General Information 1

Care & Safety 2

R
Routine Maintenance 3
Electrics C
Hydraulics E
Service Transmission F
Manual
(Supplement)
Brakes G
Steering H
525-50 RAF Engine K

PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT OF
JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
ST14 5PA, ENGLAND
Tel. 01889 - 590312
PRINTED IN ENGLAND

Publication No. 9803/3675 Initial Issue

 Overall Contents
i i

Contents Page

Section 1 General Information

Introduction
Care and Safety 1-1

Section 2 Care and Safety

Safety Notices 1-1

Safety Warnings 2-1

Section 3 Routine Maintenance

Service Schedules (Additional Items) 1-1

Category ‘C’ Safety System

Oiling 2-1

Batteries
Warning Symbols 2-1
First Aid - Electrolyte 3-2
Checking the Electrolyte Level 3-2

Section C Electrics

Technical Data 1-1

Fuse Identification 1-2

Schematic Diagram 2-1

Load Moment Indicator

Introduction 3-1
Load Chart (Example Only) 3-2
Calibration 3-3
Diagnostic Fault Codes 3-4
Testing 3-5
Fault Location Chart 3 -11

Section E Hydraulics

Schematic Diagram 2-1

9803/3675 Issue 1
 Overall Contents
ii ii

Contents Page

Section H Steering

Circuit Description
Steer Unit Operation 1-1
Steer Mode Valve Operation 1-1

Steer Mode Valve

Checking Solenoid Operation 2-1
Removal 2-1
Replacement 2-1

Section K Engine

Technical Data 1-1

Machine Start-up Procedure 2-1

Category ‘C’ Safety System

Introduction 3-1
Operation 4-1
Inlet Shutdown Valve
Overspeed Spring Adjustment 5-1
Replacing a Broken Tension Pin 5-2

Webasto Water Heater

Introduction 8-1
Operation 8-2
Heater Unit 8-3
Fault Finding 8-5
General Failure Symptoms 8-5
Failure Symptoms After Switch-off Upon Failure 8-6
Electrical Connections 8-7
Heater Unit - Removal and Refitting 8-8
Circulation Pump - Replacement 8-9
Temperature Limiter - Replacement 8 - 10
Temperature Sensor - Replacement 8 - 10
Combustion Air Fan - Replacement 8 - 12
Replacement of Burner, Flame Sensor and Glow Plug 8 - 13
Burner Head - Replacement 8 - 15
Heat Exchanger - Replacement 8 - 16
Visual Inspection 8 - 17
Electrical Component Testing 8 - 18

9803/3675 Issue 1
Section 1 General Information Section 1
i i

Contents Page No.

Introduction 1-1
Care and Safety 1-1

9803/3675 Issue 1
Section 1 General Information Section 1
1-1 Introduction 1-1

This manual is a supplement to the JCB 525-50 Loadall

Service Manual. The information covers the 525-50RAF
machines with the following serial numbers:

881917, 881918 (winterised)

881982 to 882006 (standard machines).

Note: Only those areas of the machine which are different

from the standard 525-50 Loadall are dealt with here. For all
other information refer to Loadall Service Manual 9803/3620.
Unless specified otherwise, all references to ‘Service
Manual’ in this supplement are to be taken as meaning
Loadall Service Manual 9803/3620.

Read the standard Service Manual and this Supplement

completely and carefully to familarise yourself with the
machine before carrying out any servicing procedures.

Care and Safety

Before carrying out any maintenance procedures on this
machine, make sure you read the Care and Safety
information in Section 2 of the Service Manual. The relevant
information in that Section should be observed as well as
any care and safety information contained in this
supplement.

9803/3675 Issue 1
Section 2 Care & Safety Section 2
i i

Contents Page No.

Safety Notices 1-1

Safety Warnings 2-1

9803/3675 Issue 1
Section 2 Care & Safety Section 2
1-1 1-1

Safety Notices
In this manual and on the machine there are safety notices. Each notice starts with a
signal word. The signal word meanings are given below.

! DANGER
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

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

! CAUTION
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

! DANGER
Study this Supplement and the Service Manual for the machine before carrying out any
maintenance work on the machine. You must always understand and observe the
relevant laws and regulations. If you are unsure about anything, ask your JCB
Distributor.

9803/3675 Issue 1
Section 2 Care and Safety Section 2
2-1 2-1

Before carrying out any maintenance procedures on this

machine, make sure you read the Care and Safety
information in Section 2 of the Service Manual. The relevant
information in that Section should be observed as well as
any care and safety information contained in this
supplement.

Safety Warnings

!WARNING
Working Beneath the Machine
Make the machine safe before getting underneath it. Park
the machine on level ground. Make sure the engine is
stopped, the parking brake is engaged and the transmission
is in neutral. Disconnect the battery. Chock all four wheels.
5-3-2-1

! WARNING
If the engine safety system trips whilst the machine is being
used in a hazardous area, DO NOT ATTEMPT TO RE-START
until advice has been obtained from the person in authority
and the cause of the shutdown found and corrected.
0088

! CAUTION
If the engine has been running previously, it will not be
possible to reset the engine safety shutdown system for a
period of at least 30 seconds after shutdown due to the high
engine inlet system vacuum. DO NOT attempt to push the
operating lever to the start/reset position against this
vacuum as use of excessive force will cause severe damage
to the valve mechanism.

9803/3675 Issue 1
Section 3 Routine Maintenance Section 3
i i

Contents Page No.

Service Schedules (Additional Items) 1-1

Category ‘C’ Safety System

- Oiling 2-1

Batteries
- Warning Symbols 3-1
- First Aid - Electrolyte 3-2
- Checking the Electrolyte Level 3-2

9803/3675 Issue 1
Section 3 Routine Maintenance Section 3
1-1 Service Schedules (Additional Items) 1-1

Daily Weekly 2 Weekly 6 Monthly Yearly 2 Yearly

Operation 10 50 100 500 1000 2000
Hr Hr Hr Hr Hr Hr

CATEGORY ‘C’ SAFETY SYSTEM

Control Mechanism Inspect z z z z

All Pivot Points Oil z z z z

Emergency Stop Test z z z z

Overspeed Setting Check/Adjust z z z

WEBASTO HEATER SYSTEM

System Inspect/Operate z z

9803/3675 Issue 1
Section 3 Routine Maintenance Section 3
2-1 Category ‘C’ Safety System 2-1

Oiling
Lightly oil the shut-off valve spindle A and the pivot points B
at the periods stated in the Service Schedules.
A

397580

9803/3675 Issue 1
Section 3 Routine Maintenance Section 3
3-1 Batteries 3-1

Warning Symbols THIS MACHINE IS FITTED WITH A 24 VOLT ELECTRICAL

The following warning symbols may be found on the battery. SYSTEM WHICH IS POWERED BY TWO 12 VOLT
BATTERIES WIRED IN SERIES.

Symbol Meaning ! CAUTION

Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
Keep away from children. INT- 3- 1-14

! WARNING
A289230
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
Shield eyes. INT-3-1-4

A289260
! DANGER
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
No smoking, no naked flames,
safety glasses.
no sparks. INT-3-2-1/3

A289280 ! CAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance with
Explosive Gas.
local environmental waste regulations.
INT-3-1-12

! WARNING
A289250

Batteries give off an explosive gas. Do not smoke when

Battery acid. handling or working on the battery. Keep the battery
away from sparks and flames.

A289240 Battery electrolyte contains sulphuric acid. It can burn

you if it touches your skin or eyes. Wear goggles. Handle
the battery carefully to prevent spillage. Keep metallic
Note operating instructions. items (watches, rings, zips etc) away from the battery
terminals. Such items could short the terminals and burn
you.
A289270
Set all switches in the cab to OFF before disconnecting
and connecting the battery. When disconnecting the
battery, take off the earth (-) lead first.

When reconnecting, fit the positive (+) lead first.

Re-charge the battery away from the machine, in a well

ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.

9803/3675 Issue 1
Section 3 Routine Maintenance Section 3
3-2 Batteries 3-2

First Aid - Electrolyte

Do the following if electrolyte:

GETS INTO YOUR EYES

Immediately flush with water for 15 minutes, always get

A
medical help.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns with

397432
a sterile dressing then get medical help.
5-3-4-3/1

Checking the Electrolyte Level

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

1 Remove the rear grille A or open the battery box door

B, as appropriate.

! WARNING
Keep metal watch straps, and any metal fasteners on
your clothes, clear of the positive (+) battery terminal. 397370
Such items can short between the terminal and nearby
metal work. If this happens you can get burned.
5-2-2-4

2 Disconnect and remove battery.

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

3 Remove covers C. Look at the level in each cell. The

electrolyte should be 6 mm (1/4 in) above the plates. Top
up if necessary with distilled water or de-ionized water.

4 Refit battery, close and lock the rear grille/battery box

door.
A089660

9803/3675 Issue 1
Section C Electrics Section C
i i

Contents Page No.

Technical Data 1-1

Fuse Identification 1-2

Schematic Diagram 2-1

Load Moment Indicator

Introduction 3-1
Load Chart (Example Only) 3-2
Calibration 3-3
Diagnostic Fault Codes 3-4
Testing 3-5
Fault Location Diagram 3 - 11

9803/3675 Issue 1
Section C Electrics Section C
1-1 Technical Data 1-1

Batteries 2 x 12 volts, negative earth

Cold Crank amps for 1 minute to
1.4 VPC at -18°C (0°F) I.E.C. 590
Reserve capacity (minutes) for 25 amp load 290

Alternator Bosch 24V - 55A

Starter Motor Bosch 24V LHS

Light Bulbs
Headlights - dip 24V, 70 W
Headlights - main 24V, 70 W
Work lights 24V, 70 W
Halogen
Front side lights 24V, 5 W
Stop/tail lights 24V,21/5 W
Turn indicators 24V, 21 W
Warning lights 24V, 1.2 W
Interior light 24V, 10 W
Search light 24V, 70 W

9803/3675 Issue 1
Section C Electrics Section C
1-2 Technical Data 1-2

Fuse Identification
The electrical circuits are protected by fuses. The fuses are located in a fuse box inside the door. They are in three rows,
labelled A, B and C. Each fuse position in each row is numbered. If a fuse blows, find out why before fitting a new one.

Row A Row B Row C

Fuse Circuit Rating Fuse Circuit Rating Fuse Circuit Rating

1 Brake lights 7.5 1 Junction box 5 1 Spare -

2 Panel warning lights, 5 2 Engine shut-off switch 5 2 Load Moment Indicator 3

warning buzzer, (ESOS)
instrument lights 3 Forward/reverse switch, 7.5
3 Dipped beam 15 transmission dump relay
3 L.H. sidelights, 5
number plate light, 4 Main beam 15 4 Rear fog light 3
trailer light (if fitted)
5 Working lights 7.5 5 Thermostart 15
4 R.H. sidelights, 5
number plate light, 6 Indicators 5 6 4WS 7.5
trailer light (if fitted)

5 Rear wash/wipe switch 5 7 Parking brake circuit 5 7 Heated screen 25

6 Hazard warning lights 10 8 Heater 5 8 Headlight flasher 10

7 Interior light, beacon 5 9 Spare - 9 Engine shutdown 5

8 Spare -

9 Front wash/wipe switch, 7.5

horn

Fuse links

Circuit Rating

1 Starter relay 60
2 Tracker, Radio, Hazard lights, Wipers 30
3 Lights relay 40
4 Starter switch 30
5 Not used 80

1
3
2 A
5
4 B
C
S245110 112252

9803/3675 Issue 1
Section C Electrics Section C
2-1 Schematics 2-1

Component Key (Sheet 1)

1 Batteries (two in series) 41 Water temperature switch

2 Starting aid 42 Transmission oil temperature switch
3 Starter motor 43 Engine oil pressure switch
4 Neutral start relay 44 Transmission oil pressure switch
5 Ignition switch 45 Air filter blocked switch
6 Forward relay 46 Brake pressure switch
7 Forward solenoid 47 Warning buzzer
8 Reverse relay 100 Battery isolator switch
9 Reverse solenoid 101 Intervehicle start socket
10 Reverse light 102 24V to 12V convertor
11 Forward/reverse switch
12 Transmission dump relay ....continued
13 Park brake light relay
14 Reverse alarm mute relay
15 Reverse alarm
16 Park brake switch
17 Park brake solenoid
18 Cold start advance
19 E.S.O.S.
20 Load moment indicator (LMI)
21 LMI transducer
22 Heated screen switch
23 Heated screen timer
24 Heated screen relay
25 Heated side screen
26 Heated rear screen
27 Hazard/steer mode indicator unit
A Hazard flasher indicator light
B Steer mode indicator light (see Sheet 2 for
connections)
28 Hazard switch
29 Hazard flasher unit
30 Indicator switch
31 Left hand front indicator
32 Left hand rear indicator
33 Left hand trailer indicator
34 Right hand trailer indicator
35 Right hand rear indicator
36 Right hand front indicator
36 Fuel gauge
37 Alternator
38 Water temperature sender
39 Fuel sender
40 Instrument panel
A Tachometer
B Water temperature gauge
C Fuel gauge
D Hourmeter
E Battery charge warning light
F Hand brake on warning light
G Water temperature warning light
H Transmission oil temperature warning light
J Engine oil pressure warning light
K Transmission oil pressure warning light
L Air filter blocked warning light
M Brake fault warning light
N 2-wheel steer indicator light
P 4-wheel steer indicator light
R Hazard warning indicator light
S Main beam on indicator light
T Panel illumination
U Panel illumination
V Turn signal indicator light

9803/3675 Issue 1
 2-2

101

9803/3675
Sheet 1

1
Section C

100

M
004
842

3
810A 934

4
2

40A
30A
30A
60A
003 123

PRE

IGN

200E
OFF

200G
200C
200B

200D
HEAT
START
C5
200B
001
200C
004

003A

5
4

003 934B 600FL

934A 600EZ
5

6
809 809 600AC
001B 107A

11
107M 912
912A 812 600BS

C3
810
7

107A
600AD
934
808 808
Schematic
Electrics

107N 934C
9

107M 811B 811 600BT

912 912A
107N
811C/811F
934C
8

12
10

106BM 8 7 600PA
1
1
2
811A 3
807 600CD
2
14

937C
15

13
810B 600FR
967
401 852 937 600BN
16

600GN
122
001J 936
105B 600CV

B7
17

001H 105 105A 600

B2
974 600JE
102

001G
C2
20

463
464
21

600NT

106BL 10 9 600NJ
106BP 2 3
1 935 600NS
1 3
6
22

4 600FF
23

4
8 7 2 600NY

106BN
1804A 25
600NX
200M 323 1804B 26
24

600NZ
C7

400
B
27

600BL
600DX

805E 600BC
31
805C 600G
32
28

805K 600FP
600DX
B6

33
30

001F 104 805B

802
200J 300
29

806L 600FP
803A
34
806B 806C 600H
803

A6

805
803A

35
806E 600AZ
804 804A 806 36
106F
37

200
200A
412

407

412
A

600T
106
409 600LZ
38
B

408 600CE
39
C

001D
106E
407
D

A2
E

401
F

406 600CK
41
G

404 600C
40

42
H

403 600HH
J

405
43
600BU
44
K

404 600CF
L

45
458
M

600GL
46
825B
N P

826B
804
853-00004-1(2)
R S T

830

806 805
Section C

Issue 1
2-2

U V

106C 411
406A

106
200G

200E
826B

001
001
830

825B

200D
600

837
47
 106
600

001
837
830

001

200E
825B

200G
406A

200D
826B
2-3

9803/3675
48
Sheet 2
163A 406A

49
001K
Section C

951 600PJ
163

C9
600AA

816D 600G
50

54

55
001C 108A 877 600FP
816J 51
816
108B

A1
52
600H
816E
53

56
600BW
109A
819 821

4WS
2WS
CRAB
59
A

600BV 819A
109B
820 B
C

822
819B

57
823
D

109E 845

60
826
58

824

A
109C 826A

27
E

61
824B
106AU
F

B
824A
825 600NP

62
109D

825A
002N 109 109F

63

C6
64
002F 101 600CC

B1
65

110B 839 600BG

002H 110

A9
600AK
67
66

840

841
303C
69

110J 814 600B

68
001M 600W 600W

200E 002
600EF

A5
862 600BD
002C 103 103J
70

864
103F
72

71

863 600BK

106R 600EB

808B

002L 102D 102F

800 600BH
B8
74
73

75

600BM 600BM
001L 009
600DW
200D
829P 600FP
829G 600AU
76
829D 600G
77
A3

829E 600BC
78
830S 600FP
79
106K 830J 600AX
80
830H 600H
81
A4

200G 828A 830 830D 600AZ

82
828D 83
834A 600AZ
84
B3

833
96

834A 600BC
009A 832 834B 834B 85
94

314 600AZ
837 86
C8

836 837A
B4

200R 314 600BC

837B
600N
87
106J
835A 600G
Electrics
Schematic

832A 868 88
835 835B 600H
89
C4
95

600P

009D 116
855 855B 600AS
B5
90

97

303J 600CW
91

A7

303B 303A 600AJ

200H 303C
92

106N 600DY

303A
303B 894 600AP
98
93

600EH
200L
853-00004-2
99
Section C

Issue 1
2-3
Section C Electrics Section C
2-4 Schematics 2-4

Component Key (Sheet 2)

27 Hazard/steer mode indicator unit

A Flasher indicator light (see Sheet 1 for
connections)
B Steer mode indicator light
48 Shutdown relay
49 Shutdown solenoid
50 Left hand brake light
51 Left hand trailer brake light
52 Right hand trailer brake light
53 Right hand brake light
54 Brake light relay
55 Brake light switch
56 Proximity switch - front axle
57 Proximity switch - rear axle
58 Steer mode control unit
A Crab steer relay
B Four wheel/crab steer relay
C Two wheel steer relay
D Four wheel steer relay
E 4WS/Crab selector
F 2WS/4WS selector
59 Steer mode selector switch
60 AWS solenoid
61 4WS solenoid
62 Crab steer solenoid
63 2WS solenoid
64 Junction box
65 Front washer pump
66 Front wiper
67 Front wash/wipe switch
68 Ignition relay 2
69 Front horn
70 Rear wiper
71 Rear wash/wipe switch
72 Rear washer pump
73 Heater motor
74 Heater switch
75 Lights relay
76 Left hand trailer light
77 Left hand number plate light
78 Left hand tail light
79 Left hand side light
80 Right hand trailer light
81 Righft hand number plate light
82 Right hand tail light
83 Right hand side light
84 Right hand dipped beam
85 Left hand dipped beam
86 Right hand main beam
87 Left hand main beam
88 Left hand fog light
89 Right hand fog light
90 Left hand front worklight
91 Face level fan
92 Interior light
93 Beacon
94 Headlight flasher switch
95 Fog light switch
96 Road lights switch
97 Worklight switch
98 Beacon
99 Tracker

9803/3675 Issue 1
Section C Electrics Section C
3-1 Load Moment Indicator 3-1

Introduction
The machine is fitted with a Load Moment Indicator (LMI).

The load moment indicator warns the operator when the

machine is nearing its maximum working limit (ie. when it
could tip forward). Sensors measure the load exerted on the
rear suspension and send signals to the indicator. These
sensors take the form of the top locating pins B on the rear
suspension cylinders. E
Testing procedures described in this section should be 100%
carried out on level ground with the road wheels in the D
straight ahead position.

When the load carried by the forks is within the maximum C

working limit in terms of weight and boom extension, the
green LEDs C on the display unit illuminate.

The three green LEDs illuminate progressively as the load G

increases and the amber LED D illuminates as the load nears
the maximum working limit. A
All LEDs flash as the load continues to approach the
maximum working limit.

If the load exceeds the maximum working limit, the red LED
E illuminates and an audible warning sounds. A363130

If a system fault is detected, various combinations of LEDs

indicate a fault code. See Diagnostic Fault Codes.

LED G remains on whenever power is supplied to the

display box.

9803/3675 Issue 1
Section C Electrics Section C
3-2 Load Moment Indicator 3-2

Load Chart (for example only)

A
B
0 1000 2000 3000 4000 5000

Z X A346470

9803/3675 Issue 1
Section C Electrics Section C
3-3 Load Moment Indicator 3 -3

Calibration
The LED indications described are in addition to the green 1 Park the machine on firm level ground.
power-on LED G at the bottom of the display, which remains
on whenever power is supplied to the display unit. 2 Turn the starter key to the OFF position. Press and hold
display button A. Start the engine with button A held
The display unit must be calibrated by setting the ‘100%’ down. Hold the button for approximately 30 seconds
point using a known load and boom extension. after the engine has started. All display LEDs will
illuminate during this time.
! WARNING
Note: if the button is release during this time, the entire
During the following procedure, do not raise the load
process must be repeated.
more than 600mm above ground level otherwise the
machine may be able to tip forward at a dangerous
After approximately 30 seconds, the display will show
angle. Keep all personnel clear of the front and rear of
the red LED E only and the alarm will emit short
the machine.
intermittent bleeps.
Elec 4-1

3 Release button A.

4 With the boom fully retracted, pick up a load between

1800 kg and 2000 kg. Use either pallet forks loaded
with a test weight, or a bucket filled with a high density
material.

5 Slowly extend the boom. Keep the load close to the

ground until the machine is balanced about the front
axle with the rear wheels off the ground.

Note: If the following actions are not completed within a five

minute period, the display will automatically leave the
calibration mode and the memory will revert to the previous
settings. If the transducer signal is out of range, the display
will indicate the appropriate error code. Calibration cannot
continue until the fault is rectified.

6 Press and release the display button A. The display will

change to show the amber LED D and red LED E only.
E
7 Lower the load to the ground and measure the distance
the boom is extended.
D
100%
8 Refer to the correct load chart for the machine (this
section).

9 Read up from the extension figure obtained at step 7

(example line X) to the tipping line AA.
G
A 10 Read horizontally (example line Y) to the maximum
working limit line BB.

11 Read down to the horizontal axis to get the dimension

for the boom extension (maximum working limit).

12 Draw a mark on the boom at the dimension obtained

above. Raise and retract the boom to the mark drawn
on the boom.

13 Press and release the display button. The display will

revert to normal operation. The setting of the 100%
A363130 position is now complete.

9803/3675 Issue 1
Section C Electrics Section C
3-4 Load Moment Indicator 3-4

Diagnostic Fault Codes

When the system detects a fault, the audible alarm sounds for approximately 10 seconds and various combinations of lights on
the display indicate a fault code.

The alarm cancels after 10 seconds and all the lights on the display flash as long as the fault remains. Press and release the
display button A to show the fault for a further 10 seconds. When the fault clears, the display returns to normal.

If any of the fault codes are displayed, switch the starter key off and on again. Refer to the list of fault codes below if
the fault does not clear.

Note: A new display box will not be calibrated. Always calibrate the system when fitting a new display box.

FAULT CODE POSSIBLE CAUSE REMEDY

Fault Code 1 Transducer not connected. Check transducer connection.

Transducer Faulty harness. Check for trapped or damaged

signal fault wires.

Faulty transducer. Check for water ingress. Replace

transducer.

Fault Code 2 System is incorrectly calibrated. Re-calibrate system.

Calibration Transducer not fixed down Check mounting surfaces are clean
out of range correctly. and flat. Check mounting bolts are
not bottoming-out.
Check tightness of transducer
mounting bolts (70 Nm).

Faulty transducer. Replace transducer.

Fault Code 3 System not calibrated. Calibrate system.

Calibration
required

Fault Code 4 The display box has detected an Switch the starter key off and then
internal error. on again. Replace the display box
Display if the fault does not clear.
unit faulty

Fault Code 5 Low battery voltage Do supply voltage test at display

box. Check battery voltage.
Low battery
voltage

9803/3675 Issue 1
Section C Electrics Section C
3-5 Load Moment Indicator 3-5

A 100%

TP1 TP2 TP3 TP4 TP5

RUN BOSS TEST 1

CHECK TRANS TEST 2

Power

A244691

J
H E
2
1
2 1

S244690

9803/3675 Issue 1
Section C Electrics Section C
3-6 Load Moment Indicator 3-6

Testing
Introduction

If the calibration procedure fails to rectify a problem, there
are three main areas where faults can occur: the readout
box, the transducer, and the machine electrical harness. The
test box (892/00905) is designed to assist the service
engineer to diagnose faults in the LMI system down to
component level.
This unit should be used when the standard calibration
procedure has been attempted and failed.
The test box also contains three switches: TEST 1/TEST 2,
TRANS/BOSS, RUN/CHECK to change settings for the
various tests.
The box is connected between the four-pin plug and socket
which connects the readout box to the machine wiring
harness behind the instrument panel in the cab.
Before carrying out the tests make sure that:

The test box contains five test points: TP 1 to TP 5 which (a) the machine is on level ground with the boom
allow currents in the circuits to be read as voltages by an horizontal;
AVO digital multimeter. The test points also allow continuity (b) the forks are fitted, with no load;
and open/short circuit tests to be made. (c) the boom is fully retracted;
(d) two-wheel drive is engaged (if fitted) and the machine
TP1 Earth has been driven backwards and forwards several times
TP2 Readout box supply with the wheels in the straight ahead position;
TP3 Transducer supply (e) the ignition switch is on, but the engine is not running.
TP4 Transducer output (Signal)
TP5 Transducer output (voltage) Note: The readout display will be affected by extreme steer
lock and axle angles.
Test point TP4 reads signal current in the transducer return
wire and converts this to a voltage which can be read by the Service Procedure
multimeter.
Remove the instrument panel and connect test box A as
Test point TP5 is a direct connection to the transducer shown. The BOSS/TRANS switch should be set to the
return wire. TRANS position for all tests on machines fitted with
transducers.
The Black lead of the multimeter should be connected to
TP1 (earth) when testing voltages.

Note: When returning equipment under warranty, the results

of the following tests MUST be stated.

9803/3675 Issue 1
Section C Electrics Section C
3-7 Load Moment Indicator 3-7

Test 1: Supply Voltage and Fuse Test (V1)

Test box settings: RUN

TRANS
TEST 1

1 Measure the voltage between TP1 and TP2 C2 24/12v

974 600JE
Expected reading: Convertor voltage (11.0V to 15.0V). Convertor
+12v 0v TP1
TP2

001
Note: As an additional test, LED C should be illuminated
when the display box is receiving a supply voltage.
Display
If the expected reading is not obtained, check the ignition is Box
on, fuse C2, battery condition, test box connections and test
harness. Rectify as required.

464

463
Transducer

V1
310864

Test 2: Transducer Supply Test (V2)

Test box settings: RUN

TRANS
TEST 1

1 Measure the voltage between TP1 and TP3 C2 24/12v

974 600JE
Expected reading: Convertor voltage (11.0V to 15.0V). Convertor

+12v 0v TP1
001

If the expected reading is not obtained, check the ignition is

on, fuse C2, battery condition, test box connections and test
harness. Rectify as required. Display
Box
If the expected reading is not obtained after the above
checks, the display box should be renewed.
V2
464

463

Transducer

310874

9803/3675 Issue 1
Section C Electrics Section C
3-8 Load Moment Indicator 3-8

Test 3: Display Box Functional Test

1 Park the machine (unloaded) on level ground with the
engine running. Apply the parking brake and place the
forward/reverse lever in the neutral position.

2 The green LED G at the bottom of the display will

illuminate to show that the indicator is receiving power.

3 Press the display button A and release.

4 All LEDs on the indicator will flash and the audible 100%
alarm will sound if the unit is functioning correctly.

A363130

9803/3675 Issue 1
Section C Electrics Section C
3-9 Load Moment Indicator 3-9

Test 4: Transducer Output Test (V3)

(Transducer Fitted)

Test box settings: RUN C2 24/12v

974 600JE
TRANS Convertor
TEST 1 TP1
+12v 0v

001
1 Measure the voltage between TP1 and TP4
Expected reading: 4.3V to 4.7V. Display
Box
If the expected reading is not obtained, carry out Test 5 to
check for possible harness faults.

If Test 5 is successful, a transducer fault or incorrect

464

463
transducer mounting should be suspected. Carry out Test 6
to test transducer output with the transducer removed from
310880
the axle.
Transducer

V3

Test 5: Harness Wiring Continuity And Short Circuit Test

Test box settings: CHECK

TRANS
TEST 1

1 Disconnect the display box from the test box harness If the expected readings are not obtained, check for
K, but leave the Test box harness connected to the damaged wiring and faulty connections.
machine wiring L. Disconnect the transducer harness
from the machine wiring M. If the expected readings are obtained, but the expected
voltage reading from Test 4 above is not achieved, carry out
2 Turn OFF the ignition switch and check for continuity Test 6 with the transducer removed from the axle.
between the following points on the test box and the
two pin connector E that was connected to the
transducer. Remove the plastic pin retainer on the plug
to access the connections.

Continuity Test

3 Switch the multimeter to the Ohms scale and measure

the electrical resistance between:

TP3 and pin 2 of connector M.

TP5 and pin 1 of connector M.

Expected reading: Less than 3 ohms.

Short Circuit Test

4 Measure the electrical resistance between:

TP1 and TP5

TP1 and TP3
TP3 AND TP5

Expected reading: Open Circuit.

9803/3675 Issue 1
Section C Electrics Section C
3 - 10 Load Moment Indicator 3 - 10

Test 6: Transducer Output Test (V4)

(Transducer Removed)

1 Remove the transducer from the machine, reconnect to C2 24/12v

the machine harness and support under the machine. 974 Convertor
600JE
TP1
2 Reconnect the battery and turn the starter switch to on, +12v 0v

001
but with the engine not running.
Display
3 Reconnect the display box to the test harness. Box

Test box settings: RUN

TRANS
TEST 1

464

463
4 Measure the voltage between TP1 and TP4
Expected reading: 4.48V to 4.52V.
310890
Transducer
If the transducer is not distorted, then V4 should be between
4.48V and 4.52V. If it is outside this range, but within 4.40V
V4
to 4.60V, it may still be OK providing that the conditions of
Test 4 are achieved.

If the transducer passes this test, having failed Test 4, the

apparent failure is probably due to uneven transducer
mounting.

Check mounting surfaces are clean, flat and free from paint
and rust etc. Refit the transducer to the machine and tighten
the transducer fixing screw to 70Nm.

Remove the test harness and reconnect electrical plugs.

Voltage Readings

The following table may be used to record information in the

event of an enquiry and must be submitted together with a Expected Measured
warranty claim. If applicable any warranty parts must also be Readings Readings
returned with any additional information such as: which
lights are not illuminating, if system balancing is possible, or V1 11.0V to 15.0V
if display box function test is not successful.
V2 11.0V to 15.0V
V1 12V Supply
V2 Transducer supply voltage V3 4.3V to 4.7V
V3 Transducer output voltage (Fitted)
V4 Transducer output voltage (Removed) V4 4.48V to 4.52V

IMPORTANT: The system must always be re-calibrated

after performing the above tests, and before operating
the machine.

9803/3675 Issue 1
Section C Electrics Section C
3 - 11 Load Moment Indicator 3 - 11

Fault Location Diagram

System Not Working Do Supply and Fuse Do Harness Wiring

Correctly. Test 1. Continuity & Short Yes
Yes Record voltage V1. Circuit Test 5. Done
Supply OK ? Repair as required.
OK Now ?
No
No
Check ignition ON,
fuse C2, battery
No Yes
condition, test box
Done Check for uneven
connections. Repair
as required. mounting surfaces or
OK Now ? bolts tightened
correctly.

Is the transducer No
Do Transducer
supply OK ? Supply Test 2. Yes
Done
Record voltage V2.
Yes OK Now ?

No

Check ignition ON,

fuse C2, battery
condition, test box
connections. Repair
as required.

No
Is the display Do Display Box
box OK ? Functional Test 3 Yes
Done
and re-calibrate
Yes OK Now ?

No

To next page ...

Replace display box.

Are the transducer No Do Transducer

output signals Output Tests 4 & 6.
OK ? Yes
Record voltages Done
V3, V4.
Yes OK Now ?

No

9803/3675 Issue 1
Section C Electrics Section C
3 - 12 Load Moment Indicator 3 - 12

Fault Location Diagram (continued)

Fit new
transducer
... From previous page and re-test

No
No No
Can the display box be
Do transducer output test Check transducers fixed
re-calibrated
OK Now ? securely ?
Yes
Yes Yes

Has frequent Suspect faulty

re-calibration been Yes
display box.
required ? Done
Renew display box
OK Now ?
Yes

Possible transducer
Suspect faulty
slipping. Remove Yes transducer
transducer, clean surfaces Done
and re-torque bolts to
70Nm
OK Now ?

No

Check axle oscillates

freely

9803/3675 Issue 1
Section E Hydraulics Section E
i i

Contents Page No.

Schematic Diagram 2-1

9803/3675 Issue 1
Section E Hydraulics Section E
2-1 Schematic 2-1

Component Key
C Cap
F Filter
LS Load Sensing line
P1 Main pump
S Suction strainer
S1 Main pump suction line
T Tank
X Pressure test point
1A Neutral circuit feed line
1B Neutral circuit return line
1C Steer circuit return line
2 Valve block
2A Main relief valve (M.R.V.)
2B Auxiliary 2 spool
2C Auxiliary 1 spool
2D Lift spool
2E Tilt spool
2F Extension spool
2G Auxiliary relief valve (A.R.V's)
2H Auxiliary relief valve (A.R.V's)
2J Load hold check valves (L.H.C.V's)
3 Steer unit assembly
3A Steer valve
3B Shock valves (option)
3C Relief valve
5A Front steer ram
5B Rear steer ram
5C Steering compensation ram
5D Brake packs
5E Steering alignment valve
7 Q Fit Carriage pin locking
7A Q Fit Carriage manual diverter valve
10 Lift ram check valve
11 Lift ram
12 Displacement ram
13 Tilt ram
14 Tilt ram check valve
15 Extension ram check valve
16 Extension ram
17 Brake charge/priority valve
17A Priority valve
17B Distributor valve
17C Pilot valve
17D Relief valve
17E Brake pressure switch
18 Accumulator
19 Brake valve
20 Auxiliary 1 quick release couplings
21 Auxiliary 2 quick release couplings
22 Steer mode valve
23 One-way restrictor

9803/3675 Issue 1
Section E Hydraulics Section E
2-2 Schematics 2-2

20 21 C
7
T
10
F

11 7A
S

14 S1
13 P1
17
X
17A

12
1C 17D
EF F T

15 T 3 P P
F LS
3C LS
16 17E 17C

17B
3A

23 23 1B A2 A1

2 1A X
18 18
2H 2H 2H 3B 3B 19
2A R L
2G 2G 2G
5C

5E
5B
2F 2E 2D 2C 2B 5A 5D 5D
2J 2J 2J 2J 2J
B A 22

5D 5D
397540
T P

9803/3675 Issue 1
Section H Steering Section H
i i

Contents Page No.

Circuit Description
Steer Unit Operation 1-1
Steer Mode Valve Operation 1-1

Steer Mode Valve

Checking Solenoid Operation 2-1
Removal 2-1
Replacement 2-1

9803/3675 Issue 1
Section H Steering Section H
1-1 Circuit Description 1-1

F T

S1

P1
17
X
17A

EF T
T 3 P P
LS
3C LS
17C
3D
To brake
circuits

3A

3B 3B
R L
5C

5E

5A
5B
B A
22B 22
Z Y 397541

W X
22A
T P

9803/3675 Issue 1
Section H Steering
1-2 Circuit Description
Note 1: The schematic shows priority valve 17A in the
position it adopts during a turning operation.
Note 2: Port EF is connected to the main control valve block
to provide lift end and auxiliary services.
Steer Unit Operation
Neutral
Whenever the steering wheel is stationary, irrespective of the
position of the steered road wheels, steer unit 3 adopts the
neutral position. The inner spool and sleeve are held in
neutral by the centring springs. As the steer unit is ‘closed
centre’ the flow from the pump is dead-ended by the unit.
This is sensed by the steering priority valve, whic directs flow
to port EF.
Turning
Turning the steering wheel moves the inner spool a few
degrees relative to the outer sleeve. This sends a pressure
signal to relief valve 3C and, through the LS port, back to
priority valve 17A which adopts the position shown on the
schematic. Flow from priority valve 17A enters steer unit 3 via
port P and non-return valve 3D.
The relative movement between the inner spool and outer
sleeve directs pressure oil through 6 of the 12 holes in the
bottom of the outer sleeve. 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 to the stator. The rotor lobes
pump the oil out via steer mode valve 22 to the appropriate
steering ram(s), as described in Steer Mode Valve
Operation and the required degree of turn is executed.
During a steering operation, oil returns to tank via steer unit
3, port T.
When the ram(s) reach full stroke, the pump flow is dead
ended, a higher pressure signal is felt at relief valve 2B which
opens to route excess oil back to tank or to the control valve,
as appropriate.
9803/3675
Section H
1-2
Steer Mode Valve Operation
2 Wheel Steer
The steer mode valve directs the flow of oil from the steer unit
to the appropriate axle(s) for the steer mode selected.
The valve is controlled by four solenoids which are energised
according to the position of the steer mode selector switch in
the cab (see the Electrical Schematic in Section C).
The solenoids energised for each mode are shown in the
table below.
Mode Selected Solenoid(s) Energised
2WS W
4WS X, Y
CRAB X, Z
When 2 wheel steer is selected, solenoid W is energised and
valve spool 22A is in the position opposite to that shown. In
this state, oil flows through the steer mode valve, entering
and leaving via ports P and T, according to the direction
determined by steer unit 3. The position of spool 22B has no
effect.
When either 4 wheel steer or crab steer is selected, solenoid
X energises and spool 22A moves to the position where oil
flows through the valve to spool 22B.
Selection of 4 wheel steer energises solenoid Y; spool 22B is
then in the position shown. Selection of crab steer energises
solenoid Z; spool 22B is then in the position opposite to that
shown.
Note: In the event of a power failure, e.g. fuse C6 blowing,
the valve spools will remain in the state they are at the time.
Steer rams 5A and 5B, mounted on the front and rear axles
respectively, provide the required turning moment.
Compensation ram 5C is included in the circuit in order to
make up the difference in oil volume between the head side
and rod side of the steering rams.
If it were not included, then, in 4 wheel steer and crab steer
modes, pressure would be applied to the head side of one
steer ram and the rod side of the other. As the volumes are
unequal, this would result in unequal movement of the rams
and, consequently, unequal movement of the wheels.
The inclusion of the compensation ram ensures that the flow
is always head side to head side and rod side to rod side.
Issue 1
Section H Steering Section H
2-1 Steer Mode Valve 2-1

Checking Solenoid Operation Removal

The solenoids operate according to the steer mode selected
(see table below). Operation (energisation) of a solenoid can
be easily detected by placing a steel object (e.g. screwdriver
blade) close to the outer casing. A magnetic attraction of the
steel object towards the solenoid indicates energisation.
1 Disconnect the hoses at A and B. Label the hoses and
cap the ends to prevent the ingress of dirt.
2 Disconnect the electrical connection C to each of the
solenoids. Label each connector before removal.

Mode Selected Solenoid(s) Energised 3 Unscrew retaining screws D and remove the valve.

2WS W

4WS X, Y Replacement
CRAB X, Z Replacement is the reverse of Removal.

Torque Settings
If a solenoid is not energised proceed as follows until the
reason is established: Item Nm kgf m lbf ft
D 28 2.9 21
a Check that fuse C6 is intact. If not, renew and then
check that all steer mode solenoid combinations
function correctly.

b If the fuse is intact remove the electrical connector from

the malfunctioning solenoid(s) and check that the 24V
supply is present across the connector pins. If not,
check the supply circuit.

c Check the solenoid resistance which should measure a

few ohms (if unsure compare with a known good
solenoid). Renew the solenoid if the reading indicates a
short circuit (zero ohms) or open circuit (infinite
resistance). If a reading somewhere between the two is
obtained reverse the two instrument probes and repeat
for a valid check.

X
A B
W
P

V
C

A
T

Y C

D A292780

9803/3675 Issue 1
Section K Engine Section K
i i

Contents Page No.

Technical Data 1-1

Machine Start-up Procedure 2-1

Category ‘C’ Safety System

Introduction 3-1
Inlet System 3-1
Exhaust System 3-1
Control System 3-1
Operation 4-1
Inlet Shutdown Valve
Overspeed Spring Adjustment 5-1
Replacing a Broken Tension Pin 5-2

Webasto Water Heater

Introduction 8-1
Operation 8-2
Heater Unit 8-3
Fault Finding 8-5
General Failure Symptoms 8-5
Failure Symptoms After Switch-off Upon Failure 8-6
Electrical Connections 8-7
Heater Unit - Removal and Refitting 8-8
Circulation Pump - Replacement 8-9
Temperature Limiter - Replacement 8 - 10
Temperature Sensor - Replacement 8 - 10
Combustion Air Fan - Replacement 8 - 12
Replacement of Burner, Flame Sensor and
Glow Plug 8 - 13
Burner Head - Replacement 8 - 15
Heat Exchanger - Replacement 8 - 16
Visual Inspection 8 - 17
Electrical Component Testing 8 - 18

9803/3675 Issue 1
 Section K Engine Section K
1-1 Technical Data 1-1

Type: JCB diesel engine, 4 cylinder, water cooled

Build Codes: AR 50997 - naturally aspirated, low emission, 57.5kW (77 HP)

Bore (nominal) 103mm (4.055 in)

Stroke 127mm (5.000 in)

Swept Volume 4 litres (243 in3)

Compression Ratio 17.25:1

Induction System
Air Cleaner Type 2 stage, dry element

Safety System Category ‘C’

For further engine details see Engine Manual Publication No. 9806/2140.

9803/3675 Issue1
Section K Engine Section K
2-1 Machine Start-up Procedure 2-1

1 The battery isolator must be on before attempting to

start the engine.

2 The parking brake A should have been engaged when

the machine was last parked. If it is not engaged,
engage it now. The engine will not start unless the
parking brake is engaged.

3 Put the Forward/Reverse lever B in neutral. The engine

will not start unless the forward/reverse lever is in
neutral.

4 Put the gear lever C in neutral.

5 Push the shutdown valve operating lever D to the

start/reset position (down) and hold. F
A
Note: If the engine has been running previously, it will not be
possible to reset the engine safety shutdown system for a
period of at least 30 seconds after shutdown due to the high
engine inlet system vacuum. DO NOT attempt to push the B
operating lever to the start/reset position against this vacuum
as use of excessive force will cause severe damage to the
valve mechanism.

! WARNING
If the engine safety system trips whilst the machine is E
being used in a hazardous area, DO NOT ATTEMPT TO
RE-START until advice has been obtained from the
person in authority and the cause of the shutdown found
C
and corrected.
0088

6 Fully depress the accelerator pedal E and hold it down. S240311

Turn the starter switch to position HS and hold it there
until the engine starts. Once the engine has started,
release the starter key. The switch will return to position
IGN. Ease off on the accelerator pedal to reduce engine
speed.

If the outside temperature is low, say 0°C (32°F) or

below, turn the starter switch key to the 'heat' position
H for approximately 15 seconds to warm the engine
induction manifold.
D
If the engine has not started after 20 seconds, release
the starter key. Wait two minutes before attempting
another start. This will allow the starter motor to cool
down.

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 engine is gently
run-in. Under no circumstances should the engine be
allowed to idle for extended periods; (e.g. warming up
without load).
7 Once the engine has started, check that all the warning
lights have gone off. Do not race the engine until the
engine oil pressure low light F has gone out. Check that
the audible alarm is silent.
397340
Note: If any warning lights fail to go off, or come on while the
engine is running, stop the engine as soon as it is safe to do
so.
8 Wait for a further seven seconds and then return the
shutdown valve operating lever D to the neutral (mid)
position.
9 If the engine will not start due to a flat battery, it can be
started using the inter-vehicle start connector.

9803/3675 Issue 1
Section K Engine Section K
3-1 Category ‘C’ Safety System 3-1

Introduction
The Category ‘C’ Safety System has been designed to the
Ministry of Defence PDCSS Specification 308. It shuts
down the engine on detecting a coolant temperature of
105oC and/or engine overspeed.

The Safety System comprises the inlet system, the exhaust

system and the control system.

Inlet System

The main components of the inlet system are an inlet

adaptor A, a shutdown valve B and a manual
start/reset/emergency stop control C.

Note:The valve operating gear is manufactured from

stainless steel and must not be painted.

Exhaust System
C
The exhaust sytem consists of a spark arrestor D, a flexible
exhaust E, silencer F and fume diluter G.

Control System 397340

The operation of the inlet shutdown valve is controlled by a

24V dc solenoid valve H.

393930
393930

9803/3675 Issue 1
Section K Engine Section K
4-1 Category ‘C’ Safety System 4-1

Operation
When reset/emergency stop lever is in the down position A,
the cable mechanism causes the inlet shutdown valve to be
held open to start the engine. The control cylinder is retained
in the open position by an oil operated plunger B. The
plunger holds the trip lever C until the pressurised oil feed
from the engine is shut off by the remote solenoid operated
valve allowing its release. This occurs if the system detects
flammable gas or vehicle over temperature.

The trip lever overspeed spring D also allows the inlet

shutdown valve to close with the plunger up. This occurs
when an engine overspeed condition is detected.
E
n
For emergency stop operation, reset/emergency stop lever
is pulled up E, moving the cable in the direction of arrow E,
tripping the roller over the plunger. Always ensure that the
cable control is re-centred after use. s
To reset the shutdown valve, push and hold down the A
reset/emergency stop lever in the 'reset' (down) position 397340
until maximum oil pressure is achieved (approximately seven
seconds), then return the control to the neutral (mid)
position.

Note: If the engine has been running previously, it will not be

possible to reset the engine safety shutdown system for a
period of at least 30 seconds after shutdown due to the high
engine inlet system vacuum. DO NOT attempt to push the
operating lever to the start/reset position against this vacuum
as use of excessive force will cause severe damage to the
valve mechanism.

D
C
B

E
s
n
A

397580
397580

9803/3675 Issue 1
Section K Engine
5-1 Category ‘C’ Safety System
Inlet Shutdown Valve
Overspeed Spring Adjustment
The complete inlet system, from the air filter to the engine
MUST be fully assembled before attempting to adjust the
overspeed spring setting. An accurate setting cannot
otherwise be achieved.
1 Fully warm up engine (some initial adjustment of the
inlet shutdown valve may be necessary to enable the
engine to run at a suitable speed, see item 3b below.
2 Use the control arm to reset the valve.
Note: If the engine has been running previously, it will not be
possible to reset the engine safety shutdown system for a
period of at least 30 seconds after shutdown due to the high
engine inlet system vacuum. DO NOT attempt to push the
operating lever to the start/reset position against this vacuum
as use of excessive force may result in breakage of the
tension pin securing the inner assembly of the shutdown
valve.
! WARNING
If the engine safety system trips whilst the machine is
being used in a hazardous area, DO NOT ATTEMPT TO
RE-START until advice has been obtained from the
person in authority and the cause of the shutdown found
and corrected.
0088
9803/3675
Section K
5-1
3 When the engine is fully warmed up, slacken locknut A,
remove locking wire B and adjust the overspeed spring
as follows:
a Accelerate the engine to maximum rpm.
b If the existing setting gives shutdown below engine
maximum rpm, turn the adjuster screw C one turn
clockwise and recheck. Continue this with finer
adjustments if necessary until the inlet shutdown
valve gives shutdown at or just below maximum
rpm.
c If the existing setting does not give shutdown, turn
adjuster screw C two or more turns anti-clockwise
as necessary to give shutdown below maximum
rpm and then adjust as above.
d Turn adjuster screw C one full turn clockwise.
e Rapidly accelerate the engine up to maximum rpm
three or four times. If there is any tendency for the
inlet shutdown valve to actuate, repeat steps a to d
above.
4 Tighten locknut A and wire-lock (use new locking wire).
5 Check the emergency stop using lever.
B
C
397550
Issue 1
Section K Engine Section K
5-2 Category ‘C’ Safety System 5-2

Inlet Shutdown Valve (continued)

Replacing a Broken Tension Pin

1 Disconnect the inlet hose A from the inlet shutdown

valve.

2 Remove the five button socket screws and washers B

securing cover plate C.

3 Remove cover plate C to gain access to the inlet

shutdown valve mechanism.

4 Ensure that all parts of the broken tension pin are

C
removed. Foreign objects left in the inlet shutdown
valve mechanism may cause further damage.
B
5 Fit a new tension pin D ensuring that the split in the pin
is aligned with the arrow E.

6 Clean mating faces of cover plate and inlet shutdown

valve from silicone sealant.

7 Apply a new thin film of silicone sealant, replace the

cover plate and secure using the five button socket
screws and plain washers.
A
8 If the inlet shutdown valve has been removed when
fitting a new tension pin, a new gasket MUST be used.
397560
9 Reconnect the inlet hose A to the inlet shutdown valve.

10 Check that the overspeed setting is correct and adjust

if necessary (see Inlet Shutdown Valve - Overspeed
Spring Adjustment).

393871

9803/3675 Issue 1
Section K Engine Section K
8-1 Webasto Water Heater 8-1

Introduction
Winterised machines are fitted with a fuel burning water The water is heated in the heater unit A and then flows via
heater to give efficient cold starting and to warm the the outside battery heating element B, the inside battery
operator’s cab by automatic preheating of the engine heating element C and the stop valve D to the cab heater E.
coolant, heating of the batteries and operation of the cab Return flow from the cab heater F returns to the heater unit.
heater fan.
The system is ‘teed’ into the normal heater circuit between
The system consists of a fuel-burning heater A, controlled the water pump G and the radiator H.
by a digital timer in the cab (not shown), a heating element
under each battery B and C, and the necessary hoses and
fittings to circulate the warmed coolant.

For operating details, refer to the Operator’s Handbook.

!DANGER
DO NOT operate the water heater in a confined space
such as a workshop or garage. The exhaust fumes may
kill you or someone else.
8-4-2-4
!WARNING
Switch off the heater when the machine is being
refuelled. There is a danger of fire or explosion.

At locations where combustible vapours or dust

D
accumulation can form (e.g. in the vicinity of fuel, coal,
saw-dust and grain depots and so forth) the heater must
be switched off due to the danger of explosion. to
bas
We
In the case of severe smoke development for an
extended period of time, unusual combustion noises or
A
fuel smell, the heater must be placed out of operation by
removing the fuse and may only be re-started after it has
been inspected by qualified personnel.

The heater must be inspected by a qualified person

annually, preferably prior to the heating season G
commencing.
H

397720

9803/3675 Issue 1
Section K Engine
8-2 Webasto Water Heater
Operation
Switch-on
When the Instant Heat push button A on the timer unit (in the
cab) is operated, the Heater On indication B on the timer
illuminates.
Circulation pump, glow plug, and combustion air fan are put
into operation.
Heating Operation
After approx. 50 seconds, combustion commences with the
automatically controlled heating operation in full load for a
maximum of 2 hours.
The vehicle's own heating blower starts to operate only after
the heat carrier (coolant) has accumulated enough heat.
After reaching the preset temperature, heating performance
precision control will take over in stages down to the lowest
part load operation.
Control Operation
If the coolant temperature rises up to the control idle
threshold, the heater enters the control idle phase. The
circulation pump, the vehicle's own blower, and the
operating indicator remain in operation during the control
idle period.
After the coolant has cooled down to the precoded
reactivation temperature, the heater resumes operation.
If the water heater's water temperature is above the rated
temperature but has not yet reached the threshold for
control idle with the temperature dropping within 10 minutes
back to rated temperature (after reaching it for the first time),
the water heater reverts to the 9.1kW heating stage. Should
the rated temperature be obtained after 10 minutes, there
will be an automatic reactivation only up to 7.6kW.
Switch-off
When switching the heater off, the operation indicator on the
timer/switch extinguishes. Combustion ends and run-down
is initiated. Circulation pump and combustion air fan,
however, continue operation to cool down the heater (run-
down) and are automatically deactivated after about 90
seconds. A reactivation of the heater during run-down is
permitted.
Switch-off Upon Failure
In the case of a no-flame condition, fuel is delivered for a
maximum of 180 seconds.
In the event of a flame-out during operation, fuel is delivered
foe a maximum of 90 seconds.
After switch-off by low volage protection (below 21 volts), for
more than 20 seconds, the fuel supply is stopped.
9803/3675
Section K
8-2
MO
B
P
A 397610
After the fault has been removed, an error lockout condition
exists. Reset by switching off the heater and switching on
again.
In the case of overheating, the temperature limiter must be
reset after the unit has cooled down.
!CAUTION
To avoid damage to the component, do not attempt to
reset the temperature by force whilst hot.
Fault Codes
The following fault codes are displayed on the timer display
after a Switch-off Upon Failure condition has occured.
F 01 No start (after 2 start attempts)
F 02 Flame-out during operation (repeated > 5)
F 03 Voltage too low or too high
F 04 Premature flame detection
F 05 Flame sensor open or short circuit
F 06 Temperature sensor open or short circuit
F 07 Dosing pump open or short circuit
F 08 Fan motor open or short circuit or wrong speed of
fan motor
F 09 Glow plug open or short circuit
F 10 Overheating
F 11 Circulation pump open or short circuit
After five short signals the following long flash pulses are
counted:
1x No start (after 2 start attempts)
2x Flame-out during operation (repeated > 5)
3x Voltage too low or too high
4x Premature flame detection
5x Flame sensor open or short circuit
6x Temperature sensor open or short circuit
7x Dosing pump open or short circuit
8x Fan motor open or short circuit or wrong speed of fan
motor
9x Glow plug open or short circuit
10x Overheating
11x Circulation pump open or short circuit
For further details and remedial action, see Failure
Symptoms After Switch-off Upon Failure.
Issue 1
Section K Engine Section K
8-3 Webasto Water Heater 8-3

Heater Unit
The water heater operates independently from the vehicle Component Key
engine and is connected to the cooling system, the fuel
system, and the electrical system of the vehicle. 1 Combustion air fan
2 Fuel connection
The heater operates intermittently and is controlled by the 3 Temperature sensor
temperature sensor. 4 Temperature limiter
5 Heat exchanger
Dependent on the deviation of the current coolant 6 Coolant inlet
temperature from the rated value of the temperature sensor, 7 Circulation pump
combustion performance is continuously controlled within 8 Coolant outlet
the range from 1.8 to 9.1 kW, for up to 2 hours after 9 Exhaust outlet
equipment activation. 10 Combustion air inlet
11 Control unit
The water heater consists of a combustion air fan, heat
exchanger, burner insert with combustion tube and a
circulation pump.

For control and monitoring, a control unit, flame sensor,

glow plug, temperature sensor and temperature limiter are
located inside the unit. A timer unit is mounted in the cab.

3
5
2

11

7
9 8
10

9803/3675 Issue 1
Section K Engine Section K
8-4 Webasto Water Heater 8-4

Heater Unit (continued)

12
Control unit

The control unit is the central controlling device for

sequencing and monitoring the combustion operation. 13
Combustion air fan

The combustion air fan delivers the air required for

combustion from the combustion air inlet to the burner
insert.

Temperature limiter 12

The overheat protection (bimetal) responds at a coolant

temperature above 105oC to switch off the heater. 398910

Temperature sensor 13 14
15
The temperature sensor senses the coolant temperature in
the heat exchanger as an electrical resistance. This signal is
fed to the control unit for processing.

Heat exchanger 14

The heat exchanger transfers the heat provided by

combustion to the coolant circuit.

Combustion tube 15
398920
The combustion of the fuel/air mixture takes place inside the
combustion tube.

Burner insert 16
16
The burner insert is located within the combustion tube and
distributes fuel across the burner cross-section.

Glow plug 17

The glow plug, located in the burner insert, ignites the

fuel/air mixture at the start of heater operation.

Flame sensor 18
17
The flame sensor changes its electrical resistance
dependent on its temperature. It monitors the flame
operating condition throughout the heater operation and its
signals are routed to the control unit. 398870A

Circulation pump 19 18
The circulation pump provides for circulation of the coolant
in the vehicle and heater circuits. It is switched on and off
by the control unit throughout the time of heater operation.

Dosing pump
19

The dosing pump (not shown) supplies fuel to the heater in

response to signals from the control unit.

398930

9803/3675 Issue 1
Section K Engine Section K
8-5 Webasto Water Heater 8-5

Fault Finding
This section describes fault finding procedures for the Water After correction of a failure, a functional test must be
Heater. performed in the vehicle; before doing this, switch the heater
off and on again.
!CAUTION
General Failure Symptoms
Fault finding requires profound knowledge about
structure and theory of operation of heater components
The following table lists possible, general failure symptoms.
and may only be performed by skilled personnel.
Note: In many cases, the probable cause of failure may be
Troubleshooting is normally limited to the isolation of
the condition of the burner. Perform a visual inspection of
defective components.
the burner.
The following defects are not included in the trouble
shooting procedures. Before troubleshooting, check for and
eliminate these defects:

corrosion on connector
loose contact on connector
wrong crimping on connector
corrosion on electrical wiring and fuses corrosion on
battery terminals

Failure Symptom Probable Cause Remedy

Heater switches off automatically No combustion after start or repeat start Control unit goes to error lockout
Switch heater off and on again

Flame extinguishes during operation If no-heating condition persists, carry out

further rectification (see Failure
Symptoms After Switch-off On Failure)

Heater overheats due to lack or loss Replenish coolant

of coolant After unit cools down, push the button of
temperature limiter before continuing

Switch-off caused by temperature After unit cools down, push the button of
limiter temperature limiter before continuing. If
fault still occurs, replace temperature
limiter

9803/3675 Issue 1
Section K Engine Section K
8-6 Webasto Water Heater 8-6

Failure Symptoms After Switch-off Upon

Failure
Fault codes are displayed on the timer display after a
Switch-off Upon Failure condition has occured. After five
short pulses, the following long flash pulses should be
counted.

No of Failure Symptom Probable Cause Remedy

Flashes

- No function Electrical wiring, fuses Check fuses

Check supply connections (see Pin
Assignment)
Control unit defective Replace control unit

1 No start Fuel system Check fuel level

Check fuel filter
Bleed fuel system
Combustion air or exhaust Check combustion air or exhaust duct for
duct foreign matter and clean as required
Burner Clean or replace burner as necessary

2 Flame-out during operation Fuel supply Check fuel level

Check fuel filter
Bleed fuel system
Burner Clean or replace burner as necessary

3 Low voltage Power supplies Check battery

Check electrical connections

4 Flame sensor continuously hot Flame sensor defective Replace flame sensor

5 Flame sensor defective Wiring Check wiring for damage, open or short
circuit
Flame sensor defective Replace flame sensor

6 Temperature sensor defective Wiring Check wiring for damage, open or short
circuit
Temperature sensor defective Replace temperature sensor

7 Dosing pump or overheat Coolant circuit Check coolant level

defective Bleed coolant circuit
Reset temperature limiter
Wiring Check wiring for damage, open or short
circuit
Dosing pump defective Replace dosing pump

8 Combustion air fan defective Wiring Check wiring for damage, open or short
circuit
Combustion air fan defective Replace combustion air fan

9 Glow plug defective Wiring Check wiring for damage, open or short
circuit
Glow plug defective Replace glow plug

9803/3675 Issue 1
Section K Engine Section K
8-7 Webasto Water Heater 8-7

Electrical Connections
Main Connector (X1) Pin Assignment

1 Glow plug +
2 Temperature limiter +
3 Flame sensor +
4 Temperature sensor +
5 Circulation pump +
6 Combustion air fan +
7 Combustion air fan -
8 Circulation pump -
9 Temperature sensor -
10 Flame sensor -
11 Temperature limiter -
12 Glow plug -

Main Connector (X1) Disconnecting Wires

All connections from electrical components are joined in

connector X1. Prior to removal of a component, the relevant
electrical connections have to be disconnected.

Connectors X1 on heater and X12 on control unit must be

disconnected and reconnected after making electrical
connections.

1 Remove top cover from heater.

2 Using a suitable locally manufactured tool A, withdraw

lock wedge B from connector using the hook end.

3 Use the screwdriver end to press down relevant locking

tab C and, keeping tab depressed, withdraw cable(s)
from connector.
B
Reconnecting Wires

1 Slide cable into relevant contact pocket until locked.

2 Using screwdriver end, insert lock wedge into A

connector and press in until locked.

3 Fit top cover.

9803/3675 Issue 1
Section K Engine Section K
8-8 Webasto Water Heater 8-8

Heater Unit - Removal and Refitting

Removal

1 Disconnect batteries.

2 Remove top cover.

3 Disconnect cable harness from heater unit connectors

X1, and connectors X12 and X13 from control unit.

4 Disconnect fuel inlet and plug.

5 Loosen hose clamps and disconnect coolant hoses from

heater unit.

6 Disconnect combustion air intake and exhaust outlet.

7 Remove three nuts and washetrs from heater mount and

remove heater unit.

Refitting

1 Locate heater unit in position and secure with three nuts

and washers.

2 Reconnect coolant hoses. Tighten hose clamps to 5Nm.

3 Refit fuel inlet connector on heater.

4 Refit coonections for combustion air inlet and exhaust

outlet to heater.

5 Reconnect cable harness to heater unit connectors X1,

and connectors X12 and X13 to control unit.

6 Refit top cover.

7 Reconnect batteries.

8 Bleed fuel supply system and coolant circuit.

9803/3675 Issue 1
Section K Engine Section K
8-9 Webasto Water Heater 8-9

Circulation Pump - Replacement

Removal

1 Remove heater unit - see Heater Unit - Removal and

Refitting.

2 Disconnect relevant electrical connections - see

Electrical Connections.

3 Remove screws 1 and clamp 2.

4 Remove circulation pump 3.

5 Discard gasket 4.

Refitting 2
1 Apply acid free grease (e.g. Vaseline) to new gasket 4.

2 Fit pump 3 in position, securing with clamp 2 and

screws 1. Tighten screws to 3Nm.
1
3 Remake electrical connections - see Electrical
Connections.

4 Refit heater unit - see Heater Unit - Removal and

Refitting.

9803/3675 Issue 1
Section K Engine Section K
8 - 10 Webasto Water Heater 8 - 10

5
4

9803/3675 Issue 1
Section K Engine Section K
8 - 11 Webasto Water Heater 8 - 11

Temperature Limiter - Replacement Temperature Sensor - Replacement

Removal Removal

1 Remove heater unit - see Heater Unit - Removal and 1 Remove heater unit - see Heater Unit - Removal and
Refitting. Refitting.

2 Disconnect relevant electrical connections - see 2 Disconnect relevant electrical connections - see
Electrical Connections. Electrical Connections.

3 Remove clamp 1 and withdraw protective cap 2. !WARNING

Escaping hot coolant may cause scalding.
4 Using a suitable screwdriver, carefully lever off retaining
clip and remove temperature limiter 3.
3 Unscrew temperature sensor 5 and remove, together
with O-ring 6.
Note: Whenever the temerature limiter is removed, it must
be renewed.
4 Discard O-ring 6.

Refitting
Refitting

!CAUTION 1 Apply acid free grease (e.g. Vaseline) to O-ring 6.

Incorrect installation of the temperature limiter will
cause severe damage to the heat exchanger.
1 Insert temperature limiter 3 into the heat exchanger 4
and press down retaining clip.
Note: Ensure that the retaining clip is heard to click fully in
place. Only then is the temperature limiter in the proper
installation position. If the clip does not audibly engage:
2 Screw temperature sensor 5, with O-ring 2, into heat
exchanger 4. Tighten screws to 1.5Nm.
3 Remake electrical connections - see Electrical
Connections.
4 Refit heater unit - see Heater Unit - Removal and
Refitting.

clean the seat of the temperature limiter on the heat

exchanger

clean groove on heat exchanger

ensure that locking cams are present on both sides of

the spring. Renew temperature limiter if necessary.

2 Fit protective cap 2 in position, securing with clamp 1.

Tighten clamp to 1Nm.

3 Remake electrical connections - see Electrical

Connections.

4 Refit heater unit - see Heater Unit - Removal and

Refitting.

9803/3675 Issue 1
Section K Engine Section K
8 - 12 Webasto Water Heater 8 - 12

Combustion Air Fan - Replacement

Removal Refitting

1 Remove heater unit - see Heater Unit - Removal and 1 Locate profiled packing ring 3 carefully; do not
Refitting. squeeze.

2 Disconnect relevant electrical connections - see
Electrical Connections.
3 Remove screws 1.
4 Pull combustion air fan 2 from burner head and remove,
together with profiled packing ring 3 and control unit 4.
5 Remove control unit 4 from combustion air fan.
6 Discard profiled packing ring.
2 Fit combustion air fan 2, together with packing ring 3 in
position in burner head. Secure with screws 1.
Tighten screws to 3Nm.
3 Refit control unit 4 to combustion air fan.
4 Remake electrical connections - see Electrical
Connections.
5 Refit heater unit - see Heater Unit - Removal and
Refitting.

3
2

9803/3675 Issue 1
Section K Engine Section K
8 - 13 Webasto Water Heater 8 - 13

8
6

11

10

12
3

9803/3675 Issue 1
Section K Engine Section K
8 - 14 Webasto Water Heater 8 - 14

Replacement of Burner, Flame Sensor and

Glow Plug
Removal Refitting

1 Remove heater unit - see Heater Unit - Removal and
Refitting.
2 Remove combustion air fan - see Combustion Air Fan -
Replacement.
1 Locate swirl ring 11 on burner 9.
2 Carefully and fully insert flame sensor 12 and glow plug
13 into burner 9 against stop and slide grommets 5 and
6 down slots in housing of combustion tube 7.

3 Remove screw 1 and washer 2. 3 Position burner 9 and grommet 8 in burner head 10.

4 Remove nuts 3 and withdraw bracket 4. !CAUTION

When performing the following step, ensure that cables
5 Withdraw grommets 5 and 6 from slots in housing of
of flame sensor 12 and glow plug 13 are routed as shown
combustion tube 7.
below.
6 Withdraw grommets 8 and burner 9 from burner head 10
and remove, together with swirl ring 11.

7 Pull flame sensor 12 and glow plug 13 from burner and

remove.

8 Carry out visual inspection for damage of removed

components - see Inspection and Testing.

9 Discard profiled backing ring.

12

13

4 Slide insulation 14 onto bracket 4 and locate bracket in

position.

5 Secure bracket 4, using nuts 3. Torque tighten nuts 3

to 3Nm.

6 Secure fuel line, using screw 1 and washer 2. Torque

tighten screw 1 to 3Nm.

7 Refit combustion air fan - see Combustion Air Fan -

Replacement.

8 Remake electrical connections - see Electrical

Connections.

9 Refit heater unit - see Heater Unit - Removal and

Refitting.

9803/3675 Issue 1
Section K Engine Section K
8 - 15 Webasto Water Heater 8 - 15

Burner Head - Replacement

Removal Refitting

1 Remove heater unit - see Heater Unit - Removal and
Refitting.
2 Remove combustion air fan - see Combustion Air Fan
- Replacement.
3 Remove burner, flame sensor and glow plug - see
Replacement of Burner, Flame Sensor and Glow
Plug.
4 Remove attachment screw 1 and remove V-clamp 2.
5 Withdraw burner head 3 from heat exchanger 4 and
remove.
1 Insert burner head 3 into heat exchanger 4, align as
necessary and secure with V-clamp 2. Torque V-clamp
attachment screw 1 to 3Nm.
2 Refit burner, flame sensor and glow plug - see
Replacement of Burner, Flame Sensor and Glow
Plug.
3 Refit combustion air fan - see Combustion Air Fan -
Replacement.
5 Refit heater unit - see Heater Unit - Removal and
Refitting.

9803/3675 Issue 1
Section K Engine Section K
8 - 16 Webasto Water Heater 8 - 16

Heat Exchanger - Replacement

Removal Refitting

1 Remove heater unit - see Heater Unit - Removal and
Refitting.
2 Remove circulation pump - see Circulation Pump -
Replacement.
1 Clip connector housing onto heat exchanger and
engage connector in connector housing - see
Electrical Connections.
2 Refit burner head - see Burner Head - Replacement.

3 Remove combustion air fan - see Combustion Air Fan
- Replacement.
4 Remove temperature limiter - see Temperature Limiter
- Replacement.
5 Remove temperature sensor - see Temperature
Sensor - Replacement.
6 Remove burner, flame sensor and glow plug - see
Replacement of Burner, Flame Sensor and Glow
Plug.
3 Refit burner, flame sensor and glow plug - see
Replacement of Burner, Flame Sensor and Glow
Plug.
4 Refit temperature limiter - see Temperature Limiter -
Replacement.
5 Refit temperature sensor - see Temperature Sensor -
Replacement.
6 Refit combustion air fan - see Combustion Air Fan -
Replacement.

7 Remove burner head - see Burner Head - 7 Refit circulation pump - see Circulation Pump -
Replacement. Replacement.

8 Remove connector and connector housing -see 8 Refit heater unit - see Heater Unit - Removal and
Electrical Connections. Refitting.

9803/3675 Issue 1
Section K Engine Section K
8 - 17 Webasto Water Heater 8 - 17

Visual Inspection
Visual Inspection of Burner

The starting air bore 9 must not be clogged, otherwise there 1

will be no start. If necessary, remove the glow plug and
carefully remove any contamination from the bore with a
1.5mm diameter wire. Refit glow plug.

Rear Wall with Metal Evaporator

The pilot flame exit bore 10 must not be clogged, otherwise 9

2
there will be no start.

If it is, the burner must be replaced.

Note: Cracks, delaminations as well as black or other

discolourations of the evaporator do not cause a burner
failure and should be disregarded.

Carbon deposits on the evaporator surface (except for the

pilot flame bore) are usual and must not be removed. When
the load changes from full load to part load and vice versa, 8
the burner is normally self cleaning. 3
Combustion Chamber 4
7 6
The combustion chamber 11 must not be damaged (e.g. 5
dented). This would cause insufficient combustion or coking
of the heater, in this event, the burner must be replaced.
1 Combustion tube 6 Housing
2 O-ring 7 Screw
The air bores 12 must not be coked. Coked air bores may
3 Flame sensor 8 Bracket
cause no start or insufficient combustion. Remove any
4 Insulation 9 Starting air bore
deposit by careful scraping.
5 Glow plug
Burner assembly

Check security of housing and combustion chamber.

O-ring 2 must be a tight fit around the fuel chamber edge

and must seal completely.

The gap 13 between housing and combustion chamber

should be equal around the entire circumference.

Insulation 4 must be present and in good condition.

10
2
11

12

13

9803/3675 Issue 1
Section K Engine Section K
8 - 18 Webasto Water Heater 8 - 18

Electrical Component Testing

Temperature Sensor

During electrical testing of the temperature sensor using a

digital multimeter, the following readings should be
obtained:

Resistance at 25oC 990 to 1010Ω

Test current < 1mA

Glow Plug

During electrical testing of the glow plug using a digital

multimeter, the following readings should be obtained:

Resistance at 25oC 1.3 to 1.44Ω

Test current < 5mA

Flame Sensor

During electrical testing of the flame sensor using a digital

multimeter, the following readings should be obtained:

Cold Test
Resistance at 25oC 990 to 1010Ω
Test current < 5mA

Hot Test
Resistance at 800 to 1000oC 990 to 1010Ω
Test current < 5mA

9803/3675 Issue 1