Perkins Electrical TI Bulletin - Cape Dory Sailboat Owners Association
Contents
1. International MISSIONS LTO LAST HEH SPA E 3Y EMS TRANS 7 TECHNICAL INFORMATION ELECTRICS T i BULLETIN INDEX Click on bulletin title to view Note Some of the following bulletins although containing electrical information have already been issue in different sections They are also listed here for convenience Click on the bulletin title to transfer to the appropriate bulletin T I No Gn 008 Gn 017 Gn 018 Gn 019 GX 006 GX 017 GX 022 GX 025 GX 034 GX 037 ELOO1 ELOO2 ELOO3 EL004 EL005 ELOO6 ELOO7 ELO08 ELOO9 ELO10 Issue k N k ee ee ee ee ee ee ek DATE SEP 99 Subject Alternator Connections on Mainframe Harness Starter Motors Magneti Marelli Service Warranty Support Products Affected Perkins Engines as applicable All Perkins Engines All Perkins Engines Service Department Computer Diagnostic Equipment Solenoid Valve Coils Diode Protection Solenoid Valve Coils Retaining Nuts amp O Rings Powershift Trans Electrical Changes Introduction of Autoshift Transmission E C U Powershift Electrical Changes Introduction of Speed Sensor Tester ECU Diagnostics Electrical Harness Repair Components IP67 Electrical Harness Repair Procedure IP67 Replacement Transmission Solenoids Hobbs Gear Lever with Dedicated Neutral Line Powertrain Switches Overview of Powershift Trans E C U Hobbs Wiper Turn Signal Column Switc2. 3 10 Please read the appropriate machine or gearbox service manual for full details of how to use this software to diagnose electrical faults on the transmission 3 11 Should there be a problem with the communications then the following error message will appear 3 12 The ECU can detect if there is a problem with the gearbox solenoids or the associated interconnections On Scanning the ECU if such an error is detected them the following error message will appear 3 13 The faulty solenoid connection can pinpointed within the software as explained in the next section 3 14 If the above warning is displayed or to look at the Solenoid Status at any time then click on he button A The Unit Status section bottom right corner of the window showing the status of the ECU inputs and present gear selection will freeze whilst doing this operation The left half of the window will also grey out 3 15 Faulty solenoids or connections will be shown highlighted In the example below we can see that all the solenoids are faulty This would mean that the gearbox harness is not connected ee continued 3 16 The solenoid name will be seen to become un highlighted as the fault is cured 3 17 Click on window the button to exit this feature and to unfreeze the rest of the 4 REMOVING THE SOFTWARE 4 1 Start up the control panel from the Start Menu ES Control Panel gig Settings 4 2 Double click on
3. e The OEM operator handbook details all features including relevant non standard E C U features and logic e The OEM service information details E C U differences from the ITL manual e All changes to the original E C U settings or features supplied by ITL are approved in writing including completion of the ITL E C U engineering sign off document and the OEM s own F M E A analysis carried out e The OEM service network and all OEM customers are informed accordingly of the correct operating and service procedures including SAFETY risk assessment If you do not fully understand how the E C U functions read the relevant ITL service manual and technical information or contact ITL before operating the machine or carrying out service work E C U Re programming It is possible to tailor an existing production E C U to refine the control of the transmission The OEM may consider making changes to the E C U at the prototyping or pre production stages of a machines development if the OEM feels that this would be significantly beneficial to machine operation It is recommended that changes are not made to E C U s fitted to production machines However this flexibility is useful if a critical error between E C U and application compatibility is discovered after a machine has been production released or the machine is in a special application e g speed limiting required IMPORTANT It is vitally important that modifications to any E C
4. AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 The illustrations show both a gear switch A and a multi function switch B Item A incorporates a locating pin X which engages with a drilled hole in the column to ensure correct location and prevents rotation of the switch mounting The two switches are clamped onto the shaft using two screws D If item B is not required mounting clamp C should be used instead The gear switch incorporates a rotary selector for gears 1 2 3 4 and a horn button or kickdown button Forward Reverse selection is made by lifting the lever out of its neutral detent position and moving it forward for forward direction or back for reverse direction Note An explicit neutral line is incorporated to simplify the neutral start circuit i e no additional relays are required to decode neutral Gear Switch Connections Y 1st gear 2nd gear 3rd gear 4th gear Horn or kickdown load Reverse Forward 11 Neutral 12 Feed Q O GM Multi function Switch Connections Z 1 Flasher mode Washer feed High beam Headlamp feed Low beam Wiper park Wash Wipe load Wiper feed Left turn Right turn Turn signal feed 2 3 4 5 6 T 8 9 1 1 Deutsch Mating Connector Requirements Deutsch Part No ITL Part No Qty Y Housing 12 way
5. DT06 12S 460 34901 Terminal Socket 1062 16 0122 Contact female 0462 201 16141 460 34702 Locking Wedge W12S 460 34902 Seal Plug 114017 460 34903 E LOUS Issue 1 A302480 G45 A302280 Connectors E must be protected by a suitable cover against damage and high pressure washes Intemational TECHNICAL SEE NFORMATION Electrics A SAFETY NOTICE Instructions in the Service Bulletins assume that the Number ELOOG engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Nov 1998 SUBJECT Powertrain Switches Page 1 of 2 PRODUCTS AFFECTED All Powertrains TO BE CARRIED OUT For Information only SERVICE INFORMATION This Technical bulletin is issued to answer typical service questions relating to Powertrain switches supplied to OEMs by ITL Note Some OEMs use their own switches 1 The table on page 2 indicates the switch description thread locations part number and operating values Contact ITL Technical Sales if further details are required 2 The most common reason for switch failure is water ingress into the switch through the terminals because of defective or incorrect harne
6. HOUSING SUM 14 WAY PIN HOUSING SUM 14 WAY PIN RETAINER SUM 14 WAY RECEPTICAL RETAINER SUM 31 WAY RECEPTICAL BULKHEAD HOUSING ITT 31 WAY PIN HOUSING ITT 31 WAY PIN BULKHEAD HOUSING ITT 31 WAY RECEPTICAL HOUSING ITT 4 WAY PIN BULKHEAD HOUSING ITT 4 WAY RECEPTICAL HOUSING ITT 32 WAY RECEPTICAL HOUSING ITT 32 WAY PIN BULKHEAD HOUSING ITT 19 WAY PIN BULKHEAD HOUSING ITT 19 WAY RECEPTICAL HOUSING ITT 48 WAY RECEPTICAL HOUSING ITT 48 WAY PIN BULKHEAD HOUSING ITT 18 WAY ECONOSEAL RECEPTICAL RETAINER ECON 18 WAY ECONOSEAL RECEPTICAL HOUSING ECON 36 WAY ECONOSEAL RECEPTICAL RETAINER ECON 36 WAY ECONOSEAL RECEPTICAL HOUSING ECON SINGLE RELAY BASE SLOT IN TYPE RELAY SWITCH LIGHT BULB HOLDER SWF HIRSCHMANN PLUG SEAL HIRSCH IGNITION SWITCH PLUG 1 MERIT IGNITION SWITCH PLUG 2 MERIT 8 WAY SWITCH BASE PLUG SWF BUTANE HEATER ASSEMBLY SPLICE 0 5 1 5mm RED SPLICE 1 5 2 5mm BLUE SPLICE 3 6mm YELLOW PIN RECEPTICAL REMOVAL TOOL POWER ITT PIN RECEPTICAL REMOVAL TOOL SIGNAL ITT FLYING LEAD SUMITOMO 1mm SUM FLYING LEAD SUMITOMO 2mm SUM FLYING LEAD PACKARD 1mm PACK FLYING LEAD PACKARD 2mm PACK FLYING LEAD 90DEGREE POZILOCK 1mm POZI FLYING LEAD 90DEGREE POZILOCK 2mm POZI FLYING LEAD 2mm RELAY FLYING LEAD 3mm RELAY FLYING LEAD POZILOCK amp FUSE BLADE 2mm POZI FLYING LEAD POZILOCK amp FUSE BLADE 3mm POZI FLYING LEAD POZILOCK amp FUSE BLADE 4mm POZI FLYING LEAD 1mm RELAY FLYING LEAD ITT CANON 1mm SIGNAL ITT FLYI
7. INFORMATION Warranty claims will not be accepted by ITL for installing a diode in service Correct installation is the responsibilty of the OEM WASHER FEED 2 7 WASH WIPE LOAD mnn WIPER FEED 8 ar ae 6 WIPER PARK HIGH BEAM 3 p A 1 FLASHER MODE eas es 2 TO PARK LOW BEAM 5 4 HEADLAMP FEED SWITCH ee n OS a a ae fue gee 9 LEFT TURN THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Inemational TECHNICAL io NFORMATION Electrics SAFETY NOTICE Instructions in the Service Bulletins assume that the Number EL009 engineer has a sound knowledge of safety procedures and has been trained in the JCB 5 185 C68 N Am maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice issue 1 Remember SAFETY MUST COME FIRST Date Nov 1998 SUBJECT Transmission Low Oil Pressure Light Illumination Page 1 of 3 During Gear or Direction Changes PRODUCTS AFFECTED SS600 and PS700 Transmissions TO BE CARRIED OUT Information Only SERVICE INFORMATION The transmission low oil pressure warning light on the above transmissions may illuminate momentarily
8. LL13 9UF UNITED KINGDOM Page 2 of 3 EL003 Issue 1 PROCEDURE 1 Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used For the splices detailed on page 1 the dimension is 7mm Using the correct sized splice attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool X part number 892 00349 Note that each of the splices detailed is colour coded to make size and range readily visible They are secured using the corresponding size and matching colour coded jaws of the crimp tool to ensure joint security This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size With the Butane heater assembly 892 00350 seal the connection using the procedure on the next page 189530 Page 3 of 3 189490 1 With the Butane Heater assembly 892 00350 seal the connection using the following procedure 3 1 Remove the cap A from the end of the dis posable gas cartridge B 3 5 Turn the red ring D to the right in the direction of the plus sign in order to turn on the gas IMPORTANT Before turning the heater on make sure that the cartridge is not hotter than the reflector element This may occur if the cartridge is held in the hand for a long time The temperature difference between the cartridge and the re
9. LOGIC continued Get you home facility e Ifthe speed sensor fails the buzzer will not sound All gears will be available with kickdown but there will be no downshift speed protection Care is to be taken when downshifting with either kickdown or gear selection on the column switch On restarting the machine 4th gear will be disabled to indicate to the operator that a fault has occurred and to limit the maximum speed Diagnostics facility e A 6 way AMP Econoseal connector must be provided by the OEM to allow connection by the service engineer to the on board E C U fault diagnostics system e Service Edition Diagnostics software available for use with Psion Handheld Computer ITL Standard Diagnostics Tool or Personal Computer running Windows 95 operating instructions are available for both formats This software is intended for non intrusive Diagnostics by OEM and or approved agenit s e A communications lead is available from ITL part number 892 00952 Machine performance e The overall machine performance is unchanged by the Powershift E C U feature All other features of the transmission will be as the current products without E C U IMPORTANT Non ITL standard Powershift E C U features This T I details the standard Powershift E C U only Note that the OEM may request different features from the standard Powershift E C U for example inhibiting 4th gear as different country legislation requires The OEM must ensure
10. OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM
11. U settings are carried out only by the OEM Any operator making changes must be trained and competent in the practice of making alterations to E C U settings Changes should only be carried out if their effect is judged to improve machine performance significantly All changes must be approved and recorded by ITL as stated above Using specifically designed Diagnostics software for the PSION or PC detailed re programming instructions are available for both formats it is possible to change the following characteristics of the E C U e Down shift and Kickdown speeds e Kickdown timer use and duration e Gear shift lever interpretation e Specific gear inhibiting Page 4 of 4 ELOO7 Issue 1 WARRANTY INFORMATION Any E C U which is claimed or returned under warranty will not be accepted unless the ECU settings are approved by ITL or are unchanged Almost without exception E C U s which have been claimed or returned as defective are found to have been incorrectly diagnosed or installed and therefore either work correctly when tested reset or the fault is later identified to be outside the E C U e g switches or wiring An intermittent fault is not an indication of E C U failure but indicates another cause which should be investigated before changing the E C U see T I Gn019 and the ITL service manual for further information on testing Note that a charge may be made for testing or for return carriage of correctly operating E C U
12. drops THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 3 ELOO9 Issue 1 SERVICE PROCEDURE 1 For machines in service Refer to the relevant service manual for transmission fault finding and check that the transmission and pump are functioning correctly before fitting a delay timer The following notes should be used as a guide to correct transmission operation a The transmission oil level and grade must be correct Check with the engine stopped b The transmission main line oil pressure should be checked at a temperature of 50 C at 1000 engine rev min Minimum pressure in neutral gear should be 135 Ibf in 9 2 bar If the transmission oil pressure figure is not achieved carry out a pump flow test at 1000 engine rev min to verify pump condition and performance A low pump flow will fill the clutches at a slower rate and allow the pressure to drop further If the transmission is found to be operating correctly ie pressure is above 135 Ibf in 9 2 bar and flow is between 2 5 and 3 3 UK gal min 11 and 15 I min at 1000 rev min take no further action or install the delay timer if required If the pressure sensor A is found to be signalling above 40 Ibf in 2 3 bar or not operating correctly renew the senso
13. during a gear or direction change All ITL manufactured transmissions have a low oil pressure warning light and buzzer fitted to indicate when the transmission main line pressure drops below 40 Ibf in 2 76 bar This warning light is connected to a pressure sensor fitted in the main line gallery of the transmission between the pump and the pressure maintaining valve The purpose of this light is to alert the operator to the possibility of clutch slippage due to low transmission oil pressure Under certain conditions the warning lamp can illuminate momentarily as the clutch packs fill with oil particularly when also operating a hydraulic service at engine idle which will lower the engine speed or when two or three clutch packs are filled at the same time This is particularly relevant to Powershift transmissions and can occur during a gear change from 2nd to 3rd or 3rd to 2nd or when changing direction of travel whilst at the same time selecting 2 or 4 wheel drive The momentary illumination of the lamp should not be interpreted as a transmission fault and can be attributed to the sensitivity of the pressure switch providing the light does not illuminate when no gear selection is made The sensitivity can cause concern to some operators and for this reason ITL have made available a signal delay timer unit 1 The unit delays the signal from the pressure sensor for 1 5 seconds as the clutch packs fill with oil and the pressure momentarily
14. harness will have to be modified by splicing on a new connector C Refer to JCB T I 2 174 C45 N Am March 1997 and JCB General Bulletin 020 C30 N Am Feb 93 Solenoids with connectors type D have also been superseded to the current type connector type B To enable this type of connecter to be used link harness E is available for service use SERVICE PROCEDURE IMPORTANT NOTE All later solenoids have diodes built into the coils The diodes will be damaged if the coil is connected with reverse polarity causing the coil to fail and the fuse to blow Identify the positive wire on the machine note the solenoid coil is marked positive and negative connect the wires into the new connector the correct way round as shown at F Ensure the wire seals G are fitted to the plug to prevent water ingress PARTS INFORMATION Item Part Number Description C 993 69600 Connector E 718 44900 Link Harness THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Intemational TECHNICAL DE NFORMATION Electrics A SAFETY NOTICE Instructions in the Service Bulletins assume that the Number EL005 engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure o
15. or when the pre programmed time delay expires default 6 seconds Note Care is to be taken when downshifting either by kickdown or manual selection on the column switch It is recommended that downshifting is not requested at high speed relying on the downshift protection system to avoid sudden deceleration The downshift protection system is to reduce loads on the transmission thereby improving its life and is not to be used as a means of pre selecting a downshift when slowing down If the speed sensor fails see Get you home facility next page downshift protection will not be available ECU Power up operation e A single double beep is sounded to indicate the E C U has been powered up Note On machine power up this indication may be overshadowed by other alarm sounds However this double beep can be a useful aid to diagnosing intermittent E C U power loss e lT the machine is stationary then the E C U holds the transmission in neutral until the FNR lever is placed in or passed through the neutral position e If the machine is moving when the E C U is powered up then the E C U will select the appropriate gear for the given road speed Warning buzzer light e A double bleep will sound for the following reasons Kickdown or manual downshift selected when machine speed is above the pre programmed limit Single double beep on power up or on resumption of power supply a continued Page 3 of 4 ELOO7 Issue 1 3 SYSTEM
16. s which have been service tested by substitution then returned under warranty or had the E C U settings deviated from the original ITL settings without approval B s K k N 1 E i I L vi an in national TECHNICAL aa INFORMATION Electrics SAFETY NOTICE Instructions in the Service Bulletins assume that the Number EL008 engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Oct 1998 SUBJECT Hobbs Wiper Turn Signal Column Switch Page 1 of 1 PRODUCTS AFFECTED Part Number 475 42300 TO BE CARRIED OUT As Required SERVICE INFORMATION Investigation into reports of the wiper fuse failing when the wiper control is operated slowly has identified that when the wiper park circuit is grounded to earth and not relay controlled as shown on the illustration at Y to prevent a short circuit in the lever a diode should be installed into the wiper circuit at X This is common electrical practice and is not a defect in the lever SERVICE PROCEDURE Install a diode capable of 5A minimum or suitably rated for the wiper motor amperage as shown at X or use a relay as shown at Y to switch the wiper to park The location of the diode is at the OEM s discretion WARRANTY
17. type a setup exe or use the Browse button to locate these files e mr a ie ee ee ee 2 5 The setup program will then start Windows 95 InstallShield Wizard displaying the following window 2 6 The dark blue setup window will then appear maximised to the full screen size In this main setup window the following windows will be displayed 2 7 The setup program welcomes the user and offers some helpful advice Please follow the recommendations if any problems are encountered due continued At any point the user may click on a the button to exit b the ME button to continue or o ne E button to go back to the previous window 2 8 Select the destination directory into which the application will be installed Choose Destnaton Loca hon It is recommended that the default directory is used or click on the button to select another location 2 9 Select the program folder in which the application is added this also creates the links to the application in the Start Menu Select Program Folder IS owershift ECU Dia gno stic NE oss he i Plowershift ECU Diagnostics ae continued Again it is recommended that the default folder is used 2 10 The setup program will then install the application onto the computer 2 11 Wait while the program installs the files updates the Windows 95 registry and adds the icons 2 12 When the setup process is complete the dark blue window closes and t
18. 0003 7218 0004 7219 0001 DESCRIPTION FUSE BOX TERMINAL 0 5 1 25mm FUSE BOX TERMINAL 1 0 3 2mm FUSE BOX TERMINAL 2 5 6 0mm RELAY BASE TERMINAL 0 5 1 0mm RELAY BASE TERMINAL 4 0 6 0mm RELAY BASE TERMINAL 1 3 3 4mm DUMMY PLUG DUMMY PLUG DUMMY PLUG DUMMY PLUG 1 WAY PIN HOUSING 1 WAY RECEPTICAL HOUSING 2 WAY RECEPTICAL HOUSING 2 WAY PIN HOUSING 2 WAY PIN RETAINER 2 WAY RECEPTICAL RETAINER 2 WAY RECEPTICAL HOUSING 2 WAY PIN HOUSING 2 WAY RECEPTICAL HOUSING 2 WAY RECEPTICAL RETAINER 2 WAY METRIPACK RECEPTICAL HOUSING 3 WAY METRIPACK RECEPTICAL RETAINER 2 WAY J TIMER RECEPTICAL HOUSING 2 WAY J TIMER HOUSING 3 WAY RECEPTICAL HOUSING 3 WAY PIN HOUSING 3 WAY PIN RETAINER 3 WAY RECEPTICAL RETAINER 3 WAY RECEPTICAL HOUSING DT 3 WAY PIN HOUSING DT 3 WAY PIN RETAINER DT 3 WAY RECEPTICAL RETAINER DT 3 WAY RECEPTICAL HOUSING 3 WAY PIN HOUSING 4 WAY RECEPTICAL HOUSING 4 WAY PIN HOUSING 4 WAY PIN RETAINER 4 WAY RECEPTICAL RETAINER 4 WAY RECEPTICAL HOUSING INLINE 4 WAY PIN HOUSING INLINE 4 WAY PIN HOUSING BLOCK 4 WAY RECEPTICAL HOUSING BLOCK 4 WAY ECONOSEAL PIN HOUSING 4 WAY ECONOSEAL RECEPTICAL HOUSING 4 WAY ECONOSEAL PIN RETAINER 4 WAY ECONOSEAL RECEPTICAL RETAINER 6 WAY RECEPTICAL HOUSING 6 WAY PIN HOUSING 6 WAY PIN RETAINER 6 WAY RECEPTICAL RETAINER 6 WAY RECEPTICAL HOUSING 6 WAY PIN HOUSING 6 WAY ECONOSEAL RECEPTICAL HOUSING 6 WAY ECONOSEAL RECEPTICAL RETAIN
19. CE Instructions in the Service Bulletins assume that the Number EL010 engineer has a sound knowledge of safety procedures and has been trained in the JCB 2 223 C72 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 4 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date July 1999 SUBJECT Alternator Suppressor Page 1 of 1 PRODUCTS AFFECTED Perkins Engines SERIAL NUMBERS Perkins 1000 Series onwards TO BE CARRIED OUT Information Only SERVICE INFORMATION Instances of the charge light flickering or glowing have been reported To overcome this a suppressor can be fitted to the 65 72 and 85 amp alternator Note Machines used on continual night applications with working lights on and also where machines are left idling for long periods with the lights left on may also have have the same symptoms with repetitive battery discharge SERVICE PROCEDURE 1 Park the machine on firm level ground engage the parking brake and set the transmission to neutral Lower the loader arms to the ground Switch OFF the engine and remove the starter key 2 Disconnect the battery 3 Fit suppressor A onto bolt B and connect to terminal C 4 Reconnect the battery start the engine and check for correct operation PARTS INFORMATION Item Description Part No Qty A Suppressor 714 10801 1 THIS BULLETIN IS ISSUED FOR THE PURPOSE
20. ER 6 WAY ECONOSEAL PIN HOUSING 6 WAY ECONOSEAL PIN RETAINER 6 WAY ECONOSEAL PANEL MOUNT PIN HSG 8 WAY RECEPTICAL HOUSING 8 WAY PIN HOUSING 8 WAY PIN RETAINER 8 WAY RECEPTICAL RETAINER 10 WAY RECEPTICAL HOUSING TYPE PR PR PR AMP AMP AMP SUM PACK ECON AMP PACK PACK SUM SUM SUM SUM PACK PACK ECON ECON PACK PACK AMP AMP SUM SUM SUM SUM SUM SUM SUM SUM PACK PACK SUM SUM SUM SUM PACK PACK PACK PACK ECON ECON ECON ECON SUM SUM SUM SUM PACK PACK ECON ECON ECON ECON ECON SUM SUM SUM SUM SUM PART No 7219 0002 7219 0003 7219 0004 7219 0005 7219 0006 7219 0007 7219 0008 7220 0001 7220 0002 7220 0003 7220 0004 7220 0005 7220 0006 7220 0007 7220 0008 7220 0009 7220 0010 7220 0012 7220 0013 7220 0014 7220 0015 7220 0016 7220 0017 7231 0001 7232 0002 7233 0010 7234 0003 7236 0003 7238 0001 892 00350 892 00351 892 00352 892 00353 892 00869 892 00870 993 56700 993 56800 993 56900 993 57000 993 57100 993 57200 993 57300 993 57400 993 57500 993 57600 993 57700 993 57800 993 57900 993 58000 993 58100 993 58200 993 58300 993 58400 993 58500 993 58600 993 69600 998 00001 998 00002 PR Pressac SUM Sumitumo Pack Packard Econ Econoseal ELOO2 Issue 1 DESCRIPTION TYPE 10 WAY PIN HOUSING SUM 10 WAY PIN RETAINER SUM 10 WAY RECEPTICAL RETAINER SUM 14 WAY RECEPTICAL
21. NG LEAD ITT CANON 1 5mm SIGNAL ITT FLYING LEAD ITT CANON 2mm SIGNAL ITT FLYING LEAD ITT CANON 3mm POWER ITT FLYING LEAD ITT CANON 4mm POWER ITT FLYING LEAD AMP J TIMER 1mm AMP FLYING LEAD AMP J TIMER 2mm AMP FLYING LEAD AMP POZLK amp FUSE BLADES 1mm POZI AMP JUNIOR TIMER 2mm AMP FLYING LEAD ECONOSEAL 1mm ECON FLYING LEAD ECONOSEAL 1 5mm ECON Pozi Pozilock a INFORMATION sini SAFETY NOTICE Instructions in the Service Bulletins assume that the Number EL003 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 021 maintenance and repair of ITL equipment If you are unsure or do not understand information contained in the Service Bulletins then ask your supervisor for advice issue 1 Remember SAFETY MUST COME FIRST Date Dec 1998 SUBJECT Electrical Harness Repair Procedure IP67 Standards Page 1 of 3 PRODUCTS AFFECTED All TO BE CARRIED OUT For Information Only SERVICE INFORMATION Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and repair or replace specific individual wires within a harness To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is actioned to an acceptable standard it is strongly recommended that the following tools equipment and procedures are always used to ensure the installation is maintained to IP 67 standar
22. ds The sheath covering of the recommended splice is heat shrunk onto the original wire insulation This results in a seal and corresponding joint to IP 67 specifications A CAUTION When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular circuit It is not recommended to increase the fuse rating as this can cause overloading and consequential failure of wiring along with failure of integral circuit components which the fuse is protecting A WARNING In addition to the warnings incorporated into the procedure extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair i e other wires floor panels floor mats sound proofing paintwork etc This tool should not be used in any restricted location prohibiting the use of Naked Flames or where risk of explosive gas or similar safety parameters apply No other heat source should be used to attempt a sealed joint TOOLS REQUIRED 892 00350 Butane Heater assembly 1 892 00349 Crimp tool 1 892 00351 Splice 0 5 1 5 mm Red 50 892 00352 Splice 1 5 2 5 mm Blue 50 892 00353 Splice 3 0 6 0 mm Yellow 50 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD
23. ect a lower gear if conditions demand 2 KEY COMPONENTS Transmission The existing 4 speed Powershift transmission has a speed sensor fitted to detect the speed of rotation of the output shaft This information provides road speed information to the E C U see below ECU The 18 36 way type E C U is a new component which replaces older 18 18 way type O a O E C U s 460 315xx It is a Solid State microprocessor based electronics black box LINN Based upon data supplied from the column switch kickdown button see Controls Instrumentation below parkbrake switch transmission dump switch and the speed sensor the E C U controls the gear selection solenoid valves on the transmission 36 Way Connector Controls Instrumentation The column switch is the same as non E C U transmissions 475 51090 The gears are selected on the Forward Neutral Reverse FNR lever rotary switch positions 1 2 3 and 4 manually selecting those gears as machine conditions allow An optional kickdown button can be fitted by the OEM e g button on loader lever If the kickdown is pressed the next lowest gear is selected By pressing kickdown again the transmission will revert to the previous higher gear Selecting reverse or another gear will also cancel the kickdown An optional input for connection to the parkbrake warning light switch is available This places the transmission in neutral whenever
24. eflector head opening reduced In this mode the heating is done only by the hot gas use for dark coloured plastic splices To switch off the heater turn the red ring D to the left in the direction of the minus sign CAUTION When the heater is in use the reflector and the air coming out are extremely hot Keep away to avoid accidental burns Do not touch the reflector until it has had time to cool down after switching off If flame reappears at the reflector when the heater is in use the catalytic element is damaged or used up Stop work immediately and replace the heater Internationa y TECHNICAL seama INFORMATION Electrics SAFETY NOTICE Instructions in the Service Bulletins assume that the Number EL004 engineer has a sound knowledge of safety procedures and has been trained in the JCB Gen 085 C65 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue J information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Sep 1998 SUBJECT Replacement Transmission Solenoids Page 1 of 1 PRODUCTS AFFECTED Forward and Reverse Solenoids Fitted To ITL SS600 Syncro Shuttle Transmissions TO BE CARRIED OUT For Information Only SERVICE INFORMATION Replacement transmission solenoids with connectors type A have been superseded to the current connector type B To change this type of connector the machine
25. equest is de selected For a non allowed kickdown request the buzzer will double bleep only once at the time of the request SYSTEM LOGIC The E C U will not allow gear changes to occur if outside the pre programmed conditions The following description explains the system logic Gearshifting e 1st 2nd 3rd and 4th gears are selected in the normal way on the column switch upshifts are engaged immediately on request e The E C U does not allow downshifts above certain speeds If attempted a double bleep will sound and the transmission remains in its current gear until the speed has reduced sufficiently to allow a downshift to occur Upshitting is not speed limited e Achange in direction can be made as long as the machine speed is below a specifically assigned value e lf 4WD is selected for the machine 4WD is disengaged in 4th gear Kickdown facility Manual mode e Pressing the kickdown button will result in a gear change to the next lowest gear e Kickdown operation is subject to the same pre programmed speed limits as downshifts If a non allowed kickdown is requested kickdown will not occur The buzzer will sound a double bleep Note that the E C U does not retain the kickdown request in its memory so kickdown will have to be re selected once the machine speed has reduced e The transmission will revert to the original gear either by selecting a directional or gear change on the FNR lever or by pressing the kickdown button again
26. fault finding guide and tips on common faults The Powershift ECU Diagnostics software complements the range of diagnostics software available for the PSION Workabout the standard ITL diagnostics tool For further details on the diagnostics software for the PSION Workabout please read the relevant literature on the ITL CD ROM Imernational TECHNICAL gt SE INFORMATION Electrics SAFETY NOTICE Instructions in the Service Bulletins assume that the Number EL002 engineer has a sound knowledge of safety procedures and has been trained in the JCB 2 174 C45 N Am maintenance and repair of ITL equipment If you are unsure or do not understand Issue 4 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Dec 1998 SUBJECT Electrical Harness Repair Components IP67 Standards Page 1 of 2 PRODUCTS AFFECTED All TO BE CARRIED OUT For Information Only SERVICE INFORMATION Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and repair or replace specific individual wires or connectors This bulletin introduces part numbers for various electrical connectors and terminals used in JCB IP67 wiring harnesses The bulletin should also be read in conjunction with Electrical Bulletin ELOOS 44 CAUTION When installing Auxiliary Electrical Components always ensure that the additional l
27. flector element may cause long yellow flames to appear on ignition 189490 2 3 2 Before assembling the gas cartridge to the reflector element C turn the red ring D to the left in the direction of the minus sign marked on the ring 189490 6 3 6 Hold the heater vertically and using a match or cigarette lighter light the gas as shown Note The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty No sound will be heard even when the cartridge is full Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs This is indicated when the blue flame fades and the ceramic element glows red Then turn the small ring E until the air holes at F are completely open The tool is ready for use ELO03 189490 3 3 3 Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together A click will be heard 189490 7 The heater can be used in two modes 3 7 Side wings G down reflector head com pletely open In this mode the infra red heat waves are dominant recommended for the light coloured plastic splices Issue 1 189490 4 3 4 Turn the small ring E so that the air holes at F are completely closed 189490 8 3 8 Side wings G up r
28. h Trans Low Pressure Oil Light Illumination Alternator Suppressor PAGE 1 OF 1 55600 PS700 SS400 Elec Op All fitted with Solenoid Valves All PS700 PS700 4 Speed Powershift Powershift with ECU Speed Sen Powershift with 36 way ECU All All SS600 Syncro Shuttle All Powershift with Hobbs levers All Powertrains PS700 4 Speed Part Number 475 42300 SS600 and PS700 Perkins 1000 Series Date Nov 93 Mar 96 Apr 96 Nov 97 Feb 95 Nov 96 Mar 97 Nov 98 Nov 97 Feb 98 Nov 98 Dec 98 Dec 98 Sep 98 ISSUE 2 Umemational TECHNICAL SE TRANSMISSIONS LTO INFORMATION DRITE HIGHWAY DRRAELINE SYSTEMS A SAFETY NOTICE Instructions in the Service Bulletins assume that the engineer has a sound knowledge of safety procedures and has Number ELOO1 been trained in the maintenance and repair of ITL equipment If you are JCB ref Trans003 unsure or do not understand information contained in the Service Bulletins then ask your supervisor or contact ITL SERVICE for advice Remember SAFETY MUST COME FIRST ECU DIAGNOSTICS INSTRUCTIONS PRODUCTS AFFECTED Powershift Transmissions with 36 Way ECU 1 INTRODUCTION 1 1 Literature Notation Bold blue text refers to ITL products and part numbers Bold green text refers to non ITL products brand names and trademarks Issue Date 1 Nov 1998 Page 1 of 9 The open book symbol denotes notes hints and tips which are useful t
29. he program folder window can be seen open on the desktop fa CAWINDOWSAStart Menu Programs Powershift ECU Diagnostics P At this point the installation of the Powershift ECU Diagnostics software is complete 3 RUNNING THE SOFTWARE 3 1 The simplest method of starting the software is to locate the icon in the Start Menu as shown below Programs d Powershift ECU Diagnostics t Powershift ECU Diagnostics Windowso5 3 2 ere continued 3 3 If the ECU is not connected and powered up then the application loads as shown below 3 4 Powershift ECU Diagnostics Connect the 9 pin D type connector of the communications lead into the serial port of the PC Do not worry if more than one serial port COM port e g COM1 COM2 etc is present as then 3 5 3 6 3 7 3 8 3 9 software will automatically detect which port is connected to the ECU Connect the other end of the communications lead into the ECU diagnostics connector provided on the machine Turn on the power to the ECU e g turn the key switch to the ignition position The ECU can then be interrogated by clicking on E the button The window will then Powershift ECU Diagnostics display the real time status of the ECU and example is shown below Weutral re continued The example above shows the ECU settings and status for a 4 speed manually operated ECU i e 4 gears which can be engaged independently by the operator
30. n oil cooler 12 Sensor switch G for vacuum detection is fitted in the engine air cleaner A310200 ee ete eee Sa Size Value Part No Trans Oil Trans Oil Temperature Switch Switch ala wer a ee eee re renzo rea menere eraro warTonooanno sorcer soam prre Tape DEI wiextnn Tarsonesanesmenssooo ars f osoon gt ne ow wear aesan ar s F oraso Tan vener SRB 00 8081 SealwiPTFETape o pasm pa enere vacsom sorsero sorea _ Sav Tae P erzo nm eese morima romane WA soan pree Intemational TECHNICAL S INFORMATION Electrics A SAFETY NOTICE Instructions in the Service Bulletins assume that the Number EL007 engineer has a sound knowledge of safety procedures and has been trained in the maintenance and repair of ITL equipment If you are unsure or do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Dec 1998 OVERVIEW OF POWERSHIFT TRANSMISSION ECU 460 378xx Page 1 of 4 PRODUCTS AFFECTED PS700 4 Speed Transmissions 1 INTRODUCTION The driveline comprises a Powershift transmission controlled by an Electronic Control Unit 18 Way E C U This provides the operator with manual selection of gears with added Connector protection for both operator and transmission In addition a kickdown function is incorporated allowing the operator to temporarily sel
31. o remember A The attention symbol outlines critical information which must be remembered or adhered to at all times 1 2 Overview The PC Diagnostics software is supplied on the parts CD ROM or can be supplied on a separate floppy disk The following instructions explain how to install the software onto your computer how to use the software and how to remove it if necessary A This software is intended for use on IBM compatible Personal Computers running Windows 95 or later and is not compatible with earlier versions of Windows 3 x or Windows NT A The software is the property of International Transmissions Limited and is copy protected The software may only be installed from the original disk Attempting to copy the software between PCs with render the program un usable ron L 7 i Ineta Rate Esk for Windows SE Seer Cia Polat here Tete hR and pases Hernia EF lre thes baraan aia Kag e precaed With ed dlan oF Preah CS i THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM 2 INSTALLING THE SOFTWARE 2 1 Place the original disk into the appropriate disk drive 2 2 Select Run from the Start Menu 2 3 For CD ROM installation type d Pc Powershift ECU Diagnostics setup exe 2 4 For Floppy Disk installation
32. oad rating is suitable for that particular circuit It is not recommended to increase the fuse rating as this can cause overloading and consequential failure of wiring along with failure of integral circuit components which the fuse is protecting Packard Sumitumo Ke Econoseal Connector s Connector S Connector 270470 270480 270490 Splices A Hirschmann 270500 i Connector 270510 ITT Canon Connector 270520 FLYING LEADS AMP Relay Term eR Pozilock Relay amp Connector Base Pressac Fuse 270540 270530 270550 Blade THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 PART No 7201 0008 7201 0009 7201 0010 7201 0427 7201 0428 7201 0429 7210 0001 7210 0008 7210 0015 7210 0017 7211 0001 7211 0002 7212 0001 7212 0002 7212 0003 7212 0004 7212 0005 7212 0006 7212 0008 7212 0009 7212 0014 7212 0015 7212 0020 7212 0021 7213 0001 7213 0002 7213 0003 7213 0004 7213 0005 7213 0006 7213 0007 7213 0008 7213 0009 7213 0010 7214 0001 7214 0002 7214 0003 7214 0004 7214 0005 7214 0006 7214 0007 7214 0008 7214 0009 7214 0010 7214 0011 7214 0012 7216 0001 7216 0002 7216 0003 7216 0004 7216 0005 7216 0006 7216 0007 7216 0008 7216 0009 7216 0010 7216 0011 7218 0001 7218 0002 7218
33. r Part Number Powershift 701 43700 Syncro Shuttle 701 41600 Delay Timer Installation Disconnect the pressure switch wiring Connect delay timer 1 in line between the pressure sensor A and the transmission harness B as shown Secure the delay unit to a suitable location with cable ties as example shown at C Tie any excess wiring in a convenient position using cable ties Ensure the wire routing allows for vibration movement between the pressure switch and the delay unit Production installation ITL recommends that if the OEM wishes to install the delay timer on production the timer is wired into the cab or fuse box area for an improved installation Contact ITL Technical Sales for further details of a delay timer for production installation Page 3 of 3 ELOO9 Issue 1 Warranty Information ITL will not normally accept warranty claims for the installation of a delay unit in service If the reason for failure is the switch or low transmission pressure A warranty claims should be submitted in the normal manner with the following values recorded on the claim Pressure at 50 C at 1000 rev min Ibf in2 bar Flow at 1000 rev min S g min min PARTS INFORMATION Item Part No Description Qty Comments 1 449 03808 Delay timer 1 Service installation B s K k N 1 E i I L vi i in national TECHNICAL INFORMATION Electrics EE TRANSMISSIONS LTD DALY HIGH AY Zoa IE SY Emi SAFETY NOTI
34. r do not understand Issue 1 information contained in the Service Bulletins then ask your supervisor for advice Remember SAFETY MUST COME FIRST Date Nov 1998 SUBJECT Introduction of Hobbs Gear Lever with Dedicated Neutral Line Page 1 of 2 PRODUCTS AFFECTED All Powershift Transmissions with Hobbs ITL supplied forward and reverse levers TO BE CARRIED OUT Information only SERVICE INFORMATION A new Powershift forward reverse and speed change lever ITL part number 475 51090 was introduced from July 1998 in order to simplify OEM wiring The new lever has a different 12 pin Deutsch wiring connection and provides a dedicated neutral circuit feed The previous lever 475 42100 with 8 pin connection will remain available for service use In order to fit the new lever in place of the old lever the machine wiring must be modified by adding an additional explicit neutral feed to the transmission ECU and changing the harness plug Additional Information 1 ITL notification of change 0705 applies 2 Wiring connection and the lever should be protected from pressure washing or hot water steam cleaning particularly if washing chemicals are used A suitable shroud around the wiring connections on non cabbed machines is recommended to protect the wiring connection from direct water jets Parts Information Description Part Number Gear Lever 475 51090 cont d THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION
35. ss connections ITL now supplies certain switches loose rather than fitted to the powertrain to help prevent water ingress during storage or shipping Always protect switches during pressure washing especially if cleaning chemicals or steam hot pressure washes are used Later ITL switches from mid 97 have an Epoxy resin sealer added to help protect switches against defective wire seals 4 Adaptor item H 997 22100 can be used in conjunction with switch item D 701 41600 for converting older pre 95 transmissions with the test point and previous type pressure switch with spade connections on a separate T piece to the current switch An AMP junior timer link harness item J 993 69600 is available for modifying machine harnesses 5 AMP junior timer switch harness connections are available from ITL for OEMs who are unable to source from AMP Note ITL can provide 2 Way AMP Junior Timer plug kits complete with housing terminals and wire seals 460 34600 THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 2 ELOO6 Issue 1 Sensor Switch Positions D SS600 E PS700 F S302210 Sensor switch A for transmission oil temperature is fitted in transmissio
36. the Add Remove Programs icon TREHET Date Time Programs eee continued 4 3 From the Add Remove Programs Properties window select the Powershift ECU Diagnostics item and click on the _ Add Remove button Add Remove Programs Properhes i 1 f me ca SS K e r L e K e K eam she oe g a 1 fa a gt ri D K L k be JH biek ME R ay 7 C R gt r i l G l h Le JU TO E L L kae X a d i a L pan o 1a R IU la H B OIT T ku TTT TTT TTT TTT P TT p I 1 se 3 rs 15442 L TL ee oe ee RA MA ei as 5 42 LRS l C ET L sb Ta JL Ly N tha _ N C i Es EL oH e me r i I 1 i i 1 e P i 4 4 Confirm that the application is to be removed by clicking on the button anin File Delenhon O 4 5 The Windows 95 InstallShield used to install the application will then remove the software completely a continued 4 6 All icons shortcuts and folders will be removed automatically by Windows 95 Remove Programs From Your Computer 5 ADDITIONAL INFORMATION This software does not support diagnostics of the earlier range of ITL Powershift Controllers in the 18 Way housing To diagnose faults on machine electrical systems fitted with the 18 Way ECUs a dedicated Handheld Test Unit MkII is available Part No 892 00943 This Test Unit is supplied with its own handbook Publication No 9801 0166 which includes operating instructions
37. the parkbrake is operated regardless of any other requested condition If the operator tries to select forward or reverse direction whilst the parkbrake is still applied then the E C U will sound a continuous tone on the warning buzzer whilst still holding the transmission in neutral This feature improves parkbrake life as in lower gears the transmission can easily drive with the parkbrake engaged a continued THIS BULLETIN IS ISSUED FOR THE PURPOSE OF CIRCULATING TECHNICAL INFORMATION AND DOES NOT CONSTITUTE AN INSTRUCTION TO CARRY OUT WARRANTY REPAIRS ON MACHINES ISSUED BY THE TECHNICAL SERVICE DEPARTMENT OF I T L WREXHAM CLWYD LL13 9UF UNITED KINGDOM Page 2 of 4 ELOO7 Issue 1 3 An optional input for a Four Wheel Drive 4WD command signal is provided so that the operator may manually select 4WD Note that 4WD will automatically disengage in 3rd and 4th gears to prevent drive line wind up Further control of the 4WD facility can be had by connecting the Footbrake input to the tail light brake switch Thus 4WD will be engaged whenever the operator uses the foot operated brakes This feature operates in all gears providing Four Wheel Braking 4WB The warning buzzer and red warning light on the instrument panel will be activated if a gear selection is made which is not allowed by the E C U software see System logic This comprises a double bleep which will continue either until the selection conditions are met or the r
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