How to disassemble the Cummins M11 series engine generator drive pulley and drive unit oil seal

① Remove the locating bolts on the pulley, see Figure 2-33. 

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② Use an ST-647 puller and two (5/16-18x2 1/2) bolts to remove the alternator drive pulley, see Figure 2-34. 

 ③ Remove the 5 bolts, pressure ring, oil seal, and gasket, see Figure 2-35.

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 Figure 2-32 Removing the oil filter housing and gasket

 

 

 Figure 2-33 Removing the locating bolts on the alternator pulley

 

  Figure 2-34 Removing the drive pulley with a puller and two bolts

 

 

     Figure 2-35 Removing the bolts, pressure ring, oil seal, and gasket.

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How to check the engine oil in a JCB bucket loader

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1 Make sure the park brake is engaged and the
transmission set to neutral. Lower the loader arms and
backhoe to the ground, switch OFF the engine and
remove the starter key.

2  Open the bonnet, see Engine Panels, Opening and
Closing the Bonnet.

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3 Check that the oil level is between the two marks on
the dipstick A.

4  If necessary, remove the side panel and add oil through
filler B. Make sure that the dipstick and filler cap are
fully inserted and tightened.

How to handle the problem of elevated oil temperature in the loader's transmission oil pan?

 What are the possible causes of elevated oil temperature in the loader's transmission oil pan due to a large amount of aluminum shavings or metal shavings?

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(1) A large amount of aluminum shavings in the oil pan indicates mutual wear between the torque converter's working wheels, resulting in reduced transmission efficiency and overheating of the working oil. 

 (2) A large amount of copper shavings in the oil pan indicates friction or slippage between the driving and driven friction plates. The transmission oil level and shift pressure should be checked. If normal, the problem is likely due to improper assembly or deformation of the driving and driven friction plates.

 

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 (3) Iron shavings in the oil pan indicate slippage of the overrunning clutch. When the loader transitions from high speed with light load to low speed with heavy load, there is a metallic friction sound in the transmission, and the machine lacks power.

 (4) Bearing fragments in the oil pan generally indicate bearing damage in the dual-transmission assembly. The situation should be assessed, and the damaged parts should be disassembled, inspected, and replaced. If the above phenomena are found, a judgment should be made based on the specific situation. The torque converter or gearbox should be disassembled and the damaged parts replaced. Do not continue to use it.

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How to prevent excavator from "pulling out the cylinder"

 What is the "unplugging" phenomenon? What's the harm? How to prevent it?

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 (1) Cylinder pullout: When the bucket is in the downturn limit position, the extended part of the piston rod of the bucket cylinder is the shortest.

When the boom reaches a certain height, the limit surface of the boom contacts the limit surface of the bucket. If the boom continues to be raised, the bucket will 

The bucket cannot flip downwards as the boom is raised, but at this time the relative positions of the support points on both sides of the bucket cylinder are different. 

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To change as the boom continues to lift, this forces the piston rod of the bucket cylinder to extend outward. Because the boom lift During the lifting process, the front and rear chambers of the bucket cylinder are in a closed state, and the extension of the piston rod will inevitably cause a rapid increase in the pressure in the front chamber.

The phenomenon of this kind of bucket lifting the boom when the bucket is fully unloaded causes the piston rod of the bucket to extend outward is called "pull-out".

   "tank" phenomenon. (2) Hazards: bending deformation of the bucket tie rod; damage to the spherical bearing of the bucket cylinder: bucket oil

 

The locking nut of the cylinder piston is loose. (3) Preventive measures: After unloading, retract the bucket first and then raise the boom.

JCB Loader Valve - A.R.V. Operation.

                   

                             This article introduces JCB Loader Valve - A.R.V. Operation.

 

                  Component Key:
1A
Pump Inlet
3C
Lift Ram Spool
3D
Shovel Ram Spool
3F
ARV -Head Side
3G
ARV- Rod Side
31
Shovel Ram
32
Shovel Ram

 

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 Under normal operating conditions, with the shovel in the
'carry' position, the mechanical linkage keeps the shovel
level as the arms are raised, to prevent spillage of the load.

 If, as illustrated, the shovel is fully tipped when the arms are
being raised, the shovel is unable to tip further, producing
back pressure in the head side of the shovel rams 31 and
32 and cavitation in the rod side.

As the arms continue to rise, the back pressure increases
until it reaches the setting of A.R.V. 3F.This A.R.V.then
opens, allowing the excess back pressure to be dumped to
exhaust and prevent the rams and linkage from being
damaged.

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 The rod side A.R.V.3G senses a higher pressure in the
exhaust gallery than in the service port and therefore opens
to allow exhaust oil to overcome the cavitation.

 

 

 

How to operate a hydraulic pump - variable flow JCB Backhoe Loader

 

  The pump is a variable displacement axial piston type.
Displacement of oil is achieved by the continuous operation
of nine pistons.Pump fluid output is controlled by a tilting
cam (swashplate), the angle of which is regulated to ensure
that only the amount of fluid necessary to satisfy load
conditions is delivered. If a load condition is such that no
flow is required, only sufficient fluid for cooling and
lubrication is provided.

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Main components of pump P are a cylinder barrel 1 splined
to a drive shaft 2 which is held against a kidney plate 3.
Contained in the cylinder barrel are the axial pistons 4, each
having an articulated shoe that is in held contact with the
swashplate 5 by an attachment plate 6. The tilting action of
the swashplate is exercised by a stroking piston 7 and a
control piston 8, the latter fed by servo pressure. Fitted to
the pump exterior is the valve block 9 housing the
pressure/flow regulators that provide servo control 

 Rotation of the cylinder barrel causes linear movement of the
axial pistons and fluid from the suction port is drawn into the
pump through the kidney plate to fill a developing vacuum
behind the piston. As the cylinder barrel rotates the fluid is
carried from an elongated suction kidney to an elongated
pressure kidney where linear movement starts to return the
piston into the cylinder barrel. Fluid is forced from the pump
through the pressure port.

 The stroke length of the pistons and consequently the output
of fluid is directly related to the swashplate angle.The
swashplate is normally held in its maximum displacement
angle by the stroking piston spring and system pressure
inside the stroking piston.

 

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How to diagnose and troubleshoot the Caterpillar 311B Excavator 2LS MID 161 - CID 0168 - FMI 00 fault message?

 This code is generated when the diagnostic circuitry within PL522 and 523 detects a system voltage higher than 32 VDC. Possible causes of this fault include: 

 

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 • A faulty charging system component. 

 • A faulty wiring harness conductor. 

• A faulty PL522 or 523. A module fault is unlikely.

Note: Determine if a battery charger or welding machine is being used on the machine. Disconnect the charger or welding machine from the machine. Recheck for diagnostic codes. 

 Test Procedure 1. Check the system voltage at the 70-pin connector of PL522 or 523.

A. Start the engine and run it at high idle for 5 to 10 minutes. 

 B. Measure the system voltage between the "No Switching Power" and "Ground" contacts. Pin 52 is the "No Switching Power" terminal, and pin 65 is the "Ground" terminal. 

 

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Expected Result: Voltage is 11 VDC to 32 VDC. 

Result: • Normal - Voltage is 11 VDC to 32 VDC. PL522 or 523 should not record this diagnostic code. 

Repair: Clear the diagnostic code from PL522 or 523 using a Caterpillar Electronics Technician (Cat ET). If the voltage is normal and PL522 or 523 records this diagnostic code again, replace PL522 or 523. Before replacing PL522 or 523, please contact your Caterpillar technical communicator.

  Stop • Abnormal - Voltage is not 11 VDC to 32 VDC. Proceed to Test Step 2.

Test Step 2. Check the alternator. 

  A. Run the engine at high idle for 5 to 10 minutes. 

 B. Measure the voltage output at the battery terminals.

  Expected result: The voltage should be below 32 VDC.

 

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 Result: • Normal - Voltage below 32 VDC. The battery may be faulty. Proceed to test step 3.

  • Abnormal - Voltage above 32 VDC. Troubleshoot the alternator. The voltage regulator may be faulty. If no issues are resolved, proceed to test step 3. 

  Test Step 3. Check the battery voltage.

Turn the ignition switch to the off position. Measure the voltage at the battery terminals.  

Expected result: The voltage should be below 32 VDC.

Result: • Normal - Voltage below 32 VDC. Proceed to test step 4. 

    Result: • Yes - Other "CID 168 FMI 00" diagnostic codes can be found on other Electronic Control Modules (ECMs). Repair: Clear the fault if all of the following occur: 

Monitor the module and the machine for any further faults. If the fault recurs, the PL522 or 523 module is not faulty because other electronic control modules are displaying the same fault. Recheck the system voltage. 

Stop • No - No other "CID 168 FMI 00" diagnostic codes can be found on other ECMs. Repair: Clear the fault if all of the following occur: 

 ◦ No fault was found in the charging system. 

 ◦ No fault was found in the wiring.

  ◦ The fault has recurred several times.  

Monitor the module and machine for further faults. If the fault recurs, the PL522 or 523 module may be faulty. The PL522 or 523 should be replaced. Refer to System Operation, Troubleshooting & Repair, Testing & Adjustment, "Electronic Control Module (ECM) - Replacement". After replacing the PL522 or 523, recheck the system and check the status of the diagnostic codes.

  Stop

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