Ransomes G - PLEX WD series, Service Course Manual

Page 1: ...incorrectly used this machine can cause severe injury Those who use and maintain this machine should be trained in its proper use warned of its dangers and should read the entire manual before attemp...

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Page 3: ...heel Groundpressure 1 0 kg cm Brakes S ervice Positive hydostatic braking Parking 152 mm Caliper Disk Capacities Cooling S ystem 3 8 litres FuelTank 31 litres Hydraulic Tank 18 2 litres Total S ystem...

Page 4: ...ing device was rotating with the machine stationary S tandard IS O 5349 1986 Mechanical vibration Guidelines for the meas urement and the as s es s ment of human expos ure to hand trans mitted vibrati...

Page 5: ...when the engine oil pressure is too low for operation Ignition Switch has four positions OFF prevents all electrical functions from operating Switch must be in the OFF position to remove the key ON fo...

Page 6: ...With key switch ON push up forward and hold the pre heat switch until the glow plug light goes out Temperature Gauge and Warning Light gauge indicates coolant temperature and light warnsofoverheatsitu...

Page 7: ...en the reel and the frame resulting in serious injury Use a ratchet with a 9 16 socket on the end of the cutting head shaft to rotate the reel during adjustment and testing See Fig 15 1 Cutting Head S...

Page 8: ...block by turning the wingnut until the distance between the bottom of the screw head and the top of the gauge block equals the desired height of cut See Fig 18 2 Loosen the locking nut on one of the f...

Page 9: ...sparks that can ignite explosivematerials ALWAYS use good judgement when operating on or near hills or slopes NEVER start or stop suddenly you may cause unstable operatingconditions NEVER change direc...

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Page 11: ...engine does not start after operating the starter for 10 seconds stop the starter Wait for 30 seconds and repeat the start sequence Do not use ether or starter fluid severe engine damage may occur 7 A...

Page 12: ...ition Figure23 Rear Section of Unit Raised DAILYSERVICEGUIDE ENGINEOILLEVEL Damage to engines due to improper maintenance or use of incorrect oil quality and or viscosity is not covered by the engine...

Page 13: ...INSTALLINGELEMENT 1 Clean the dust from inside the filter housing with a damp cloth Make sure that dust does not enter the engine air intake 2 Check the soft gasket material at both ends of the eleme...

Page 14: ...w plugs turn the ignition switch to START to operate the fuel pump Allow the starter to run the pump until a steady stream of fuel is coming out of the fuel filter air vent Stop the starter and close...

Page 15: ...4 SECTION 4 DRIVE TRAIN THIS SECTION INTENTIONALLY LEFT BLANK...

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Page 17: ...nit is stoped push the parking brake latch foward to hold the brake pedal Disengage the parking brake by depressing and releasing the brake pedal It is important to note on the ZX series machines and...

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Page 19: ...6 SECTION 6 STEERING THIS SECTION INTENTIONALLY LEFT BLANK...

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Page 21: ...with a low pressure tire gauge before connecting an air hose to a partly inflated tire CAUTION Duetothelowairvolumerequirementsofasmalltyre overinflationmaybereachedin a matter of a few seconds which...

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Page 23: ...Steering To One side 8B 8 Front Units Raises 8B 9 Centre Units Raise 8B 10 Front Units Lower 8B 11 8C Cutting Circuit 8C 13 Specifications 8C 13 Circuit Description 8C 13 Reels Engaged Forward 8C 14 B...

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Page 25: ...Pressure Gauge test kit 1 x 0 6000psi gauge 1 x 0 600psi gauge 2 x rubber covers for gauges and 1 x micro bore connector hose A810954 0 600psi pressure gauge A810955 0 6000psi pressure gauge A810939 M...

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Page 27: ...extend and raise the units The flow combiner divider ensures that the front rams lift at equal speed by controlling the rate that oil is displaced from the rams The oil also goes to the centre ram but...

Page 28: ...y li nder driv e m otors 2100 Rpm Oi l Cooler RH Div ider c om biner v alv e Lift v alv e Li ft ram right Li ft ram left Li ft ram c entre Sequenc e v alv e Cy li nder driv e v alv e Relief v alv e 21...

Page 29: ...m 081 LH C harge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre S equence valve Cylinder drive valve...

Page 30: ...081 LH Charge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre S equence valve Cylinder drive valve Re...

Page 31: ...081 LH Charge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Sequence valve Cylinder drive valve Reli...

Page 32: ...Charge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Sequence valve Cylinder drive valve Relief valv...

Page 33: ...LH Charge pump 18 3 Lpm 050 050 Cy linder drive motors 2100 Rpm Oil Cooler RH Divider combiner v alve Lift valv e Lift ram right Lift ram left Lift ram centre Sequence valve Cy linder driv e valve Re...

Page 34: ...1 LH Charge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Sequence valve Cylinder drive valve Relief...

Page 35: ...as been selected the oil goes to the front right hand unit the front left hand unit and then to the centre unit before returning to the back lap valve the cooler and the reservoir Within the Reel driv...

Page 36: ...050 Cy linder driv e motors 2100 Rpm Oil Cooler RH Div ider c ombiner v alv e Lift valv e Lift ram right Lift ram left Lift ram c entre Sequenc e v alv e Cy linder driv e valv e Relief v alv e 210 Bar...

Page 37: ...18 3 Lpm 050 050 C y linder driv e motors 2100 R pm Oil C ooler R H D iv ider c ombiner v alv e Lift v alv e Lift ram right Lift ram left Lift ram c entre Sequenc e v alv e C y linder driv e v alv e...

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Page 39: ...e The transmission system is not protected by any form of shock or relief valve This is considered unnecessary as overloading the system will result in spinning the slick tyres Oil from the pump goes...

Page 40: ...3 Lpm 050 050 C y linder driv e motors 2100 R pm Oil C ooler R H D iv ider c ombiner v alv e Lift v alv e Lift ram right Lift ram left Lift ram c entre Sequenc e v alv e C y linder driv e v alv e R e...

Page 41: ...81 LH Charge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre S equence valve Cylinder drive valve Reli...

Page 42: ...v alv e LH Charge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Sequence valve Cylinder drive valve...

Page 43: ...LH Charge pump 18 3 Lpm 050 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre S equence valve Cylinder drive valve Relief...

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Page 45: ...8 SECTION 8 HYDRAULICS FOR ZV SERIES Master Hydraulic Schematic Diagrams ZV Series machines fitted with pressure switch and variable needle valve...

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Page 47: ...8 SECTION 8 HYDRAULICS FOR DP SERIES Hydraulic Schematic Diagrams DP Series machines fitted with Bi directional relief valve no pressure switch as used with the new timed lift lower pic module...

Page 48: ...oil shuttle 4 Lpm Tank Transmission Pump 48 45 Lpm 081 LH Charge pump 18 3 Lpm 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram...

Page 49: ...050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Cylinder drive valve Relief valve 210 Bar 3000 psi T P M G T P A B T P...

Page 50: ...050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Cylinder drive valve Relief valve 210 Bar 3000 psi T P M G T P A B T P...

Page 51: ...Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Cylinder drive valve Relief valve 210 Bar 3000 psi T P M G T P A B T P PB R...

Page 52: ...Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Cylinder drive valve Relief valve 210 Bar 3000 psi T P M G T P A B T P PB R...

Page 53: ...drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Cylinder drive valve Relief valve 210 Bar 3000 psi T P M G T P A B T P PB R L Filter...

Page 54: ...050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Cylinder drive valve Relief valve 210 Bar 3000 psi T P M G T P A B T P...

Page 55: ...8 3 Lpm 050 Cylinder drive motors 2100 Rpm Oil Cooler RH Divider combiner valve Lift valve Lift ram right Lift ram left Lift ram centre Cylinder drive valve Relief valve 210 Bar 3000 psi T P M G T P A...

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Page 57: ...8 SECTION 8 HYDRAULICS FN FJ SERIES Hydraulic Schematic Diagrams FN FJ Series machines fitted with new cutting and lift circuit Plus 1 Controller...

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Page 59: ...arge Relief Valve 10 15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder 2 mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Hydraulic Circuit M...

Page 60: ...ve 10 15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder 2 mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A...

Page 61: ...ve 10 15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder 2 mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A...

Page 62: ...ve 10 15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder 2 mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A...

Page 63: ...ve 10 15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder 2 mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A...

Page 64: ...mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A P Backlap Valve Relief Valve 100 bar 1400 psi Transport 300 rpm Mowing 110 140 rpm Reverse 140 170 rpm a...

Page 65: ...ve 10 15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder 2 mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A...

Page 66: ...gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A P Backlap Valve Relief Valve 100 bar 1400 psi Transport 300 rpm Mowing 110 140 rpm Reverse 140 170 rpm actual measurements Transmission Pu...

Page 67: ...ve 10 15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder 2 mm 0 08 Hot Oil Shuttle 4 l min 1 gal min US RH LH TRW Me10 Soft Drop Valve Lift Valve T P B A...

Page 68: ...15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder Flushing Valve l min gal min US RH LH TRW Me10 3WD Circuit Forward Soft Drop Valve Lift Valve T P B A...

Page 69: ...15 bar 150 210 psi Implement Relief Valve 55 bar 800 psi Steering Valve R L T P Steering Cylinder Flushing Valve l min gal min US RH LH TRW Me10 3WD Circuit Reverse Soft Drop Valve Lift Valve T P B A...

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Page 71: ...Heat Switch Pressed After 5 Seconds 10C 8 Start Engine Crank 10C 9 Engine Running 10C 10 Sit In seat Drive Machine To Green 10C 11 Engage Reel Enable Switch 10C 12 Depress LowerEngage Reel Enable Swi...

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Page 73: ...A REPAIR SERVICE TOOLS AND MATERIALS 10A 3 Tools required Digital Multimeter Jumper wires 60 amp Ammeter Battery Tester Cleaning Materials Baking soda and water Water repellent WD40 Other service item...

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Page 75: ...Al te rn a to r Am m e te r L o we r s o l Ra i s e s o l O G G G D7 D5 D6 Se q u e n c e s o l W BL Se q u e n c e re l a y Y B W G D3 Y Y Re e l s o l B Fu e l p u m p W Y Sta rte r re l a y W W BR...

Page 76: ...l te rn ato r Am m ete r L o we r s o l Ra is e s o l O G G G D7 D5 D6 Se q u en c e s o l W BL Se q ue n c e re la y Y B W G D3 Y Y Re e l s o l B Fue l p u m p W Y Sta rte r re l ay W W BR W G B Re...

Page 77: ...Y Y W R W R B O B B B R Alterna to r Am m e te r L owe r s o l Rai s e s o l O G G G D7 D5 D6 Sequ en c e s o l W BL Se qu en c e rel ay Y B W G D3 Y Y Ree l s o l B Fuel pum p W Y Sta rte r rela y W...

Page 78: ...Al te rn a to r Am m e te r L o we r s o l Ra i s e s o l O G G G D7 D5 D6 Se q u e n c e s o l W BL Se q u e n c e re l a y Y B W G D3 Y Y Re e l s o l B Fu e l p u m p W Y Sta rte r re l a y W W BR...

Page 79: ...i t G W R G R Y Y W R W R B O B B B R Alternator Am m eter Lower s ol Rais e s ol O G G G D7 D5 D6 Sequenc e s ol W BL Sequenc e rel ay Y B W G D3 Y Y Reel s ol B Fuel pum p W Y Starter relay W W BR W...

Page 80: ...Ra i s e s o l O G G G D7 D5 D6 Se q u e n c e s o l W BL Se q u e n c e re l a y Y B W G D3 Y Y Re e l s o l B Fu e l p u m p W Y Sta rte r re l a y W W BR W G B Re e l e n a b l e s wi tc h 2 0 a m...

Page 81: ...R G R Y Y W R W R B O B B B R A lternator A mmeter Low er sol R aise sol O G G G D 7 D 5 D 6 S equence sol W B L S equence relay Y B W G D 3 Y Y R eel sol B Fuel pump W Y S tarter relay W W B R W G B...

Page 82: ...B B R A l t ernat or A mmet er Low er sol R ai s e sol O G G G D 7 D 5 D 6 S equence sol W B L S equence rel a y Y B W G D 3 Y Y R eel sol B F uel pump W Y S t art er rel a y W W B R W G B R eel enabl...

Page 83: ...o we r s o l Ra i s e s o l O G G G D7 D5 D6 Se q u e n c e s o l W BL Se q u e n c e re l a y Y B W G D3 Y Y Re e l s o l B Fu e l p um p W Y Sta rte r re l a y W W BR W G B Re e l e n a b l e s wi...

Page 84: ...R Y Y W R W R B O B B B R Alternator Ammeter Lower sol Raise sol O G G G D7 D5 D6 Sequence sol W BL Sequence relay Y B W G D3 Y Y Reel sol B Fuel pump W Y Starter relay W W BR W G B Reel enable switc...

Page 85: ...B O B B B R A l t ernat or A mmet er Low er sol R ai s e sol O G G G D 7 D 5 D 6 S equence sol W B L S equence rel a y Y B W G D 3 Y Y R eel sol B Fuel pump W Y S t art er rel a y W W B R W G B R eel...

Page 86: ...R W R B O B B B R A l t ernat or A mmet er Low er sol R ai s e sol O G G G D 7 D 5 D 6 S equence sol W B L S equence rel a y Y B W G D 3 Y Y R eel sol B Fuel pump W Y S t art er rel a y W W B R W G B...

Page 87: ...te r L o we r s o l Ra i s e s o l O G G G D7 D5 D6 Se q u e n c e s o l W BL Se q u e n c e rel ay Y B W G D3 Y Y Re e l s o l B Fu e l p u m p W Y Sta rte r rel ay W W BR W G B Re e l e n a b l e s...

Page 88: ...R Y Y W R W R B O B B B R A lternator A mmeter Low er sol R aise sol O G G G D 7 D 5 D 6 S equence sol W B L S equence relay Y B W G D 3 Y Y R eel sol B Fuel pump W Y S tarter relay W W B R W G B R ee...

Page 89: ...down l im i t G W R G R Y Y W R W R B O B B B R Alternator Am m eter Lower s ol Rais e s ol O G G G D7 D5 D6 Sequenc e s ol W BL Sequenc e relay Y B W G D3 Y Y Reel s ol B Fuel pum p W Y Starter rela...

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Page 91: ...ff Poistion Pre Heat Switch Start Engine Crank Engine Running Engine Running PTO on Reels lowering Engine running PTO on rear unit lowering Engine running all units lowered Engine running PTO on raise...

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Page 101: ...Off Poistion Pre Heat Switch Start Engine Crank Engine Running brake applied PTO off Engine Running sit in seat release brake in drive Engine running PTO on lower units using foot switch Activate pres...

Page 102: ...ter temp lamp Overheat buzzer Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Seat Rais e Relay Lower Relay S IG O O R Y R R R Fuel pump W Y Brak...

Page 103: ...ater temp lamp Overheat buz zer Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Seat R ais e R elay Low er R elay S IG O O R Y R R R Fuel pump W...

Page 104: ...lamp Ov erheat buz z er Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U W P W P W P W P W P G 20 amp 3WD Seat R ais e R elay Low er R elay S IG O O R Y R R R Fuel pump W Y B...

Page 105: ...lamp Overheat buzz er Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Rais e Relay Lower Relay S IG O O R Y R R R Fuel pump W Y WR WR 1 2 4 5 20...

Page 106: ...erheat buz z er Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U W P W P W P W P W P G 20 amp 3WD Seat R ais e R elay Low er R elay S IG O O R Y R R R Fuel pump W Y Brak e WR...

Page 107: ...er Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Seat R ais e R elay Low er R elay S IG O O R Y R R R Fuel pump W Y Brak e WR WR 1 2 4 5 20 amp...

Page 108: ...zer Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Seat R ais e R elay Low er R elay S IG O O R Y R R R Fuel pump W Y Brak e WR WR 1 2 4 5 20 a...

Page 109: ...temp lamp Overheat buz zer Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Seat Rais e Relay Lower Relay S IG O O R Y R R R Fuel pump W Y Brak e...

Page 110: ...uzzer Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U W P W P WP W P W P G 20 amp 3WD Seat R ais e R elay Low er R elay S IG O O R Y R R R Fuel pump W Y Brake WR WR 1 2 4 5...

Page 111: ...buz zer Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Seat Rais e Relay Lower Relay S IG O O R Y R R R Fuel pump W Y Brak e WR WR 1 2 4 5 20 a...

Page 112: ...nder Water temp lamp Overheat buzzer Earth W B W R W R W R Y W G B B B B B W O W U W R B 30 amp N N N N N U U U WP WP WP WP WP G 20 amp 3WD Seat Rais e Relay Lower Relay S IG O O R Y R R R Fuel pump W...

Page 113: ...ELECTRICAL SYSTEM DP Series with Paddle Control Schematic diagrams Hot Ignition Start Engine Engine Running Brake Applied Drive to Green PTO Switch ON Lower Units Paddle onto Green PTO ON Raise Units...

Page 114: ...G Y O G PREHEAT W P B PREHEAT SHUT DOWN TIMER RELAY W G STARTER RELAY B W N G W R U B GND VE B W R SW LIGHT HEADLIGHT W U N 30A 20A N O P TRIG W Y W G W Y W SWITCH W Y W Y 2 U 1 3 5 HEADLIGHT SWITCH C...

Page 115: ...W B G G 3 W D SOL W R FUEL PUMP W Y R A R W R W G Y M O PARKING BRAKE NEUTRAL SW W R SWITCH BACKLAP C NO REEL SOL Y SEAT SW R A C NO W LOWER SOL O B N N N N N W O W P W W G W U W R W R W P W R G R Y R...

Page 116: ...O G PREHEAT W P B PREHEAT SHUT DOWN TIMER RELAY W G STARTER RELAY B W N G W R U B GND VE B W R SW LIGHT HEADLIGHT W U N 30A 20A N O P TRIG W Y W G W Y W SWITCH W Y W Y 2 U 1 3 5 HEADLIGHT SWITCH C U...

Page 117: ...B G G 3 W D SOL W R FUEL PUMP W Y R A R W R W G Y M O PARKING BRAKE NEUTRAL SW W R SWITCH BACKLAP C NO REEL SOL Y SEAT SW R A C NO W LOWER SOL O B N N N N N W O W P W W G W U W R W R W P W R G R Y RAI...

Page 118: ...G PREHEAT W P B PREHEAT SHUT DOWN TIMER RELAY W G STARTER RELAY B W N G W R U B GND VE B W R SW LIGHT HEADLIGHT W U N 30A 20A N O P TRIG W Y W G W Y W SWITCH W Y W Y 2 U 1 3 5 HEADLIGHT SWITCH C U 1...

Page 119: ...G G 3 W D SOL W R FUEL PUMP W Y R A R W R W G Y M O PARKING BRAKE NEUTRAL SW W R SWITCH BACKLAP C NO REEL SOL Y SEAT SW R A C NO W LOWER SOL O B N N N N N W O W P W W G W U W R W R W P W R G R Y RAISE...

Page 120: ...AT W P B PREHEAT SHUT DOWN TIMER RELAY W G STARTER RELAY B W N G W R U B GND B W R SW LIGHT HEADLIGHT W U N 30A 20A N O P W Y W G W Y W SWITCH W Y W Y 2 U 1 3 5 HEADLIGHT SWITCH C U 1 NO W P PREHEAT W...

Page 121: ...D SOL W R FUEL PUMP W Y R A R W R W G Y M O PARKING BRAKE NEUTRAL SW W R SWITCH BACKLAP C NO REEL SOL Y SEAT SW R A C NO W LOWER SOL O B N N N N N W O W P W W G W U W R W R W P W R G R Y RAISE SOL HEA...

Page 122: ...AT W P B PREHEAT SHUT DOWN TIMER RELAY W G STARTER RELAY B W N G W R U B GND B W R SW LIGHT HEADLIGHT W U N 30A 20A N O P W Y W G W Y W SWITCH W Y W Y 2 U 1 3 5 HEADLIGHT SWITCH C U 1 NO W P PREHEAT W...

Page 123: ...D SOL W R FUEL PUMP W Y R A R W R W G Y M O PARKING BRAKE NEUTRAL SW W R SWITCH BACKLAP C NO REEL SOL Y SEAT SW R A C NO W LOWER SOL O B N N N N N W O W P W W G W U W R W R W P W R G R Y RAISE SOL HEA...

Page 124: ...P B PREHEAT SHUT DOWN TIMER RELAY W G STARTER RELAY B W N G W R U B GND B W R SW LIGHT HEADLIGHT W U N 30A 20A N O P W Y W G W Y W SWITCH W Y W Y 2 U 1 3 5 HEADLIGHT SWITCH C U 1 NO W P PREHEAT W Y L...

Page 125: ...FUEL PUMP W Y R A R W R W G Y M O PARKING BRAKE NEUTRAL SW W R SWITCH BACKLAP C NO REEL SOL Y SEAT SW R A C NO W LOWER SOL O B N N N N N W O W P W W G W U W R W R W P W R G R Y RAISE SOL HEADLIGHT W...

Page 126: ...EHEAT W P B PREHEAT SHUT DOWN TIMER RELAY W G STARTER RELAY B W N G W R U B GND B W R SW LIGHT HEADLIGHT W U N 30A 20A N O P W Y W G W Y W SWITCH W Y W Y 2 U 1 3 5 HEADLIGHT SWITCH C U 1 NO W P PREHEA...

Page 127: ...G W R FUEL PUMP W Y R A R W R W G Y M O PARKING BRAKE NEUTRAL SW W R SWITCH BACKLAP C NO REEL SOL Y SEAT SW R A C NO W LOWER SOL O B N N N N N W O W P W W G W U W R W R W P W R G R Y RAISE SOL HEADLI...

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Page 129: ...SECTION 10 ELECTRICAL SYSTEM FH Series Diesel Engine Schematic diagrams...

Page 130: ...1 0 G N 1 2 0 5 0 5 Red Blue TWISTED PAIR PROGRAM PORT 37 3 LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0...

Page 131: ...R B SP 5 SP 9 WORK LAMP 33 1 2 1 0 1 0 U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4...

Page 132: ...0 G N 1 2 0 5 0 5 Red Blue TWISTED PAIR PROGRAM PORT 37 3 LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 1...

Page 133: ...SP 5 SP 9 WORK LAMP 33 1 2 1 0 1 0 U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G...

Page 134: ...ue TWISTED PAIR PROGRAM PORT 37 3 LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10...

Page 135: ...2 1 0 1 0 U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8...

Page 136: ...TWISTED PAIR PROGRAM PORT 37 3 LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A...

Page 137: ...1 0 1 0 U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP...

Page 138: ...PAIR PROGRAM PORT 37 3 LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0...

Page 139: ...U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4...

Page 140: ...PAIR PROGRAM PORT 37 3 LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0...

Page 141: ...U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4...

Page 142: ...D PAIR PROGRAM PORT 37 3 LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2...

Page 143: ...U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT...

Page 144: ...3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G SP 7 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START AC I P RUN ST W N W W R KEY SWITCH 5 1 1 0 2...

Page 145: ...4 5 5 4 5 2 3 0 6 2 0 15 1 0 6 1 0 17 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 17 1 0 16 2 0 18 1 0 9 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4 5 5 1 0 6 2 0 6 2 0 6 2...

Page 146: ......

Page 147: ...SECTION 10 ELECTRICAL SYSTEM FJ Series Petrol Engine Schematic diagrams...

Page 148: ...LG CAN ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START...

Page 149: ...1 0 U R B SP 5 SP 9 WORK LAMP 33 1 2 1 0 1 0 U R B SP 5 SP 9 SP 1 BRN 4 5 5 4 5 2 2 0 15 1 0 6 2 0 4 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 16 2 0 18 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2...

Page 150: ...N ADAPTOR SERVICE TOOL 4143951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START AC I...

Page 151: ...15 1 0 6 2 0 4 SP 2 BLK 1 0 8 1 0 15 2 0 1 1 0 16 2 0 18 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4 5 5 1 0 6 2 0 6 2 0 6 2 0 6 2 0 6 SP 5 U R 2 0 14 1 0 32 1 0...

Page 152: ...43951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START AC I P RUN ST W N W W R KEY S...

Page 153: ...0 16 2 0 18 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4 5 5 1 0 6 2 0 6 2 0 6 2 0 6 2 0 6 SP 5 U R 2 0 14 1 0 32 1 0 33 SP 6 YEL 1 0 13 1 0 21 1 0 19 1 0 22 1 0...

Page 154: ...43951 40 SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START AC I P RUN ST W N W W R KEY S...

Page 155: ...0 16 2 0 18 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4 5 5 1 0 6 2 0 6 2 0 6 2 0 6 2 0 6 SP 5 U R 2 0 14 1 0 32 1 0 33 SP 6 YEL 1 0 13 1 0 21 1 0 19 1 0 22 1 0...

Page 156: ...SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START AC I P RUN ST W N W W R KEY SWITCH 5 1...

Page 157: ...18 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4 5 5 1 0 6 2 0 6 2 0 6 2 0 6 2 0 6 SP 5 U R 2 0 14 1 0 32 1 0 33 SP 6 YEL 1 0 13 1 0 21 1 0 19 1 0 22 1 0 8 1 0 20...

Page 158: ...P 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START AC I P RUN ST W N W W R KEY SWITCH 5 1...

Page 159: ...18 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4 5 5 1 0 6 2 0 6 2 0 6 2 0 6 2 0 6 SP 5 U R 2 0 14 1 0 32 1 0 33 SP 6 YEL 1 0 13 1 0 21 1 0 19 1 0 22 1 0 8 1 0 20...

Page 160: ...SP 11 N SP 3 2A 7 1 1 0 W 1 0 G O 10A 8 2 2 0 W 1 0 G 10A 10 4 1 0 W 2 0 G N 30A 9 3 2 0 W 2 0 U 15A 12 6 2 0 W 2 0 G B 10A 11 5 2 0 FUSE BOX 6 ACC OFF RUN START AC I P RUN ST W N W W R KEY SWITCH 5 1...

Page 161: ...0 18 1 0 10 1 0 13 1 0 11 1 0 14 1 0 12 GND SP 4 G N 1 0 7 2 0 6 1 0 7 1 0 8 SP 3 WHT 4 5 5 1 0 6 2 0 6 2 0 6 2 0 6 2 0 6 SP 5 U R 2 0 14 1 0 32 1 0 33 SP 6 YEL 1 0 13 1 0 21 1 0 19 1 0 22 1 0 8 1 0 2...

Page 162: ......

Page 163: ...11 SECTION 11 PREVENTATIVE MAINTENANCE...

Page 164: ......

Page 165: ...15 15 1 SECTION 15 NOTES...

Page 166: ...NOTES 15 2...

Page 167: ...15 NOTES 15 3...

Page 168: ...NOTES 15 4...

Page 169: ...15 NOTES 15 5...

Page 170: ...NOTES 15 6...

Page 171: ...15 NOTES 15 7...

Page 172: ...NOTES 15 8...

Page 173: ...15 NOTES 15 9...

Page 174: ...NOTES 15 10...

Page 175: ...15 NOTES 15 11...

Page 176: ...NOTES 15 12...

Page 177: ...15 NOTES 15 13...

Page 178: ...NOTES 15 14...

Page 179: ...15 NOTES 15 15...

Page 180: ...NOTES 15 16...

Page 181: ...Revision Date Author Description of Change Material Up date Sheet...