<TABLE ROW
81
Left hand number plate light (rear grille)
Table 19.
Table 19.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C109
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C110
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C111
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C112
K Fig 45. ( T C-43)
K Fig 45. ( T C-43)
<TABLE ROW
C113
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C114
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C115
K Fig 51. ( T C-55)
K Fig 51. ( T C-55)
<TABLE ROW
C116
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C117
K Fig 46. ( T C-45)
K Fig 46. ( T C-45)
<TABLE ROW
C118
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C119
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
C120
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
C121
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
C122
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C123
K Fig 51. ( T C-55)
K Fig 51. ( T C-55)
<TABLE ROW
C124
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C125
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C126
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C127
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C128
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C129
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C130
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C131
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C132
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C133
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C134
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C135
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C136
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C137
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C138
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C139
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C140
K Fig 43. ( T C-39)
K Fig 43. ( T C-39)
<TABLE ROW
C141
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C142
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C143
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C144
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C145
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C146
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C147
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C148
K Fig 48. ( T C-49)
K Fig 48. ( T C-49)
<TABLE ROW
C149
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C150
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<GRAPHIC
<GRAPHIC
Fig 47. Road Lighting, Sheet 7 of 13
For component key
K Table 18. ( T C-46)
For key to connecting circuits
K Table 19. ( T C-46)
Table 20.
Table 20.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 48. ( T C-49)
Main Components
K Fig 48. ( T C-49)
<TABLE ROW
82
Tow hitch switch
<TABLE ROW
83
Tow hitch solenoid 1
<TABLE ROW
84
Tow hitch solenoid 2
<TABLE ROW
85
Radio power 24v
<TABLE ROW
86
Left hand radio speaker
<TABLE ROW
87
Right hand radio speaker
<TABLE ROW
88
24/12v Dropper
<TABLE ROW
89
Cigar lighter 12v
<TABLE ROW
90
radio power 12v
<TABLE ROW
91
Cigar lighter 24v
<TABLE ROW
92
CCTV system
<TABLE ROW
93
CCTV Camera
<TABLE ROW
<TABLE ROW
<TABLE ROW
Table 21.
Table 21.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C151
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C152
K Fig 49. ( T C-51)
K Fig 49. ( T C-51)
<TABLE ROW
C153
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C154
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C155
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C156
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<GRAPHIC
<GRAPHIC
Fig 48. Radio, Cigar Lighter, CCTV and Tow Hitch, Sheet 8 of 13
For component key
K Table 20. ( T C-48)
For key to connecting circuits
K Table 21. ( T C-48)
Table 22.
Table 22.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 49. ( T C-51)
Main Components
K Fig 49. ( T C-51)
<TABLE ROW
94
Immobiliser control unit
<TABLE ROW
95
Dallas key pad
<TABLE ROW
96
Shutdown relay
<TABLE ROW
97
ESOS (Tier 2 only)
<TABLE ROW
98
Heated mirror switch
<TABLE ROW
99
Left hand heated mirror
<TABLE ROW
100
Right hand heated mirror
<TABLE ROW
101
Seat
<TABLE ROW
102
Heated seat switch
<TABLE ROW
103
Reverse fan relay
<TABLE ROW
104
Reverse fan solenoid
<TABLE ROW
105
Emergency steer test switch
<TABLE ROW
106
Emergency steer relay 1
<TABLE ROW
107
Emergency steer relay 2
<TABLE ROW
108
Emergency steer motor
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Table 23.
Table 23.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C157
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C158
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C159
K Fig 44. ( T C-41)
K Fig 44. ( T C-41)
<TABLE ROW
C160
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C161
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C162
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C163
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C164
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C165
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C166
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C167
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C168
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C169
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C170
K Fig 42. ( T C-37)
K Fig 42. ( T C-37)
<TABLE ROW
C171
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C172
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<GRAPHIC
<GRAPHIC
Fig 49. ESOS, Heated Mirrors Heated Seat, Seat Suspension, Reverse Fan and Emergency Steering, Sheet 9 of 13
For component key
K Table 22. ( T C-50)
For key to connecting circuits
K Table 23. ( T C-50)
Table 24.
Table 24.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 50. ( T C-53)
Main Components
K Fig 50. ( T C-53)
<TABLE ROW
109
24/12V Dropper
<TABLE ROW
110
Left hand indicator relay
<TABLE ROW
111
Right hand indicator relay
<TABLE ROW
112
Left hand tail light relay
<TABLE ROW
113
Right hand tail light relay
<TABLE ROW
114
Brake light relay
<TABLE ROW
115
Fog light relay
<TABLE ROW
116
12v trailer socket plug
<TABLE ROW
117
Weighload/Autolube plug
<TABLE ROW
118
Lift reset
<TABLE ROW
119
Detent (loader valve)
<TABLE ROW
120
Shovel reset
<TABLE ROW
121
Reset switch (456 HT only)
<TABLE ROW
122
Detent (loader valve)
<TABLE ROW
123
Fork reset
<TABLE ROW
124
Float detent (loader valve)
<TABLE ROW
125
4th Spool change over switch
<TABLE ROW
126
Changeover solenoid
<TABLE ROW
<TABLE ROW
Table 25.
Table 25.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C99
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C135
K Fig 47. ( T C-47)
K Fig 47. ( T C-47)
<TABLE ROW
C173
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C174
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C175
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C176
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C177
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C178
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C179
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C180
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C181
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C182
K Fig 51. ( T C-55)
K Fig 51. ( T C-55)
<GRAPHIC
<GRAPHIC
Fig 50. 12v Trailer Electrics and Loader Functions, Sheet 10 of 13
For component key
K Table 24. ( T C-52)
For key to connecting circuits
K Table 25. ( T C-52)
Table 26.
Table 26.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components K Fig 51. ( T C-55)
Main Components
K Fig 51. ( T C-55)
<TABLE ROW
127
Quick hitch isolator switch
<TABLE ROW
128
Quick hitch locking solenoid
<TABLE ROW
129
Servo isolator switch
<TABLE ROW
130
Servo isolator solenoid
<TABLE ROW
131
Neutral relay
<TABLE ROW
132
Joystick connection
<TABLE ROW
133
3rd Spool recovery switch
<TABLE ROW
134
Diode pack
<TABLE ROW
135
UCU4 Auxiliary controller
<TABLE ROW
136
Proportional joystick
<TABLE ROW
137
ECU4 Indicator
<TABLE ROW
138
Changeover relay
<TABLE ROW
139
Resistor
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Table 27.
Table 27.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
C183
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C184
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C185
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
C186
K Fig 53. ( T C-57)
K Fig 53. ( T C-57)
<TABLE ROW
C187
K Fig 50. ( T C-53)
K Fig 50. ( T C-53)
<TABLE ROW
C188
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<GRAPHIC
<GRAPHIC
Fig 51. Loader Auxiliaries (Proportional), Sheet 11 of 13
For component key
K Table 26. ( T C-54)
For key to connecting circuits
K Table 27. ( T C-54)
<GRAPHIC
<GRAPHIC
Fig 52. Earthing – Cab Roof and 12v Trailer Electrics, Sheet 12 of 13
Table 28.
Table 28.
<TABLE
<TABLE HEADING
<TABLE ROW
Connection:
Refer to:
<TABLE BODY
<TABLE ROW
X
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
Y
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<TABLE ROW
Z
K Fig 52. ( T C-56)
K Fig 52. ( T C-56)
<GRAPHIC
<GRAPHIC
Fig 53. Earthing – Front Chassis, Rear Chassis and Engine, Sheet 13 of 13
For connections
K Table 28. ( T C-56)
Harness Data
Harness Data
Drawings and Interconnection
Drawings and Interconnection
Harnesses: 434S Machines
Harnesses: 434S Machines
The harness number refers to and corresponds with the annotations in the schematic drawing.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Harness No.
Harness No.
Issue
Issue
Remarks
Remarks
Drawing
Drawing
<TABLE ROW
1
1
Cab Roof Harness
Cab Roof Harness
<TABLE ROW
721/11818
3
K ( T C-65)
K ( T C-65)
<TABLE ROW
Main components connected to this harness:
Cab harness
<TABLE ROW
Front work light switch
<TABLE ROW
Rear work light switch
<TABLE ROW
Beacon switch
<TABLE ROW
Front work lights
<TABLE ROW
Front auxiliary work lights
<TABLE ROW
Rear work lights
<TABLE ROW
Rear auxiliary work lights
<TABLE ROW
Beacon socket
<TABLE ROW
Interior light
<TABLE ROW
Number plate lights
<TABLE ROW
Radio power and speakers
<TABLE ROW
Heated mirror switch
<TABLE ROW
Heated mirrors
<TABLE ROW
Earth point
<TABLE ROW
<TABLE ROW
2
2
Transmission Harness
Transmission Harness
<TABLE ROW
721/11826
3
K ( T C-68)
K ( T C-68)
<TABLE ROW
Main components connected to this harness:
Output speed sensor
<TABLE ROW
Turbine speed senor
<TABLE ROW
Gear chain speed sensor
<TABLE ROW
Engine speed
<TABLE ROW
Control unit
<TABLE ROW
Cab connector
<TABLE ROW
<TABLE ROW
3
3
Engine Harness
Engine Harness
<TABLE ROW
721/12214
1
K ( T C-70)
K ( T C-70)
<TABLE ROW
Main components connected to this harness:
Torque converter
<TABLE ROW
Engine ECU
<TABLE ROW
CAN Bus system
<TABLE ROW
Steer pressure switch
<TABLE ROW
Air conditioning compressor
<TABLE ROW
Brake pressure switch
<TABLE ROW
Foot throttle
<TABLE ROW
<TABLE ROW
4
Quickhitch Locking Harness
Quickhitch Locking Harness
<TABLE ROW
721/11922
1
K ( T C-73)
K ( T C-73)
<TABLE ROW
Main components connected to this harness
Front chassis connector
<TABLE ROW
Quickhitch solenoid
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
5
5
Front Chassis Harness HT
Front Chassis Harness HT
<TABLE ROW
721/11928
1
K ( T C-75)
K ( T C-75)
<TABLE ROW
Main components connected to this harness
Front lights
<TABLE ROW
Horn
<TABLE ROW
Fork reset
<TABLE ROW
Lift reset
<TABLE ROW
Shovel reset
<TABLE ROW
Quickhitch locking
<TABLE ROW
Servo isolator
<TABLE ROW
Change over
<TABLE ROW
Load suspension
<TABLE ROW
Main harness connector
<TABLE ROW
<TABLE ROW
6
6
Rear Cab Harness
Rear Cab Harness
<TABLE ROW
721/11941
1
K ( T C-77)
K ( T C-77)
<TABLE ROW
Main components connected to this harness
Park brake switch
<TABLE ROW
Cab connector
<TABLE ROW
Front wash pump
<TABLE ROW
Rear wash pump
<TABLE ROW
<TABLE ROW
7
7
Proportional Auxiliary Harness
Proportional Auxiliary Harness
<TABLE ROW
721/11943
2
K ( T C-79)
K ( T C-79)
<TABLE ROW
Main components connected to this harness
Proportional auxiliary options plug
<TABLE ROW
ECU 4
<TABLE ROW
Recovery switch
<TABLE ROW
Joystick
<TABLE ROW
ECU 4 indicator
<TABLE ROW
Change over/Neutral relay
<TABLE ROW
Side console connection
<TABLE ROW
Diode pack ECU 4
<TABLE ROW
Diode pack
<TABLE ROW
3rd/4th spool connection
<TABLE ROW
<TABLE ROW
8
8
3rd/4th Spool Harness
3rd/4th Spool Harness
<TABLE ROW
721/11944
1
K ( T C-82)
K ( T C-82)
<TABLE ROW
Main components connected to this harness
Cab connector
<TABLE ROW
3rd Spool solenoid C1
<TABLE ROW
4th Spool solenoid C2
<TABLE ROW
4th Spool solenoid C3
<TABLE ROW
3rd Spool solenoid C4
<TABLE ROW
<TABLE ROW
9
9
3rd Spool Harness
3rd Spool Harness
<TABLE ROW
721/11945
1
K ( T C-84)
K ( T C-84)
<TABLE ROW
Main components connected to this harness
Cab connector
<TABLE ROW
3rd Spool solenoid C1
<TABLE ROW
3rd Spool connector
<TABLE ROW
<TABLE ROW
10
10
Multi-Lever Harness
Multi-Lever Harness
<TABLE ROW
721/11967
1
K ( T C-86)
K ( T C-86)
<TABLE ROW
Main components connected to this harness
Cab harness joystick plug
<TABLE ROW
FNR paddle switch
<TABLE ROW
Dump/Kickdown switch
<TABLE ROW
<TABLE ROW
11
11
Rear Chassis Harness
Rear Chassis Harness
<TABLE ROW
721/12215
1
K ( T C-88)
K ( T C-88)
<TABLE ROW
Main components connected to this harness
Primary fuses
<TABLE ROW
Rear lights
<TABLE ROW
Park brake solenoid
<TABLE ROW
Cab connectors 1 and 2
<TABLE ROW
Emergency steering relay
<TABLE ROW
Grid heater relays
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
12
12
Rear Grille Harness
Rear Grille Harness
<TABLE ROW
721/12218
1
K ( T C-92)
K ( T C-92)
<TABLE ROW
Main components connected to this harness
Rear chassis connector
<TABLE ROW
Auxiliary lighting
<TABLE ROW
Reverse alarm
<TABLE ROW
Number plate light
<TABLE ROW
<TABLE ROW
13
13
Cab Harness
Cab Harness
<TABLE ROW
721/12117
1
K ( T C-94)
K ( T C-94)
<TABLE ROW
Main components connected to this harness
Ignition switch
<TABLE ROW
Column switch
<TABLE ROW
Wiper motor
<TABLE ROW
Chassis connector
<TABLE ROW
EMS
<TABLE ROW
Cab switches
<TABLE ROW
Loader control lever
<TABLE ROW
Transmission computer
<TABLE ROW
Fuse boxes
<TABLE ROW
Air conditioning
<TABLE ROW
Diagnostic port
<TABLE ROW
Heated screen
<TABLE ROW
Roadlighting
<TABLE ROW
Hazard switch
<TABLE ROW
Park brake switch
<TABLE ROW
ZF Computer
<TABLE ROW
Dallas key pad
<TABLE ROW
CCTV
<TABLE ROW
Ignition relays
<TABLE ROW
<TABLE ROW
14
14
CAN Backbone Harness
CAN Backbone Harness
<TABLE ROW
727/00004
1
K ( T C-100)
K ( T C-100)
<TABLE ROW
Main components connected to this harness
?
<TABLE ROW
<TABLE ROW
<TABLE ROW
15
15
Throttle Link Harness (T3 Only)
Throttle Link Harness (T3 Only)
<TABLE ROW
721/12119
1
K ( T C-102)
K ( T C-102)
<TABLE ROW
Main components connected to this harness
Foot throttle
<TABLE ROW
Engine harness
<TABLE ROW
<TABLE ROW
16
16
Grid Heater Link
Grid Heater Link
<TABLE ROW
718/20291
1
K ( T C-104)
K ( T C-104)
<TABLE ROW
Main components connected to this harness
Rear Chassis Harness
<TABLE ROW
Grid Heater Relay 1
<TABLE ROW
Grid Heater Relay 2
Drawings
Drawings
Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connectio…
Cab Roof Harness – CAD 721/11818 Issue 3
Cab Roof Harness – CAD 721/11818 Issue 3
K Fig 54. ( T C-66) and
K Fig 54. ( T C-66)
K Fig 55. ( T C-67)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
RA
Cab Connector 1
<TABLE ROW
RB
Cab Connector 2
<TABLE ROW
RC
Front Work Light Switch
<TABLE ROW
RD
Rear Work Light Switch
<TABLE ROW
RE
Beacon Switch
<TABLE ROW
RF
LH Front Work Light
<TABLE ROW
RG
RH Front Work Light
<TABLE ROW
RH
LH Front Auxiliary Work Light
<TABLE ROW
RJ
RH Front Auxiliary Work Light
<TABLE ROW
RK
LH Rear Work Light
<TABLE ROW
RL
RH Rear Work Light
<TABLE ROW
RM
LH Rear Auxiliary Work Light
<TABLE ROW
RN
RH Rear Auxiliary Work Light
<TABLE ROW
RP
Beacon Socket
<TABLE ROW
RQ2
Interior Light
<TABLE ROW
RQ3
Interior Light
<TABLE ROW
RS
RH Number Plate Light
<TABLE ROW
RT
LH Number Plate Light
<TABLE ROW
RU
Radio Power 24v
<TABLE ROW
RV
Radio Speakers
<TABLE ROW
RW1
LH Speaker
<TABLE ROW
RW2
LH Speaker
<TABLE ROW
RX1
RH Speaker
<TABLE ROW
RX2
RH Speaker
<TABLE ROW
RY
Heated Mirror Switch
<TABLE ROW
RZ
LH Heated Mirror
<TABLE ROW
TA
RH Heated Mirror
<TABLE ROW
TB
Heated Seat Switch
<TABLE ROW
TC
Earth Point
<TABLE ROW
TD
Radio Power 12v
<TABLE ROW
TE2
Interior Light 2
<TABLE ROW
TE3
Interior Light 2
<GRAPHIC
<GRAPHIC
Fig 54.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Cab Roof Harness – CAD 721/11818 Issue 3 ( T C-65)
K Cab Roof Harness – CAD 721/11818 Issue 3 ( T C-65)
<GRAPHIC
<GRAPHIC
Fig 55.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Cab Roof Harness – CAD 721/11818 Issue 3 ( T C-65)
K Cab Roof Harness – CAD 721/11818 Issue 3 ( T C-65)
Transmission Harness – CAD 721/11826 – Issue 3
Transmission Harness – CAD 721/11826 – Issue 3
K Fig 56. ( T C-69)
K Fig 56. ( T C-69)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
TA
Output Speed Sensor
<TABLE ROW
TB
Engine Speed
<TABLE ROW
TC
Turbine Speed
<TABLE ROW
TD
Int. Gear Chain Speed
<TABLE ROW
TE
Control Unit
<TABLE ROW
TF
Cab Connector
<GRAPHIC
<GRAPHIC
Fig 56.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Transmission Harness – CAD 721/11826 – Issue 3 ( T C-68)
K Transmission Harness – CAD 721/11826 – Issue 3 ( T C-68)
Engine Harness – CAD 721/12214 Issue 1
Engine Harness – CAD 721/12214 Issue 1
K Fig 57. ( T C-71) and
K Fig 57. ( T C-71)
K Fig 58. ( T C-72)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
JA
Cab Connector
<TABLE ROW
JB
Torque Converter Temperature Sender
<TABLE ROW
JN
ECM Power Converter
<TABLE ROW
JP
Engine ECM
<TABLE ROW
JR
ECM CAN Connector
<TABLE ROW
JJ
Air Filter
<TABLE ROW
JK
Air Conditioning Compressor
<TABLE ROW
JL
Steer Pressure Switch
<TABLE ROW
JU-1
Grid Heater Relay 1
<TABLE ROW
JU-2
Grid Heater Relay
<TABLE ROW
JS
Alternator
<TABLE ROW
JT
Earth
<TABLE ROW
JV
Starter Solenoid
<TABLE ROW
JW
Brake Pressure Switch
<TABLE ROW
JX
Foot Throttle
<TABLE ROW
S69
Earth Splice
<GRAPHIC
<GRAPHIC
Fig 57.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Engine Harness – CAD 721/12214 Issue 1 ( T C-70)
K Engine Harness – CAD 721/12214 Issue 1 ( T C-70)
<GRAPHIC
<GRAPHIC
Fig 58.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Engine Harness – CAD 721/12214 Issue 1 ( T C-70)
K Engine Harness – CAD 721/12214 Issue 1 ( T C-70)
Quickhitch Locking Harness – CAD 721/ 11922 Issue 1
Quickhitch Locking Harness – CAD 721/ 11922 Issue 1
K Fig 59. ( T C-74)
K Fig 59. ( T C-74)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
AA
Front Chassis Connector
<TABLE ROW
AB
Quickhitch Solenoid
<GRAPHIC
<GRAPHIC
Fig 59.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Quickhitch Locking Harness – CAD 721/11922 Issue 1 ( T C-73)
K Quickhitch Locking Harness – CAD 721/11922 Issue 1 ( T C-73)
Front Chassis Harness – CAD 721/11928 Issue 1
Front Chassis Harness – CAD 721/11928 Issue 1
K Fig 60. ( T C-76)
K Fig 60. ( T C-76)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
FA
Right Hand Front Lights
<TABLE ROW
FB
Left Hand Front Lights
<TABLE ROW
FC
Shovel Reset
<TABLE ROW
FD
Lift Reset
<TABLE ROW
FE
Horn
<TABLE ROW
FF
Main Harness Connector
<TABLE ROW
FG
Change Over
<TABLE ROW
FH
Quickhitch locking
<TABLE ROW
FJ
Load Suspension
<TABLE ROW
FK
Fork reset
<TABLE ROW
FL
Servo Isolator
<GRAPHIC
<GRAPHIC
Fig 60.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Front Chassis Harness – CAD 721/11928 Issue 1 ( T C-75)
K Front Chassis Harness – CAD 721/11928 Issue 1 ( T C-75)
Rear Cab Harness – CAD 721/11941 Issue 1
Rear Cab Harness – CAD 721/11941 Issue 1
K Fig 61. ( T C-78)
K Fig 61. ( T C-78)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
KA
Cab Connector
<TABLE ROW
KB
Front Washer Pump
<TABLE ROW
KC
Rear Washer Pump
<TABLE ROW
KF
Park Brake Switch
<GRAPHIC
<GRAPHIC
Fig 61.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Rear Cab Harness – CAD 721/11941 Issue 1 ( T C-77)
K Rear Cab Harness – CAD 721/11941 Issue 1 ( T C-77)
Proportional Auxiliary Harness – CAD 721/ 11943 Issue 2
Proportional Auxiliary Harness – CAD 721/ 11943 Issue 2
K Fig 62. ( T C-80) and
K Fig 62. ( T C-80)
K Fig 63. ( T C-81)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
AA
Proportional Auxiliary Options Plug
<TABLE ROW
AB
ECU 4
<TABLE ROW
AC
Recovery Switch
<TABLE ROW
AD
Joystick
<TABLE ROW
AE
ECU 4 Indicator
<TABLE ROW
AF
Change Over/Neutral Relay
<TABLE ROW
AG
Joystick
<TABLE ROW
AH
Diode Pack
<TABLE ROW
AK
Resistor
<TABLE ROW
AJ
Side Console Connection
<TABLE ROW
AL
Diode Pack ECU 4
<TABLE ROW
AM
3rd/4th Spool Connection
<GRAPHIC
<GRAPHIC
Fig 62.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Proportional Auxiliary Harness – CAD 721/11943 Issue 2 ( T C-79)
K Proportional Auxiliary Harness – CAD 721/11943 Issue 2 ( T C-79)
<GRAPHIC
<GRAPHIC
Fig 63.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Proportional Auxiliary Harness – CAD 721/11943 Issue 2 ( T C-79)
K Proportional Auxiliary Harness – CAD 721/11943 Issue 2 ( T C-79)
3rd/4th Spool Harness – CAD 721/11944 Issue 1
3rd/4th Spool Harness – CAD 721/11944 Issue 1
K Fig 64. ( T C-83)
K Fig 64. ( T C-83)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
BA
Cab Connector
<TABLE ROW
BB
3rd Spool Solenoid C1
<TABLE ROW
BC
3rd Spool Solenoid C4
<TABLE ROW
BD
4th Spool Solenoid C2
<TABLE ROW
BE
4th Spool Solenoid C3
<GRAPHIC
<GRAPHIC
Fig 64.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K 3rd/4th Spool Harness – CAD 721/11944 Issue 1 ( T C-82)
K 3rd/4th Spool Harness – CAD 721/11944 Issue 1 ( T C-82)
3rd Spool Harness – CAD 721/11945 Issue 1
3rd Spool Harness – CAD 721/11945 Issue 1
K Fig 65. ( T C-85)
K Fig 65. ( T C-85)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
BA
Cab Connector
<TABLE ROW
BB
3rd Spool Solenoid C1
<TABLE ROW
BC
3rd Spool Solenoid C4
<GRAPHIC
<GRAPHIC
Fig 65.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K 3rd Spool Harness – CAD 721/11945 Issue 1 ( T C-84)
K 3rd Spool Harness – CAD 721/11945 Issue 1 ( T C-84)
Multi-Lever Harness – CAD 721/11967 Issue 1
Multi-Lever Harness – CAD 721/11967 Issue 1
K Fig 66. ( T C-87)
K Fig 66. ( T C-87)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
C001
Cab Harness Joystick Plug
<TABLE ROW
C002
FNR Paddle Switch
<TABLE ROW
C003
Dump/Kickdown Switch
<GRAPHIC
<GRAPHIC
Fig 66.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Multi-Lever Harness – CAD 721/11967 Issue 1 ( T C-86)
K Multi-Lever Harness – CAD 721/11967 Issue 1 ( T C-86)
Rear Chassis Harness – CAD 721/12100 Issue 1
Rear Chassis Harness – CAD 721/12100 Issue 1
K Fig 67. ( T C-89) and
K Fig 67. ( T C-89)
K Fig 68. ( T C-91)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
RA
Primary Fuses 1 and 3
<TABLE ROW
RB
Primary Fuses 2 and 4
<TABLE ROW
RC
Hydraulic Oil Temperature Switch
<TABLE ROW
RD
Fuel Sender
<TABLE ROW
RF
Right Hand Side Rear Lights
<TABLE ROW
RH
Left Hand Side Rear Lights
<TABLE ROW
RK
Park brake Solenoid
<TABLE ROW
RL
Cab Connector 2
<TABLE ROW
RM
Cab Connector 1
<TABLE ROW
RN
12V Trailer Feed
<TABLE ROW
RS
Emergency Steering Switch
<TABLE ROW
RT-1
Emergency Steer Relay 1
<TABLE ROW
RT-2
Emergency Steer Relay 2
<TABLE ROW
RU
Primary Fuses 5 and 7
<TABLE ROW
RW
Primary Fuses 6 and 8
<TABLE ROW
RX
Rear Grille Connector
<TABLE ROW
RY
Grid Heater Relay 1
<TABLE ROW
RZ
Binary Switch
<TABLE ROW
TA
Earth
<TABLE ROW
SB
<TABLE ROW
SC
<TABLE ROW
SD
<TABLE ROW
SE
<TABLE ROW
SF
LH Sidelights
<GRAPHIC
<GRAPHIC
Fig 67. Sheet 1 of 2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Rear Chassis Harness – CAD 721/12100 Issue 1 ( T C-88)
K Rear Chassis Harness – CAD 721/12100 Issue 1 ( T C-88)
<GRAPHIC
<GRAPHIC
Fig 68. Sheet 2 of 2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Rear Chassis Harness – CAD 721/12100 Issue 1 ( T C-88)
K Rear Chassis Harness – CAD 721/12100 Issue 1 ( T C-88)
Rear Grille Harness – CAD 721/12218 Issue 1
Rear Grille Harness – CAD 721/12218 Issue 1
K Fig 69. ( T C-93)
K Fig 69. ( T C-93)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
RA
Rear Chassis Connector
<TABLE ROW
RB
Right Hand Auxiliary Light
<TABLE ROW
RC
Left hand Auxiliary Light
<TABLE ROW
RD
Reverse Alarm
<TABLE ROW
RE
Number Plate Light
<TABLE ROW
RF
Prop Fan
<TABLE ROW
RG
Reverse Fan
<TABLE ROW
S12
Aux Light
<TABLE ROW
S51
Earth Splice
<GRAPHIC
<GRAPHIC
Fig 69.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Rear Grille Harness – CAD 721/12218 Issue 1 ( T C-92)
K Rear Grille Harness – CAD 721/12218 Issue 1 ( T C-92)
Cab Harness – CAD 721/12104 Issue 1
Cab Harness – CAD 721/12104 Issue 1
K Fig 70. ( T C-95),
K Fig 70. ( T C-95)
K Fig 71. ( T C-96)
K Fig 72. ( T C-97)
K Fig 73. ( T C-98)
K Fig 74. ( T C-99)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
DA
Ignition Switch
<TABLE ROW
DB
Ignition Switch 2
<TABLE ROW
DD
Hazard Switch
<TABLE ROW
DE
Right Hand Column Switch
<TABLE ROW
DF
Left Hand Column Switch
<TABLE ROW
DG
Front Wiper Motor
<TABLE ROW
DH
Front Chassis Connector
<TABLE ROW
DJ
EMS
<TABLE ROW
DK
EMS
<TABLE ROW
DL-1
Buzzer
<TABLE ROW
DL-2
Buzzer 2
<TABLE ROW
DM
Park Brake switch (456 only)
<TABLE ROW
DP
Loader Lever
<TABLE ROW
DQ
Earth Point Front Console
<TABLE ROW
DR
Earth Point Side Console 1
<TABLE ROW
DS
Loader Lever
<TABLE ROW
DT
Air Conditioning Unit
<TABLE ROW
DU
Earth Point Side Console 2
<TABLE ROW
DV
Heater Blower
<TABLE ROW
DW
ZF Computer
<TABLE ROW
DX
Heater Switch
<TABLE ROW
DY
Cab Connection 1
<TABLE ROW
DZ
Cab Connection 2
<TABLE ROW
EA
CAN J1939 Connection
<TABLE ROW
EB
Auto/Manual Switch
<TABLE ROW
EC
Dump Switch
<TABLE ROW
ED
Rear Wiper Switch
<TABLE ROW
EH
Roadlight Switch
<TABLE ROW
EJ
Rear Fog Light Switch
<TABLE ROW
EM
Immobiliser Control Switch
<TABLE ROW
EN
Dallas Keypad
<TABLE ROW
EP
Dallas Keypad Earth
<TABLE ROW
ER
CCTV System
<TABLE ROW
ES
Work Light Diode
<TABLE ROW
FA
Fuse Box A
<TABLE ROW
FB
Fuse Box B
<TABLE ROW
FC
Fuse Box C
<TABLE ROW
FD
Fuse Box D
<TABLE ROW
FE
Dump Relay
<TABLE ROW
FF
Ignition Relay 1
<TABLE ROW
FG
FWL relay
<TABLE ROW
FH
Lights Relay
<TABLE ROW
FJ
Diagnostic Port
<TABLE ROW
FK
Start Relay
<TABLE ROW
FL
Ignition Relay 2
<TABLE ROW
FM
Ignition Relay 3
<TABLE ROW
FP
Cigar lighter 24v
<TABLE ROW
FP-1
Cigar Lighter Illumination
<TABLE ROW
FQ
Flasher Unit
<TABLE ROW
FR
Rear Wiper Motor
<TABLE ROW
FS-1
Air Conditioning Switch
<TABLE ROW
FS-2
Air Conditioning Switch
<TABLE ROW
FT
4th Spool Switch
<TABLE ROW
FU
Air Conditioning Shut-Down Relay
<TABLE ROW
FV
SRS Switch
<TABLE ROW
FX
Rear Cab Connector
<TABLE ROW
FY
Engine Connector
<TABLE ROW
FZ
Rear Chassis Connector 1
<TABLE ROW
GA
transmission Connector
<TABLE ROW
GB
ZF Diagnostic Plug
<TABLE ROW
GD-1
Heated Rear Screen 1
<TABLE ROW
GD-2
Heated Rear Screen 2
<TABLE ROW
GF
Proportional Auxiliary Connector
<TABLE ROW
GG
24/12v Converter
<TABLE ROW
GJ
Cigar Lighter 12v
<TABLE ROW
GK
12v Auxiliary Feed
<TABLE ROW
GM
Seat Connector
<TABLE ROW
GN
Tow-Hitch Connector
<TABLE ROW
GP
Brake/Reverse Relay
<TABLE ROW
GR
Reverse Fan and E/Steer Relay
<TABLE ROW
GS
Reset C/O Switch
<TABLE ROW
GT
Shovel Reset Switch
<TABLE ROW
GV
Weigh-Load/Autolube Plug
<TABLE ROW
GW
Heated Screen Timer
<TABLE ROW
GY
Heated Screen Relay
<TABLE ROW
HA
Emergency Steer Test Switch
<TABLE ROW
HB
Quickhitch Switch
<TABLE ROW
HC
Servo Isolator Switch
<TABLE ROW
HD
Heated Rear Screen switch
<TABLE ROW
HE
Rear Chassis Connector 2
<TABLE ROW
HF
EMS CAN Connection
<TABLE ROW
HG
Diagnostic Connector CAN Connector
<TABLE ROW
HH
ZF CAN Connector
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 70. Sheet 1 of 5
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
<GRAPHIC
<GRAPHIC
Fig 71. Sheet 2 of 5
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
<GRAPHIC
<GRAPHIC
Fig 72. Sheet 3 of 5
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
<GRAPHIC
<GRAPHIC
Fig 73. Sheet 4 of 5
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
<GRAPHIC
<GRAPHIC
Fig 74. Sheet 5 of 5
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
K Cab Harness – CAD 721/12104 Issue 1 ( T C-94)
CAN Backbone Harness – CAD 727/00004 Issue 1
CAN Backbone Harness – CAD 727/00004 Issue 1
K Fig 75. ( T C-101)
K Fig 75. ( T C-101)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
C001
CAN Backbone End A
<TABLE ROW
C002
CAN Backbone End B
<GRAPHIC
<GRAPHIC
Fig 75.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K CAN Backbone Harness – CAD 727/00004 Issue 1 ( T C-100)
K CAN Backbone Harness – CAD 727/00004 Issue 1 ( T C-100)
Throttle Link Harness – CAD 721/12119 – Issue 1
Throttle Link Harness – CAD 721/12119 – Issue 1
K Fig 76. ( T C-103)
K Fig 76. ( T C-103)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
LA
Engine Harness
<TABLE ROW
LB
Foot Throttle
<GRAPHIC
<GRAPHIC
Fig 76.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Throttle Link Harness – CAD 721/12119 – Issue 1 ( T C-102)
K Throttle Link Harness – CAD 721/12119 – Issue 1 ( T C-102)
Grid Heater Link Harness – CAD 708/20291 – Issue 1
Grid Heater Link Harness – CAD 708/20291 – Issue 1
K Fig 77. ( T C-105)
K Fig 77. ( T C-105)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
C001
Rear Chassis Harness
<TABLE ROW
C002-1
Grid Heater Relay 1
<TABLE ROW
C002-2
Grid Heater Relay 2
<GRAPHIC
<GRAPHIC
Fig 77.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Grid Heater Link Harness – CAD 708/20291 – Issue 1 ( T C-104)
K Grid Heater Link Harness – CAD 708/20291 – Issue 1 ( T C-104)
Electronic Monitoring System (EMS)
Electronic Monitoring System (EMS)
C164 EMS
C164 EMS
General
General
C164 (EMS 728/80077) is the latest level EMS system first introduced in January 2006.
<GRAPHIC
<GRAPHIC
Fig 78.
With the introduction of this new type EMS there is a requirement for advanced Standard Software Tools. These tools are available within JCB Servicemaster 2. They will come under the Large Wheeled Loader screen shown:
K Fig 79. ( T C-107)
<GRAPHIC
<GRAPHIC
Fig 79.
For these diagnostic tools to work correctly, the Data Link Adaptor (892/01174) must be connected (in conjuction with the interrogation lead 71820237) between the Diagnostic Connector and the PC, and the machine’s ignition must be turned ON.
EMS Tools
EMS Tools
Following is an outline of the available software tools and how they are to be used.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Service Tools
<TABLE BODY
<TABLE ROW
1
1
<GRAPHIC
<GRAPHIC
Flash Loader program – to download the latest software files to the EMS (these are called Application files). This can be used by double clicking the icon as shown.
Flash Loader program
<TABLE ROW
<TABLE ROW
2
2
<GRAPHIC
<GRAPHIC
Set-up program – to enter the machine Serial Number, Rolling Radius etc. and Languages. This program can be used by double clicking the icon as shown
Set-up program
<TABLE ROW
3
3
<GRAPHIC
<GRAPHIC
Diagnostics program – to help fault find on the machine. This includes information about the Electronic Engine, Transmission and the EMS. This program can be used by double clicking the icon as shown.
Diagnostics program
<TABLE ROW
<TABLE ROW
4
4
<GRAPHIC
<GRAPHIC
Service History program – for checking when the machine was last maintained by a JCB Dealer. This program can be used by double clicking on the icon as shown.
Service History program
<TABLE ROW
<TABLE ROW
5
5
<GRAPHIC
<GRAPHIC
Data Logger program – this program logs various conditions of the machine before a failure, which will help in the diagnosis of certain problems. This program can be selected by double clicking on the icon as shown.
Data Logger program
Flash Loader Program
Flash Loader Program
In order to download the latest software, the following has to be done: –
1 Connect the DLA (Data Link Adapter), to the 9 Pin Deutsch diagnostic connector in the cab and to the PC.
1 Connect the DLA (Data Link Adapter), to the 9 Pin Deutsch diagnostic connector in the cab and to the PC.
K Connecting the Interrogation Lead ( T C-115)
2 Turn the ignition to the first position so that the EMS is powered up.
3 Double click on the “Flash Loader” icon.
K EMS Tools ( T C-107)
This icon is used to download the latest Software to the EMS. This Software is referred to as the “Application code”. The icon launches a windows application called the “Flash Downloader”.
4 The following “Flash Downloader” screen will appear:
<GRAPHIC
<GRAPHIC
Fig 80.
The icon
1
With the mouse, click this icon once. Doing this will fill the boxes
A
E
5 With the icon now selected, the software can be downloaded. Click on the button indicated by
2
a D:MachineSoftwareUpdates/Earthmovers LargeWheeled Loading ShovelsLWLS C164 EMS 728-90269.vsf
a D:MachineSoftwareUpdates/Earthmovers LargeWheeled Loading ShovelsLWLS C164 EMS 728-90269.vsf
a D:MachineSoftwareUpdates/Earthmovers LargeWheeled Loading ShovelsLWLS C164 EMS 728-90269.vsf
Ensure you are entering the correct and most up to date software.
b Once the correct software has been selected, click “OK” in the window. The Software and its directory path (see example above) will then be shown in the box labelled
3
6 To start downloading the Software into the EMS, click the “Start” button labelled
4
OK
5
OK
7 Once this has done, close the “Flash Loader” window by clicking the cross (
x
8 The EMS will now have the new software installed.
If you are just loading the latest software, you do not need to re enter all the settings for the EMS (which can be done using the following
Set-up Program)
Set-up Program
Set-up Program
When a machine is being set-up for the first time, or a new EMS unit has been fitted, the machine’s details and the required language must be entered into the EMS.
This is achieved using the following procedure:
1 Double click on the Set-up icon on the desktop.
1 Double click on the Set-up icon on the desktop.
K EMS Tools ( T C-107)
2 The following screen should then appear.
K Fig 81. ( T C-109)
<GRAPHIC
<GRAPHIC
Fig 81. Set-up Screen 1
a Select the ‘Vehicle Set-up’ tab
a Select the ‘Vehicle Set-up’ tab
a Select the ‘Vehicle Set-up’ tab
6
b Select the `Model Number’
8
Once the serial Number has been entered into the EMS it will locked and cannot be changed again.
c Enter the `Serial Number’ in box
9
d With the mouse, click the `Next’ button
11
If you just want to use this tool to read what settings are in the EMS for the particular machine you are looking at, just click…
e Once the `Next’ button identified by
11
7.
K Fig 81. ( T C-109)
<GRAPHIC
<GRAPHIC
Fig 82. Set-up Screen 2
3 Depending on which particular machine was selected at the start of the `Set-up procedure’, a list of tyre options will appear in box
12
Once the user has selected a tyre type from box
12
13
If the tyre type fitted to the machine does not appear on the drop-down listing from box 12, the user can select `Other’ from th…
4 If the machine requires an idle shutdown feature, which means that the EMS will shut down the machine if the machine is in `neutral’ and the `time’ value entered in box
14
14
The value to be entered can be any value required by the operator, however, the entered value must be expressed in minutes.
5 After the machine has been working/running for specific periods of time, the EMS will display a warning to the operator that a service by a JCB Dealer is due. The specific time for the service request is entered into box
15
6 In certain circumstances, machines can be set-up to be tracked by a satellite system and certain parameters can be made visible via the Internet. This feature can be turned On by checking box
16
This feature will not yet be available to the early machines.
7 In order to track how many miles/kilometers the machine has covered throughout its life, the EMS contains an optional feature …
8 Certain machines have the option of having an Electric Emergency Steering Pump fitted to the machine. If this is required then this option is toggled and a check mark will be displayed in box
18
9 On 456 Large Wheeled Loading Shovels, a different type of Park Brake system is fitted. The option (box
19
10 The engine cooling fan is proportionally controlled by the EMS. Box
20
11 The heated rear screen option can, once selected by checking the box, have a custom operating time value entered by the user into box
21
12 The Anti-stall feature:
To reduce the loading on the engine during cold cranking, the anti-stall feature can be selected by checking the box. When selected this feature enables the EMS to isolate the hydraulic load from the engine.
When selected the user can enter a custom value of RPM (Revolutions Per Minute) into box
22
13 The Reverse Fan option:
This option once selected can have custom time values entered by the user for both the forward and reverse running time of the fan. These values can be entered at boxes
23
14 Hydraulic Flow and Pressure Monitoring:
This option once selected can have custom values of flow measure in PPL (Pulse Per Litre) and Bar entered by the user into boxes
24
15 Engine Specification:
The Large Wheeled Loading Shovels are gradually changing over from Mechanically Controlled Engines to higher specification Electronically Controlled Engines. The EMS incorporates a `Toggle Facility’, boxes
25,
It is important that you select the correct ‘Engine Specification’ toggle for the machine. The way the EMS translates the engine information depends on which option, ‘Electronic Engine’ or ‘Manual Engine’, has been selected. See Box
25
16 All the unit settings displayed within the Set-up tool have `Metric’ and `Imperial’ interpretations. The toggle, boxes
26
To advance to the next screen to complete the `Set-up’, the user now needs to click on the `Next’, box
28
In order to review the previous page (the first `Set-up’ screen) the user needs to click on the `Prev’, box
27
Once the user clicks on the `Next’, box
28
<GRAPHIC
<GRAPHIC
Fig 83. Set-up Screen 3
17 To select the country of operation the user has to select box
17 To select the country of operation the user has to select box
29
Once the country of operation has been selected from the list, first, second and third language options will automatically appear in the areas
30
31
32
If all the settings have been entered for all the domains of each tab, the user should now click on the button identified as
34
Until the user clicks on Transfer of Setting button
34
If the user has made a mistake or needs to change a setting they have already entered onto this or either of the two preceding screens, they can, by clicking on the `Prev’ buttons
33
27
If the user returns to change any input information or setting after the settings have been transferred to the EMS, the changes must be written to the EMS by clicking on button
34
Diagnostic Program
Diagnostic Program
As an aid to fault diagnosis, the EMS contains a tool that can diagnose the electrical circuits of the EMS, Electronic Engine faults and parameters and also the fault codes and parameters of the Smoothshift transmission.
In order to activate the diagnostic program proceed as follows:
1 Double click on the `Diagnostic’ icon.
1 Double click on the `Diagnostic’ icon.
K EMS Tools ( T C-107)
2 The following systems diagnostic screen will appear.
<GRAPHIC
<GRAPHIC
Fig 84. Diagnostic Screen 1
3 Before you can see any information, the `Green’ light
35
The software will start the process of communicating on the CAN-Bus network with all the electronic controllers.
4 Each diagnostic aspect of the machine can be viewed by making a selection from the menu toolbar
36
K Diagnostic Screen 2 ( T C-112)
<GRAPHIC
<GRAPHIC
Fig 85. Diagnostic Screen 2
5 This will then allow you to make a further selection from the dropdown menu
37
To select an item from this menu, click the `tick box’ alongside the required item. This will open up a window with the required information.
6 Various information appertaining to the displayed circuits, Voltages, pressures, states etc. will be displayed in the window, and a key (
38)
The information will be displayed in `real time’, which means the information is accurately displayed and instantly updated from the relevant source.
Engine Diagnosis
Engine Diagnosis
Under the `Engine’ menu and `Fault codes’ selection, the following screen appears. This screen is split into `Active Fault Codes’ and any historic ones, `Previously Active Fault Codes’.
K Diagnostic Screen 3 ( T C-113)
<GRAPHIC
<GRAPHIC
Fig 86. Diagnostic Screen 3
The `Active Fault Codes’ box
A
The `Previously Active Fault Codes’ box
B
Previously active fault codes will not be displayed on the EMS LCD. These faults can only be seen through use of this service software tool.
The operator can, if required, erase all the previously active fault codes by clicking on the button identified as item
39
To exit the program, click on the small cross (
X
Service History Program
Service History Program
A comprehensive history of the machines maintenance is contained in the EMS. To view this history proceed as follows:
1 Double click on the `Service History’ icon.
1 Double click on the `Service History’ icon.
K EMS Tools ( T C-107)
2 This will open up the following screen:
<GRAPHIC
<GRAPHIC
Fig 87. Service History Screen
With this tool the Dealer can add and retrieve service records created for an individual machine.
To Start a Service Record, the dealer has to `Add a Service Record’ from the windows file menu as identified by
A
The file `Import’ and `Export’ selections will enable the service records to be seen and saved to the Dealer’s PC only.
Data Logger Program
Data Logger Program
The Data Logger program enables the dealers to see various statistics appertaining to a particular machine. This information can be details of minimum and maximum values of the machine recorded throughout the life of its current EMS unit.
To enable this program proceed as follows:
1 Double click on the `Data Logger’ icon.
1 Double click on the `Data Logger’ icon.
K EMS Tools ( T C-107)
2 The following screen will appear.
<GRAPHIC
<GRAPHIC
Fig 88. Data Logger Screen
3 To read the Data Logger information for the machine:
a Select `File’ from the windows menu toolbar.
a Select `File’ from the windows menu toolbar.
b Select `Read Data’ from the File dropdown menu.
c The software will take a few seconds to gather the required information.
d Once the required data has been retrieved, it will be displayed as shown above.
K Data Logger Screen ( T C-114)
Other information, for example, `Engine Coolant’ and `Error Logs’ can be seen by clicking on the relevant tabs.
An additional feature of this tool enables the user to produce a report for the machine.
To activate this facility proceed as follows:
1 Select `File’ on the windows menu toolbar.
1 Select `File’ on the windows menu toolbar.
2 Select `Report’ from the File dropdown menu.
3 This will produce a Report file as shown below.
<GRAPHIC
<GRAPHIC
Fig 89. Report File
4 This report can be saved or printed as required. To achieve either of these select the required option from the menu toolbar as illustrated at
A
Connecting the Interrogation Lead
Connecting the Interrogation Lead
To install the laptop computer to the EMS:
1 Connect plug
1 Connect plug
C
A
It is possible to use a serial port lead (718/20236), supplied with the diagnostic kit (892/01174), in place of the USB port Lead.
<GRAPHIC
<GRAPHIC
Fig 90.
2 Connect plug
B
The fuse/relay panel is located behind the operator’s seat. To access the interrogation lead connector, release the single fastener on the panel cover and remove the cover.
<GRAPHIC
<GRAPHIC
Fig 91.
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Section E – Hydraulics
Section E
Section E
Hydraulics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
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Technical Data
Technical Data
Components
Components
Pump
Pump
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Type
Rexroth. Tandem variable displacement axial piston
<TABLE ROW
Ref
A20VO60
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Pump 1
litres/min
UK gal/min
US gal/min
<TABLE BODY
<TABLE ROW
Standby flow
5
1.1
1.3
<TABLE ROW
Full flow at 2200 rev/min
132
29.0
34.8
<TABLE ROW
Flow at max. pressure (220 bar)
5
1.1
1.3
<TABLE ROW
<TABLE ROW
Pump 2
Pump 2
<TABLE ROW
Standby flow
5
1.1
1.3
<TABLE ROW
Full flow at 2200 rev/min
132
29.0
34.8
<TABLE ROW
Flow at max. pressure (160 bar)
5
1.1
1.3
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Engine Driven Charge Pump
<TABLE ROW
Type
Parker. Single, Fixed Displacement with Charge Valve
<TABLE ROW
Ref
tba
<TABLE ROW
Displacement
20 cc/rev
<TABLE ROW
Direction of Rotation
Clockwise
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Engine Driven Charge Pump
litres/min
UK gal/min
US gal/min
<TABLE BODY
<TABLE ROW
Full flow at 2200 rev/min
42
9.24
11.1
Loader Valve
Loader Valve
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Type
Rexroth, stacked directional control, model MP-22.
<TABLE ROW
Closed centre, load sensing parallel circuit
<TABLE ROW
Services Operated
<TABLE ROW
Section 1 (SV)
SV
Priority Steer
<TABLE ROW
Section 2 (LV1)
LV1
Loader arms
<TABLE ROW
Section 3 (LV2)
LV2
Shovel
<TABLE ROW
Section 4 (LV3)
LV3
Auxiliary (Quickhitch)
<TABLE ROW
Section 5 (LV4)
LV4
Auxiliary (Clam) (optional)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Relief Valve Operating Pressures
bar
kgf/cm2
2
lbf/in2
2
<TABLE BODY
<TABLE ROW
Pump 1
Pump 1
<TABLE ROW
Standby pressure
27 +3 -0
27.5 +3.06 -0
391.5 +43.5 -0
<TABLE ROW
System control pressure
245 – 255
250 – 260
3552 – 3697
<TABLE ROW
Pump 2
Pump 2
<TABLE ROW
Standby pressure
25 +3 -0
25.5 +3.06 -0
362.5 +43.5 -0
<TABLE ROW
System control pressure
155 – 165
158 – 168
2247 – 2394
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Charge Valve Settings (Engine Driven Gear Pump)
bar
kgf/cm2
2
lbf/in2
2
<TABLE BODY
<TABLE ROW
Cut In Pressure
160
163.2
2320
<TABLE ROW
Cut Out Pressure
200
204
2900
<TABLE ROW
Max Pressure @ Port EF
220
224.4
3190
<TABLE ROW
<TABLE ROW
litres/min
litres/min
UK gal/min
UK gal/min
US gal/min
US gal/min
<TABLE ROW
Total Flow to Accumulators
5
1.1
1.32
Auxiliary Relief Valve (ARV) Settings
Auxiliary Relief Valve (ARV) Settings
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Operating Pressures
bar
kgf/cm2
2
lbf/in2
2
<TABLE BODY
<TABLE ROW
Inlet section Clipper relief valve
272
277.4
3944
<TABLE ROW
Lift ram, head side
345
352
4985
<TABLE ROW
Shovel ram, head side
260
265
3770
<TABLE ROW
Shovel ram, rod side
260
265.2
3770
<TABLE ROW
Servo
27-35
27.5-35.6
391.5-508
<TABLE ROW
Brake (non-adjustable)
80
81.6
1160
<TABLE ROW
Steer relief pressure (at ram)
175
178.5
3262
<TABLE ROW
Steer relief pressure (at pump)
190
193.8
2755
<TABLE ROW
Pilot control pressure
27-33
27.5-33.6
391.5-478.6
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Engine Cooling Fan
rev/min
<TABLE BODY
<TABLE ROW
Fan Speed (tested @ engine speed of 2200 rev/min)
1500
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
By-pass Pressures
bar
kgf/cm2
2
lbf/in2
2
<TABLE BODY
<TABLE ROW
Filter
1.5
1.53
22
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Capacities
Litres
UKgal
US gal
<TABLE BODY
<TABLE ROW
Hydraulic tank
181
39.8
47.9
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Emergency Steer
<TABLE BODY
<TABLE ROW
Operating Pressure
40 bar
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Rams
Bore
Rod Dia.
Stroke
<TABLE ROW
mm
in
mm
in
mm
in
<TABLE BODY
<TABLE ROW
Shovel Ram
130
5.1
70
2.8
575
22.6
<TABLE ROW
<TABLE ROW
Lift Ram
130
5.1
70
2.8
814
32.0
<TABLE ROW
<TABLE ROW
Steer Ram
80
3.1
50
2.0
312
12.3
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Filter
<TABLE BODY
<TABLE ROW
Filtration Size
10 Micron
<TABLE ROW
By pass Setting
1.5 bar
<TABLE ROW
Suction Strainer Size
140 Micron
Accumulators
Accumulators
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Gas Type
<TABLE BODY
<TABLE ROW
– Nitrogen
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Gas Pre-Charge Pressures @ 20˚ C
Bar
Bar
PSI
PSI
<TABLE BODY
<TABLE ROW
Accumulator Function
<TABLE ROW
– Brakes
57 +/- 1
825 + 30 – 15
<TABLE ROW
– Automatic Carry Control System
24 +/- 1.0 bar
350 +/-15
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Gas Volume (each)
Litre
Cubic inch
<TABLE BODY
<TABLE ROW
Accumulator Function
<TABLE ROW
Brakes
0.75
45.8
<TABLE ROW
Automatic Carry Control System
0.95
58
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Basic Operation
Basic Operation
General Description
General Description
Valve Block Tie-Rods
The main components of the Wheeled Loader hydraulic system are the pump, priority valve, loader valve block, servo control valve…
The pump is driven by the engine and delivers pressurised oil to the system. A priority valve ensures that the steering circuit …
When the servo control valve is operated, it causes the selected service valve spool in the loader valve block to direct pressur…
Relief valves in the system prevent undue pressure rises through internal and external sources.
Valve Block Tie-Rods
Valve Block Tie-Rods
When assembling MP22 valve blocks, the tie-rods should be torque tightened to 55 – 60 lbf ft (74.6 – 81.4 Nm, 7.6 – 8.3 kgf m).
Introduction to Hydraulic Schematic Symbols
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
General (Basic and Functional Symbols)
Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.
There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only…
Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components.
Table 1. General
Table 1. General
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Spring
<TABLE ROW
<GRAPHIC
<GRAPHIC
Flow restriction affected by viscosity
<TABLE ROW
<GRAPHIC
<GRAPHIC
Direction of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indication of rotation
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indication of direction and paths of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable control
Table 2. Rams
Table 2. Rams
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Single acting
<TABLE ROW
<GRAPHIC
<GRAPHIC
Double acting
<TABLE ROW
<GRAPHIC
<GRAPHIC
Double ended
<TABLE ROW
<GRAPHIC
<GRAPHIC
Double acting with damping at rod area end
Table 3. Pumps and Motors
Table 3. Pumps and Motors
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable capacity pump two directions of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fixed capacity motor one direction of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fixed capacity motor two directions of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable capacity motor one direction of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable capacity motor two directions of flow
Table 4. Control Valves
Table 4. Control Valves
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Used to enclose several valves indicating they are supplied as one unit
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-Position, 4-port spring centered pilot operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-position, 6-port spring centered pilot operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-Position, 4-port spring centered solenoid & pilot pressure operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-Position, 4-port spring centered detent hand operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Non-return valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Non-return valve with back pressure spring
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot operated non-return valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
One way restrictor
<TABLE ROW
<GRAPHIC
<GRAPHIC
High pressure selector (shuttle valve)
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Throttling orifice – normally closed
<TABLE ROW
<GRAPHIC
<GRAPHIC
Throttling orifice – normally open
<TABLE ROW
<GRAPHIC
<GRAPHIC
Relief valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable restrictor
Table 5. Energy Transmissions and Conditioning
Table 5. Energy Transmissions and Conditioning
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Working line, return or feed
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot control
<TABLE ROW
<GRAPHIC
<GRAPHIC
Drain lines
<TABLE ROW
<GRAPHIC
<GRAPHIC
Flexible pipe
<TABLE ROW
<GRAPHIC
<GRAPHIC
Line junction
<TABLE ROW
<GRAPHIC
<GRAPHIC
Crossing lines
<TABLE ROW
<GRAPHIC
<GRAPHIC
Air bleed
<TABLE ROW
<GRAPHIC
<GRAPHIC
Line plugged, also pressure test point
<TABLE ROW
<GRAPHIC
<GRAPHIC
Line plugged with take off line
<TABLE ROW
<GRAPHIC
<GRAPHIC
Quick release couplings – connected
<TABLE ROW
<GRAPHIC
<GRAPHIC
Quick release couplings – disconnected
<TABLE ROW
<GRAPHIC
<GRAPHIC
Reservoir – return line above fluid level
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Reservoir – return line below fluid level
<TABLE ROW
<GRAPHIC
<GRAPHIC
Header tank
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure sealed tank
<TABLE ROW
<GRAPHIC
<GRAPHIC
Accumulator
<TABLE ROW
<GRAPHIC
<GRAPHIC
Filter or strainer
<TABLE ROW
<GRAPHIC
<GRAPHIC
Water trap
<TABLE ROW
<GRAPHIC
<GRAPHIC
Cooler – with no indication of coolant flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Cooler – indicating direction of coolant flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Heater
Table 6. Control Mechanisms
Table 6. Control Mechanisms
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Rotating shaft – one direction
<TABLE ROW
<GRAPHIC
<GRAPHIC
Rotating shaft – two directions
<TABLE ROW
<GRAPHIC
<GRAPHIC
Detent
<TABLE ROW
<GRAPHIC
<GRAPHIC
Locking device
<TABLE ROW
<GRAPHIC
<GRAPHIC
Over centre device
<TABLE ROW
<GRAPHIC
<GRAPHIC
Simple linkage
<TABLE ROW
<GRAPHIC
<GRAPHIC
General control
<TABLE ROW
<GRAPHIC
<GRAPHIC
Push button operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Lever operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pedal operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Stem operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Spring operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Roller operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Roller trip operated (one directional)
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Solenoid one winding
<TABLE ROW
<GRAPHIC
<GRAPHIC
Solenoid two windings
<TABLE ROW
<GRAPHIC
<GRAPHIC
Electric motor operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Internal pressure pilot operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
External pressure pilot operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure operated spring release
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot operated by solenoid pilot valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot operated by a solenoid or seperate pilot valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure guage
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure switch
Control Valves
Control Valves
Control valves are usually represented by one or more square boxes.
K Fig 1. ( T E-12) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes – 3 positions etc).
K Fig 1. ( T E-12)
<GRAPHIC
<GRAPHIC
Fig 1.
K Fig 2. ( T E-12) – In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).
K Fig 2. ( T E-12)
<GRAPHIC
<GRAPHIC
Fig 2.
K Fig 4. ( T E-12) shows a valve described as a 3- position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position
K Fig 4. ( T E-12)
2
<GRAPHIC
<GRAPHIC
Fig 3.
If the valve spool was moved to Position
1
P1
P2
P3
P4
K Fig 4. ( T E-12)
If the valve spool was moved to Position
3
P1
P4
P3
K Fig 4. ( T E-12)
<GRAPHIC
<GRAPHIC
Fig 4.
It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares.
Three typical JCB style spools are known as ‘D’ spools, ‘F’ spools and ‘N’ spools.
The ‘D’ spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement.
K Fig 4. ( T E-12)
K Fig 5. ( T E-12) – ‘F’ spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to ‘float’.
K Fig 5. ( T E-12)
<GRAPHIC
<GRAPHIC
Fig 5.
K Fig 6. ( T E-12) – ‘N’ spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port
K Fig 6. ( T E-12)
<GRAPHIC
<GRAPHIC
Fig 6.
Example of Schematic Circuit
Example of Schematic Circuit
<GRAPHIC
<GRAPHIC
Fig 7. Simple Schematic Circuit
Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit.
K Fig 7. ( T E-13)
Hydraulic tank
7-A
7
7-B
7
7-C
7
7-D
7
Valve spool
7-E
7
If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram
7-G
7
7-F
7
Example Circuit Key
Example Circuit Key
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7-A
7-A
7
Hydraulic Tank
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7-B
7-B
7
Strainer
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7-C
7-C
7
Fixed Displacement Pump
<TABLE ROW
7-D
7-D
7
Relief Valve
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7-E
7-E
7
Spool
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7-F
7-F
7
One Way Valve
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7-G
7-G
7
Double Acting Hydraulic Ram
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Circuit Diagrams
Circuit Diagrams
Schematic Drawings
Schematic Drawings
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K 3-Spool Z-Bar Circuit ( T E-17)
K 3-Spool Z-Bar Circuit ( T E-17)
<TABLE ROW
K 3 Spool HT Circuit ( T E-18)
K 3 Spool HT Circuit ( T E-18)
<TABLE ROW
K 4-Spool Standard ZX/HT ( T E-19)
K 4-Spool Standard ZX/HT ( T E-19)
<TABLE ROW
K Single Spool Proportional Auxiliary Circuit ( T E-20)
K Single Spool Proportional Auxiliary Circuit ( T E-20)
<TABLE ROW
K Twin Spool Proportional Auxiliary Circuit ( T E-21)
K Twin Spool Proportional Auxiliary Circuit ( T E-21)
<TABLE ROW
K Automatic Carry Control System (ACCS) Circuit ( T E-22)
K Automatic Carry Control System (ACCS) Circuit ( T E-22)
<TABLE ROW
K Reverse Fan (Option) Circuit ( T E-23)
K Reverse Fan (Option) Circuit ( T E-23)
Component Key
Component Key
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1
1
Servo Control Isolator Valve
<TABLE ROW
2
2
Servo Control Circuit Accumulator
<TABLE ROW
3
3
Auxiliary Circuit (Solenoid Q-Hitch Locking)
<TABLE ROW
3a
3a
Quickhitch Locking Valve
<TABLE ROW
3b
3b
Quickhitch Ram
<TABLE ROW
3c
3c
Auxiliary Ram
<TABLE ROW
4
4
Auxiliary Circuit (Manually Operated)
<TABLE ROW
4a
Manual Changeover Valve
<TABLE ROW
4b
4b
Quickhitch Ram
<TABLE ROW
4c
4c
Auxiliary Ram
<TABLE ROW
5
5
Servo Control Valve
<TABLE ROW
6
6
Loader Valve
<TABLE ROW
7
7
Pressure Reducing Valve – Pilot Servo
<TABLE ROW
8
8
Auxiliary Circuit A.R.V. (Optional)
A.R.V. Auxiliary Relief Valve
<TABLE ROW
9
9
Auxiliary Circuit Spool (Optional)
<TABLE ROW
10
10
Primary Shuttle Valve
<TABLE ROW
11
11
Secondary Shuttle Valve
<TABLE ROW
12
12
Auxiliary Circuit Compensator
<TABLE ROW
13
13
Shovel Ram Head Side A.R.V.(1)
(1)
<TABLE ROW
14
14
Shovel Ram Rod Side A.R.V.(1)
(1)
<TABLE ROW
15
15
Shovel Circuit Spool
<TABLE ROW
16
16
Shovel Circuit Compensator
<TABLE ROW
17
17
Lift Ram Head Side A.R.V.(1)
(1)
<TABLE ROW
18
18
Lift Circuit Spool
<TABLE ROW
19
19
Lift Circuit load Check Valve
<TABLE ROW
20
20
Priority Spool
<TABLE ROW
21
21
Clipper Valve
<TABLE ROW
22
22
Shovel Ram(s)
<TABLE ROW
23
23
Lift Rams
<TABLE ROW
24
24
Steer Rams
<TABLE ROW
25
25
Steer valve
<TABLE ROW
26
26
Steer Shock Valves
<TABLE ROW
27
27
Emergency Steer Combined Pump and Motor
<TABLE ROW
28
28
Emergency Steer Pressure Switch
<TABLE ROW
29
29
Brake Actuators
<TABLE ROW
30
30
Transmission Dump Switch
<TABLE ROW
31
31
Brake Light Switch
<TABLE ROW
32
32
Brake Valve
<TABLE ROW
33
33
Brake Accumulators
<TABLE ROW
34
34
Oil Cooler
<TABLE ROW
35
35
Low Pressure Switch
<TABLE ROW
36
36
Main Pump Stand-by Pressure Relief Valve
<TABLE ROW
37
37
Main Pump System Pressure Relief Valve
<TABLE ROW
38
38
Main Pump Control Piston
<TABLE ROW
39
39
Main Pump Stroking Piston
<TABLE ROW
40
40
Secondary Pump Stand-by Pressure Relief Valve
<TABLE ROW
41
41
Secondary Pump System Pressure Relief Valve
<TABLE ROW
42
42
Secondary Pump Control Piston
<TABLE ROW
43
43
Secondary Pump Stroking Piston
<TABLE ROW
44
44
Engine Driven Gear Pump and Charge Valve
<TABLE ROW
45
45
Low Brake Pressure Switch
<TABLE ROW
46
46
Return Filter/Diffuser
<TABLE ROW
47
47
Filler/Breather
<TABLE ROW
48
48
Tank
<TABLE ROW
49
49
Suction Strainer
<TABLE ROW
50
50
Cooling Fan Motor
<TABLE ROW
51
51
Changeover Valve (4 Spool Only)
<TABLE ROW
52
52
Supply from P2
<TABLE ROW
53
53
Auxiliary Circuit A.R.V.(1) (Optional 4th Spool)
(1)
<TABLE ROW
54
54
Auxiliary Circuit Spool (Optional 4th Spool)
<TABLE ROW
55
55
Auxiliary Circuit Compensator (4th Spool)
<TABLE ROW
56
56
Proportional Control Valve
<TABLE ROW
57
57
A.C.C.S. Valve
A.C.C.S. Automatic Carry Control System
<TABLE ROW
58
58
A.C.C.S. Accumulators
<TABLE ROW
59
59
A.C.C.S. Shut Off Valve
<TABLE ROW
60
60
Cooling Fan Motor Reversing Valve (Optional)
<TABLE ROW
BR1
BR1
Front Brakes
<TABLE ROW
BR2
BR2
Rear Brakes
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Fig 8. 3-Spool Z-Bar Circuit
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K Component Key ( T E-16)
K Component Key ( T E-16)
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Fig 9. 3 Spool HT Circuit
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<TABLE ROW
K Component Key ( T E-16)
K Component Key ( T E-16)
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<GRAPHIC
Fig 10. 4-Spool Standard ZX/HT
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K Component Key ( T E-16)
K Component Key ( T E-16)
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<GRAPHIC
Fig 11. Single Spool Proportional Auxiliary Circuit
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K Component Key ( T E-16)
K Component Key ( T E-16)
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Fig 12. Twin Spool Proportional Auxiliary Circuit
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K Component Key ( T E-16)
K Component Key ( T E-16)
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Fig 13. Automatic Carry Control System (ACCS) Circuit
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K Component Key ( T E-16)
K Component Key ( T E-16)
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Fig 14. Reverse Fan (Option) Circuit
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K Component Key ( T E-16)
K Component Key ( T E-16)
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Circuit Descriptions
Circuit Descriptions
Pump Operation
Pump Operation
The hydraulic system of the machine is powered by one pump with a rated flow of 100 cc/rev.
The pumps are of the variable displacement axial piston type. Displacement of oil is achieved by the continuous operation of nin…
Main components of pump
15P
15
15P1
15
15P2
15
15P3
15
15P4
15
15P5
15
15P6
15
15P8
15
15P9
15
15P10
15
Rotation of the cylinder barrel causes linear movement of the axial pistons and fluid from the suction port is drawn into the pu…
The stroke length of the pistons and consequently the output of fluid is directly related to the swashplate angle. The swashplat…
<GRAPHIC
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Fig 15.
Pump Pressure/Flow Regulator Valves
Pump Pressure/Flow Regulator Valves
Start Up
Start Up
The Start Up Valve
16SUV
16
16P14
16
This allows spool
16P15
16
16P14
16
16P9
16
Hydraulic Service Operated
Hydraulic Service Operated
The Start Up Valve
16SUV
16
16P14
16
A signal from loader valve moves spool
16P15
16
16P9
16
16P13
16
Minimum Flow/Maximum Pressure
Minimum Flow/Maximum Pressure
The Start Up Valve
16SUV
16
16P14
16
System pressure acts on spool
16P12
16
16P11
16
16P9
16
16P13
16
<GRAPHIC
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Fig 16.
Start Up Valve
Start Up Valve
Associated with the pump and fitted adjacent to it is a start-up valve. The start-up valve operates on engine turnover prior to starting and prevents the development of a hydraulic lock in the pump circuit.
A 12 volt coil, linked to the
17HS
17
A 12 volt coil is used to ensure a good start. This is because the electrical system voltage falls to about 15 – 18 volts whilst the starter is in operation.
Once the engine has started and the starter key returned to the
17IGN
17
<GRAPHIC
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Fig 17.
Loader Valve
Loader Valve
The loader valve
18LV
18
19LV1
19
19LV2
19
19LV4
19
19LV4
19
Additionally, one or two optional valve sections may be fitted. The illustration shows a typical valve block with one optional section,
19LV3
19
When operated, the designated valve section controls the volume and direction of oil by way of service ports
19A
19
19B
19
The valve sections spools are of the following type and service:
LV1 Loader Arms.
LV1
Double acting A to B, double acting B to A, float A to B to tank.
LV2 Shovel.
LV2
4-ram machines – Regenerative B to A, double acting A to B.
Z-bar machines – Double acting A to B, double acting B to A.
LV3 (if fitted) Auxiliary.
LV3
Double acting A to B, double acting B to A.
<GRAPHIC
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Fig 18.
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Fig 19.
Loader Valve – Arms Raise/Lower
Loader Valve – Arms Raise/Lower
With the raise service selected, servo pressure is applied to the loader valve section
20LV1
20
20A
20
20P
20
20B
20
20C
20
When the lower service is selected, servo pressure moves the spool so that the pressure and return line galleries are interchang…
<GRAPHIC
<GRAPHIC
Fig 20.
Loader Valve – Shovel Float
Loader Valve – Shovel Float
Operation of the servo control valve from arms lower to arms float selection increases the servo pressure acting on the loading valve section
21LV1
21
21A
21
21B
21
21C
21
Lifting ram oil can now be freely displaced to and from rod and piston faces allowing the rams to extend and retract as required. This condition allows the arms and bucket attachment to follow ground contours with no demand on pump pressure.
<GRAPHIC
<GRAPHIC
Fig 21.
Loader Valve – Shovel Tip
Loader Valve – Shovel Tip
The loader valve section
22LV2
22
22A
22
Oil returning from the bucket rams is used in a regenerative action to supplement pressure oil from the pumps and speed shovel tipping. Because movement of the spool
22A
22
22B
22
During shovel tip selection, servo pressure is also fed to the 2 stage (80/225 bar) Auxiliary Relief Valve 2
22ARV
22
Stage 1 (80 bar) controls pressure on the total head side of the ram. Stage 2 (225 bar) controls pressure in the rod side of the…
<GRAPHIC
<GRAPHIC
Fig 22.
Loader Valve – Shovel Crowd
Loader Valve – Shovel Crowd
With shovel crowd servo pressure applied to the loader valve section
23LV2
23
23A
23
23B
23
23ARV
23
232-ARV
23
<GRAPHIC
<GRAPHIC
Fig 23.
Compensator Spool – Operation 1
Compensator Spool – Operation 1
When the loader valve section
24LV1
24
24A
24
Pressure from port B assisted by spring action moves the Compensator Spool A to close the pump pressure inlet at
24B
24
<GRAPHIC
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Fig 24.
Compensator Spool – Operation 2
Compensator Spool – Operation 2
If pump pressure continues to be delivered to the loader valve block section
25LV1
25
25A
25
25A
25
25B
25
Compensator Spools are fitted to all loader valve block sections.
<GRAPHIC
<GRAPHIC
Fig 25.
Auxiliary Services
Auxiliary Services
With the B port power selected for the Auxiliary Services (Quick hitch or Clam circuits), servo pressure is applied to the loader valve section
26LV3
26
26LV4
26
26A
26
26B
26
26C
26
When A port power is selected, servo pressure moves the spool so that the pressure and return line galleries are reversed. Pressure oil is then directed from port A, whilst port B is connected to exhaust.
<GRAPHIC
<GRAPHIC
Fig 26.
Servo Pressure Regulating Valve
Servo Pressure Regulating Valve
A pressure regulating valve (PRV) is incorporated in the loader valve end cover section
27LV5
27
Neutral Standby Pressure
Neutral Standby Pressure
Initial servo pressure is generated by pump ‘stand by’ pressure set at 27 bar.
Service Operating
Service Operating
Pressure at 30 bar lifts spool
27A
27
27A
27
<GRAPHIC
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Fig 27.
Automatic Carry Control System (ACCS)
Automatic Carry Control System (ACCS)
General
General
ACCS is a hydraulic suspension system that is designed to enable a “cushion” effect for the loader lift rams, giving the benefit…
The system utilises a valve block, the main operations of which are given below.
The circuits that follow are for description purposes only. When fault finding the system always refer to the main hydraulic schematic circuits.
Circuit Descriptions
Circuit Descriptions
System Charging
System Charging
K Fig 28. ( T E-49).
K Fig 28. ( T E-49)
With the engine running and the ACCS isolator valve
59
When the lift service is operated, pressurised oil flows from the loader valve spool
19
17
57
<GRAPHIC
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Fig 28. System Charging
System Fully Charged
System Fully Charged
K Fig 29. ( T E-50).
K Fig 29. ( T E-50)
With the engine running, the system isolator valve
59
When the charge pressure of the hydraulic oil rises above a predetermined level, this level being set by the pressure relief val…
Simultaneously, a second internal pilot pressure acts upon the right side of the operating spool causing it to move to the left….
As the internal pressure is lowered by the relief valve, the pilot pressure on the right side of the operating spool is also reduced, allowing the spring pressures to center the spool to the charging position, ready for the cycle to begin again.
At this stage the stem is charged but not active.
<GRAPHIC
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Fig 29. System Fully Charged
System Operating
System Operating
K Fig 30. ( T E-51).
K Fig 30. ( T E-51)
With the engine running, the system isolator valve
59
With the system activation switch turned ON, and the road speed above the required activation speed, the solenoid in the ACCS va…
With the spool in this position, oil from the head end of the lift rams is connected to the accumulators, thereby allowing the f…
With the loader valve lift spool
19
19
<GRAPHIC
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Fig 30. System Operating
System Pressure Equalisation
System Pressure Equalisation
K Fig 31. ( T E-52).
K Fig 31. ( T E-52)
With the system activating cab switch turn ON and the machine carrying out loading operations, there is a sequence of events tha…
The machine travelling with a loaded shovel, and with the ACCS system operating, stops and empties the load from the shovel. On …
The effect of this pressure differential causes the combined spring and pilot pressure acting on the right side of the ACCS operating spool to move it fully to the left.
With the spool in this position, the high pressure oil from the accumulators is allowed to bleed to tank, thereby reducing the internal pressures, while dead ending the connections from the loader rams.
Once the pressure differential equalises, the combined spring and pilot pressure acting on the left side of the operating spool …
<GRAPHIC
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Fig 31. Pressure Equalisation
System Isolation
System Isolation
K Fig 32. ( T E-53).
K Fig 32. ( T E-53)
An isolation valve
When the isolator valve is opened, lift ram head side pressure is vented to tank. Before opening the isolator valve, the loader end must be either lowered to the ground or be suitably supported to prevent unexpected movement of the loader end.
An isolation valve
59
When the valve is opened, the stored hydraulic pressure in the ACCS valve and accumulators is vented to tank.
Only the stored hydraulic pressure is vented. The accumulators gas charge pressure will still be stored inside the accumulators. For more information on the accumulators refer to
K Accumulators ( T E-77)
Should the loader arms be raised with the isolator valve open, the arms will slowly lower to the ground.
<GRAPHIC
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Fig 32. System Isolation
Maintenance Safety
Maintenance Safety
Before attempting any maintenance work on the load suspension hydraulic system, the isolating ball valve must be OPEN.
The isolating ball valve is normally CLOSED for ACCS to be operative.
<GRAPHIC
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Fig 33.
The loader arms will fall to the ground if they are not on the ground or securely supported before the isolating ball valve is o…
Electronic Emergency Steering
Electronic Emergency Steering
General
General
The emergency steering is provided by an electronically- driven pump controlled by the EMS system.
The EMS system monitors the main hydraulic system pressure. If the pressure falls below a preset limit the emergency steering system will be activated automatically.
The system self tests every time the ignition is turned on and will disable the machines starting system if a fault is detected.
A switch is provided in the cab for the manual testing of the system.
The pump and motor are located mounted to the front bulk- head beneath the engine cover.
The system basically consists of a cab switch, low pressure switch, pump
34A
34
34B
34
34C
34
34D
34
34E
34
34F
34
<GRAPHIC
<GRAPHIC
Fig 34.
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Fault Finding
Fault Finding
Hydraulic Fault Finding
Hydraulic Fault Finding
To use this section, look for the fault in the list below and refer to the probable causes and actions required listed against the fault.
Remember safety must always be the first priority, refer to
Section 2 – Care and safety
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Fault
Possible Cause
Action
<TABLE BODY
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1 Lack of power in all hydraulic functions.
1 Lack of power in all hydraulic functions.
1 Lack of power in all hydraulic functions.
Insufficient hydraulic fluid.
Check for leaks and top up as required.
<TABLE ROW
Hydraulic leaks in system.
Check hoses, replace as required.
<TABLE ROW
Engine performance.
Check engine performance.
<TABLE ROW
Pump control setting incorrect.
Check and adjust as required.
<TABLE ROW
Low pump flow.
Check for external leaks, replace seals.
<TABLE ROW
Priority valve sticking.
Check priority valve.
<TABLE ROW
2 All hydraulic rams slow to operate.
2 All hydraulic rams slow to operate.
2 All hydraulic rams slow to operate.
Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.
Check pipe lines and replace as required.
<TABLE ROW
Pump control setting incorrect.
Check and adjust as required.
<TABLE ROW
Low pump flow
Check pump flow.
<TABLE ROW
Check for external leaks, replace seals.
<TABLE ROW
Check for priority valve sticking.
<TABLE ROW
3 One hydraulic service fails to operate or is slow to operate.
3 One hydraulic service fails to operate or is slow to operate.
3 One hydraulic service fails to operate or is slow to operate.
Associated service pipe lines leaking, damaged, trapped or kinked.
Check hoses, replace as required.
<TABLE ROW
Associated ram leaking.
Replace seals.
<TABLE ROW
A.R.V. setting incorrect.
Check and adjust as required.
<TABLE ROW
Associated valve block section leaking or not operating.
Check for leaks, rectify as required.
<TABLE ROW
Check that the control lever is operating the spool, rectify as required.
<TABLE ROW
Associated check valve not opening to allow return of oil to tank.
Check and rectify as required.
<TABLE ROW
Diverter not opening.
Check electrical power supply and valve operation, rectify as required.
<TABLE ROW
4 The engine tends to stall when hydraulics are under load.
4 The engine tends to stall when hydraulics are under load.
4 The engine tends to stall when hydraulics are under load.
Pump control setting incorrect.
Check and adjust as required.
<TABLE ROW
Engine performance.
Check engine performance.
<TABLE ROW
5 Ram creep.
5 Ram creep.
5 Ram creep.
Ram seals.
Check and rectify as required.
<TABLE ROW
A.R.V.
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Service Procedures
Service Procedures
Hydraulic Contamination
Hydraulic Contamination
Hydraulic Fluid Quality
Hydraulic Fluid Quality
Construction machinery uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust …
Effects of Contamination
Effects of Contamination
Once inside the system, hydraulic circuit contaminants greatly effect the performance and life of hydraulic equipment. For examp…
1 Solid Particles – sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.
1 Solid Particles – sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.
1 Solid Particles
2 Liquid – usually water and incompatible oils and greases.
2 Liquid
3 Gases – Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid.
3 Gases
These contaminants can appear during manufacture, assembly and operation.
Cleaning Operation
Cleaning Operation
The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a cleaning unit.
K Fig 35. ( T E-59)
Procedure
Procedure
Connect the cleaning unit in place of the hydraulic filter.
K Fig 35. ( T E-59)
<GRAPHIC
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Fig 35. Cleaning Unit
Contaminant Standards
Contaminant Standards
Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns.
1 micron = 0.001 mm (0.0000394 in).
Listed below are a few typical comparisons:
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
– Human Hair = 70 microns (0.07 mm, 0.00275 in)
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
Smallest particle visible to the naked eye is 40 microns (0.00157) approximately.
Standards will often be quoted to ISO (International Standards Organisation) for which literature can be obtained.
Filters
Filters
The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated through use to the required level of cleanliness. The filter must be serviced to the requirements of the machine Service Schedules.
To ensure optimum performance and reliability it is important that the machines hydraulic system is serviced periodically in accordance with the manufacturers requirements.
Venting the Hydraulic Pressure
Venting the Hydraulic Pressure
Procedure
Procedure
Machines are now fitted with a new generation loader control valve. A feature of this new valve is that when the ignition is tur…
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and carry out the full venting procedure. Make sure the engine cannot be started while the hoses are open.
Machines are now fitted with a new generation loader control valve. A feature of this new valve is that when the ignition is tur…
1 Park the machine on firm level ground. Lower the attachments to the ground, apply the park brake and set the transmission to neutral.
1 Park the machine on firm level ground. Lower the attachments to the ground, apply the park brake and set the transmission to neutral.
2 Switch the engine OFF.
3 Turn the ignition ON, but DO NOT start the engine.
4 Ensured the loader isolation switch in the right hand side cab switch bank is turned ON. (The switch will be illuminated when ON.)
K Fig 36. ( T E-61)
<GRAPHIC
<GRAPHIC
Fig 36.
5 Operate the loader control lever repeatedly to vent any residual pressure.
6 Turn OFF the ignition and disconnect the batteries to ensure the machine cannot be started while the hydraulic system is open.
Automatic Carry Control System Venting
Automatic Carry Control System Venting
Before attempting any maintenance work on the load suspension hydraulic system, the isolating ball valve must be OPEN.
The isolating ball valve is normally CLOSED for ACCS to be operative.
<GRAPHIC
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Fig 37.
The loader arms will fall to the ground if they are not on the ground or securely supported before the isolating ball valve is o…
Connecting and Disconnecting Hydraulic Hoses
Connecting and Disconnecting Hydraulic Hoses
The following paragraphs describe how to connect and disconnect hydraulic hoses safely.
Connecting the Hoses
Connecting the Hoses
1 Connect the hoses. Where the connection is of the quick release type, see section A, contents. For all other hose connections,…
1 Connect the hoses. Where the connection is of the quick release type, see section A, contents. For all other hose connections,…
2 Check for leaks as follows:
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 prot…
2 Check for leaks as follows:
a Start the engine.
a Start the engine.
b Operate the controls to pressurise the required hose.
c Switch off the engine. Remove the starter key. Check for signs of leakage at the hose connections.
Disconnecting the Hoses
Disconnecting the Hoses
1 Vent the hydraulic pressure as described
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
1 Vent the hydraulic pressure as described
1 Vent the hydraulic pressure as described
K Venting the Hydraulic Pressure ( T E-61)
2 Disconnect the hoses. Where the connection is of the quick release type, see
Section A
`Positional Type’ Hydraulic Adaptors
`Positional Type’ Hydraulic Adaptors
Fitting Procedure
Fitting Procedure
On a typical machine, some hydraulic components may utilise `Positional Type’ SAE Hydraulic Adaptors. When fitting `Positional T…
38
38
A
1 Ensure the locknut
1 Ensure the locknut
38
38
B
2 Check the `O’ ring backing washer
38
38
C
3 Check the `O’ ring
38
38
A
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.
5 Set the angular position of the adaptor as required, then secure by tightening the locknut
38
38
B
When fitted correctly no more than one thread should be visible at
39
39
Z
6 Torque tighten the locknut to 81 Nm (60 lbf ft).
<GRAPHIC
<GRAPHIC
Fig 38.
<GRAPHIC
<GRAPHIC
Fig 39.
Flow and Pressure Tests
Flow and Pressure Tests
Main Pump
Main Pump
Standby Pressure
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
Standby Pressure
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
Standby Pressure
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
Standby Pressure
Standby Pressure
1 Connect Pressure Test Gauge Kit 892/00253 (see
1 Connect Pressure Test Gauge Kit 892/00253 (see
Note
41A
41
2 Remove the ESOS connector
After checking the standby pressure, turn the starter key to HS to allow the engine rotation to stop. Do not turn the key to OFF while the engine is turning; otherwise the test gauge may be damaged.
2 Remove the ESOS connector
40B
40
K Technical Data ( T E-3)
42C
42
System control pressure will only show with the ESOS disconnected. When the ESOS is reconnected, the pressure shown will be approximately 50 bar.
<GRAPHIC
<GRAPHIC
Fig 40.
System Control Pressure
System Control Pressure
1 If you are using individual gauges, rather than Gauge Kit 892/00253, remove the existing gauge from test point
1 If you are using individual gauges, rather than Gauge Kit 892/00253, remove the existing gauge from test point
41A
41
Note
2 Ensure that the engine rotation has stopped. Reconnect the ESOS connector
40B
40
3 Run the engine
at idle
Do not select ‘Float’
4 This will cause the hydraulic pressure to rise to the idle control pressure setting, which should be as stated in
K Technical Data ( T E-3)
E
If the pressure is correct, Slowly increase engine speed to Maximum. Pressure should rise to system control pressure stated in
K Technical Data ( T E-3)
Note the engine speed at which the gauge indicates the pressure rise and check against the figures in
K Technical Data ( T E-3)
K Idle Control Setting ( T E-71)
If necessary adjust pressure at
42D
42
If Pressure Test Gauge Kit 892/00253 is not available, use a suitable gauge which incorporates protection against over pressurisation. See
K Technical Data ( T E-3)
<GRAPHIC
<GRAPHIC
Fig 41.
<GRAPHIC
<GRAPHIC
Fig 42.
Pressure Testing the Loader Valve A.R.V.’s Using a Hand Pump
Pressure Testing the Loader Valve A.R.V.’s Using a Hand Pump
To pressure test and re-set the loader auxiliary relief valves (A.R.V.), the following equipment must be used:
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
To pressure test and re-set the loader auxiliary relief valves (A.R.V.), the following equipment must be used:
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
892/00340
Test Block Body
<TABLE ROW
892/00223
Hand Pump
<TABLE ROW
892/00279
Pressure Gauge 0 – 400 bar
Other associated equipment as detailed in
Section 1 – Service Tools.
1 Remove the loader valve A.R.V.’s from the loader valve block. Note their positions for correct reassembly.
1 Remove the loader valve A.R.V.’s from the loader valve block. Note their positions for correct reassembly.
2 Install the first A.R.V. assembly in the test block at the port marked ‘
RV
<GRAPHIC
<GRAPHIC
Fig 43.
3 Connect a hydraulic hand pump to port ‘
P
4 Connect a 0 to 400 bar (0 to 6000 lbf/in
2
G
5 Port ‘
T
6 Raise the pressure at the valve inlet using the hydraulic hand pump, when the A.R.V. ‘cracks’ and oil escapes from the port marked ‘
T
7 If the A.R.V. setting is correct as stated in
K Technical Data ( T E-3)
8 If the A.R.V. setting needs to be adjusted release locknut
44W
44
44V
44
9 When the correct A.R.V. setting has been attained, release the pressure in the test block. Remove the A.R.V. assembly and refit it to its correct position in the loader valve block.
10 Repeat the procedure for the other A.R.V.’s.
<GRAPHIC
<GRAPHIC
Fig 44.
Steering Relief Valve
Steering Relief Valve
1 Connect Pressure Test Gauge Kit 892/00253 to test point
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
1 Connect Pressure Test Gauge Kit 892/00253 to test point
1 Connect Pressure Test Gauge Kit 892/00253 to test point
45A
45
Note
2 Turn the steering wheel and check that the indicated pressure is as stated in
K Technical Data ( T E-3)
3 If the indicated pressure does not meet the specified pressure, do the following:
a Separate the hydraulic steering unit from the steering column, leaving the hoses connected.
a Separate the hydraulic steering unit from the steering column, leaving the hoses connected.
b Remove the steer relief valve (see
Section H – Steering
If Pressure Test Gauge Kit 892/00253 is not available, use a suitable gauge which incorporates protection against over pressurisation. See
K Technical Data ( T E-3)
Two-Stage Shovel Ram (Head Side)
Two-Stage Shovel Ram (Head Side)
To Set First Stage Pressure
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
To Set First Stage Pressure
1 Connect Pressure Test Gauge Kit 892/00253 to test point
1 Connect Pressure Test Gauge Kit 892/00253 to test point
45A
45
Note
<GRAPHIC
<GRAPHIC
Fig 45.
If Pressure Test Gauge Kit 892/00253 is not available, use a suitable gauge which incorporates protection against over pressurisation. See
K Technical Data ( T E-3)
2 Remove the hose from point
46L
46
3 Operate the shovel tip with the loader arms as close to the ground as possible.
4 Check that the pressure gauge reads the value stated in
K Technical Data ( T E-3)
46M
46
46P
46
5 Tighten locknut
46M
46
4
To set 2nd stage pressure
1 Unplug and reconnect hose to connector
1 Unplug and reconnect hose to connector
46L
46
2 Operate the shovel tip with the loader arms as close to the ground as possible.
3 Release locknut
46N
46
46P
46
K Technical Data ( T E-3)
As the pressure increases beyond 150 bar, the engine may labour. Counteract this by increasing the engine revs.
4 Once the reading is stable tighten the locknut
46N
46
3
Rechecking 1st stage setting
To ensure that the 2nd stage adjustment procedure has not affected the 1st stage setting, remove the connector from
46L
46
1 Run the engine at idle speed and operate the shovel tip with the loader arms as close to the ground as possible.
1 Run the engine at idle speed and operate the shovel tip with the loader arms as close to the ground as possible.
2 If an adjustment is necessary, release locknut
46M
46
46P
46
46L
46
If pressure settings, as detailed in Technical Data, prove difficult to attain proceed as follows:
1 Remove connector from
1 Remove connector from
46L
46
2 Slacken locknut
46N
46
3 Rotate
46P
46
4 Repeat the pressure setting procedures.
<GRAPHIC
<GRAPHIC
Fig 46.
Idle Control Setting
Idle Control Setting
Procedure
Procedure
1 Connect Pressure Test Gauge Kit 892/00253 (see
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
1 Connect Pressure Test Gauge Kit 892/00253 (see
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
1 Connect Pressure Test Gauge Kit 892/00253 (see
1 Connect Pressure Test Gauge Kit 892/00253 (see
Note
47A
47
<GRAPHIC
<GRAPHIC
Fig 47. Test point
2 Run the engine
at idle
Do not select ‘Float’
3 Slowly increase engine speed to Maximum. Pressure should rise to system control pressure stated in
K Technical Data ( T E-3)
Note the engine speed at which the gauge indicates the pressure rise.
The pressure reading should rise at the engine speeds stated in
K Technical Data ( T E-3)
Before adjusting the position of the proximity switch check the gap
48X
48
<GRAPHIC
<GRAPHIC
Fig 48.
If the pressure rises below the engine speed stated, move the proximity switch forward in the slot. If the pressure rises above the engine speed stated, move the proximity switch back in the slot. Secure the proximity switch.
Repeat step
3
If Pressure Test Gauge Kit 892/00253 is not available, use a suitable gauge which incorporates protection against over pressurisation. See
K Technical Data ( T E-3)
Hydraulic Cooling Fan Setting
Hydraulic Cooling Fan Setting
Procedure
Procedure
Checking the Fan Speed
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
Checking the Fan Speed
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
Checking the Fan Speed
When working close to the machine with the engine running, protective clothing must be worn, ie. Safety glasses, ear protection, gloves etc.
Checking the Fan Speed
Checking the Fan Speed
1 Attach tacho-reflective tape to the fan hub rather than to the fan blades.
1 Attach tacho-reflective tape to the fan hub rather than to the fan blades.
2 Warm up the hydraulic system until 4 or 5 segments show on the hydraulic oil temperature gauge.
3 Hold the engine at Max specified revs as detailed in
K Technical Data ( T E-3)
4 Check the fan reaches its recommended speed as detailed in
K Technical Data ( T E-3)
Adjusting the Fan Speed
Adjusting the Fan Speed
K Fig 49. ( T E-73) and
K Fig 49. ( T E-73)
K Fig 50. ( T E-74)
Make adjustments to the adjusting screw in small increments only. Recheck the fan speed after each adjustment. Screw the adjuster in to increase the fan speed and pressure, out to decrease.
1 Slacken the locknut
1 Slacken the locknut
A
If the fan exceeds the recommended speed, reduce the speed by at least 100 rpm below the requirement then slowly increase until the correct speed is obtained.
<GRAPHIC
<GRAPHIC
Fig 49. Uni-Directional Fan Motor
<GRAPHIC
<GRAPHIC
Fig 50. Bi-Directional Fan Motor
2 Tighten the locknut
A
Reversing Fan Software
Reversing Fan Software
Two files are required:
1 ***emslang.ini. Replace the existing file in the JCB2 directory on the laptop hard drive.
1 ***emslang.ini. Replace the existing file in the JCB2 directory on the laptop hard drive.
2 Instal FAN/00004.hex or latest version into EMS.
Programming the Reversing Fan Frequency and Duration
Programming the Reversing Fan Frequency and Duration
Fan direction and duration can be programmed via the
EMS
1 In “Prestart Mode” (i.e. mode where you can set the time clock), press the SETUP key and scroll through the Clock/Date settings until you reach FAN F DLY. Set the fan forwards duration using the arrow keys.
1 In “Prestart Mode” (i.e. mode where you can set the time clock), press the SETUP key and scroll through the Clock/Date settings until you reach FAN F DLY. Set the fan forwards duration using the arrow keys.
2 Press the SETUP key again to display FAN R DLY. Set the reverse duration using the arrow keys.
Recommended initial settings are: 3600 Forwards, 20 Reverse (time displayed in SECONDS)
3 Press the manual key to exit set-up.
4 Reverse direction can be manually selected at any time by pressing the “Down Arrow” (providing FAN R DLY0). The fan will change direction immediately and run in reverse for the programmed duration.
5 To disable the fan reversing function set the FAN R DLY = 0 or unplug the wires to the reversing valve.
Emergency Steering (Electronic)
Emergency Steering (Electronic)
Checking/Adjusting the System Pressure
Checking/Adjusting the System Pressure
Checking the pressure
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
Checking the pressure
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
Checking the pressure
Checking the pressure
1 Connect a 400 bar test gauge to the test point
1 Connect a 400 bar test gauge to the test point
51T
51
The emergency steering system test point (
51T
51
2 With the engine switched OFF, turn on the ignition. Wait for the EMS System to carry out its self diagnostic test (approximate…
3 Release the switch once the pressure reading has been obtained. Check the pressure reading against the system max pressure as detailed in
K Technical Data ( T E-3)
4 Remove the 400 bar test gauge.
<GRAPHIC
<GRAPHIC
Fig 51.
Adjusting the Pressure
Adjusting the Pressure
If the pressure needs to be adjusted, providing the pressure is not greater than 50 bar, replace the 400 bar test gauge with a 5…
the adjuster is very sensitive, make only very small adjustments at the adjusting screw.
1 Connect a 50 bar test gauge to the test point
1 Connect a 50 bar test gauge to the test point
51T
51
2 Turn on the ignition but do not start the engine. Depress and hold the emergency steering test switch and check the pressure.
3 Release the switch (there is no need to run the pump whilst adjusting).
4 Hold the nut
52H
52
52G
52
52F
52
5 After each small alteration to the adjuster
52F
52
52G
52
6 Release the switch before making any adjustment to the pressure.
7 Continue making small alterations to the adjuster until the correct pressure as detailed in
K Technical Data ( T E-3)
8 Tighten the locknut and recheck the pressure.
9 Remove the test gauge.
<GRAPHIC
<GRAPHIC
Fig 52.
Automatic Carry Control System (ACCS)
Automatic Carry Control System (ACCS)
Accumulators
Accumulators
All hydraulic pressure must be removed from the accumulator BEFORE any attempts to adjust the Gas Charge Pressures are made. Refer to
K Venting the Hydraulic Pressure ( T E-61)
Charging the Accumulators
Charging the Accumulators
The accumulators must be charged before fitting. Charge the accumulators as follows:
Piston Type 2
Piston Type 2
1 Remove the steel cap
Use only nitrogen gas to charge accumulators. The use of any other gas can cause the accumulators to explode. Remember that alth…
1 Remove the steel cap
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
1 Remove the steel cap
1 Remove the steel cap
A
B
2 Connect the nitrogen charging tool kit
892/01042
892/01043
3 Making sure not to loop or twist the hose, connect the charging tool to a bottle of compressed nitrogen gas fitted with a regulator set to minimum pressure.
4 Via the charging device, open the charge valve plug
C
5 Open the discharge valve
D
Carefully open the nitrogen gas bottle valve and confirm that the nitrogen gas flows freely.
Shut the gas bottle valve
E
D
6 Carefully open the gas bottle valve
E
2
Close the gas bottle valve
E
7 Adjust the pressure in the accumulator by carefully opening and closing the discharge valve
D
to the value listed in
K Technical Data ( T E-3)
Via the charging device, shut filler plug
C
8 Release the pressure from the gas bottle hose by opening the discharge valve
D
9 Disconnect the charging device from the accumulator.
10 Check the gas-tightness of filler plug
B
11 Replace the steel cap
A
<GRAPHIC
<GRAPHIC
Fig 53.
Pumps
Pumps
Removal and Replacement
Removal and Replacement
When Removing
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
When Removing
When Removing
Release the hydraulic tank cap to vent system pressure before removing the pump.
Disconnect all hoses and blank off to prevent ingress of dirt.
With the pump adequately supported and the two mounting bolts
54A
54
If it is intended to replace the pressure/flow regulator or the drive shaft seal, follow the procedures given on
K Replacing the Pressure/Flow Regulator ( T E-82)
K Renewing Drive Shaft Seal ( T E-83)
K Fig 58. ( T E-85)
When Replacing
When Replacing
Before refitting ensure that the pump casing has been filled with the specified quantity of hydraulic oil.
Renew all ‘O’ rings.
Apply JCB Lock & Seal to the threads of bolts
54A
54
54A
54
When all hose connections have been made run the pump without load and allow it to deliver without pressure for a few seconds to ensure adequate lubrication.
Run the pump to check for fluid leakage at connections. If the pump is not delivering without air bubbles after approximately one minute, a pipe connection leakage is indicated.
Table 7. Torque Settings
Table 7. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
A
A
244
25
180
<GRAPHIC
<GRAPHIC
Fig 54.
Tandem Pumps
Tandem Pumps
General
General
The ‘Tandem Pump Set’ is driven from the rear of the transmission Access to the pumps is via the gap between the rear chassis an…
The pumps share a common suction hose.
Removal and Replacement
Removal and Replacement
K Fig 55. ( T E-81).
K Fig 55. ( T E-81)
The following procedure describes removal and replacement of the tandem pumps.
Removal
Removal
1 Park the machine on firm level ground, lower the attachments to the ground. Apply the park brake, set the transmission to neutral, stop the engine and remove the starter key to prevent the machine being started while you are working on it.
Soft Ground
A machine can sink into soft ground. Never work under a machine on soft ground.
1 Park the machine on firm level ground, lower the attachments to the ground. Apply the park brake, set the transmission to neutral, stop the engine and remove the starter key to prevent the machine being started while you are working on it.
1 Park the machine on firm level ground, lower the attachments to the ground. Apply the park brake, set the transmission to neutral, stop the engine and remove the starter key to prevent the machine being started while you are working on it.
2 Install the articulation lock. Refer to
Section 3 – Routine Maintenance.
3 Block both sides of all four wheel.
4 Carry out the hydraulic pressure venting procedure as detailed.
K Venting the Hydraulic Pressure ( T E-61)
5 Drain the hydraulic fluid from the hydraulic tank.
6 Remove the four flange bolts
A
7 Label and disconnect the pumps outlet hoses from the pumps. Blank off all exposed connections to prevent the ingress of dirt.
8 Support the pump assembly and remove the four bolts
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
8 Support the pump assembly and remove the four bolts
B
Replacement
Replacement
Replacement is the reverse of the removal procedure, however, please note the following:
1 Clean off all traces of sealant compound from the pump and transmission housing faces. Apply a thin bead of Loctite 5910 sealant to the transmission mounting face.
1 Clean off all traces of sealant compound from the pump and transmission housing faces. Apply a thin bead of Loctite 5910 sealant to the transmission mounting face.
The pump set must be assembled onto the transmission within 15 minutes of applying the sealant.
2 Pour a small amount of clean hydraulic fluid into the pumps inlet and outlet ports prior to installation to assist with initial lubrication.
3 Locate the splined shaft of the pump into the transmission drive. Apply JCB Threadlocker and sealer to the bolts
B
4 Torque tighten the bolts
B
K Torque Settings ( T E-81)
5 Reconnect the pumps outlet hoses as detailed in
K Connecting and Disconnecting Hydraulic Hoses ( T E-62)
All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal sealant applied to the threads of the adaptor.
6 Fit a new sealing O-ring to the suction hose flange. Reconnect the pumps suction hose flange to the pumps body with bolts
A
7 Fill the hydraulic tank with the correct grade of hydraulic fluid.
Section 3 – Routine Maintenance.
Replace the suction strainer and return line filter if fitting a new or serviced pump set.
8 When all hose connections have been made run the pump without load and allow it to deliver without pressure for a few seconds to ensure adequate lubrication.
9 Check the main and stand-by pressures as detailed in
K Flow and Pressure Tests ( T E-64)
Table 8. Torque Settings
Table 8. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
B
B
130
13.26
95.8
<GRAPHIC
<GRAPHIC
Fig 55.
Replacing the Pressure/Flow Regulator
Replacing the Pressure/Flow Regulator
Remove the capscrews
56-1
56
56-2
56
56-3
56
<GRAPHIC
<GRAPHIC
Fig 56.
Renewing Drive Shaft Seal
Renewing Drive Shaft Seal
Remove the retaining ring
57-1
57
57- 2
57
57-3
57
Examine the seal running area (drive shaft and housing) for wear or damage. Damage in these areas will require the pump to be further dismantled as shown on
K Fig 58. ( T E-85)
Lubricate a new seal with Mobilplex or equivalent grease containing Molybdenum Disulphide. Fit new seal ensuring it enters the housing evenly and with the grooved face correctly positioned. Position a new ‘O’ ring on the pump housing.
<GRAPHIC
<GRAPHIC
Fig 57.
Dismantling, Inspecting and Assembly
Dismantling, Inspecting and Assembly
The numerical sequence shown on the illustration is intended as a guide to dismantling and assembly.
Before dismantling the pump make sure the exterior of the pump and the working area is thoroughly clean and free from possible sources of contamination.
Dismantling
Dismantling
During dismantling note the following:
Mark covers and housing to ensure correct replacement. Use a soft-faced hammer to separate components. Do not use levers or other tools that may damage machined surfaces.
The port plate
58-2
58
58-6
58
58-8
58
58-9
58
The rotary group
58-3
58
58- 11
58
58-10
58
58-13
58
58-12
58
Remove the outer bearing races from the port plate and pump casing only if unserviceable and need to be renewed.
Inspecting
Inspecting
Generally check all pump parts for damage and/or wear. The shaft ‘O’ ring grooves and all sealing faces must be free of burrs and scores. Carry out a check for free running of the rotary group and control pistons during assembly.
Assembly
Assembly
For assembly the sequence should be reversed but note the following:
Renew all ‘O’ rings.
Apply JCB Lock & Seal to the securing threads of the control pistons
58-8
58
58-9
58
The cradle
58-12
58
<GRAPHIC
<GRAPHIC
Fig 58.
Page left intentionally blank
Cooling Fan Motor
Cooling Fan Motor
Removal and Replacement
Removal and Replacement
Removal
Removal
The following procedure’s illustrations depict a Uni- Directional Motor; the Bi-Directional motor has an additional hose. In all other aspects the procedures are the same.
1 Park the machine on firm level ground, lower the attachments to the ground, apply the park brake and set the transmission to neutral. Stop the engine. Block both sides of all four wheels.
1 Park the machine on firm level ground, lower the attachments to the ground, apply the park brake and set the transmission to neutral. Stop the engine. Block both sides of all four wheels.
The procedure detailed below must be followed to correctly vent the residual hydraulic pressure.
2 Vent the hydraulic pressure as detailed in
K Venting the Hydraulic Pressure ( T E-61)
3 Disconnect the batteries to prevent the engine being started whilst carrying out this procedure.
4 Open the left and right-hand side engine covers. From inside the right-hand side cover pull the release cable
59A
59
<GRAPHIC
<GRAPHIC
Fig 59.
5 Remove the six bolts securing the fan grille to the fan housing. (The lower three are fitted on the under side of the grille.)
6 Label and disconnect the hoses
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and carry out the full venting procedure. Make sure the engine cannot be started while the hoses are open.
6 Label and disconnect the hoses
60A
60
60B
60
K Connecting and Disconnecting Hydraulic Hoses ( T E-62)
<GRAPHIC
<GRAPHIC
Fig 60. Uni-Directional Motor
7 Open the fan housing and remove the four bolts
61A
61
<GRAPHIC
<GRAPHIC
Fig 61.
8 Remove the four bolts
61B
61
9 Lower the fan housing to the closed position and remove the two Allen bolts
62A
62
<GRAPHIC
<GRAPHIC
Fig 62.
Replacement
Replacement
Replacement is the reverse of the removal procedure, however note the following:
1 Take care to secure the hydraulic hoses inside the fan housing to prevent possible contact with the fan.
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 prot…
1 Take care to secure the hydraulic hoses inside the fan housing to prevent possible contact with the fan.
1 Take care to secure the hydraulic hoses inside the fan housing to prevent possible contact with the fan.
2 Top up the hydraulic fluid as necessary with the correct grade of fluid. Refer to
Section 3 – Routine Maintenance.
Uni-Directional Motor
Uni-Directional Motor
General
General
Before removing or dismantling the motor, check that its performance is as specified in
Technical Data
Dismantling, Inspection and Assembly
Dismantling, Inspection and Assembly
For motor components,
K Fig 63. ( T E-91)
Dismantling
Dismantling
It is very important to work in a clean environment when repairing hydraulic motors. Plug all ports and wash the exterior of the motor with a proper cleaning solvent before stripping the motors.
1 Remove the port plugs and ensure all oil is drained from the motor.
1 Remove the port plugs and ensure all oil is drained from the motor.
2 Prior to dismantling the motor, mark the motor body
9
3
16
3 Mount the motor vertically in a vice (use vice soft- jaws to protect the motor mounting flange) by the mounting flange, with the driveshaft pointing downwards and slacken the bolts
23
4 Remove the bolts
23, washers
22
16
5 Carefully remove the gear housing
9
13
12
11
6 Remove the rear bearing block
13
11
12
7 Remove the front bearing block
6
8 Turn the mounting flange over, with the shaft seal uppermost, and remove the retaining circlip
1
2
9 Clean all sealant from mating surfaces, discard the seal and O-rings
Inspection
Inspection
1 Clean and dry all parts thoroughly prior to inspection. (It is not necessary to check the seals as all seals need to be replaced). Inspect all O- ring grooves and shaft seal recesses, make sure there are no burrs.
1 Clean and dry all parts thoroughly prior to inspection. (It is not necessary to check the seals as all seals need to be replaced). Inspect all O- ring grooves and shaft seal recesses, make sure there are no burrs.
2 Check the driveshaft for damage. Check for marks or grooves on the driveshaft in the area of the seal. Slight discolouration of the shaft is allowable.
3 Inspect the faces of the gears for scoring or excessive wear. If the face of the gear is sharp, it could mill into the bearing block. If wear is evident then the parts must be replaced.
4 Inspect the bearing blocks for excessive wear or scoring on the surfaces that are in contact with the gears. Also inspect the bearing for excessive wear or damage.
5 Inspect the area inside the gear housings. It is normal for the surface inside the gear housing to show a clean “wipe” on the surface of the intake side. There should however be no excessive wear or scoring.
The motor must be renewed if any of the following defects are found:
i The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
i The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
i The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
i The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
ii The PTFE coated bearings in the body or flanges are worn through so that the bronze base is visible.
iii The gear side faces or bearing blocks are scarred.
iv The driveshaft has a wear groove where the shaft seal lips run.
Assembly
Assembly
K Fig 63. ( T E-91)
K Fig 63. ( T E-91)
Wash all components in a suitable aromatic solvent. When dry apply hydraulic fluid immediately to prevent moisture collecting.
1 Install a new shaft seal
1 Install a new shaft seal
2
3,
1
3
2 Place the front
6
13
3 Place the E-seals
5
14
6
13
4
15
In the centre of the back-up seal and the E-seal there is a “notch”. Make sure these notches line up, so that the back-up seal sits flush with the E-seal.
4 Place the mounting flange
3
5 Apply a light coating of petroleum jelly to the exposed face of the front bearing block
6
6 Insert the drive end of the driveshaft
12
6
7 Install a sleeve over the driveshaft threads to protect the seal
2
2
8 Install the idler gear shaft
11
9 Pick up the rear bearing block
13
10 Ensure the dowel pins
8
9
On later housings there are two long dowels through the housing that locate in the front mounting flange and the rear cover. These replace the four short dowels item
8
11 Apply a coating of petroleum jelly to the seal grooves in both sides of the housing
9
7
10
12 Gently slide the gear housing
9
14
3
14
13 The surface of the rear bearing block
13
9
14 Install the rear housing
16
9
15 Install the four bolts
23
22
16 Place the assembled motors into a vice (using soft jaws to protect the mounting flange) and alternately tighten the bolts
23
K Table 9. Torque Settings ( T E-91)
17 Remove the motor assembly from the vice.
18 Place a small amount of clean hydraulic oil in the inlet of the motors and rotate the driveshaft away from the inlet by one r…
Table 9. Torque Settings
Table 9. Torque Settings
<TABLE
<TABLE BODY
<TABLE ROW
Item
Item
Nm
Nm
Kgf m
Kgf m
lbf ft
lbf ft
<TABLE ROW
17
40
4.08
29.5
<TABLE ROW
23
23
56
5.71
41.3
<GRAPHIC
<GRAPHIC
Fig 63. Uni-Directional Motor Components
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For Component key see:K Table 10. ( T E-92)
K Table 10. ( T E-92)
Table 10. Uni-Directional Motor
Table 10. Uni-Directional Motor
<TABLE
<TABLE HEADING
<TABLE ROW
Component Key: K Fig 63. ( T E-91)
K Fig 63. ( T E-91)
<TABLE BODY
<TABLE ROW
1
Circlip
<TABLE ROW
2
Seal
<TABLE ROW
3
Front housing
<TABLE ROW
4
Back-up seal
<TABLE ROW
5
E-seal
<TABLE ROW
6
Front bearing block
<TABLE ROW
7
O-ring
<TABLE ROW
8
Locating dowels
<TABLE ROW
9
Gear housing
<TABLE ROW
10
O-ring
<TABLE ROW
11
Idler gear
<TABLE ROW
12
Driveshaft gear
<TABLE ROW
13
Rear bearing block
<TABLE ROW
14
E-seal
<TABLE ROW
15
Back-up seal
<TABLE ROW
16
Rear housing
<TABLE ROW
17
Proportional relief valve cartridge
<TABLE ROW
18
Measuring coupling
<TABLE ROW
19
Spring
<TABLE ROW
20
Ball
<TABLE ROW
21
Valve seat
<TABLE ROW
22
Washer
<TABLE ROW
23
Bolt
Bi-Directional Motor
Bi-Directional Motor
General
General
Before removing or dismantling the pump, check that its performance is as specified in
Technical Data
Dismantling, Inspection and Assembly
Dismantling, Inspection and Assembly
For motor components,
K Fig 64. ( T E-95)
Dismantling
Dismantling
It is very important to work in a clean environment when repairing hydraulic motors. Plug all ports and wash the exterior of the motor with a proper cleaning solvent before stripping the motors.
1 Remove the port plugs and ensure all oil is drained from the pump.
1 Remove the port plugs and ensure all oil is drained from the pump.
2 Prior to dismantling the motor, mark the motor body
7
3 and the solenoid operated control valve 14
3 Mount the motor vertically in a vice (use vice soft- jaws to protect the motor mounting flange) by the mounting flange
3
16
4 Remove the bolts
16,
17
14
5 Carefully remove the gear housing
7
12
11
10
6 Remove the rear bearing block
12
11
10
7 Remove the front bearing block
5
8 Turn the mounting flange over, with the shaft seal uppermost, and remove the retaining circlip
1
2
9 Clean all sealant from mating surfaces, discard all seals and “O” rings.
Inspection
Inspection
1 Clean and dry all parts thoroughly prior to inspection. (It is not necessary to check the seals as all seals need to be replaced). Inspect all “O” ring grooves and shaft seal recesses, make sure there are no burrs.
1 Clean and dry all parts thoroughly prior to inspection. (It is not necessary to check the seals as all seals need to be replaced). Inspect all “O” ring grooves and shaft seal recesses, make sure there are no burrs.
2 Check the driveshaft for damage. Check for marks or grooves on the driveshaft in the area of the seal. Slight discolouration of the shaft is allowable.
3 Inspect the faces of the gears for scoring or excessive wear. If the face of the gear is sharp, it could mill into the bearing block. If wear is evident then the parts must be replaced.
4 Inspect the bearing blocks for excessive wear or scoring on the surfaces that are in contact with the gears. Also inspect the bearing for excessive wear or damage.
5 Inspect the area inside the gear housings. It is normal for the surface inside the gear housing to show a clean “wipe” on the surface of the intake side. There should however be no excessive wear or scoring.
The motor must be renewed if any of the following defects are found:
v The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
v The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
v The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
v The gear cut-in track in the body low pressure side is deeper than 0.08 mm or has a scarred and matt appearance.
vi The PTFE coated bearings in the body or flanges are worn through so that the bronze base is visible.
vii The gear side faces or bearing blocks are scarred.
viii The driveshaft has a wear groove where the shaft seal lips run.
Assembly
Assembly
For motor components,
K Fig 64. ( T E-95)
Wash all components in a suitable aromatic solvent. When dry apply hydraulic fluid immediately to prevent moisture collecting.
1 Install a new shaft seal
1 Install a new shaft seal
2
3
1
3
2 Place the front
5
12
4
13
3 Place the seals
4
13
5
12
4 Place the mounting flange
3
5 Apply a light coating of petroleum jelly to the exposed face of the front bearing block
5
6 Insert the drive end of the driveshaft
11
5
7 Install a protective sleeve over the driveshaft to protect the seal
2
2
8 Install the idler gear shaft
10
9 Pick up the rear bearing block
12
10 Ensure the dowel pins
8
7
On later housings there are two long dowels through the housing that locate in the front mounting flange and the rear cover. These replace the four short dowels item
8
11 Apply a coating of petroleum jelly to the seal grooves in both sides of the housing
7
6
9
12 Gently slide the gear housing
7
12
3
13 The surface of the rear bearing block
12
7
14 Install the solenoid operated control valve
14
7
15 Install the four bolts
16
17
16 Place the assembled motor into a vice (using soft jaws to protect the mounting flange) and alternately tighten the bolts
16
K Table 9. Torque Settings ( T E-91)
17 Remove the motor assembly from the vice.
18 Place a small amount of clean hydraulic oil in the inlet of the motors and rotate the driveshaft away from the inlet by one r…
Table 11. Torque Settings
Table 11. Torque Settings
<TABLE
<TABLE BODY
<TABLE ROW
Item
Item
Nm
Nm
Kgf m
Kgf m
lbf ft
lbf ft
<TABLE ROW
15
40
4.08
29.5
<TABLE ROW
16
56
5.71
41.3
<GRAPHIC
<GRAPHIC
Fig 64. Bi-Directional Motor Components
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For Component key see:K Table 12. ( T E-96)
K Table 12. ( T E-96)
Table 12. Bi-Directional Motor
Table 12. Bi-Directional Motor
<TABLE
<TABLE HEADING
<TABLE ROW
Component Key: K Fig 64. ( T E-95)
K Fig 64. ( T E-95)
<TABLE BODY
<TABLE ROW
1
Circlip
<TABLE ROW
2
Seal
<TABLE ROW
3
Front housing
<TABLE ROW
4
Seal
<TABLE ROW
5
Front bearing block
<TABLE ROW
6
O-ring
<TABLE ROW
7
Gear housing
<TABLE ROW
8
Locating dowels
<TABLE ROW
9
O-ring
<TABLE ROW
10
Idler gear
<TABLE ROW
11
Driveshaft gear
<TABLE ROW
12
Rear bearing block
<TABLE ROW
13
Seal
<TABLE ROW
14
Solenoid operated control valve
<TABLE ROW
15
Proportional relief valve cartridge
<TABLE ROW
16
Bolt
<TABLE ROW
17
Washer
Rams
Rams
Precautions During Use
Precautions During Use
Installation
Installation
1 Precautions when installing the ram on the machine.
1 Precautions when installing the ram on the machine.
a When installing and removing from the machine, suspend the ram safely.
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 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.
2 Welding after installing the ram may result in damage.
a 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.
a 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.
3 When painting the machine, mask the ram.
a If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly an…
a If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly an…
4 Install the ram only when it is clean.
Caution During Use
Caution During Use
1 Use only under designated conditions.
1 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.
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. 90˚C and above) or low temperature environments (below -20˚C), seals quickly become damaged. Special seal materials are necessary so check to see if the ram that you are using is suitable or not.
c The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod.
2 Warm up sufficiently before beginning work.
a 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.
a 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. …
c Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder.
3 When stopping or storing, do it at a safe and fixed position.
a 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.
a The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools. Stop or store the machine in a safe and fixed position.
Maintenance, Inspection Points
Maintenance, Inspection Points
1 Carry out daily maintenance and inspection.
1 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 …
a The key point for correct long-term ram function is daily maintenance and inspection. Carry out maintenance and inspection so …
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.
a If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts.
3 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.
a Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur. Remove the ram from the machine and then dismantle.
b If reassembled with dirty hands, foreign matter can enter the ram causing a shorter life span and also the other hydraulic equipment may be damaged. Reassemble in a clean state.
c Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low, it can cause damage.
Typical Ram
Typical Ram
Dismantle and Assembly
Dismantle and Assembly
K Fig 66. ( T E-100). The numerical sequence shown on the illustration is intended as a guide to dismantling.
K Fig 66. ( T E-100)
Dismantle
Dismantle
1 Place ram assembly on a locally manufactured strip/ rebuild bench.
1 Place ram assembly on a locally manufactured strip/ rebuild bench.
K Fig 65. ( T E-99)
<GRAPHIC
<GRAPHIC
Fig 65.
2 Use the correct size spanner to release end cap
66-1
66
66-9
66
3 Position piston rod assembly on bench in place of ram cylinder. Remove seals
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.
3 Position piston rod assembly on bench in place of ram cylinder. Remove seals
66-5
66
66-6
66
66- 4
66
66-7
66
66-3
66
4 Extract dowel
66-2
66
5 Use the correct size spanner, remove piston head
66- 3
66
66-9
66
66-8
66
6 Remove gland bearing and end cap
66-1
66
66-10
66
66-12
66
66-11
66
7 Ensure that metal components are free from scoring, nicks and burrs. A damaged piston rod will impair the life of the gland seals. Check the bore of the ram cylinder for damage.
<GRAPHIC
<GRAPHIC
Fig 66. Typical Ram
Assemble
Assemble
1 Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner and Degreaser to ensure tha…
1 Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner and Degreaser to ensure tha…
Ensure that seals or ‘O’ rings do not come into contact with JCB Activator or anaerobic sealing and retaining compounds such as JCB Threadlocker and Sealer.
2 Fit new seals, ‘O’ rings and wear rings.
For the correct method of fitting seals to the end cap and piston head,
K JCB Ram Sealing Procedure ( T E-102)
Ensure that lubricants used during assembly do not come into contact with degreased components or sealing/retaining compounds.
3 Fit locking dowel
66-2
66
66-3
66
K Piston Head Retention ( T E-104)
4 Position cylinder
66-19
66
5 Apply JCB Activator to threads of end cap and cylinder. Allow JCB Activator to dry for 15 minutes before bringing into contact with JCB Threadlocker.
6 Apply JCB Threadlocker to threads of cylinder and torque tighten end cap
66-1
66
K Table 13. Torque Settings ( T E-101)
If hydraulic oil contacts uncured JCB Threadlocker a weakening of the bond will result. Cure times vary according to the ambient…
JCB Threadlocker & Sealer (High Strength) or JCB Threadlocker with JCB Activator – 1 hour.
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.
Table 13. Torque Settings
Table 13. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Ram size
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
All except 60 x 30 & 50 x 25
1
1
678
69
500
<TABLE ROW
All except 60 x 30 & 50 x 25
3
3
405
41
300
<TABLE ROW
60 x 30 only
1
1
450
46
332
<TABLE ROW
60 x 30 only
3
3
300
31
221
<TABLE ROW
50 x 25 only
1
1
400
41
295
<TABLE ROW
50 x 25 only
3
3
250
25
184
JCB Ram Sealing Procedure
JCB Ram Sealing Procedure
1 Fit new rod seals.
1 Fit new rod seals.
Use seal fitting tool
67-A
67
67-B
67
<GRAPHIC
<GRAPHIC
Fig 67. Seal Fitting Tool
The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals.
a Open the tool and insert the new rod seal
a Open the tool and insert the new rod seal
68-A
68
<GRAPHIC
<GRAPHIC
Fig 68.
Later ram end caps and piston heads are metric threads. The seals are also different, make sure the correct seals are fitted. On metric threaded rams make sure the seals are fitted the correct way round, as shown at
69-A
69
69-B
69
<GRAPHIC
<GRAPHIC
Fig 69.
b Close the tool.
K Fig 70. ( T E-102)
<GRAPHIC
<GRAPHIC
Fig 70.
c Before fitting the rod seals check the seal grooves are free of contamination and sharp edges.
d Locate the seal in the end cap groove.
K Fig 71. ( T E-102)
<GRAPHIC
<GRAPHIC
Fig 71.
e Fit rod wiper seal
69-A
69
Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to ensure the seal is square before it is pressed in.
f Sleeve
72-A
72
Service Tools
<GRAPHIC
<GRAPHIC
Fig 72.
2 Fit new head piston seals.
a Use a blunt instrument
a Use a blunt instrument
73-A
73
73-B
73
<GRAPHIC
<GRAPHIC
Fig 73.
b Fit outer seal
73-C
73
73-B
73
c Ensure the O-ring is fitted into the internal seal groove on the piston head. Screw the piston head onto the thread of the piston rod, refer to the relevant section for torque figure and completion of ram assembly.
d Fit the piston head retaining dowel, refer to the relevant section for torque figure and completion of ram assembly.
e Fit wear rings
74-A
74
74-B
74
74-C
74
<GRAPHIC
<GRAPHIC
Fig 74.
3 Fit the piston rod and head assembly into the cylinder.
a Insert the piston/rod assembly into the cylinder. Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.
a Insert the piston/rod assembly into the cylinder. Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.
b Fit the end cap, refer to the relevant section for torque figure and completion of ram assembly.
Piston Head Retention
Piston Head Retention
Fit locking dowel to piston
Existing piston head and rod
Existing piston head and rod
Align holes so that dowel can be fitted with tapped extractor hole showing.
New piston head and rod
New piston head and rod
Drill and ream piston head and rod to the diameter and depth indicated.
K Drilling Dimensions ( T E-104)
Ensure that the top of the dowel is below the level of the bearing ring groove and use an undersized pilot drill before drilling to the final size shown in the table.
Existing piston head and new rod
Existing piston head and new rod
Drill through existing hole in piston head to the diameter and depth indicated.
K Drilling Dimensions ( T E-104)
Ensure that the top of the dowel is below the level of the bearing ring groove and use an undersized pilot drill before drilling to the final size shown in the table.
New piston head and existing rod
New piston head and existing rod
Same as Existing piston head and new rod but at 90 degrees to existing hole in rod.
Drilling Dimensions
Drilling Dimensions
<GRAPHIC
<GRAPHIC
Fig 75.
Table 14. Drill Depth Chart
Table 14. Drill Depth Chart
<TABLE
<TABLE HEADING
<TABLE ROW
Ram size
Diameter X
Depth Y
<TABLE BODY
<TABLE ROW
90 x 50
8.02mm – 8.10mm
27.0mm – 28.0mm
<TABLE ROW
60 x 30
6.02mm – 6.10mm
22.0mm – 23.0mm
<TABLE ROW
100 x 60
8.02mm – 8.10mm
27.0mm – 28.0mm
<TABLE ROW
70 x 40
6.02mm – 6.10mm
22.0mm – 23.0mm
<TABLE ROW
80 x 50
6.02mm – 6.10mm
22.0mm – 23.0mm
<TABLE ROW
50 x 25
6.02mm – 6.10mm
22.0mm – 23.0mm
<TABLE ROW
130 x 70
12.02mm -12.10mm
37.0mm – 38.0mm
<TABLE ROW
110 x 60
12.02mm -12.10mm
32.0mm – 33.0mm
<TABLE ROW
110 x 65
12.02mm -12.10mm
32.0mm – 33.0mm
<TABLE ROW
140 x 75
12.02mm -12.10mm
47.0mm – 48.0mm
Section F – Transmission
Section G – Brakes
Section G
Section G
Brakes
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
Page left intentionally blank
Technical Data
Technical Data
Brakes
Brakes
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Brake
Service Brake
<TABLE ROW
Type
Oil-Immersed Multi-Plate Disc Actuation
<TABLE ROW
Actuation
Dual Circuit, Full Hydraulic with compact valve and pressure accumulators
<TABLE ROW
Location
Front and Rear Axle (4 plates per hub)
<TABLE ROW
Control Valve Type
Control Valve Type
Compact
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Pressure Regulator Setting
Pressure Regulator Setting
<TABLE ROW
Cut-in Pressure
164 bar
2378 lbf/in2
2
<TABLE ROW
Cut-out Pressure
200 bar
2900 lbf/in2
2
<TABLE ROW
Maximum Pressure Differential
36 bar
522 lbf/in2
2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Charge Valve Setting
Charge Valve Setting
<TABLE ROW
Cut-in Pressure
145 bar
2103 lbf/in2
2
<TABLE ROW
Cut-out Pressure
180 bar
2611 lbf/in2
2
<TABLE ROW
Maximum Pressure Differential
35 bar
508 lbf/in2
2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Brake Operating Pressure
Service Brake Operating Pressure
80 bar
1160 lbf/in2
2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Pressure Switch Operating Pressure
Pressure Switch Operating Pressure
<TABLE ROW
Low Pressure Warning on
105 bar
1523 lbf/in2
2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Accumulator
Accumulator
<TABLE ROW
Capacity (per circuit)
0.75 litre
1.3 pint
<TABLE ROW
Number (fitted)
4
<TABLE ROW
Accumulator Gas
Nitrogen
<TABLE ROW
Pre-charge
57 bar
826 lbf/in2
2
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Parking Brake
Parking Brake
<TABLE ROW
Type
Manually Adjusted Disc, cable operated
<TABLE ROW
Location
Front face of transmission
Brake Circuits
Brake Circuits
Schematic
Schematic
<GRAPHIC
<GRAPHIC
Fig 1.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Component Key
Component Key
<TABLE ROW
1
1
Suction Strainer
<TABLE ROW
2
2
Engine Driven Gear Pump and Charge Valve
<TABLE ROW
3
3
Accumulators
<TABLE ROW
4
4
Brake Valve
<TABLE ROW
5
5
Front Axle Brakes
<TABLE ROW
6
6
Rear Axle Brakes
<TABLE ROW
7
7
Oil Cooler
<TABLE ROW
8
8
Return Filter/Diffuser
<TABLE ROW
9
9
Filler Breather
<TABLE ROW
10
10
Engine Cooling Fan Hydraulic Motor
<TABLE ROW
T
Tank
Page left intentionally blank
Service Procedures
Service Procedures
Service Brakes
Service Brakes
System Testing
System Testing
Testing the System Pressure
Before working on the brake system make sure the machine is on level ground and chock all four wheels.
Testing the System Pressure
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
Testing the System Pressure
Before disconnecting any part of the brake hydraulic system, make sure that engine is switched off and hydraulic pressure is fully discharged.
Testing the System Pressure
Testing the System Pressure
<GRAPHIC
<GRAPHIC
Fig 2.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Key:
Key:
<TABLE ROW
A
A
Brake Test Point
<TABLE ROW
B
B
Hydraulic Engine Fan Test Point
<TABLE ROW
C
C
Low Pressure Switch
1 Switch off the engine and operate the brake pedal repeatedly to make sure that all the hydraulic pressure stored in the accumulators is discharged.
1 Switch off the engine and operate the brake pedal repeatedly to make sure that all the hydraulic pressure stored in the accumulators is discharged.
2 Connect a 400 bar test gauge to the test point
2A
2
3 Switch on the engine and check that the gauge reading rises to the Charge Valve Cut-out Pressure. (See
K Technical Data ( T G-1)
4 With the engine running and the maximum charge pressure obtained, repeatedly operate the brake pedal. Check that the pressure is recharged to its maximum pressure as each stoke of the brake pedal is applied.
There is no noticeable successive reduction in the system pressure (with each stoke of the brake pedal) until the Cut-in pressure is reached. The system will start to recharge after the first full stroke of the pedal.
5 Fully charge the system.
6 Switch off the engine. Switch the ignition ON. Slowly and repeatedly operate the brake pedal (apply full pedal stokes) until the low brake pressure warning lamp illuminates. Check the pressure reading on the gauge. (See
K Technical Data ( T G-1)
7 Continue to operate the brake pedal until the pressure drop-off point is reached.
There must be a Minimum of 5 Full Pressure Strokes Before the pressure drop off point is reached
As the brake pedal is repeatedly applied (engine switched OFF) the stored accumulator pressure is gradually depleted At a pressure normally below 80 bar, the stored pressure will be exhausted. At this point the pressure gauge reading will fall to zero.
The system charge pressures (cut-in, cut-out pressures) are pre-set and non-adjustable. If the pressures are found to be outside the given parameters, the charge valve will need to be replaced.
If you suspect the pressure depletion per full stoke of the brake pedal is excessive, or the minimum number of strokes before drop-off are not obtained, check the accumulator charge pressures and where necessary correct, (See
K Charging the Accumulators ( T G-9)
Brake Pressure Setting
Brake Pressure Setting
Use the following procedure to test and set the brake pressure if the heat shrink sleeving
3A
3
3B
3
1 With the brake pedal fully up, check that there is a little free play between the brake push rod and the pedal assembly.
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
1 With the brake pedal fully up, check that there is a little free play between the brake push rod and the pedal assembly.
Before disconnecting any part of the brake hydraulic system, make sure that engine is switched off and hydraulic pressure is fully discharged.
1 With the brake pedal fully up, check that there is a little free play between the brake push rod and the pedal assembly.
A minimum of 10 applications of the service brake is possible from the stored accumulator pressure. Disconnect service brake accumulator hoses with extreme caution.
1 With the brake pedal fully up, check that there is a little free play between the brake push rod and the pedal assembly.
1 With the brake pedal fully up, check that there is a little free play between the brake push rod and the pedal assembly.
2 With the engine stopped and brake pressure released, connect a “T” adaptor at point
3C
3
3 With the brake system operational, depress the brake pedal until the gauge shows the correct Operating Pressure. (See
K Technical Data ( T G-1)
3D
3
4 Apply heat shrink sleeving as shown at
3A
3
5 Without changing the adjustment, disconnect the push rod from the pedal. Apply heat shrink sleeving as shown at
3B
3
6 Re-check the pressure. Remove the test point and gauge.
<GRAPHIC
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Fig 3.
Bleeding the System
Bleeding the System
The braking systems are fed from the main hydraulic system and incorporate brake accumulators. These allow approximately nine applications of the brakes with the engine stopped.
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.
The braking systems are fed from the main hydraulic system and incorporate brake accumulators. These allow approximately nine applications of the brakes with the engine stopped.
Bleed each axle separately as follows:
– Attach a tube to the brake bleed screw, located near the axle centre. Ensure that the free end of the tube is immersed in fluid contained in a suitable container.
– Attach a tube to the brake bleed screw, located near the axle centre. Ensure that the free end of the tube is immersed in fluid contained in a suitable container.
– Open the brake bleed screw and fully depress the brake pedal. Hold the pedal fully depressed until air free fluid flow from the bleed screw.
– Close the brake bleed screw with the pedal fully depressed.
Repeat the procedure for the rear axle.
Check the hydraulic fluid level.
System Accumulators
System Accumulators
Charging the Accumulators
Charging the Accumulators
For details on the identification of and charging procedures for the accumulators, please refer to
Section E – Hydraulics – ACCS – Accumulators.
Park Brake
Park Brake
Adjusting the Park Brake
Adjusting the Park Brake
1 Disengage the park brake (lever horizontal).
1 Disengage the park brake (lever horizontal).
2 Turn adjuster
4X
4
3 Test the park brake. See
K Park Brake Testing ( T G-14)
4 If the brake fails the test, repeat steps 1 to 3.
If after completing the above steps, the park brake does not pass the testing procedure.
K Adjusting the Cable Slack ( T G-11)
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Fig 4.
Adjusting the Cable Slack
Adjusting the Cable Slack
1
1
Parking brake lever with safety catch
K Fig 5. ( T G-11)
5X
5
5Y
5
5Z
5
2 Loosen locknut
6A
6
6B
6
3 Screw in the clevis
6C
6
4 Refit pin
6B
6
6A
6
5 Test the parking brake, see
K Park Brake Testing ( T G-14)
6 If the brake fails the test, repeat steps 1 to 5.
If the brake cannot be adjusted by adjusting the cable slack, replace the brake pads and/or the brake cable.
Operating arm
6D
6
6B
6
MOST IMPORTANT
6B
6
ONLY
CENTRE HOLE
If the operating arm securing bolt
6E
6
MOST IMPORTANT
6D
6
MUST
ORIGINAL POSITION
NO CIRCUMSTANCES
<GRAPHIC
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Fig 5.
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Fig 6.
Renewing the Brake Pads
Renewing the Brake Pads
Renew pads when thickness of friction material is 1mm (0.039 in).
1 Release brake and disconnect actuator from brake lever.
1 Release brake and disconnect actuator from brake lever.
2 Slacken one and remove the other brake mounting bolt
7-1
7
7-2
7
7-3
7
3 Use flat bladed screw driver to remove pads
7-4
7
7-5
7
Take care when removing pad from the plastic actuator cover.
4 Place pads in position.
Centre hole in lever side pad snaps over tabs on actuator cover. Align pad with flat on rotor cover
7-B
7
5 Remove pad adhesive from pad compartment in pad carrier plate
7-A
7
6 Apply adhesive along back edge of pad carrier plate and press into place.
7 Push lever side pad as far as possible into the brake.
8 Position brake over disc, fit mounting bolt
7-1
7
7-2
7
7-3
7
9 Attach cable to lever.
10 Adjust pad gap.
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Fig 7.
Park Brake Testing
Park Brake Testing
Testing The Parking Brake
Testing The Parking Brake
Test the brake on a level, dry surface. Make sure your seat belt is securely fastened.
Before testing the park brake make sure the area around the machine is clear of people.
Test the brake on a level, dry surface. Make sure your seat belt is securely fastened.
1 The attachment should be in the travelling position.
1 The attachment should be in the travelling position.
2 Make sure the parking brake is fully engaged.
3 Switch off transmission dump.
4 Switch off Auto/Manual switch.
a On the EMS press the two arrow keys and the SETUP key at the same time, to select the AEB setup menu.
a On the EMS press the two arrow keys and the SETUP key at the same time, to select the AEB setup menu.
b Use the UP or DOWN arrows to select the park brake test menu.
c Press SETUP key to select
park brake test on
5 Select third gear/range (
3
a Push down hard on the brake pedal and select forward drive.
a Push down hard on the brake pedal and select forward drive.
An audible alarm will sound and a warning light will show when the parking brake is engaged with the machine in forward (
F
N
6 Release the brake pedal.
If the machine starts to move during the following test, immediately apply the foot brake and reduce the engine speed.
6 Release the brake pedal.
a If the machine has not moved, use the accelerator pedal to gradually increase the engine speed to 1500rpm. The machine should not move.
a If the machine has not moved, use the accelerator pedal to gradually increase the engine speed to 1500rpm. The machine should not move.
b Reduce the engine speed to idle and set the forward/ reverse lever (or switch) to neutral.
Do not do this test for longer than 20 seconds.
Do not
7 Return the parking brake lever to the fully on position from its partially applied position.
8 Press SETUP key again to select
park brake test off
9 Lower attachment and stop the engine.
If the machine moved during the test, see
K Adjusting the Park Brake ( T G-10)
If you have any queries concerning this test procedure or parking brake adjustment, consult your local JCB dealer.
If you have any queries concerning this test procedure or parking brake adjustment, consult your local JCB dealer.
Do not use a machine with a faulty park brake.
Non approved modifications to drive ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake.
Parking Brake Transmission Disconnect
Parking Brake Transmission Disconnect
When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parking brake on.
Brake Valves
Brake Valves
Foot Valve
Foot Valve
Removal and Replacement
Removal and Replacement
Removal
Make sure the articulation safety lock is fitted before transporting the machine. The articulation safety lock must also be fitted if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.
If the articulation lock is not fitted you could be crushed between the two parts of the chassis.
Removal
Removal
1 Park the machine on firm, level ground. Apply the parking brake and stop the engine. Securely chock all four wheels. Repeatedly apply and release the service brakes and parking brake until all the pressure in the accumulators is exhausted.
1 Park the machine on firm, level ground. Apply the parking brake and stop the engine. Securely chock all four wheels. Repeatedly apply and release the service brakes and parking brake until all the pressure in the accumulators is exhausted.
2 Disconnect and blank all hydraulic hoses having first identified them to ensure correct replacement.
Before disconnecting any part of the brake hydraulic system, make sure that engine is switched off and hydraulic pressure is fully discharged.
2 Disconnect and blank all hydraulic hoses having first identified them to ensure correct replacement.
A minimum of 10 applications of the service brake is possible from the stored accumulator pressure. Disconnect service brake accumulator hoses with extreme caution.
2 Disconnect and blank all hydraulic hoses having first identified them to ensure correct replacement.
3 Identify then unplug the electrical connections from the three pressure switches.
4 Remove the clip
8-1
8
5 Remove cap screws
8-2
8
Replacement
Replacement
1 Refit the valve by reversing the removal sequence.
1 Refit the valve by reversing the removal sequence.
2 When connecting the foot pedal linkage, adjust clevis
8-3
8
If there are two holes in the brake pedal lever, connect the valve push rod to the upper hole.
3 After refitting the valve, start the engine and wait for a few minutes until the accumulators are charged. Bleed the service brakes as described in
K Bleeding the System ( T G-8)
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Fig 8.
Dismantling and Assembly
Dismantling and Assembly
The valve may only be dismantled to renew seals. If any other part fails the complete valve must be renewed.
Remove only sufficient components to gain access to the seals. DO NOT dismantle further.
Two repair kits are available: one consists of all the seals and the other is a repair kit for the brake linkages and includes the necessary rubber gaiters.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Key
Key
<TABLE ROW
1
1
Brake valve
<TABLE ROW
2
2
Foot brake push rod assembly
<TABLE ROW
3
3
Brake light switch
<TABLE ROW
4
4
Transmission dump switch
<TABLE ROW
5
5
Accumulator inlet adaptors (2 off)
<TABLE ROW
6
6
Low pressure warning switch
<TABLE ROW
7
7
Pilot valve adjuster
<TABLE ROW
8
8
90˚ Adaptor (return to tank)
<TABLE ROW
9
9
Tee adaptors (brake supply)
<TABLE ROW
10
10
Adaptor (Pressure from pump)
<TABLE ROW
11
11
Adaptor (Return to tank via loader valve)
<TABLE ROW
12
12
Straight adaptors (2 off)
<TABLE ROW
13
13
Seal washer (4 off)
<TABLE ROW
14
14
Seal washer (M18)
<TABLE ROW
15
15
Seal washer (5 off)
<TABLE ROW
16
16
Adaptor (Return to tank)
<GRAPHIC
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Fig 9.
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Park Brake
Park Brake
Dismantling and Assembly
Dismantling and Assembly
Dismantling
Dismantling
1 Disconnect actuator cable and remove brake.
1 Disconnect actuator cable and remove brake.
2 Remove friction pads
10-4
10
10-5
10
Before dismantling, mark the relative position of the lever
10-10
10
3 Unbend anti-rotation clip
10-12
10
10-13
10
10-12
10
10-11
10
10-10
10
10- 14
10
4 Push out rotor assembly
10-6
10
10-9
10
5 Remove 3 ball bearings
10-8
10
6 Only if shaft seal
10-15
10
7 Remove any plastic left in casting.
Before assembly insure all parts are clean and serviceable
Assembly
Assembly
1 Insert seal
1 Insert seal
10-15
10
2 Grease ball pockets in casting
10-9
10
10-6
10
3 Insert 3 ball bearings
10-8
10
10-7
10
10-9
10
4 From the inside of the casting
10-9
10
10-6
10
10-15
10
10-8
10
5 Place the spring
10-14
10
10-9
10
6 Install lever
10-10
10
10-14
10
7 Set the lever
10-10
10
8 Install washer
10-11
10
10-12
10
9 Insert screw
10-13
10
10-6
10
10-10
10
10 Bend up tab on the ant-rotation clip
10-12
10
11 Install the friction pads
10-4
10
10-5
10
12 Stroke lever
10-10
10
10-5
10
<GRAPHIC
<GRAPHIC
Fig 10.
Section H – Hydraulic Steering
Section H
Section H
Hydraulic Steering
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
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Technical Data
Technical Data
General data
General data
Pump
Pump
Supply from hydraulic system. Refer to
K Pumps ( T E-79)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Steering Valve
Steering Valve
<TABLE ROW
Type
Eaton Steering Control Unit ABV.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Relief Valve Operating Pressure
bar
bar
kgf/cm2
kgf/cm
2
lbf/in2
lbf/in
2
<TABLE ROW
Shock valve
176
180
2550
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Ram Dimensions
Ram Dimensions
mm
mm
in
in
<TABLE ROW
Bore
80
3.1
<TABLE ROW
Rod Dia.
50
2.0
<TABLE ROW
Stroke
312
12.3
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Circuit Descriptions
Circuit Descriptions
Steering Operations
Steering Operations
General Description
General Description
Steering is hydraulically controlled. Two rams, one either side of a centre pivot articulate the front chassis in the required direction.
Hydraulic oil is delivered from the pump via a steering priority valve to the steering valve. When the steering is turned the st…
Pressurised oil enters the ram cylinders (rod side first ram and head side second ram) and causes the rams to extend or retract to turn the machine in the required direction.
A pressure relief valve is fitted to guard against shock steering loads.
A gearbox driven emergency steer pump may be fitted which provides pressure for steering in the event of hydraulic pump or engine failure. Instructions for removal and refitting of this pump are given in
Section F – Transmission
Steering Valve – Operation
Steering Valve – Operation
Fitted as an extension of the steering column, the steering valve
1-SV
1
1-SV1
1
1-SV2
1
1- SV3
1
1-SV4
1
1-SV5
1
1-SV6
1
Pressure oil is supplied to the steering valve by way of the steering priority valve
1-PV
1
When actuated by the steering column, the spool turns within the sleeve, oil galleries are aligned and a demand pressure signal …
With the main pump inoperative, or the engine stopped but the machine still moving, hydraulic steering supply is maintained by a gearbox driven emergency pump, see
K Emergency Steering Operation ( T H-5)
In the unlikely event of failure of both the main and emergency pumps, the supply line is closed by a spring assisted non-return…
<GRAPHIC
<GRAPHIC
Fig 1.
Emergency Steering Operation
Emergency Steering Operation
Under normal conditions, the flow from the main pump
2-1
2
2-2
2
2- 3
2
2-SV
2
2-LV
2
Flow from the emergency steering pump
2-4
2
2-5
2
2-T
2
If the pilot pressure is lost but the machine is still moving, the emergency steering valve spool
2-6
2
2- 7
2
The check valves
2-3
2
2-7
2
2-8
2
<GRAPHIC
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Fig 2.
Hydraulic Steering Unit
Hydraulic Steering Unit
Dismantling and Assembly
Dismantling and Assembly
<GRAPHIC
<GRAPHIC
Fig 3.
Dismantling
Dismantling
Use the numerical sequence on
K Fig 3. ( T H-7)
Before removing items
3-11
3
3-14
3
3-21
3
3-11
3
Inspecting
Inspecting
Examine all contact surfaces and replace any parts that have scratches, wear or other damage that could cause leakage. Do not use abrasive or try to file or grind the surfaces. Clean all metal parts with a solvent and blow dry with air.
Assembling
Assembling
1 Assemble the check valve
1 Assemble the check valve
Lower check ball retainer
4-20
4
4-19
4
4-A
4
4-B
4
4-18
4
4- 18
4
4-17
4
2
When fitted the top of the set screw should be slightly below the housing top surface.
<GRAPHIC
<GRAPHIC
Fig 4.
2 Assemble the spool and sleeve
Assemble the spool
5-23
5
5-24
5
5-A
5
<GRAPHIC
<GRAPHIC
Fig 5.
3 Fit the spring assembly
Make sure the spring slots are lined up and insert the spring installation tool (Eaton part number 60057) through the slots. Assemble a set of low torque springs
6-22
6
6-B
6
6-C
6
6-21
6
6-24
6
<GRAPHIC
<GRAPHIC
Fig 6.
4 Installing the spool and sleeve assembly
Position the spool and sleeve assembly so that the splined end of the spool enters the valve housing as shown. Push the assembly gently into place with a slight rotating action until the parts are flush at the insertion end face
7A
7
Do not move the spool and sleeve assembly beyond the flush position because the pin
6-21
6
<GRAPHIC
<GRAPHIC
Fig 7.
5 Fit the drive end seals
a Place the housing
a Place the housing
3-25
3
8-16
8
8-14
8
<GRAPHIC
<GRAPHIC
Fig 8.
b Assemble the Teflon seal components
9-13
9
9-A
9
9-B
9
9-C
9
9-14
9
<GRAPHIC
<GRAPHIC
Fig 9.
c Fit the dust seal
10-12
10
10-11
10
10-15
10
10-10
10
10-24
10
<GRAPHIC
<GRAPHIC
Fig 10.
6 Fitting the meter end seal and drive
Insert seal
11-9
11
11-25
11
11-7
11
11-8
11
11- 15
11
11-21
11
11-A
11
11-6
11
11-B
11
<GRAPHIC
<GRAPHIC
Fig 11.
7 Time and fit the meter
Fit seal
12-4
12
12-3
12
12-25
12
12-C
12
12-A
12
12-B
12
12-C
12
12-6
12
<GRAPHIC
<GRAPHIC
Fig 12.
8 Fit and secure the end cap
Fit any drive spacers
13-5
13
13-2
13
13-1
13
13-A
13
<GRAPHIC
<GRAPHIC
Fig 13.
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Section K – Engine
Section K
Section K
Engine
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Hydraulic Steering
Section H – Hydraulic Steering
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
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Technical Data
Technical Data
434S from Serial No. 124400
434S from Serial No. 124400
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Type
QSB6.7/SO 75928 Tier 3
<TABLE ROW
434S from Serial No. 124400
<TABLE ROW
Bore
Info not available
<TABLE ROW
Stroke
Info not available
<TABLE ROW
Cylinder Capacity
6.7 litre
<TABLE ROW
Gross Power Output at 2200 rev/min
220 hp (164 Kw)
<TABLE ROW
Compression Ratio
17.2: 1
<TABLE ROW
Idling Speed
850 ± 25 rev/min
<TABLE ROW
Rated Speed (Full Load)
2200 rev/min
<TABLE ROW
Max. No-Load Speed
2430 rev/min
<TABLE ROW
Max. Net Torque at 1500 rev/min
949 Nm
<TABLE ROW
Fuel System
Fuel System
<TABLE ROW
Injection Pump Type
Bosch CP3.3 common rail
<TABLE ROW
Governing
Electronic
<TABLE ROW
ISOSetting Code
N/A
<TABLE ROW
Injection Timing
Electronic
<TABLE ROW
Induction System
Induction System
<TABLE ROW
Air Cleaner Type
2 stage, dry element
<TABLE ROW
Maximum Air Cleaner Restriction
635 mm (25 in) H2O
2
<TABLE ROW
Restriction Indicator
Vacuum switch on air cleaner inlet
<TABLE ROW
Lubrication System
Lubrication System
<TABLE ROW
Oil Pump Type
Concentric gear
<TABLE ROW
Oil Pressure at maximum rated speed
55.1 psi @ 2200 rev/min
<TABLE ROW
Oil Pressure at idle speed
10 psi (0.7 bar) @ 850 ± 20 rev/min
<TABLE ROW
Oil Capacity With Filter
17.5 litre
<TABLE ROW
Cooling System
Cooling System
<TABLE ROW
Coolant Pressure Cap Setting
15 psi (1.03 bar) max
<TABLE ROW
Coolant Temperature (Normal)
82 ºC – 110 ºC (179 – 203 ºF)
<TABLE ROW
Thermostat Opens at
88 ºC
<TABLE ROW
Thermostat Fully Open at
96 ºC
<TABLE ROW
Capacity
35 litre (7.7 UK gal)
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