Eco Manual Gear Pump.pdf

TECHNICAL EXCELLENCE PROGRAMME BACKHOE LOADER INTRODUCTION TRAINING COURSE WORKBOOK

ENGLISH - 9817/0000 - ISSUE 1 - JUNE 2009

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. JCB Service - World Parts Centre, Waterloo Park, Beamhurst, Staffordshire, England ST14 5PA www.jcb.com

Developing and delivering inspirational learning

SERVICE MANUAL MANUEL D’ATELIER WARTUNGSANLEITUNG MANUAL DE SERVICIO MANUAL DE MANUTENZIONE

AFTERMARKET TRAINING

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Contents Page No. Backhoe Loader Familiarisation Introduction .................................................................................................... 1 Course Content ............................................................................................. 2 Section One - Backhoe Familiarisation .................................................... 2 Section Two - Maintenance ...................................................................... 2 Section Three - Electrics .......................................................................... 2 Section Four - Hydraulics ......................................................................... 2 Section Five - Steering ............................................................................. 2 Presentation Slides ........................................................................................ 3 Backhoe Loader ....................................................................................... 3 Section One - Backhoe Familiarisation Contents ...................................................................................................... 37 Health and Safety ........................................................................................ 38 Important Information .................................................................................. 39 The Operator Manual ............................................................................. 39 Safety Warnings ..................................................................................... 39 Safety Check List ......................................................................................... 40 Safety - Yours and Others ...................................................................... 40 General Safety ....................................................................................... 40 Operating Safety .................................................................................... 42 Maintenance Safety ................................................................................ 45 Safety Labels ............................................................................................... 50 Introduction ............................................................................................. 50 Safety Label Identification ...................................................................... 51 Course Objectives ....................................................................................... 52 Pre-Course Assessment .............................................................................. 53 Machine Walkaround ................................................................................... 55 Introduction ............................................................................................. 55 Engine .................................................................................................... 55 Transmission .......................................................................................... 60 Brakes .................................................................................................... 68 Backhoe Machine Options ........................................................................... 72 Wheels and Tyres ................................................................................... 72 Hydraulic System ................................................................................... 72 Cab ......................................................................................................... 72 Loader End ............................................................................................. 73 Excavator End ........................................................................................ 73 Additional Backhoe Information ................................................................... 74 3CX Works Order ................................................................................... 74 Excavator Lever Patterns ....................................................................... 75 Main Differences between P12 and P21 Machines ................................ 76 After Sales Service Information ................................................................... 83 JCB Service CD ..................................................................................... 83 Backhoe Loader Service Manuals Part Numbers .................................. 84 Identifying Your Machine ............................................................................. 85 Machine Identification Plate ................................................................... 85 ROPS/FOPS Certification plate .............................................................. 86 FOPS Data Plate .................................................................................... 86 Component Identification Plates ............................................................. 87 Identification of Machine Components ................................................... 88 Cab Layout (Manual Controls) ..................................................................... 90 Component Key ...................................................................................... 91

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Contents

Contents Page No. Drive Controls, Switches and Instruments ................................................... 92 Drive Controls ......................................................................................... 92 Switches ................................................................................................. 99 Instruments ........................................................................................... 107 TorqueLock ........................................................................................... 112 Section Two - Maintenance Contents .................................................................................................... 113 Service Schedules ..................................................................................... 115 Introduction ........................................................................................... 115 How to Use the Service Schedules ...................................................... 115 Calendar Equivalents ........................................................................... 115 Pre-start Cold Checks, Service Points and Fluid Levels ...................... 116 Functional Test and Final Inspection .................................................... 119 Fluids, Lubricants and Capacities .............................................................. 121 Section Three - Electrics Contents .................................................................................................... 123 3CX / 4CX - Fuses and Relays .................................................................. 125 Fuses - NOT Servo Machines .............................................................. 125 Link Box Fuses ..................................................................................... 126 Relays - NOT Servo Machines ............................................................. 127 Relays - Gearbox/Steer Control ........................................................... 128 3C-14 (214e) & 3C - Fuses and Relays .................................................... 129 Fuses .................................................................................................... 129 Link Box Fuses ..................................................................................... 130 Relays .................................................................................................. 131 3CX / 4CX - Schematic Circuits ................................................................. 132 Basic Machine ...................................................................................... 132 Gearbox Control ................................................................................... 137 Options ................................................................................................. 140 3C-14 (214e) / 3C Machines - Schematic Circuits .................................... 150 Basic Machine ...................................................................................... 150 Wire and Harness Number Identification ................................................... 154 Introduction ........................................................................................... 154 Wire Numbers and Functions ............................................................... 155 Earth Point Locations ................................................................................ 156 Harness Data (Drawings and Interconnection) .......................................... 158 Harnesses - NOT Servo Machines ....................................................... 158 Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/12290 Issue 3 ..................................................................................................... 162 Side Console - CAD 721/12167 Issue 4 ............................................... 166 Engine Mainframe - CAD 721/11727 Issue 3, 721/12351 Issue 1 ....... 174 Section Four - Hydraulics Contents .................................................................................................... 177 Technical Data ........................................................................................... 178 Gear Pump ........................................................................................... 178 Loader Valve ........................................................................................ 184 Excavator Valve .................................................................................... 189 Auxiliary Valve - if fitted ........................................................................ 193 Smooth Ride System (SRS) - if fitted ................................................... 194

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Contents

Contents Page No. Introduction to Hydraulic Schematic Symbols ........................................... 195 General (Basic and Functional Symbols) ............................................. 195 Control Valves ...................................................................................... 199 Example of Schematic Circuit .............................................................. 200 Basic System Operation ............................................................................ 202 Gearpump - (Double Pump Machines) ................................................. 202 Schematic Circuits ..................................................................................... 204 3CX Gear Pump Machines ................................................................... 204 3CX `S' Series Options ......................................................................... 207 3CX `S' Series and 4CX Gearpump Options ........................................ 208 Machines from September 2007 .......................................................... 210 3C-14 (214e) Backhoe ......................................................................... 212 3C-14 (214e) Landscaper .................................................................... 214 Schematic Trace - Loader Lift .............................................................. 216 Hydraulic Pump ......................................................................................... 218 Gear Pump Operation - Double Pump ................................................. 218 Tandem Gear Pump - JCB Approval Test ............................................ 220 3CX/4CX Pump Combinations ............................................................. 221 Hydraulic Pump Failures ...................................................................... 222 Gearpump Flow and Pressure Testing - 3CX 4CX ............................... 225 Checking Pump Flow - 3C Sideshift Machines .................................... 227 Main Relief Valve ....................................................................................... 229 Operation .............................................................................................. 230 JCB Engine Power and Torque Curves ................................................ 231 Loader Valve Pressure Testing - 3CX / 4CX ........................................ 233 Loader Valve Pressure Testing - 3C-14 (214e) .................................... 234 Loader Valve Pressure Testing - 3C Sideshift Machines ...................... 235 Unloader Valve and Hydraulic Speed Control ........................................... 236 Unloader - Neutral Circuit ..................................................................... 236 Unloader - Operation ............................................................................ 236 Hydraulic Speed Control ....................................................................... 238 Additional Hydraulic Information ........................................................... 249 Ram Creep Tests ....................................................................................... 250 Ram Creep Tests - All Services ............................................................ 250 Supplementary Circuits ............................................................................. 256 Hydraclamp Valve Operation (Sideshift Machines) .............................. 256 Smooth Ride System ............................................................................ 258 Hydraulic Ram - End Damping ............................................................. 260 Hose Burst Protection Valves (if fitted) ................................................. 263 Hi-Flow Rockbreaker ............................................................................ 268 Fault Finding - Hydraulic System ............................................................... 279 Gearpump Machines ............................................................................ 279 Smooth Ride System (SRS) - if fitted ................................................... 286 Section Five - Steering Contents .................................................................................................... 287 Technical Data ........................................................................................... 288 Hydraulic Steer Unit .............................................................................. 288 Priority Valve ........................................................................................ 289 Priority Valve - 3C Machines (Sideshift) ............................................... 290 Basic Operation ......................................................................................... 291 2 Wheel Steer Machines ...................................................................... 291 4 Wheel Steer Machines ...................................................................... 292

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Contents Page No. Steer Circuit Schematics ........................................................................... 294 2 Wheel Steer Machines ...................................................................... 294 4 Wheel Steer Machines (Steer Mode Valve Type 1) ........................... 295 Priority Valve Operation ............................................................................. 297 Neutral .................................................................................................. 297 Fault Finding - Steering ............................................................................. 298 Fault Finding Tables ............................................................................. 298 Service Procedures ................................................................................... 304 Hydraulic Pressure Tests ..................................................................... 304 Steer Priority Valve ............................................................................... 306 4 Wheel Steer Machines ...................................................................... 307 Hydraulic Steer Unit (Orbitrol) .............................................................. 310

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Backhoe Loader Familiarisation Introduction

Backhoe Loader Familiarisation Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving training by JCB Technical Training Department. The delegates must have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earth moving equipment.

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Backhoe Loader Familiarisation Course Content

Course Content Section One - Backhoe Familiarisation - Health and Safety - Course Objectives - Pre-Course Assessment - Machine Walkaround - Backhoe Machine Options - Additional Backhoe Information - After Sales Service Information - Identifying Your Machine - Cab Layout - Drive Controls, Switches and Instruments

Section Two - Maintenance - Service Schedules - Fluids, Lubricants and Capacities

Section Three - Electrics - 3CX / 4CX Fuses and Relays - 3C-14 (214e) / 3C Fuses and Relays - 3CX / 4CX Schematic Circuits - 3C-14 (214e) / 3C Schematic Circuits - Wire and Harness Number Identification - Earth Point Locations - Harness Data

Section Four - Hydraulics - Technical Data - Introduction to Hydraulic Schematics - Basic System Operation - Schematic Circuits - Hydraulic Pump - Main Relief Valve - Unloader Valve and Hydraulic Speed Control - Ram Creep Tests - Supplementary Circuits - Fault Finding - Hydraulic System

Section Five - Steering - Technical Data - Basic Operation - Priority Valve Operation - Fault Finding - Service Procedures - Steer Unit - Dismantle

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Backhoe Loader Familiarisation Presentation Slides

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Section One - Backhoe Familiarisation Contents

Section One - Backhoe Familiarisation Contents - Health and Safety - Course Objectives - Pre-Course Assessment - Machine Walkaround - Backhoe Machine Options - Additional Backhoe Information - After Sales Service Information - Identifying Your Machine - Cab Layout - Drive Controls, Switches and Instruments

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Section One - Backhoe Familiarisation Health and Safety

Health and Safety T11-020

Welcome to JCB Aftermarket Training. We want the time you spend at JCB Aftermarket Training to be enjoyable and informative but most importantly safe. To help us maintain your safety we respectfully ask that you follow and adhere to the following guidelines which will benefit not only yourself but also your fellow colleagues enrolled on the course: - ALL mobile phones must be switched off during course delivery time. - ALL delegates are required to attend the course wearing JCB dealer corporate clothing. - ALL delegates are required to attend equipped with JCB dealer corporate overalls and safety boots. - ALL delegates are required to be aware of the location of facility fire exits, the location of fire extinguishers and the location of the fire assembly point in the event of the fire alarm being activated. - ALL delegates are required to be aware of the location of the facility first aid box and the name of the facility registered first aider in the event of an accident. - The JCB training facility will ensure that the first aid box is fully equipped and well stocked with basic cleansing and bandaging products for basic cuts, burns and grazes. It is the responsibility of ALL delegates and JCB training staff to report to the facilities registered first aider when items need replacing. - ALL health & safety Incidents must be reported to the facility management team and recorded. - ALL delegates must be fully aware of the facilities no smoking policy, times for smoking breaks and the location of the facilities smoking area.

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Section One - Backhoe Familiarisation Important Information

Important Information T1-015

The Operator Manual

Safety Warnings

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

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

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

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

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

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

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Section One - Backhoe Familiarisation Safety Check List

Safety Check List P2-1003

Safety - Yours and Others

General Safety INT-1-3-1_3

All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

!MWARNING

T1-007_3

Operator Manual You and others can be injured if you operate or maintain the machine without first studying the Operator Manual. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB dealer to explain it. Keep the Operator Manual clean and in good condition. Do not operate the machine without an Operator Manual, or if there is anything on the machine you do not understand. INT-1-3-2_3

!MWARNING

Do not work with the machine until you are sure that you can control it.

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.

Do not start any job until you are sure that you and those around you will be safe.

INT-1-3-5

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE

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

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

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Section One - Backhoe Familiarisation Safety Check List

!MWARNING

!MDANGER

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

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

8-1-2-4

!MWARNING

!MWARNING Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.

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

Switch off and do not use your mobile phone when refuelling the machine. INT-3-3-9

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

!MWARNING Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped). 13-2-3-7_2

!MWARNING Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed. INT-3-3-7_1

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Section One - Backhoe Familiarisation Safety Check List

!MWARNING

Operating Safety

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

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

INT-2-1-2_2

INT-2-2-3

!MWARNING

!MWARNING

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

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

!MWARNING

INT-2-1-4

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

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

!MWARNING

INT-2-1-5

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

!MWARNING Work Sites Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures. INT-2-2-1

Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers. INT-2-2-6

!MWARNING Safety Barriers Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away. INT-2-2-8

!MDANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. INT-2-2-10

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!MWARNING

!MWARNING

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

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

INT-2-1-14

!MWARNING

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

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

INT-1-3-3

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

!MWARNING Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. INT-2-1-1

!MWARNING

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

!MCAUTION

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

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

5-3-1-12_3

5-5-1-1_2

!MWARNING

!MWARNING

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

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

2-2-3-6

The use of non-approved attachments could invalidate your warranty. 2-4-5-2_1

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!MDANGER

!MWARNING

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

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

5-1-5-9

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

INT-2-2-7

!MWARNING

5-2-6-5

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

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

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

!MWARNING Reversing Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions. INT-2-2-9_1

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

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

5-1-3-2

!MWARNING

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

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

5-1-4-1

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!MWARNING

Maintenance Safety

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

!MWARNING Road Wheel Alignment At the start of each working period, and at least once a day, or if having difficulty in steering, check and, if necessary, re-align the road wheels. 2-1-1-10

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

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

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

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

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Section One - Backhoe Familiarisation Safety Check List

!MWARNING

!MCAUTION

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

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

!MWARNING

INT-3-1-10_3

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

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

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

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

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

INT-3-2-2_3

!MCAUTION

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

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

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

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Section One - Backhoe Familiarisation Safety Check List

!MCAUTION

!MWARNING

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

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

INT-3-2-12

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

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

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

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

5-3-1-9

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

area

with

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

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

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Section One - Backhoe Familiarisation Safety Check List

!MWARNING

!MWARNING

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

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

HYD-1-3_2

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

!MWARNING

INT-3-1-17

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

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

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

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

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

!MWARNING 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. 0125

0147_1

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Section One - Backhoe Familiarisation Safety Check List

!MWARNING

!MWARNING

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

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

INT-3-1-8

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

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

INT-3-1-16

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

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

INT-3-2-1_3

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

8-3-4-8

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

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.

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

!MWARNING

5-1-6-1

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

!MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it. INT-3-2-8

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Section One - Backhoe Familiarisation Safety Labels

Safety Labels Introduction

!MWARNING

T1-014_2

Safety Labels Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown. INT-1-3-11

Safety labels are strategically placed around the machine to remind you of possible hazards. If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-stretch or place yourself in dangerous positions to read the safety labels. If you do not understand the hazard shown on the safety label, then refer to Safety Label Identification. Note: The illustration(s) show a typical machine model. Your machine may look different from the model shown. Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety labels where necessary. Each safety label has a part number printed on it, use this number to order a new safety label from your JCB distributor.

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Introduction Safety Labels

Safety Label Identification ISO-06B

ISO-09F

ISO-02B

ISO-05C

ISO-10A

ISO-01A +

332/P4679

817/70012-1

817/700104

817/70014

817/70029

ISO-06A

ISO-04D

ISO-15C

817/70021-2 817/70042-2

817/70108-4

ISO-11C 332/P7135

ISO-09D

817/70018

ISO-07B

817/70112

ISO-07D

332/D6029

ISO-14F 711680-21

Fig 3.

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Introduction Safety Labels ISO-01A

ISO-06A

Part Number: 817/70014

Part Number: 332-F5855

Description: Warning. Read the operator manual before you operate the machine.

Description: Pressure hazard. Read operators manual

817-70014-3

332-F5855-1

ISO-02B

ISO-06B

Part Number: 817/70104

Part Number: 332/P7131

Description: Crushing of whole body. Install the maintenance strut before you start maintenance work below a raised attachment. Refer to Making the Machine Safe (Routine Maintenance Section).

Description: Pressure hazard. Refer to Cooling System (Routine Maintenance Section).

817-70104-4 332-P7131-1

ISO-04D Part Number: 817/70042

ISO-07B

Description: Explosion hazard. Remove the source of ignition. Refer to Health and Safety, Battery (Routine Maintenance Section).

Part Number: 817/70018 Description: Crush hazard. Do not operate the controls from outside of the machine.

817-70042-2 817-70018-2

ISO-05C Part Number: 817/70012

ISO-07D

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

Part Number: 817/70112 Description: Crush hazard. Keep a safe distance from the moving parts.

817-70012-2 817-70112-2

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Introduction Safety Labels ISO-09D

ISO-015C

Part Number: 332/P7135-1

Part Number: 817/70021

Description: Crush hazard (to feet). Keep a safe distance. The attachment/part may move when released.

Description: Noise warning. Wear applicable ear protection.

332-P7135-1

817-70021-2

ISO-09F

ISO-014F

Part Number: 332/P4679

Part Number:

Description: Severing of hands or fingers. Keep clear of/do not reach into the moving parts. Stop the engine and remove the starter key before you start maintenance work. Refer to Making the Machine Safe (Routine Maintenance Section).

Non-European Specification - 332/D6029 European Specification - Contact your JCB Dealer. Description: Stability hazard. Make sure that the load is within the capability of the machine. Refer to Object Handling (Operation Section). 332-P4679-1

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

MACHINE 4CX 3CX 2CX 3C

SWL (kgs) 718 718 440 158

SWL (lbs) 1583 1583 969 348

SWL

332/D6029

332-D6029-1

817-70029-3

ISO-011C Part Number: 817/70108 Description: Fall from raised attachment. Do not stand/ride on the bucket or forks.

817-70108-4

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Section One - Backhoe Familiarisation Course Objectives

Course Objectives At the end of the course I will be able to: 1

2

3

4

5

6

7

8

9

10

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Section One - Backhoe Familiarisation Pre-Course Assessment

Pre-Course Assessment 1

Identify the Backhoe models below 1CX, 2CX, 3CX, 3CX Super or 4CX.

2

If the Hydraulic oil level was too low, what would the operator complain of?. Give 3 complaints.

A B C

3

What is the function of this switch?. K Fig 5. ( T 53)

Fig 2.

T040370-46

Fig 5. 4

When measuring system pressures, where would you connect your pressure gauge(s)?.

5

Over a period of 10 minutes, how much is a ram allowed to creep?.

6

What is the primary function of the Main relief valve (MRV)?.

Fig 3.

Fig 4.

53

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53

Section One - Backhoe Familiarisation Pre-Course Assessment 7

What are the 3 possible functions of the Auxiliary relief valve (ARV)?.

A

B T040370-55

Fig 8. C

8

Identify the following symbols.

T040370-56

Fig 9.

T040370-53

Fig 6.

T040370-54

Fig 7.

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54

Section One - Backhoe Familiarisation Machine Walkaround

Machine Walkaround Introduction

Engine

Before commencing the walkaround, park the machine on firm level ground, apply the handbrake, lower the stabiliser legs to the ground, lift the loader arms, tilt the shovel forward and fit the safety strut, switch off the engine. Make sure both doors are open and raise the bonnet. Fit the exhaust extraction system.

Engine Component Identification

Potentially, JCB can build 1.5 million machines where no two are the same.

The following identifies the main components of a typical engine assembly visible from the exterior. Some variants may differ in detail. Remember that the left and right sides are determined when viewing the flywheel (rear) end of the engine. Engine Options

55

1

85hp (63kW) SA build, Naturally aspirated

2

92hp (68kW) SB build, Turbocharged

3

100hp (74kW) SC build Turbocharged

4

Thermostart

5

E block heater

6

Immobiliser

7

Climate builds for different ROW territories

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Section One - Backhoe Familiarisation Machine Walkaround Engine as viewed on the left hand side

T040370-39

Fig 10. 1

Rocker cover

13

Lubrication oil filler cap

2

Fuel injectors and high pressure fuel pipes

14

Lubrication oil filter

15

Lubrication oil cooler housing

3

Lubrication oil filler cap

16

Lubrication oil dip stick

4

Timing gear case

17

5

Flywheel housing

Low duty PTO (blanking cover if no device is fitted)

6

Bed plate

18

Water temperature sender (cold start)

7

Lubrication oil pan (sump)

19

Low pressure fuel line (to tank)

8

Engine lifting eye

20

Oil drain plug (sump)

9

Air inlet manifold

21

Oil pressure switch

10

Fuel injection pump

22

Inlet manifold induction heater (if fitted)

11

Fuel lift pump

12

Fuel filter

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Section One - Backhoe Familiarisation Machine Walkaround Engine as viewed on the right hand side

T040370-40

Fig 11. 1

Rocker cover

2

Breather chamber inspection cover

3

Cylinder block

12

Alternator and drive pulley assembly (belt not fitted)

13

Coolant pump drive pulley (belt not fitted)

14

Coolant pump housing (cylinder block)

15

Coolant inlet/radiator hose connector

16

Heavy duty PTO (blanking cover if no device is fitted)

17

Starter motor assembly

18

Turbocharger oil drain line (turbocharged engine only)

4

Timing gear case

5

Flywheel housing

6

Bed plate

7

Lubrication oil pan (sump)

8

Engine lifting eye

9

Turbocharger (turbocharged engine only)

10

Turbo charger waste gate actuator assembly

19

Turbocharger oil feed line (turbocharged engine only)

11

Exhaust manifold

20

Oil drain plug (sump)

57

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Section One - Backhoe Familiarisation Machine Walkaround Engine as viewed on the crankshaft pulley (front end)

T040370-41

Fig 12. 1

Rocker cover

11

Idler pulley

2

Cylinder head

12

Alternator and drive pulley assembly

3

Cylinder block

13

Cab heater water hose connector

4

Bed plate

14

Coolant temperature sender

5

Lubrication oil pan (sump)

15

6

Crankshaft pulley

Coolant thermostat housing/radiator hose connector

7

Front end accessory drive belt

8

Idler pulley

9

Drive belt tensioner and pulley

10

Coolant pump and drive pulley assembly

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Section One - Backhoe Familiarisation Machine Walkaround Engine as viewed on the flywheel (rear end)

T040370-42

Fig 13. 1

Rocker cover

2

Cylinder head

3

Flywheel

4

Fuel injection pump drive gear cover

5

Flywheel housing

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59

60

Transmission Synchro Shuttle Gearbox Component Identification K Fig 14. ( T 61).

9817/0000

B

Transmission oil pump

C

Torque converter pressure regulating valve

D

Oil pressure maintenance valve

E

Solenoid control valve

F

Mainshaft

G

Synchromesh unit - 3rd/4th gears

H

Layshaft

J

Synchromesh unit - 1st/2nd gears

K

Transfer gear, output shaft and yoke

L

4WD output yoke (if fitted)

M

2/4WD clutch unit (if fitted)

N

4WD solenoid control valve (if fitted)

P

Oil strainer

Q

Oil filter

R

Gear selection turret assembly

S

Torque converter

T

Driveshaft (drives machine main hydraulic pump)

U

Hydraulic pump mounting face

V

Torque converter relief valve

W

Oil pressure switch

X

Hose connection - to cooler

Y

Hose connection - from cooler

Z

Gearbox oil cooler

60

Section One - Backhoe Familiarisation

Forward/reverse clutch unit

Machine Walkaround

A

61

R

A

E

9817/0000

V C W

N

G

J

F

Section One - Backhoe Familiarisation

Fig 14. Synchro Shuttle Gearbox

X U H M

Q K

Y C003440

61

Machine Walkaround

P L

B S T

D

Section One - Backhoe Familiarisation Machine Walkaround Powershift Gearbox Component Identification K Fig 15. ( T 63) A

Torque converter

B

Forward/input clutch assembly

C

Reverse clutch assembly

D

Mainshaft assembly

E

Layshaft assembly

F

2/4 wheel drive clutch assembly

G

Torque converter relief valve

H

Oil pressure maintenance valve

J

Transmission oil pump

K

Park brake actuator

L

Park brake pack

M

Hose connection - to oil cooler

N

Hose connection - from oil cooler

P

6-Speed assembly (if fitted)

Q

Oil filter

R

Driveshaft (drives machine main hydraulic pump)

S

Gear drive to reverse unit clutch assembly

T

Solenoid control valves

U

Transmission oil pressure switch

V

Speed sensor

W

Steering column mounted gear selection switch

X

Gearbox oil cooler

62

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62

63

D R

G 9817/0000

L

F D

Section One - Backhoe Familiarisation

C003460

Fig 15. Component Identification

M V P C

U T

63

Machine Walkaround

E L K

S B

A J

N H

C

Q

Section One - Backhoe Familiarisation Machine Walkaround Options

Component Key: K Fig 16. ( T 65). A

Lock up clutch

B

Clutch friction material

C

Torque converter casing

1

Synchro-Shuttle manual

2

4-speed Powershift with or without JCB Torquelock

3

6-speed Powershift with or without JCB Torquelock

D

Turbine

E

Gearbox input drive shaft

4

2 or 4-wheel drive

F

Solenoid control valve

5

2WS or AWS

G

Speed sensor, gearbox output shaft

6

LSD axles optional with reduced road speed axles for German markets

H

Speed sensor, engine crankshaft pulley

J

ECU (electronic control unit)

K

Gear select lever

L

Lubrication bypass valve (part of item F)

Y

Test Point - Converter inlet and converter relief valve pressure

Lock Up Torque Converter The lock up torque converter incorporates a clutch which, when engaged, enables a direct mechanical connection between the engine and the gearbox. This eliminates any slippage in the drive line and results in improved efficiency. The system is only available on Powershift machines. Principle of Operation

Note: For lock up torque converter test procedure, see Service Procedures, Powershift Gearbox (ShiftMaster).

K Fig 16. ( T 65). The lock up clutch assembly A is fixed to the turbine D (output section) of the torque converter. The turbine is connected to the gearbox input shaft E via a splined hub. For a description of how the turbine is driven see Torque Converter, Principle Of Operation. The clutch is engaged and disengaged hydraulically by utilising the normal oil flow through the torque converter. Solenoid control valve F changes the direction of oil the flow to engage or disengage the clutch as applicable. The solenoid control valve F is energised via an electrical output from the gearbox ECU J (electronic control unit) The ECU J receives inputs from the gear select lever K, engine speed sensor H and gearbox output shaft speed sensor G. An output from the ECU energises the solenoid control valve F (enabling torque converter lock up) under the following conditions: 4th gear forward (4speed gearbox) or A - 5th or 6th (6 speed gearbox) must be selected, AND the speed difference between the engine flywheel and gearbox output drive shaft must be within pre-determined values.

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Section One - Backhoe Familiarisation Machine Walkaround

H D

K

B A

C

J Y

F

E

G Fig 16. Component Identification

65

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66

Front Axle - Steer Drive Type SD55, SD80

A

Yoke connection to propshaft

F

Universal coupling

Component Identification

B

Pinion

G

Reduction gear hub

C

Crownwheel

H

Steer swivel trunnion bearings

D

Differential unit

J

Axle pivot

E

Drive shaft

K

Oil fill and drain plugs

K Fig 17. ( T 66) The illustration, shows a typical steer drive front axle.

9817/0000

Section One - Backhoe Familiarisation

66

Machine Walkaround

Fig 17. Typical Steer Drive Front Axle

67

Rear Axle - Steer Drive Type SD80

Park brake disc. The disc is fitted to the pinion instead of a yoke. The propshaft is bolted to the centre of the disc. The axle casing also carries a bracket for location of the park brake caliper.

E

Drive shaft

F

Universal coupling

G

Reduction gear hub

H

Steer swivel trunnion bearings

B

Pinion

L

In-board oil immersed multi-plate disc brakes

C

Crownwheel

M

Brake actuating piston

Differential.

N

Hydraulic brake lines

A(1)

Component Identification K Fig 18. ( T 67). The illustration shows a typical steer drive rear axle. 2WS machines are fitted with non steer axles (PD70). These axles are similar to the axle shown but do not feature steer swivels or drive shaft universal joints.

D

Note: Items A, B, C and D form the `drive head' part of the axle.

C 9817/0000

D N

(1) The park brake disc is only fitted to machines with Synchro Shuttle gearboxes.

ML E F G

A B

67

Machine Walkaround

A396760-C2

Fig 18. Typical Steer Drive Rear Axle

Section One - Backhoe Familiarisation

H

Section One - Backhoe Familiarisation Machine Walkaround

Brakes

Pedals Locked - Compensating Operation

Compensating Master Cylinder

When the brake pedals are pushed down (the brake pedals are mechanically locked together), actuation of the brake packs H and H1 is as described in Pedals Locked Normal Operation. If however, the brakes have not worn equally, then the amount of fluid displaced from each master cylinder will vary and some form of compensation is required.

Compensating master cylinders overcome the problem of unequal wear between the right and left brake. The units incorporate both master cylinder and compensating valve. K Fig 19. ( T 69). Each brake has its own master cylinder A, A1, brake pedals B, B1, servo units N, N1 and associated pipework. Both master cylinders have one common reservoir C. Note: Dual pedal braking is applicable only to 2WS machines. 4WS machines have a single brake pedal. Pedals Locked - Normal Operation When the brake pedals are pushed down (the brake pedals are mechanically locked together), rod D pushes the plunger E down the bore of the master cylinder. Pressurised oil acting on centre valve seal F via valve stem G causes the seal to close off the reservoir supply port. As the plunger continues to move down the bore, pressurised oil flows to the brake pack H via service port J and the associated pipework. Master cylinder A1 operates in the same way to feed brake pack H1. With valve stem G at maximum travel, further movement of plunger E causes valve K to lift off its seat. Both master cylinders are interconnected via bridge pipe M, therefore hydraulic pressure in both cylinders will be equal. If the brake packs H and H1 have worn equally, then the amount of oil displacement between cylinders will be minimal and the brakes will be applied evenly.

68

Pedal application moves plungers E down the bores of master cylinders A and A1. Linings of brake H are brought into contact before the linings of brake H1 because they have not worn as severely. If further displacement took place at the linings, brake H would be applied before brake H1. Therefore master cylinder A begins to compensate for master cylinder A1. Fluid is displaced from A to A1 via bridge pipe M until the pressures are equalised. In this condition both compensating valves are open and both brakes are applied evenly. Pedals Unlocked - Normal Operation When a single brake pedal is pushed down, rod D pushes the plunger E down the bore of the master cylinder. Pressurised oil acting on centre valve seal F via valve stem G causes the seal to close off the reservoir supply port. As the plunger continues to move down the bore, pressurised oil flows to the brake pack H via service port J and associated pipework, thus braking one wheel only. With valve stem G at maximum travel, further movement of plunger E causes valve K to lift off its seat. Fluid is displaced through drillings P from the active cylinder A via bridge pipe M to passive cylinder A1. Valve K1 in the passive cylinder is held on its seat by the displaced pressurised fluid.

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Section One - Backhoe Familiarisation Machine Walkaround

C

M

N1

H1 B1

A1

H J

A

F

G

K E

D

B

P N

A265570

Fig 19. Schematic Diagram

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Section One - Backhoe Familiarisation Machine Walkaround 2 and 4 Wheel Braking Modes Although the machine only has brakes in the rear axle (2wheel braking), 4-wheel braking is achieved by engaging 4-wheel drive. In this way all 4 wheels are effectively braked via the machine transmission. 4WD (and therefore brake mode) is controlled electrically by selector switches in the cab. There are 2 switch configurations dependent on machine variant as described below: 2 Wheel Steer Machines The system is controlled by a rotary 3 position mode switch, K Fig 20. ( T 71). 4 Wheel Steer Machines The system is controlled by a 2 position switch, K Fig 21. ( T 71). Auto 2 and 4 Wheel Braking The 2 or 4WD setting is overridden automatically by application of the service brakes and, on Powershift Shiftmaster machines, selection of 4th or Auto gear. For a full description of the 2 and 4 wheel braking electrical system, see Electrical Connections, 2 and 4 Wheel Braking Modes.

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Section One - Backhoe Familiarisation Machine Walkaround

2WD 2WD 4W( ) 4WD 2W( ) 4W( )

2WD 2WD 4W( ) 4WD 2W( ) 4W( )

2WD 2WD 4W( ) 4WD 2W( ) 4W( )

NORMAL OPERATION

2WD/2WB

NORMAL OPERATION

2WD

AUTO MODE 1

AUTO 4WD/4WB

NORMAL OPERATION

4WD/4WB

AUTO MODE 1

4/A

AUTO MODE 2

4/A

AUTO 2WD

AUTO 4WD/4WB

Powershift/Shiftmaster machines only

Fig 20. 2 Wheel Steer Machines (Not German Specification)

NORMAL OPERATION

C004160

4WD/4WB

AUTO MODE 1

4/A

AUTO 2WD/2WB

AUTO MODE 2

4/A

AUTO 4WD/4WB

NORMAL OPERATION

2WD

AUTO MODE 1

AUTO 4WD/4WB

Powershift/Shiftmaster machines only

Fig 21. 4 Wheel Steer Machines (Not German Specification)

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Section One - Backhoe Familiarisation Backhoe Machine Options

Backhoe Machine Options Wheels and Tyres

16 Hand throttle / Green band on rev counter.

1

214e (now called 3C) for USA - 16 inch or 17.5 inch wheels on the front.

2

3CX - 18in or 20 inch on front.

3

3CX Super - 24 inch all round.

4

4CX - 26 inch or 28 inch all round. Can be specified with 30 inch as a special order for certain territories.

5

There are 66 different tyre options including Goodyear, Titan, Michelin, JCB Sitemaster.

6

Mudguards.

Hydraulic System 1

Standard gear pump.

2

Variable flow hydraulics - 4CX Super.

3

Precision Control (Servo) - PC3 or APC.

4

Bio-Degradeable oil.

Cab 1

Fully glazed cab.

2

Heater with or without Air Conditioning.

3

Canopy cab without glass or HVAC system

4

Precision Control with levers on seat.

5

Different seat options.

6

Battery isolator.

7

Toolbox.

8

79 different language packs.

9

Beacon.

10 Extra worklights. 11 Reversing alarm. 12 SAE, ISO or JCB ‘X’ pattern controls. 13 Fuse and relay location. 14 Split brakes. 15 ECU connector location.

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Section One - Backhoe Familiarisation Backhoe Machine Options

Loader End

14 Ram design and geometry.

1

57 different front shovels types.

2

4:1, 6:1, flip forks, general Purpose 1.0m3, 1.1m3, 1.2m3, 1.3m3.

3

With teeth or with a toeplate.

4

Direct mount or Quickhitch mount.

5

Front auxiliary with or without Quickhitch.

6

Many other attachments supplied by the attachments division.

7

Standard or heavylift Loader rams 80mm or 90mm diameter.

8

Optional Hose Burst Check Valves for some territories.

9

Float and Optional return to dig function (demonstrate both if fitted).

10 SRS (Smooth Ride System). 11 Longer loader arms standard on 4CX for extra lift height, or for extra counterweighting if a longer dipper option is selected.

Excavator End

1

Centremount with cantilever stabiliser legs.

2

Sideshift with stabiliser leg towers.

3

Optional check valves.

4

Streetpads.

5

Power Sideshift.

6

4 Boom sizes with optional end damping (demonstrate dipper and slew damping).

7

Knuckle boom option for Nordic region only.

8

Dipper sizes 14, 15 or 17ft fixed, or 14 – 18ft, 15 – 19ft extending dipper.

9

Hammer kit High flow or Low flow.

10 Hydraulic Tool Circuit on right hand side of machine (as a kit from attachments only). 11 41 different buckets; 400mm, 450mm, 600mm, 800mm, 1100mm etc. 12 Direct or Quickhitch mounted. 13 Rear frame 92 inch standard with narrow 88 inch for certain territories.

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Section One - Backhoe Familiarisation Additional Backhoe Information

Additional Backhoe Information 3CX Works Order

Fig 22.

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Section One - Backhoe Familiarisation Additional Backhoe Information

Excavator Lever Patterns

ISO

SAE

JCB ‘X’

T040370-2

Fig 23.

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Section One - Backhoe Familiarisation Additional Backhoe Information

Main Differences between P12 and P21 Machines

Battery Location The P12 Battery is located on the left hand side of the machine attached to the hydraulic tank.

Hydraulic Pump Location The P12 Hydraulic pump is in the front of the machine driven by a short driveshaft from the engine front pulley.

T040370-6

Fig 26. P12 Battery T040370-4

The P21 Battery moved to the front of the machine.

Fig 24. P12 Hydraulic Pump The P21 Hydraulic pump moved to the rear of the transmission driven from the engine flywheel.

T040370-7

Fig 27. P21 Battery

T040370-5

Fig 25. P21 Hydraulic Pump

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Section One - Backhoe Familiarisation Additional Backhoe Information Front end The front end of the P21 machine was lowered by 130mm to improve visibility.

T040370-9

Fig 29. P21 Front End

T040370-8

Fig 28. P12 Front End

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Section One - Backhoe Familiarisation Additional Backhoe Information Loader Arms

Rear Corner Glass

The P12 ‘A’ section loader arms replaced by ‘D’ section on P21. This provides a much stronger loader end and removes the need for welding in certain stressed areas.

P12 rear corner glass deleted.

T040370-12

Fig 32. P12 Rear Corner T040370-10a

Fig 30. P12 Loader Arms

The P21 rear corner with wider rear glass.

T040370-13

T040370-11a

Fig 33. P21 Rear Corner

Fig 31. P21 Loader Arms

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Section One - Backhoe Familiarisation Additional Backhoe Information Rear Screen

Increased Fuel tank Capacity

The P21 Rear screen has been lowered to give improved visibility.

The P12 Toolbox has moved to the other side on P21 machines to enable fitment of an enlarged fuel tank.

T040370-18

Fig 36. P12 Toolbox

T040370-14

Fig 34. P12 Rear Screen

T040370-19

Fig 37. P21 Enlarged Fuel Tank

T040370-15

Fig 35. P21 Rear Screen

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Section One - Backhoe Familiarisation Additional Backhoe Information Battery Box The P12 battery box is replaced with steps or an optional toolbox on P21 machines.

T040370-17

Fig 39. P21 machine with Steps

T040370-16

Fig 38. P12 Battery box

T040370-17A

Fig 40. P21 machine with Toolbox

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Section One - Backhoe Familiarisation Additional Backhoe Information Park Brake Disc The park brake disc has moved to the rear axle on early P21 machines to accommodate the new position of the hydraulic pump on the rear of the transmission. The current P21 Park Brake disc (JCB Dieselmax engines) has an integral park brake in the transmission.

T040370-21

Fig 42. P21 Park Brake Disc (Early machines)

T040370-20

Fig 41. P12 Park Brake Disc

T040370-22

Fig 43. P21 Park Brake Disc (Current machines)

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Section One - Backhoe Familiarisation Additional Backhoe Information Operator Levers

Decals

P12 machines have yellow ‘snooker ball’ type levers as opposed to the chrome type on P21 machines.

P12 machines have black Decals, these are changed to chrome type decals on P21 machines.

T040370-23

Fig 44. P12 Operator levers

T040370-25

Fig 46. P12 Decals

T040370-24

Fig 45. P21 Operator levers

82

T040370-26

Fig 47. P21 Decals

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Section One - Backhoe Familiarisation After Sales Service Information

After Sales Service Information JCB Service CD

Fig 48.

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Section One - Backhoe Familiarisation After Sales Service Information

Backhoe Loader Service Manuals Part Numbers Part Number Machine Model

Serial Numbers

9803/7110

2CX, 2DX

657001 to 763230

210, 212

481196 Onwards

2CX

930000 Onwards

210, 212

903000 Onwards

MIDI CX

972021 to 985136

9803/7130

9803/9400

1327001 to 1349999 9803/3250

3CX, 4CX

290000 to 400000

9803/3260

3CX, 4CX

400001 to 460000

214e, 214, 215, 217 9803/3270

3CX, 4CX

460001 to 499999 920001 to 930000

9803/3280

9803/3290

214e, 214, 215, 217

900001 Onwards

3CX, 4CX

930001 to 960000

214e, 214, 215, 217

903000 Onwards

3C, 3CX, 4CX (JCB 444 Engine)

1327001 to 1349999 960001 to 985136 1616000 to 1625999

550/42426

84

3DX (India)

TBA

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Section One - Backhoe Familiarisation Identifying Your Machine

Identifying Your Machine Machine Identification Plate

Typical Product Identification Number (PIN) P2-1004

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

T016220-5

Fig 50. 1

World Manufacturer Identification (3 Digits)

2

Machine Model (5 Digits)

3

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

4

5

Year of Manufacture (1 Digit) 7 = 2007

A = 2010

8 = 2008

B = 2011

9 = 2009

C = 2012

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

T025210-1

Fig 49.

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Section One - Backhoe Familiarisation Identifying Your Machine

ROPS/FOPS Certification plate

- Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services. - Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry.

Fig 51. Cab Machines built to ROPS/FOPS standards have an identification label fitted to the inside of the cab. K Fig 51. ( T 86) The FOPS structure provides Level II Impact Protection against falling objects (as defined in ISO 3449:2005).

Definition of terms: ROPS Roll Over Protection Structure FOPS

Falling Objects Protection Structure

FOPS Data Plate

!MWARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17

If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides. There are two levels of FOPS:

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Section One - Backhoe Familiarisation Identifying Your Machine

Component Identification Plates

E Typical Engine Identification Number T1-005_3

Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). K Fig 52. ( T 87). The data label contains important engine information and includes the engine identification number E. A typical engine identification number is explained as follows: SA

320/40001

U

00001

04

1

2

3

4

5

1

D B

Engine Type S = 4.4 litre series.

C

JCB Dieselmax (Tier 2)

B C007820-C2

Fig 52. Engine

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

Engine part number

3

Country of manufacture U = United Kingdom

4

Engine Serial Number

5

Year of Manufacture

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

87

00001

04

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Section One - Backhoe Familiarisation Identifying Your Machine

Identification of Machine Components

5

Boom

Component List

6

Fuel tank

1

Loader arm

7

Stabilisers

2

ROPS/FOPS cab

8

Kingpost

3

Hydraulic oil tank

9

Dipper

4

Battery compartment

10

Toolbox (If Fitted)

10 711680-2

Fig 53.

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Section One - Backhoe Familiarisation Identifying Your Machine Notes:

89

Notes:

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Operation Cab Layout (Manual Controls)

Cab Layout (Manual Controls)

28

27 1 20

23

10

12 4

7 2

11 5 9

3

13 6

25 26

14 21

16 15 8

18

24 17 22 19 T039550-7

Fig 24.

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Operation Cab Layout (Manual Controls)

Component Key 1

K Steering Wheel ( T 42).

2

K Gear Selection ( T 45).

3

K Transmission Kickdown Switch (6-Speed Powershift Transmission) ( T 47).

4

K Gear Lever (Syncro Shuttle Transmission) ( T 47).

5

K Accelerator Pedal ( T 43).

6

K Foot Brake Pedals ( T 43).

7

K Transmission Lever (4- and 6-Speed Powershift Transmission) ( T 45).

7

K Transmission Lever (4-Speed Syncro Shuttle Transmission) ( T 46).

8

K Hand Throttle Lever ( T 43).

9

K Park Brake Lever ( T 44).

10

K Instruments ( T 60).

11

K Front Console Switches ( T 50).

12

K Multi-Purpose Steering Column Switch ( T 55).

13

K Loader Controls ( T 77).

14

K Starter Switch ( T 57).

15

K Side Console Switches ( T 51).

16

K Cab Heater Controls ( T 75).

17

K Boom Lock ( T 115).

18

K Stabiliser Controls ( T 108).

19

K Excavator Controls ( T 87).

20

K Speedometer Option ( T 61).

21

K Auxiliary Options Control ( T 113).

22

K Hammer (If Fitted) ( T 324).

23

K Visibility Aids ( T 35).

24

K Overload Override Warning Switch ( T 169).

25

K Auxiliary Controls ( T 110).

26

K Auxiliary Power Socket ( T 58).

27

K Roof Switches ( T 54).

28

K Extreme Cold Climate Heater Switch (If fitted) ( T 71).

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Operation Drive Controls, Switches and Instruments

Drive Controls, Switches and Instruments Drive Controls Steering Wheel Turn the steering wheel in the direction you want to go. Important: Before you drive the machine, understand how the three steer modes change the operation of your machine (for example, the machines turning circle). Refer to Steer Mode Selector.

C

Steering Column Adjustment

!MWARNING

B

P2-2006

Make sure the steering column is locked in position. Do not adjust the steering column while driving. INT-2-1-16

Tilt Adjustment Pull the lever A up to unlock the steering column, move the steering column to the position required, release the lever to lock in position. Height Adjustment Option To unlock the steering column, twist the knob counterclockwise B. Raise or lower the steering wheel to the required height, twist the knob clockwise C to lock in position.

A

807820

Fig 27.

42

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42

Operation Drive Controls, Switches and Instruments Accelerator Pedal T2-031

!MWARNING

When driving the machine, use only the accelerator pedal to control the engine speed. Do not use the hand throttle lever to set the engine speed while driving. 2-2-2-2

Push this pedal down to increase engine speed. Let the pedal up to reduce engine speed. With your foot off the pedal the engine will idle.

applied. Do not drive the machine unless both stop lights work correctly.

!MWARNING You and others can be killed or injured if the brake pedal locking bar is not engaged as recommended. If only one brake is applied for a quick stop, the machine could swerve out of control. 2-2-2-3

Lock the pedals together when driving on the road in any gear.

Hand Throttle Lever T2-032

!MWARNING

When driving the machine, use only the accelerator pedal to control the engine speed. Do not use the hand throttle lever to set the engine speed while driving. 2-2-2-2

Move this lever to increase B or decrease the engine speed as required when working with the excavator. Pushing the accelerator pedal or brake pedals or ignition cycle (on/off) will return control to the foot throttle. To reactivate the hand throttle lever, return the lever to the idle position A and then re-set the throttle lever to the required engine rpm.

Separate the pedals only when driving in 1st or 2nd gear (1 or 2) off the road. The left rear brake is operated by the left pedal. The right rear brake is operated by the right pedal. The pedals can be locked together by a steel locking bar. The left and right brakes are operated simultaneously by the brake pedal.

Note: Both brake pedals and the accelerator pedal must be fully off for the hand throttle to work.

A

B

Fig 28.

Foot Brake Pedals Push down on the brake pedals to slow or stop the machine. Use the brakes to prevent overspeeding down a slope. The stop lights should come on when the brakes are

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Operation Drive Controls, Switches and Instruments Park Brake Lever Use this lever to engage the park brake before leaving the machine. Note: The transmission drive is automatically disconnected when the park brake is engaged. Note: 4WD is automatically connected when the park brake is applied. To engage the park brake, pull the lever up (vertical). Note: If the park brake is engaged when forward/reverse is selected, the Park Brake Engaged Indicator will come on and the buzzer will sound. To release the park brake, squeeze the release lever and lower the lever as far as it will go (horizontal).

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Operation Drive Controls, Switches and Instruments Transmission Lever (4- and 6-Speed Powershift Transmission)

2

6-Speed. 1st, 2nd and 3rd gears are selected by rotating the column switch to the required position. When the column switch is rotated to position A, the machine will gear change automatically according to road speed (4th, 5th and 6th gears only).

T2-068_3

Functions

Switch position A is recommended for road use only. In reverse only 1st to 4th are available. A warning buzzer will sound if a selection is made which is not allowed by the electronic control unit (E.C.U.). The 'double-beep' will continue to sound until the selection conditions are met (e.g. travel speed reduced), or the request is deselected.

S240120-9

Fig 29. K Gear Selection ( T 45).

+/-

Drive Selection

F/N/R K Drive Selection ( T 45).

!MWARNING

K Horn ( T 45).

X

Gear Selection There are two types of transmission, 4-speed and 6-speed.

!MWARNING

2-2-2-4_2

Do not change from a high gear to a low gear in one sudden movement when the machine is moving. Otherwise the machine will rapidly decelerate, you or others could be killed or seriously injured. When selecting lower gears, allow the engine speed to drop before each gear change. 2-1-1-9_2

When selecting lower gears, allow the engine speed to drop before each gear change. Take notice of the warning above, do not change from a high gear to a low gear in one sudden movement whilst the machine is moving, otherwise the machine will rapidly decelerate. When moving or stationary, to select a gear, rotate the barrel so that the arrow marked on the barrel aligns with the required gear. All gears are selected by rotating the column switch to the required position. 1

4-Speed. The gears are selected by rotating the column switch to the required position.

45

You and others can be killed or injured if you operate the forward/reverse lever while you travel. The machine will immediately reverse direction without warning to others. Follow the recommended procedure for proper use of this selector.

Stop the machine before moving this lever. To select forward, reverse or neutral, 'lift' and move the lever to the required position. The engine will only start if the lever is at neutral. All gears are available in forward and reverse except the 6-speed Powershift when only 4 gears are available in reverse. To reverse direction: 1

Stop the machine: keep the foot brakes applied.

2

Let the engine speed drop to idle.

3

Select the new direction.

4

Release the foot brakes and accelerate away.

Horn The horn button X is at the end of the forward/reverse lever. Push the button to operate the horn. It functions only with the starter switch set to on.

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Operation Drive Controls, Switches and Instruments Transmission Lever (4-Speed Syncro Shuttle Transmission) T2-023_3

Note: If the park brake is engaged when forward/reverse is selected, the Park Brake Engaged Indicator will come on and the warning buzzer will sound.

Functions Horn The horn button X is at the end of the forward/reverse lever. Push the button to operate the horn. It functions only with the starter switch set to on.

S240120-8

Fig 30. F/N/R K Drive Selection ( T 46) K Horn ( T 46)

X

Drive Selection

!MWARNING You and others can be killed or injured if you operate the forward/reverse lever while you travel. The machine will immediately reverse direction without warning to others. Follow the recommended procedure for proper use of this selector. 2-2-2-4_2

Stop the machine before moving the lever. To select forward (F), reverse (R) or neutral (N), 'lift' and move the lever to the required position. All four gears are available in forward and reverse. When reverse is selected an alarm will sound. The engine will only start if the lever is at neutral. The lever has 'detent' positions in forward, reverse and neutral. To move the lever from the detent position pull the lever towards you. Procedure for reversing direction: 1

Stop the machine: keep the foot brakes applied.

2

Let the engine speed drop to idle.

3

Select the new direction.

4

Release the foot brakes and accelerate away.

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Operation Drive Controls, Switches and Instruments Gear Lever (Syncro Shuttle Transmission) To select a gear, move the lever A as shown on the shift pattern. When the machine is stationary, make sure that forward/reverse lever is at neutral (N) and the engine at idle, before selecting a gear.

The machine will remain in the kickdown gear, even if the speed increases, until either the kickdown is pressed or next higher gear is selected.

The machine can be moved off in any gear, depending on the ground conditions. To change gear on the move:

A warning buzzer (double-bleep) will sound once if a selection is made which is not allowed by the electronic control unit (E.C.U.). For example, travel speed may be too fast. In this instance, reduce speed and select kickdown again.

1

Press the transmission dump switch B.

Transmission Dump Switches

2

Select the new gear.

3

Release the transmission dump switch B.

On Syncro Shuttle machines depress and hold the switch on the gear lever to disconnect the drive while changing gear on the move.

4

Use the accelerator to produce a smooth gear change.

On Powershift machines you do not need to depress a switch when changing gear.

T2-024_2

B

1

3

2

4

On both Powershift and Syncro Shuttle machines, the dump switch on the boom and carriage control lever can be used to momentarily dump the transmission pressure to improve the hydraulic performance and reduce engine load.

A

765300-3

Fig 31.

Transmission Kickdown Switch (6-Speed Powershift Transmission) T2-067

Press the foot operated switch to operate transmission kickdown. When the kickdown switch is pressed, the next lowest gear is selected. Pressing the kickdown switch again will select the previous higher gear. The previous higher gear will also be selected if the forward/reverse lever is moved through neutral position.

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Operation Drive Controls, Switches and Instruments Steer Mode Selector (4 Wheel Steer Machines)

Steer Mode Selector Switch

Introduction

This is a three-position rotary switch, equipped with a flexible lockplate. The lockplate locks the selector switch in the 2-wheel steer mode, when the machine is driven on public roads. To unlock the switch, depress the lockplate B and turn the switch to the required position.

!MWARNING

T2-016

In 4-wheel steer, the back end of the machine will swing out when you make a turn. Check for clearance before making a turn. 5-2-3-3

This machine is a 4-wheel steer machine. Before you drive the machine, understand how the three steer modes change the operation of your machine (for example, the machines turning circle). Select the steer mode which is most suitable for the terrain and type of work you are doing.

Never change steer mode on the move, the machine should be stationary. Only change the steer mode when the engine is at low engine rpm/idling. Never change from 4 wheel steer to crab steer (or vice versa) without first selecting 2 wheel steer for approximately 5 seconds (as shown by the decal A) K Fig 32. ( T 48). 1

2-Wheel Steer. The front wheels only are controlled by the steering wheel. This position must be used for driving on public roads. Make sure the lockplate is engaged.

!MDANGER Failure to align the steering before selecting the required steer mode will cause the machine to steer incorrectly.

2

4-Wheel Steer. The front wheels steer one way and the rear wheels steer in the opposite direction. This position provides the tightest turning circle.

5-2-6-7

!MWARNING Failure to phase 4-wheel steer at least once per day may mean a reduction in steering effectiveness.

3

5-2-1-6

The steering must be re-phased: 1

At least once per day.

2

If having difficulty in steering.

3

After travelling for 15 miles (24 km) or more on the road (in 2-wheel steer).

Crab Steer (if fitted). The front and rear wheels steer in the same direction. This position improves manoeuvrability in confined spaces. Crab steer may not be available on all models.

1

For further information, refer to Wheel Alignment.

A

2

B

3

Fig 32.

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48

Operation Drive Controls, Switches and Instruments Steer Mode Indicator Lights

Electronic Control Unit

Sensors on the axles prevent the steer mode from changing until all wheels straighten up or pass through the straight ahead position. Because of this, there will be a short period when the indicator lights do not agree with the switch position.

The steer mode system is controlled by an electronic control unit (ECU). The steer mode indicator lights are used to indicate faults in the steer system. 1

Indicator lights on the front panel tell you what steer mode the machine is in. If you have any doubt about the steer mode the machine is in, always remember that it is the indicator light which is correct.

As a bulb and system check, each of the indicator lights will illuminate briefly when the starter switch C is set to position I. K Fig 34. ( T 49).

The indicator light for the current steer mode will remain illuminated until the change is complete, the light will then extinguish. 1

2-Wheel steer engaged. Located in the front console. Lights up when 2-wheel steer mode is engaged.

C T039550-73

2

Fig 34.

4-Wheel steer engaged. Lights up when 4-wheel steer mode is engaged.

3

2

The 2-wheel indicator light Z on the front console will flash, (two flashes per second) until the steer mode change is complete. The indicator light will remain illuminated when in 2-wheel steer. K Fig 35. ( T 49).

3

If the 2-wheel steer indicator light on the front console flashes repeatedly, (four flashes per second), when the machine is in any of the steer modes, the steering is out of phase.

4

If the 2-wheel steer indicator light on the front console flashes repeatedly (irregular flash pattern) when the machine is in any of the steer modes, contact your JCB dealer.

Crab steer engaged. Lights up when crab steer mode is engaged.

Note: The light may sometimes temporarily disagree with the position of the steer mode selector. K Steer Mode Selector Switch ( T 48).

2

1

3

Important: Until the fault has been rectified, restrict the machine to 2-wheel steer mode. T052360-4

Fig 33. Front console

Z

T052360-2

Fig 35. Front console

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Operation Drive Controls, Switches and Instruments

Switches

Front Console Switches

Console Switches

Side Lights and Headlights Three position rocker switch with backlight. The switch functions operate when the starter switch is in the ON and OFF positions.

Introduction The installed switches and their positions can change according to the specification of the machine.

Position 1: OFF (Backlight OFF) Each switch has a graphic symbol A to show the function of the switch. Before you operate a switch, make sure that you understand its function K Fig 36. ( T 50).

340151-1

Position 3: Side Lights ON (Backlight ON) Position 2 (starter switch in the ON position): Headlights ON (Backlight ON)

The rocker switches have two or three positions (as shown).

Position 2 (starter switch in the OFF position): Side Lights ON (Backlight ON)

If the switch is active, then the light B will come on to show that the switch function is active.

Machines without headlights or side lights are designed for site use. You may be breaking local laws if you travel on the road without headlights or side lights. Hazard Warning Lights

A

Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON and OFF positions. Position 1: OFF (Backlight OFF). 339861-1

B

Position 2: ON (Backlight ON). A light on the instrument panel flashes with the outside lights.

4 Wheel Drive Selector Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

T042100-2

Fig 36.

339650-3

Position 1: 2-Wheel (Backlight OFF).

drive

engaged

Position 2: 4-Wheel (Backlight ON).

drive

engaged

Before you operate the switch, refer to Getting the Machine Moving K Getting The Machine Moving ( T 134).

50

9821/3000-3

50

Operation Drive Controls, Switches and Instruments Side Console Switches

Smooth Ride System (if fitted) Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Beacon Two position rocker switch. The switch functions operate when the starter switch is in the ON and OFF positions.

Position 1: OFF (Backlight OFF) Position 2: ON (Backlight ON)

Position 1: OFF

340161-1

Position 2: ON

Before you operate the switch, refer to Preparing the Machine for Travel.

339711-1

Before you operate the switch, refer to Beacon K Beacon ( T 119).

Smooth Ride System with HBCV (if fitted)

!MWARNING

Three position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Do not drive on the road with the work lights switched on. You can interfere with other drivers visibility and cause an accident.

Position 1: OFF (Backlight OFF)

2-2-2-5_1

340161-1

Position 2: ON (Backlight ON) Position 3: SRS ACTIVATION ON (Backlight ON).

Front Work Lights Three position rocker switch. The switch functions operate when the starter switch is in the ON position.

Before you operate the switch, refer to Preparing the Machine for Travel K Preparing The Machine For Travel ( T 129).

Position 1: OFF Position 3: Outer Work Lights ON 340100-1

Rear Window Wiper (if fitted)

Position 2: Inner and Outer Work Lights ON

Three position rocker switch. The switch functions operate when the starter switch is in the ON position.

Note: The work lights work independently of the main lights circuit.

Position 1: OFF Position 3: Wiper ON (if fitted)

Note: On Italian and German machines, it is not possible to have the headlights and the front worklights switched on at the same time.

340070-1

Position 2: Wash/Wipe ON - Push and Hold (if fitted)

Note: The wiper will self-park when switched off. Rear Fog Light (if fitted) Two position rocker switch. The switch functions operate when the starter switch is in the ON position.

Rear Work Lights

Position 1: OFF

Two position rocker switch. The switch functions operate when the starter switch is in the ON position.

Position 2: ON

Position 1: OFF

340051-1

Position 2: ON 340090-1

Note: The work lights work independently of the main lights circuit.

51

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51

Operation Drive Controls, Switches and Instruments Air-Conditioning (if fitted)

Return To Dig Enable Switch - EcoLOAD (if fitted)

Two position push switch. The switch functions operate when the starter switch is in the ON position.

Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Position 1: OFF

Position 1: OFF (Backlight OFF)

Position 2: ON

Position 2: ON (Backlight ON)

339681-1

340110-2

Before you operate the switch, refer to AirConditioning and Cab Heater Controls.

Before you operate the switch, refer to Loader Controls K Loader Controls ( T 77).

Kingpost Clamps

Overload Warning Switch (if fitted)

Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Two position rocker switch. The switch functions operate when the starter switch is in the ON position.

Position 1: OFF (Backlight OFF)

Position 1: ON - Lifting Position (Lights ON Overload and buzzer sounds)

Position 2: ON (Backlight ON) 339970-3

T032730-8

Before you operate the switch, refer to Working with the Excavator.K Working With The Excavator ( T 146). Hammer Switch (if fitted) Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Before you operate the switch, refer to Overload Warning System (if Fitted) K Overload Warning System (If fitted) ( T 118). Loader Quickhitch (if fitted) Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position. Position 1: OFF

-332-F8808-2

Position 1: OFF (Backlight OFF) A339941-1

Position 2: ON (Backlight ON) Before you operate the switch, refer to Hammer (if fitted), Hydraulic Tool Circuit (HTC) or Hydraulic Flow Control (HI / LO mode) K Hammer (If Fitted) ( T 324), K Hydraulic Tool Circuit (H.T.C) (If fitted) ( T 331), K Hydraulic Flow Control - EcoDIG (If fitted) ( T 67).

-701-E8866

Hydraulic Flow Control - EcoDIG (if fitted)

Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

Before you operate the switch, refer to Hydraulic Tool Circuit (HTC) K Hydraulic Tool Circuit (H.T.C) (If fitted) ( T 331).

52

HI

Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position.

LO

Position 1: High Backlight ON)

332-G0109-3

Position 1: OFF (Backlight OFF) Position 2: ON Hydraulic pump flow (Backlight ON)

Position 2: ON - Push and Hold (Buzzer sounds)

Before you operate the switch, refer to Loader Quickhitch (Powered) (Attachments Section) K Loader Quickhitch Attachments ( T 299).

Hydraulic Tool Circuit Switch (if fitted)

HTC

Position 2: OFF - Digging Position (Backlight OFF)

flow

rate

(Green

Position 2: Low flow rate (Red Backlight ON)

Before you operate the switch, refer to EcoDIG (Operation Section) K Hydraulic Flow Control EcoDIG (If fitted) ( T 67).

9821/3000-3

52

Operation Drive Controls, Switches and Instruments Bi-Directional and Hammer Mode Selector (if fitted)

Seat Mounted Switches Excavator/Loader Control Selector (if fitted)

332-F8808-1

Three position rocker switch with backlights. The switch functions operate when the starter switch is in the ON position. Position 1: Bi-Directional mode - for use with double acting attachments (Bi-directional Backlight ON) Position 3: OFF (Backlight OFF) Position 2: Hammer mode - for use with single acting attachments (Hammer Backlight ON) Before you operate the switch, refer to Bi-Directional and Hammer Circuits (Optional Attachments Section) or Hydraulic Flow Control (HI / LO mode) and Hammer Circuits (If K Bi-Directional fitted) ( T 326), K Hydraulic Flow Control - EcoDIG (If fitted) ( T 67).

T027680-5

Three position rocker switch with backlights. The switch functions operate when the starter switch is in the ON position. Position 1: Excavator controls enabled (Excavator Backlight ON) Position 3: Neutral (Backlight OFF) Position 2: Loader controls enabled (Loader Backlight ON) Before you operate the switch, refer to Operating Levers. Excavator/Loader Control Selector (if fitted) Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position. Position 1: Excavator controls enabled (Backlight OFF) A340000-1

Position 2: Loader controls enabled (Backlight ON)

Before you operate the switch, Levers.

53

9821/3000-3

refer to Operating

53

Operation Drive Controls, Switches and Instruments Roof Switches Hot Drinks (if fitted) Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position. Position 1: OFF (Backlight OFF) Position 2: ON (Backlight ON) 701/H3026

Before you operate the switch, refer to Hot Drinks Machine K Hot Drinks Machine (If fitted) ( T 59).

Heated Front Screen (if fitted) Two position rocker switch with backlight. The switch functions operate when the starter switch is in the ON position. Position 1: OFF (Backlight OFF) Position 2: ON (Backlight ON) 701/E8878

Before you operate the switch, refer to Heated Front Screen K Heated Front Screen (If fitted) ( T 59). Note: The front and rear worklights override this switch, make sure the worklights are switched off before operating this function.

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54

Operation Drive Controls, Switches and Instruments Multi-Purpose Steering Column Switch 1

Turn Signals (Right)

T2-058

Pull the lever towards you to indicate a right turn. Switch the turn signals off when you have completed the turn. Functions only with the starter switch at position I. 2

Turn Signals (Left) Push the lever away from you to indicate a left turn. Switch the turn signals off when you have completed the turn. Functions only with the starter switch at position I.

3

Windscreen Wiper Rotate the lever barrel to switch the windscreen wipers on and off. The following functions are available (only with the starter switch turned on).

146040-1

Fig 37.

J Intermittent Wipe 0 Off I Slow II Fast 4

Windscreen Washer Push the button towards the steering wheel to operate the windscreen washer. Functions only with the starter key at position I.

5

Headlights Flash Lift the lever to flash the headlights. Functions only with the starter switch at position I.

6

Headlight/Main Beam Push the lever down for main beam. Centre position is low beam. Functions only with the parking/head lights on. Switch the high beams off for on-coming vehicles.

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55

Operation Drive Controls, Switches and Instruments 4 Wheel Drive Select Switch

2 Wheel Steer Machines Only

Note: The transmission will default to 2-wheel drive when 4th gear is selected (Powershift Machines Only).

This is a three position rotary switch C that allows the operator to select the status of the drive/brake system. The two modes are:

4 Wheel Steer Machines Only – Position 2 - Two Wheel Drive-All Wheel Braking Note: With 2-wheel drive selected, when the brake pedal or handbrake is activated, the machine will automatically go into 4-wheel drive and the indicator light on the switch will lluminate.

Use this position when travelling on public highways. Make sure that the lockplate is engaged. – Position 3 - Two Wheel Drive-Two Wheel Braking

Press down the rocker switch A for 4-wheel drive, the switch will illuminate. K Fig 38. ( T 56).

– Position 4 - Four Wheel Drive-All Wheel Braking Use this position when operating in heavy duty site conditions, for instance, deep mud, undulating surfaces, slurry etc. The switch has a flexible lockplate. The lockplate locks the selector switch in Position 2 (2WD - All Wheel Braking) when the machine is driven on public highways. To unlock the switch, depress the lockplate B and turn the switch to the required position K Fig 39. ( T 57).

A

Note: Front wheel braking is via the drive to the front axle (there are no 'brakes' in the front axle). When Position 2 is selected, the machine is in 2-wheel drive. However, when the brakes are applied, a microswitch operated by the movement of the brake pedals automatically engages 4wheel drive. This has the effect of 'all wheel braking'.

402520-4

Fig 38. 4WS Machines Only

56

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56

Operation Drive Controls, Switches and Instruments Starter Switch This is operated by the starter key. It has four positions. The key can be removed only with the switch set to 0.

2

0

Turn the key to this position to stop the engine. Make sure the transmission is in neutral, the attachments have been lowered and the park brake is engaged before stopping the engine.

I

Putting the switch to this position connects the battery to all the electrical circuits except the lights and the hazard warning circuit. (The lights and hazard warning circuits are permanently live.) The starter key will spring back to this position when it is released from II or III. At -10°C (14°F), the Cold Start warning light will illuminate to indicate the cold start inlet manifold heater has come on. Refer to Warning Lights.

II

This position is not used in this application

III

Operates the starter motor to turn the engine. As soon as the engine starts, release the key which will return to the run position

2WD 2WD 4W(O) 4WD 2W(O) 4W(O)

C 3

4

B

402531-2

Fig 39.

!MCAUTION Do not operate the starter motor for more than 20 seconds at one time. Let the starter motor cool for at least 2 minutes. 0124

Note: If the engine does not start at the first attempt, return the key to the off (O) position and allow the starter to cool for a few minutes before attempting to start the engine again.

H04432-4

Fig 40.

57

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57

Operation Drive Controls, Switches and Instruments Removing and Installing the Radio (If fitted)

Auxiliary Power Socket

If your machine has a radio fitted we suggest that you remove the radio from its carrier at the end of each working day.

The socket X supplies a 12 Volt DC power supply to electrical accessories (from the battery). Only connect items which are compatible with the power rating of the socket (Refer to Electrical System, Fuses) and have the correct plug.

To remove the radio, gently pull radio carrier handle. To install, make sure you have the radio positioned the correct way up. Otherwise you may damage the connecting pins. Gently push the radio into position.

Always operate the engine during prolonged use of electrical accessories, otherwise the battery can discharge. Make sure that the socket cap is closed when the socket is not in use.

X

T039550-10

Fig 41.

Cab Interior Light

Fig 43. T2-020

Press either end of the light unit A to switch on the cab interior light. Pressing the other end will switch the light off. Make sure the light is turned off when you intend to leave the machine for a long period of time.

C007130-1

Fig 42.

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58

Operation Drive Controls, Switches and Instruments Hot Drinks Machine (If fitted)

Heated Front Screen (If fitted)

Note: If the hot drinks machine switch is on it will isolate the servo controls on Advanced Easy Control machines.

The heated front screen option provides a fast defrost function at start up in cold temperatures. Press the switch A in the roof to activate this function, the backlight in the switch will illuminate to indicate the function is ON, the switch will automatically turn off after approximately 10 minutes K Fig 45. ( T 59).

This option is designed to be located in the cupholder / beacon storage position. Make sure the machine is in neutral, with the park brake ON, the rear work lights OFF and the control levers isolated:– Control lever locks B fitted (Manual and Easy Control Lever Locks (If Machines) K Control Fitted) ( T 117)

Note: This option will only operate when the ignition is ON and the front and rear worklights are switched OFF. Note: Demist is available using the Cab heater controls. K Air Conditioning and Cab Heater Controls ( T 75).

– Excavator/Loader switch in the central position C (Advanced Easy Control Machines) K Switches ( T 50),

D 123

before you operate K Fig 44. ( T 59).

the

hot

drinks

machine.

Mo Mo AM PM Tu Di We Mi Th Do Fr Fr Sa Sa Su So

A

P

O K

Press the switch D to activate this option, the backlight in the switch will illuminate to indicate the function is ON. K Fig 45. ( T 59). Follow the manufacturers instructions for operation and cleaning instructions.

795860-2

Fig 45.

D

C

B T053820

Fig 44.

59

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59

Operation Drive Controls, Switches and Instruments

Instruments

5

The driving indicators are located on the front console. There are additional instruments and gauges located at the side of the driver's seat.

Direction indicators. Flashes with the direction indicators. Use the indicators to signal before turning the machine.

6

All instruments power down when the starter switch is set to O, apart from the hazard warning lights indicator K Starter Switch ( T 57).

Crab Wheel Steer. Lights ( T 49).

K Steer

Mode

Indicator

1

8

7

6

3

4

5

11

2

B

9

10

Front Console On the front console, the master warning light (and buzzer) B will illuminate when any of the following warning lights on the side console are illuminated: K Fig 46. ( T 60). Air Filter Blocked; Water Temperature; Transmission Oil Temperature; Engine Oil Pressure; Park Brake Engaged; Transmission Oil Pressure.

T052360-2

Fig 46. Front console There are also additional warning lights mounted in the front console. The master warning light B is also linked with the front console lights 2 - Service Brake Malfunction, 9 - Stabiliser leg down and 10 - Water in Fuel indicator K Fig 46. ( T 60).

7

2-Wheel steer. Lights ( T 49).

K Steer

Mode

Indicator

8

4-Wheel steer. Lights ( T 49)

K Steer

Mode

Indicator

9

Stabiliser legs. K Stabiliser Controls ( T 108).

Warning Lights 1

Main beam on. Lights up when the headlight main beams are switched on. Switch the main beams off for oncoming vehicles.

2

10

Rear fog light. Lights up when the rear fog light is switched on.

Service Brake Malfunction. If the master buzzer sounds or brake warning lights up to indicate a brake pressure failure, bring the machine safely to a halt as soon as possible. Do not use the machine again until the brake system is serviceable.

3

Lights up when the stabiliser legs are down (and drive is selected in certain countries).

11

Torque converter lock up. Lights up when the torque converter is locked up, for description and operation. K TorqueLock (EcoROAD) ( T 70).

Front work lights. Lights up when the front work lights are switched on.

4

Rear work lights. Lights up when the rear work lights are switched on.

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60

Operation Drive Controls, Switches and Instruments Speedometer Option

temperature enters the red zone, an alarm will sound and the Malfunction Indicator Lamp will illuminate and a critical fault will be raised K Fig 48. ( T 62).

Indicates the road speed in miles per hour (MPH) and/or kilometres per hour (km/h). K Fig 47. ( T 61).

Note: These warnings will remain active until the temperature drops below the red zone. Stop the machine as soon as safety permits and switch OFF the engine. This will allow the temperature to reduce. 4

Fuel gauge.

20 30

10

40

Indicates the level of diesel fuel in the tank. Do not let the tank run dry, or air will enter the fuel system. Replenish at the earliest opportunity, if the tank empties the engine may require bleeding to start. K Refuelling the Machine ( T 171)

30

20

50

10 MPH

0

km/h 60

40

a

LOW FUEL - As pointer reaches red zone. Amber MIL lamp. The digital display will show a text message when the fuel level is less than 20 litres (4.3 gallons) for 2.5 seconds. LOW FUEL will be displayed when the fuel gauge enters the red area and the buzzer will sound for 1 second..

b NO FUEL - Amber MIL lamp displays NO FUEL. When the fuel goes to less than 10 litres (2.15 gallons) for 2.5 seconds. The buzzer will sound for 1 second when the fuel level goes up to more than 10 litres (2.15 gallons). Fig 47.

5

Side Console

The Clock must be on, press the increase E+ or the decrease E- button to adjust the time. For rapid adjustment, press and hold either button for 5 seconds K Fig 48. ( T 62).

The side console is located at the side of the drivers seat, for indicator and gauge positions. K Fig 48. ( T 62). 1

Note: The clock cannot be adjusted from the fuel computer or error code screen.

Tachometer. Indicates the engine speed in revolutions per minute (RPM). The RPM is shown on the outer ring. Each division is 500 RPM. A green band on the scale indicates the RPM which gives best fuel economy. Operate within that band whenever possible K Fig 48. ( T 62).

2

Digital Display. K Digital Display ( T 64).

3

Coolant temperature gauge.

Cab clock.

6

Warning Lights. K Warning Lights ( T 62).

Indicates the temperature of the engine coolant. The gauge pointer will gradually swing upwards as the coolant temperature increases. When the coolant

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61

Operation Drive Controls, Switches and Instruments Warning Lights

3 5

1

Red Malfunction Indicator Lamp (MIL) - (Critical Fault). The digital display LCD will show STOP NOW and a continuous buzzer will sound. Stop the machine immediately, rectify the fault or contact your JCB distributor for advice.

2

Water in Fuel Sensor detected - LCD message WATER IN FUEL displayed. Warning light ON continuously. Amber MIL lamp and 1 second buzzer. Fault code raised. Drain water from water separator bowl. Refer to K Water Separator and Engine Fuel Filter ( T 255).

3

Amber Malfunction Indicator Lamp (MIL) - Service Fault. The LCD flashes SERVICE, a buzzer tone for 1 second when a fault occurs. Certain operator faults will display an instruction.

2

6 E+ E-

4

1 T039550-71

Fig 48.

Note: If lights 4, 6, 7, 8, 9 come on while the engine is running, stop the engine as soon as it is safe to do so. Do not use the machine until the fault is put right These lamps will flash to indicate less critical faults are present K Fig 49. ( T 63). 4

No charge. Amber MIL Lamp - Lights if the battery charging circuit fails while the engine is running. The LCD flashes SERVICE, a buzzer tone for 1 second when a fault occurs. The light should go out a few seconds after the engine is started.

5

Park brake engaged. Lights when the park brake is engaged with the machine in forward or reverse. The buzzer will also sound if forward or reverse drive is selected.

6

Engine oil pressure low / Coolant temperature high. Red MIL Lamp - Operates if the engine oil pressure drops too far. Red MIL Lamp - Operates if the engine coolant overheats. The light should go out after the engine is started. Amber MIL Lamp flashes SERVICE, a buzzer tone for 1 second if Engine oil pressure, Coolant temperature or the Engine speed is faulty.

62

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62

Operation Drive Controls, Switches and Instruments 7

Transmission oil (Pressure low / Temperature high). Red MIL Lamp - Lights if the transmission oil pressure drops too far / oil temperature rises too far. The light should go out after the engine is started. Amber MIL Lamp Flashes SERVICE, a buzzer tone for 1 second if a fault occurs.

8

Air filter blocked. When illuminated it could indicate that the engine air filter is blocked. If the air filter warning light comes ON, stop the machine and switch OFF the engine. After a short pause start the engine. If the warning light has extinguished carry on operating the machine in the normal manner. If the warning light is still illuminated after the engine has been started check that the engine air filter elements are not blocked. Amber MIL Lamp Flashes SERVICE, a buzzer tone for 1 second if a fault the Air Filter occurs. K Changing Elements ( T 232).

9

Wait to Start With the starter switch in position I, if the outside air temperature is -10ºC (16ºF) or below the light will illuminate indicating that the manifold heater (if fitted) is ON. When the light extinguishes the engine is ready to start. MIL Lamp Flashes if a fault occurs (Where this option is fitted). K Starter Switch ( T 57).

9

2

1

7 8

3

6 5

4

T039550-72

Fig 49.

63

9821/3000-3

63

Operation Drive Controls, Switches and Instruments Digital Display

Press the Information switch B to move to the next information screen.

The digital display A is located on the side console. K Fig 50. ( T 64). The digital display contains the following information screens:

Example of operation: 1

1

Total Vehicle Hours

2

Time Until Next Service

3

Fuel Computer

4

Fault Code List (only when faults are active)

Display 1 - Vehicle Hours The total running time of the engine is shown in increments of 0.1 hours. In the example, the current running time is 1185.4 hours. A service book icon will flash if a service is due.

Note: When the display is set to the Vehicle Hour screen, the Hour Glass symbol 1A comes on K Fig 50. ( T 64). 2

The Time Until Service is the difference between the next service interval and the current Vehicle hours. In the example, the Time Until Service is 314.6 hours (1500 hours - 1185.4 hours).

B A

4

4A

Note: When the display is set to the Time Until Service screen, the Service symbol 2A comes on permanently. A negative number means you have gone past the service interval K Fig 50. ( T 64).

1

P00001

Note: When you complete a machine service, make sure that you reset the value shown on the Time Until Service screen. K Resetting The Time Until Service Screen ( T 65).

1A L/h > 7.2

3

3

3A

2

Display 2 - Hours to Service

Display 3 - Fuel Computer a

2A

current fuel rate

b Trip average fuel rate T039550-81

Fig 50.

c

Fuel range of the machine (based in hours, assuming the average fuel rate is maintained)

Starter Switch OFF To view the current vehicle hours, switch ON the side lights. In this mode, the digital display will show the Total Vehicle Hour screen 1 K Fig 50. ( T 64). Starter Switch ON As a system check, all of the LCD segments illuminate briefly when the starter switch is set to position I K Starter Switch ( T 57).

64

9821/3000-3

Use the arrow buttons C to navigate around the fuel data K Fig 52. ( T 65). The trip average fuel rate and the fuel range use a fuel trip computer. To reset the trip computer, short press the information button B. The display will show RESET and a buzzer tone will sound to acknowledge the reset.

64

Operation Drive Controls, Switches and Instruments 4

Display 4 - Fault Code List

Resetting The Time Until Service Screen

This screen will appear if faults are active. Position icons 4A indicate where you are in the list K Fig 50. ( T 64).

When you complete a machine service, make sure that you reset the value shown on the Time Until Service screen.

Use the arrow buttons C to navigate up and down the list K Fig 52. ( T 65).

1

Make the machine safe with the loader arm lowered. the Machine for Refer to K Prepare Maintenance ( T 206).

2

Make sure that the park brake is engaged, then Switch ON the ignition.

3

Quickly push then release the Information i button. Repeat as necessary until the Time Until Service screen (with the open book symbol 1) is shown on permanently.

a

top of list

b middle of list c

bottom of list

d no icon - only one item in list

a b

i

c

C

T039550-86

Fig 51. Red or Amber MIL lamp flashes to show severity of the currently displayed fault. Fault codes scroll, followed by description.

RESET SERVICE INTERVAL

SERVICE INTERVAL RESET

T039550-82

Fig 52. 4

65

9821/3000-3

Push then hold the Information button for 20 seconds. Release the information i button.

65

Operation Drive Controls, Switches and Instruments

2

se c

i

Quick Press: < 2 Secs Short Press: >= 2 Secs And < 20 Secs

5

Units - To change the Unit options, enter into this option and select METRIC, IMPERIAL or US IMPERIAL. Push then hold the Information i button for two seconds to store the option STORED.

6

Scroll Speed - To change the scroll speed choose from Regular, Fast or Slow. Push then hold the Information i button for two seconds and a buzzer beeps to acknowledge the option is STORED.

7

Time to next Service - Shows time until next service Interval.

8

Service Interval Reset - Use this option to reset the time until next service Interval. As described above.

9

Grid Heater - To change the Grid Heater options, enter into this option and select Fitted or Not Fitted. Push then hold the Information i button for two seconds and a buzzer beeps to acknowledge the option is STORED.

10

Pump Type - To change the Pump option and associated control. Select from CCVP or GEAR PUMP. Push then hold the Information i button for two seconds and a buzzer beeps to acknowledge the option is STORED.

11

Block Heater - To change the Block Heater options, enter into this option and select FITTED or NOT FITTED. Push then hold the Information i button for two seconds and a buzzer beeps to acknowledge the option is STORED.

12

Buzzer Mute - To change the Buzzer mute options. Select MUTED BUZZER or ACTIVE BUZZER. Only works on 1 cycle of ignition switch, defaults to ON every time the ignition is switched off. Exit - Exits from the service options screen.

20

se c

i

hold the Information i button for two seconds and a buzzer beeps to acknowledge the option is STORED.

i

Long Press: >= 20 Secs Fig 53.

5

6

Use the up or down arrow button C to navigate to the 8>SERVICE INTERVAL RESET to 8A>RESET SERVICE INTERVAL (other options can be changed here, refer to Machine Options) K Fig 52. ( T 65). Push then hold the Information i button for two seconds to reset the service hours (The word RESET flashes up for 2 seconds and a buzzer beeps). Release the information i button.

7

Quickly press the Information i button to go back up one level. K Fig 52. ( T 65).

8

Use the up or down arrow buttons to move to 13>Exit.

9

Quickly push then release the Information i button to go back to the normal display screens.

Machine Options Listed below are the information screens to tell you about the status of your machine: 1

Fault List - Lists current active diagnostic fault codes.

13

2

Software Version - Shows the Software version of the Instrument panel.

Note: Do not change the Grid heater, Pump Type or Block Heater options without consulting your JCB distributor.

3

Hardware Version - Shows the Hardware version of the Instrument panel.

4

Language - To change language, enter into this option and select the language required. Push then

66

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66

Section One - Backhoe Familiarisation Drive Controls, Switches and Instruments

TorqueLock Description T2-035

This feature is designed to eliminate torque converter slip when roading, providing improved fuel consumption and machine road performance. Because the torque converter ratio remains 1-1 in top gear this does not alter the overall top speed. The Torque Lock feature is automatically engaged by the transmission Electronic Control Unit (ECU) hydraulically engaging a clutch plate in the converter at a pre determined machine road speed and engine RPM preventing torque converter slip.

Because the ECU is programmed only to lock up when it senses minimal torque converter slip (the difference between the engine RPM and road speed), with practice the lock up engagement can be brought in earlier by momentarily releasing the foot throttle to reduce the engine rpm then re-applying once the lock up is felt to occur. It is good practice to endeavour to drive the machine on the road with the torque converter locked up as further fuel saving can be achieved over the normal torque converter operation.

This feature would normally only engage when the machine is driven at road speeds, and will disengage automatically when the machine or engine speed fall below these settings. Selecting reverse or engaging the park brake will also disconnect the lockup.

Operation P2-2007

1

6-Speed transmission. a

When A is engaged on the column switch the machine will engage 4th gear. Higher gears and the lock up will engage automatically at the predetermined settings.

b Lock up operates in 5th and 6th gear only. c

When the foot throttle pedal is in the up position e.g. descending hills in a low gear, the machine will hold 4th or 5th gear and not change up.

d Kick down remains unchanged from the standard machine but does not operate in auto or lock up mode. 2

4-Speed transmission. a

When 4th gear is engaged on the column switch the lock up will engage automatically at the predetermined settings and disengage in a similar way or when other gears are selected.

b Lock up operates in 4th only. c

112

There is no kick down fitted with the 4-speed option.

9817/0000

112

Section Two - Maintenance Contents

Section Two - Maintenance Contents - Service Schedules - Fluids, Lubricants and Capacities

113

9817/0000

113

Section Two - Maintenance Contents Notes:

114

Notes:

9817/0000

114

Section Two - Maintenance Service Schedules

Service Schedules Introduction

How to Use the Service Schedules T3-036-2

T3-012_3

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.

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

!MWARNING

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

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

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately. 795390-1

Calendar Equivalents Every 10 Hours = Daily

T3-051

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

115

9817/0000

115

Section Two - Maintenance Service Schedules

Pre-start Cold Checks, Service Points and Fluid Levels Operation

10

50

100(1)

500

1000 2000 6000

ENGINE Coolant Quality and Level Cooling System Oil level

- Check - Drain and Refill - Check

Oil and Filter (2)(3)

- Change

Air Cleaner Outer Element(4)

- Change

Air Cleaner Inner Element

- Change

Water Separator and Engine Fuel Filter

- Drain

Water Separator Fuel Filter(5)

- Change

Engine Fuel Filter(5)

- Change

Front End Accessory Drive (FEAD) Belt Condition

- Check

Front End Accessory Drive (FEAD) Belt

- Change

Engine Mounting Bolts for Tightness

- Check

All Hoses - Condition

- Check

Radiator(4)

- Clean

Breather Gauze

- Clean

Valve Clearances(6)

- Check and Adjust

Oil Filler and Dipstick Seals(6)

- Check and Adjust

Rocker Cover and Injector Seals(6)

- Change

Injectors(6)

- Change

Injector(s) Leak Off Rail(6)

- Change

High Pressure Fuel Lines(6)

- Inspect

TRANSMISSION, AXLES AND STEERING Transmission Oil Level

- Check

Transmission Oil(7)

- Change

Transmission Filter

- Change

Axle Oil Level (incl. Hubs when applicable)(8)

- Check

Axle Oil (incl. Hubs when applicable)(9)

- Change

Axle Oil - Limited Slip Differential

- Change

Tyre Pressures and Condition

116

- Check

9817/0000

116

Section Two - Maintenance Service Schedules Operation Wheel Nut Security

- Check

Front Hub Bearings

- Check

Transmission Strainer

- Clean

Drive Shafts(10) Steer Axle Movement and Shimming(6)

10

50

100(1)

500

1000 2000 6000

- Security and Grease - Check

Steer Axle Pivots and Linkages(10)

- Grease

Front Axle Main Pivot

- Grease

HYDRAULICS Oil Level(11) Oil Oil Filter

- Check - Sample, Change - Change

Rams - Chrome Condition

- Check

Hydraulic Oil Cooler

- Clean

Hydraulic Oil Strainer

- Clean

Hydraulic Tank Filler Cap (with integral filter)

- Change

Hammer 1inch (diameter) return line Filter (if fitted)

- Change

BRAKES Brake System Fluid Level Brake System Fluid Park Brake

- Check - Change - Check and Adjust

ELECTRICS Battery Electrolyte Level (if applicable)

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

BODYWORK AND CAB All Pins and Bushes

- Check and Grease

Door/Window Hinges

- Lubricate

All Cables

- Lubricate

Cab Heater Fresh Air Filter(4)

- Clean/Change

Cab Air Conditioning Recirculation Filter (if fitted) (4)

- Clean/Change

Extending Dipper

- Adjust/Grease

117

9817/0000

117

Section Two - Maintenance Service Schedules Operation Hydraclamp

- Check

Cab Seat - Operation

- Check

Front Mudguards - Security (if fitted)

- Check

Windscreen Washer Fluid Level

- Check

Boom Lock Engagement

- Check

Condition of Paintwork

- Check

Machine Generally

500

1000 2000 6000

- Check and Clean - Grease

Power Sideshift Wear Pads

- Check

Power Sideshift Chain Tension

100(1)

- Check/Adjust

Power Sideshift Wear Pads

Power Sideshift Chain

50

- Check and Adjust

Door - Fit and Catches

Stabiliser Legs (Sideshift)

10

- Lubricate - Check/Adjust

ATTACHMENTS 6-in-1 Clam Shovel

- Grease

Backhoe & Loader Quick Hitch

- Grease

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) If operating under arduous conditions, change the engine oil and filter every 250 hours. (3) The oil service interval will be affected if there is a high sulphur content in the fuel. Refer to Fuel System for more information. (4) If operating in dusty working environments, change more frequently. (5) If the engine is difficult to start or the engine has poor performance, fit new filters. For the water separator filter, use a 30 micron filter for normal conditions and a 150 micron filter for cold climate (-10°C, 14°F). (6) Jobs which should only be done by a specialist. (7) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (8) Check for leaks every 50 hours, check level if leaking. (9) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted. (10) The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice. (11) Check the hydraulic fluid level with the loader and backhoe in the travel position.

118

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118

Section Two - Maintenance Service Schedules

Functional Test and Final Inspection Operation

10

50

100(1)

500

1000 2000 6000

ENGINE - Check and Adjust

Idle Speed(2) (2)

- Check and Adjust

Exhaust Smoke (excessive)

- Check

Maximum No-Load Speed

- Check

(2)

Exhaust System Security Air Inlet System Security

- Check

Throttle System and Control Cable

(2)

- Check

TRANSMISSION, AXLES AND STEERING Steer Modes - Operation/Phasing

- Check

2WD/4WD Selection

- Check

Wheel Nuts Torque

- Check

Forward/Reverse and Gear Change Operation

- Check

Hydraulic Speed Control - Operation (if fitted)

- Check

Steer Circuit Pressure(2)

- Check

Transmission Main Line Pressure(2)

- Check

Transmission Dump Operation

- Check

Neutral Start Operation

- Check

Clutch Pack Pressures(2)

- Check

HYDRAULICS - Check and Adjust

MRV Pressure(2) Operation All Services

- Check

Hose Burst Protection Valves (if fitted)

- Check - Check and Adjust

Offloader Valve Pressure(2) (2)

Auxiliary Circuit & Pressures

- Check and Adjust

BRAKES Foot Brake - Operation

- Check

Park Brake - Operation

- Check

Servo Operation (if fitted)

- Check

ELECTRICS Starter Motor

- Check

Alternator - Output

- Check

119

9817/0000

119

Section Two - Maintenance Service Schedules Operation All Electrical Equipment Operation, (e.g. warning lights, beacon, alarms, horn, wipers etc.)

- Check

Operation of Stop Control/E.S.O.S.

- Check

10

50

100(1)

500

1000 2000 6000

BODYWORK AND CAB Teeth and Side Cutters

- Check

Doors and Windows - Fitment/Leaks

- Check

Seat/Seat Belts

- Check

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

120

9817/0000

120

Section Two - Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the

ITEM

CAPACITY

Fuel Tank

Litres

UK Gal

150

33

Engine (Oil)

Min.

12

2.64

Max.

15

3.3

engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load).

Table 1. FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Diesel Oil

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

JCB Extreme Performance

SAE 15W/40, ACEA E5/B3/ A3,API CH-4/SG

(-10°C to +50°C (14°F to 122°F) JCB Cold Climate Engine Oil

SAE 5W-40, ACEA E5/B3/A3, API CH4/SJ

(-20°C to +50°C (-4°F to 122°F) ! CAUTION: DO NOT USE ORDINARY ENGINE OIL (1)

Engine (Coolant)

Syncro Shuttle (2WD)

(2)

Syncro Shuttle (4WD)(2)

Powershift 6 speed

Powershift 4 speed

(2)

(2)

17.5

3.85 Wet JCB High Performance Antifreeze and Inhibitor/ Water.

18.5

4.07 Dry

14.4

3.2 Dry

JCB Extreme Performance

10

2.2 Wet

-32ºC to 40ºC (-25ºF to 104ºF)

10W, EL4117

-5ºC to 46ºC (23ºF to 115ºF)

SAE30, EL4118

15.4

3.4 Dry

JCB Extreme Performance

11

2.4 Wet

-32ºC to 40ºC (-25ºF to 104ºF)

10W, EL4117

11

2.4 Wet

-5ºC to 46ºC (23ºF to 115ºF)

SAE30, EL4118

16

3.5 Dry

JCB Extreme Performance

11.5

2.5 Wet

-32ºC to 40ºC (-25ºF to 104ºF)

10W, EL4117

-5ºC to 46ºC (23ºF to 115ºF)

SAE30, EL4118

15.5

3.4 Dry

JCB Extreme Performance

11

2.4 Wet

-32ºC to 40ºC (-25ºF to 104ºF)

10W, EL4117

-5ºC to 46ºC (23ºF to 115ºF)

SAE30, EL4118

JCB HD90 Gear Oil (without LSD)

API-GL-5 API-GL-4

Front Axle (4WD) Housing (2WS)

ASTM D6210

13

2.86

JCB Gear Oil HP Plus (with LSD)

Housing (4WS)

18

3.96

Must be suitable for use with limited slip differentials (LSD).

Hubs (x2)

2.0

0.44

(3)

Rear Axle (4WS) Housing Hubs (x2)

JCB Gear Oil HP Plus 16.5

3.62

1.9

0.41

Rear Axle (2WS)

21

4.61

Brake System

1.4

0.3

121

API-GL-4

Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

JCB Light Hydraulic Fluid

9817/0000

ISO VG15

121

Section Two - Maintenance Fluids, Lubricants and Capacities ITEM

CAPACITY

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

! CAUTION: DO NOT USE ORDINARY BRAKE FLUID Hydraulic System (4)

130

28.6

JCB High Performance Hydraulic Oil

ISO VG46

(Above 38 °C, 100 °F) JCB Hydraulic Fluid HP32

ISO VG32

(Below 38 °C, 100 °F) Grease Points

---

---

JCB HP Grease

Lithium complex NLGI No.2 consistency including extreme pressure additives

or JCB Special MPL-EP Grease(5)

Lithium based NLGI No.2 consistency including extreme pressure additives

Extending Dipper

---

---

Waxoyl(6)

Electrical connections

---

---

As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.

Power Sideshift Chains

---

---

JCB Chain Lubricant

(1) 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. (2) The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within 1.0 litre (0.22 U.K. gal). (3) 4WS axles with limited slip differential must use JCB Special Gear Oil Plus. (4) The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank. (5) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently. (6) WARNING: Waxoyl contains turpentine substitute, which is inflammable. 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.

122

9817/0000

122

Section Three - Electrics 3CX / 4CX - Schematic Circuits Notes:

136

Notes:

9817/0000

136

Section Three - Electrics Contents - 3CX / 4CX Fuses and Relays - 3CX / 4CX Schematic Circuits - Wire and Harness Number Identification - Earth Point Locations - Harness Data

123

9817/0000

123

Section C1 - Electrics Fuses and Relays Fuses (Manual Controls) S1

Fuses (Manual Controls) S1

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

Fuse Circuit No.

Fuse Rating

A4

Steer mode proximity switches

7.5

A5

Transmission

10

8-3-3-5

A6

3

The electrical circuits are protected by fuses. The fuses are located in the side console underneath cover A. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

Gear select - Forward/Reverse - Lock up torque converter speed sensors (if fitted)

A7

Transmission

10

A8

Brake lights

7.5

A9

Left hand side lights

5

A10

Right hand side lights

5

B1

Instruments, Buzzer

5

B2

Front horn, Front washer/wiper

15

B3

Rear horn

7.5

B4

Heated seat, Cigar lighter, face level fan 15

B5

Rear washer/wiper

10

B6

Brake switch

10

Return to dig, Smooth ride system (SRS)

5

B8

Rear working lights

25

B9

Headlights, heated screen

20

B10

Front working lights

25

C1

Lights

7.5

C2

Hazard warning lights, immobiliser

15

C3

Beacon, Interior light

10

C4

Radio

5

C5

Thermostart

3

C6

Heater blower

30

C7

Ignition relay coils, immobiliser

3

C8

Main beam

15

C9

Fog light

3

C10

Dip beam

15

Note: All the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

C

10 9 8 7 6 5 4 3 2 1

A

B

R12

R8

R13

R9

B7

R1

A

R3 R2

A

Fig 1.

711260-C1

Table 3. Fuse Circuit No.

Fuse Rating

A1

Engine shut-off solenoid (ESOS)

10

A2

Auxiliary hydraulics

10

A3

Direction indicators

7.5

C1-4

(1)

(1) 10 Amp if Smooth Ride System (SRS) with Hose Burst Protection Valves (HBPV) is fitted.

9813/0250-04(C-09-04)

C1-4

Section C1 - Electrics Fuses and Relays Fuses (Manual Controls) S2

Fuses (Manual Controls) S2

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

The electrical circuits are protected by fuses. The fuses are located in the side console underneath cover A. If a fuse ruptures, find out why and rectify the fault before fitting a new one. Note: All the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

Fuse Circuit No.

Fuse Rating

A8

Brake lights

7.5

A9

Left hand side lights

5

A10

Right hand side lights

5

B1

Instruments, Buzzer

5

B2

Front horn, Front washer/wiper

15

B3

Rear horn

7.5

B4

Heated seat, Cigar lighter, face level fan 15

B5

Rear washer/wiper

10

Brake switch

10

Return to dig, Smooth ride system (SRS)

7.5

B8

Rear working lights

25

B9

Headlights

20

B10

Front working lights

25

C1

Lights

7.5

C2

Hazard warning lights

15

C3

Beacon, Interior light

10

C4

Radio

5

C5

Crank / ECU

3

C6

Heater blower

30

C7

Ignition relay coils

3

C8

Main beam

15

C9

Fog light

3

C10

Dip beam

15

B6 B7

10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

C R12

R13

10 9 8 7 6 5 4 3 2 1

B R8

R9

A R1

R3 R2 711260-1

Fig 3. Table 5. Fuse Circuit No.

Fuse Rating

A1

Blank

-

A2

Auxiliary hydraulics

10

A3

Direction indicators

7.5

A4

Steer mode proximity switches

7.5

A5

Transmission

10

A6

Gear select - Forward/Reverse - Lock up torque converter speed sensors (if fitted)

3

A7

Transmission

10

C1-6

(1)

(1) 10 Amp if Smooth Ride System (SRS) with Hose Burst Protection Valves (HBPV) is fitted.

9813/0250-04(C-09-04)

C1-6

Section C1 - Electrics Fuses and Relays Engine Fuse / Relay Box

Engine Fuse / Relay Box The engine fuse / relay box is located at the rear of the engine compartment on the LH side. For more information about the engine fuse / relay box refer to Section M. K Related Topics ( T C1-3)

R2

R3

Remember to check the main circuit relays / fuses as well as the link box fuses. Relay

Function

R1

Power Hold

R2

Starter

R3

Fuel Lift Pump

R1

Fuse Function

Rating

F1

Steer Proximity Switch (front axle)

10A

F2

Engine ECU (Power Supply)

10A

F3

Spare

10A

F4

Engine ECU (Power Supply)

10A

F5

Engine ECU (Power Supply)

10A

F6

Power Hold Relay Coil

3A

F7

Water in Fuel Sensor

3A

F8

Coolant level, Washer Coolant level

10A

F9

Engine ECU (Power Supply)

10A

F10

Spare

10A

F11

VGT Actuator

10A

F12

Spare

5A

F13

Exhaust Gas Recirculation Actuator

10A

F14

Starter Relay Coil

3A

F15

Fuel Lift Pump Motor

10A

F16

Fuel Lift Pump Relay Coil

3A

F17

Inlet Manifold Heater Relay Coil

5A

C1-9

F17 F16 F15 F14 F13 F12 F11 F10 F9 F8 F7

F6 F5 F4 F3 F2 F1

Fig 5.

717/h9667-2

Note: An additional maxi fuse is located on the battery which provides a live feed to the engine fuse / relay box from the battery. 1

9813/0250-04(C-09-04)

Engine fuse / relay box supply

50 Amp

C1-9

Section C1 - Electrics Fuses and Relays Link Box Fuses

Link Box Fuses To further protect the machine wiring harnesses and electrical circuits, a fuse link box A is fitted as shown. Remember to check the main circuit fuses as well as the link box fuses shown on this page. 1

Hazard warning lights, Parking lights, 40 Amp Face level fan

2

Wash and Wipe, Transmission, indicators

50 Amp

3

Work lights, Fog lights, Brake lights

60 Amp

4

Ignition, Heater, Thermostart

50 Amp

5

Cold start inlet manifold heater (if fitted)

120 Amp(1) 150 Amp(2)

6

Hot drinks machine (if fitted)

20 Amp

7

Heated front screen (if fitted)

70 Amp

(1) Mechanical F.I. Engines (2) Electronic F.I. Engines

6 A

7

5

3

1

4

2 Fig 6.

C1-10

9813/0250-04(C-09-04)

C005140-3

C1-10

Section C1 - Electrics Fuses and Relays Live Link Fuses

Live Link Fuses The Live Link ECU is protected by fuses. The fuses are located in the side console underneath instrument panel A. If a fuse ruptures, find out why and rectify the fault before fitting a new one.

A

1

2 3 Fig 7.

C126570

Fuse Function

Rating

1

Earth (- ve)

3A

2

Power supply (+ ve)

3A

3

Engine running signal

3A

C1-11

9813/0250-04(C-09-04)

C1-11

Section C1 - Electrics Fuses and Relays Relays (Manual Controls) S1

Relays (Manual Controls) S1 Side Console The relays listed below are located in the side console underneath cover A.

A

Note: All the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown.

Standard variant

Table 7. Immobiliser variant

1

Blank

Neutral

2

Ignition 1

Ignition 1

3

Bi-Directional 1

Bi-Directional 1

4

Bi-Directional 2

Bi-Directional 2

5

Direction indicators

Direction indicators

6

Hammer

Hammer

7

Blank

Neutral start

8

Blank

Blank

9

Ignition 2

Ignition 2

10

Blank

Headlights

11

Neutral start

Neutral start, HSC

12

Main lights

Main lights

13

Engine run

Engine run

14

Stabiliser leg alarm 1

Stabiliser leg alarm 1

15

Front working lights

Front working lights

16

Park brake warning light Park brake warning light

17

Rear horn, rear lights

Rear horn, rear lights

18

Hydraulic flow control

Hydraulic flow control

19

Instruments warning lights buzzer relay

Instruments warning lights buzzer relay

20

Stabiliser leg alarm 2

Stabiliser leg alarm 2

21

Rear working lights

Rear working lights

22

Boom overload alarm

Boom overload alarm

23

High Flow / ECO mode

High Flow / ECO mode

C1-12

9813/0250-04(C-09-04)

1

3

5 12

4

3

2

1

11 10

9

8

7

6

17 16

15 14 13 12

23 22

21 20 19 18

4

9

2

7

5

8

6 10

C089200-C1

Fig 8.

C1-12

Section C1 - Electrics Fuses and Relays Relays (Manual Controls) S1

Front Console There are additional relays located in the front console B. K Relays - 4 speed Powershift, Synchro Shuttle Machines ( T C1-26) K Relays - Shiftmaster Machines ( T C1-27) K Relays - Heated Front Screen ( T C1-28)

B

Fig 9.

Cab Front Bulkhead Machines with an immobiliser have additional relays mounted on the outside of the cab front bulkhead. K Relays - Cab Front Bulkhead ( T C1-29)

C1-13

9813/0250-04(C-09-04)

C1-13

Section C1 - Electrics Fuses and Relays Relays (Manual Controls) S2

Relays (Manual Controls) S2 Side Console The relays listed below are located in the side console underneath cover A K Fig 16. ( T C1-20).

A

Note: All the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown. Table 11. 1

Boom Overload

2

Ignition 1

3

Instruments

4

Ignition 2

5

Direction indicators

6

High Flow / ECO mode

7

HSC

8

Rear working lights

9

Front working lights

10

High Beam

11

Neutral Start

12

Blank

13

Hammer 1

14

Headlights

15

Engine Run

16

Park Brake

17

Rear Horn

18

Hammer / Bi-Directional 1

19

Hammer / Bi-Directional 2

20

Neutral flow

21

Neutral

22

Stabiliser leg alarm 2

23

Stabiliser leg alarm 1

C1-20

5 12

4

3

2

1

11 10

9

8

7

6

17 16

15 14 13 12

23 22

21 20 19 18

C089200-1

Fig 16.

9813/0250-04(C-09-04)

C1-20

Section C1 - Electrics Fuses and Relays Relays (Manual Controls) S2

Front Console There are additional relays located in the front console B. K Relays - 4 speed Powershift, Synchro Shuttle Machines ( T C1-26) K Relays - Shiftmaster Machines ( T C1-27) K Relays - Heated Front Screen ( T C1-28)

B

Fig 17.

C1-21

9813/0250-04(C-09-04)

C1-21

Section C1 - Electrics Fuses and Relays Relays - 4 speed Powershift, Synchro Shuttle Machines

Relays - 4 speed Powershift, Synchro Shuttle Machines

FC1 FB1 FC2 FB2

Note: Data not applicable to machines with lock up torque converter. K Relays - Shiftmaster Machines ( T C1-27).

FD1 FE1 FF1 FG1 FH1 FD2 FE2 FF2 FG2 FH2

Fig 22.

C065450-C1

The relays listed below are located in the front console. K Fig 22. ( T C1-26). FB1

Blank

FB2

Steer mode changeover

FC1

Brake lights

FC2

Auto 4 wheel drive in park mode

FD2

Forward HI/LO

FD1

Forward

FE2

Reverse HI/LO

FE1

Reverse

FF2

Interlock (1)

FF1

Drive (1)

FG2

Hydraulic speed control (HSC) cut-out

FG1

Transmission dump

FH2

Auto 2 wheel drive

FH1

4 Wheel Braking

(1) Blank on Synchro Shuttle machines.

C1-26

9813/0250-04(C-09-04)

C1-26

Section C1 - Electrics Fuses and Relays Relays - Shiftmaster Machines

Relays - Shiftmaster Machines Note: Data also applicable to machines fitted with a lock up torque converter.

FH1 FG1 GH1 FH2 FG2 GH2

Fig 23. The relays listed below are located in the front console. K Fig 24. ( T C1-28). FG2

Reverse Alarm

FG1

Transmission dump

FH2

2 Wheel Braking

FH1

Brake lights

GH2

Steer mode changeover

GH1

Hydraulic speed control (HSC) cut-out

C1-27

9813/0250-04(C-09-04)

C1-27

Section C1 - Electrics Fuses and Relays Relays - Heated Front Screen

Relays - Heated Front Screen

HS10 HS01

HS1 HS2 Fig 24.

C112680

The relays listed below are located in the front console. K Fig 24. ( T C1-28). HS01

Power relay

HS1

Cut out relay

HS2

LED cut out relay

HS10

Timer

C1-28

9813/0250-04(C-09-04)

C1-28

Section C1 - Electrics Fuses and Relays Relays - Cab Front Bulkhead

Relays - Cab Front Bulkhead To get access to the relays proceed as follows: 1

2

Park the machine and make it safe. Raise the loader arms and fit the safety strut. Obey the care and safety procedures. Refer to Section 2 - General Procedures.

The relays 2 and 3 are located under the protective cover on the front of the RH cab front bulkhead. Remove the screws 1 and ease back the rubber bulkhead cover to reveal the relays.

2

Neutral start

3

Immobiliser

1 2

3

1 Fig 25.

C1-29

9813/0250-04(C-09-04)

C112690

C1-29

Section C1 - Electrics Fuses and Relays Relays - Cab Roof

Relays - Cab Roof The relays 2 and 3 are located inside the cab under the cab roof liner. To get access to the relays remove the roof liner. Refer to Section B.

1

Stabiliser low relay

3

Engine run relay

1 Fig 26.

C1-30

9813/0250-04(C-09-04)

2 C127550

C1-30

C2-1

9813/0250-04 (C-10-04)

Fuse box B

Relay

Harness interconnection

Harness interconnection

Horn

Splice

CP27

CP18

CP06 / MF01

MF40A / RL15A

MF33

SRL2

Earth

SMF3

MF22

- ve earth

energised

closed

+ ve supply

State

8

1-2

16

30

1-2

6

Pins(2)

600A

600ET

600EL

871

118

Wire No.

Fig 1. Example - Horn Energised

7

7

7

7

7

7

7

7

14

Sheet

Use the applicable schematic set to trace wires and connections between electrical devices. In most cases it will be necessary to trace wires across more than one schematic sheet.

Connects to chassis earth point

completes circuit to horn

Power supply from 7.5 A fuse

Explanation

C126900

The example shows how to follow a typical set of wires from a power supply (+ ve) through to the path to earth (- ve).

(1) Item identification code is the same as the connector code shown on the applicable harness drawing. (2) The pin number is the same as the pin number of the harness connector shown on the applicable harness drawing. (3) Splices are not normally accessible. Splices are inside the harness sheath and not visible on the outside.

Harness interconnection

Splice

MF40A / RL15A

(3)

Description

SHEET 7

Item(1)

SHEET 14

This section contains sets of electrical schematics for different machine variants.

Overview

Schematics

Section C2 - Electrics Schematics Overview

C2-1

C2-2

9813/0250-04 (C-10-04)

K Sheet 18 of 18 Gearbox control solenoids, gearbox oil pressure switch, oil temperature switch ( T C2-20)

K Sheet 17 of 18 Immobiliser, livelink ( T C2-19)

K Sheet 16 of 18 Front heated screen ( T C2-18)

K Sheet 15 of 18 Splices ( T C2-17)

K Sheet 14 of 18 Splices ( T C2-16)

K Sheet 13 of 18 Hydraulic flow control, rear wash wipe, rear wiper motor, rear steer proximity switch, HVAC, steer mode solenoids, heated seat ( T C2-15)

K Sheet 12 of 18 RH instrument panel ECU ( T C2-14)

K Sheet 11 of 18 Power distribution fuses, interior light, radio ( T C2-13)

K Sheet 10 of 18 Rear quick hitch, front quickhitch, HTC ( T C2-12)

K Sheet 9 of 18 Bi-direction auxiliary circuit control, hammer circuit control, HTC solenoid, front quickhitch solenoid ( T C2-11)

K Sheet 8 of 18 Front console warning lights, park brake switch, boom overload warning, speedo ( T C2-10)

K Sheet 7 of 18 Ignition switch, work lights control, fog lights control ( T C2-9)

K Sheet 6 of 18 Drive control, wash/wipe control, front wiper motor, main lights control, hazard lights control ( T C2-8)

K Sheet 5 of 18 Hydraclamps, rear horn, stabiliser warning, rear lights ( T C2-7)

K Sheet 4 of 18 Lights ( T C2-6)

K Sheet 3 of 18 Steer mode control, brake mode control, transmission control, HSC ( T C2-5)

K Sheet 2 of 18 Front axle proximity switch, ESOS, cold start, screen washers, shovel reset, SRS, fuel level, coolant temp, engine oil pressure, air filter vacuum, horn ( T C2-4)

K Sheet 1 of 18 Battery, starter, alternator, inlet manifold heater ( T C2-3)

Sheets

Manual Control (Mechanical F.I. Engines)

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-2

C2-3

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 2. Sheet 1 of 18 Battery, starter, alternator, inlet manifold heater

852-C5076-3-sheet1

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-3

C2-4

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

852-C5076-3-sheet2

Fig 3. Sheet 2 of 18 Front axle proximity switch, ESOS, cold start, screen washers, shovel reset, SRS, fuel level, coolant temp, engine oil pressure, air filter vacuum, horn

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-4

C2-5

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 4. Sheet 3 of 18 Steer mode control, brake mode control, transmission control, HSC

852-C5076-3-sheet3

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-5

Section C2 - Electrics Schematics

C2-6

9813/0250-04 (C-10-04)

K Sheets ( T C2-2) K Component Keys ( T C2-21)

Fig 5. Sheet 4 of 18 Lights

852-C5076-3-sheet4

Manual Control (Mechanical F.I. Engines)

C2-6

C2-7

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 6. Sheet 5 of 18 Hydraclamps, rear horn, stabiliser warning, rear lights

852-C5076-3-sheet5

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-7

C2-8

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 7. Sheet 6 of 18 Drive control, wash/wipe control, front wiper motor, main lights control, hazard lights control

852-C5076-3-sheet6

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-8

C2-9

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 8. Sheet 7 of 18 Ignition switch, work lights control, fog lights control

852-C5076-3-sheet7

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-9

C2-10

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 9. Sheet 8 of 18 Front console warning lights, park brake switch, boom overload warning, speedo

852-C5076-3-sheet8

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-10

C2-11

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 10. Sheet 9 of 18 Bi-direction auxiliary circuit control, hammer circuit control, HTC solenoid, front quickhitch solenoid

852-C5076-3-sheet9

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-11

C2-12

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 11. Sheet 10 of 18 Rear quick hitch, front quickhitch, HTC

852-C5076-3-sheet10

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-12

C2-13

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 12. Sheet 11 of 18 Power distribution fuses, interior light, radio

852-C5076-3-sheet11

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-13

C2-14

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 13. Sheet 12 of 18 RH instrument panel ECU

852-C5076-3-sheet12

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-14

C2-15

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

852-C5076-3-sheet13

Fig 14. Sheet 13 of 18 Hydraulic flow control, rear wash wipe, rear wiper motor, rear steer proximity switch, HVAC, steer mode solenoids, heated seat

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-15

Section C2 - Electrics Schematics

C2-16

9813/0250-04 (C-10-04)

K Sheets ( T C2-2) K Component Keys ( T C2-21)

Fig 15. Sheet 14 of 18 Splices

852/C5076-3-sheet14

Manual Control (Mechanical F.I. Engines)

C2-16

Section C2 - Electrics Schematics

C2-17

9813/0250-04 (C-10-04)

K Sheets ( T C2-2) K Component Keys ( T C2-21)

Fig 16. Sheet 15 of 18 Splices

852-C05076-3-sheet15

Manual Control (Mechanical F.I. Engines)

C2-17

Section C2 - Electrics Schematics

Fig 17. Sheet 16 of 18 Front heated screen

852/C5076-3-sheet16

Manual Control (Mechanical F.I. Engines)

C2-18

9813/0250-04 (C-10-04)

C2-18

C2-19

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 18. Sheet 17 of 18 Immobiliser, livelink

852/C5076-3-sheet17

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-19

C2-20

9813/0250-04 (C-10-04)

K Component Keys ( T C2-21)

K Sheets ( T C2-2)

Fig 19. Sheet 18 of 18 Gearbox control solenoids, gearbox oil pressure switch, oil temperature switch

852/C5076-3-sheet18

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-20

C2-21 Resistor

9813/0250-04 (C-10-04)

AS04 AS05 AS06 AS07 AS08 AS09 AS11

K Table 11. ‘HS’ Heated screen ( T C2-22)

K Table 12. ‘FQ’ Front quick hitch ( T C2-23)

K Table 13. ‘GH’ Grid heater ( T C2-23)

K Table 14. ‘HT’ Hydraulic tool ( T C2-23)

K Table 15. ‘MF’ Main frame ( T C2-23)

K Table 16. ‘RQ ’ Rear quick hitch ( T C2-23)

K Table 17. ‘RL ’ Rear lights ( T C2-23)

Boom Switch

BL02

Thumb wheel control

Foot switch

AH06

RQH solenoid

Diode pack Diode pack Park brake Pump P3 dump solenoid relay

CP14 CP14A CP16 CP17 1-5

Horn relay

Dump Switch Rear work light relay

CP22 CP23 1-5

CP23 6-10 Low legs warning relay

Fusebox

Flasher relay

CP20 CP21

Start inhibit relay

CP19 1-5

CP18 6-10 Park brake relay

CP18 1-5

Engine run relay CP30 6-10 Lights relay

CP30 1-5

CP29 6-10 HSC relay

Fusebox Warning lights relay

CP29 1-5

Ignition 2 relay CP27

CP25 1-5

Front work light relay CP24 6-10 Low legs control relay

Change over relay

AH05

AH07

Heater

CP12

BD1

AH04/04A Quick hitch switch

Hammer solenoid

AH02

HSC Switch

CP11

CP24 1-5

HTC solenoid

Diode gate

CP09E

CP17 6-10 Alarm relay

Diode gate

CP09D

Diode

CP09B

Earth

CP05 Diode

Earth

CP04 CP09A

Earth

CP03

Table 7. ‘CP’ Cab panel Key to Connectors:

Table 5. ‘BD’ Key to Connectors:

AT02

Table 6. ‘BL’ Boom Key to Connectors:

Bi-directional solenoid

AH01

Table 1. ‘AH’ Auxiliary Hydraulics Key to Connectors:

K Table 21. ‘TL ’ Livelink ( T C2-23)

K Table 20. ‘ST’ Heated seat ( T C2-23)

Forward

Mainshaft solenoid (Y)

Layshaft solenoid (Z)

Reverse slow solenoid (W)

Forward slow solenoid (T)

Reverse fast solenoid (Y)

6 speed solenoid (X)

Transmission oil temperature switch

Transmission oil pressure switch

Table 4. ‘AT’ Key to Connectors:

AS03

K Table 10. ‘FC’ Front console ( T C2-22)

K Table 19. ‘SRS’ Smooth ride system ( T C2-23)

Front quick hitch

Table 3. ‘AS’ Key to Connectors:

AL02

AS02

K Table 18. SM’ Steer mode ( T C2-23)

Diode

Table 2. ‘AL’ Front quick hitch Key to Connectors:

AH15

Diode

AH11 AH12

Bi-directional control

AH10

K Table 9. ‘CL’ Ceiling liner ( T C2-22)

K Table 8. ‘CR’ Cab roof ( T C2-22)

K Table 7. ‘CP’ Cab panel ( T C2-21)

K Table 6. ‘BL’ Boom ( T C2-21)

K Table 5. ‘BD’ ( T C2-21)

K Table 4. ‘AT ’ ( T C2-21)

K Table 3. ‘AS’ ( T C2-21)

K Table 2. ‘AL’ Front quick hitch ( T C2-21)

K Table 1. ‘AH’ Auxiliary Hydraulics ( T C2-21)

Component Keys

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-21

C2-22

9813/0250-04 (C-10-04)

Fusebox

Brake pressure switch

Rear wiper motor

Ignition switch

Ignition switch

RH instruments (ECU)

RH instruments (ECU)

Power socket

Radio

SRS

Flow switch

Beacon switch

Front work lights

Shovel reset

Bi direction/hammer switch

Rear work lights

Switch rear wipe/wash

Hydraclamp switch

Boom overload switch

Heated screen switch

Diode

Diode gate

CP33

CP45

CP49

CP55A

CP55B

CP57 J1

CP57 J2

CP60

CP61/61A

CP63

CP64

CP65

CP66

CP67

CP68

CP69

CP70

CP71

CP87

CP91

CP93

CP110

LH Work light

Beacon

RH work light

LH front headlight

RH front headlight

CR01

CR02

CR03

CR04

CR05

Table 8. ‘CR’ Cab roof Key to Connectors:

CR08

Ignition 1 relay

CP32

LH rear lights

RH rear lights

RH front indicators

Auxiliary beacon

LH Front indicators

Auxiliary beacon

Auxiliary beacon

LH rear inner work light

LH rear inner work light

RH rear inner work light

RH rear work light

Earth

Interior light

Steer mode ECU Reverse relay

FC03 FC04 1-5 Auto 4WB relay Diode gate Foot brake switch Main lights switch Speedometer illumination Speedometer illumination Front warning lights

FC06 FC07 FC08 FC09 FC10 FC11

FC05 6-10 Auto 2WD relay

FC05 1-5

FC04 6-10 Reverse hi/lo relay

Earth

FC02

Table 10. ‘FC’ Front console Key to Connectors:

CL04A/B RH speaker

CL03A/B LH speaker

CL02

Table 9. ‘CL’ Ceiling liner Key to Connectors:

CR75

CR50

CR35

CR33

CR15

CR13

CR12

CR11

CR10

CR09

CR07

CP31 6-10 Hammer relay

Transmission dump relay

Diode

Fog light switch

Speedometer

Front warning lights

RH column switch

2/4 WD switch

LH column switch

Hazard switch

Brake mode

Steer mode switch

Brake lights relay

Forward relay

Front wiper motor

Diodes Drive relay

Steer mode relay

Front warning lights link connector

HS06

Cut out relay

Diode HS10 6-10 LED cut out relay

HS10 1-5

HS09

Front warning lights link connector

Timer relay

HS02 HS08

Power relay

HS01

Table 11. ‘HS’ Heated screen Key to Connectors:

FC39 6-10 Interlock relay

FC39 1-5

FC38 1-5

FC37

FC36 6-10 Forward hi/lo relay

FC36 1-5

FC35

FC34 6-10 4WD park relay

FC34 1-5

FC33 6-10 HSC cut out relay

FC33 1-5

FC26

FC25

FC23

FC22

FC21

FC20

FC19

FC18

FC17

FC16

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-22

C2-23 Reverse alarm Rear socket Rear fog light Number plate

MF35 MF36 MF37 MF38

Table 13. ‘GH’ Grid heater Key to Connectors:

GH03

HTC switch

9813/0250-04 (C-10-04)

Primary fuse

Primary fuse

Inlet manifold heater relay

Cold start solenoid

Cold start advance

ESOS

Water temperature

Air filter

Air conditioning compressor

Engine oil pressure

Water in fuel

Front proximity switch

Horn

Rear washer motor

Front washer motor

MF03

MF04

MF05

MF07

MF08

MF09

MF10

MF11

MF12

MF13

MF14

MF15

MF17

MF18

MF19

Earth

Starter motor

MF22

MF23

MF20/MF21 Alternator

Fuel sender

MF02

Table 15. ‘MF’ Main frame Key to Connectors:

HT4 1-5 HTC relay

HT3

Table 14. ‘HT’ Hydraulic tool Key to Connectors:

Grid heater relay

Tilt switch relay

RQ4 1-5

Diode Diode

RQ12 RQ13

Hydraclamp solenoid RH leg switch LH leg switch RH rear lights LH rear lights Rear horn button Rear horn

RL02 RL03 RL04 RL06 RL07 RL08 RL09

Table 17. ‘RL’ Rear lights Key to Connectors:

Diode

Diode

RQ09 Diode

Diode

RQ7

RQ11

Select relay

RQ6

RQ10

Buzzer

RQ5

RQ4 6-10 Earth relay

Rear quick hitch switch

Diode

RQ3

RQ2

Table 16. ‘RQ’ Rear quick hitch Key to Connectors:

Boom boost solenoid

Shovel reset switch

MF39

Shovel reset solenoid

MF26

Front quick hitch switch

MF25

FQ3

HSC solenoid

MF24

Table 12. ‘FQ’ Front quick hitch Key to Connectors:

2WS 4WS

SM04 SM05 SM06

SRS RHS solenoid

SRS2

Heated seat

TL09

TL07

TL08

TL06

TL05

TL03

TL02

Run feed fuse

Negative fuse

Battery feed fuse

Livelink ECU (inputs)

CANbus end resistor

CANbus

Livelink ECU

Table 21. ‘TL’ Livelink Key to Connectors:

ST09

Table 20. ‘ST’ Heated seat Key to Connectors:

SRS LHS solenoid

SRS1

Table 19. ‘SRS’ Smooth ride system Key to Connectors:

4WS connector Crab

SM03

Rear proximity switch

SM02

Table 18. SM’ Steer mode Key to Connectors:

Section C2 - Electrics Schematics

Manual Control (Mechanical F.I. Engines)

C2-23

Section C3 - Electrics

Electrical Harness SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Related Topics ( T C3-2) K Earth Points ( T C3-26) K Wire Numbers and Functions ( T C3-3) K Harnesses - Manual Controls (Mechanical F.I. Engine Machines) ( T C3-5) K Harnesses - EC, AEC (Mechanical F.I. Engine Machines) ( T C3-10) K Harnesses - Manual, EC, EC - Vari, AEC (Electronic F.I. Engine Machines) ( T C3-16) K Earth Points ( T C3-26) K Drawings ( T C3-28) K Test Procedures ( T C3-395) K How to Use a Multimeter ( T C3-395) K Measuring DC Voltage ( T C3-396) K Measuring Resistance ( T C3-396) K Measuring Continuity ( T C3-397) K Measuring Frequency ( T C3-397) K Testing a Diode or a Diode Wire ( T C3-398) K Wiring Harness Repair ( T C3-399)

C3-1

9813/0250-04 (C-03-04)

C3-1

Section C3 - Electrics Electrical Harness SYSTEM Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Where applicable the text in this section contains cross references to this page to help you find the correct information. Sections

Topic Titles

Sub Titles

2

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

C3-2

9813/0250-04 (C-03-04)

C3-2

Section C3 - Electrics Electrical Harness SYSTEM Wire Numbers and Functions

Wire Numbers and Functions This section details the allocation of wire numbers and the identification of wires in the wiring harness.

Fig 1. Typical Wire and Harness Number K Fig 1. ( T C3-3). The illustration shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it's length.

The number stamped on the wire identifies the following:

Table 2. Wire and Harness Number Identification Ident. No.

Description

#

The # indicates the start of the identification number. It is always printed to the left of the identification number.

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

The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. K Wire Numbers and Functions ( T C3-3).

9/371

If applicable - The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).

C3-3

9813/0250-04 (C-03-04)

C3-3

Section C3 - Electrics Electrical Harness SYSTEM Wire Numbers and Functions

Wires 000-199

Wires 800-999

These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:

These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc.

– Wires 000 - 099 are allocated to unfused ignition feeds.

Wires In Splices

Note: Feeds via ignition relays are classed as ignition feeds.

The main input wire is allocated with a wire number and a suitable description, i.e. Wire 640 earth splice to earth. The additional wires in the splice are allocated the same wire number and a postfix, i.e. 640A, 640B, etc. K Fig 3. ( T C3-4).

Wires 200-399

Note: The letters I, O, Q and S are not used.

– Wires 100 - 199 are allocated to fused ignition feeds.

These numbers are reserved for battery feeds, They can be further categorised by: – Wires 200 - 299 are allocated to unfused battery feeds. – Wires 300 - 399 are allocated to fused battery feeds.

Wires 400-599 These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems.

Wires 600-799

Fig 3.

These numbers are used for earth wires. When the number is printed onto a wire A it is prefixed by the Earth symbol B. K Fig 2. ( T C3-4). This symbol is printed onto the wire, it may however be omitted from harness drawings.

General Points 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.

Fig 2. 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.

C3-4

9813/0250-04 (C-03-04)

C3-4

Section C3 - Electrics Electrical Harness SYSTEM Harnesses - Manual Controls (Mechanical F.I. Engine Machines)

Harnesses - Manual Controls (Mechanical F.I. Engine Machines) The harness number refers to and corresponds with the annotations in the schematic drawing. K Fig 4. ( T C3-9). Harness No. 1

Issue Remarks

Drawing

Front Console 721/G3581

3

4 speed Powershift / Synchro Shuttle - to Jan 2011 K ( T C3-29)

721/G3582

3

ShiftMaster, including Lock Up Torque Converter variants - to Jan 2011

K ( T C3-33)

721/C2045 (includes heated screen option)

1

4 speed Powershift / Synchro Shuttle - Jan to July 2011

K ( T C3-37)

721/C2042 (includes heated screen option)

1

ShiftMaster, including Lock Up Torque Converter variants - Jan to July 2011

K ( T C3-41)

721/C4644

4

4 Speed Powershift / Synchro Shuttle with immobiliser - July 2011 on

K ( T C3-45)

721/C4875

4

Shiftmaster, including Lock Up Torque Converter variants with immobiliser - July 2011 on

K ( T C3-49)

721/E0641

1

Synchro Shuttle 2 WS March 2012 on

K ( T C3-53)

Main components connected to this harness:

Left and right column switches Gearbox control relays ShiftMaster E.C.U. (if applicable) Front wiper motor Front console switches Speedometer Front console warning lamps Steer mode control unit (if fitted)

2

Side Console/Cab To 2005536

K ( T C3-69)

721/H3665

1

2005536 to July 2011

K ( T C3-94)

721/C4640

4

July 2011 on - machines without immobiliser

K ( T C3-128)

721/H9187

3

July 2011 on - machines with immobiliser

K ( T C3-152)

721/G4758

8

Main components connected to this harness:

Side console instruments Side console switches Side console warning lamps Starter switch Heater controls Fuses and Relays Immobiliser (if fitted)

3

4

Cab Roof 721/G3561

3

USA Only

K ( T C3-249)

721/G3562

2

Not USA

K ( T C3-252)

721/H1874

2

USA Only - 2001644 on

K ( T C3-255)

721/H1871

2

Not USA - 2001644 on

K ( T C3-258)

Interior Light, Radio Speakers 721/11050

5

K ( T C3-261)

1

Steer Controls

C3-5

9813/0250-04 (C-03-04)

C3-5

Section C3 - Electrics Electrical Harness SYSTEM Harnesses - Manual Controls (Mechanical F.I. Engine Machines)

6

721/11206

1

721/12300

1

K ( T C3-262) K ( T C3-263)

Transmission 332/E9959

1

Synchro Shuttle SS700

K ( T C3-264)

721/C6807

1

Synchro Shuttle SS750

K ( T C3-266)

721/E7558

1

Synchro Shuttle SS750 speed sensor variant

K ( T C3-278)

332/E9971

1

Powershift

K ( T C3-268)

332/E9968

1

Shiftmaster

K ( T C3-270)

Main components connected to this harness: 7

Not crab steer

Gearbox control solenoids

Engine/Mainframe 721/G3752

3

721/G5850 721/C3406

3 1

Main components connected to this harness:

Sideshift to M2013418

K ( T C3-280)

Centremount to M2013418

K ( T C3-284)

M2013419 on

K ( T C3-288)

Alternator Starter motor Primary fuses Front steer proximity switch Shovel reset proximity switch ESOS Smooth ride solenoids Air conditioning compressor

10 Auxiliary Hydraulics 721/G4422

1

Excavator - (Hammer - Jaw - Hydraulic excavator quickhitch)

K ( T C3-294)

721/11719

1

Excavator - (Hammer - Jaw)

K ( T C3-296)

721/11323

1

HTC solenoid valve link

721/G4378

1

HTC control

K ( T C3-304)

721/G4379

1

Loader quickhitch - changeover switch harness

K ( T C3-306)

721/11704

1

Loader quickhitch - changeover solenoid harness

K ( T C3-307)

Auxiliary (Bi-Directional) Harness. To M2013640

K ( T C3-313)

721/G7722

2

721/D1155

1

Auxiliary (Bi-Directional) Harness. M2013641 on

K ( T C3-316)

721/G7723

1

Bi-Directional Relay Harness

K ( T C3-319)

1

Loader quickhitch, HTC - link harness

K ( T C3-308)

332/E9050

1

Boom overload link

K ( T C3-342)

332/E9078

2

Boom overload link

K ( T C3-343)

721/G4427 Overload Warning System

C3-6

9813/0250-04 (C-03-04)

C3-6

Section C3 - Electrics Electrical Harness SYSTEM Harnesses - Manual Controls (Mechanical F.I. Engine Machines) Heating, Ventilation and Air Conditioning (HVAC) (Bergstrom)

-

Heater unit harness

K ( T C3-344)

(Bergstrom)

-

Air conditioning unit harness

K ( T C3-346)

721/12034

2

Eiberspacher Heater (Cold Climate Option)

K ( T C3-348)

721/C4643

1

Heated front screen harness - July 2011 on

721/C3409

2

Centre Mount

K ( T C3-361)

721/C3407

3

Side Shift

K ( T C3-363)

721/D0509

1

Power cable

K ( T C3-371)

721/C4643

1

Control harness

K ( T C3-372)

721/H5858

1

Earth cable

K ( T C3-374)

Rear Lights

Heated Front Screen

In Cab Drinks Machine 721/G6432

1

K ( T C3-377)

1

K ( T C3-386)

2

K ( T C3-387)

In Cab Drinks Machine Power Lead 721/D0789 Immobiliser LED Lead 718/00001 Rear Horn 721/C6640

1

Centre mount USA

K ( T C3-388)

LiveLink Data System 721/C1271

1

To 2004455

K ( T C3-355)

721/H8113

1

2004456 to July 2011

K ( T C3-357)

721/C3411

1

July 2011on

Main components connected to this harness:

LiveLink ECU Power and earth fuses CAN bus terminating resistors

Cab Roof LIner 721/11050

C3-7

K ( T C3-391)

2

9813/0250-04 (C-03-04)

C3-7

Section C3 - Electrics Electrical Harness SYSTEM Harnesses - Manual Controls (Mechanical F.I. Engine Machines)

Access Details K Fig 4. ( T C3-9) C1

Inside cab - remove console from around loader controls.

C2

Inside cab - remove front/steer console.

C3

Lift bonnet - located at cab front bulkhead, just below windscreen.

C3-8

9813/0250-04 (C-03-04)

C3-8

C3-9

7

9813/0250-04 (C-03-04)

2

1

FA

CB

S

G

AS01

PS01

ME

C10

6

5

10

Fig 4.

C3

1

FA

C2

CA NH

2 CB

7

C10 ME 10 5

2

4

CP CS

7

1

2

3

AS01 6

C40 CR

PS01

K Harnesses - Manual Controls (Mechanical F.I. Engine Machines) ( T C3-5) and K Access Details ( T C3-8)

NH

CS

CR

CA

CP

4

C40

3

C1

C000020-C1

Section C3 - Electrics

Electrical Harness SYSTEM

Harnesses - Manual Controls (Mechanical F.I. Engine Machines)

C3-9

Section C3 - Electrics Electrical Harness SYSTEM Earth Points

Earth Points K Fig 6. Earth Points ( T C3-27). The illustration shows the machine electrical earth point locations. This can be

useful when tracing electrical faults, typically when several electrical devices are malfunctioning.

Item

Description

Access

A

Earth strap, cab. From DR to chassis.

Remove loader control console.

C47

Earth, cab roof harness.

Remove - inside cab: `B' post covers, roof lining. Outside cab: lift moulded roof panel.

DR

Earths, side console harness.

Remove loader control console.

E

Earth cable, isolator switch to starter motor.

Remove front grille.

F

Earth cable, battery switch to isolator.

Remove front grille

FB1

Earth, front console harness.

Remove front console, see Section B, Body and Framework.

H

Earth, work lights harness.

Remove - inside cab: `B' post covers, roof lining. Outside cab: lift moulded roof panel.

P

Battery isolator switch

Remove front grille.

C3-26

9813/0250-04 (C-03-04)

C3-26

Section C3 - Electrics Electrical Harness SYSTEM Earth Points

C47 C47 DR A

FB1 H

A

S

E P F

F

Fig 6. Earth Points

C3-27

9813/0250-04 (C-03-04)

C007410-C3

C3-27

Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness. To identify the correct harness drawing for a particular machine refer to the relevant Harness Interconnection page for the machine serial number range.

Drawings

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-28

9813/0250-04 (C-03-04)

C3-28

Section C3 - Electrics Electrical Harness SYSTEM Drawings

Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/G3581 Issue 3 FC01

Table 16. Key to Connectors Side Console

FC02

Ground

FC03

Steer Mode Control Unit

FC04

Reverse Hi/Lo / Reverse

FC05

Auto 4WB / Auto 2WD

FC06

4WB Diode Gate

FC07

Brakelight Switch

FC08

Roadlight Switch

FC09

Speedometer Illumination

FC10

Speedometer Illumination

FC11

Warning Light Cluster

FC16

Steer Mode Switch

FC17

Brake Mode Switch

FC18

Hazard Switch

FC19

LH Column Switch

FC20

2WD Switch

FC21

RH Column Switch

FC22

Warning Light Cluster

FC23

Speedometer

FC25

Fog Light Switch

FC26

Steer Mode Diode

FC33

Trans Dump / HSC Cutout

FC34

Brake Lights / 4WD Park

FC35

Front Wiper Motor

FC36

Forward Hi/Lo / Forward

FC37

Diode Gate

FC38

Steer Mode Relay

FC39

Interlock Drive

C3-29

9813/0250-04 (C-03-04)

C3-29

C3-30

9813/0250-04 (C-03-04)

K Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/G3581 Issue 3 ( T C3-29)

Fig 7.

721-G3581-3 Sheet 1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-30

C3-31

9813/0250-04 (C-03-04)

K Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/G3581 Issue 3 ( T C3-29)

Fig 8.

721-G3581-3Sheet 2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-31

C3-32

9813/0250-04 (C-03-04)

K Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/G3581 Issue 3 ( T C3-29)

Fig 9.

721-G3581-3Sheet 3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-32

Section C3 - Electrics Electrical Harness SYSTEM Drawings

Front Console, ShiftMaster - CAD 721/ G3582 Issue 3 Note: This harness is applicable to machines fitted with a lock up torque converter.

FC01

Table 17. Key to Connectors Side Console

FC02

Ground

FC03

Steer Mode Control Unit

FC04

Reverse Alarm / Trans Dump

FC05

2WB / Brake Lights

FC06

Diode Gate

FC07

Brakelight Switch

FC08

Roadlight Switch

FC09

Speedometer Illumination

FC10

Speedometer Illumination

FC11

Warning Light Cluster

FC16

Steer Mode Switch

FC17

Brake Mode Switch

FC18

Hazard Switch

FC19

LH Column Switch

FC20

2WD Switch

FC21

RH Column Switch

FC22

Warning Light Cluster

FC23

Speedometer

FC25

Fog Light Switch

FC26

Steer Mode Diode

FC27

ECU II Inputs/Comms

FC28

ECU II B Plug

FC29

Diagnostics Plug

FC30

Resistor Plug

FC31

Resistor Plug

FC32

Throttle Switch

FC33

HSC Cutout / Steer Mode

FC35

Front Wiper Motor

FC36

Diode

C3-33

9813/0250-04 (C-03-04)

C3-33

C3-34

9813/0250-04 (C-03-04)

K Front Console, ShiftMaster - CAD 721/G3582 Issue 3 ( T C3-33)

Fig 10.

721-G3582-3 Sheet 1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-34

C3-35

9813/0250-04 (C-03-04)

K Front Console, ShiftMaster - CAD 721/G3582 Issue 3 ( T C3-33)

Fig 11.

721-G3582-3 Sheet 2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-35

C3-36

9813/0250-04 (C-03-04)

K Front Console, ShiftMaster - CAD 721/G3582 Issue 3 ( T C3-33)

Fig 12.

721-G3582-3 Sheet 3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-36

Section C3 - Electrics Electrical Harness SYSTEM Drawings

Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/C2045 Issue 1 FC01

Table 18. Key to Connectors Side Console

FC02

Ground

FC03

Steer Mode Control Unit

FC04

Reverse Hi/Lo / Reverse

FC05

Auto 4WB / Auto 2WD

FC06

4WB Diode Gate

FC07

Brakelight Switch

FC08

Roadlight Switch

FC09

Speedometer Illumination

FC10

Speedometer Illumination

FC11

Warning Light Cluster

FC12

Butt Diode

FC16

Steer Mode Switch

FC17

Brake Mode Switch

FC18

Hazard Switch

FC19

LH Column Switch

FC20

2WD Switch

FC21

RH Column Switch

FC22

Warning Light Cluster

FC23

Speedometer

FC25

Fog Light Switch

FC26

Steer Mode Diode

FC33

Trans Dump / HSC Cutout

FC34

Brake Lights / 4WD Park

FC35

Front Wiper Motor

FC36

Forward Hi/Lo / Forward

FC37

Diode Gate

FC38

Steer Mode Relay

FC40

Heated Screen

C3-37

9813/0250-04 (C-03-04)

C3-37

C3-38

9813/0250-04 (C-03-04)

K Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/C2045 Issue 1 ( T C3-37)

Fig 13.

721-C2045-1 Sheet 1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-38

C3-39

9813/0250-04 (C-03-04)

K Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/C2045 Issue 1 ( T C3-37)

Fig 14.

721-C2045-1Sheet 2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-39

C3-40

9813/0250-04 (C-03-04)

K Front Console, 4 speed Powershift, Synchro Shuttle, CAD 721/C2045 Issue 1 ( T C3-37)

Fig 15.

721-C2045-1Sheet 3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-40

Section C3 - Electrics Electrical Harness SYSTEM Drawings

Front Console, ShiftMaster - CAD 721/ C2042 Issue 1 Note: This harness is applicable to machines fitted with a lock up torque converter.

FC01

Table 19. Key to Connectors Side Console

FC02

Ground

FC03

Steer Mode Control Unit

FC04

Reverse Alarm / Trans Dump

FC05

2WB / Brake Lights

FC06

Diode Gate

FC07

Brakelight Switch

FC08

Roadlight Switch

FC09

Speedometer Illumination

FC10

Speedometer Illumination

FC11

Warning Light Cluster

FC16

Steer Mode Switch

FC17

Brake Mode Switch

FC18

Hazard Switch

FC19

LH Column Switch

FC20

2WD Switch

FC21

RH Column Switch

FC22

Warning Light Cluster

FC23

Speedometer

FC25

Fog Light Switch

FC26

Steer Mode Diode

FC27

ECU II Inputs/Comms

FC28

ECU II B Plug

FC29

Diagnostics Plug

FC30

Resistor Plug

FC31

Resistor Plug

FC32

Throttle Switch

FC33

HSC Cutout / Steer Mode

FC35

Front Wiper Motor

FC36

Diode

FC40

Heated Screen

C3-41

9813/0250-04 (C-03-04)

C3-41

C3-42

9813/0250-04 (C-03-04)

K Front Console, ShiftMaster - CAD 721/C2042 Issue 1 ( T C3-41)

Fig 16.

721-C2042-1 Sheet 1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-42

C3-43

9813/0250-04 (C-03-04)

K Front Console, ShiftMaster - CAD 721/C2042 Issue 1 ( T C3-41)

Fig 17.

721-C2042-1 Sheet 2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-43

C3-44

9813/0250-04 (C-03-04)

K Front Console, ShiftMaster - CAD 721/C2042 Issue 1 ( T C3-41)

Fig 18.

721-C2042-1 Sheet 3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-44

C3-45

9813/0250-04 (C-03-04)

Brake Lights / 4WD Park

Forward Hi/Lo / Forward

Diode Gate

FC36

FC37

Trans Dump / HSC Cutout

FC33

Front Wiper Motor

Steer Mode Diode

FC26

FC35

Fog Light Switch

FC34

Speedometer

Hazard Switch

FC18

FC25

Brake Mode Switch

FC17

FC23

Steer Mode Switch

FC16

Warning Light Cluster

Butt Diode

FC12

FC22

Warning Light Cluster

FC11

RH Column Switch

Speedometer Illumination

FC10

FC21

Speedometer Illumination

FC09

LH Column Switch

Roadlight Switch

FC08

2WD Switch

Brakelight Switch

FC07

FC20

4WB Diode Gate

FC06

FC19

Reverse Hi/Lo / Reverse

Auto 4WB / Auto 2WD

FC05

Steer Mode Control Unit

FC03

FC04

Ground

FC02

FC01

Table 20. Key to Connectors Side Console

K Fig 19. ( T C3-46)

Front Console Harness (Powershift and Manual) - CAD 721/C4644 Issue 4

Heated Screen

Spare

FC38C FC40

Spare

FC38B Interlock Drive

Spare

FC38A

FC39

Steer Mode Relay

FC38

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-45

C3-46

9813/0250-04 (C-03-04)

K Front Console Harness (Powershift and Manual) - CAD 721/C4644 Issue 4 ( T C3-45)

Fig 19.

721-C4644-4-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-46

C3-47

9813/0250-04 (C-03-04)

K Front Console Harness (Powershift and Manual) - CAD 721/C4644 Issue 4 ( T C3-45)

Fig 20.

721-C4644-4-SHEET2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-47

C3-48

9813/0250-04 (C-03-04)

K Front Console Harness (Powershift and Manual) - CAD 721/C4644 Issue 4 ( T C3-45)

Fig 21.

721-C4644-4-SHEET3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-48

C3-49

Speedometer Illumination

Warning Light Cluster

FC10

FC11

9813/0250-04 (C-03-04)

Diagnostics Plug

Resistor Plug

Resistor Plug

Throttle Switch

FC31

FC32

ECU 2 ‘B’ Plug

FC28

FC30

ECU 2 Inputs/Comms

FC27

FC29

Fog Light Switch

FC23

Steer Mode Diode

Speedometer

FC22

FC26

Warning Light Cluster

FC21

FC25

2WD Switch

RH Column Switch

FC20

LH Column Switch

Speedometer Illumination

FC09

FC19

Roadlight Switch

FC08

Hazard Switch

Brakelight Switch

FC07

FC18

Diode Gate

FC06

Steer Mode Switch

2WB/ Brake Lights

FC05

Brake Mode Switch

Reverse Alarm/ Transmission Dump

FC04

FC17

Steer Mode Control Unit

FC03

FC16

Ground

FC02

FC01

Table 21. Key to Connectors Side Console

K Fig 22. ( T C3-50)

Front Console Harness (Autoshift 6 speed) - CAD 721/C4875 Issue 4

Spare Heated Screen

FC38C FC40

FC38A Spare

Spare

FC36 FC38B

Front Wiper Motor Diode

FC35

HSC Cutout/ Steer Mode

FC33

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-49

C3-50

9813/0250-04 (C-03-04)

K Front Console Harness (Autoshift 6 speed) - CAD 721/C4875 Issue 4 ( T C3-49)

Fig 22.

721-C4875-4-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-50

C3-51

9813/0250-04 (C-03-04)

K Front Console Harness (Autoshift 6 speed) - CAD 721/C4875 Issue 4 ( T C3-49)

Fig 23.

721-C4875-4-SHEET2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-51

C3-52

9813/0250-04 (C-03-04)

K Front Console Harness (Autoshift 6 speed) - CAD 721/C4875 Issue 4 ( T C3-49)

Fig 24.

721-C4875-4-SHEET3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-52

C3-53

9813/0250-04 (C-03-04)

Transmission Dump/Head Light Flash Relays

FC33

Not Used

Fog Light Switch

FC25

FC39

Speedometer

FC23

Diode

Warning Light Cluster

FC22

FC37

RH Column Switch

FC21

Front Wiper Motor

LH Column Switch

FC19

Forward/4WD Park Relays

Hazard Switch

FC18

FC36

Brake Mode Switch

FC17

FC35

Diode

Speedometer Illumination

FC09

FC12

Roadlight Switch

FC08

Speedometer Illumination

Brakelight Switch

FC07

Warning Light Cluster

4 Wheel Brake Relay

FC05

FC11

Reverse/Brake Lights Relays

FC04

FC10

Ground

Table 22. Key to Connectors Side Console

FC02

FC01

K Fig 25. ( T C3-54)

Front Console Harness (Synchro Shuttle 2WS) - CAD 721/E0641 Issue 1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-53

C3-54

9813/0250-04 (C-03-04)

K Front Console Harness (Synchro Shuttle 2WS) - CAD 721/E0641 Issue 1 ( T C3-53)

Fig 25.

721-E0641-1-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-54

C3-55

9813/0250-04 (C-03-04)

K Front Console Harness (Synchro Shuttle 2WS) - CAD 721/E0641 Issue 1 ( T C3-53)

Fig 26.

721-E0614-1-SHEET2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-55

C3-56

9813/0250-04 (C-03-04)

K Front Console Harness (Autoshift 6 speed) - CAD 721/C4875 Issue 4 ( T C3-49)

Fig 27.

721-C4875-4-SHEET3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-56

C3-57

9813/0250-04 (C-03-04)

Speedometer

FC23

HSC Cutout / Steer mode

Warning Light Cluster

FC22

FC33

RH Column Switch

FC21

Foot Throttle

Diode

FC20B

FC32A

Diode

FC20A

Fog Light Switch

2WD Switch

FC20

Steer Mode Diode

LH Column Switch

FC19

FC26

Hazard Switch

FC18

FC25

Brake Mode Switch

FC17

Speedometer Illumination

FC09

Steer Mode Switch

Roadlight Switch

FC08

FC16

Brakelight Switch

FC07

Speedometer Illumination

Diode

FC06A

Warning Light Cluster

Auto 4WB / Auto 2WD

FC05

FC11

Rev Hi-Low, Rev

FC04A

FC10

Steer Mode Control Unit

Reverse Alarm / Transmission Dump

FC04

Ground

FC02

FC03

Side Console

FC01A

FC01

Table 23. Key to Connectors Side Console

K Fig 28. ( T C3-58)

Front Console Harness (Powershift) CAD 721/D2236 Issue 3

Heated Screen

Diode Pack

FC37 FC40

Forward Hi / Lo / Forward

FC36 Interlock Drive

Front Wiper Motor

FC35

FC39

Brake Lights / 4WD Park

FC34

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-57

C3-58

9813/0250-04 (C-03-04)

K Front Console Harness (Powershift) - CAD 721/D2236 Issue 3 ( T C3-57)

Fig 28.

721-C2236-3-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-58

C3-59

9813/0250-04 (C-03-04)

K Front Console Harness (Powershift) - CAD 721/D2236 Issue 3 ( T C3-57)

Fig 29.

721-C2236-3-SHEET2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-59

C3-60

9813/0250-04 (C-03-04)

K Front Console Harness (Powershift) - CAD 721/D2236 Issue 3 ( T C3-57)

Fig 30.

721-C2236-3-SHEET3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-60

C3-61

Speedometer Illumination

Warning Light Cluster

FC10

FC11

9813/0250-04 (C-03-04)

HSC Cutout / Steer Mode

Front Wiper Motor

Heated Screen

Side Console

FC40

FC01A

ECU 2 ‘B’ Plug

FC28

FC35

ECU 2 Inputs/Comms

FC27

FC33

Fog Light Switch

FC23

Steer Mode Diode

Speedometer

FC22

FC26

Warning Light Cluster

FC21

FC25

2WD Switch

RH Column Switch

FC20

LH Column Switch

Speedometer Illumination

FC09

FC19

Roadlight Switch

FC08

Hazard Switch

Brakelight Switch

FC07

FC18

Diode Gate (Hazard Diode)

FC06

Steer Mode Switch

2WB/ Brake Lights

FC05

Brake Mode Switch

Reverse Alarm/ Transmission Dump

FC04

FC17

Steer Mode Control Unit

FC03

FC16

Ground

FC02

FC01

Table 24. Key to Connectors Side Console

K Fig 31. ( T C3-62)

Front Console Harness (Autoshift) CAD 721/D2238 Issue 3

4WD Park Brake Lights

Diode

FC20A FC34

Diode

FC20B Auto 4WB, Auto 2WB

Diode

FC36B

FC05

Foot Throttle

FC32A

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-61

C3-62

9813/0250-04 (C-03-04)

K Front Console Harness (Autoshift) - CAD 721/D2238 Issue 3 ( T C3-61)

Fig 31.

721-D2238-3-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-62

C3-63

9813/0250-04 (C-03-04)

K Front Console Harness (Autoshift) - CAD 721/D2238 Issue 3 ( T C3-61)

Fig 32.

721-D2238-3-SHEET2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-63

C3-64

9813/0250-04 (C-03-04)

K Front Console Harness (Autoshift) - CAD 721/D2238 Issue 3 ( T C3-61)

Fig 33.

721-D2238-3-SHEET3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-64

Section C3 - Electrics Electrical Harness SYSTEM Drawings

Front Console Harness (Synchro Shuttle SS750) - CAD 721/E3609 Issue 1 K Fig 34. ( T C3-66)

FC01

Table 25. Key to Connectors Side Console

FC01A

Side Console

FC02

Ground

FC04

Transmission Dump

FC05

Auto 4WB / Auto 2WD

FC07

Brakelight Switch

FC08

Roadlight Switch

FC09

Speedometer Illumination

FC10

Speedometer Illumination

FC11

Warning Light Cluster

FC17

Brake Mode Switch

FC18

Hazard Switch

FC19

LH Column Switch

FC21

RH Column Switch

FC22

Warning Light Cluster

FC23

Speedometer

FC25

Fog Light Switch

FC32A

Foot Throttle

FC33

HSC Cutout / Steer Mode

FC34

Brake Lights / 4WD Park

FC35

Front Wiper Motor

FC36

FWD

FC37A

Diode Pack

FC39

Spare

FC40

Heated Screen

C3-65

9813/0250-04 (C-03-04)

C3-65

C3-66

9813/0250-04 (C-03-04)

K Front Console Harness (Synchro Shuttle SS750) - CAD 721/E3609 Issue 1 ( T C3-65)

Fig 34.

721-E3609-1-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-66

C3-67

9813/0250-04 (C-03-04)

K Front Console Harness (Synchro Shuttle SS750) - CAD 721/E3609 Issue 1 ( T C3-65)

Fig 35.

721-E3609-1-SHEET2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-67

C3-68

9813/0250-04 (C-03-04)

K Front Console Harness (Synchro Shuttle SS750) - CAD 721/E3609 Issue 1 ( T C3-65)

Fig 36.

721-E3609-1-SHEET3

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-68

Section C3 - Electrics Electrical Harness SYSTEM Drawings

Side Console - CAD 721/G4758 Issue 8 CP01

Table 26. Key to Connectors Front Console

CP57 J1

Grey Connector

CP57 J2

Black Connector

CP60

Auxiliary Power Socket Radio

CP02A

Gearbox

CP61

CP02B

Gearbox

CP61A

Speakers

CP03

Ground

CP63

S.R.S.

CP04

Ground

CP64

Flow

CP05

Ground

CP65

Beacon

CP06

Mainframe

CP66

Front Worklights

CP09A

Diode

CP67

Shovel Reset

CP09B

Diode

CP68

Auxiliary Hydraulics / Bi Dir

CP09C

Diode

CP69

Rear Worklights

CP09D

Diode

CP70

Rear W/Wipe

CP09E

Diode

CP71

hydraclamp

CP10

Worklight Link

CP72

Seat Connector

CP10A

Worklight Link

CP87

Boom Overload

CP11

HSC Switch

CP93

Diode

CP12

Heater Unit

CP94

CANBUS Module

CP13

Quickhitch and HTC Plug

CP96

Telematics

CP14

Auxiliary Buzzer Diode

CP99

Power Link

CP15G

Auxiliary

CP110

Low Legs

CP15S

Steer Mode

CP16

Parkbrake Switch

CP17

Relay

CP18

Relay

CP19

Relay

CP20

Hazard

CP21

Fusebox C

CP22

Dump Switch

CP23

Relay

CP24

Relay

CP25

Relay

CP26

Spare

CP27

Fusebox B

CP29

Relay

CP30

Relay

CP31

Relay

CP32

Relay

CP33

Fusebox A

CP43

Headliner

CP44

Cab Roof

CP45

Brake Pressure

CP49

Rear Wiper motor

CP55A

Ignition Switch

CP55B

Ignition Switch

C3-69

9813/0250-04 (C-03-04)

C3-69

Section C3 - Electrics Electrical Harness SYSTEM

C3-70

9813/0250-04 (C-03-04)

K Side Console - CAD 721/G4758 Issue 8 ( T C3-69)

Fig 37.

721-G4758-8 Sheet 1

Drawings

C3-70

Section C3 - Electrics Electrical Harness SYSTEM

C3-71

9813/0250-04 (C-03-04)

K Side Console - CAD 721/G4758 Issue 8 ( T C3-69)

Fig 38.

721-G4758-8 Sheet 2

Drawings

C3-71

Section C3 - Electrics Electrical Harness SYSTEM

C3-72

9813/0250-04 (C-03-04)

K Side Console - CAD 721/G4758 Issue 8 ( T C3-69)

Fig 39.

721-G4758-8 Sheet 3

Drawings

C3-72

Section C3 - Electrics Electrical Harness SYSTEM

C3-73

9813/0250-04 (C-03-04)

K Side Console - CAD 721/G4758 Issue 8 ( T C3-69)

Fig 40.

721-G4758-8 Sheet 4

Drawings

C3-73

Section C3 - Electrics Electrical Harness SYSTEM

C3-74

9813/0250-04 (C-03-04)

K Side Console - CAD 721/G4758 Issue 8 ( T C3-69)

Fig 41.

721-G4758-8 Sheet 5

Drawings

C3-74

Section C3 - Electrics Electrical Harness SYSTEM

C3-75

9813/0250-04 (C-03-04)

K Side Console - CAD 721/G4758 Issue 8 ( T C3-69)

Fig 42.

721-G4758-8 Sheet 6

Drawings

C3-75

Section C3 - Electrics Electrical Harness SYSTEM Drawings

Side Console - CAD 721/H3665 Issue 1 CP01

Table 29. Key to Connectors Front Console

CP33

Fusebox A

CP43

Headliner

CP44

Cab Roof Brake Pressure

CP02A

Gearbox

CP45

CP02B

Gearbox

CP49

Rear Wiper motor

CP03

Ground

CP55A

Ignition Switch

CP04

Ground

CP55B

Ignition Switch

CP05

Ground

CP57 J1

Grey Connector

CP06

Mainframe

CP57 J2

Black Connector

CP09A

Diode

CP60

Auxiliary Power Socket

CP09B

Diode

CP61

Radio

CP09C

Diode

CP61A

Speakers

CP09D

Diode

CP63

S.R.S.

CP09E

Diode

CP64

Flow

CP10

Worklight Link

CP65

Beacon

CP10A

Worklight Link

CP66

Front Worklights

CP11

HSC Switch

CP67

Shovel Reset

CP12

Heater Unit

CP68

Auxiliary Hydraulics / Bi Dir

CP13

Quickhitch and HTC Plug

CP69

Rear Worklights

CP14

Auxiliary Buzzer Diode

CP70

Rear W/Wipe

CP15G

Auxiliary

CP71

hydraclamp

CP15S

Steer Mode

CP72

Seat Connector

CP16

Parkbrake Switch

CP87

Boom Overload

CP17

Relay

CP93

Diode

CP18

Relay

CP94

CANBUS Module

CP19

Relay

CP96

Telematics

CP20

Hazard

CP99

Power Link

CP21

Fusebox C

CP110

Low Legs

CP22

Dump Switch

CP23

Relay

CP24

Relay

CP25

Relay

CP26

Spare

CP27

Fusebox B

CP29

Relay

CP30

Relay

CP31

Relay

CP32

Relay

C3-94

9813/0250-04 (C-03-04)

C3-94

Section C3 - Electrics Electrical Harness SYSTEM

C3-95

9813/0250-04 (C-03-04)

K Side Console - CAD 721/H3665 Issue 1 ( T C3-94)

Fig 57.

721-H3665-1 Sheet 1

Drawings

C3-95

Section C3 - Electrics Electrical Harness SYSTEM

C3-96

9813/0250-04 (C-03-04)

K Side Console - CAD 721/H3665 Issue 1 ( T C3-94)

Fig 58.

721-H3665-1 Sheet 2

Drawings

C3-96

Section C3 - Electrics Electrical Harness SYSTEM

C3-97

9813/0250-04 (C-03-04)

K Side Console - CAD 721/H3665 Issue 1 ( T C3-94)

Fig 59.

721-H3665-1 Sheet 3

Drawings

C3-97

Section C3 - Electrics Electrical Harness SYSTEM

C3-98

9813/0250-04 (C-03-04)

K Side Console - CAD 721/H3665 Issue 1 ( T C3-94)

Fig 60.

721-H3665-1 Sheet 4

Drawings

C3-98

Section C3 - Electrics Electrical Harness SYSTEM

C3-99

9813/0250-04 (C-03-04)

K Side Console - CAD 721/H3665 Issue 1 ( T C3-94)

Fig 61.

721-H3665-1 Sheet 5

Drawings

C3-99

C3-391

CP

Cab harness connector

Cab Roof Liner Harness - CAD 721/ 11050 Issue 2 LH speaker RH speaker

LS RS

9813/0250-04 (C-03-04)

K Cab Roof Liner Harness - CAD 721/E8380 Issue 1 ( T C3-393)

Fig 270.

Interior light

IL

721-11050-2

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-391

Section C3 - Electrics Electrical Harness SYSTEM

C3-392

9813/0250-04 (C-03-04)

K Cab Roof Liner Harness - CAD 721/E8380 Issue 1 ( T C3-393)

Fig 271.

721-E8380-1-SHEET2

Drawings

C3-392

C3-393

Cab harness connector

Interior light

CL01

CL02

Cab Roof Liner Harness - CAD 721/ E8380 Issue 1 C008

9813/0250-04 (C-03-04)

Fig 272.

Low legs relay

C013

C012

C011

C010 1-5

K Cab Roof Liner Harness - CAD 721/E8380 Issue 1 ( T C3-393)

C009 6-10

Door open relay

RH speaker Cab harness connector 2

CL04A/B C009 1-5

LH speaker

CL03A/B

Warning buzzer

RH door switch

LH door switch

Engine run relay

721-E8380-1-SHEET1

Section C3 - Electrics

Electrical Harness SYSTEM Drawings

C3-393

Section C3 - Electrics Electrical Harness SYSTEM

C3-394

9813/0250-04 (C-03-04)

K Cab Roof Liner Harness - CAD 721/E8380 Issue 1 ( T C3-393)

Fig 273.

721-E8380-1-SHEET2

Drawings

C3-394

Section Three - Electrics 3CX / 4CX - Fuses and Relays

3CX / 4CX - Fuses and Relays Fuses - NOT Servo Machines

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

Fuse Circuit No.

Rating (Amps)

A4

Steer mode proximity switches

7.5

A5

Transmission

10

A6

Gear select - Forward, Reverse Lock up torque converter speed sensors (if fitted)

3

A7

Transmission

10

A8

Brake lights

7.5

A9

Left hand side lights

5

A10

Right hand side lights

5

B1

Instruments, Buzzer

5

B2

Front horn, Front washer/wiper

15

B3

Rear horn

7.5

B4

Heated seat, Cigar lighter, Face level fan

15

B5

Rear washer/wiper

10

B6

Brake switch

10

B7

Return to dig, Smooth Ride System 5 (1) (SRS)

B8

Rear working lights

25

B9

Headlights

20

B10

Front working lights

25

C1

Lights

7.5

C2

Hazard warning lights

15

C3

Beacon, Interior light

10

C4

Radio

5

C5

Thermostart

3

C6

Heater blower

30

C7

Ignition relay coils

3

C8

Main beam

15

C9

Fog light

3

C10

Dip beam

15

8-3-3-5

If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to 10). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

C

A

B

A A

Fig 76. The fuses listed below are located in the side console underneath cover A. K Fig 76. ( T 125). Fuse Circuit No.

Rating (Amps)

A1

Engine shut-off solenoid (ESOS)

10

A2

Auxiliary hydraulics

10

A3

Direction indicators

7.5

125

(1) Fuse B7 is 10 Amp if Smooth Ride System (SRS) with Hose Burst Protection Valves (HBPV) is fitted.

9817/0000

125

Section Three - Electrics 3CX / 4CX - Fuses and Relays

Link Box Fuses To further protect the machine wiring harnesses and electrical circuits, a fuse link box B is fitted on the engine compartment bulkhead. K Fig 77. ( T 126). Remember to check the main circuit fuses as well as the link box fuses shown on this page. Fuse Circuit No.

Rating (Amps)

1

Hazard warning lights, Beacon, Lights

40

2

Wash/Wipe, Transmission, Indicators

50

3

Work lights, Fog lights, Brake lights 60

4

Ignition, Heater

B

50

An additional optional fuse may be fitted for cold start. 5

Cold start grid heater - if fitted

5

150

1

3

4

C005140-C1

2

Fig 77.

126

9817/0000

126

Section Three - Electrics 3CX / 4CX - Fuses and Relays

Relays - NOT Servo Machines

A 10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

C

10 9 8 7 6 5 4 3 2 1

4 12 10 9

A

B 3 8

7

2

1

6

5

16 15

14 13 12 11

22 21

20 19 18 17

8

Blank

9

Neutral start

10

Blank

11

Main lights

12

Engine run

14

Front working lights

15

Park brake warning light

16

Rear horn

17

Hydraulic speed control (HSC)

18

Instruments warning lights buzzer relay

20

Rear working lights

22

Air conditioning compressor (not used)

Machines from serial no. 1347278 13

Stabiliser leg alarm cut-out

19

Stabiliser leg alarm

21

Boom overload alarm

C086560

Fig 78. The relays listed below are located in the side console underneath cover A. K Fig 78. ( T 127). Note: All the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown. 1

Ignition 1

2

Blank

3

Buzzer unit

4

Direction indicators

5

Hammer

6

Auxiliary (jaw bucket)

7

Ignition 2

127

9817/0000

127

Section Three - Electrics 3CX / 4CX - Fuses and Relays

Relays - Gearbox/Steer Control 4 speed Powershift, Synchro Shuttle Machines Note: Data not applicable to machines with lock up torque converter. .

FZ1 FZ2

FD1 FE1 FF1 FG1 FH1 FD2 FE2 FF2 FG2 FH2 C065450

Fig 79. The relays listed below are located in the front console. K Fig 79. ( T 128). FD2

Forward HI/LO

FD1

Forward

FE2

Reverse HI/LO

FE1

Reverse

FF2

Interlock (1)

FF1

Drive (1)

FG2

Hydraulic speed control (HSC) cut-out

FG1

Transmission dump

FH2

Auto 2 Wheel Drive

FH1

4 Wheel Braking

FZ2

Blank

FZ1

Steer mode changeover (2)

(1) Blank on Synchro Shuttle machines. (2) 4WS machines from serial no. 1327630.

128

9817/0000

128

Section Three - Electrics 3C-14 (214e) & 3C - Fuses and Relays

3C-14 (214e) & 3C - Fuses and Relays Fuses

Fuse Circuit No.

A

Rating (Amps)

A1

Auxiliary hydraulics

5

A2

Engine shut-off solenoid (ESOS)

10

A3

Direction indicators

7.5

A4

Grid heater relay

5

A5

Gearbox control, Transmission

10

A6

Smooth ride system

10

A7

Blank

A8

Brake lights

7.5

A9

Right hand sidelights

3

A10

Left hand sidelights

3

B1

Instruments, buzzer

5

B2

Front horn, front wiper/washer

15

B3

Beacon

10

B4

Auxiliary power socket

20

B5

Rear wiper/washer

15

B6

Brake switch

10

B7

Rear work lights

25

B8

Headlights

20

B9

Front work lights

25

B10

Blank

C1

Blank

C2

Dip beam

A706530-C3

Fig 80.

!MCAUTION Fuses Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5

The fuses are located underneath cover A. If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A, B and C) and row numbers (1 to10). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

10

9

8

7

6

5

4

3

2

1

A A 3A

3A

5A

10A

3A

7.5A

5A

5A

B B 10A 25A 20A

15

15A

5A

C 15A

3A

1A

15A

7.5A

15

C3

Lights

7.5

C4

Hazard warning lights

15

C5

Face level fan

10

C6

Radio

5

C7

Thermostart

3

C8

Heater blower

30

C9

Ignition relay coils

3

C10

Main beam

15

15A C024460

Fig 81.

129

9817/0000

129

Section Three - Electrics 3C-14 (214e) & 3C - Fuses and Relays

Link Box Fuses To further protect the machine wiring harnesses and electrical circuits, a fuse link box B is fitted on the engine compartment bulkhead. K Fig 82. ( T 130). Remember to check the main circuit fuses as well as the link box fuses shown on this page. Fuse Circuit

Rating

No.

(Amps)

1

Hazard warning lights, Beacon, Lights

40

2

Wash/Wipe, Transmission, Indicators

50

3

Work lights, Fog lights, Brake lights 60

4

Ignition, Heater

50

5

Cold start grid heater

150

B

5

1

3

4

C005140-C1

2 C005140-C1

Fig 82.

130

9817/0000

130

Section Three - Electrics 3C-14 (214e) & 3C - Fuses and Relays

Relays

2

3

4

5

6

7

8

9

10

11

12

14

15

1 4W

A

A706530-C3

13

Fig 83. The relays are K Fig 83. ( T 131). Relay

located

underneath

cover

1 2

A.

16

2

17

Circuit

No. 1

4 Wheel brake

2

Lights

3

Neutral start

4

Smooth ride system

5

Reverse drive

6

Forward drive

7

Front work lights

8

Rear work lights

9

Parking brake

10

Transmission dump

11

Shovel re-set

12

Blank

13

Hazards

14

Ignition 1

15

Ignition 2

16

Buzzer

17

Blank

C024450

131

Fig 84.

9817/0000

131

132

3CX / 4CX - Schematic Circuits Basic Machine

52

Water in Fuel Warning Light

24

Engine Coolant Temperature Sender

53

Engine Coolant Temperature Switch

25

Fuel Gauge Sender

54

Transmission Oil Temperature Switch

26

Engine Coolant Temperature Gauge

55

Engine Oil Pressure Switch

27

Fuel Gauge

56

Transmission Oil Pressure Switch

Table 2. Main Components: K Fig 85. ( T 133).

28

Clock

57

Air Filter Restriction Switch

29

Tachometer

58

Water in Fuel Switch

1

Cold Start Heater ECU (if fitted)

30

Hourmeter

59

Coolant Level Switch

2

Battery Isolator

31

Side Instrument Console

60

LH Speaker

3

Battery

32

Alternator Warning Indicator Light

61

RH Speaker

4

Starter Switch

33

Parking Brake Indicator Light

62

Radio (if fitted)

5

Neutral Start Relay

34

Engine Coolant Temperature Indicator Light

6

Starter Solenoid

35

Transmission Oil Temperature Indicator Light

Fuses:

7

Starter Motor

36

Engine Oil Pressure Indicator Light

A1 - A10

8

Alternator

37

Transmission Oil Pressure Indicator Light

B1 - B10

9

Cold Start Advance Solenoid

38

Air Filter Blocked Indicator Light

C1 - C10

10

Cold Start Advance Switch

39

Panel Illumination

11

Engine Shut-Off Solenoid (ESOS)

40

Warning Buzzer Relay

Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

12

Ignition Relay `1'

41

Warning Buzzer

13

Ignition Relay `2'

42

Front Instrument Console

14

Rear Horn Relay

43

Master Warning Light

15

Rear Horn Switch

44

Turn Signal Indicator

16

Rear Horn

45

Side Lights Indicator

17

Hazard Warning Switch

46

Hazard Warning Indicator

18

Indicator Flasher Unit

47

Main Beam Warning Indicator Light

19

Direction Indicator Switch

48

Rear Working Light Indicator

20

LH Front Indicator

49

Front Working Light Indicator

21

LH Rear Indicator

50

Rear Fog Light Indicator

22

RH Front Indicator

51

Coolant Level Warning Light

The basic circuit shows a standard machine. The remaining pages in this section show machine circuits that differ from the `basic'. Note that ONLY the differences are shown.

9817/0000

132

Section Three - Electrics

RH Rear Indicator

3CX / 4CX - Schematic Circuits

23

W

DIRECT EARTH

EARTH

60

59

109L

860 1896

105D

1897

402

405

B/N

58

601 403

23

859

53 54 55 56 57

404

25

406

21

10 8

24

617

16

7 3

22

408

11

409

9

B/O

133

20

2

61 62

602

412 407 805

407

1

6

401

C D

4 4 0 3

-

U +

+

-

U

C2

26

27

28

29

43 52 51

30

32 33 34 35 36 37 38 39

802

804

B

A

49

105

49a

31

14

1 411

5

18

1

3

2

41

200

133

804

45 46 47 48 49 50

837

E F G H

830

J

200

K

835 855

304

106

200

FUSE C7

133

FUSE C4

8

3

200

007

L

133

N

001

P Q

PRIMARY FUSE 1

PRIMARY FUSE 3

200

1

200 PRIMARY FUSE 4

109

M

001

18

300

10

13

002

4

44

861

FUSE B1

6

2

806

2

104

007 8

4

17

FUSE C2

6

12

2

830 5

FUSE A3

4

8

803

FUSE B3

FUSE A2

FUSE A5 002

004

9817/0000

010

FUSE A4

107

118

31 830

17

304A

806

805

921

200

842 003 FUSE C5

109M

6

810

2

5

5 8

42

40 7

19

4

2

806

420

15

Section Three - Electrics

133

3CX / 4CX - Schematic Circuits

C001450-C1

Fig 85. Basic Machine, Sheet 1

134

Table 3. Main Components: 70

Cigar Lighter

71

Face Level Fan

72

Face Level Fan Switch

73

Heated Seat

74

Heated Seat Switch

75

Rear Washer/Wiper Switch

76

Rear Wiper Motor

77

Rear Washer Motor

78

Front Washer/Wiper Switch

79

Front Washer Motor

80

Front Wiper Intermittent Electronic Control Unit

81

Front Wiper Motor

9817/0000

82

Head Light Flasher Switch

83

Front Horn Switch

84

Front Horn

85

Rear Fog Light Switch

87

Removed For Territories - Italy, Germany

88

Fitted For Territories - Italy, Germany

89

Road Lights Relay

90

Road Lights Switch

91

Head Light Dip Switch

92

LH Main Beam Light

93

RH Main Beam Light

134

94

LH Dip Beam Light

95

RH Dip Beam Light

96

LH Tail Light

97

LH Side Light

98

Socket (Dipper Light)

100

RH Tail Light

101

RH Side Light

102

Engine Running Relay

103

Front Working Lights Relay

104

Rear Working Lights Relay

105

Front Working Lights Switch

106

Rear Working Lights Switch

107

Front Working Lights

108

Rear Working Lights

109

Cab Interior Light/Switch

110

Beacon Switch

111

Beacon

112

Heater Switch

113

Heater Motor

114

Heater Resistor

115

Air Conditioning - On/Off Switch

115a

Air Conditioning - Binary Pressure Switch

115b

Air Conditioning - Freeze Thermostat

116

Air Conditioning - Compressor Solenoid

Fuses: A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

Section Three - Electrics

Rear Fog Light

Number Plate Light

3CX / 4CX - Schematic Circuits

86

99

B

101

M

115b

3

FUSE A9

5

83

894

115

2 4

8

115a

FUSE A10

7

6

1

3

88 4

6

3

7

7

5

2

106

116

1

3

828

829

6

830

829

7

6

112

832

75

2

303

5

114 105

91

78

74

861

833

836 FUSE C1

840

984

982

983

839

864

862

830

72

M

2

868

863

8

113 861

80

FUSE C9

FUSE C10

M

407

108

855

3

855

85

76

834

7

837

M

73

903

111

98

M

81

C

116

109

107

B/P

100

B/G

B/Y

96 B/Y

79

B/U

835

814

M

71

95

94

B/U

70

99

97

B

93 92

77

B

B

B

86

B

135

84

8

7

3

855

N P

2

4

829

2

110

2

103

861

104 6

8

6

8

837

829 1853

FUSE C7

FUSE B8

FUSE B10

303

1

FUSE C3

134 311 6

3

407

8

7

FUSE C1

89 10

309

2

310

5

127

110

82

FUSE B9

007

102

87 FUSE B2

200

103

830

FUSE B5

K L

8

4

102

114

R J

90

835

FUSE B4

9817/0000

E F G H

2

134

5

117

110

133

001

C069120

Fig 86. Basic Machine, Sheet 2

135

Section Three - Electrics

PRIMARY FUSE 2

3CX / 4CX - Schematic Circuits

Q

Section Four - Hydraulics Contents

Section Four - Hydraulics Contents -6FKHPDWLF&LUFXLWV Technical Data - Introduction to Hydraulic Schematics - Basic System Operation - Schematic Circuits - Hydraulic Pump - Main Relief Valve - Unloader Valve and Hydraulic Speed Control -)DXOW)LQGLQJ+\GUDXOLF6\VWHP - Supplementary Circuits -5DP&UHHS7HVWV 

177

9817/0000

177

Section E1 - Hydraulics Systems and Schematics Systems

Systems Table 1. System Variants - Identification References SYSTEM Type

SYSTEM Topic

Manual Controls K Manual Controls - Parallel system Hydraulic SYSTEM ( T E2-1) with lever controls

Main Pump Type

Control Lever Type

Fixed flow double pump. Third engine Parallel control valves with manual driven pump for ‘ECO’ operating lever operated spools on loader and mode. excavator valves.

K Schematics Parallel System Manual Controls to November 2011 ( T E1-5)

Easy Controls (EC) - Parallel system with loader lever control and excavator servo controls

K EasyControl Hydraulic SYSTEM ( T E3-1)

Fixed flow double pump. Third engine Parallel control valves with manual driven pump for ‘ECO’ operating lever operated spools on loader valve mode. (proportional electro servo controlled auxiliary spool). Proportional servo controlled spools on the excavator valve (proportional electro servo controlled auxiliary spool).

K Schematics Parallel System EasyControls to November 2011 ( T E1-15)

Advanced Easy Controls (AEC) Closed centre variflow servo system

K Advanced EasyControl Hydraulic SYSTEM ( T E5-1)

Variable flow pump.

Proportional servo controlled spools on loader and excavator valves (proportional electro servo controlled auxiliary spools). Seat mounted control levers with thumb wheel control for auxiliary services.

K Schematics Closed Centre System - Advanced EasyControls to November 2011 ( T E1-42)

E1-3

9813/0250-04 (E-00-04)

E1-3

E1-5

9813/0250-04 (E-00-04)

Unloader Valve Spool

Main Relief Valve (MRV)

Pressure Test Point (P2)

Excavator Valve Block

3l

3m

3k

4

Loader Auxiliary Spool

3E

Pump Dump Solenoid

Loader Shovel Ram Spool

3D

3j

Loader Lift Ram Spool

3C

Shovel Ram Head Side (ARV)

Unloader Pilot Valve

3b

Shovel Ram Rod Side (ARV)

Pressure Test Point (MRV)

3a

3g

Loader Valve Block

3

3f

Twin Check Manifold

Pump - Secondary Section (P2)

2a

Diverter Valve

Pump - Main Section (P1)

2

2e

Tank Breather Cap

1c

2D

Suction Strainer

1b

Pump - Boost (P3)

Return Filter

1a

2c

4C

Tank

1

Smooth Ride System Selector Valve Assembly Smooth Ride System Accumulator Hydraulic Oil Cooler Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Clam Shovel Ram R.H. Clam Shovel Ram L.H. 2 Wheel Steer Power Track Rod

10 11 12 13 14 15 16 17 18

Diverter Valve - if fitted (hammer option)

Priority Valve

Tool Circuit Valve (if fitted)

Auxiliary (ARV)

Auxiliary (ARV)

Auxiliary Spool

Auxiliary Valve Block - if fitted (foot operated)

ARV

Hydraclamp Valve (Sideshift Machines Only)

Bucket Spool

Dipper Spool

Stabiliser Spool

Stabiliser Spool

Boom Spool

Slew Spool

9

8

7

6

5c

5b

5A

5

4h

4G

4F

4E

4D

4B

Component Key: K Fig 1. ( T E1-6)

4A

Excavator services shown here are to the JCB control pattern. If another control pattern is used, the excavator spools and relief valves will apply to different services.

Main Circuit

The policy of JCB is one of continuous improvement, therefore as products develop, there may be variations to the circuits.

Excavator HBPV One Way Restrictor Hammer Powerslide Select Valve Powerslide Ram Extending Dipper Ram Hydraclamps (Sideshift Machines Only) Auxiliary Tool Couplings Excavator Slew Mechanism (Centremount Machines) Slew Rams (Sideshift Machines) Pilot Operated Check Valve (Sideshift Machines Only)

32 33 34 35 36 37 38 39 40

Dipper Ram

29 31

Stabiliser Ram

28 30

Boom Ram Stabiliser Ram

Bucket Ram

25 27

Steer Control Valve Relief Valve

24 26

Steer Control Valve Shock Valves

AWS Valve Assembly

21 23

AWS Front Axle Power Track Rod

20 22

AWS Rear Axle Power Track Rod

19

Schematics - Parallel System - Manual Controls to November 2011

Section E1 - Hydraulics Systems and Schematics

Schematics - Parallel System - Manual Controls to November 2011

E1-5

E1-6

2e

11

1a

1

1c

2 2a

1b

2D

2c

13

15

12

9 10

14

17

16

3j 3b

3l

3C 3m

3f 3g

3k

3

3D

3E

3a

7

9813/0250-04 (E-00-04)

23

22

21

6

Fig 1. Main Circuit

24

23

19

20

36

37

18

5

8

5A

4

4F

4E

4D

4D

4B

4A

4G

5b

4h

4h

4h

4h

4h

4h

4h

5c

40

40

32

33

28

38

27

39

34

31

26

35

30

38

30

25

332/G6493-1-SHEET1

29

Section E1 - Hydraulics Systems and Schematics

Schematics - Parallel System - Manual Controls to November 2011

E1-6

E1-7

Brake Charge Accumulator

Brake Charge Accumulator Pressure Switch

Left Brake Pack - Rear Axle

Right Brake Pack - Rear Axle

Steer Valve

62

63

64

65

70

Front Power Track Rod

Brake Valves

61

73

Brake Charge Valve

60

Rear Power Track Rod

Priority Valve

11

72

Loader Valve

3

Steer Mode Valve

Pump

2

71

Tank

1

Component Key: K Fig 2. ( T E1-8)

Steering and Brakes Circuit

Section E1 - Hydraulics Systems and Schematics

Schematics - Parallel System - Manual Controls to November 2011

9813/0250-04 (E-00-04)

E1-7

Section E1 - Hydraulics Systems and Schematics 332/G6493-1-SHEET2

64

Fig 2. Steering and Brakes Circuit

60 11

1

2

3

71

70

73

72

62

63

61

65

Schematics - Parallel System - Manual Controls to November 2011

E1-8

9813/0250-04 (E-00-04)

E1-8

E1-9

9813/0250-04 (E-00-04)

Unloader Valve Spool

Main Relief Valve (MRV)

Pressure Test Point (P2)

Excavator Valve Block

3l

3m

3k

4

Loader Auxiliary Spool

3E

Pump Dump Solenoid

Loader Shovel Ram Spool

3D

3j

Loader Lift Ram Spool

3C

Shovel Ram Head Side (ARV)

Unloader Pilot Valve

3b

Shovel Ram Rod Side (ARV)

Pressure Test Point (MRV)

3a

3g

Loader Valve Block

3

3f

Twin Check Manifold

Pump - Secondary Section (P2)

2a

Diverter Valve

Pump - Main Section (P1)

2

2e

Tank Breather Cap

1c

2D

Suction Strainer

1b

Pump - Boost (P3)

Return Filter

1a

2c

4C

Tank

1

Smooth Ride System Selector Valve Assembly Smooth Ride System Accumulator Hydraulic Oil Cooler Shovel Ram R.H. Shovel Ram L.H. Lift Ram R.H. Lift Ram L.H. Clam Shovel Ram R.H. Clam Shovel Ram L.H. 2 Wheel Steer Power Track Rod

10 11 12 13 14 15 16 17 18

Diverter Valve - if fitted (hammer option)

Priority Valve

Tool Circuit Valve (if fitted)

Auxiliary (ARV)

Auxiliary (ARV)

Auxiliary Spool

Auxiliary Valve Block - if fitted (foot operated)

ARV

Hydraclamp Valve (Sideshift Machines Only)

Bucket Spool

Dipper Spool

Stabiliser Spool

Stabiliser Spool

Boom Spool

Slew Spool

9

8

7

6

5c

5b

5A

5

4h

4G

4F

4E

4D

4B

Component Key: K Fig 3. ( T E1-10)

4A

Excavator services shown here are to the JCB control pattern. If another control pattern is used, the excavator spools and relief valves will apply to different services.

Main Circuit

The policy of JCB is one of continuous improvement, therefore as products develop, there may be variations to the circuits.

Powerslide Select Valve Powerslide Ram Extending Dipper Ram Hydraclamps (Sideshift Machines Only) Auxiliary Tool Couplings Excavator Slew Mechanism (Centremount Machines) Slew Rams (Sideshift Machines) Pilot Operated Check Valve (Sideshift Machines Only)

33 34 35 36 37 38 39 40

44

43

42

Return from Sheet 3 - BB

Return from Sheet 3 - AZ

Feed to Sheet 3 - AZ

Feed to Sheet 3 - BE

Hammer

32

41

Excavator HBPV One Way Restrictor

Dipper Ram

29 31

Stabiliser Ram

28 30

Boom Ram Stabiliser Ram

Bucket Ram

25 27

Steer Control Valve Relief Valve

24 26

Steer Control Valve Shock Valves

AWS Valve Assembly

21 23

AWS Front Axle Power Track Rod

20 22

AWS Rear Axle Power Track Rod

19

Schematics - Parallel System - Manual Controls November 2011 on

Section E1 - Hydraulics Systems and Schematics

Schematics - Parallel System - Manual Controls November 2011 on

E1-9

E1-10

11

1a

1

2e

1c

2 2a

1b

44

2D

2c

13

15

12

17

9 10

14

16

3j 3b

3l

3C 3m

3f 3g

41

3k

3

3D

3E

3a

7

9813/0250-04 (E-00-04)

23

22

21

6

Fig 3. Main Circuit

24

23

19

36

37

18

5

5A

8

4F 4

4E

4D

4D

4B

4A

4G

5b

4h

4h

4h

4h

4h

4h

4h

5c

40

40

32

33

28

38

27

39

34

31

42

26

35

30

38

30 29

332-g6493-3-sheet1

43

25

Section E1 - Hydraulics Systems and Schematics

Schematics - Parallel System - Manual Controls November 2011 on

E1-10

E1-11

Brake Charge Accumulator

Brake Charge Accumulator Pressure Switch

Left Brake Pack - Rear Axle

Right Brake Pack - Rear Axle

Steer Valve

62

63

64

65

70

Front Power Track Rod

Brake Valves

61

73

Brake Charge Valve

60

Rear Power Track Rod

Priority Valve

11

72

Loader Valve

3

Steer Mode Valve

Pump

2

71

Tank

1

Component Key: K Fig 4. ( T E1-12)

Steering and Brakes Circuit

Section E1 - Hydraulics Systems and Schematics

Schematics - Parallel System - Manual Controls November 2011 on

9813/0250-04 (E-00-04)

E1-11

Section E1 - Hydraulics Systems and Schematics 332-g6493-3-sheet2

64

60

Fig 4. Steering and Brakes Circuit

11

70

71

1

2

3

73

72

62

63

61

65

Schematics - Parallel System - Manual Controls November 2011 on

E1-12

9813/0250-04 (E-00-04)

E1-12

E1-13

Check Valve

90

92

Filter

Accumulator

89

Diverter Valve

Return To Sheet 1 - AZ

88

91

Feed From Sheet 1 - AZ

87

Accumulator

84

Dual Pilot Valve

Check Valve

83

Aux Valve ISP

Pressure Reducing Valve

82

86

Feed From Sheet 1 - BB

81

85

Feed From Sheet 1 - BE

80

Component Key: K Fig 5. ( T E1-14)

Bi-Dir Circuit

Section E1 - Hydraulics Systems and Schematics

Schematics - Parallel System - Manual Controls November 2011 on

9813/0250-04 (E-00-04)

E1-13

Section E1 - Hydraulics Systems and Schematics

E1-14

81

80

82

85

83

84

Fig 5. Bi-Dir Circuit

86

87

88

89

90

91

92

332-g6493-3-sheet3

Schematics - Parallel System - Manual Controls November 2011 on

9813/0250-04 (E-00-04)

E1-14

Section E2 - Hydraulics

Manual Controls Hydraulic SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.

K Specifications ( T E2-4) K Loader Valve - Basic (Including Float) ( T E2-4) K Excavator Valve ( T E2-6) K Auxiliary Valve - if fitted ( T E2-8) K Hydraulic Pump - Gearbox Mounted ( T E2-9) K Hydraulic Pump - Engine Mounted ( T E2-11) K Operation Overview ( T E2-12) K Component Location and Identification ( T E2-12) K Operation ( T E2-13) K Hydraulic Operation and Schematics ( T E2-14) K No Services Operated ( T E2-14) K Service Operation ( T E2-14) K Hydraulic Flow Mode Control ( T E2-15) K Unloader Operation ( T E2-14) K Pilot Operated Main Relief Valve (MRV) Operation ( T E2-21) K Gearpump ( T E2-22) K Loader Valve ( T E2-23) K Excavator Valve ( T E2-29) K Electrical Operation and Schematics ( T E2-39) K Hydraulic Flow Mode Control ( T E2-39) K Hydraclamp Valve Operation ( T E2-44) K Shovel Reset Operation ( T E2-45) K Fault Finding ( T E2-46) K Tables ( T E2-47) K Test Procedures ( T E2-54) K Pump Flow and Pressure Testing ( T E2-54) K Main Relief Valve (MRV) ( T E2-55)

E2-1

9813/0250-04(E-01-11)

E2-1

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Introduction K Unloader Valve ( T E2-57) K Auxiliary Relief Valves ( T E2-58) K Ram Creep Tests - All Services ( T E2-59)

E2-2

9813/0250-04(E-01-11)

E2-2

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Where applicable the text in this section contains cross references to this page to help you find the correct information. Sections

Topic Titles

Sub Titles

2

ALL (Care and Safety)(1)

ALL

(1) You must obey all of the relevant care and safety procedures.

E2-3

9813/0250-04(E-01-11)

E2-3

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications

Specifications Loader Valve - Basic (Including Float) Relief Valve Pressures: K Fig 1. ( T E2-4)

bar

kgf/cm2

lbf/in2

Main Relief Valve (MRV)

248 - 252

253 - 256

3600 - 3650

Unloader Valve

224 - 231

228 - 235

3250 - 3350

Shovel Ram Head Side

172 - 179

176 - 183

2500 - 2600

Shovel Ram Rod Side

310 - 317

316 - 323

4500 - 4600

Auxiliary Relief Valves (ARV)

1

2

3

7 9 12

5

12

12

8

6

13 10

4

12

12

11

12

9 14

A262160-C2

Fig 1. Component Key: 1

Arms lift service

8

Unloader solenoid

2

Shovel service

9

Auxiliary relief valve (ARV)

3

Auxiliary service (optional)

10

Tank port

4

Pump section 2 - inlet

11

High pressure carry-over (HPCO) port

5

Pump section 1 - inlet

12

Service ports

6

Pressure test port

13

Load hold check valve assemblies

7

Unloader assembly

14

Main relief valve (MRV)

E2-4

9813/0250-04(E-01-11)

E2-4

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications

Loader Valve - (Including Float, Reset and SRS) Relief Valve Pressures: K Fig 1. ( T E2-4)

bar

kgf/cm2

lbf/in2

Main Relief Valve (MRV)

248 - 252

253 - 256

3600 - 3650

Unloader Valve

224 - 231

228 - 235

3250 - 3350

Shovel Ram Head Side

172 - 179

176 - 183

2500 - 2600

Shovel Ram Rod Side

310 - 317

316 - 323

4500 - 4600

Auxiliary Relief Valves (ARV)

1

2

3 15

7 9 12

8

12 B

B

B

5

12

6

13 12

A

A

A

4

12

10

12

11

17 9 15

14 16 C097930

Fig 2. Component Key: 1

Arms lift service

10

Tank port

2

Shovel service

11

High pressure carry-over (HPCO) port

3

Auxiliary service (optional)

12

Service ports

4

Pump section 2 - inlet

13

Load hold check valve assemblies

5

Pump section 1 - inlet

14

Main relief valve (MRV)

6

Pressure test port

15

SRS solenoid control valves

7

Unloader assembly

16

Shovel reset solenoid coil

8

Unloader solenoid

17

SRS port

9

Auxiliary relief valve (ARV)

E2-5

9813/0250-04(E-01-11)

E2-5

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications

Excavator Valve Auxilary Relief Valve Pressures: K Fig 3. ( T E2-6)

Bar

kgf/cm2

lbf/in2

Boom Ram Head Side

262 - 269

267 - 274

3800 - 3900

Boom Ram Rod Side

345 - 352

351 - 358

5000 - 5100

Centremount (17' , 15' 6" backhoe - except knuckle)

310 - 317

316 - 323

4500 - 4600

Centremount (14' backhoe, 15' 6" backhoe with a knuckle fitted)

262 - 269

267 - 274

3800 - 3900

Sideshift

262 - 269

267 - 274

3800 - 3900

262 - 269

267 - 274

3800 - 3900

Bucket Ram Head Side

Bucket Ram Rod Side (Machines with Rockbreaker only) Dipper Ram Head Side

262 - 269

267 - 274

3800 - 3900

Dipper Ram Rod Side

262 - 269

267 - 274

3800 - 3900

Slew Left and Right

262 - 269

267 - 274

3800 - 3900

6B

6A

5B

5A

4B

3B

2B

1B

4A

3A

2A

1A

CLAMP VALVE

CLAMP

DRAIN PORT

PORT

1A 262

1B 262

2A 345

2B

3A

3B

4A

262

4B

5A 262

5B 262

6A

6B

262

OUTLET

INLET HPCO

SLEW

BOOM

STABILISER

STABILISER

DIPPER

CROWD

C089240

Fig 3.

E2-6

9813/0250-04(E-01-11)

E2-6

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications Component Key: 1

Bucket service

8

Service ports

9

Load hold check valve assemblies

2

Dipper service

3

Stabiliser service

10

Tank port

4

Stabiliser service

11

High pressure carry-over (HPCO) port

5

Boom service (1)

12

Hydraclamp port (Sideshift)

6

Slew service

13

Hydraclamp solenoid (Sideshift)

7

Auxiliary relief valve (ARV)

14

Inlet port

(1)

(1) System shown is for JCB plus pattern and JCB diagonal pattern. For ISO system, the boom and dipper spools change position, i.e. boom is position 2 and dipper is position 5. The bottom ARV from spool 5 will also be swapped with the bottom ARV from spool 2. Auxilary Relief Valve Positions

4Q 4N

4L 4J

4P 4M

4K 4H C007390-C3

Control Layout JCB

ISO

Case

Ford

Slew Right

4H

4H

4H

4H

Slew Left

4J

4J

4J

4J

Boom Rod

4K

4M

4M

4K

Boom Head

4L

4N

4N

4L

Dipper Rod

4N

4L

4K

4N

Dipper Head

4M

4K

4L

4M

Bucket Rod

4Q

4Q

4Q

4P

Bucket Head

4P

4P

4P

4Q

Note: The bucket rod side ARV 4Q is only fitted to machines equipped with a Rockbreaker.

E2-7

9813/0250-04(E-01-11)

E2-7

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications

Auxiliary Valve - if fitted Relief Valve Pressures: K Fig 4. ( T E2-8)

Bar

kgf/cm2

lbf/in2

Extradig Ram Head Side

138 - 145

141 - 148

2000 - 2100

Extradig Ram Rod Side

207 - 214

211 - 218

3000 - 3100

Jaw Bucket Ram Head Side

138 - 145

141 - 148

2000 - 2100

Jaw Bucket Ram Rod Side

207 - 214

211 - 218

3000 - 3100

Knuckle Ram Head Side

138 - 145

141 - 148

2000 - 2100

Knuckle Ram Rod Side

207 - 214

211 - 218

3000 - 3100

Hammermaster

207 - 214

211 - 218

3000 - 3100

Power Sideshift (both)

207 - 214

211 - 218

3000 - 3100

Hand Held Tools

138 - 150

141 - 153

2000 - 2200

Weight: 5.6 kg (12.3 lbs)

1

4

B A T

7

3 5 2

6

P

HPCO

4 C002020-C2

Fig 4. Component Key: 1

Auxiliary Spool

2

Inlet port `P'

3

Outlet port `T'

4

Auxiliary relief valve (ARV)

5

High pressure carry-over (HPCO) port

6

Service port `A'

7

Service port `B'

E2-8

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E2-8

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications

Hydraulic Pump - Gearbox Mounted Model Reference:

Double pump PGP620 33-23

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

33

2.01

Pump section 2

23

1.40

Flow at 2200 rev/min and system pressure (90% min displacement): litres min

UK gal min

US gal min

Pump section 1 (mounting flange end)

65.3

14.4

17.2

Pump section 2

45.5

10.0

12.0

Maximum speed

3000 rev/min

Minimum speed

500 rev/min

Weight

28.6 kg (63 lbs)

Model Reference:

Double pump PGP620 36-26

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

36

2.19

Pump section 2

26

1.59

Flow at 2200 rev/min and system pressure (90% min displacement): litres min

UK gal min

US gal min

Pump section 1 (mounting flange end)

71.3

15.7

18.8

Pump section 2

51.5

11.3

13.5

Maximum speed

3000 rev/min

Minimum speed

500 rev/min

Weight

26.9 kg (59 lbs)

Model Reference:

Double pump PGP620 36-29

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

36

2.19

Pump section 2

29

1.77

Flow at 2200 rev/min and system pressure (90% min displacement): litres min Pump section 1 (mounting flange end) Pump section 2

UK gal min

US gal min

71.3

15.7

18.8

57.4

12.6

15.1

Maximum speed

3000 rev/min

Minimum speed

500 rev/min

Weight

28 kg (61.5 lbs)

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E2-9

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications Model Reference:

Double pump PGP620 37-33

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

37

2.26

Pump section 2

33

2.01

Flow at 2200 rev/min and system pressure (90% min displacement): litres min

UK gal min

US gal min

Pump section 1 (mounting flange end)

73.26

16.14

19.38

Pump section 2

65.3

14.4

17.2

Maximum speed

3000 rev/min

Minimum speed

500 rev/min

Weight

28.5 kg (63 lbs)

Model Reference:

Double pump PGP620 37-37

Mounting

Gearbox

Theoretical displacement:

cc/rev

cu in/rev

Pump section 1 (mounting flange end)

37

2.26

Pump section 2

37

2.26

Flow at 2200 rev/min and system pressure (90% min displacement): litres min Pump section 1 (mounting flange end) Pump section 2

UK gal min

US gal min

73.26

16.14

19.38

73.26

16.14

19.38

Maximum speed

3000 rev/min

Minimum speed

500 rev/min

Weight

24.2 kg (53 lbs)

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E2-10

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Specifications

Hydraulic Pump - Engine Mounted Model Reference:

Single pump PGP620A0140

Mounting

Engine

Theoretical displacement:

cc/rev

cu in/rev

14

0.85

Pump section 3

Flow at 2200 rev/min and system pressure (90% min displacement): litres min Pump section 3

27.7

Maximum speed

3000 rev/min

Minimum speed

500 rev/min

Weight

14 kg (31 lbs)

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9813/0250-04(E-01-11)

UK gal min

US gal min

6.0

7.3

E2-11

Section Four - Hydraulics Introduction to Hydraulic Schematic Symbols

Introduction to Hydraulic Schematic Symbols TE-001

General (Basic and Functional Symbols) Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.

Table 11. Rams Single acting

Double acting There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219. Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components. Table 10. General

Double ended

Double acting with damping at rod area end

Table 12. Pumps and Motors Variable capacity pump two directions of flow

Spring Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow Fixed capacity motor two directions of flow

Indication of rotation

Variable capacity motor one direction of flow

Indication of direction and paths of flow

Variable capacity motor two directions of flow

Variable control

195

9817/0000

195

Section Four - Hydraulics Introduction to Hydraulic Schematic Symbols Table 13. Control Valves Used to enclose several valves indicating they are supplied as one unit

Relief valve

3-Position, 4-port spring centered pilot operated valve

Variable restrictor

3-position, 6-port spring centered pilot operated valve

3-Position, 4-port spring centered solenoid & pilot pressure operated valve 3-Position, 4-port spring centered detent hand operated valve

Non-return valve

Non-return valve with back pressure spring

Pilot operated non-return valve

One way restrictor

High pressure selector (shuttle valve)

Throttling orifice - normally closed

Throttling orifice - normally open

196

9817/0000

196

Section Four - Hydraulics Introduction to Hydraulic Schematic Symbols Table 14. Energy Transmissions and Conditioning Working line, return or feed Header tank Pilot control Drain lines Pressure sealed tank Flexible pipe

Accumulator Line junction

Filter or strainer

Crossing lines

Water trap

Cooler - with no indication of coolant flow Air bleed Cooler - indicating direction of coolant flow

Line plugged, also pressure test point Line plugged with take off line

Heater

Quick release couplings connected Quick release couplings disconnected

Reservoir - return line above fluid level

Reservoir - return line below fluid level

197

9817/0000

197

Section Four - Hydraulics Introduction to Hydraulic Schematic Symbols Table 15. Control Mechanisms Rotating shaft - one direction

Rotating shaft - two directions

M

Electric motor operated

Internal pressure pilot operated

Detent External pressure pilot operated Locking device Pressure operated spring release Over centre device Pilot operated by solenoid pilot valve Simple linkage Pilot operated by a solenoid or seperate pilot valve General control Pressure guage Push button operated Pressure switch Lever operated

Pedal operated

Stem operated

Spring operated

Roller operated

Roller trip operated (one directional)

Solenoid one winding

Solenoid two windings

198

9817/0000

198

Section Four - Hydraulics Introduction to Hydraulic Schematic Symbols

Control Valves Control valves are usually represented by one or more square boxes. K Fig 129. ( T 199) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes - 3 positions etc).

Fig 132. Fig 129. K Fig 130. ( T 199) - In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).

It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares. Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. K Fig 132. ( T 199) shows a 'D' type spool.

Fig 130. K Fig 132. ( T 199) shows a valve described as a 3position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked.

K Fig 133. ( T 199) - 'F' spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to 'float'.

Fig 133. K Fig 134. ( T 199) - 'N' spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port

Fig 131. If the valve spool was moved to Position 1, movement of the spool would connect Port P1 to Port P2, and Port P3 to Port P4. K Fig 132. ( T 199). If the valve spool was moved to Position 3, movement of the spool would connect Port P1 to Port P4, and Port P3 to Port P2. K Fig 132. ( T 199).

199

9817/0000

Fig 134.

199

Section Four - Hydraulics Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

A

B

C

D

E

G

F

Fig 135. Simple Schematic Circuit Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit. K Fig 135. ( T 200).

135-E Spool 135-F One Way Valve 135-G Double Acting Hydraulic Ram

Hydraulic tank 135-A is a pressurised tank with an internally mounted strainer 135-B on the suction line to the fixed displacement pump 135-C. System pressure is limited to the setting of relief valve 135-D. Valve spool 135-E is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank. 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 135-G. Notice that the fluid must first open one way valve 135-F before flowing to the ram.

Example Circuit Key 135-A Hydraulic Tank 135-B Strainer 135-C Fixed Displacement Pump 135-D Relief Valve

200

9817/0000

200

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Operation Overview

Operation Overview Component Location and Identification

4

9

5

7

8

5

3

10 P2 P3 P1

6 12

11

13

C096690-C1

Fig 5. Component Key:

Component Key:

P1

Twin hydraulic pump (main section)

9

High pressure carry-over

P2

Twin hydraulic pump (secondary section)

10

Return line check valve

P3

Single hydraulic pump

11

Hydraulic tank

3

Loader valve block

13

Hydraulic oil cooler

4

Excavator valve

5

Auxiliary valve(1)

6

Return line filter

7

Steer circuit priority valve

8

Solenoid diverter valve

E2-12

(1) When an auxiliary valve block is fitted, oil flows from pump P1 to the loader valve block 3 via the auxiliary valve block.

9813/0250-04(E-01-11)

E2-12

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Operation Overview

Operation K Fig 5. ( T E2-12) Oil is drawn from the hydraulic tank T by the twin hydraulic pump. The pump is mounted on the rear of the gearbox and is driven by the engine via a driveshaft. The pump has two sections, P1 and P2. Oil is also drawn from the hydraulic tank T by the single hydraulic pump P3. The pump is mounted on the engine and driven by the engine heavy duty power take off drive gear. Oil from pump section P1 flows to the loader valve 3 via the auxiliary valve 5 (if fitted). Oil from pump section P2, flows to steering priority valve 7. and then to the loader valve 3 where it combines with the flow from P1. Oil from pump P1 is dumped to tank by the integral unloader valve when the system pressure reaches 227 bar. Oil from pump P3 flows to the solenoid diverter valve 8. When the system requires flow from the pump, the diverter valve solenoid energises and oil flow from pump P3 connects to the main circuit. When the system does not require oil flow from pump P3 the diverter valve deenergises and oil from the pump flows directly back to tank. From the loader valve neutral gallery, oil flows via a high pressure carry-over line 9 to the excavator valve 4. Some of the exhaust oil flows directly back to the tank through an in-tank filter 6, and some of the exhaust oil returns to tank via the hydraulic oil cooler 26. To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve 13 fitted to the return line. The check valve raises approximately 5 bar (75 lbf/in2) of pressure in the line, which improves the operation of the respective anti-cavitation valves. On sideshift machines only, hydraclamp exhaust hose 62 is fitted. The hose connects the hydraclamp spool directly into the exhaust circuit. This prevents the clamps from `locking-up' when the sideshifting operation is required.

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9813/0250-04(E-01-11)

E2-13

E2-14

9813/0250-04(E-01-11)

Note: Oil flows back to tank via hammer diverter valve 8 (if fitted).

Note: Oil from pump P1 flows to the loader valve via the auxiliary valve 5 (if fitted).

Note: Oil from pumps P2 and P3 flows to the loader valve via the tool circuit valve 6 (if fitted).

Oil from pump P2 supplies the steer circuit S and brake circuit B via steer priority / brake charge valve valve 2.

The main system pressure will be equal to the neutral circuit pressure.

With all the hydraulic services in neutral, the combined oil flow from the pumps passes across the open-centre service spools 3a and through the high pressure carry-over (HPCO) port to the inlet port of the excavator valve 4. The combined oil flow passes across the open-centre service spools 4a and back to tank.

When diverter valve solenoid 2d is energised oil from boost pump P3 also flows to the inlet section of loader valve 3.

The service spools are open-centre. Oil from primary pump P1 and secondary pump P2 flows to the inlet section of the loader valve 3.

K Fig 6. ( T E2-16)

No Services Operated

Note: To make the description as clear as possible the diagram shows only part of the complete hydraulic system. For the complete hydraulic schematics, see Systems and Schematics.

This creates a pressure differential and system pressure in gallery acts on the face of unloader spool at 3L causing the spool to be moved off its seat.

If the pressure in the inlet gallery 3f rises to the setting of the pilot valve 3d, the valve opens, allowing oil to escape more quickly than it can be replaced by oil entering through the orifice.

Pump Flow P1 Dumped to Tank K Fig 8. ( T E2-18)

Unloader spool operation protects the engine from being overloaded if a service is being worked particularly hard, for example when using the excavator to tear out. It does this by dumping the oil from the pump section P1 to tank, thus reducing the hydraulic flow and load on the engine.

Unloader Operation

Oil flow is also available to the other service spools in the valve block via the gallery 4d. This enables operation of more than one service at a time.

Oil from the other side of the ram 7 flows across the service spool and back to tank.

The main system pressure will now be equal to the working pressure (load from the boom lift ram).

When a service is operated, boom lift for example, movement of the applicable control lever 4c controls how far the service spool is displaced. Main system pressure continues to rise until load hold check valve 4b opens and the boom lift ram 7 operates.

K Fig 7. ( T E2-17)

Service Operation

Hydraulic Operation and Schematics

When pressure in inlet gallery 3f falls, for example if the excavator has stopped tearing out, pilot valve 3d will close. System pressure is restored to both ends of the unloader spool. The force from the spool spring moves the spool diverting oil from P1 into the system neutral circuit.

Pump Flow P1 in Circuit

High pressure in gallery 3f also holds check valve 3e firmly closed, preventing oil from pump section P2 from also being dumped.

Oil entering the valve block from pump section P1 now flows directly to tank.

Section E2 - Hydraulics

Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics

E2-14

E2-15

9813/0250-04(E-01-11)

Because the unloader chamber is now connected to tank, system pressure acts on the face of unloader spool 3L causing the spool to move off its seat. Oil

When the solenoid valve 3Q is energised its spool makes a connection from the unloader spool chamber 3P to tank.

Flow Dumped to Tank K Fig 10. ( T E2-20)

Pump P1

Flow from three gear pumps P1, P2 and P3 feed the machine hydraulic system. Flow from pumps P1 and P3 can be dumped directly back to tank via solenoid control valves. This enables selection of different hydraulic flow rates depending on the machine status. Pump flow combinations are given in Electrical Operation and Schematics. K Hydraulic Flow Mode Control ( T E2-39)

Hydraulic Flow Mode Control

Note: The pressure values given are examples for the purpose of explanation only. Actual values may be different depending on the machine variant. All pressure relief valves are factory set. No adjustment is normally required. K Pump Flow and Pressure Testing ( T E2-54)

When a service ram reaches the end of its stroke, or the service meets resistance and generates pressure around 250 bar in the main system, the main relief valve 3g opens and oil is dumped back to tank, preventing further pressure rise.

The maximum main system pressure is set by the main relief valve (MRV).

K Fig 9. ( T E2-19)

Main System Pressure Relief

When the solenoid valve is energised oil from pump P3 flows past non return valve 2e and into the system neutral circuit.

Flow in Circuit

When the solenoid valve is de-energised oil from pump P3 flows directly to tank. Non return valve 2e prevents oil from pump P2 also flowing to tank.

The diverter solenoid valve 2d controls the flow from pump P3.

Flow Dumped to Tank K Fig 10. ( T E2-20)

Pump P3

Since the output from pump section P2 is also required for operation of the machine steering and brake systems the pump flow is always in circuit.

Pump P2

The flow from pump P1 is also controlled by the hydraulic pressure in the circuit via the unloader valve. K Unloader Operation ( T E2-14)

When solenoid valve 3Q de-energises its spool closes the connection from the unloader valve spool chamber to tank. System pressure is restored to both ends of spool 3L. The force from the spool spring moves the spool diverting oil from P1 into the system neutral circuit.

Flow in Circuit

Non return valve 3J closes to prevent the flow from pump section P2 from also returning directly to tank.

entering the valve block from pump section P1 now flows directly to tank. K No Services Operated ( T E2-16) K Service Operation ( T E2-17) K Unloader Operation ( T E2-18) K Main System Pressure Relief ( T E2-19) K Hydraulic Flow Mode ( T E2-20)

Schematics

Section E2 - Hydraulics

Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics

E2-15

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM

8

4a

Fig 6. No Services Operated

P1

2

P2

S

B

P3

2d

6

3a

3

5

4

4a

C097870-C1

Hydraulic Operation and Schematics

E2-16

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E2-16

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM

P1

2

P2

S

B

P3

2d

6

3a

3

Fig 7. Service Operation

5

4

4d

4c

8

4a

4b

7

C097870-C2

Hydraulic Operation and Schematics

E2-17

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E2-17

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM

3e

P1

2

P2

S

B

P3

2d

6

3d

3L

3f

3a

3

Fig 8. Unloader Operation

5

4

4d

4c

8

4a

7

C097870-C4

Hydraulic Operation and Schematics

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E2-18

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM

Fig 9. Main System Pressure Relief

3e

P1

2

P2

S

B

P3

2d

6

3g

3L

3f

3a

3

5

4

4d

4c

8

4a

7

C097870-C5

Hydraulic Operation and Schematics

E2-19

9813/0250-04(E-01-11)

E2-19

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM

8

4a

Fig 10. Hydraulic Flow Mode

2d

P1

2

P2

S

B

P3

2e

6

3Q

3P

3L

3a

3J

3

5

4

4a

C097870-C3

Hydraulic Operation and Schematics

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9813/0250-04(E-01-11)

E2-20

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics

Pilot Operated Main Relief Valve (MRV) Operation

E G

G F D C

F

F C B

H

H

H

B A

A

A 2

1

3

Fig 11. 1

Valve at Rest: Oil pressure in gallery A will be acting on the bottom face of the main poppet B, and will also be felt inside the valve through the drilling in the piston C.

the main poppet B, causing it to lift and vent oil pressure from gallery A directly into the exhaust gallery H.

Oil pressure on the top face of the main poppet B, combined with the force of the springs D and E, keep the main poppet and the pilot poppet F tightly seated. 2

Pilot Valve Poppet Opens: When the pressure in gallery A reaches the pilot setting of the valve, pilot poppet F lifts, allowing oil to escape through cavity G into the exhaust gallery H.

3

Main Poppet Opens: As the pressure in gallery A continues to rise and oil escapes through cavity G, the pressure differential between the top and bottom surfaces of piston C, causes the piston to lift and seat against the end of the pilot poppet F. The oil flow through cavity G is then closed off. This produces a pressure drop above

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E2-21

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics

Gearpump

A

B A P1

D

P2 Component Key: A

Spur Gears

B

Wear Plates

C

Channel

D

Recess

P1

Main Section

P2

Secondary Section

C A396380

Fig 12. Double Pump The side of each wear plate that faces the gears has two recesses D. The recess on the inlet side of the pump assists the flow of oil into the gear spaces, thus raising the cavitation threshold of the pump. The recess on the outlet side vents oil trapped between meshing gear teeth to prevent compression loads on the bearings.

Both sections P1 and P2 operate as described below: Note: Single pump P3 operates in the same way as pump sections P1 and P2. The basic principle of the gear pump depends on the meshing of two spur gears A, one of which is engine driven while the other is an idler. Oil is picked up by the gear teeth on the inlet side of the pump and carried around between the teeth and the pump body. As the gears come into mesh, the space carrying the oil is filled by a gear tooth on the mating gear, forcing the oil out of the space and the through the pump outlet. The wear plates B are loaded towards the gears by pressurised oil which is fed to the backs of the wear plates via channels C. This ensures that the clearance between the wear plates and gears is prevented from becoming excessive as outlet pressure rises.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics

Loader Valve Service Spool Operation The loader valve may have both manually operated and servo pilot operated spools 1 depending on the machine variant. The valve spools are of a open-centre design.

1

With the spools 1 in the neutral position, the oil from the hydraulic pump(s) flows through the valve block neutral gallery N (around the central waist of the spool) and eventually back to tank. When a service is selected, the spool 1 moves against the force of the centering spring 2, allowing oil to flow out of one of the service ports (either A or B) to move the applicable service ram. When the service is de-selected, the centering spring 2 returns the spool to the neutral position.

A

The load hold check valve 3 prevents the load falling back if the load pressure is greater than the pump pressure.

N

The open-centre design means that the hydraulic services are connected in parallel.

3 B

2 C082480

Fig 13. Manually operated spool shown

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E2-23

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Load Hold Check Valves Operation 1

3C B 3J 1A

D

33 34 A396410

Fig 14. Load Hold Check Valve Operation The illustration shows 'arms raise' being selected by the lift ram spool 3C. The weight of the loaded shovel, as indicated by the arrows, produces a higher pressure in service line D than in the parallel gallery B. This pressure differential causes load hold check valve 3J to close, thus preventing the load from dropping.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Operation 2

3C B 3J 1A

D

33 34 A396420

Fig 15. Load Hold Check Valve Operation As the neutral circuit has been blocked by the central land of the selected spool 3C, the pressure in parallel gallery B increases until it is greater than that in service line D. At this point, load hold check valve 3J opens, allowing oil to flow from the parallel gallery into the service line and operate the lift rams 33 and 34.

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E2-25

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Arms Lower

3C D 3J

B

1A C

E

33 34

A396390

Fig 16. When a spool is selected as shown at 3C, the central land of the spool C blocks the neutral circuit. Oil from the pump, entering at 1A, is diverted into the parallel gallery B, opens the load hold check valve 3J, and flows around the waisted section of the spool D and out to the rod side of lift rams 33 and 34. The lower land of the selected spool E blocks the flow from the parallel gallery to the head side port and oil returning from the rams is diverted into the exhaust gallery.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Float

3C A

A

33 34

A396400

Fig 17. The float facility is provided to allow the arms to move up and down so that the shovel can follow the surface contours as the machine is driven over uneven ground. This is achieved by moving the lift spool 3C down beyond 'arms lower' into the 'float' detent, when the feed from the parallel gallery to the service ports is blocked and the neutral circuit is re-opened. Both service ports are connected to exhaust via the spool waists A. Oil can then be displaced from either end of the lift rams 33 and 34 into the exhaust gallery, allowing the rams to open and close as required.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Auxiliary Relief Valve (ARV) Operation

3C 3G

1A

32 31 3F

A396370

Fig 18. Under normal operating conditions, with the shovel in the 'carry' position, the mechanical linkage keeps the shovel level as the arms are raised, to prevent spillage of the load.

The rod side A.R.V. 3G senses a higher pressure in the exhaust gallery than in the service port and therefore opens to allow exhaust oil to overcome the cavitation.

If, as illustrated, the shovel is fully tipped when the arms are being raised, the shovel is unable to tip further, producing back pressure in the head side of the shovel rams 31 and 32 and cavitation in the rod side. As the arms continue to rise, the back pressure increases until it reaches the setting of A.R.V. 3F. This A.R.V. then opens, allowing the excess back pressure to be dumped to exhaust and prevent the rams and linkage from being damaged.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics

Excavator Valve Service Spool Operation The excavator valve may have both manually operated and servo pilot operated spools 1 depending on the machine variant. The valve spools are of a open-centre design.

1

With the spools 1 in the neutral position, the oil from the hydraulic pump(s) flows through the valve block neutral gallery N (around the central waist of the spool) and eventually back to tank. When a service is selected, the spool 1 moves against the force of the centering spring 2, allowing oil to flow out of one of the service ports (either A or B) to move the applicable service ram. When the service is de-selected, the centering spring 2 returns the spool to the neutral position.

A

The load hold check valve 3 prevents the load falling back if the load pressure is greater than the pump pressure.

N

3

The open-centre design means that the hydraulic services are connected in parallel.

B

2 C082480

Fig 19. Manually operated spool shown

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Load Hold Check Valves Operation 1

4B

D B

4S

A401200

Fig 20. Flow to the service via a typical solid spool 4B is controlled by the load hold check valve 4S which is a spring-loaded non-return valve operating across the pressure feed from the parallel gallery B. The valve prevents reverse flow from the rams into the pressure feed line, so maintaining ram pressure until exceeded by system pressure. The illustration shows a service selected but back pressure D exceeds system pressure which closes the load hold check valve 4S.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Operation 2

4B

4S

E

A401210

Fig 21. When pressure in the feed line exceeds back pressure, the load check valve 4S opens and oil operates the ram. The remaining load hold check valves are also opened by system pressure but the galleries are dead-ended because the spools are in neutral.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics One Way Restrictor Operation

E

A396350

Fig 22. Because of its weight, the excavator end could take over control when boom lower was selected. The falling boom would tend to push oil out of the ram faster than the head side was being filled. Consequently, when the excavator had reached the ground, there would be a time lapse while the ram filled with oil before the service would operate again. To prevent this from happening, the boom service is fitted with a one way restrictor. When the boom is being raised, the poppet in restrictor E is held off its seat by the pressurised oil flow, therefore oil delivery to the boom ram rod side is unrestricted. When the boom is being lowered, the oil flow through the one way restrictor E re-seats the poppet, therefore the flow of oil is restricted through the small drilling in the base of the poppet. This slows the boom down to a controllable speed.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Slew Operation

4A

4J

D B

C

4H A401220

Fig 23. The illustration shows R.H. slew selected. The lower port C has been pressurised by the spool. Oil flows from the parallel gallery B, out past A.R.V. 4H to both the head side of the L.H. slew ram and the rod side of the R.H. slew ram. The boom therefore slews to the right hand side of the machine. Displaced oil from the rod side of the L.H. slew ram and from the head side of the R.H. slew ram flows back through the upper service port D and back to tank.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Slew Ram End Damping D

As ram A nears the closed position, damping rod B seats in cone C, where it is held by spring D. Tapered flutes on the end of the rod produce a restricting orifice, thus restricting the speed of the oil being exhausted from the ram. This provides a cushioning effect between the piston and the dump end of the ram, effectively damping out the shock loads which would otherwise occur when the boom reaches the end of its slewing arc.

A

w

B

C

A230420

Fig 24.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Slew A.R.V. and Anti-Cavitation Operation

4A

4J

4H A396360

Fig 25. The spool 4A is in neutral but the momentum of the slewing excavator end creates back pressure in the head side of the R.H. slew cylinder and in the rod side of the L.H. slew cylinder. This opens A.R.V. 4J and dumps oil to exhaust. At this point the cylinders cavitate and exhaust oil pressure causes A.R.V. 4H to open, allowing oil from the exhaust gallery to fill the L.H. cylinder.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics A.R.V. Operation

4E

4E

4F

4Q

4N

4M

4P A396430

Fig 26. The illustration shows the bucket spool 4F selected to operate the service against an immovable object. This forces the dipper away from the obstruction and pressurises the head side of the dipper ram. When this pressure reaches the setting of A.R.V. 4M, this valve opens, relieving the pressure into the exhaust gallery. Cavitation occurs in the rod side of the dipper service until A.R.V 4N opens, allowing the higher pressure in the exhaust gallery to supplement that in the service line. Note: A.R.V. 4Q is only fitted to machines with a Rockbreaker.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Hydraclamp Valve Operation (Sideshift Machines)

C097260

Fig 27. When the backhoe is being used for excavating duties, the kingpost assembly must be 'clamped' to the sideshift rearframe. The hydraclamp control valve cartridge (items G, D and C) is positioned in the inlet end of the excavator valve block and is connected directly to the parallel gallery B. The valve operates in conjunction with solenoid valve E housed in the side of the excavator valve block. 1

Clamps Pressurised

When the hydraclamp switch A is in the OFF position (not pressed), the solenoid valve E is de-energised. The solenoid valve in this de-energised state blocks the exhaust path from the parallel gallery B to the drain port (tank).

E2-37

When an excavator service is operated, pressure is generated in parallel gallery B, this pressurised oil enters the clamp valve C and lifts poppet D off its seat against the force of spring G. The oil flows past the poppet and out to the hydra-clamps 62. 2

Clamps Released

When the hydraclamp switch A is in the ON position (pressed down), the solenoid valve E is energised. The solenoid valve in this energised state now allows a connection to be made from the parallel gallery B to the drain port (tank) via gallery F. Oil from the hydra-clamps is vented through the clamp valve and gallery F to the drain port (tank).

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E2-37

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Hydraulic Operation and Schematics Also, pressure resulting from the operation of an excavator service passes by poppet D as before but the oil takes the path of least resistance and is vented via gallery F to the drain port (tank). Restrictor H ensures that not all oil in gallery B is dumped back to tank. 3

Clamps Locked Up

If no service is being operated, pressure in the parallel gallery falls to that of the neutral circuit and the force of spring G is sufficient to keep the poppet seated. Pressure is therefore trapped in the line to the clamps, maintaining the excavator end in a securely clamped condition.

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Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control

Unloader Valve and Hydraulic Speed Control Unloader - Neutral Circuit

Unloader - Operation

K Fig 164. ( T 237).

K Fig 165. ( T 237).

The loader valve is mounted on the chassis frame, right hand side (when viewed from the rear).

Unloader spool operation protects the engine from being overloaded if a service is being worked particularly hard, for example when using the excavator to tear out. It does this by dumping the oil from the pump section P2 to tank, allowing engine power to be applied fully to the main pump section P1.

It includes the lift ram spool 3C, shovel ram spool 3D and auxiliary spool 3E. Linkage rods connect the spool ends to the control levers. In neutral circuit hydraulic oil from the pump section P2 enters the loader valve at 1C via the steering priority valve. On entering the valve block, oil flows around the waisted section of the unloader valve 3L, past check valve 3N and joins the flow from pump section P1. Oil from pump section P1 enters the loader valve at 1A. Combined oil flow from P1 and P2 passes the main relief valve (MRV) 3B and fills the parallel gallery B. From the parallel gallery the oil flows around the waisted central portions of spools 3C, 3D and 3E (all in neutral position) and flows on to feed the excavator valve via high pressure carry over line 1B. Pressure in inlet gallery C is sensed by pilot valve 3M via the bore of spool 3L. At pressures below the setting of the unloader valve, both pilot valve 3M and spool 3L remain closed. See also K Table 16. Key to Oil Flow and Pressure ( T 219).

If the pressure in the inlet gallery C rises to the setting of the pilot valve 3M, this valve will open, allowing oil in spring cavity 3P to escape more quickly than it can be replaced by oil entering through the small drilling D. This creates a pressure differential between the spring cavity 3P and gallery C. Higher pressure in gallery C acts on the face of spool 3L causing the spool to be moved off its seat. Oil entering the valve block from pump section P2 now flow directly to tank T. High pressure in gallery C also holds check valve 3N firmly closed, preventing oil from pump section P1 from also being dumped. When pressure in inlet gallery C falls, for example if the excavator has stopped tearing out, pilot valve 3M will close. This means oil in spring cavity 3P will be at the same pressure as oil in gallery C, spring pressure will move spool 3L back onto its seat, closing pump section P2 connection to tank. See also K Table 16. Key to Oil Flow and Pressure ( T 219).

236

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Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control

3C 3M B

3D 3E

3L 1B

T

1C(P2) C 3Q 3B

1A(P1)

3N 3J A401150

Fig 164.

3M 3L

3P

T

C P2 D

3N P1 A401160

Fig 165.

237

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Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control

Hydraulic Speed Control Hydraulic Speed Control (HSC)- Operation K Fig 166. ( T 239). Solenoid valve 3Q allows the operator to control the unloader spool movement (to dump flow from the hydraulic pump section P2) using a switch in the cab. There are two main applications for this operation: 1

More tractive force can be applied to the loader end when entering a stock pile. This is because more power is available from the engine as flow from pump section P2 is being dumped directly to tank.

2

More power can be made available from the engine whilst the machine is travelling on the highway. Again, this is because flow from pump section P2 is being dumped directly to tank.

When the solenoid valve 3Q is de-energised its spool is moved by spring pressure. This spool movement makes a connection from the unloader spool chamber 3P to tank. Because the unloader chamber is now connected to tank, and so at exhaust pressure, pressure in gallery C (neutral shown) acts on the face of unloader spool 3L causing the spool to be moved off its seat. Oil entering the valve block from pump section P2 now flows directly to tank. When solenoid valve 3Q is energised its spool closes the connection from the unloader valve spool chamber to tank. Spool 3L is once again controlled by system pressure. For a full description of the HSC electrical system and connections see Electrical Connections, Hydraulic Speed Control (HSC).

238

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Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control

3D

W 3C

3E

3M 3P 3L

T 1C(P2) 3Q C

1A(P1)

3N 3J A401170

Fig 166. Hydraulic Speed Control (HSC) See also K Table 16. Key to Oil Flow and Pressure ( T 219).

239

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Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Electrical Operation K Fig 167. ( T 241). The illustration shows how the HSC electrical system works in different modes: - HSC selector switch OFF - HSC selector switch ON - HSC selector switch OFF and override pushbutton pressed. - HSC selector switch ON and override pushbutton pressed. - HSC selector switch OFF and 4th/Auto gear selected (Powershift/Shiftmaster machines only). When the hydraulic speed control (HSC) system is `ON', the unloader valve solenoid NA on the loader valve block is energised, which dumps the output flow from the secondary pump (P2) back to tank. Dumping the P2 pump output flow in this way reduces the load on the engine, and ensures that more of the engine power is available to the machine transmission. In addition, the oil flow to the hydraulic services is also reduced, which makes the services operate slower for more precise work. See the machine Operator Handbook for full details. For a detailed description of the HSC electrical circuit and connections, see Circuit Descriptions Section E. For a description of the hydraulic operation, see Section E, Hydraulics.

240

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Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control (1)

FL -

FJ

(2)

-

DT

(1)

DE

-

NF

2-1

CN

-

-

NA -

1 8

7

5

1, 2, 3

-

-

-

8 7 9

3 1 6 4

2

2-3

-

10 6

9-6

1-2

2 8

7

1, 2, 3

-

5

-

-

8 7 9

3 1 6 4

2

2-1

A-B

10 6

8 - 10, 7 - 6

-

3 8

7

1, 2, 3

-

4

5

-

-

2-3

8

14 - 13

1-4

2 - 1, 5 - 4

8

-

-

10 6

8 - 10, 7 - 6

1-2

7 3 1 6 4

2

4th, A

6

8 - 10

8 7 9

3 1 6 4

5

8-9

A-B

10

7

2

1, 2, 3

5

8 7 9

3 1 6 4

2

5

8 7 9

10 6

Fig 167. Quick Reference The illustration shows the different switch positions with the HSC relay and solenoid status. Modes of Operation: 1

NA

Unloader Valve Solenoid (Loader valve block)

NF

HSC Override Pushbutton (Loader lever)

(1) Powershift and Shiftmaster machines only. (2) Powershift machines only.

HSC selector switch OFF

2

HSC selector switch ON

3

HSC selector switch OFF and override pushbutton pressed

4

HSC selector switch ON and override pushbutton pressed

5

HSC selector switch OFF and 4th/Auto gear selected (1)

Component Key: CN

HSC Relay

DE

HSC Selector Switch

DT(1)

Diode

FJ(2)

Diode

FL

(1)

241

Column Gear Lever Switch

9817/0000

241

Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Hydraulic Speed Control - Electrical Circuits

T040370-38

Fig 168.

242

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242

Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Notes:

243

Notes:

9817/0000

243

Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Unloader Valve Sectional View Pumps 1 and 2 Combined

T040370-36

Fig 169.

244

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244

Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Pump 2 to Tank

T040370-37

Fig 170.

245

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245

Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Notes:

246

Notes:

9817/0000

246

Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Unloader Valve Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. Make sure that the `hydraulic speed control' and `smooth ride system' facilities are NOT switched on, otherwise the correct unloader valve pressure cannot be obtained. If the machine has a front-mounted roadbreaker, ensure that the roadbreaker control valve lever is in the 'off' position (lever down), otherwise the roadbreaker relief valve will operate and prevent unloader valve pressure from being reached. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A.

2

With the engine running at 1500 revs/min, slowly operate arms raise or lower.

S266300-C1

Fig 171.

Note: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the M.R.V. and not an A.R.V. 3

When the service reaches full travel, return the lever to the neutral position. Select the service again, very slowly, the pressure gauge will rise until a step or kick is seen in the rate of change in the pressure increase. This is the start of unloader operation. Keep selecting the service until a sudden sharp increase in pressure is observed with a change of engine sound, this point is the unloader setting and should be as specified in Technical Data.

4

If the pressure is incorrect, slacken locknut E and adjust cap F. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required. If the correct pressure cannot be achieved, add or subtract shims as required, refer to Loader Valve - Fixed Flow, Dismantling and Assembly - Unloader Valve.

247

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Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control Hydraulic Speed Control (HSC) The following procedure can be used to establish if the hydraulic speed control facility is working correctly. Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure. 1

2

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to the hydraulic test point A at the loader valve as shown. With the engine running at 1500 revs/min, slowly operate arms raise, the pressure should be approximately 138 bar (2000 lbf/in2).

3

Make sure that the HSC rocker switch (mounted on the console) is in the OFF position. Raise the arms slowly and select the rocker switch to ON, the arms should raise slower.

4

Make sure that the HSC rocker switch (mounted on the console) is in the OFF position. Raise the arms slowly and press the button on the loader control knob, the arms should raise slower.

5

If the loader arms fail to respond, then check the HSC hydraulic and electrical circuits for any faults.

248

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A

C042330

Fig 172.

248

Section Four - Hydraulics Unloader Valve and Hydraulic Speed Control

Additional Hydraulic Information Possible Unloader Faults Slow Hydraulics (P2 always to tank) Hydraulic

Electrical

Excessive Engine Pull down (P2 will not dump) Hydraulic

249

Electrical

9817/0000

249

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Electrical Operation and Schematics

Electrical Operation and Schematics Hydraulic Flow Mode Control Depending on the status of the machine, flow from gear pumps P1 and P3 is diverted to tank via solenoid valves. Flow from pump P2 is always available to ensure correct operation of the steering and braking systems.

Flow Switch ECO ECO ECO ECO(1) LO(2) LO

A flow switch in the cab controls the flow from pump P1. The instrument ECU controls the flow from pump P3 automatically. The instrument display indicates the status of the hydraulic system. The table shows pump flow depending on machine status.

Pump Flow P1

P2

z z z

z z z z z z

Status

LCD Display

P3

Engine R.P.M. below 650 or above 1900

Drive (FNR) Transmission ratio(1) N HYD-STD

z

650-1700

N

-

HYD-ECO

-

F, R

1,2,3

HOURS

-

F, R

4

HOURS

-

N

-

HYD-LO

-

F, R

-

HOURS

z

(1) Powershift machines only (2) Hydraulic speed control setting (HSC)

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Electrical Operation and Schematics Schematics

energises. HSC relay CP29 de-energises and prevents HSC solenoid MF24 energising.

Before fault finding make sure that you understand how the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and solenoids.

The flow mode switch CP64 is set to ‘ECO’. The hydraclamp switch CP71 is set to engage the clamps. HSC solenoid MF24 does not energise.

Component Key: CP09B

Diode

CP11

HSC button

CP17

P3 pump relay

CP29

HSC relay

CP57

Instruments ECU

CP64

Flow mode switch

CP71

Hydraclamp switch

FC19

LH column switch

FC33

HSC cut out relay

FC37

Diode

MF24

HSC solenoid

MF39

Pump P3 dump solenoid

K Hydraulic Mode Control - ECO Mode - 4th Gear (Powershift only) ( T E2-43)

When the drive control is set to F or R the input at pin 9 of the instruments ECU CP57 is low. The ECU de-energises P3 dump solenoid MF39. The hydraulic system now functions with flow from pumps P1, P2. When the gear selector is set to 4 or A HSC relay CP29 energises and energises HSC solenoid MF24. The hydraulic system now functions with flow from pump P2 only. This ensures engine efficiency when travelling in 4th gear (or A).

K Hydraulic Mode Control - LO Mode ( T E2-41) The flow mode switch CP64 is set to ‘LO’. The hydraclamp switch CP71 is set to engage the clamps. The HSC solenoid MF24 energises via relay CP29. The flow from pump P1 is diverted to tank. When the drive control is set to N the input at pin 9 of the instruments ECU CP57 is high. The ECU energises P3 dump solenoid MF39. The hydraulic system functions with flow from pump P2 and P3. When the drive control is set to F or R the input at pin 9 of the instruments ECU CP57 is low. The ECU de-energises P3 dump solenoid MF39. The hydraulic system functions with flow from pump P2 only. K Hydraulic Mode Control - ECO Mode - 4th Gear (Powershift only) and Neutral ( T E2-42) The flow mode switch CP64 is set to ‘ECO’. The hydraclamp switch CP71 is set to engage the clamps. HSC solenoid MF24 does not energise. The hydraulic system functions with flow from pump P1 and pump P2. Input at pin 10 of the instruments ECU CP57 is high. When the drive control is set to N the input at pin 9 at the instruments ECU CP57 is also high. When the ECU detects the engine speed is between 650 and 1700 R.P.M. it energises P3 dump solenoid MF39. The hydraulic system now functions with flow from pumps P1, P2 and P3. Powershift only; If the operator leaves the gear selector set to 4 or A, cut out relay FC33 ensures correct hydraulic mode operation. When the drive is set to N relay FC33

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Electrical Operation and Schematics

HSC CUT OUT RELAY

FC33 4th

13

14

10

FC37 N

6

6

9 7

10

8

DIODE FC02

FC19 LH COLUMN SWITCH

CP01/FC01 CP06/MF01

22

2

1

MF22

45

MF24 HSC (P1 DUMP SOLENOID)

A4

FUSE

8

4 2 5

1 3

CP06/MF01

2

1

36

CP17

MF39

P3 PUMP RELAY

P3 DUMP SOLENOID 9 14

HSC RELAY

CP29

ECU

10

6

9 7

10

8

CP57 INSTRUMENTS J2

2

1

7

CP09B

3

DIODE

1

8 2

6 A

B

5

4

CP11

9

10

ECO

CP64

HSC BUTTON

FLOW MODE SWITCH

LO CP04

7

8

3

2

1 6

A2

FUSE

4

5

4

CP71 HYDRACLAMP SWITCH C096720

Fig 28. Hydraulic Mode Control - LO Mode

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Electrical Operation and Schematics

HSC CUT OUT RELAY

FC33 4th

13

14

10

FC37 N

6

6

9 7

10

8

DIODE FC02

FC19 LH COLUMN SWITCH

CP01/FC01 CP06/MF01

22

2

1

MF22

45

MF24 HSC (P1 DUMP SOLENOID)

A4

FUSE

8

4 2 5

1 3

CP06/MF01

2

1

36

CP17

MF39

P3 PUMP RELAY

P3 DUMP SOLENOID 9 14

HSC RELAY

CP29

ECU

10

6

9 7

10

8

CP57 INSTRUMENTS J2

2

1

7

CP09B

3

DIODE

1

8 2

6 A

B

5

4

CP11

9

10

ECO

CP64

HSC BUTTON

FLOW MODE SWITCH

LO CP04

7

8

3

2

1 6

A2

FUSE

4

5

4

CP71 HYDRACLAMP SWITCH C096720-C2

Fig 29. Hydraulic Mode Control - ECO Mode - 4th Gear (Powershift only) and Neutral

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Electrical Operation and Schematics

HSC CUT OUT RELAY

FC33 4th

13

14

10

FC37 N

6

9 7

10

8

DIODE

6

FC02

FC19 LH COLUMN SWITCH

CP01/FC01 CP06/MF01

22

2

1

MF22

45

MF24 HSC (P1 DUMP SOLENOID)

A4

FUSE

8

4 2 5

1 3

CP06/MF01

2

1

36

CP17

MF39

P3 PUMP RELAY

P3 DUMP SOLENOID 9 14

HSC RELAY

CP29

ECU

10

6

9 7

10

8

CP57 INSTRUMENTS J2

2

1

7

CP09B

3

DIODE

1

8 2

6 A

B

5

4

CP11

9

10

ECO

CP64

HSC BUTTON

FLOW MODE SWITCH

LO CP04

7

8

3

2

1 6

A2

FUSE

4

5

4

CP71 HYDRACLAMP SWITCH C096720-C1

Fig 30. Hydraulic Mode Control - ECO Mode - 4th Gear (Powershift only)

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Section Four - Hydraulics Hydraulic Pump

Hydraulic Pump Failures Abrasive Wear caused by Fine Particle Contamination

T040370-29

Fig 148.

222

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222

Section Four - Hydraulics Hydraulic Pump Wear Caused by Incorrect Pump Assembly

T040370-30

Fig 149.

Wear Caused by Aeration or Cavitation

T040370-31

Fig 150.

Damage Caused by Foreign Objects

T040370-32

Fig 151.

223

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223

Section Four - Hydraulics Hydraulic Pump Damage due to Over Pressure

T040370-33

Fig 152.

Damage Caused by Overheating

T040370-34

Fig 153.

224

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224

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding

Fault Finding The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the hydraulics section. To help identify circuits, valves, rams etc mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams (near the beginning of the Hydraulics Section). 1

Before you begin fault finding, read the Safety information at the beginning of this manual.

2

Make simple checks before say, stripping a major component.

3

Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

4

What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

5

Make any relevant electrical checks before moving on to the hydraulics.

6

Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.

7

Replace any seals such as 'O' rings before reassembling hydraulic components.

E2-46

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E2-46

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding

Tables Fault Descriptions: 1

Lack of power in all hydraulic functions.

K Table 2. ( T E2-48).

2

All hydraulic rams slow to operate.

K Table 3. ( T E2-49).

3

One hydraulic service fails to operate or is slow to operate.

K Table 4. ( T E2-50).

4

The engine tends to stall when the hydraulics are under load.

K Table 5. ( T E2-51).

5

A spool is sticking.

K Table 6. ( T E2-52).

6

Leaking oil seal (control valves).

K Table 7. ( T E2-53).

7

Ram creep.

K Table 8. ( T E2-53).

8

Hydraulic oil becomes too hot.

K Table 9. ( T E2-53).

9

Hydraulic flow mode does not respond as expected.

K Table 9. ( T E2-53).

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E2-47

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding Fault

Table 2. Probable Cause

Lack of power in all hydraulic functions. Insufficient hydraulic fluid.

E2-48

Action Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance, see transmission section for stall speed test procedures.

Main Relief Valve (MRV) setting incorrect.

Check and adjust the MRV as required.

Low pump pressure.

Check pump pressure, if required service or replace pump.

Hydraulic tank breather.

Clean or replace the breather.

Tank filter by-pass valve.

Check condition of hydraulic filter.

Unloader valve pressure setting too high.

Check pressure setting of the unloader valve.

9813/0250-04(E-01-11)

E2-48

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding Fault All hydraulic rams slow to operate.

E2-49

Table 3. Probable Cause

Action

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Check pipe lines and replace as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Main Relief Valve (MRV) setting incorrect.

Check and adjust as required.

Unloader valve defective.

Check if unloader valve is sticking, i.e. dumping flow from pump section P2.

Flow control mode system defective.

Check HSC and P3 pump control solenoid operation. Check flow control mode electrical system.

Tank filter by-pass valve.

Check condition of hydraulic filter.

Hydraulic tank Breather.

Clean or replace the breather.

9813/0250-04(E-01-11)

E2-49

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding Fault

Table 4. Probable Cause

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.

Associated ram leaking.

Complete ram leakage check, replace seals as required.

Auxiliary Relief Valve (ARV) setting incorrect.

Replace the applicable ARV. Ensure that the ARV is the correct part.

Action

Associated valve block section leaking Check for leaks, rectify as required. See or not operating also `Leaking Oil Seal (Control Valves)'. Ensure that the associated load hold check valve is operating. Check that the control lever and associated linkage is operating the spool, rectify as required. See also `A Spool is Sticking'. Check valve malfunctioning (if fitted), e.g. stabiliser circuit.

Test check valve, rectify as required.

Hose burst protection valve malfunctioning (if fitted).

Test HBPV, service as required.

Piston rod is bent.

Replace piston rod, check pressure settings of the MRV. Replace the applicable ARV. Ensure that the ARV is the correct part. Check that associated pivot points are adequately greased.

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E2-50

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding Fault The engine tends to stall when hydraulics are under load.

E2-51

Table 5. Probable Cause

Action

MRV setting incorrect.

Check and adjust the MRV as required.

Poor engine performance.

Check engine performance, see transmission section for stall speed test procedure.

Unloader valve pressure setting too high.

Check pressure setting of the unloader valve.

9813/0250-04(E-01-11)

E2-51

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding Fault A spool is sticking.

Table 6. Probable Cause

Action

Oil temperature abnormally high.

Check for correct fluid, see lubricants and capacities. Check oil cooler and grille for blockage.

The hydraulic fluid is dirty.

Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system. Fill with clean hydraulic fluid.

The service pipe connection is over tightened.

Check tightening torque.

The valve housing was twisted during installation.

Loosen retaining bolts and tighten to correct torque figures.

A control linkage is bent.

Disconnect the linkage. Repair the linkage if possible, or fit a new one.

A spool is bent.

Dismantle the control valve. Renew spool as necessary.

A return spring is broken.

Renew as necessary.

A return spring or cap is out of alignment.

Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts.

Temperature distribution within control Warm the entire system up before valve not uniform. servicing.

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E2-52

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Fault Finding Fault Leaking Oil Seal (Control Valves)

Fault

Table 7. Probable Cause

Action

Paint or dirt on the seal face.

Remove the seal and clean.

The back pressure in the valve circuit is excessively high.

Check circuit pressures, adjust if possible. Otherwise investigate thoroughly.

Spool damaged.

Dismantle. Inspect all parts. Renovate or renew as necessary.

The seal is not secured.

Clean the seal and tighten the retaining bolts to the correct torque.

The seal is cut or damaged.

Fit a new seal.

Table 8. Probable Cause

Action

Ram creep. K Ram Creep Tests - All Associated ram or pipe lines from ram Check and rectify as required. Services ( T E2-59) leaking.

Fault Hydraulic oil becomes too hot.

E2-53

Check valve malfunctioning (if fitted), e.g. stabiliser circuit.

Test check valve, rectify as required.

Associated valve section spools leaking.

Rectify, check for contamination.

Associated ARV leaking

Rectify, check for contamination. Replace the applicable ARV. Ensure that the ARV is the correct part.

Table 9. Probable Cause

Action

Oil cooler obstructed.

Remove debris from cooler fins.

Restriction in neutral circuit lines.

Check hoses, replace as necessary.

Hydraulic filter clogged and by-pass valve not working.

Change hydraulic filter.

9813/0250-04(E-01-11)

E2-53

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

Test Procedures Pump Flow and Pressure Testing

2

Before removing the pump it is necessary to determine the source of any problem by measuring the output flow at system pressure from both of the pump outlet ports.

Pump section 2 - disconnect hose D from the pump. Fit the flow meter and load valve (refer to Note 2) between hose D and the pump.

3

Pump section 3 (engine driven pump) - disconnect hose E from the pump. Fit the flow meter and load valve (refer to Note 2) between hose E and the pump.

To check flow it is necessary to fit flow meter into the output line of each pump section in turn. If available, load valve (service tool 892/00270) should also be installed (refer to Note 1). Make sure the flow meter is installed with its arrow pointing away from the pump and, if applicable, located between the pump and the load valve.

Note: 2) Make sure the load valve is in the open position, i.e. with the adjusting knob screwed fully out, before carrying out the Checking Flow procedure.

D

Note: 1) If no load valve is available, ignore the references to the load valve in Fitting and Removing a Flow Meter and Load Valve below. An alternative method of determining flow is included in the Checking Flow procedures following.

C

Fitting and Removing a Flow Meter and Load Valve Before fitting or removing a flow meter and load valve, vent the hydraulic pressure. Refer to Section 2 - General Procedures.

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

A396190

Fig 31. Removing Removing is the reverse of fitting.

INT-3-1-11_2

!MWARNING

Checking the Pump Flow

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

1

TRANS-1-2

2

Fitting 1

Pump section 1 - disconnect hose C from the pump. Fit the flow meter and load valve (refer to Note 2) between hose C and the pump.

E2-54

Check the setting of the Main Relief Valve (MRV) as described in Loader Valve, Pressure Testing. Adjust if necessary.

a

9813/0250-04(E-01-11)

Using a load valve - fit a flow meter and load valve, as described in Fitting, to each pump outlet in turn. Fit a 0-400 bar (0-6000 lbf/in2) pressure gauge to the load valve pressure test connector.

E2-54

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures b If no load valve is available - fit a flow meter, as described in Fitting, to each pump output in turn. 3

the pressure is correct, tighten the lock nut and check the pressure again. Adjust as required.

Start the engine and bring the hydraulics up to working temperature 50ºC (122ºF). Set the engine speed to 2200 rpm.

4 a

Using a load valve - adjust the load valve so that the pressure gauge reading is just below the MRV setting.

b If no load valve is available - raise or lower the loader arms until the rams are fully open or closed. Continue to operate the raise or lower control so that system pressure builds up. Watch the flow meter and note its reading at the moment the MRV operates. 5

The flow reading Specifications.

should

be

as

listed

in

Main Relief Valve (MRV) Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. Vent the hydraulic pressure. Refer to Section 2 - General Procedures. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A on the loader valve, (see Service Tools).

2

With the engine running at 1500 revs/min, check M.R.V. pressure by raising or lowering the loader arms until the rams are fully open or closed and noting the maximum gauge reading. CAUTION: Do not select 'float'. The maximum pressure should be as listed in Specifications.

Note: The rams must be 'held' open or closed when reading gauge. 3

If the pressure is incorrect, loosen lock nut D and adjust screw C. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When

E2-55

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

C000340-C1

Fig 32.

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E2-56

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

Unloader Valve Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F). Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures. Vent the hydraulic pressure. Refer to Section 2 - General Procedures. Make sure that the `hydraulic speed control' and `smooth ride system' facilities are NOT switched on, otherwise the correct unloader valve pressure cannot be obtained. If the machine has a front-mounted roadbreaker, ensure that the roadbreaker control valve lever is in the 'off' position (lever down), otherwise the roadbreaker relief valve will operate and prevent unloader valve pressure from being reached. 1

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to pressure test connector A.

2

With the engine running at 1500 revs/min, slowly operate arms raise or lower.

Fig 33.

Note: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the M.R.V. and not an A.R.V. 3

When the service reaches full travel, return the lever to the neutral position. Select the service again, very slowly, the pressure gauge will rise until a step or kick is seen in the rate of change in the pressure increase. This is the start of unloader operation. Keep selecting the service until a sudden sharp increase in pressure is observed with a change of engine sound, this point is the unloader setting and should be as specified. Refer to Specifications.

4

If the pressure is incorrect, slacken locknut E and adjust cap F. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required. If the correct pressure cannot be achieved, add or subtract shims as required. Refer to Loader Valve - Fixed Flow, Dismantling and Assembly - Unloader Valve.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

Auxiliary Relief Valves Some hydraulic services are fitted with Auxiliary Relief Valves (ARVs). K Specifications ( T E2-4) ARVs are set at pressures less than, or more than, the Main Relief Valve (MRV) pressure setting depending on the applicable hydrauilc service. This is to prevent damage to the machine and ensure the safe handling of loads. To identify possible faulty ARVs refer to the applicable fault finding tables. K Fault Finding ( T E2-46) The pressure setting of the auxiliary relief valves is not adjustable. If a faulty auxiliary relief valve is suspected replace it with a new one with the correct pressure setting. Refer to the applicable valve topic.

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E2-58

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

Ram Creep Tests - All Services A

If ram creep is suspected the following procedures must be carried out to define if the leakage is within tolerance. Ram creep can be caused by a number of reasons: cylinder or piston leakage, spool leakage or ARV leakage.

C The text and illustrations show a typical ram installation (in this instance the boom ram), the principle applies to all rams. Note: The procedures are not applicable for rams fitted with hose burst protection valves.

B C

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

Fig 34. 5

Measure the actual piston rod movement over 10 minutes. Measure the movement by checking the pivot pin to pivot pin dimensions as at C. Alternatively mark the rod with a felt tip pen 150mm (5.9 in) from the end cap and check the movement after 10 minutes, this is not possible on the majority of boom extending dipper rams.

6

Check if the piston rod movement is within the recommended tolerance. If so, the ram creep is acceptable. K Table 10. Creep Rates ( T E2-61)

INT-3-1-11_2

!MWARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS-1-2

A 1

Test for Ram Creep Operate the machine to bring the hydraulic oil to a normal working temperature of 50°C (122°F) which can be measured using a hydraulic oil temperature probe (service tool 892/00285).

2

Fit an appropriate pressure gauge A to a tee piece in the service hose which is pressurised when the ram in question is supported. K Fig 34. ( T E2-59)

3

Operate the rams to ensure they are full of hot oil.

4

Apply a load to the suspect ram for example the boom ram by raising the dipper to the horizontal as at B.

E2-59

Note: The table indicates the MAXIMUM permitted ram movement. 7

If the rate of movement is unacceptable, identify if the fault is as a result of cylinder or piston leakage, or spool leakage at the control valve, see procedures B and C.

9813/0250-04(E-01-11)

E2-59

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures B

C

Test Cylinder or Piston Leakage

1

Ensure that the oil temperature is at 50°C (122°F) by using the hydraulic oil temperature probe detailed in step A1.

2

Take the weight off the ram to be tested, in this example, by positioning the backhoe with dipper vertical and bucket on the ground.

3

Use a suitable pressure gauge A to blank off the supporting port of the ram. K Fig 35. ( T E2-60)

Test Spool Leakage

Note: The following procedure applies only to services fitted with A.R.V.'s. Note A.R.V.'s are not fitted to loader lift, loader auxiliary, stabilisers or to the bucket rod side service except when a Rockbreaker is fitted. K Fig 36. ( T E2-61) A.R.V.

Control Layout: JCB

ISO

- Right

B1

B1

- Left

A1

A1

- Rod

B2

B5

- Head

A2

A5

- Rod

A5

A2

- Head

B5

B2

- Rod

A6

A6

- Head

B6

B6

Slew

A

Boom

D

C

Dipper

Bucket

B C

Note: Bucket ram rod side ARV only fitted to machines equipped with Rockbreakers. 1

Disconnect the hose from the opposite port D and leave the port open to atmosphere.

Render the A.R.V.'s inoperative in the suspect service. This is achieved by removing the A.R.V. and replacing with a blanking plug (part no. 25/609901) and seal kit (25/610301).

2

Apply a load to the suspect ram for example the boom ram by raising the dipper to the horizontal as at B.

Recheck the piston rod movement as described steps A1 to A6.

3

If the rod movement is now acceptable the A.R.V. must be at fault. The A.R.V. may only require cleaning and then resealing. If dirt is evident, the hydraulic tank should be drained and cleaned. It is recommended that when re-filling the hydraulic tank that new oil and filter be used to prevent further contamination. If the A.R.V. is worn it should be replaced.

Fig 35. 4

5

6

After the initial movement measure the pin to pin movement as at C and note the rod movement over 10 minutes.

7

If rod movement is evident the ram is defective.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

4Q

4N

4L

4J

4P

4M

4K

4H

Fig 36. ARV Positions Table 10. Creep Rates Total Displacement - mm/10 minutes @ Ram

Cylinder Dia. Rod Dia. (mm) (mm)

69 bar (1000 lb/in2) 138 bar (2000 lb/in2) 207 bar (3000 lb/in2)

HEAD SIDE Backhoe: S/shift Jack Leg

70

40

13

44

91

Knuckle

100

60

6

16

32

Bucket

90

50

11

45

114

Bucket

100

60

10

40

99

Extending Dipper

70

40

13

32

65

Clam

70

40

6

22

45

Lift

80

50

5

17

35

Lift

90

50

4

13

28

110

60

8

26

52

Loader:

ROD SIDE Backhoe: Boom

E2-61

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E2-61

Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures Total Displacement - mm/10 minutes @ Ram

Cylinder Dia. Rod Dia. (mm) (mm)

69 bar (1000 lb/in2) 138 bar (2000 lb/in2) 207 bar (3000 lb/in2)

Boom

120

65

6

22

44

Boom

130

70

5

19

37

Boom

140

75

5

16

32

Dipper

100

60

10

34

70

Dipper

110

65

8

28

57

Extending Dipper

70

40

19

66

96

70

40

10

33

68

Loader: Shovel

Using the figures above, a graph can be plotted and the maximum amount of movement determined. See the working example. K Example Graph - Boom Ram 110 x 60 ( T E2-63) 1

Using the figures given in the table, plot a graph for the ram to be tested. Example: Boom Ram 110 x 60. K Fig 37. ( T E2-63)

2

Check the pressure in the ram (induced by the applied load). In this example the pressure on the gauge reads 107 bar; 1500 lb/in2.

3

Draw a vertical line from the pressure reading to the plotted graph line. Where the vertical line intercepts the graph line, draw a horizontal line and read the permitted ram displacement. In this example the permitted maximum displacement is 18 mm.

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

100

80

60

x

60

52mm

om

R

am

11

0

40 Bo

MAXIMUM RAM MOVEMENT PERMITTED (MM)

120

26mm

20

18mm

8mm

0

50

100 69bar

107bar

150 138bar

200

250

207bar

PRESSURE (BAR) Fig 37. Example Graph - Boom Ram 110 x 60 Note: For a blank graph sheet to copy and use as required. K Fig 38. ( T E2-64)

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Section E2 - Hydraulics Manual Controls Hydraulic SYSTEM Test Procedures

MAXIMUM RAM MOVEMENT PERMITTED (MM)

120

100

80

60

40

20

0

50

100 69bar

150 138bar

200

250

207bar

PRESSURE (BAR) Fig 38. Blank Graph Sheet

E2-64

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E2-64

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Introduction

Smooth Ride SYSTEM (SRS) Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T E7-3) K Specifications ( T E7-4) K Operation Overview ( T E7-5) K Hydraulic Operation and Schematics ( T E7-7) K Integral Type ( T E7-5) K Remote Type ( T E7-6) K Hose Burst Check Valves (HBCV) Option ( T E7-9) K Electrical Operation and Schematics ( T E7-12) K Hose Burst Check (HBCV) Option ( T E7-15) K Fault Finding ( T E7-17) K Accumulator Removal and Replacement ( T E7-18) K Integral Type ( T E7-18) K Remote Type ( T E7-19) K Accumulator Charging and Discharging ( T E7-20) Table 1. Procedure and Specification Variants Variant

Procedures, Specifications(1)

Hydraulic Systems Manual

EC

AEC

K Integral Type ( T E7-5)

2 spool loader valve

2 spool loader valve

z

K Remote Type ( T E7-6)

3 spool loader valve

3 spool loader valve

K Integral Type ( T E7-18)

2 spool loader valve

2 spool loader valve

K Remote Type ( T E7-19)

3 spool loader valve

3 spool loader valve

K Hydraulic Operation and Schematics ( T E7-7)

K Accumulator Removal and Replacement ( T E7-18)

E7-1

9813/0250-04 (E-05-07)

z

E7-1

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Introduction (1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure you refer to the correct information.

E7-2

9813/0250-04 (E-05-07)

E7-2

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Related Topics

Related Topics Table 2. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Where applicable the text in this section contains cross references to this page to help you find the correct information. Sections

Topic Titles

Sub Titles

2

ALL (Care and Safety)(1)

ALL

C

Fuses and Relays

C

Schematics

C

Harness SYSTEM

E

Systems and Schematics

Schematics

(1) You must obey all of the relevant care and safety procedures.

E7-3

9813/0250-04 (E-05-07)

E7-3

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Specifications

Specifications Accumulator A piston type accumulator operates as a liquid spring absorbing displaced fluid from the lift rams. Selectable from a switch in the cab. Charging Gas

Air Free Dry Nitrogen

Accumulator Capacity

0.95 litre (58 cu/in)

Accumulator Weight

TBA

Accumulator Nitrogen Precharge Pressures As a general guide for given shovel weights (loaded) see below:Bar

kgf/cm2

lbf/in2

Shovel weights up to 700 kg (1540 lb)

13.8

14

200

Shovel weights 700 kg to 950 kg (1540 - 2100 lb)

19

19.4

275

Shovel weights over 950 kg (2100 lb)

24

24.5

350

Note: Replacement accumulators will only be supplied in an uncharged, non-pressurised condition to meet Health and Safety, and Airfreight hazardous goods requirements.

E7-4

9813/0250-04 (E-05-07)

E7-4

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Operation Overview

Operation Overview There are two SRS component variants:

machine by the movement of the loader arms as the machine travels over uneven surfaces.

– Integral control type This is achieved by connecting the head side of the loader rams A to a pressurised piston type accumulator E.

– Remote control type Both variants operate in the same way.

Component Key: Some machines may have hose burst protection valves installed. The SRS system has an additional solenoid to operate the hose burst protection valve when SRS is active. The SRS system is otherwise the same as machine without hose burst protection. The Smooth Ride System (SRS) enhances the comfort of the ride by damping out the forces imposed on the

A

Loader Lift Rams

B

SRS Accumulator Solenoid

C

SRS Drain Solenoid

D

SRS Valve Block

E

Piston Accumulator

F

Tank Return

A

B

A

C

D

E

F

C097310

Fig 1. Integral Type

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E7-5

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Operation Overview Component Key:

Component Key:

A

Loader Lift Rams

D

Loader Control Valve Block

B

SRS Accumulator Solenoid

E

Piston Accumulator

SRS Drain Solenoid

F

Tank Return

C

C F

D B

B

B

A

A

A

B

E A

A C097320

Fig 2. Remote Type

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E7-6

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Hydraulic Operation and Schematics

Hydraulic Operation and Schematics K Schematic Circuit - Integral Type ( T E7-7)

head side is dead ended at the loader valve block and is connected to the accumulator. Hydraulic oil from the rod side is connected to tank to make up or dissipate oil as required.

K Schematic Circuit - Remote Type ( T E7-8) When the SRS switch in the cab is operated, the SRS solenoids are energised. Hydraulic oil from the loader ram

2

1

3

P1

P2

3A

3B

T

ACC

4 5 A439860-C3

Fig 3. Schematic Circuit - Integral Type Component Key:

Component Key:

1

Loader lift rams

3B

Accumulator solenoid valve

2

Loader valve block

4

Piston accumulator

3

SRS valve block

5

Tank

3A

Drain solenoid valve

E7-7

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E7-7

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Hydraulic Operation and Schematics 1

4 ACC

2

2B

2A T

5

C097330

Fig 4. Schematic Circuit - Remote Type Component Key: 1

Loader lift rams

2

Loader control valve block

2A

Drain solenoid valve

2B

Accumulator solenoid valve

4

Piston accumulator

5

Tank

E7-8

9813/0250-04 (E-05-07)

E7-8

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Electrical Operation and Schematics

Electrical Operation and Schematics K Schematic Circuit - SRS Not Active ( T E7-13) K Schematic Circuit - SRS Active ( T E7-14) The schematic diagrams in this section show how the electrical circuit works when different functions are operated. The wires coloured red show the electrical live feeds. The wires coloured green show the electrical returns to earth. Before fault finding make sure that you understand how the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and solenoids. Note: There are additional solenoid valves on machines with hose burst check valves. K Hose Burst Check (HBCV) Option ( T E7-15) Component Key: A

SRS switch warning light

C002

SRS solenoid valve

C003

SRS solenoid valve

CP63

SRS switch

CP67

Shovel reset switch

E7-12

9813/0250-04 (E-05-07)

E7-12

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Electrical Operation and Schematics

2

1

MF01/CP06

MF56/C001

12

1

C002

MF56/C001

SRS SOLENOID

S1

MF22

S2

2

SMF3

2

1

C003

SRS SWITCH

SRS SOLENOID 2

3

8

7

SCP37

CP03

CP63 A

CP27 FUSE

B7

2

3

8

7

CP67 SHOVEL RESET SWITCH

C097370

Fig 8. Schematic Circuit - SRS Not Active

E7-13

9813/0250-04 (E-05-07)

E7-13

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Electrical Operation and Schematics

2

1

MF01/CP06

MF56/C001

12

1

C002

MF56/C001

SRS SOLENOID

S1

MF22

S2

2

SMF3

2

1

C003

SRS SWITCH

SRS SOLENOID 2

3

8

7

SCP37 CP03

CP63 A

CP27 FUSE

B7

2

3

8

7

CP67 SHOVEL RESET SWITCH

C097370-C1

Fig 9. Schematic Circuit - SRS Active

E7-14

9813/0250-04 (E-05-07)

E7-14

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Electrical Operation and Schematics

Hose Burst Check (HBCV) Option K Schematic Circuit - SRS System Active (HBCV Not Active) ( T E7-16) The schematic diagrams in this section show how the electrical circuit works when different functions are operated. The wires coloured red show the electrical live feeds. The wires coloured green show the electrical returns to earth. Before fault finding make sure that you understand how the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and solenoids. Component Key: C002

SRS solenoid valve

C003

SRS solenoid valve

CC

Control relay

CD

Diode

CP27

Fusebox B

CP63

SRS Switch

CP63/LA

Panel harness SRS switch connector / Link harness connector

CP67

Shovel Reset Switch

LB/CA

Link connector / SRS and HBPC harness connector

LC

HBPV solenoid valve - LH

LD

HBPV solenoid valve - RH

E7-15

9813/0250-04 (E-05-07)

E7-15

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Electrical Operation and Schematics

2

1

LD R/H HBPV SOLENOID

SA

SB

2

1

LC L/H HBPV SOLENOID 2

CP06/MF01

MF56/LB

C002

LA/C001

SRS SOLENOID 12

1

LB/MF56

2

2

MF22 S2

S1

1

C001/LA

2

1

C003 SRS SOLENOID

4

1

2

5

CD

3

DIODE GATE

CC CONTROL RELAY

SRS SWITCH LINK ADAPTOR CP63/LA

SRS/HBPV SWITCH

SRS SWITCH FEED CONNECTOR LB/CA

2

1

3

2

1

2

3

4 5

7

6

3

7

8

CB CP27 FUSE

SCP37

B7

CP03

2

CP67 SHOVEL RESET SWITCH C097410

Fig 10. Schematic Circuit - SRS System Active (HBCV Not Active)

E7-16

9813/0250-04 (E-05-07)

E7-16

Section E7 - Hydraulics Smooth Ride SYSTEM (SRS) Fault Finding

Fault Finding Fault

Table 3. Probable Cause

Action

1

Unable to power down loader arms with SRS switched OFF.

Rod side solenoid valve faulty. (Valve remains open)

Check, clean, renew solenoid valve as applicable.

2

Springy loader arm lift with SRS switched OFF.

Head side solenoid valve faulty. (Valve Check solenoids are not energised. If remains open) they are, check the electrical circuit.

3

Restricted loader arm suspension movement when SRS switched ON.

Rod side solenoid valve faulty. (Valve remains closed)

Check, clean, renew solenoid valve as applicable.

Head side solenoid valve faulty. (Valve Check, renew solenoid coil. remains closed) Hose Burst Check Valve (HBCV) solenoid valve faulty. (Valve remains closed) 4

No suspension when SRS switched ON.

Inspect all relevant wiring for damage and test for open or short circuits. Repair as applicable. Check fuses and replace as required.

Accumulator gas pressure low. (Leak across accumulator piston)

Recharge accumulator. K Accumulator Charging and Discharging ( T E7-20)

Oil in gas side of accumulator. (Leak across accumulator piston)

Renew seals in accumulator or renew accumulator as applicable. K Accumulator Removal and Replacement ( T E7-18)

HBCV only: Solenoid valve on HBCV faulty

Check, renew solenoid coil.

Note: It is normal for the loader arms to lift or lower slightly, when SRS is switched ON.

E7-17

9813/0250-04 (E-05-07)

E7-17

Section Five - Steering Contents - Technical Data - Basic Operation - Fault Finding - Service Procedures - Steer Unit

287

9817/0000

287

Section H - Steering

Notes:

H-0

9813/0250-04

H-0

H0-1

Auto Steer Mode Valve - S1

Auto Steer Mode Valve - S2

H6

AWS

AWS

Steering Column

H5

Steer Mode Select Switch

Power Track Rod

H4

Steer Mode ECU

Priority Valve

H3

H8

AWS (no crab mode)

Hydraulic Steer Unit

H2

H7

AWS

Steering SYSTEM

Variants

Table entries shaded grey indicate a topic not included in this issue of the manual.

H1

Topic Ref Title

Important: The machine model names are NOT referred to in the topics. You must refer to the applications table for the applicable machine models.

Table

Applications

Section H0 - Steering Applications Table

9813/0250-04 (AH-00-03)

H0-1

Section H0 - Steering Applications Table

H0-2

9813/0250-04 (AH-00-03)

H0-2

Section H1 - Steering

Steering SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T H1-2) K Specifications ( T H1-3) K Hydraulic Steer Unit ( T H1-3) K Priority Valve ( T H1-4) K Operation Overview ( T H1-6) K All Wheel Steer System ( T H1-6) K 2 Wheel Steer System ( T H1-7) K Steer Modes ( T H1-8)(1) K Hydraulic Operation and Schematics - Steer Unit ( T H1-9) K Hydraulic Operation and Schematics - Priority Valve - Gearpump Type ( T H1-16) K Hydraulic Operation and Schematics - Priority Valve - Variflow Type ( T H1-19) K Electrical Operation and Schematics (All Wheel Steer Machines) ( T H1-22) K ECU Controlled Steer Mode ( T H1-22) K Fault Finding ( T H1-25) K Tables ( T H1-25) K Diagnostic `Blink' Codes - All Wheel Steer Machines ( T H1-31) K Test Procedures ( T H1-32) K Checking Components for Internal Hydraulic Leakage ( T H1-32) K Hydraulic Pressure Tests ( T H1-33) K Steer Mode Valve - Checking Solenoid Operation ( T H1-35)(1) K Re-phasing the Road Wheels ( T H1-36)(1) K Bleeding the System ( T H1-37) K All Wheel Steer Machines ( T H1-37) K 2 Wheel Steer Machines ( T H1-37) K Proximity Switch - Setting ( T H1-38)(1) (1) All wheel steer machines only

H1-1

9813/0250-04 (H-01-04)

H1-1

Section H1 - Steering Steering SYSTEM Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Where applicable the text in this section contains cross references to this page to help you find the correct information. Sections

Topic Titles

Sub Titles

2

ALL (Care and Safety)(1)

ALL

H

Power Track Rod

ALL

H

Steering Column

ALL

H

Steer Mode Valve

ALL

H

Steer Mode ECU

ALL

G

Combined Priority/Charge Valve

ALL

(1) You must obey all of the relevant care and safety procedures.

H1-2

9813/0250-04 (H-01-04)

H1-2

Section H1 - Steering Steering SYSTEM Specifications

Specifications Hydraulic Steer Unit Steer unit with load sensing, complete with integral relief valve and shock valves. Model Reference:

200 OSPC

Volumetric Displacement

200 cc/rev

Relief Valve Operating Pressure (at 1500 revs/min)

120 +/- 3 bar (122 +/- 3.5 kgf/cm2, 1740 +/- 50 lbf/in2)

Shock Valve Operating Pressure

175 - 190bar (178 - 199 kgf/cm2, 2538 - 2756 lbf/in2)

Model Reference:

250 OSPC

Volumetric Displacement

250 cc/rev

Relief Valve Operating Pressure (at 1500 revs/min)

120 +/- 3 bar (122 +/- 3.5 kgf/cm2, 1740 +/- 50 lbf/in2)

Shock Valve Operating Pressure

Shock Valve - Not Fitted

Model Reference:

160 OSPC

Volumetric Displacement

160 cc/rev

Relief Valve Operating Pressure (at 1500 revs/min)

120 +/- 3 bar (122 +/- 3.5 kgf/cm2, 1740 +/- 50 lbf/in2)

Shock Valve Operating Pressure

175 - 190bar (178 - 199 kgf/cm2, 2538 - 2756 lbf/in2)

T

L

P

R

LS

LS

Fig 1.

H1-3

9813/0250-04 (H-01-04)

H1-3

Section H1 - Steering Steering SYSTEM Specifications

Priority Valve Gearpump Machines Standby Pressure:

9 bar (9.1 kgf/cm2, 130 lbf/in2)

EF

T S LS

P

A1

LS

T

G

A1

S

EF

P

G C097500

Fig 2.

H1-4

9813/0250-04 (H-01-04)

H1-4

Section H1 - Steering Steering SYSTEM Operation Overview

Operation Overview All Wheel Steer System

C A1

A2

LS E

P2

B

D

C003150-C2

Fig 4. The main components of the steering system are the priority valve load sensing steer unit B, steer mode control valve C and double acting power track rod rams D and E mounted on the front and rear axles. When the steering wheel is turned, a pressure signal (demand) is generated in the load sense line LS from the steer unit to the priority valve. The priority valve A1/A2 directs oil from the secondary hydraulic pump P2 to the steer unit B. When left turn is selected, the steer unit directs the flow through the steer mode control valve C to the rear power track rod ram E. When right turn is selected,

H1-6

the steer unit directs the flow to the front power track rod ram D. When the steering lock is held, the pressure signal in the load sense line LS ceases. The priority valve then directs the oil from the secondary hydraulic pump P2 into the main hydraulic system for operation of the hydraulic services. The maximum steering system pressure is set by a relief valve housed inside the steer unit B.

9813/0250-04 (H-01-04)

H1-6

Section H1 - Steering Steering SYSTEM Operation Overview

2 Wheel Steer System

A1

A2

LS

P2 C

B

C003140-C2

Fig 5. The main components of the steering system are the priority valve A1 (Gearpump Machines), A2 (Variflow Machines), load sensing steer unit B and double acting power track rod ram C mounted on the front axle.

The maximum steering system pressure is set by a relief valve housed inside the steer unit B.

When the steering wheel is turned, a pressure signal (demand) is generated in the load sense line LS from the steer unit to the priority valve. The priority valve A1/A2 directs oil from the secondary hydraulic pump P2 to the steer unit B, which in turn directs the flow to the power track rod ram until the required steering lock is achieved. When the steering lock is held, the pressure signal in the load sense line LS ceases. The priority valve then directs the oil from the secondary hydraulic pump P2 into the main hydraulic system for operation of the hydraulic services.

H1-7

9813/0250-04 (H-01-04)

H1-7

Section H1 - Steering Steering SYSTEM Operation Overview

Steer Modes

C047511-C1

Fig 6. Three steering modes are available: – 2-Wheel Steer (front axle only) – 4-Wheel Steer – Crab Steer The steering modes are selected from a three position switch A. The switch sends an electrical signal to the steer mode ECU B, which in turn energises the appropriate steer mode control valve solenoid C. Indicator lights D on the instrument panel illuminate to show the steer mode currently operative.

The system is prevented from changing mode until all the wheels are in the straight ahead position. This is detected by proximity sensors E mounted on the front and rear axles. E.g. If the system is set in 4-wheel steer and 2-wheel steer is then selected, the system will stay in 4-wheel steer until the rear wheels are turned to the straight ahead position. The rear wheels are then hydraulically locked in the straight ahead position.

In 2-wheel steer mode only the front wheels are steered. In 4-wheel steer mode both axles are steered, giving a smaller turning circle. The crab steer mode allows the machine to be driven diagonally.

H1-8

9813/0250-04 (H-01-04)

H1-8

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Steer Unit

Hydraulic Operation and Schematics - Steer Unit Neutral

D B

C

L T R P

A

Fig 7. 4 Wheel steer machine shown Oil from the priority valve enters the steering unit through the inlet port (P), opening the non-return valve A. When the steering wheel is stationary, the inner spool B and outer sleeve C are held in the neutral position by the centring springs D. The steering unit is 'closed centre' therefore the flow from the priority valve is dead ended by the steering unit. 2 Wheel Steer Machines: On 2 wheel steer machines the hydraulic steer unit operation is identical to that described for the 4 wheel steer machines, except the unit pumps oil out directly to a power track rod ram fitted on the front axle only. Also, therefore the 2 wheel steer machines do not have a steer mode control valve.

H1-9

9813/0250-04 (H-01-04)

H1-9

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Steer Unit

Left Turn

B K

C

E

L T

J R

LS

P

F

Fig 8. The illustration shows the flow through the steering unit in a left-hand turn condition. Turning the steering wheel rotates the inner spool B a few degrees relative to the outer sleeve C, and sends a pressure signal (demand) to relief valve E, and through the load sense port LS back to the priority valve. The relative movement between B and C directs oil pressure through 6 of the 12 holes in the bottom of outer sleeve C. The metering unit is linked to the spools by a cross pin. As the steering is operated the oil is diverted by the inner spool B into the stator F. The rotor lobes pump the oil out to one side of the rear power track rod ram J, turning the rear wheels to the right. At the same time, the oil displaced from the other side of the power track rod ram J is directed to the front power track rod ram K, hence turning the front wheels the required degree of left turn.

H1-10

9813/0250-04 (H-01-04)

H1-10

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Steer Unit

Right Turn

B K

L T

J R P

F

Fig 9. The illustration shows the flow through the steering unit in a right-hand turn condition. The operation is identical to that described for a left-hand turn, except that the oil is diverted by inner spool B to the other side of stator F and power track rod rams J and K.

H1-11

9813/0250-04 (H-01-04)

H1-11

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Steer Unit

Right turn, Unassisted

B K

C

L T

J R

G

P

F

Fig 10. The illustration shows the circuit operation with the engine stopped. Turning the steering wheel rotates the inner spool B until the cross pin engages with and rotates outer sleeve C, metering oil to the stator F, and pumping it out to power track rod rams J and K under manual pressure only. As there is no supply from the pump, oil from one side of the power track rod rams (supplemented by exhaust oil if necessary), is used to feed the other side via non-return valve G.

H1-12

9813/0250-04 (H-01-04)

H1-12

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Steer Unit

Shock Valve

H L T R P

X Y

A

Fig 11. In normal operation, oil from the priority valve enters the steering unit through the inlet port (P), opening a springloaded non-return valve A. The flow is directed by the steering unit to achieve the desired turn (right-hand shown). In the event of a pressure shock wave being generated in the system by an outside force, shock valve H vents this pressure to exhaust preventing damage to the steering unit. Non-return valve X is held on its seat by the generated pressure and non-return valve A closes to prevent the shock wave being fed back to the pump. Some of the excess flows via non-return valve Y to the opposite side of the power track rod ram to prevent cavitation occurring.

H1-13

9813/0250-04 (H-01-04)

H1-13

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Steer Unit

2 Wheel Steer Mode - Right Turn

L T R

Z

J

P

Fig 12. The illustration shows the flow through the steering unit in a right-hand turn condition. The operation is identical to that described for the 4 wheel steer mode, except the steer mode control valve Z isolates the oil flow to the rear power track rod ram J, consequently the rotor lobes pump oil out to the front power track rod only. The rear wheels are held in the straight ahead position by the locked-up oil in the rear power track rod ram.

H1-14

9813/0250-04 (H-01-04)

H1-14

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Steer Unit

Crab Steer Mode - Right Turn

K

L T R

Z

J

P

Fig 13. The illustration shows the flow through the steering unit in a right-hand turn condition. The operation is identical to that described for the 4 wheel steer mode, except the steer mode control valve Z directs the oil displaced from the front power track rod ram K to the other side of the rear power track rod ram J, hence turning the rear wheels in the same direction as the front wheels, causing the machine to crab to the right.

H1-15

9813/0250-04 (H-01-04)

H1-15

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Priority Valve - Gearpump Type

Hydraulic Operation and Schematics - Priority Valve - Gearpump Type Note: The schematics on the pages that follow are for illustration only. For full schematics refer to Section E Systems and Schematics. The priority valve supplies the steer valve and brake valve/ accumulator, and regulates the supply to the hydraulic service control valve. The valve moves according to the pressures applied to each side of the spool. The spool 4 constantly senses the steering circuit demand via the load sense pressure line and regulates the supply to the steering circuit and hydraulic service control valve. The priority valve also houses a charge valve 5, which gives priority to the brake accumulator upon machine start up.

H1-16

Item

Table 2. Key to Components K Fig 14. ( T H1-17) K Fig 15. ( T H1-18)

1

Pump

2

To Hydraulic Service Control Valve

3

Priority Valve Housing

4

Priority Valve Spool

5

Charge Valve

6

Steer Valve

7

To Steer Rams

8

Brake Accumulator

9

To Brake Valve

10

Tank

9813/0250-04 (H-01-04)

H1-16

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Priority Valve - Gearpump Type

Charge Valve Open - No Steer Demand

7

7 8 6 9 LS

P

T

9

3

R

5 LS1 P

2

T EF

10 4 S

1 C097560-C1

Fig 14. Charge valve open - no steer demand At machine start up the charge valve 5 remains closed until the brake accumulator 8 is fully charged. When the brake accumulator 8 is fully charged the charge valve 5 opens against the spring pressure to connect the load sense pressure line from the steer valve 6 to the priority valve spool 4. As there is no steering demand the steer valve load sense pressure returns to tank 10.

H1-17

9813/0250-04 (H-01-04)

H1-17

Section H1 - Steering Steering SYSTEM Hydraulic Operation and Schematics - Priority Valve - Gearpump Type

Turning

7

7 8 6 9

P

LS

T

9

3

R

5 LS1 P

2

T EF

10 4 S

1 C096750-C3

Fig 15. Steer valve operating When the steering wheel is turned, a pressure signal (demand) is generated in the load sense line LS from the steer valve 6. The load sense pressure acts upon the priority valve spool 4 to ensure that priority is given to the steering circuit. The pump output flow available is always greater than the actual flow required to operate the steering system, therefore flow to the hydraulic service control valve is never completely cut off but is reduced. The maximum steering system pressure is set by a relief valve housed inside the steer valve.

H1-18

9813/0250-04 (H-01-04)

H1-18

Section H1 - Steering Steering SYSTEM Electrical Operation and Schematics (All Wheel Steer Machines)

Electrical Operation and Schematics (All Wheel Steer Machines) Use the information in this topic together with the following machine specific information in Section C: – Electrical schematics – Harness and electrical connector details – Earth points – Fuse and relay locations – General electrical test procedures Note: The schematics shown in this topic are intended to show the principle of operation. The actual wires and connectors may be different on each machine variant.

ECU Controlled Steer Mode

The front wheels must be in the straight ahead position before 4-wheel steer mode is enabled. When the front wheels are in the straight ahead position, the proximity switch 3 on the front axle operates and sends an electrical input to the steer mode control unit (ECU) 1 pin 6. With the steer mode selector switch 2 in the 4-wheel steer position, there is an electrical input to the ECU pin 8. In this condition, the ECU sends an output on pin 10 to energise the 4-wheel steer valve solenoid 5. The ECU also completes the return path on pin 2 so that the steer mode changeover relay 9 energises. The changeover relay contacts then connect a live feed to the all-wheel steer valve solenoid 7 which also energises. Crab Steer Selected: K Fig 20. ( T H1-24)

The schematic diagrams in this section show how the electrical circuit works when different functions are operated. The wire numbers and colours, where appropriate, are shown as an aid to identification while fault finding. The wires coloured red show the electrical live feeds. The wires coloured green show the electrical returns to earth. Before fault finding make sure that you understand how the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and solenoids. Important: DO NOT use a multimeter on the ECU connector pins. Only test the associated harness wiring. Uncouple the harness from the ECU and then use a multimeter on the pins inside the harness connector as applicable.

The front wheels must be in the straight ahead position before crab steer mode is enabled. When the front wheels are in the straight ahead position, the proximity switch 3 on the front axle operates and sends an electrical input to the steer mode control unit (ECU) 1 pin 6. With the steer mode selector switch 2 in the crab steer position, there is an electrical input to the ECU pin 7. In this condition, the ECU sends an output on pin 11 to energise the crab steer valve solenoid 6. The ECU also completes the return path on pin 2 so that the steer mode changeover relay 9 energises. The changeover relay contacts then connect a live feed to the all-wheel steer valve solenoid 7 which also energises.

2-Wheel Steer Selected: K Fig 18. ( T H1-23) The rear wheels must be in the straight ahead position before 2-wheel steer mode is enabled. When the rear wheels are in the straight ahead position, the proximity switch 4 on the rear axle operates and sends an electrical input to the steer mode control unit (ECU) 1 pin 9. With the steer mode selector switch 2 in the 2-wheel steer position, there is no electrical input to the ECU on pin 7 or pin 8. In this condition, the ECU does not send an output on pin 10 or pin 11, and interrupts the return path on pin 2 so that the steer mode changeover relay 9 is de-energised. The changeover relay contacts connect a live feed to the 2-wheel steer valve solenoid 8 which then energises. When the solenoid is energised, an electrical input is sent to the ECU pin 5. The ECU then sends an output on pin 4 to illuminate the indicator light on the front console. 4-Wheel Steer Selected: K Fig 19. ( T H1-24)

H1-22

9813/0250-04 (H-01-04)

H1-22

Section H1 - Steering Steering SYSTEM Electrical Operation and Schematics (All Wheel Steer Machines) Component Key: 1

Steer mode control unit (ECU)

2

Steer mode selector switch - front console

3

Proximity switch - front axle

4

Proximity switch - rear axle

5

4-Wheel steer mode valve solenoid

6

Crab steer mode valve solenoid

7

All Wheel steer mode valve solenoid

8

2-Wheel steer mode valve solenoid

9

Steer mode changeover relay

ECU Pin

6

5

Table 4. ECU Connections Function:

1

1

Earth connection

2

Earth connection - Steer mode changeover relay coil

3

Not used

4

Low side output - 2WS indicator light/Front console

5

High side input - 2WS mode valve solenoid energised

6

Proximity switch input - Front wheels straight ahead

7

Switch input - Crab steer mode selected

8

Switch input - 4WS steer mode selected

9

Proximity switch input - Rear wheels straight ahead

10

High side output - 4WS mode valve solenoid

11

High side output - Crab steer mode valve solenoid

12

Power supply

7

8

9

2

3

4

Fig 18. 2-Wheel Steer Selected

H1-23

9813/0250-04 (H-01-04)

H1-23

Section H1 - Steering Steering SYSTEM Electrical Operation and Schematics (All Wheel Steer Machines)

6

5

1

7

8

1

9

2

3

4

7

8

9

2

3

Fig 19. 4-Wheel Steer Selected

H1-24

6

5

4

Fig 20. Crab Steer Selected

9813/0250-04 (H-01-04)

H1-24

Section H1 - Steering Steering SYSTEM Fault Finding

Fault Finding The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc.). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the steering section. To help identify circuits, valves, rams etc. mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams (near the beginning of the Hydraulics Section). 1

Before you begin fault finding, read the Safety information at the beginning of this manual.

2

Make simple checks before say, stripping a major component.

3

Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

4

What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

5

Make any relevant electrical checks before moving on to the hydraulics.

6

Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.

7

Replace any seals such as 'O' rings before reassembling hydraulic components.

H1-25

Tables Fault Descriptions: 1

Steering wheel difficult to turn.

K Table 5. ( T H1-26)

2

Steering wheel turns on its own.

K Table 6. ( T H1-27)

3

Machine will not turn when the steering wheel turned.

K Table 7. ( T H1-28)

4

Steering fails to respond to selected K Table 8. mode. ( T H1-29)

5

Steering fails to phase accurately or K Table 9. `drifts' out of phase during operation. ( T H1-30)

9813/0250-04 (H-01-04)

H1-25

Section H1 - Steering Steering SYSTEM Fault Finding Fault Steering wheel difficult to turn.

Table 5. Probable Cause

Action

Tyres not inflated to correct pressure

Inflate tyres to correct pressure

Insufficient hydraulic fluid.

Check for leaks and top up the hydraulic tank as required.

Leaks in the relevant hoses or component connections

Check hoses and connections for leaks

Air in the hydraulic system.

Bleed system - bleed the load sense line.

Low pump flow.

Check pump flow, if required service or replace pump.

Steer relief valve set incorrectly

Check pressure setting of steer unit relief valve, adjust as required.

Worn or damaged parts in the steer control valve.

Remove and inspect.

Priority valve not operating correctly.

Check if the priority valve is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.

Steer mode valve not operating correctly (4WS Machines only)

Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required

Mechanical failure

Check for damaged axle components, such as rams, trackrods, linkages etc.

K Tables ( T H1-25)

H1-26

9813/0250-04 (H-01-04)

H1-26

Section H1 - Steering Steering SYSTEM Fault Finding Fault Steering wheel turns on its own.

Table 6. Probable Cause

Action

Dirt in the steer control unit (causing sleeves to stick open)

Clean and inspect unit.

Steer control valve centring springs damaged, broken or missing.

Check steer unit.

Steer control valve - position of rotor to Refer to Hydraulic Steer Unit. Correct shaft slot incorrect. as required. K Tables ( T H1-25)

H1-27

9813/0250-04 (H-01-04)

H1-27

Section H1 - Steering Steering SYSTEM Fault Finding Fault

Table 7. Probable Cause

Machine will not turn when the steering Insufficient hydraulic fluid. wheel turned.

Action Check for leaks and top up the hydraulic tank as required.

Leaks in the relevant hoses or component connections

Check hoses and connections for leaks

Air in the hydraulic system.

Bleed system - bleed the load sense line.

Low pump flow.

Check pump flow, if required service or replace pump.

Steer relief valve set incorrectly.

Check pressure setting of steer unit relief valve, adjust as required.

Worn or damaged parts in the steer control valve.

Remove and inspect.

Priority valve not operating correctly.

Check if the priority valve is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.

Steer mode valve not operating correctly (4WS Machines only)

Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required

Mechanical failure

Check for damaged axle components, such as rams, trackrods, linkages etc.

Steer column splined shaft not fully engaged in steer valve.

Check shaft engagement.

Power track rod failure

Check power track rod for signs of damage, leaks etc.

K Tables ( T H1-25)

H1-28

9813/0250-04 (H-01-04)

H1-28

Section H1 - Steering Steering SYSTEM Fault Finding Fault

Table 8. Probable Cause

Action

Steering fails to respond to selected mode.

Selector switch faulty.

Check selector switch, replace as required.

Note: The steer mode ECU will generate a blink code for certain fault conditions. K Diagnostic `Blink' Codes - All Wheel Steer Machines ( T H1-31)

Proximity switches not operating correctly.

Check setting of Proximity switches, reset or replace switches as required.

Steer mode valve not operating correctly.

Check if spools sticking, rectify as required. Check if solenoids operating, replace solenoids as required.

Leaks in the relevant hoses or component connections.

Check hoses and connections for leaks

Electrical failure.

Check relevant electrical connectors, if problem still persists, do a wiring continuity check on relevant circuits.

K Tables ( T H1-25)

H1-29

9813/0250-04 (H-01-04)

H1-29

Section H1 - Steering Steering SYSTEM Fault Finding Fault

Table 9. Probable Cause

Action

Steering fails to phase accurately or `drifts' out of phase during operation.

Incorrect re-phasing procedure.

Ensure phasing is carried out correctly and at the correct intervals. K Rephasing the Road Wheels ( T H1-36)

Note: Where phasing problems are limited to 2WS mode, faults will be related to the rear power track rod system. 4WS mode problems require front and rear track rod systems to be investigated for possible faults.

Air in steer hydraulic system.

Bleed the system. K Bleeding the System ( T H1-37)

Incorrectly set proximity switches.

Re-set the proximity switches. K Proximity Switch Setting ( T H1-38)

Power track rod internal or external hydraulic leaks, refer to Note.

Check relevant hose and pipework for leaks. Check track rod seals for leakage. K Checking Components for Internal Hydraulic Leakage ( T H1-32)

Steer mode valve internal or external hydraulic leaks, refer to Note.

Check relevant hose and pipework for leaks. K Checking Components for Internal Hydraulic Leakage ( T H1-32)

K Tables ( T H1-25)

H1-30

9813/0250-04 (H-01-04)

H1-30

Section H1 - Steering Steering SYSTEM Fault Finding

Diagnostic `Blink' Codes - All Wheel Steer Machines The AWS ECU has the facility to detect faults with the steer mode electrical system. These faults are indicated using the 2WS indicator light A in the front console. The blink code sequence consists of the light being switched ON for approximately one second followed by a number of flashes (the code). The sequence is repeated until the fault is cleared.

A T052360-C1

Fig 21. Blink Code:

Fault:

Action:

1 Flash

`C' solenoid coil or circuit fault (open or short circuit). Check the solenoid coil and related harness wires and connectors.

2 Flashes

`D' solenoid coil or circuit fault (open or short circuit). Check the solenoid coil and related harness wires and connectors.

3 Flashes

Steer mode changeover relay, diode or circuit fault (open or short circuit).

Check the steer mode changeover relay and related harness wires and connectors.

.

H1-31

9813/0250-04 (H-01-04)

H1-31

Section H2 - Steering Hydraulic Steer Unit Dismantle and Assemble

Dismantle and Assemble Dismantle K Fig 2. ( T H2-6) The numerical sequence shown on the illustration is intended as a guide to dismantling. Note: During manufacture, a small mark X will have been made on sleeve 12 and spool 15, close to one of the slots for the centring springs 13. Before removing the centring springs, check that this mark is visible; if not, make a new mark to ensure correct assembly. Note: Shock valves (items 29 to 35) are pressure set during manufacture and the adjusting screw 31 secured with Loctite. Due to the difficulty of resetting the pressure it is recommended that the valves are not disturbed. If dismantling is unavoidable, however, measure and record the depth of adjusting screw 31 below the top face of the steering unit before removing the screw.

H2-5

9813/0250-04 (H-02-03)

H2-5

Section H2 - Steering Hydraulic Steer Unit Dismantle and Assemble

Fig 2. Hydraulic Steer Unit

H2-6

9813/0250-04 (H-02-03)

H2-6

Section H2 - Steering Hydraulic Steer Unit Dismantle and Assemble

Assemble Note: The unit illustrated in the following sequence represents a typical hydraulic steer valve. The relief valve (items 25 to 28) and shock valves (items 29 to 35) are not therefore shown in the following illustrations. 1

Fit spool 15 into sleeve 12, aligning slots for centring springs 13 and checking that the small marks X are aligned. Ensure that three slots in spool partially uncover three holes in sleeve, as at A.

2

Fit two flat centring springs 13 with four curved springs between them, as shown at B.

3

Fit seal 24 into steer unit body and insert sleeve of service tool 892/00180. Fit back up ring 20 and seal 21 onto plastic boss, and position on tool spindle, as shown.

4

Lower steering unit body and tool sleeve over tool spindle until plastic bush is flush with end of bore. Assemble sleeves 12 and 15 with cross pin 14 and centring springs 13. Fit bearing components 16 to 19 with chamfered face of 17 facing away from bearing 18.

5

Remove body from tool leaving plastic bush in position, and lower body over assembled spool. Fig 3.

6

Apply downward pressure on body until plastic boss is forced out of bore, leaving seals correctly located. K Fig 4. ( T H2-7)

Fig 4.

H2-7

9813/0250-04 (H-02-03)

H2-7

Section H2 - Steering Hydraulic Steer Unit Dismantle and Assemble 7

Invert unit and place on a suitable hollow support so that body does not rest on protruding sleeve, thus preventing displacement of the new seals. Place ball 23 into check valve hole and fit bush 22.

8

Fit new 'O' ring 10.

9

Fit distributor plate 9 ensuring that holes align. Locate shaft 11 onto cross-pin 14, noting position of slot B. When rotor 7 is fitted, slot must align with hollows of rotor as shown at C.

13

Refit the end plate and fit at least one bolt 2 before removing support material.

14

Fit remaining bolts, ensuring that special bolt 1 is correctly located. Torque tighten the bolts. K Table 2. Torque Settings ( T H2-8)

Fig 6.

Item Fig 5. 10

Use a suitable piece of rigid flat material, 0.25mm (0.010 in.) thick, to support the shaft and ensure positive engagement with the splines of rotor 7.

11

Locate rotor onto shaft, ensuring alignment as at C. Fit spacing bush 6 into rotor.

12

Fit 'O' rings 4 and 8 each side of body 5, then position body over rotor.

H2-8

Table 2. Torque Settings Nm kgf m

lbf ft

1

29

3.0

22

2

29

3.0

22

15

Pressure Relief K Fig 2. ( T H2-6) a

Valve

(items

25

to

28).

If removed during the dismantling, clean the threads of the adjusting screw 27 and the threads in the bore of the steering unit body.

b Assemble the valve into the steer unit body.

9813/0250-04 (H-02-03)

H2-8

Section H2 - Steering Hydraulic Steer Unit Dismantle and Assemble c

16

Check the relief valve setting after fitting the steering unit to the machine. Refer to Steering SYSTEM .

Shock Valves (items 29 to 35). K Fig 2. ( T H2-6) a

If removed during the dismantling, clean the threads of the adjusting screw 31 and the threads in the bore of the steering unit body using JCB Cleaner and Degreaser. Allow to dry.

b Assemble seat 35, ball 34, cap 33 and spring 32 into the steer unit body. c

Apply JCB Threadlocker and Sealer to the threads of screw 31. Fit the screw to the depth measured during dismantling.

d Fit plug 29 and washer 30.

H2-9

9813/0250-04 (H-02-03)

H2-9

Section Five - Steering Service Procedures

Hydraulic Steer Unit (Orbitrol)

Fig 219. Exploded View

310

9817/0000

310

Section Five - Steering Service Procedures

T040370-50

Fig 220. Hydraulic Steer Unit - Cross Sectional View

311

9817/0000

311

Section 6L[ - %UDNHV Contents - Technical Data - Basic Operation - )DXOW)LQGLQJ -7HVW3URFHHGXUHV

Section G - Brakes

Notes:

G-0

9813/0250-04

G-0

Section G1 - Brakes Service Brakes SYSTEM Specifications

Specifications Service Brakes Type

Table 3. Single circuit, oil-immersed multi-plate disc.

Actuation

Hydraulic

Location

Rear axle, centre mounted (2 brake packs).

Friction plates (5 per brake pack) Positive retraction type Outside diameter

220 mm (7.992 in)

Inside diameter

160 mm (6.299 in)

Facing area (per plate)

18603 mm2 (28.8 in2)

Brake piston diameter

216 mm (8.5 in)

Note: Because the service brakes are located in the rear axle, the procedures for dismantling and assembly are described in a separate publication, refer to Transmissions Service Manual (Publication No. 98038610) which includes procedures for the axle subassemblies.

G1-4

9813/0250-04 (G-01-05)

G1-4

Section G1 - Brakes Service Brakes SYSTEM Specifications

Brake Valve Table 4. Operating pressure Input (charge pressure)

110 - 140 bar (1600 - 2000 lbf in2)

Output (brake pressure)

0 - 110 bar (0 - 1600 lbf in2)

Accumulator pre-charge (nitrogen gas)

40 bar (575 lbf in2)

Pressure switch setting

80 bar (1150 lbf in2)

Weight

6 kg (13 lbs)

RR BL N

R

BR RL

C096920

Fig 1. Key: BL

Brake port - LH Brake

BR

Brake port - RH Brake

N

Tank port

R

Inlet port (charge pressure)

RL

Pressure switch port

RR

Accumulator port

G1-5

9813/0250-04 (G-01-05)

G1-5

Section G1 - Brakes Service Brakes SYSTEM Specifications

Priority/Charge Valve (Gearpump) Table 5. Charge pressure (brakes) Cut-in

110 bar (1600 lbf in2)

Cut-out

140 bar (2000 lbf in2)

Standby pressure (steering)

9 bar (130 lbf in2)

Weight

7 kg (15 lbs)

EF S

LS 1 T P A1

G

C096930

Fig 2. Key: A1

Outlet port (brakes)

EF

Excess flow port (to hydraulic services)

G

Gauge port - Charge pressure test point

LS 1

Load sense port (steering)

P

Priority port (steering)

S

Inlet port

T

Tank port

G1-6

9813/0250-04 (G-01-05)

G1-6

Section G1 - Brakes Service Brakes SYSTEM Specifications

Priority/Charge Valve (Variflow) Table 6. Charge pressure (brakes) Cut-in

110 bar (1600 lbf in2)

Cut-out

140 bar (2000 lbf in2)

Standby pressure (steering)

9 bar (130 lbf in2)

Weight

5 kg (11 lbs)

R TEST EF

LS OUT 2

LS ST

T

ST

R P P TEST

LS OUT 1 C096940

Fig 3. Key: EF

Excess flow port (to hydraulic services)

LS OUT 1

Gauge port - Load sense pressure test point

LS OUT 2

Load sense port (brakes)

LS ST

Load sense port (steering)

P

Inlet port

P TEST

Gauge port - Pump pressure test point

R

Outlet port (brakes)

G1-7

R TEST

Gauge port - Charge pressure test point

ST

Priority port (steering)

T

Tank port

9813/0250-04 (G-01-05)

G1-7

Section G1 - Brakes Service Brakes SYSTEM Operation Overview

Operation Overview General Description

C096790

Fig 4. Gearpump machine shown The hydraulic supply to operate the service brakes is derived from the engine-driven hydraulic pump. The flow from the hydraulic pump is regulated by the combined priority/charge valve A. The charge valve provides a constant supply of oil at charge pressure to the brake valve B and brake accumulator C.

When there is no hydraulic supply for the brakes, or when the accumulator is exhausted, the brake pressure switch E operates to activate a low pressure warning light F and audible alarm in the cab. Variflow Machines: The combined priority/charge valve is flange mounted on the variflow pump outlet port.

When the brake pedals are pressed, the brake valve directs the oil in the charge circuit to the brake piston housings D in the rear axle. The resulting brake pressure is proportional to the pedal movement. The brake accumulator stores pressure in the charge circuit, so that there is a limited supply for the brakes when the engine is stopped.

G1-8

9813/0250-04 (G-01-05)

G1-8

Section G1 - Brakes Service Brakes SYSTEM Hydraulic Operation and Schematics - Gear Pump System

Hydraulic Operation and Schematics - Gear Pump System Charge

1

Hydraulic pump (Second pump P2)

K Fig 7. ( T G1-13)

2

Steer control valve

3

Pressure test point

At machine start up spring pressure on the priority spool 12 connects the flow from pump P2 directly to the brake and steering systems. Brake charge valve 11 remains closed until the brake accumulator 6 is fully charged. This prevents oil flow returning to tank via the steering load sense circuit when there is no steering demand.

4

Priority/Charge valve

5

Hydraulic tank

6

Brake accumulator

7

Brake pressure low switch

8

Brake valve

Standby

9

RH Brake pack

10

LH Brake pack

11

Charge valve spool

12

Priority valve spool

K Fig 8. ( T G1-14) When the accumulator 6 is fully charged the charge valve 11 opens against spring pressure. This connects the load sense pressure line from the steer valve 2 to the priority valve spool 12 in the normal way. Refer to Section H Steering SYSTEM. System pressure now acts on the opposite end of priority spool 12 and it moves to allow oil to flow into the main hydraulic system at port EF.

Brake Operation K Fig 9. ( T G1-15) When the operator presses the brake pedals the brake valve 8 opens to pressurise the brake packs 9 and 10.This causes a pressure imbalance at the charge valve spool 11. Spring force moves the spool and prevents oil flow returning to tank via the steering load sense circuit when there is no steering demand. This ensures that priority is always given to maintaining the brake charge pressure. During brake operation the pressure imbalance at the charge valve spool quickly reverses. This causes the charge and priority valve spools to operate in a dynamic way, constantly moving from one port connection to the other.

Schematics Note: The schematics on the pages that follow are for illustration only. For full schematics refer to Section E Systems and Schematics.

G1-12

9813/0250-04 (G-01-05)

G1-12

Section G1 - Brakes Service Brakes SYSTEM Hydraulic Operation and Schematics - Gear Pump System

9 8 6 L

BR

RR

R

R

2 7 P LS

RL

T N

BL

R

3 LS1 P

11

10

T

EF

12

4 S

1

P2

5 C096700-C1

Fig 7. Charge - From Start Up

G1-13

9813/0250-04 (G-01-05)

G1-13

Section G1 - Brakes Service Brakes SYSTEM Hydraulic Operation and Schematics - Gear Pump System

9 8 6 L

BR

RR

R

R

2 7 P LS

RL

T N

BL

R

3 LS1 P

11

10

T

EF

12

4 S

1

P2

5 C096700-C2

Fig 8. Brake System - Standby

G1-14

9813/0250-04 (G-01-05)

G1-14

Section G1 - Brakes Service Brakes SYSTEM Hydraulic Operation and Schematics - Gear Pump System

9 8 6 L

BR

RR

R

R

2 7 P LS

RL

T N

BL

R

3 LS1 P

11

10

T

EF

12

4 S

1

P2

5 C096700-C3

Fig 9. Brake System Operation

G1-15

9813/0250-04 (G-01-05)

G1-15

Section G1 - Brakes Service Brakes SYSTEM Electrical Operation and Schematics - Relay Control Gearboxes

Electrical Operation and Schematics - Relay Control Gearboxes Use the information in this topic together with the following machine specific information in Section C: – Electrical schematics – Harness and electrical connector details – Earth points – Fuse and relay locations – General electrical test procedures Note: The schematics shown in this topic are intended to show the principle of operation. The actual wires and connectors may be different on each machine variant.

G1-20

9813/0250-04 (G-01-05)

G1-20

Section G1 - Brakes Service Brakes SYSTEM Electrical Operation and Schematics - Relay Control Gearboxes

Brake Pressure Warning SCP20 CP04

ECU

16

1

A

CP57

CP27 FUSE

B1

SCP32

1 3

5

SCP4 CP05

CP45

INSTRUMENTS J2 4 2

2

BRAKE PRESSURE SWITCH

SCP12 2

1

CP29

SCP54

CP93

WARNING LIGHT RELAY

DIODE

B 11

14

CP01/FC01 59

CP01/FC01

4

C

1

40

FC22 CP01/FC01

WARNING LIGHT CLUSTER

SFC7

46 C097230

Component Key: A

Warning Buzzer

B

Brake Pressure Warning Light

C

Master Warning Light

CP01/FC01 Cab Panel Harness to Front Console Harness Connector CP27

Fusebox B

CP29

Warning Light Relay

CP45

Brake Pressure Switch

CP57

Instrument Panel Connector J2

CP93

Diode

FC22

Warning Light Cluster

Fig 13. The switch CP45 when closed provides an earth connection for the warning light relay CP29 and the brake pressure warning light B (on the warning light cluster FC22). The relay CP29 when activated provides an earth connection for the master warning light C (on the warning light cluster FC22) and the buzzer A (on the instrument panel CP57). Therefore when the switch CP45 is closed the master warning light C and brake pressure warning light B illuminate and the buzzer A is activated.

The brake pressure switch CP45 is a normally open switch. When the hydraulic supply to the brake valve is below 80 bar the switch closes. Important: The illuminated brake pressure warning light B indicates the brake valve is not receiving full hydraulic pressure from the hydraulic pump or that the brake accumulator is empty. The light will not illuminate if there is a fault in the brake circuit such as a failure in the brake valve, accumulator or leaks.

G1-21

9813/0250-04 (G-01-05)

G1-21

Section G1 - Brakes Service Brakes SYSTEM Fault Finding

Fault Finding Introduction

Fault Finding Tables

The purpose of this section is to help you trace a particular fault. The tables identify possible causes and give a suggested action with specific tests where applicable.

K Table 9. Poor braking (not pulling to one side). ( T G1-35)

Before you begin fault finding, read the safety information at the beginning of this manual. Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. Note: 4WS machines do not have dual pedal braking.

K Table 10. Pulling to one side when pedals locked together. ( T G1-35) K Table 11. Pedal travel excessive. ( T G1-36) K Table 12. Brakes not releasing. ( T G1-36) K Table 13. Excessive brake noise from brake packs in operation. ( T G1-36) K Table 14. Fluid escaping from axle breather. ( T G1-36) K Excessive noise from brake valve/pedal in operation. ( T G1-37)

G1-34

9813/0250-04 (G-01-05)

G1-34

Section G1 - Brakes Service Brakes SYSTEM Fault Finding Possible Cause

Table 9. Poor braking (not pulling to one side). Action

Axle oil level low, or incorrect oil type.

Check the axle for leaks. Fill the axle with clean oil of the correct type. – Check the brake pressure. K Checking the Brake Pressure ( T G1-38)

Brake valve faulty.

– Renew the brake valve. – Check the charge pressure. K Checking the Charge Pressure ( T G1-39)

Charge valve faulty.

– Renew the priority/charge valve. Annular brake piston(s) binding in axle.

– Check the annular brake piston seals are in good condition. – Check the annular brake piston rotates freely in its housing with no seals fitted. – Check the annular brake piston seal retracts the piston approximately 0.5 mm (0.020 in).

Friction and counter plates in poor condition, or worn beyond limits.

– Check for distortion, surface pitting and roughness of friction and counter plates (annular grooving of counter plates is acceptable). – Renew the friction and counter plates - BOTH sides of axle.

Possible Cause

Table 10. Pulling to one side when pedals locked together. Action

Brake circuit is inoperative on one side.

Unlatch the pedals and check the brake operation individually.

Brake valve push-rods out of adjustment, or brake valve faulty.

– Check the brake pressure. K Checking the Brake Pressure ( T G1-38) – Renew the brake valve.

Annular brake piston binding in axle.

– Check the annular brake piston seals are in good condition. – Check the annular brake piston rotates freely in its housing with no seals fitted. – Check the annular brake piston seal retracts the piston approximately 0.5 mm (0.020 in).

Friction and counter plates in poor condition, or worn beyond limits.

– Check for distortion, surface pitting and roughness of friction and counter plates (annular grooving of counter plates is acceptable). – Renew the friction and counter plates - BOTH sides of axle.

G1-35

9813/0250-04 (G-01-05)

G1-35

Section G1 - Brakes Service Brakes SYSTEM Fault Finding Table 11. Pedal travel excessive. Action

Possible Cause Air in the brake circuit.

Bleed the brakes. K Bleeding ( T G1-44)

Fluid leaks.

Check the brake pipes and hoses for leaks, rectify as required. Table 12. Brakes not releasing. Action

Possible Cause Brake pedal(s) does not return properly.

– Check the area around the brake pedal is free of obstructions. – Check the operation of the pedal return spring. Check for tightness of pedal pivot, lubricate pivot if required. – Check the pedal stop bolt is adjusted correctly.

Brake valve push-rods out of adjustment, or brake valve faulty.

– Check the brake pressure. K Checking the Brake Pressure ( T G1-38) – Disconnect the brake pedals, and check the push-rod lengths are correct. – Renew the brake valve.

Kinked or crushed brake pipes or hoses.

Inspect the brake pipes and hoses for damage. Renew as required.

Annular brake piston(s) binding in axle.

– Check the annular brake piston seals are in good condition. – Check the annular brake piston rotates freely in its housing with no seals fitted. – Check the annular brake piston seal retracts the piston approximately 0.5 mm (0.020 in).

Friction and counter plates are not free on splines or dowels. Check the friction and counter plates for free movement. Renew if required - BOTH sides of axle.

Possible Cause(1)

Table 13. Excessive brake noise from brake packs in operation. Action

Axle oil level low, or incorrect oil type.

Check the axle for leaks. Fill the axle with clean oil of the correct type.

Friction and counter plates in poor condition, or worn beyond limits.

– Check for distortion, surface pitting and roughness of friction and counter plates (annular grooving of counter plates is acceptable). – Renew the friction and counter plates - BOTH sides of axle.

(1) Due to the metal to metal contact of oil immersed brakes, limited noise can be heard which is consistent with this type of design - this is normal.

Possible Cause

Table 14. Fluid escaping from axle breather. Action

Brake piston seals in poor condition, or damaged. K Brake Renew the piston seals - Both sides of axle. Piston Seal Leakage Test ( T G1-42)

G1-36

9813/0250-04 (G-01-05)

G1-36

Section G1 - Brakes Service Brakes SYSTEM Fault Finding

Possible Cause(1) Air in the system.

Table 15. Excessive noise from brake valve/pedal in operation. Action Pump the pedals several times. Bleed the system

(1) Noise is similar to the sound made by an air horn. Noise is possible after hydraulic oil change.

G1-37

9813/0250-04 (G-01-05)

G1-37

Section G1 - Brakes Service Brakes SYSTEM Test Procedures

Test Procedures Checking the Brake Pressure The maximum brake pressure achieveable is 110 bar (1600 lbf/in2). This is factory set inside the brake valve and cannot be adjusted. There is no test point in the circuit down stream of the brake valve to measure the brake pressure to the brake packs. To measure brake pressure it will be necessary to connect a pressure gauge into the brake hose at the axle casing.

G1-38

9813/0250-04 (G-01-05)

G1-38

Section G1 - Brakes Service Brakes SYSTEM Test Procedures

Checking the Charge Pressure The brake system charge valve cycles the charge pressure between pre-set limits to ensure the brake accumulator is filled with hydraulic fluid.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Make sure that the hydraulic fluid is at working temperature (50 ºC, 122 ºF). 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures.

2

Vent the braking system pressure. Refer to Section 2 - General procedures.

3

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to the test point A on the side of the combined priority/charge valve.

4

Operate the engine for a minimum of two minutes and occasionally press the brake pedals. This makes sure that the brake system charge valve has filled the accumulator.

5

With the engine running, check the reading on the pressure gauge. The charge pressure will be between:

C096770

Fig 24. Gearpump Machine

A

CUT IN - 110 bar (1600 lbf/in2) minimum. CUT OUT - 140 bar (2000 lbf/in2) maximum. 6

Press the brake pedals repeatedly and check that the charge pressure is maintained within the minimum and maximum limits.

7

Vent the braking system pressure before removing the pressure gauge. Refer to Section 2 - General procedures.

C097780

Fig 25. Variflow Machine

Adjustment The charge pressure is factory set and cannot be adjusted.

G1-39

9813/0250-04 (G-01-05)

G1-39

Section G1 - Brakes Service Brakes SYSTEM Test Procedures

Checking the Brake Accumulator The brake system accumulator (situated on the brake valve) is pre-charged with nitrogen gas. This procedure describes how to check the accumulator gas pressure is correct by measuring the oil pressure in the charge circuit.

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Make sure that the hydraulic fluid is at working temperature (50 ºC, 122 ºF). 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures.

2

Vent the braking system pressure. Refer to Section 2 - General procedures.

3

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to the test point A on the side of the combined priority/charge valve.

4

Operate the engine for a minimum of two minutes and occasionally press the brake pedals. This makes sure that the brake system charge valve has filled the accumulator.

5

Stop the engine.

6

Press the brake pedals repeatedly and check the reading on the pressure gauge.

C096770

Fig 26. Gearpump machine shown

A

Note when the reading on the pressure gauge falls to zero. This indicates the oil in the accumulator is exhausted. The lowest reading before the accumulator is exhausted is equal to the accumulator gas pressure. The accumulator gas pressure should be 40 bar (575 lbf/in2). C097780

7

Vent the braking system pressure before removing the pressure gauge. Refer to Section 2 - General procedures.

G1-40

9813/0250-04 (G-01-05)

Fig 27. Variflow Machine

G1-40

Section G1 - Brakes Service Brakes SYSTEM Test Procedures

Checking the Brake Low Pressure Switch Operation

!MWARNING Before working on the brake system make sure the machine is on level ground and chock all four wheels. BRAK-1-4

Make sure that the hydraulic fluid is at working temperature (50 ºC, 122 ºF). 1

Park the machine and make it safe. Obey the care and safety procedures. Refer to Section 2 - General Procedures.

2

Vent the braking system pressure. Refer to Section 2 - General procedures.

3

Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to the test point A on the side of the combined priority/charge valve.

4

Operate the engine for a minimum of two minutes and occasionally press the brake pedals. This makes sure that the brake system charge valve has filled the accumulator.

5

Stop the engine.

6

Make sure that the starter switch is turned on but do not start the engine.

7

Press the brake pedals repeatedly and monitor the pressure on the gauge at the point the low pressure warning light B illuminates.

C096770

Fig 28. Gearpump Machine

A

The pressure at which the light illuminates should be about 90 bar (1305 lbf/in2). 8

Continue pressing the brake pedals until there is no pressure in the system.

9

Start the engine and note the pressure on the gauge when the warning light goes out. This should be about 90 bar (1305 lbf/in2).

10

Vent the braking system pressure before removing the pressure gauge. Refer to Section 2 - General procedures.

C097780

Fig 29. Variflow Machine

B

C097790

Fig 30.

G1-41

9813/0250-04 (G-01-05)

G1-41

Section G2 - Brakes

Internal Park Brake SYSTEM Introduction This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system. Descriptions and procedures relate to the system and not the individual devices. For information about the devices refer to the relevant topics. This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble. K Related Topics ( T G2-2) K Specifications ( T G2-3) K Test Procedures ( T G2-5) K Adjustment (PS760) ( T G2-6) K Adjustment (SS750) ( T G2-9) K Switch Adjustment ( T G2-11) K Renewing the Park Brake Cable (PS760) ( T G2-12) K Renewing the Park Brake Cable (SS750) ( T G2-15) K Dismantle, Inspection and Assemble (PS760) ( T G2-17) K Dismantle, Inspection and Assembly (SS750) ( T G2-24)

G2-1

9813/0250-04 (G-02-04)

G2-1

Section G2 - Brakes Internal Park Brake SYSTEM Related Topics

Related Topics Table 1. Related Topics in This Publication The table lists other topics in the manual that contain information related to this topic. Where applicable the text in this section contains cross references to this page to help you find the correct information. Sections

Topic Titles

2

ALL (Care and Safety)

G

Park Brake Switch

Sub Titles (1)

ALL

(1) You must obey all of the relevant care and safety procedures.

G2-2

9813/0250-04 (G-02-04)

G2-2

Section G2 - Brakes Internal Park Brake SYSTEM Specifications

Specifications

Type

JCB Oil-immersed multi-plate disc.

Actuation

Cable operated.

Location

Housed inside the gearbox.

Friction Plates

5 per brake pack

Brake Pack Overall Thickness New (Max.)

38.9 mm (1.531 in)

Service Limit (Min.)

37.1 mm (1.460 in)

G2-3

9813/0250-04 (G-02-04)

G2-3

Section G2 - Brakes Internal Park Brake SYSTEM Operation Overview

Operation Overview The park brake is Independent of the service brakes. It operates on the drive to the rear axle via an oil immersed, multi-plate brake pack A housed inside the gearbox. The brake assembly is mounted on the gearbox layshaft. When the operator moves the park brake lever to the vertical position, the cable causes the brake plates to be pressed together. The lever has a simple system for adjustment of the cable when necessary. An electrical switch senses if the park brake lever is set to the brake ON or brake OFF position. The switch controls operator warnings and transmission interlocks.

C084690-C2

Fig 1.

G2-4

9813/0250-04 (G-02-04)

G2-4

Section G2 - Brakes Internal Park Brake SYSTEM Test Procedures

Test Procedures

!MWARNING Before testing the park brake make sure the area around the machine is clear of people.

If you have any queries concerning this test procedure or parking brake adjustment, consult your local JCB distributor.

!MWARNING

2-2-4-5

1

Enter the machine. Fasten your seat belt and park the machine on a level dry surface.

Do not use a machine with a faulty park brake. 3-2-3-10_2

!MWARNING

2

Fully apply the parking brake A.

3

On machines with two brake pedals B ensure they are locked together.

4

Start the engine and raise the attachments to the appropriate travelling position.

5

Select fourth gear, C for synchro shuttle machines or D for powershift machines.

6

Push down hard on foot brake pedal B.

7

Select forward drive E.

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

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

P

2-2-5-1

Test the parking brake as follows: 8

Move the parking brake lever fractionally forward until the warning light F is just extinguished.

9

Slowly release the foot brake pedal B.

10

If the machine has not moved, use the accelerator pedal to gradually increase the engine speed to 1500 RPM. The machine should not move.

11

Do not do this test for longer than 20 seconds.

12

Reduce the engine speed to idle and select neutral C or D.

13

Return the park brake lever A to the fully on position from its partially applied position.

14

Lower attachments and stop the engine.

15

If the machine moved during this test, adjust the parking brake and repeat the test.

C004690-C2

Fig 2.

K Adjustment (PS760) ( T G2-6) K Adjustment (SS750) ( T G2-9)

G2-5

9813/0250-04 (G-02-04)

G2-5

Section G2 - Brakes Internal Park Brake SYSTEM Adjustment (PS760)

Adjustment (PS760) During normal operation little or no adjustment of the brake cable at the lever is required. In the event of poor brake performance it is likely that components have failed or, after extended service, friction material is worn away. Dismantle, inspect and renew components as required. Inspection and Assemble K Dismantle, (PS760) ( T G2-17)

1

Disengage the park bake (lever horizontal)

!MCAUTION The park brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced. Whenever the park brake has been used in an emergency, always renew both brake pads.

Fig 3. 2

Turn the hand grip E clockwise, half a turn.

!MWARNING

3

Test the park brake. K Test Procedures ( T G2-5)

Before adjusting the park brake, make sure that the machine is on level ground. Put blocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

4

If the brake fails the test repeat steps 1 and 2. If there is no more adjustment and pin F is at the end of its travel, dismantle, inspect and renew park brake components as required. K Dismantle, Inspection and Assemble (PS760) ( T G2-17)

4-2-1-1_2

2-3-2-4

!MWARNING Over adjustment of the park brake could result in the park brake not fully releasing. 0011

Adjustment at the park brake lever should only be required after renewal of the cable, brake components or extended service. Proceed as follows:

Important: After adjusting the park brake lever the following steps MUST be carried out to confirm correct brake operation. Incorrect adjustment can result damage to the brake components and excessive overheating of the brake assembly. 5

Put chocks under the wheels.

6

K Fig 4. ( T G2-7) Remove five screws A and two bolts B. Using a flat blade screwdriver located in the housing cut out C, lever off the cover plate D.

Note: Before attempting to adjust the park brake after an emergency stop remove and inspect the brake friction components. Renew components if necessary. Inspection and Assemble K Dismantle, (PS760) ( T G2-17)

Lever Adjustment The park brake should be fully engaged when the lever is vertical. The park brake indicator light should light when the brake is engaged with the forward and reverse lever away from neutral (starter switch at IGN).

G2-6

9813/0250-04 (G-02-04)

G2-6

Section G2 - Brakes Internal Park Brake SYSTEM Adjustment (PS760) 8

Fully apply the park brake (lever vertical). If the brake is within service limits the clevis pin C hexagon MUST NOT BE VISIBLE above the cover plate. Renew the friction pack if any of the clevis pin hexagon is visible. Inspection and Assemble K Dismantle, (PS760) ( T G2-17)

Note: If friction pack components are distorted (typically after performing an emergency stop) the clevis pin may not be visible in the check described. If the park brake performance is poor it may be due to distorted components. Dismantle and inspect the park brake assembly. K Dismantle, Inspection and Assemble (PS760) ( T G2-17) 9

Fig 4. 7

K Fig 5. ( T G2-7) Use the cover plate A as a wear indicator. Use a bolt B to fit the plate at right angles to the housing as shown.

Disengage the park brake (lever horizontal). Make sure that the brake is fully released. Remove the cover plate A and feel the edge of the brake pack plates. When the brake is released free play between the plates should be easily detectable. K Fig 6. ( T G2-7) If the plates are not free DO NOT OPERATE THE MACHINE. Dismantle, inspect and renew park brake components as required. Inspection and Assemble K Dismantle, (PS760) ( T G2-17)

Pull the plate down when tightening the bolt to take up the clearance in the bolt hole.

Fig 6. 10

Fig 5.

G2-7

If the brake pack is serviceable clean off all traces of old sealant from the cover plate and brake housing. Make sure that no sealant enters the gearbox. Apply a bead of JCB Multigasket to the brake housing.

9813/0250-04 (G-02-04)

G2-7

Section G4 - Brakes Brake Valve Hydraulic Operation and Schematics

Hydraulic Operation and Schematics The brake valve has two valve spool assemblies each operated by a push rod connected to a brake pedal. One valve assembly operates the left side brake pack and the other the right side brake pack.

The valve assembly enables pressure balance between the two spools. This ensures equal brake force if the pedals do not move the push rods exactly the same distance.

For normal operation both brake pedals are connected together so that the brake valve spools operate the left and right side brakes at the same time.

3 6

5 9

8

4

9

8

1

7 2

C097950

Fig 2. Brake Valve - Section View Key: 1

Brake valve body

2

Right side axle brake pack

3

Left side axle brake pack

4

Inlet port from pump P2

5

Return to tank port

G4-4

6

Brake pressure balance gallery from right side brake valve spool

7

Brake pressure balance gallery from left side brake valve spool

8

Actuation push rod

9

Clevis - push rod to brake pedal

9813/0250-04 (G-12-01)

G4-4

Section G4 - Brakes Brake Valve Hydraulic Operation and Schematics

Brake Operation When the brake pedals 1 are pressed pressurised oil flows from the valve inlet port 2 to the brake packs 3 and 4 via the brake valve spools.

The spools modulate the brake pressure in proportion to the foot pedal input by means of springs and internal pilot ports 5. Hydraulic balancing chambers 6 are connected to pressure from the opposite brake valve. Oil pressure acts on the brake valve spools to equalise the left and right brake pressure if the pedal input is unequal.

4

6

5

1

2

1

5

6

3 C097970

Fig 3.

G4-5

9813/0250-04 (G-12-01)

G4-5