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Section C - Electrics

Harness Data

Drawings and Interconnection

C - 28 C - 28

9803-9450-1

Fig 21.

Mainframe Harness Sheet 5 K

Fig 22. ( T C-29)

721/12434 issue 1, sheet 5

Main Page

Section 1 - General Information3
Table of Contents4
Introduction6
About this Publication6
Identifying Your Machine7
Machine Model and Serial Number7
Machine Identification Plate7
Typical Product Identification Number (PIN)8
Engine Number8
Torque Settings9
Zinc Plated Fasteners and Dacromet Fasteners9
Introduction9
Bolts and Screws9
Hydraulic Connections13
O' Ring Face Seal System13
Torque Stop' Hose System16
Service Tools17
Numerical List Section B - Body and Framework17
Tool Detail Reference Section B - Body and Framework18
Numerical List Section C - Electrics23
Tool Detail Reference Section C - Electrics24
Numerical List Section E- Hydraulics25
Tool Detail Reference Section E- Hydraulics28
Service Consumables33
Sealing and Retaining Compounds33
Section 2 - Care and Safety35
Safety Notices38
Safety Check List38
Safety - Yours and Others39
General Safety39
Operating Safety40
Maintenance Safety45
Safety Decals50
Safety Checklist50
Routine Maintenance56
Service Requirements56
Introduction56
Owner/Operator Support56
Service/Maintenance Agreements56
Lifting Regulations - Inspections and Tests56
Obtaining Replacement Parts57
Health and Safety58
Lubricants58
Battery60
First Aid - Electrolyte60
Service Schedules62
Introduction62
How to Use the Service Schedules62
Pre-Start Cold Checks, Service Points and Fluid Levels63
Functional Test and Final Inspection65
Fluids, Lubricants and Capacities67
Coolant Mixtures67
Cleaning the Machine69
Cleaning the Cab Interior70
Checking for Damage71
Seat Belt72
Checking the Seat Belt Condition and Security72
ROPS/FOPS Structure73
Checking the ROPS/FOPS Structure73
Boom Safety Strut74
Installing74
Removing75
Greasing76
Greasing 10 Hours76
Every 50 Hours77
Oiling78
Every 500 Hours78
Access Panels79
Engine Cover79
Rear Panel79
Electrical System80
Battery80
Jump Starting the Engine81
Fuses and Relays83
Primary Fuses83
Engine Air Filter86
Changing the Elements86
Cleaning the Air Filter Dust Valve87
Engine88
Checking the Oil Level88
Changing the Oil and Filter89
Checking the Coolant Level91
Changing the Coolant92
Checking the Alternator Belt Tension94
Adjusting the Alternator Belt94
Fuel System95
Types of Fuel95
Filling the Tank96
Changing the In-Line Fuel Filter97
Bleed the Fuel System97
Draining the Fuel Filter97
Changing the Fuel Filter Element98
Bleeding the Fuel System99
Hydraulic System100
Checking the Hydraulic Oil Level100
Changing the Charge Filter Element101
Changing the Return Filter Element102
Drive Chain Lubrication103
Checking the Oil Level103
Changing the Oil103
Tyres and Wheels104
Tyre Inflation104
Checking the Wheel Nut Torque104
Renewing Segments of Optional Non-Inflatable Tyres105
Tracks106
Track Adjustment106
Windscreen Washer (Optional)107
Checking the Level107
Hydraulic Connections112
General Information112
Quick Release Couplings113
Connecting and Disconnecting113
Connecting/Disconnecting Hydraulic Hoses115
Connecting the Hoses115
Disconnecting the Hoses115
Maintenance116
Shovels116
General Purpose and Light Duty Shovels116
6-In-1 Shovel116
Pallet Forks117
Daily Maintenance117
Manure/Silage Fork with Top Grab118
Daily Maintenance118
Attachment Frame118
Section B - Body and Framework121
Loader Arm124
Removal and Replacement124
Removal125
Replacement126
Rivet Nuts127
Fitting Procedure128
Technical Data134
General Electrical Data134
Light Bulbs134
Sensing Switches135
Test Methods Using a Multimeter136
Measuring DC Voltage137
Measuring Resistance137
Measuring Continuity138
Measuring Frequency138
Testing a Diode or a Diode Wire139
Service Procedures140
Battery140
Maintenance140
First Aid - Electrolyte140
Testing141
Specific Gravity Testing142
Alternator143
General Description143
Service Precautions143
Charging Circuit Test143
Alternator Charging Test144
Starting Circuit Test146
Problem Solving147
Circuit Diagrams149
Main Components149
Lamps150
Fuses150
Harness Data153
Wire and Harness Number Identification153
Introduction153
Wire Numbers and Functions154
General Points154
Harness Structure155
Drawings and Interconnection156
Harnesses156
Removal and Replacement179
Removal179
Replacement179
Dismantling and Assembling180
Dismantling180
Assembling181
Starter Motor182
Removal and Replacement182
Dismantling and Assembly183
Section D - Controls188
Manual Controls190
Technical Data198
General Data198
Loader Pump - Standard (P3)198
Loader Pump - High-Flow (P3 and P5)198
Charge Pump (P4)198
Relief Valve Operating Pressures198
Transmission Pump199
Hydraulic Motors - Wheeled Machines199
Hydraulic Motors - Tracked Machines199
Loader Valve Block - Servo Machines199
Loader Valve Block - Manual Machines199
Self Level Valve (Optional)200
Filters200
Hydraulic Tank200
Operation Description201
Introduction to Hydraulic Schematic Symbols201
General (Basic and Functional Symbols)201
Control Valves205
Example of Schematic Circuit206
Neutral Circuits207
Standard Machines207
High-Flow Machines208
Loader Circuit209
Transmission Circuit209
Servo Circuits209
Transmission Pump Operation210
Charge Pressure210
High Pressure Relief Valves210
Transmission Motor Operation212
Loop Flushing System212
Speed Operation (Optional)212
Servo Transmission Operation213
Neutral213
Forward214
Reverse215
Right Spin Turn216
Loader Valve Operation217
Neutral Circuit218
Shovel Tilt219
Lift Arm Raise220
Lift Arm Lower221
Self Level Valve222
Loader Arm Raise - Self Levelling222
Tilt Ram Fully Extended223
Loader Arm Lower223
Tilt Ram Extend224
Tilt Ram Retract224
Power Management System (P.M.S.)225
Operation225
Fault Finding227
Hydrostatic Transmission227
Hydrostatic Transmission230
Checking for Faulty Pump or Motor230
Checking Wheel Speed232
Machine Veers to One Side When Travelling234
Transmission Pump Neutral Adjustment235
Checking Motor Leakage Rate237
Pump Main Relief Pressure Test Points238
Testing Main Relief Valves238
Checking the Joystick Hydraulic Lines239
Loader Circuit240
Levelling Circuit243
High-Flow Circuit244
Checking Flow and Pressure244
Warning Light Indications247
Blink Codes247
System Check247
Power Management System (P.M.S.)247
Fault Tracing248
General250
Bleeding the Hydraulic System250
Circuit Diagrams251
Standard and High-Flow Servo Machines251
Component Key251
Control Variations253
Component Key253
Service Procedures254
Hydraulic Contamination254
Hydraulic Fluid Quality254
Effects of Contamination254
Cleaning Operation254
Contaminant Standards255
Filters255
Cleaning Operation256
Procedure256
Pressure Testing257
Loader Main Relief Valve (M.R.V.)257
Transmission Charge Pressure259
Power Management System (P.M.S.)260
Calibration Procedure260
To Fit Sensitivity Control to Non High Flow Machines263
Transmission Pumps264
Removal and Replacement264
Removal264
Replacement264
Replacement265
Pump/Engine Coupling267
Dismantling and Assembly268
Input Shaft Seal269
Output Shaft Cover 'O' Ring269
High Pressure Relief Valves269
Removal and Replacement269
Charge Valve270
Start-Up Procedure271
Loader Pumps272
Typical Loader Pump272
Removal272
Replacement272
Loader Pump - Standard Machines273
Dismantling and Assembly273
Loader Pump - High-Flow Machines275
Dismantling and Assembly275
Drive Motors277
Motors - Wheeled Machine277
Removal and Replacement277
Dismantling278
Inspection279
Assembly279
Motor Bearing Housing281
Assembly284
Motors - Tracked Machine287
Removal and Replacement287
Brake Dismantling and Assembly289
Front Housing291
Section F - Transmission294
Drive Train296
Section F - Transmission Description297
Tracked Machines298
Tyres and Wheels299
Roadwheels299
Removal299
Replacement299
Wheel Hubs and Drive Shafts300
Wheel Hub Assembly (Right Hand)300
Removal300
Replacement300
Dismantling302
Assembly303
Drive Shaft Assembly (Left Hand)305
Dismantling306
Assembly306
Drive Chains308
Removal and Replacement308
Removal308
Replacement309
Adjustment310
Section G - Brakes314
Moving a Disabled Machine316
Basic System and Operation322
Description322
Track Damage324
Types of Rubber Track Damage324
Additional Notes325
Track Repair334
Recommended Repair Procedures334
Track Removal and Replacement336
Removal336
Replacement338
Idler Wheels and Rollers339
Front Idler Wheel and Recoil Unit339
Rear Idler Wheel341
Guide Roller343
Track Frame Assembly345
Removal345
Replacement346
Technical Data352
Section K - Engine Specification352
Removal and Replacement353

jcb Robot 160 - Page 161

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