Benford TV1200 Wiring Diagram and Troubleshooting Guide

[MikePhua]

The Benford TV1200 is a versatile and heavy-duty site dumper commonly used in construction and other industrial settings for transporting materials across rough terrains. Its compact design and powerful engine make it a popular choice for navigating tight spaces and uneven ground. However, like any complex piece of machinery, the Benford TV1200 requires regular maintenance and troubleshooting, especially when it comes to its electrical and wiring systems.
Understanding the wiring diagram of the TV1200 is crucial for diagnosing electrical problems, repairing wiring faults, and maintaining the overall health of the machine. This guide will explore the TV1200's electrical systems, common issues faced by operators, and tips on using the wiring diagram for effective troubleshooting.
Overview of the Benford TV1200
The Benford TV1200 is designed for heavy lifting and transporting tasks on construction sites. It is known for its durability, compact size, and the ability to handle a wide range of loads. The TV1200 typically comes with the following features:

• Load Capacity: The TV1200 can carry up to 12,000 lbs (approximately 5,443 kg), making it suitable for large loads.
  
• Engine: It is powered by a robust diesel engine that provides ample power for tackling tough terrains.
  
• Drive System: The TV1200 is equipped with a hydrostatic drive, ensuring smooth and efficient operation in various conditions.
  
• Cab and Operator Controls: The controls are straightforward, offering essential features like forward/reverse motion, dumping functionality, and steering, all while being user-friendly.
  

Despite its rugged build, the electrical system of the Benford TV1200 can encounter issues over time, especially with prolonged use in harsh conditions. Therefore, having a clear understanding of the machine's wiring and how each electrical component connects is essential for effective troubleshooting.
The Importance of the Wiring Diagram
The wiring diagram of the Benford TV1200 is a critical tool for anyone who needs to work on the machine’s electrical systems. It visually represents the layout of the electrical circuits, showing how power is distributed from the battery to various components such as the starter, lights, ignition, and hydraulic systems.
A wiring diagram typically includes:

• Power Sources: Such as the battery and alternator, which provide electricity to the system.
  
• Control Circuits: Including switches, relays, and sensors that manage the machine's operations.
  
• Grounding System: Electrical grounding, which is crucial for safety and preventing electrical faults.
  
• Connectors and Terminals: Details of where wires connect to various components, helping to identify faulty connections or short circuits.
  

The wiring diagram acts as a guide to understanding how electrical signals and power flow through the machine, which is invaluable when diagnosing problems.
Common Electrical Issues with the TV1200
Several electrical issues may arise during the operation of the Benford TV1200. Understanding these issues and using the wiring diagram to trace the problem can save time and reduce unnecessary repairs.

1. Starting Problems
   • If the TV1200 fails to start, the issue may be related to the battery, ignition system, or starter motor.
     
   • Troubleshooting Tip: Use the wiring diagram to check the connections from the battery to the starter motor and ignition switch. If the wiring is intact, check the voltage output of the battery and alternator to ensure the system is charging properly.
     
2. Faulty Lighting System
   • If the headlights, tail lights, or other electrical lights aren’t functioning correctly, it may be due to a broken fuse, faulty wiring, or malfunctioning switch.
     
   • Troubleshooting Tip: Refer to the wiring diagram to locate the fuse and check if it is blown. If the fuse is intact, use the diagram to check the integrity of the wiring leading to the lights.
     
3. Hydraulic System Malfunctions
   • The TV1200’s hydraulic system is electrically controlled, and electrical failures can result in the inability to raise or lower the dumper.
     
   • Troubleshooting Tip: Check the wiring connections from the control switch to the hydraulic pump. Ensure that all connections are secure and that the electrical components (like solenoids and relays) are working correctly.
     
4. Electrical Shorts or Grounding Issues
   • A common issue that can cause erratic behavior or failure in various components is an electrical short or grounding problem. These issues can lead to random shut-offs or inconsistent operation.
     
   • Troubleshooting Tip: Using the wiring diagram, trace the grounding system to ensure that all components are properly grounded. Inspect for any exposed wires or frayed connections that may be causing shorts.
     
5. Sensor or Control Switch Failures
   • The TV1200 uses several sensors and control switches to monitor various functions like engine speed, load weight, and hydraulic pressure.
     
   • Troubleshooting Tip: If the machine exhibits strange behaviors such as inconsistent load handling or engine stalling, check the wiring and connectors associated with these sensors. The wiring diagram will help you pinpoint the exact location of these components for easier testing.
     

Using the Wiring Diagram for Effective Troubleshooting
When dealing with electrical issues, the first step is always to have a reliable wiring diagram. Here are a few tips for using the diagram effectively:

1. Locate the Problem Area: Identify the specific area where the issue is occurring. This could be in the starter circuit, the lighting system, or the hydraulic control system. The more specific you are, the easier it is to find the relevant section in the wiring diagram.
   
2. Check for Corroded or Loose Connections: One of the most common electrical issues in heavy machinery is corroded or loose connections. Use the wiring diagram to trace all connections from the battery, switches, and relays to the relevant components. Tighten or clean connections as needed.
   
3. Use a Multimeter: After following the wiring diagram to locate possible problem areas, use a multimeter to test for continuity, voltage, and resistance. This will help confirm if a wire is live, broken, or carrying the correct signal.
   
4. Test Components Individually: When troubleshooting components like switches, relays, or sensors, it’s crucial to test each part individually. Use the wiring diagram to see how each component connects within the circuit and test them accordingly.
   

Where to Find the Wiring Diagram and Service Manual
The wiring diagram and service manual for the Benford TV1200 are essential for effective troubleshooting and repair. These documents provide comprehensive details on the electrical systems, including how each part of the machine works and interacts with the others.

1. Manufacturer’s Website: Benford, now part of JCB, often provides downloadable service manuals and diagrams for their equipment through their official website or authorized dealers.
   
2. Third-Party Equipment Suppliers: Many equipment supply websites offer downloadable versions of service manuals and wiring diagrams, especially for older or discontinued models like the TV1200.
   
3. Online Forums and Communities: Websites like Heavy Equipment Forums often have users who share manuals or offer troubleshooting advice based on their experience with similar machinery.
   

Conclusion
The Benford TV1200 is a robust and reliable site dumper that is essential for heavy lifting and material transport in demanding construction environments. Like any complex piece of machinery, electrical problems can arise over time, affecting performance and safety. The wiring diagram is an essential tool for troubleshooting and maintaining the electrical systems of the TV1200. By understanding the electrical layout, common issues, and using the diagram to identify faults, operators and mechanics can ensure that the machine operates efficiently and safely.
Routine maintenance, attention to wiring integrity, and prompt troubleshooting are key to prolonging the life of the Benford TV1200 and keeping it running smoothly. Whether it's a simple fuse replacement or a more complex wiring fault, having the right tools and resources at hand is crucial for any repair job.