Hi all, First of all thank you for this forum, i have used this forum allot for info but now it is my first time to post a thread of my own, and hopefully help someone in return. I run a workshop on a farm and have to maintain equipment we use here on the farm, tractors, excavators, road grader and among other machines and implements. We have a JCB 540 and it quit moving forward or backwards. i have installed a new F-N-R lever on the steering column, new transmission spool valve solenoid harness and changed two solenoids. Can someone please help me ID the solenoids 1 to 7 in the picture (its a transmission i have in the scrap yard which is similar to the one i am working on) as i'm not getting 12V DC to the coils and only 1V DC on 2 coils depending the position of the forward reverse lever. (trans ser#455/1045/02/0376) so it must be a short in the harness somewhere, and i want power the coils directly to test from were the short lies in the harness. I have tried moving the relays around in the fuse panel but still no voltage, you can hear them click when you shift the forward and backward lever. Any help much appreciated.
If you have lost forward and reverse I would not think it was a solenoid as you have lost everthing may be check the dump switch circuit the one on the loader lift lever the electrical switch that allows you to change gear .there are a few fuses as well as relays you may also have a ecu under the seat as well .
Hi JCB Jeff I will test and check if can find anything there, i do know if you squeeze the trigger on the stick you hear one relay click, i also checked all fuses with multi meter just to make sure they are not defective in some way that you can not see with the eye. and no ECU under seat, will it be somewhere else on the machine? I was testing voltage on the solenoids today again,what i don't get is that there is not one plug with 12V DC out of seven plugs...strange!! like its a safety cutout of some sort.. Three wires on the shift lever has 12.5 v Dc when tested, black, red and a blue wire on the connector.
check wiring loom where it exits cab near the front right pillar of the cab at the front as there is a plug there. On the stalk in the cab you also have the horn button .check the connection plug that clips up to the steering column also in side of the stalk you have two micro switches that can play up try taking boot of end and look see and may be try and poke with a small screwdriver to see if they work .It is odd to loos every solenoid as you usually have at least two working at any time for each gear along the lines of forward sol and then either main or layshaft and then grouped as 1 &3 and 2 & 4 gear clutch packs sol .The ecu is under where you put your grease gun or it could be on the top of the gearbox but you would of seen that testing the solenoids. Also check hand brake switch as this could be your fault also as its all linked. Also check the fuses next to battery i think its a 40 amp fuse that controls forward and reverse and brake lights.
I will do more tests as you suggested and see if can find the fault. The stalk is a brand new one, so i can assume that it should work fine. But will test as you suggested.
The other possible thing is I believe the harness for the transmission has a plug on the chassis it is on the later ones not sure on this one but may have come apart the plug would be about level with the radiator on the inner chassis near gearbox more towards the front.
Okay after some testing and with the help from the diagrams i have found a mechanical fault also on the transmission, the spool valve on solenoid M is not opening and it controls the lay-shaft clutch and so no F1 and F2 gears and same for reverse. also cant remove the spool-valve as the caps screws are to rusted and they strip. will have to remove valve block, and will have to drill them out. I then directly activated solenoid L1 and M1 witch gave me R3 (i assume) and the machine moved, same for G2 and M1 (F3) then forward motion. but still no signal from the stalk. I check the fuses in battery box and they are fine no problems there, and also the connectors from the cab has no issues. i will concentrate on the relays/fuse box and try to figure out witch one powers each solenoid on the valve block, and maybe find what is causing the no power issue. Is the dump switch responsible for a neutral condition by removing power from the drive stalk? and how does this switch achieve this?
The dump switch will put the trans in N via the relays the wire used to rub on the linkage and short to earth putting it into N and also the hand brake switch if you have a S/No I possible be able to produce the relay positions for you .
Hi Jeff, the serial is SLP540CEA4E1066853. Much appreciated
Ok so after testing wire loom and relays and replaced the ground wire to solenoids it is running for now, only in 3 and 4 gear until i replace the spool valve for gears 1 and 2. Here are the wire numbers and solenoid for each gear.Wire #600 is common ground for all solenoids. solenoid N is used for 4X4 De-energized and 2wd energized. the park brake switch and dump switch removes the 12v dc signal for the F and R relays putting it in neutral. F1. #859 G2 - #857 M F2. #812 G1 - #857 M F3. #859 G2 - #858 M1 F4. #812 G1 - #858 M1 R1. #860 L1 - #857 M R2. #1811 L2 - #857 M R3. #860 L1 - #858 M1 R4. #1811 L2 - #858 M1 Thanks for the help and hope someone else having the same issue can get some info from this thread. This is all from testing on my machine and may not apply to others, but its a guideline never the less!
Heno No Problem hope it helped and that you now have it running. jeff